PM4000 10 5 0 English

User guide
PowerMACS 4000
Atlas Copco Tools and Assembly Systems
9836 3521 01
2011-12
Edition 10.5.0
Contents
Contents
1 Introduction ....................................................................................................................................... 15
1.1 Introduction - Overview ....................................................................................................................... 15
1.1.1 ToolsTalk PowerMACS, the friendly user interface ................................................................. 16
1.1.2 Intelligent tightening controllers, TCs ....................................................................................... 16
1.2 Tightening and Gauging ....................................................................................................................... 18
1.2.1 Gauging Functions .................................................................................................................... 18
1.2.2 Gauging Applications ................................................................................................................ 18
1.2.2.1 Torque To Turn Gauging Application ....................................................................... 19
1.2.2.2 Valve Lash Gauging Application .............................................................................. 20
1.3 Installing ToolsTalk PowerMACS ....................................................................................................... 21
1.3.1 Settings needed when running on Windows 7........................................................................... 22
2 System Architecture .......................................................................................................................... 25
2.1 System Architecture - Overview .......................................................................................................... 25
2.2 System Structure ................................................................................................................................... 26
2.3 Hardware Structure ............................................................................................................................... 28
2.3.1 Tightening Controller ................................................................................................................ 29
2.3.1.1 PTC Description ........................................................................................................ 32
2.3.1.2 TC Description .......................................................................................................... 34
2.3.1.3 The TC HMI Menu System ....................................................................................... 36
2.3.2 Version conflict message........................................................................................................... 40
2.3.3 Console Computer (CC) ............................................................................................................ 40
2.3.4 Ethernet ..................................................................................................................................... 41
2.3.5 Peripheral Devices..................................................................................................................... 42
2.4 Automatic update of TC, Servo and Spindle ........................................................................................ 43
2.4.1 Automatic update Overview ...................................................................................................... 43
2.4.2 General function ........................................................................................................................ 43
2.4.3 Replacement of the System TC and Backup TC ....................................................................... 45
2.4.4 Replacement of TC3 – TCn....................................................................................................... 45
2.4.5 Updating a system with new software ....................................................................................... 45
2.4.6 Troubleshooting ........................................................................................................................ 45
2.4.7 Automatic Update of Servo software ........................................................................................ 46
2.4.8 Automatic Update of Spindle software ..................................................................................... 47
3 Basic Functions .................................................................................................................................. 49
3.1 Basic Functions - Overview ................................................................................................................. 49
3.2 Windows ............................................................................................................................................... 50
3.3 Help ...................................................................................................................................................... 53
3.4 The File menu ....................................................................................................................................... 54
3.5 How to Start up ..................................................................................................................................... 56
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3.6 Viewing ................................................................................................................................................ 59
3.6.1 Assembly Overview .................................................................................................................. 59
3.6.1.1 Station Views ............................................................................................................. 62
3.6.2 System Map ............................................................................................................................... 63
3.6.3 View Cycle Data ....................................................................................................................... 66
3.6.4 View Statistics ........................................................................................................................... 68
3.6.5 View Trace ................................................................................................................................ 70
3.6.5.1 Select which trace to display ..................................................................................... 71
3.6.5.2 View of trace curves .................................................................................................. 74
3.6.5.3 Select Trace ............................................................................................................... 81
3.6.6 View Tightening Path................................................................................................................ 82
3.6.7 View Event Log ........................................................................................................................ 83
3.6.8 View I/O signals ........................................................................................................................ 86
3.7 Reporter ................................................................................................................................................ 87
3.7.1 Predefined reporter settings ....................................................................................................... 87
3.7.2 New reporter.............................................................................................................................. 88
3.7.3 Remove reporter ........................................................................................................................ 91
3.7.4 Edit reporter .............................................................................................................................. 92
3.7.4.1 Adding Cycle Data Variables .................................................................................... 94
3.7.4.2 Layout of Cycle Data ................................................................................................. 96
3.7.4.3 Cycle Data layout example ........................................................................................ 99
3.7.4.4 Reporter Preview ..................................................................................................... 104
3.7.4.5 Advanced Event settings ......................................................................................... 105
3.7.4.6 Advanced CD settings ............................................................................................. 105
3.8 Security ............................................................................................................................................... 107
3.8.1 Registering groups................................................................................................................... 107
3.8.2 Registering users ..................................................................................................................... 108
3.8.3 Login and Logout .................................................................................................................... 109
3.9 Printing ............................................................................................................................................... 111
4 Set Up and Maintenance ................................................................................................................. 113
4.1 Set Up and Maintenance - Overview .................................................................................................. 113
4.2 Setups and How to handle them ......................................................................................................... 114
4.2.1 Backwards compatibility ......................................................................................................... 115
4.2.1.1 PLC conversion ....................................................................................................... 116
4.2.1.2 Compatibility between PM4000 Tightening and Gauging ...................................... 117
4.2.1.3 Upgrade of PLC environment .................................................................................. 117
4.3 Set up of a new system ....................................................................................................................... 118
4.3.1 Creating a new system using the Set Up Wizard ..................................................................... 118
4.4 System Map ........................................................................................................................................ 126
4.4.1 Logical view ............................................................................................................................ 127
4.4.1.1 System node............................................................................................................. 128
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4.4.1.2 Station node ............................................................................................................. 128
4.4.1.3 Bolt node ................................................................................................................. 130
4.4.1.4 Programs node ......................................................................................................... 130
4.4.1.5 Reporters node ......................................................................................................... 131
4.4.2 Hardware node ........................................................................................................................ 132
4.4.2.1 TC node ................................................................................................................... 133
4.4.2.2 Spindle node ............................................................................................................ 135
4.4.2.3 Other device nodes .................................................................................................. 136
4.5 Station Set Up ..................................................................................................................................... 137
4.5.1 Advanced Station Settings....................................................................................................... 139
4.5.1.1 Work piece identifier ............................................................................................... 140
4.5.1.2 Multiple identifiers .................................................................................................. 140
4.5.1.3 PLC Event handling................................................................................................. 144
4.5.1.4 Conversion table ...................................................................................................... 144
4.6 Spindle Set Up .................................................................................................................................... 147
4.6.1 General page ............................................................................................................................ 147
4.6.2 Calibration page ...................................................................................................................... 148
4.6.3 Application page ..................................................................................................................... 149
4.6.4 Application External Equipment ............................................................................................. 150
4.6.5 Angle Channels page ............................................................................................................... 151
4.6.5.1 Angle Double Transducer Check ............................................................................. 151
4.6.6 Torque Channels page ............................................................................................................. 153
4.6.6.1 Torque Double Transducer Check .......................................................................... 153
4.6.7 Diagnostic page ....................................................................................................................... 155
4.6.7.1 Static Zero Offset..................................................................................................... 155
4.6.7.2 Dynamic Zero Offset and Angle Count ................................................................... 156
4.6.7.3 Flying Zero Offset ................................................................................................... 156
4.6.7.4 Order of execution ................................................................................................... 157
4.6.8 Motortune page ....................................................................................................................... 158
4.6.9 Automatic transducer protections ............................................................................................ 159
4.7 I/O....................................................................................................................................................... 160
4.7.1 Local I/O ................................................................................................................................. 163
4.8 ID device Set Up ................................................................................................................................ 164
4.9 Assembly Overview Set Up ............................................................................................................... 165
4.10 PLC Parameters Set Up ...................................................................................................................... 169
4.11 SRAM ................................................................................................................................................. 170
4.12 Options ............................................................................................................................................... 171
4.12.1 Set Customer step names ......................................................................................................... 173
4.12.2 Set Customer error codes ........................................................................................................ 174
4.13 Setup Problems ................................................................................................................................... 176
4.14 Table Export and Import..................................................................................................................... 177
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4.15 Table Copy ......................................................................................................................................... 179
4.16 Handling of the setup in the target system .......................................................................................... 180
4.16.1 Backup of the setup ................................................................................................................. 180
4.16.2 Replacement of TCs ................................................................................................................ 182
4.17 Maintenance ....................................................................................................................................... 183
4.17.1 Select Target System ............................................................................................................... 184
4.17.2 Test Bolts ................................................................................................................................ 186
4.17.3 Calibration procedures in PowerMACS .................................................................................. 190
4.17.3.1 General .................................................................................................................. 190
4.17.3.2 Torque ................................................................................................................... 192
4.17.3.3 Angle ..................................................................................................................... 194
4.17.3.4 Wind Up Coefficient ............................................................................................. 195
4.17.3.5 Current (torque) ..................................................................................................... 197
4.17.4 Event Statistics ........................................................................................................................ 198
4.17.5 Service Log ............................................................................................................................. 199
4.17.6 Replace ID String .................................................................................................................... 200
4.17.7 Configure Target System......................................................................................................... 201
4.17.7.1 Advanced mode ..................................................................................................... 202
4.17.7.2 Restart of TC’s after download .............................................................................. 203
4.17.7.3 Information fields .................................................................................................. 203
4.17.7.4 Prepare TC for download of software .................................................................... 207
4.17.7.5 Change Net Data .................................................................................................... 209
4.17.8 Clear data ................................................................................................................................ 210
4.17.9 Compare programs .................................................................................................................. 211
4.17.10 Check for System Conflicts ............................................................................................... 213
4.17.11 TC Crash Log..................................................................................................................... 214
4.17.12 Maintain Spindle Parameters ............................................................................................. 214
5 PLC ................................................................................................................................................... 217
5.1 PLC - Overview .................................................................................................................................. 217
5.2 General ............................................................................................................................................... 218
5.3 System Globals ................................................................................................................................... 220
5.3.1 Station variables ...................................................................................................................... 220
5.3.1.1 Loosening cycles ..................................................................................................... 227
5.3.2 Bolt variables .......................................................................................................................... 233
5.3.3 ID device variables .................................................................................................................. 237
5.3.4 Multiple identifier variables .................................................................................................... 238
5.3.5 GM DeviceNet variables ......................................................................................................... 240
5.3.6 DC PLUS variables ................................................................................................................. 242
5.3.7 Globals .................................................................................................................................... 245
5.3.8 Bolt specific commands .......................................................................................................... 246
5.3.9 Device commands ................................................................................................................... 249
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5.4 Programming the PLC ........................................................................................................................ 251
5.5 PLC Console ....................................................................................................................................... 256
5.6 PLC Parameters .................................................................................................................................. 258
5.7 Display PLC Status ............................................................................................................................. 259
6 Tightening......................................................................................................................................... 260
6.1 Tightening - Overview........................................................................................................................ 260
6.2 Create a new Tightening Program ...................................................................................................... 261
6.3 The Tightening Program form ............................................................................................................ 262
6.3.1 Tightening Program step operations ........................................................................................ 264
6.4 The Mode Table form ......................................................................................................................... 266
6.5 Tightening Program ............................................................................................................................ 268
6.5.1 Program Properties .................................................................................................................. 270
6.5.1.1 Program Common properties ................................................................................... 270
6.5.1.2 Program User variables ........................................................................................... 270
6.5.1.3 Program Settings...................................................................................................... 272
6.5.2 Step – Control ......................................................................................................................... 275
6.5.2.1 DT - Run until Dyna-TorkTM ................................................................................... 276
6.5.2.2 DT2 - Run until Dyna-TorkTM, method 2 ................................................................ 278
6.5.2.3 DT3 - Run until Dyna-TorkTM, method 3 ................................................................ 279
6.5.2.4 T - Run until Torque ................................................................................................ 280
6.5.2.5 TC - Run until Torque with Current Control ........................................................... 281
6.5.2.6 AO - Run until Angle with overshoot compensation ............................................... 282
6.5.2.7 A - Run until Angle ................................................................................................. 284
6.5.2.8 Y1 - Run until Yield point, method 1 ...................................................................... 285
6.5.2.9 Y2 - Run until Yield point, method 2 ...................................................................... 286
6.5.2.10 LT - Loosen until torque ........................................................................................ 287
6.5.2.11 RA - Release angle ................................................................................................ 289
6.5.2.12 PA - Run until Projected angle .............................................................................. 291
6.5.2.13 TD - Run until Torque has decreased .................................................................... 292
6.5.2.14 TI - Run until Time ................................................................................................ 293
6.5.2.15 E1 - Run Engage method 1 .................................................................................... 293
6.5.2.16 E2 - Run Engage method 2 .................................................................................... 293
6.5.2.17 NS - Run until next step ........................................................................................ 293
6.5.2.18 GS - Run Gear Shift............................................................................................... 294
6.5.2.19 PLC - Run PLC step .............................................................................................. 294
6.5.2.20 JOG - Run until digital input goes high / low ........................................................ 295
6.5.2.21 W - Wait ................................................................................................................ 295
6.5.2.22 TA – Run Torque-Angle with no stop ................................................................... 296
6.5.2.23 SR – Socket Release .............................................................................................. 302
6.5.2.24 ADT-Angle Delta Torque ...................................................................................... 303
6.5.2.25 SG - Snug Gradient................................................................................................ 305
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6.5.2.26 D - Diagnostic Step................................................................................................ 306
6.5.2.27 BCT – Backlash correction (only available for Gauging) ..................................... 307
6.5.2.28 POS - Run to Position (only available for Gauging) ............................................. 307
6.5.2.29 MS4 – Measurement step method 4 (only available for Gauging) ........................ 309
6.5.2.30 AD2 – Adjust step method 2 (only available for Gauging) ................................... 310
6.5.3 Step – Restriction .................................................................................................................... 312
6.5.3.1 Fail Safe Torque ...................................................................................................... 313
6.5.3.2 Fail Safe Time ......................................................................................................... 314
6.5.3.3 Fail Safe Angle ........................................................................................................ 315
6.5.3.4 Min Torque Restriction ........................................................................................... 316
6.5.3.5 Gradient ................................................................................................................... 318
6.5.3.6 Cross Thread and Gradient ...................................................................................... 320
6.5.3.7 Torque Profile .......................................................................................................... 321
6.5.3.8 Angle Difference ..................................................................................................... 323
6.5.3.9 Torque Difference.................................................................................................... 324
6.5.4 Step – Check ........................................................................................................................... 325
6.5.4.1 Result values from checks ....................................................................................... 326
6.5.4.2 Check peak torque ................................................................................................... 327
6.5.4.3 Check torque in angle window ................................................................................ 329
6.5.4.4 Check torque in time window .................................................................................. 330
6.5.4.5 Check mean torque .................................................................................................. 331
6.5.4.6 Check angle ............................................................................................................. 333
6.5.4.7 Check Post view Torque .......................................................................................... 335
6.5.4.8 Check T/T3 (Current as Torque) ............................................................................. 337
6.5.4.9 Check shut off torque .............................................................................................. 338
6.5.4.10 Check torque rate ................................................................................................... 339
6.5.4.11 Check Zero Crossing (only available for Gauging) ............................................... 342
6.5.4.12 Check time ............................................................................................................. 344
6.5.4.13 Check Yield Point Angle ....................................................................................... 344
6.5.4.14 Check Stick Slip .................................................................................................... 346
6.5.4.15 Delta T (only available for Gauging) ..................................................................... 348
6.5.4.16 Low Spot Torque (only available for Gauging) ..................................................... 349
6.5.4.17 Check Position (only available for Gauging)......................................................... 349
6.5.4.18 Check Backlash angle (only available for Gauging) ............................................. 350
6.5.4.19 Check external input (only available for Gauging) ................................................ 350
6.5.5 Step – Rejects .......................................................................................................................... 351
6.5.5.1 Checking the bolt status ........................................................................................... 352
6.5.5.2 Deciding what to do ................................................................................................. 353
6.5.5.3 Configuring Reject Management ............................................................................. 356
6.5.5.4 Advanced RM Actions ............................................................................................ 358
6.5.5.5 Cycle RM................................................................................................................. 359
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6.5.5.6 Reject management states ........................................................................................ 361
6.5.5.7 Reject management examples .................................................................................. 367
6.5.6 Step – Ramps & Other ............................................................................................................ 369
6.5.6.1 Ramps & Other – Ramps ......................................................................................... 370
6.5.6.2 Ramps & Other – Other ........................................................................................... 371
6.5.6.3 Ramps & Other – Store Position (only available for Gauging) ............................... 372
6.5.6.4 Ramps & Other – Signals at step start and end (only available for Gauging) ......... 373
6.5.7 Zones (only available for Gauging) ......................................................................................... 374
6.6 Bolt Monitoring .................................................................................................................................. 375
6.6.1 Monitoring Check – Final Peak Torque .................................................................................. 378
6.6.2 Monitoring Check – Angle ...................................................................................................... 379
6.6.3 Monitoring Check – Torque Rate ............................................................................................ 382
6.6.4 Monitoring Check – Monitoring Yield point torque and angle ............................................... 385
6.6.5 Monitoring Check – Follow the Curve .................................................................................... 388
6.7 Result variables .................................................................................................................................. 391
6.7.1 Statuses .................................................................................................................................... 391
6.7.2 Station level result variables.................................................................................................... 392
6.7.3 Bolt level result variables ........................................................................................................ 394
6.7.3.1 Errors ....................................................................................................................... 399
6.7.3.2 Warnings.................................................................................................................. 404
6.7.4 Step level result variables ........................................................................................................ 405
6.8 Servo and spindle protections ............................................................................................................. 410
6.8.1 Stall protection ........................................................................................................................ 410
6.8.2 How to avoid the problems ..................................................................................................... 410
7 SPC and Statistics ............................................................................................................................ 412
7.1 SPC - Overview .................................................................................................................................. 412
7.2 SPC, Statistical Process Control ......................................................................................................... 413
7.2.1 Data Collection ........................................................................................................................ 413
7.2.2 Calculations for subgroups ...................................................................................................... 414
7.2.3 Calculations and checks .......................................................................................................... 414
7.2.4 SPC constants .......................................................................................................................... 418
7.3 SPC set up .......................................................................................................................................... 419
7.4 Shift Reports and Shift Set Up............................................................................................................ 421
7.4.1 Shift Set Up ............................................................................................................................. 422
8 Peripheral Devices ........................................................................................................................... 425
8.1 Peripheral Devices - Overview ........................................................................................................... 425
8.2 Add a device ....................................................................................................................................... 427
8.3 Status of a device ................................................................................................................................ 429
8.4 Standard Accessory Devices............................................................................................................... 430
8.4.1 Stacklight................................................................................................................................. 430
8.4.2 Indicator Box ........................................................................................................................... 431
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8.4.3 Operator Panel ......................................................................................................................... 433
8.5 I/O Device .......................................................................................................................................... 435
8.6 Printer on TC ...................................................................................................................................... 436
8.7 Printer or File on CC .......................................................................................................................... 436
8.8 PLC ..................................................................................................................................................... 437
8.9 ID device ............................................................................................................................................ 441
8.9.1 Type specific parameters ......................................................................................................... 442
8.9.1.1 Barcode scanner ....................................................................................................... 442
8.9.1.2 Pepperl + Fuchs escort memory .............................................................................. 443
8.9.1.3 Allen Bradley escort memory .................................................................................. 444
8.9.1.4 Omron escort memory ............................................................................................. 445
8.9.1.5 Euchner card reader ................................................................................................. 447
8.10 ToolsNet ............................................................................................................................................. 448
8.11 Ethernet Protocols .............................................................................................................................. 451
8.11.1 Open Protocol.......................................................................................................................... 454
8.11.1.1 Automatic/manual mode ........................................................................................ 455
8.11.1.2 Supported message types ....................................................................................... 457
8.11.1.3 TC Status Record Formats ..................................................................................... 460
8.11.1.4 TC Result Record Formats .................................................................................... 461
8.11.2 DaimlerChrysler PFCS ............................................................................................................ 463
8.11.2.2 PFD Result Record Formats .................................................................................. 464
8.11.3 FSH ......................................................................................................................................... 465
8.11.3.2 TC Result Record Formats .................................................................................... 467
8.11.4 DC PLUS ................................................................................................................................ 468
8.11.4.1 Parameters for PDT ............................................................................................... 469
8.11.4.2 Parameters for PQD ............................................................................................... 471
8.11.4.3 Handling of PN, KN and LI, in protocol version PDT .......................................... 473
8.11.4.4 Handling of QO and FP ......................................................................................... 474
8.11.4.5 SAW / WIS ............................................................................................................ 475
8.11.4.6 SPS ........................................................................................................................ 477
8.11.4.7 VBA....................................................................................................................... 478
8.11.4.8 SSE ........................................................................................................................ 479
8.11.4.9 TC Result Formats for PDT ................................................................................... 480
8.11.4.10 TC Result Format for PQD .................................................................................. 482
8.11.4.11 Selecting the data to report .................................................................................. 484
8.11.4.12 Selecting the data to report .................................................................................. 484
8.11.5 I-P.M. ...................................................................................................................................... 485
8.11.5.1 Mapping of data ..................................................................................................... 485
8.11.5.2 Value sent as Maintenance Sequence (AFO-number) ........................................... 487
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8.11.5.3 Possible error codes ............................................................................................... 488
8.11.5.4 Characteristic Identifications ................................................................................. 489
8.11.5.5 Parameter Identifications ....................................................................................... 489
8.11.6 Audi XML ............................................................................................................................... 490
8.12 Fieldbus Interface ............................................................................................................................... 492
8.12.1 Access to PLC data ................................................................................................................. 497
8.12.1.1 PLC Areas ............................................................................................................. 499
8.12.1.2 Complex data types ............................................................................................... 500
8.12.1.3 Set up shared variables .......................................................................................... 503
8.12.1.4 Fieldbus form......................................................................................................... 507
8.12.2 Access to Process data............................................................................................................. 510
8.12.2.1 Using the extended format ..................................................................................... 516
8.12.3 Fieldbus specific Information .................................................................................................. 518
8.12.3.1 DeviceNet .............................................................................................................. 518
8.12.3.2 Profibus DP and DP-V1 ........................................................................................ 522
8.12.3.3 ProfiNet IO ............................................................................................................ 526
8.12.3.4 Modbus TCP .......................................................................................................... 530
8.12.3.5 Ethernet/IP ............................................................................................................. 535
8.12.3.6 CC-Link ................................................................................................................. 538
8.13 Serial Communication ........................................................................................................................ 541
8.13.1 Accesses from External communication device ...................................................................... 542
8.13.2 Access to PLC data ................................................................................................................. 544
8.13.3 Access to Process data............................................................................................................. 546
8.13.4 Serial Communication Protocol Information .......................................................................... 546
8.13.4.1 JBUS ...................................................................................................................... 548
8.13.4.2 Siemens 3964R ...................................................................................................... 549
8.13.4.3 Telemechanique UNI-TE....................................................................................... 550
8.13.4.4 SATT Comli .......................................................................................................... 552
8.13.4.5 Allen-Bradley Data Highway (Plus) ...................................................................... 553
8.14 API, Application Programmers Interface ........................................................................................... 554
8.14.1 Subscriptions ........................................................................................................................... 558
8.14.2 Object model ........................................................................................................................... 559
8.14.3 Enumerators exported by the API ........................................................................................... 560
8.14.4 Api object ................................................................................................................................ 563
8.14.4.1 Properties ............................................................................................................... 563
8.14.4.2 GetPLCBoolEx ...................................................................................................... 564
8.14.4.3 SetPLCBoolEx ...................................................................................................... 564
8.14.4.4 GetPLCByteEx ...................................................................................................... 565
8.14.4.5 SetPLCByteEx ....................................................................................................... 565
8.14.4.6 GetPLCIntEx ......................................................................................................... 566
8.14.4.7 SetPLCIntEx .......................................................................................................... 566
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8.14.4.8 GetPLCRealEx ...................................................................................................... 567
8.14.4.9 SetPLCRealEx ....................................................................................................... 567
8.14.4.10 GetPLCStringEx .................................................................................................. 568
8.14.4.11 SetPLCStringEx................................................................................................... 568
8.14.4.12 GetPLCBool ........................................................................................................ 569
8.14.4.13 SetPLCBool ......................................................................................................... 569
8.14.4.14 GetPLCByte ........................................................................................................ 570
8.14.4.15 SetPLCByte ......................................................................................................... 570
8.14.4.16 GetPLCInt............................................................................................................ 571
8.14.4.17 SetPLCInt ............................................................................................................ 571
8.14.4.18 GetPLCReal ......................................................................................................... 572
8.14.4.19 SetPLCReal ......................................................................................................... 572
8.14.4.20 GetPLCString ...................................................................................................... 573
8.14.4.21 SetPLCString ....................................................................................................... 573
8.14.4.22 GetCycleData....................................................................................................... 574
8.14.4.23 GetCycleDataBin ................................................................................................. 574
8.14.4.24 GetLastCycleData ................................................................................................ 575
8.14.4.25 GetLastCycleDataBin .......................................................................................... 575
8.14.4.26 GetCycleDataById ............................................................................................... 575
8.14.4.27 SubscribeCD ........................................................................................................ 576
8.14.4.28 RecNewCD .......................................................................................................... 576
8.14.4.29 FlushCDQueue .................................................................................................... 576
8.14.4.30 RewindCDQueue ................................................................................................. 576
8.14.4.31 GetEvent .............................................................................................................. 577
8.14.4.32 GetEventEx .......................................................................................................... 578
8.14.4.33 GetEventObj ........................................................................................................ 578
8.14.4.34 SubscribeEvent .................................................................................................... 579
8.14.4.35 RecNewEvent ...................................................................................................... 579
8.14.4.36 FlushEventQueue................................................................................................. 579
8.14.4.37 RewindEventQueue ............................................................................................. 579
8.14.4.38 GetTrace .............................................................................................................. 580
8.14.4.39 GetTraceEx and GetTraceEx_v2 ......................................................................... 580
8.14.4.40 GetLastTrace and GetLastTrace_v2 .................................................................... 580
8.14.4.41 SubscribeTrace .................................................................................................... 581
8.14.4.42 RecNewTrace ...................................................................................................... 581
8.14.4.43 FlushTraceQueue ................................................................................................. 581
8.14.4.44 RewindTraceQueue ............................................................................................. 582
8.14.4.45 SubscribeStStatus ................................................................................................ 582
8.14.4.46 RecNewStStatus .................................................................................................. 582
8.14.4.47 GetSetup .............................................................................................................. 583
8.14.4.48 SetSetup ............................................................................................................... 583
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8.14.4.49 GetSetupItem ....................................................................................................... 584
8.14.4.50 SetSetupItem........................................................................................................ 584
8.14.4.51 GetSystemDesc .................................................................................................... 585
8.14.4.52 GetStationDesc .................................................................................................... 585
8.14.4.53 GetDateAndTime................................................................................................. 586
8.14.4.54 SetDateAndTime ................................................................................................. 586
8.14.4.55 GetTime ............................................................................................................... 587
8.14.4.56 SetTime................................................................................................................ 587
8.14.5 System object .......................................................................................................................... 588
8.14.5.1 Properties ............................................................................................................... 588
8.14.6 Stations object (collection) ...................................................................................................... 589
8.14.6.1 Properties ............................................................................................................... 589
8.14.6.2 Item ........................................................................................................................ 589
8.14.6.3 Exists ..................................................................................................................... 590
8.14.7 Station object ........................................................................................................................... 591
8.14.7.1 Properties ............................................................................................................... 591
8.14.8 Bolts object (collection) .......................................................................................................... 592
8.14.8.1 Properties ............................................................................................................... 592
8.14.8.2 Item ........................................................................................................................ 592
8.14.8.3 Exists ..................................................................................................................... 593
8.14.9 Bolt object ............................................................................................................................... 594
8.14.9.1 Properties ............................................................................................................... 594
8.14.10 TraceData object ................................................................................................................ 595
8.14.10.1 Properties ............................................................................................................. 595
8.14.10.2 Press traces .......................................................................................................... 596
8.14.11 Channels object (collection) .............................................................................................. 596
8.14.11.1 Properties ............................................................................................................. 596
8.14.11.2 Item ...................................................................................................................... 596
8.14.11.3 Exists ................................................................................................................... 597
8.14.12 Channel object ................................................................................................................... 598
8.14.12.1 Properties ............................................................................................................. 598
8.14.12.2 GetSampleValueNo ............................................................................................. 598
8.14.12.3 GetSampleValueTime.......................................................................................... 598
8.14.12.4 GetSampleValues ................................................................................................ 599
8.14.13 StepBounds object (collection) .......................................................................................... 600
8.14.13.1 Properties ............................................................................................................. 600
8.14.13.2 Item ...................................................................................................................... 600
8.14.13.3 Exists ................................................................................................................... 601
8.14.14 StepBound object ............................................................................................................... 602
8.14.14.1 Properties ............................................................................................................. 602
8.14.15 EventData object ................................................................................................................ 603
9836 3521 01 13
Contents
8.14.15.1 Properties ............................................................................................................. 603
8.14.16 How to use the API ............................................................................................................ 604
8.15 GM DeviceNet .................................................................................................................................... 609
8.15.1 Interface definition input ......................................................................................................... 611
8.15.2 Interface definition output ....................................................................................................... 613
8.15.2.1 Indication schema .................................................................................................. 614
8.16 ACTA 3000 ........................................................................................................................................ 617
8.17 Process data ........................................................................................................................................ 619
8.17.1 Data types ................................................................................................................................ 621
8.17.2 Layout of Cycle data in Process data ...................................................................................... 621
8.17.3 Layout of Events in Process data ............................................................................................ 622
8.17.4 Layout of Traces in Process data ............................................................................................. 623
8.17.5 Layout of Setup Item Descriptions .......................................................................................... 624
8.17.5.1 Bolt ........................................................................................................................ 625
8.17.5.2 Spindle, Parameters ............................................................................................... 626
8.17.5.3 Spindle, Channel data ............................................................................................ 627
8.17.5.4 Program, General data ........................................................................................... 628
8.17.5.5 Program, Trace data ............................................................................................... 629
8.17.5.6 Program, Monitoring data ...................................................................................... 630
8.17.5.7 Sequence and Program, Step, Control data ............................................................ 631
8.17.5.8 Sequence and Program, Step, Speed data .............................................................. 631
8.17.5.9 Sequence and Program, Step, Speed, Ramp down data ......................................... 632
8.17.5.10 Sequence and Program, Step, Other data ............................................................. 633
8.17.5.11 Sequence and Program, Step, Surveillance data .................................................. 634
8.17.6 Layout of Setups...................................................................................................................... 634
9 Specification ..................................................................................................................................... 636
9.1 Specification ....................................................................................................................................... 636
9.2 Requirements ToolsTalk PC ............................................................................................................... 637
10 Appendix........................................................................................................................................... 638
10.1 List of events ...................................................................................................................................... 638
10.2 ToolsTalk PowerMACS command line .............................................................................................. 669
10.3 Cycle Data Storage ............................................................................................................................. 670
10.3.1 Store 5000 Cycle Data ............................................................................................................. 670
10.3.1.1 Storing and retrieving cycle data ........................................................................... 671
10.4 Configuration of the Conversion Box ................................................................................................. 673
10.5 Fatal Software Errors .......................................................................................................................... 676
11 References......................................................................................................................................... 679
11.1 References to external documents ...................................................................................................... 679
12 Glossary of Terms ............................................................................................................................ 681
12.1 Glossary .............................................................................................................................................. 681
14 9836 3521 01
Introduction
1 Introduction
1.1 Introduction - Overview
The PowerMACS 4000 system is the seventh generation of tightening systems from Atlas Copco Tools
and Assembly Systems. It is the perfect solution for all tightening applications in your assembly plant,
however complex.
Building on the successful PowerMACS concept the PowerMACS 4000 delivers even more performance
and benefits to customers by increased intelligence in tightening controllers and simplified configuration
through the new ToolsTalk PowerMACS software.
PowerMACS 4000 supports all known tightening and process monitoring methods and builds further on
the proven PowerMACS concept to deliver even more performance using the new intelligent QST
spindles.
PowerMACS 4000 is not only the most productive, cost-effective and user-friendly tightening system on
the market today, it also offers an impressive new level of installation flexibility.
9836 3521 01 15
Introduction
1.1.1 ToolsTalk PowerMACS, the friendly user interface
The new improved ToolsTalk PowerMACS (TTPM) builds on the experiences from the earlier WinTC and
with increased simplicity and flexibility make the user experience more rewarding without loosing any
functionality.
Simplicity has been greatly increased by the introduction of the Basic and Advanced concepts into
ToolsTalk PowerMACS, most functionality is hidden for inexperienced users but available at a mouse-click
for more those who feel they need the extra functionality.
Increased user friendliness by drag & drop functionality.
Full reporting ToolsTalk PowerMACS offers full reporting of tightening results, set values and limits. An
easily adapted annunciator shows the tightening results in read-at-a-glance graphics. The combined
SystemMap shows the tightening status of the bolts and the status of all equipped hardware. The system
provides reports for any chosen parameters, trace curves, and advanced SPC and log files.
User guides Accessible via Hyperlinks, the software includes SetUp Wizards, Tutorials, Tightening
Templates which guide you through the most common tightening sequences, Spare Parts Lists with
drawings and article numbers, service, fault-finding and FAQ functions, and a complete on-line manual.
If you need to configure the system for Ethernet or Fieldbus communication, the PowerMACS 4000 Set
Up Wizards make the task simple.
API for easy access ToolsTalk PowerMACS includes the popular Application Program Interface (API)
enabling the engineer to access data from the Tightening Controller. For example: read and write PLC,
cycle and trace data and store cycle data to media. All internal and external communications are via
Ethernet TCP/IP thin wire 100 Mbit/s.
PowerMACS 4000 can be tailored to any assembly process. A built-in PLC (IEC 61131-3), fully
programmable using the ToolsTalk interface, supports various in-station control requirements.
1.1.2 Intelligent tightening controllers, TCs

PowerMACS 4000 is modular in concept, utilizing the new improved intelligent Tightening Controller (TC)
with state-of-the-art software and a wide range of peripheral support and communication possibilities. The
TC is designed for IP43 and is easy to integrate into a production line as a stand-alone unit or integrated
in a panel.
Even more expanded capacity than it‟s predecessor it is an attractive piece of industrial design, the
PowerMACS 4000 TC is equipped with an impressive amount of memory, more than enough to handle
the Real- Time Operative System, Application Programs and the PLC program.
Tightening controllers are now separated in the Primary Tightening Controller (TC) featuring more
connectability and external communication possibilities and the more basic tightening controller (TC).
One Primary TC (PTC) is configured as a System TC and the rest as Spindle TCs. In a system all Spindle
TCs can be replaced without needing to download the setup once again. One system can include a
maximum of 15 stations. Up to 50 TC's can be connected in one system, controlling 50 nut runners.
16 9836 3521 01
Introduction
Full interchangeability means fewer spare parts are required, maintenance time is reduced and availability
is increased.
All common interfaces All PTC's are designed to interface with Ethernet, the most common Fieldbuses,
and industrial PLCs. The Application Program Interface (API) ensures easy external access to the system.
Peripherals simply added A wide range of peripherals can be connected to the PowerMACS 4000 TC
including printers, bar code readers, operator table, operator annunciators, etc.
Flexible installation The plug-and-play modular design of the TC means maximum installation flexibility.
Series communication in line control and data collection enables the PowerMACS TC's to be discreetly
integrated into the production line by the connection of two cables. The appropriate reporting system and
suitable operator interface can be mounted next to the work area.
9836 3521 01 17
Introduction
1.2 Tightening and Gauging

There are two types of PM4000 products:
PM4000 Tightening
PM4000 Gauging
PM4000 Tightening contains all functions needed for normal tightening of bolts. It can read and write
Tightening setups on disk or a TC. It cannot read or write a Gauging setup.
PM4000 Gauging has all the functions of PM4000 Tightening but also additional functions for gauging
applications. It can read a Tightening setup from file and convert it to a Gauging setup but not vice versa.
1.2.1 Gauging Functions

The following functions are only available if you run PM4000 Gauging:
Step BCT
Step Run to Position
Step MS (Measurement step method) and AD (Adjust step method)
Step Wait, PLC signal addition
Check Delta T
Check Low Spot
Check Pos
Check Peak T, additions
Zones (within step)
Store positions
Backlash compensation
1.2.2 Gauging Applications

PM4000 Gauging can be used for applications where turning and measuring of torque and angle with high
precision is needed. Examples:
Torque To Turn
Valve lash
Indexer
18 9836 3521 01
Introduction
Hub nuts
1.2.2.1 Torque To Turn Gauging Application

An example of a Torque To Turn application is when an engine manufacturer wants to rotate the crank or
cam shaft under controlled conditions for the first time. Metal chips, burrs, sharp edges (spot distortions)
may cause excessive drag and eventually lead to early bearing shell failure and warranty repairs.
With PM4000 Gauging it is easy to create a program that rotates the shaft 360 or 720 degrees and
continuously monitor the torque and angle.
The curve present torque vs. time. There are two critical points.
1. Break-Away
2. Low Torque Rotation Test
To check break-away the torque is gently increased without rotation. If the torque reaches a preset limit
before any rotation starts the test stops immediately, preventing any damage.
If the break-away torque is within limits the rotation starts and the torque is monitored for the full rotation at
slow speed. Any friction out of limit indicates mechanical problems that should be corrected.
The combination of the two tests will show up any mechanical problems at a very early stage, before the
motor has been built into e.g. a vehicle. This eliminates the risk that the motor later experience expensive
service warranties.
9836 3521 01 19
Introduction
1.2.2.2 Valve Lash Gauging Application
In a Valve Lash application a bolt and a nut should be rotated and locked to each other to achieve a
specific valve lash. This can be done with a special coaxial spindle, e.g. QMX 42-2RT.
It is easy to create a program that operates the two spindles in a controlled way to make up perfectly
adjusted valve lash.
20 9836 3521 01
Introduction
1.3 Installing ToolsTalk PowerMACS

You can install ToolsTalk PowerMACS from CD or from a hard disk. To install PM4000 Tightening you
execute the file “PM4000 10.X.X ToolsTalk.exe” located in the folder ToolsTalk. PM4000 Gauging is
installed with the file “PM4000 10.X.X ToolsTalk Gauging.exe” located in the folder ToolsTalk Gauging.
After installing ToolsTalk PowerMACS you have up to 90 days to register it.
Register buttons are found at the bottom left part of the window for an unregistered ToolsTalk, and in the
Help-About window.
To register, press a Register button to invoke the below form, and follow the instructions.
9836 3521 01 21
Introduction
When registering please note that there are three types of products:
PM4000 Tightening
PM4000 Gauging
PM4000 Press
The license only covers one of the products. For more information on differences between the two first
products see Tightening and Gauging.
Until registered ToolsTalk PowerMACS will display an extra status bar at the bottom of the main window
showing you the number of days left of the evaluation period. When this time expires the application will
no longer be possible to start and is automatically shut down if it is running.
1.3.1 Settings needed when running on Windows 7

When after installing and starting ToolsTalk PowerMACS program following window pops up check
marked with red color check boxes and click Allow access push button.
If downloading of TC software from PowerMACS ToolsTalk doesn‟t work do the following according to the
pictures below.
Click System and Security from Control Panel.
22 9836 3521 01
Introduction
Click Allow a program through Windows Firewall.
9836 3521 01 23
Introduction
Check all check boxes for PowerMACS4000 or PowerMACS4000G (for Gauging) or PowerMACS4000P
(for Press) program and click OK.
24 9836 3521 01
System Architecture
2 System Architecture
2.1 System Architecture - Overview
This section describes the architecture of the PowerMACS 4000 system. It includes the descriptions of the
hardware components, including computers and devices, the structures of the system, station and
spindles.
9836 3521 01 25
System Architecture
2.2 System Structure

A PowerMACS System consists of one or more stations where each station may control one or more
bolts.
A o n e sta tio n P o w e rM A C S S yste m A th re e sta tio n P o w e rM A C S S yste m
S ta tio n S ta tio n S ta tio n S ta tio n
B o lt B o lt B o lt B o lt
S p in d le S p in d le S p in d le S p in d le
System
A system comprises one or more Tightening Controllers linked together. A system works autonomously,
performing the programmed tightening task(s).
ToolsTalk PowerMACS can only connect to one PowerMACS system at the time. This means that the
user cannot edit or display data from two or more systems simultaneously while using one ToolsTalk. If
you need to display data from two or more stations at the same time you must design them in one system.
Multiple PowerMACS systems may be networked together in a single facility but are limited by the number
of available IP addresses. There is no limitation when networking is not used.
One system can contain up to 50 Tightening Controllers and up to 50 Spindles.
Station
Within a system you can have up to 15 stations and 100 Bolts totally. One station can control up to 50
bolts but there must be no more than 100 Bolts in a system. The Station has a PLC to control the
tightening cycles and interface with automation controllers. Cycle data is generated for each Station
consisting of the result of all bolts controlled by the Station.
Bolt
A Bolt is the object that will be tightened by the system. A spindle does the actual tightening.
26 9836 3521 01
System Architecture
Spindle
A Spindle performs the actual tightening task. One Spindle can be used to tighten several Bolts and it
normally comprises of:
Motor
Intelligent CPU with complete measuring system
One or more torque sensors
One or more angle sensors
ToolsTalk
ToolsTalk PowerMACS is a Windows application used to set up a PowerMACS 4000 system. It is not
needed for automatic running, but it can optionally be used to monitor the system and to collect and
display various data.
ToolsTalk PowerMACS can be used for multiple systems, if they are hooked up on the same computer
network, but only one system at a time can be accessed.
9836 3521 01 27
System Architecture
2.3 Hardware Structure

The figure below describes the hardware structure of a PowerMACS 4000 system, i.e. how hardware
components are used.
Peripheral
Router
Factory
Network
Console with ToolsTalk
Ethernet
Peripheral Hub
Serial bus
Field bus
............
I/O bus
TC 1 (primary) TC 2 (secondary) ...... TC n (secondary)

I/O-module
Digital I/O Sp 1 Sp 2.. ..Sp n
28 9836 3521 01
System Architecture
2.3.1 Tightening Controller
A Tightening Controller (TC) takes care of various tasks around tightening: driving and controlling a
spindle, measuring and storing angle and torque, running PLC, etc. Each TC contains all functions
necessary to monitor and control one (1) spindle.
Two different Tightening Controllers exist; the PTC is intended to run as a System TC and Station TC. The
PTC has more external interfaces (sockets) than the standard TC.
The System TC is the TC that communicates directly with ToolsTalk PowerMACS. It is on this TC that the
setup, downloaded from ToolsTalk PowerMACS, is stored and is responsible for starting the system when
powered on, or after downloading a new setup.
A single TC belongs to one system only. The System TC, and the setup downloaded to it, defines the
system. When the System TC starts up, either at power on or after receiving a new setup, it will try to
attach to the Spindle TCs it needs. It will assume that IP-address of the Spindle TCs are consecutive to its
own IP-address. That is, if the System TC has address 192.168.0.1 TC 2 should have 192.168.0.2, TC 3
192.168.0.3, and so on.
A Spindle TC will only accept the request of the first System TC that attach to it after a cold start. It will
then remember the IP-address of the System TC and refuse requests from a System TC having another
IP-address until cold started again. See chapter: Configure Target System for more information on how to
configure a TC as a System TC and set its IP-address. Chapter: Configure Target System describes a tool
for detecting overlapping systems, that is, several System TCs trying to use the same Spindle TC.
Spindle TCs can be replaced while the system is operational, without requiring the setup to be
downloaded to the new TC before starting it again. They will fetch their part of the setup from the System
unit when activated.
For security and redundancy a back up copy of the setup is maintained on the second TC in a
PowerMACS 4000 system. This means that the System TC in a system can be replaced without requiring
the setup to be downloaded to the new System TC before starting the system again. See chapter:
Handling of the setup in the target system for details.
Should both the System TC and TC 2 be found nonfunctional and must be replaced then the setup must
be downloaded from a backup media using ToolsTalk PowerMACS. You should therefore always keep
backups of your setups in a safe place.
Note! After replacing the System TC you are strongly recommended to cold start the complete
system.
All TCs in a system, System TCs as well as Spindle TCs, must use the same TC System Software
version in order to function properly. There are several methods to verify that this is the case for all TCs in
a system. The TCs themselves checks for version conflicts at start up and indicates this using the display
on the their front (see chapter: Version conflict message) and ToolsTalk PowerMACS has several forms
that can be used for the same purpose (see chapter: Configure Target System and Check for System
Conflicts).
9836 3521 01 29
System Architecture
The TC board has the following layout:
S T b us
E th e rn e t
L o ca l I/O
CPU
M A C S I/O
RAM
E m e rg . S to p
F la sh -P R O M
S e ria l
SRAM
B a tte ry RTC
30 9836 3521 01
System Architecture
Item Function Use
Ethernet Ethernet interfaces For communication with other TCs. In System TC:s the
second Ethernet interface is used for communication
with the Consol Computer (ToolsTalk PowerMACS),
100 MBits
CPU Central Processing Unit PowerPC 880, 120 MHz
RAM Random Access Memory For storage of program and data when executing, 32
MB
Flash-PROM Programmable Read Only For storage of boot and application software.
Memory of Flash type
SRAM Static RAM with battery For storage of set-ups, traces, cycle data etc.
backup
2 MB
ST bus St bus (2 ch) ST bus 1 is for communication with the drive and the
spindle, located in the tool connector. ST bus 2 is for
communication with ST based accessories.
Emerg. stop Emergency Stop Class 3 Emergency Stop, breaks the gate drive
voltage.
Local DI Digital input Opto Isolated Digital Input
Local DO Digital Output Relay Outputs
Serial Serial interface Interface to serial devices, 3 channels RS232, 1
channel RS422, 2 channels RS485
MACS I/O CAN bus interface Opto Isolated interface to MACS I/O and other
accessories
AnyBus FieldBus interfaces Interface to superior devices
Battery RAM-backup Expected life length >10 years
RTC Real Time Clock Battery backed Real Time Clock
9836 3521 01 31
System Architecture
2.3.1.1 PTC Description

All indicators are located on the front of the PTC:
LEDs
HMI Display
HMI
Soft buttons
Reset emergency stop
The following LED indicators can be found on top of the PTC and are common with the LEDs found on
regular TCs.
OK is lit green when last cycle (tightening) performed by the PTC was OK.
NOK is lit red when last cycle (tightening) performed by the PTC was NOK.
ALARM is lit red when a servo or spindle hardware or system error has been detected on the PTC.
To acknowledge the alarm the PLC variable RESET can be used, an attempt to acknowledge the
alarm is also performed automatically at each cycle start.
The second row of LED indicators can only be found on the PTC.
ALL OK is PTC specific and indicates that the cycle (tightening) for all bolts for the station was OK.
PRIM. Indicates that the PTC is also the System TC for a system.
E-STOP is lit when the station controlled by the PTC is emergency stopped.
32 9836 3521 01
System Architecture
The Reset emergency stop button acknowledges an emergency stop for a station.
Sockets on the PTC

The following picture shows the input and output sockets on the PTC.
E m S to p In : 1 2 p ole E m S to p O u t: 1 2
D ig In : 1 0 p ole P h oen ix p o le P h oen ix
P h oen ix . 4 E m erg en c y sto p in E m erg en c y sto p
D igital in p u ts an d M A C S I/O ou t
M A C S I/O : 9 p ole P ow er c on n ector

D -su b
D ip sw itc h for
R S 4 8 5 an d M A C S I/O
S erial 1 : 9 p ole
T erm in ation
D -su b
R S 2 3 2 /R S 4 8 5
S erial 2 : 1 5 p ole
D -su b H D
R S 2 3 2 /R S 4 2 2 Q S T S p in d le
C o n n ector
E x t E th : R J4 5
E x tern al E th ern et R ela y O u t 1 2 p ole
P h oen ix
In t E th : R J4 5 4 R ela y O u tp u ts
In tern al E th ern et
2 4 V in p u t: 2 p ole
E S : 2 p ole JS T O p tion al A n yb u s
P h oen ix
P ow er S u p p ly fo r C C m o d u le
2 4 V in p u t
E th ern et S w itch on ly
9836 3521 01 33
System Architecture
2.3.1.2 TC Description
All indicators are located on the front of the TC.
LED s
H M I D is p la y
HMI
S o ft b u tto n s
The following LED indicators can be found on top of the TC and are common with the LEDs found on
PTCs.
OK is lit green when last cycle (tightening) performed by the TC was OK.
NOK is lit red when last cycle (tightening) performed by the TC was NOK.
ALARM is lit red when a servo or spindle hardware or system error has been detected on the TC.
To acknowledge the alarm the PLC variable RESET can be used, an attempt to acknowledge the
alarm is also performed automatically at each cycle start.
34 9836 3521 01
System Architecture
Sockets on the TC
The following picture shows the input and output sockets on the TC.
E m S top In : 1 2 pole
P h oen ix
E m erg en cy stop in
E m S top O u t: 1 2 pole
P h oen ix
E m erg en cy stop ou t
P ow er C on n ector
Q S T S pind le C on n ector
2 4 V In pu t 2 pole
In t E th : R J45
P h oen ix . 24 V in pu t
In tern al E th ern et
E S : 2 pole JS T
P ow er S u pply for
E th ern et S w itch on ly
9836 3521 01 35
System Architecture
2.3.1.3 The TC HMI Menu System

The TC HMI menu system provides a flexible and intuitive interface to configure and interact with
individual TCs. The TC HMI also shows the status for certain operations, these include downloading of
software, copying or restoring the setup from System TC to a Spindle TC and possible version conflicts
detected in the system.
Default Menu
The default menu contains two view items, you can select which view by pressing the up/down buttons
(the two middle soft buttons). Press the Setup button to go to the Setup menu and the Info button to go to
the information menu.
Default view
TC 01
Shows TC Number (Last
Setup Info digits of internal IP address)
T: 120.32 Torque view

A: 245.21
Setup Info Shows last measured Bolt T
and Bolt A
The torque and angle values shown are collected from the monitoring buffer – select the monitoring buffer
to use by adjusting the properties on the TC in the System Map, see chapter:
36 9836 3521 01
System Architecture
TC node. The selected default menu is remembered between TC restarts.
Setup Menu
The setup menu is divided into two groups Basic Setup and IP Setup. Press the Select button to enter a
settings group or press the Back button to return to the Default menu.
Basic Setup
Basic Setup
Basic settings for a TC
Select Back
Setup Menu – Basic Setup

IP Setup
The Basic Setup menu contains aIPnumber
Setup of settings. To browse between the settings press the
Up/Down buttons. ToBack
Select
edit a setting press the Change button, when editing it is possible to Store the new
IP Address settings for TC
value or Cancel the editing. The picture below shows an example editing the TC Number property on a
TC.
TC Number Edit Settings Example

31 Select Change to edit
Change Back
TC Number Edit Settings Example

32
Store Cancel Press Up/Down to Modify
Store or Cancel when done.
The following options can be set in Basic Setup.
Menu Description
System TC If a PTC is the System TC (option only available on PTC)
TC Number The TCs number (equivalent to the TCs last digit in the internal
IP-address).
Clear Setup Clear the setup stored in the TC
Restart TC Option to restart the TC
9836 3521 01 37
System Architecture
Setup Menu – IP Setup
The IP Setup is used to configure the IP addresses of the TC. PTC:s are equipped with two interfaces
(internal and external) whereas regular TC:s only have one interface (internal).
The following options can be set in IP Setup.
Menu Description
IF 1 IP Address IP Address for interface 1
IF 1 Net Mask Net Mask for interface 1
IF 1 Gateway Default gateway for interface 1
IF 2 IP Address IP Address for interface 2 (PTC only)
IF 2 Net Mask Net Mask for interface 2 (PTC only)
IF 2 Gateway Default gateway for interface 2 (PTC only)
Note:
It is possible to lock the display from the system node in the system map in ToolsTalk PowerMACS. If the
display is locked it is not possible to use the display to make any changes. Instead of the text Change in
the Setup menus it will say Locked. It is still possible to look at all the information, but nothing can be
changed. To unlock the display you must connect with ToolsTalk PowerMACS change the setting in the
system map.
Info Menu
The Info menu contains information about the TC, press the Select button to go to either events or system
information.
Events Menu
Events: 1
Lists system events
Select Back
Sys info System Information
Select Back Shows Information about TC
Info Menu – Events
38 9836 3521 01
System Architecture
The events menu contains all hardware and critical system errors that have occurred on the TC since the
last reset. When the ALARM led is lit on a TC the error message can be found in the events menu.
Show Event
Ev# 5094
DC Bus Low The event code and a short
10:36 Back
description is shown. The
time of the event is shown in
the lower left part of the
screen.
Press Up/Down buttons to

scroll between events.
Info Menu – Sys info

The System Information menu is grouped by TC, Servo and Spindle.
Information Menu Description

TC Info
System Type System Type (PowerMACS Tightening)
Appl Ver PowerMACS Application Version
Boot Ver PowerMACS Boot Version
PCB PCB Version
Hw Ver Hardware Version
Unit Serial No Unit Serial Number
Unit Art No Unit Article Number
TC serial No Serial number of TC board
IF1 MAC Address MAC Address of interface 1
IF2 MAC Address MAC Address of interface 2
Setup Name Name of currently loaded setup
Servo Info
Software Ver Servo Software Version
Boot Ver Servo Boot Version
Serial No Servo Serial Number
HW Ver Servo hardware version
Spindle Info
Software Ver Spindle Software Version
Boot Ver Spindle Boot Version
9836 3521 01 39
System Architecture
HW Serial No Spindle Hardware Serial Number
HW Ver Spindle Hardware Version
Serial No Spindle Serial Number
Type Spindle Type
2.3.2 Version conflict message

a system. The TCs themselves checks for version conflicts at start up and indicates this using the panel
on the their front and TTPM has several forms that can be used for the same purpose (see chapter:
Configure Target System and Check for System Conflict in the manual).
The information on the TC panel has been improved to better display to the operator that a Spindle TC
does not have the same software version as the System TC. When there is a version conflict with software
versions 7.3.0 or higher the Automatic download function takes care of that problem and the messages
shown is as described in the chapter Automatic Download.
If a Spindle TC with software version 7.3.0 or higher is inserted in a system with a software version prior to
7.3.0 then the following message is displayed on the TC panel:
Ver. Conflict Version conflict.

Syst. 7.3.0
Shows the version of the
system TC.
This message is only for information and shows the software version of the System TC, by using the up
and down arrows the TC panel could be used as usual.
Note: This message could also appear with Automatic download function as described in the chapter
Replacement of System TC and Backup TC.
2.3.3 Console Computer (CC)

The Console Computer is used for set up of the system and for monitoring and controlling using the
ToolsTalk PowerMACS program. It is optional for normal running.
The console computer comprises a standard IBM PC-compatible computer with Microsoft Windows XP
operating system (or later) and is not location dependent.
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2.3.4 Ethernet
Communication between the Console Computer and the Tightening Controllers or between two Tightening
Controllers is done with use of an Ethernet network. This runs with 100 Mbit/s and uses TCP/IP as
protocol. Physical media is 10Base-TX, i.e. twisted pair, max length 100 m. By use of commercially
available products it is possible to build a network with optically isolated components.
Via a router other computers in the factory can access the Console Computer. To isolate the PowerMACS
system from the rest of the factory (and vice versa) communication is done through an internal separated
network, only PTCs provides a second ethernet interface to be used for communication with external
equipment.
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2.3.5 Peripheral Devices

The following peripheral devices can be connected to the TC or Console Computer:
I/O device
Printer on CC (Console Computer running ToolsTalk PowerMACS)
Printer on TC
ID device
Communication via serial protocols
Communication via fieldbus interface
Communication from an external PC based application using the PowerMACS API, Application
Programmers Interface.
Except for the devices that are to be connected to the Console Computer, most devices can be connected
to any PTC tightening controller within the system. For a more complete description of peripheral devices
see chapter: Peripheral Devices.
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2.4 Automatic update of TC, Servo and Spindle

2.4.1 Automatic update Overview
a system. The TCs themselves checks for version conflicts at start up and indicate this using the display
on their front and ToolsTalk PowerMACS has several forms that can be used for the same purpose.
As from version 7.3.0 it is no longer necessary to use the TTPM to download new software to a replaced
TC in a system. When replacing a TC in a system the correct TC software would be downloaded
automatically to the replaced TC from the System TC or the Backup TC (TC2).The software that is
downloaded consists of the following:
The TC application software
The Servo application software
The Spindle application software

The automatic download function makes it possible to replace any TC in a system with a TC that has
different software loaded, and to automatically update the software in that TC with the same as the rest of
the system.
2.4.2 General function

The purpose of the Automatic Download function is to ensure that all TC in a system has the same
software version after a TC has been replaced. When a new TC is inserted in a system the version
handling function detects if the TC has a different software version. If the software in the replaced TC
supports Automatic Download (version 7.3.0 or newer) the download of new software is started when an
operator initiate it through the replaced TC:s panel.
The Automatic Download function is always enabled in systems that support it and consist of two or more
TCs. Normally all software updates is initiated by the System TC that uses its own software to update all
other TC:s in the system, if however the System TC is replaced it will be updated with the software from
the Backup TC (TC2) before any other TC is updated.
Before the replaced TC is inserted in the system it must be prepared by an operator to have the right TC
number and the right type (P or S). When a replaced TC with a different software version is detected the
following text appears on the TC panel:
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Fig 1.
Ver. Conflict Version conflict.

Is this a Replacement TC?
Yes No
Press Yes if this is
replacement TC. Press No if
not.
If the operator presses No, no software update is made and the TC panel shows the normal version
conflict text. (If the operator by mistake has answer No to the above questions the TC has to be restarted
(power on/off) in order for the questions to appear again.)
If the operator presses Yes, the following control text appears on the TC panel:
Fig 2.
Ver. Conflict Version conflict

Update Software?
Yes No
Press Yes if this TC should
be updated. Press No to
return to the previous level.
If the operator presses No, no software update is made and the TC panel shows the text in Fig 1.
If the operator presses Yes, the software downloads starts and the TC panel shows the normal download
information text. If by any reason the download process to any TC is interrupted by loss of power or
network error etc. then a TTPM must be used to update these TC since the Automatic Download function
would not be a part of the boot loader.
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2.4.3 Replacement of the System TC and Backup TC
If the System TC detects a conflict compared with the backup TC then this situation must first be resolved
before updating any other TC in the system. If the System TC detects that a backup TC with different
software version exists in the system then there is no possibility to automatically detect which TC that has
been replaced.
The solution to this is to show the above described text on both the System TC and the backup TC and let
an operator decide which TC to update.
Any other TC in the system will show the normal version conflict message as long as there is a conflict
between the System TC and the backup TC.
Note: It is not possible to download new software to the backup TC from a System TC that has no valid
setup.
2.4.4 Replacement of TC3 – TCn

If the System TC and backup TC contains the same software version and has a valid setup the System
TC continues to check for any software version conflict among TC3 – TCN. If one or several Spindle TCs
are found with a different software version the above described dialog appears on all the replaced TC. The
Spindle TC then starts to download the new software from the System TC by using functions provided by
the System TC.
Note: Since the System TC only initiates the download of new software any number of Spindle TCs could
download new software simultaneous without any interference from the System TC.
2.4.5 Updating a system with new software

As described in the previous chapter it would be possible to update a whole system with new software by
only download it to the System TC and then let the Automatic Download function update the rest of the
TCs in the system.
Note: For this to be possible the System TC must have a valid setup loaded.
2.4.6 Troubleshooting
If by any reason the download software process to any TC is interrupted by loss of power or network error
etc. then a TTPM must be used to update these TC since the Automatic Download function would not be a
part of the boot loader.
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2.4.7 Automatic Update of Servo software
When the TC is powered up a control is made to verify if the software that is running in the servo is
different than the servo software stored in the TC flash memory. If it is found to be different and older that
the software stored in the TC the servo is automatically updated with the newer version.
During the update of the servo software the following message is shown on the TC panel:
Updating Updating
Servo software
Indicates that the TC is
updating the servo
software..
It is also possible to downgrade a servo with software that is older than the version running in the TC. This
could be done by using the Configure Target function described in this release note.
Note: During the start and end of the servo updating the servo switches the power to the TC off and on.
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2.4.8 Automatic Update of Spindle software

When the TC is powered up or when a spindle is connected a control is made to verify if the software that
is running in the spindle is different than the spindle software stored in the TC flash memory. If it is found
to be different and older that the software stored in the TC the spindle is automatically updated with the
newer version.
During the update of the spindle software the following message is shown on the TC panel:
Updating Updating
Spindle software
Indicates that the TC is
updating the spindle
software..
It is also possible to downgrade a spindle with software that is older than the version running in the TC.
This could be done by using the Configure Target function described in this release note.
Note: If the updating of the spindle software should fail due to that the power is switched off or the spindle
is disconnected before the download has been completed, then the spindle needs to be updated manually
by using the Configure Target function.
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3 Basic Functions
3.1 Basic Functions - Overview
This part covers the basic functions, like how to handle windows and screen, security, help, etc.
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3.2 Windows
This chapter gives a general presentation of the parts of ToolsTalk PowerMACS and how to operate them.
Title bar
On top of the screen there is a title bar. In this you can see the name and version of the application
(ToolsTalk PowerMACS 7.3.0) and the name and version of the setup that you currently are working with.
If no specific setup is active <no name> is displayed instead of the system name.
Menu bar
On top of the screen, just below the title bar, there is a menu bar.
When selecting one of the menus it drops down and you can see a set of menu items or menu choices.
Tool bar
Below the menu bar you have a tool bar. This contains buttons to reach the most frequently used
functions of the system. You can move the toolbar to a different location by dragging the toolbar using the
grip-handle on the left side.
Status bar
On the bottom of the screen you have a status bar.
This is used by the system to show (from left to right):

Status fields (information from the system online, offline, errors, problems etc.)
Target (IP address of System TC)
Current user logged in (”Anonymous” if no one has logged in)
Current date and time
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Commonly used Windows controls
The following Windows controls are commonly referred to in this document:
Textbox – Holds text that you can either enter or change
Frame – Groups a number of controls that belongs together
Button – Carries out a command when pressed
Check box – Represents parameters of Boolean type, that is that either are True or False
Radio button – Represents multiple choices from which you can choose only one
Combo box – Another way to represent multiple choices from which you can choose only one
Spread – An Excel style control used to display table oriented data
Property grid – A list of properties for an object
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Handling of windows
With the menu View you can select which dockable windows you want to show and also if the toolbar
and/or the status bar should be displayed.
It is also possible to restore the factory default view from here and save your own view configuration..
If you have a number of windows on the screen at the same time you can get these rearranged in a
structured way. Use the menu choices Window-Cascade etc. Note that these options will not scale the
dockable windows.
The layouts of most windows are saved when ToolsTalk PowerMACS is closed and will be restored when
ToolsTalk PowerMACS is started again.
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3.3 Help
Function key F1
When running the ToolsTalk PowerMACS application you can get all information you need, by a press of a
button.
Whenever in trouble, press the function key F1
F1 activates the help system and displays information relevant the topic you are just using. This is called
context sensitive help.
Automatic Help Window

The automatic help window on the right side of ToolsTalk PowerMACS will automatically display detailed
help about certain items you are working on. For example it will automatically show the help text for the
selected step in the tightening window.
Help menu
It is also possible to get help by use of the Help menu. Contents bring up a list of topics with hyper links.
Site Specific Help presents information that is specific for the current site.
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3.4 The File menu

On the File menu you can find basic functions for ToolsTalk PowerMACS.
The items New, Open, Close, Save, and Save as are for handling setups. Convert is used to convert an
old setup to a newer version. Import and Export are also used in connection with setups. Handling setups
are described in chapter: Set Up and Maintenance.
Page setup and Print is used for printing of setups. See chapter: Printing.
Security, Login, and Logout is described in detail in chapter: Security.
Connect, Disconnect indicates if ToolsTalk PowerMACS is in contact with a running system. If you want
to work off-line, even though you have a connection, select this item to switch it off. See also chapter: How
to Start up.
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An MRU list (Most Recently Used) shows previous setups that have been opened recently. Select one of
these to get an instant opening of it, instead of using the Open item.
Use Exit to shut down the ToolsTalk PowerMACS application. If you have modified the current setup you
will be asked to save it first.
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3.5 How to Start up

Depending on what you want to do you start ToolsTalk PowerMACS in either Connected or Disconnected
mode.
If ToolsTalk PowerMACS was connected when it was last shut down it will try and reconnect to the same
system upon startup.
The Welcome screen

When ToolsTalk PowerMACS is first started it will present a welcome screen containing the most
common starting points for working with ToolsTalk PowerMACS.
From this window it is possible to select Create a new setup to begin working on a new setup in
disconnected mode, select Open an existing setup to open an already saved setup from disk. The option
Select a target system allows you to select the target system to connect to, to connect to the target
system most recently used select Connect to current target system. You can also select one of the
most recently used setups to open in disconnected mode.
If you do not want the welcome screen to be shown when ToolsTalk PowerMACS is started check the Do
not show this again checkbox before closing the window. The welcome screen can be enabled again in
the Setup -- Options.. menu.
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To edit a setup when Disconnected
This is how you start up when you want to check or edit a setup, without connecting to a running system:
1. From the File menu select Open, or from the welcome screen, select Open an existing setup
2. In presented file list, select an existing setup
If you want to create a completely new setup, select New from the File menu or Create a new setup from
the welcome screen.
To connect to the current target system

This is how you start up ToolsTalk PowerMACS when you want to connect to the current target system
(that is the system ToolsTalk PowerMACS was most recently connected to).
Using the welcome screen:
1. Make sure your console computer is connected to the network of the system in question.
2. Press the Connect to the current target system to connect.
Using the regular interface:
2. Press the Connect button on the toolbar.
To connect to a specified system

This is how you start up ToolsTalk PowerMACS when you wan to connect to a specified target system.
Using the welcome screen:
2. Press the Connect to system..
3. From the Select Target System window select the system.
Using the regular interface:

2. Press the down-arrow on the Connect toolbar button and select Select target system...
3. From the Select Target System window select the system.
If you want to download a setup to the target fist make sure it is loaded in ToolsTalk PowerMACS, either
by reading it from disk (menu: File – Open) or by Creating a new system using the Set Up Wizard (menu:
File – New).
Connecting to a system
When ToolsTalk PowerMACS connects to a system over the network the following can occur:
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If the setup version and the TC software version differ, you will be notified and if there is a solution to the
version conflict a solution will be suggested.
If there is no setup loaded in ToolsTalk PowerMACS the setup will automatically be fetched from the
System TC and ToolsTalk will connect normally.
If a setup is present in ToolsTalk PowerMACS and it is equal compared to the setup in the System TC
ToolsTalk will connect normally.
If a setup is loaded in ToolsTalk PowerMACS and it is different from the setup stored on the TC the
following dialog is displayed:
Select Write to TC to transfer the setup currently loaded in ToolsTalk PowerMACS to the target system.
The target will wait for any ongoing cycles to be completed before the setup is loaded. Should the cycle
not finish within time the download is canceled and you are informed.
Note! Selecting Write to TC will restart the target system. This may disturb any eventually ongoing
communication that the target has with other systems, for example over a fieldbus.
Select Read from TC to transfer the setup in the target system to ToolsTalk PowerMACS. Please note
that this will replace the setup currently stored in ToolsTalk PowerMACS.
Select Compare programs to compare the programs in the target system setup to the programs in the
ToolsTalk setup before deciding which setup to use.
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3.6 Viewing
If you have your console PC connected to the tightening controllers (connected), you can view several
items in the system. You can start View displays by use of the menu View or by pressing one of the
corresponding buttons on the tool bar.
3.6.1 Assembly Overview

The Assembly Overview displays current status of the system, its stations and bolts using a descriptive
picture of the object being assembled. You can easily add pictures as background for the system and the
respective station. See chapter: Assembly Overview Set Up form for instructions.
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The color of the items indicates the current status of the item.
Color Status
Green OK - Idle after OK cycle
Red NOK – Idle after NOK cycle
Orange NOKRM - Idle NOK only due to reject management after a cycle. For bolts only
Yellow Running cycle
Blue Bolt is disconnected. This color is only used if the checkbox Display disconnected bolts with blue
color in the Options form is checked.
If not checked then disconnected OK bolts will be green and disconnected NOK bolts will be red.
For bolts only
If you want more information on the stations or bolts, expand the box by clicking on the box of interest.
The information that is displayed in the different boxes and the size and position of them is set up using
the Assembly Overview Set Up form.
If you have several stations in your PowerMACS system they can all be displayed in expanded mode over
a common system background picture.
When a cycle is started, the station box and bolt boxes (for running bolts) are cleared of its result
information and the background is set to yellow. For bolt boxes of bolts that are not started the previous
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result information and background color remains. When the cycle is finished, the background color and
result information is updated.
In the case that the cycle is ended without any cycle data being produced (for example a sub cycle is
ended in a stitching cycle using PLC station output variable DATAHOLD); the bolt boxes background
color is updated to show the status of the finished cycle.
Note! The station box is still yellow to indicate that the complete tightening cycle is not yet finished and
that there is no result information in the bolt boxes. The reason for this is that the cycle data is not yet
produced by the system and therefore it is not possible to show any result information either. When the
complete cycle is finished and the cycle data is received, the station and bolt boxes are updated with
status and result information.
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3.6.1.1 Station Views

For a station, different background pictures and layouts of the station and bolt boxes can be used. The
currently selected Mode number triggers which so called Station View to display. The mapping between
Station Views and Mode numbers are done using the Assembly Overview Set Up form.
The Station View change is triggered by a change in the Mode number. That means that if the Mode
number is changed before a cycle is started, the Station View is also changed before the cycle is started.
Changing Mode number is done by using the PLC station output variable MODE (see Station variables). If
a cycle is running when the Mode number changes, the Station View is not changed until the cycle is
finished.
If the Mode number changes to a Mode number that does not map to any Station view (or the Mode
number is reset to zero), the currently shown Station View remains.
When the Station View changes, the status color and result variables of all station and bolt boxes remains.
If it is desired to clear these values, use the PLC station output variable RESETSTATUS (see Station
variables). A positive edge on this variable will cause all result information in Assembly Overview to be
cleared and set the background color of all station and bolt boxes to grey. The status information in the
System Map will also be cleared.
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3.6.2 System Map
The System Map gives an overview of all functional parts in the system. It can be used both as an
indicator of current status for all parts, but also as a navigation tool within the system. The default location
for the System Map is on the left side of ToolsTalk PowerMACS but it can be placed anywhere on the
screen.
When first started the System Map displays a page with the system shown in a tree structure. You can
expand and collapse the tree structure by pressing the small squares with + or -, or clicking on items.
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When connected to a system the Station and Bolt nodes will display certain colors depending on the last
status.
Color Status
Green OK - Idle after OK cycle
Red NOK - Idle after NOK cycle
Orange NOKRM - Idle NOK only due to reject management after a cycle. For bolts only
Yellow Running cycle
Blue Bolt is disconnected. This color is only used if the checkbox Display disconnected bolts with blue
color in the Options form is checked.
If not checked then disconnected OK bolts will be green and disconnected NOK bolts will be red.
For bolts only
Below the actual tree are the particular Details for the currently selected item listed. Use the Details
window to edit data for an item. By default the Details window is placed below the actual system tree but it
can be placed anywhere on the screen by drag & drop.
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Problems with equipment (hardware or devices) are indicated with a red cross over the icon. For certain
devices Online info is shown below the Details window.
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3.6.3 View Cycle Data
The Cycle Data window is used to display data from the tightening cycles.
The display shows the last cycle. When new cycles are added older cycles are scrolled upwards. By use
of the vertical scrollbar you can go back to earlier cycles. If the text is wider than the window, a horizontal
scrollbar appears.
If you press Hold the display is temporarily stopped. Cycle data are still recorded and when you release
the Hold by pressing the Hold button again the presentation will continue. Press Clear to clear the list.
Press Refresh to clear the list and retrieve all cycle data stored on the System TC.
If the Advanced button is pressed you can specify the format settings by pressing the Layout button, if
you want to present just specific cycles press the Settings button, the following frame will then appear
below the cycle data window:
Here you can specify if you want to present OK and/or NOK cycles, for specific stations and/or tightening
programs, or cycles with specific errors.
In the ID field write as many characters you like. All cycles that have an ID that contains the string of
characters will be displayed.
You can also present cycles between certain times, e.g. 99-12-31, 23:59..00-01-01, 00:01. Enter date and
time in the format your computer is set up for. Use “..” as separator between start and stop times. If you do
not enter any date, today is assumed. If you do not enter any time, start time is assumed to be 00:00 and
stop time 23:59.
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Note! To be able to filter out the results for a specific program you must have included the bolt level result
variable “Program” in the reporter named “Screen”. The result will include all cycles where at least
one bolt has executed the selected program.
Cycle data can be saved to file when pressing the “Get cycledata” button. Select a file to save the data to
or type a new file name. The data will be saved into this file with the extension .csv
The picture below shows the result when the file is opened with Excel. Please note that the file can have
different columns depending of the settings in the screen reporter.
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3.6.4 View Statistics

The Statistics window displays the statistical curves generated by the function "SPC, Statistical Process
Control".
First select with Station, Bolt or Spindle, Program, Variable, and Step what variable you want to study
the statistics for. Only values earlier configured for SPC using the SPC set up form can be displayed.
Then use the radio buttons in the upper right corner of the form to select which type of display you want.
The following types are available:
Average and Standard Deviation/Range curves for SPC and TDA
Average and Standard Deviation/Range curves for Short Term Trend
Histogram
With the cursor you can mark a specific part of the trace to zoom in. Place the mouse pointer on the upper
left corner of the area you want to enlarge. Press the left mouse button and drag the mouse pointer to the
lower right corner of the area to zoom in and release the mouse button. This will cause the graph to be
redrawn displaying only the selected area. Click on the right mouse button to zoom out.
When the mouse pointer is located over the graph area a box under it will display the value of the x and y
coordinates pointed at.
If you select All Bolts or All spindles the SPC diagram will show you SPC statistics based on data from
all bolts or spindles in a station weighed together to a measure of the station as a whole. Only variables
already set up for collection from this station are used when calculating the resulting values.
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If there is a subgroup, which has possible corrupt data, you can delete it. Click in the diagram on the
subgroup you want to delete. Press Delete Subgroup. This is possible only when the selection SPC and
TDA is active.
To the left current capability values are displayed. The window is automatically updated whenever a new
cycle is completed. Values displayed are calculated over same data as shown in the curve, for subgroups
or for short-term trend.
If Cp or Cpk is not presently within limits, a warning message is presented.
If you select Histogram you will be presented the following view:
This form displays the frequency distribution of the selected variable. The X-axis, displayed in the unit of
the variable, is divided in 20 classes scaled so that 25% of the screen is left of LTL, and 25% is right of
UTL.
The boundaries of each class are marked using dashed vertical lines where green indicates classes in
between LTL and UTL.
On Y-axis is shown the count of values with in each of the classes.
If you want to have the current view on paper, press Print.
The viewed statistics is updated cyclically when online.
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3.6.5 View Trace

The Trace viewing window is used to present the traces of current and prior cycles.
For each individual bolt's tightening cycle a trace can be generated and recorded. The maximum length of
a trace is 20 seconds. If a trace is recorded for longer time than 20 seconds the oldest values will be
overwritten with new samples.
The conditions for when a trace is started are configured under the general settings for each program.
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3.6.5.1 Select which trace to display

The controls in the top of the Trace viewing window is used to select which cycles to show traces for and
which quantities to show for these cycles. You can also save and open traces from both file and the TC.
Select cycle
Select the bolt you are interested in by use of the Station and Bolt fields. Select the spindle used to
tighten the bolt by use of the Spindle field. “All” means that the trace for selected Bolt is viewed
regardless of which spindle was used to tighten the bolt.
To view traces for a particular spindle, regardless of which bolt the spindle tightened, select “All” in the
Bolt field and then select the spindle in the Spindle field.
Quantities
Select which quantities you want to display for the trace by use of the three menus on the upper right side
of the trace viewing window (Bottom axis, Left axis and Right axis). You can study one or two different
quantities of the trace against a third quantity.
For the two vertical axis, the following quantities can be selected:
Angle - Views the recorded angle values.
Current - Views the recorded current values.
Current as T - Views the recorded current values scaled as torque using the values of the spindle
setup parameters Gear Ratio and T/C factor from when the cycle was executed.
Torque - Views the recorded torque values.
Gradient - Views the recorded gradient values.
Pos. Angle - Views the recorded angle values filtered so that all angle movements are positive, i.e.
the angle of the cycle is always increasing, even if the bolt was moving backwards.
Pos. Torque - Views the absolute values of the recorded torque values.
If Advanced view is enabled it is also possible to select the following for the second angle and torque
channels:
nd
Angle 2 - Views the recorded angle values for the second angle channel.
nd
Torque 2 - Views the recorded torque values for the second torque channel.
nd
Pos. Angle 2 - Views the recorded angle values for the second angle channel filtered so that all
angle movements are positive, i.e. the angle of the cycle is always increasing, even if the bolt was
moving backwards.
nd
Pos. Torque 2 - Views the absolute values of the recorded torque values for the second torque
channel.
For the horizontal axis, the following quantities can be selected:
Time - Displays values over sample time.
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Angle - Displays values over recorded angle.
Pos. Angle - Displays values over positive angle. All angle movements are positive, i.e. the angle
of the cycle is always increasing, even if the bolt was moving backwards.
If Advanced view is enabled it is also possible to select the following for the second angle channel:
nd
Angle 2 - Displays values over recorded second angle channel.
nd
Pos. Angle 2 - Displays values over positive second angle channel. All angle movements are
positive, i.e. the angle of the cycle is always increasing, even if the bolt was moving backwards.
For all quantities except angle and time, there may be gaps in the recorded values. For example when
spindle functional test is performed, torque values are not recorded. When the torque curve is displayed
on the graph, a small gap in the curve is shown when the spindle functional test was performed. Another
example is Gradient values which are only recorded when the restriction Gradient is active.
If Torque (or Pos. Torque) is selected, the torque unit displayed is the one used when the trace was
recorded. If many traces are displayed with different torque units, the torque unit for each trace can be
found in the identity list. This list is displayed by clicking on the button Identity>>.
The second torque and angle channels are only available when the following conditions are true:
Equipped on spindle and marked as enabled in the spindle setup.
Selected as included in the general program settings.
Note! The actual second Angle and Torque channel used is the channel that is not configured as
Monitoring channel (regular Angle and Torque channels).
Note! Collection of Secondary Torque and Angle channels in the trace must be enabled for each program,
this is described in chapter Program Settings.
Automatically updated traces

Under the View menu it is possible to select if the Latest trace should be automatically displayed or only
the Latest NOK or Latest NOK. When a specific trace is selected the choice is set to Selected.
Open and save traces

Using the menu Trace is possible to select a trace stored on the TCs or as a disk file on your PC.
To read a trace from a TC selects the Select from TC option from the Trace menu. This will invoke
the Select Trace form with which you can select not only one but several traces, and from one or
multiple bolts and spindles.
To read a trace earlier saved on disk select the Open file option from the Trace menu. This will
invoke a file selection dialogue in which you can select the file to display.
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If you see a trace that is interesting in some respect you can choose to save it, either in the TC or to a disk
file on your PC.
To save it in the TC, select the Save at TC from the Trace menu. This will cause the currently
displayed trace to be tagged for save which protects it.
To save it as a disk file select the Save to file option from the Trace menu. This will display a Save
As dialogue where you specify the name and the format of your file. Chose extension *.trc ("Trace
Files"), to save it in PowerMACS internal format, or extension *.txt ("Text Files"), to save the trace
as a text file. A trace saved in PowerMACS internal format includes all data of the trace and can
later be opened using the Trace|Open file alternative. A trace file stored as text only includes the
curves, the step boundaries (as a curve) and the cycle data printed as text. The curves are written
as columns, separated by a tab character, with each sample on an own row. This makes the text
file easy to import to, for example, Excel.
Reference trace
It is possible to save any displayed trace as a reference trace. The reference trace is stored by selecting
Trace | Save as reference from the menu. There can only be one reference trace on ToolsTalk
PowerMACS.
If a reference trace is stored it can be displayed in the background of all other traces by checking the View
| Reference trace option. The reference trace is displayed with more transparent colors than normal.
Show Program
It is possible to see which program that was used to run a trace stored on TCs or as a disk file on your PC.
The used program can be seen by selecting Trace | Show Program from the menu. The program is
shown in the form: Show Program from Trace.
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3.6.5.2 View of trace curves

In the middle of the Trace viewing window, the curves are plotted for the selected traces and selected
quantities.
Zoom
With the cursor you can mark a specific part of the trace to zoom in. Place the mouse pointer on the
corner of the area you want to enlarge. Press the left mouse button and drag the mouse pointer to the
opposite corner of the area to zoom in and release the mouse button. This will cause the graph to be
redrawn displaying only the selected area.
Click on the right mouse button to zoom out.
Scroll
When the graph is zoomed in, you can scroll the graph to be able to follow a curve. Place the mouse
pointer on the graph. Press the right mouse button and drag the mouse pointer while holding down the
right button. The graph is redrawn continuously while the mouse is moved.
Trace and sample details

Click on the link "Show Details" in the lower right corner to show detailed information about the trace and a
specific point on the curve.
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Under the heading Selected Trace, information about the currently selected trace is displayed. When
several traces are displayed (using the Select option to open traces from TC) you can use the buttons
and to browse through all traces. Note that two curves can be displayed for each trace.
In the identity list (displayed by clicking on the button Identity>>) more information can be found for the
trace.
Under the heading Selected Sample, information about the currently selected sample is displayed. To
select a sample, click with the mouse on the graph. The point on a curve that is nearest to the mouse
pointer is selected and marked with a black dot.
The information that belongs to the actual curve is displayed with black text. Other information about the
selected sample is displayed with gray text.
Use the buttons to fine tune which sample that is selected. The buttons and moves the point 10
samples backwards or forwards in the buffer. The buttons and moves the point only 1 sample
backwards or forwards. Use the button to toggle between the two quantities curves for the trace. In
the picture above, clicking on this button would move the selected point from the Angle over Time curve
to the Torque over time curve.
Use the checkbox Highlight if you want to study one specific trace among all the others.
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The curves of the selected trace are highlighted compared to the other traces. This makes it easy to study
a specific trace while still having several others displayed. Change the selected trace to highlight another
trace. This makes it possible to browse through all traces viewing them one by one.
Show Tightening limits and parameters

If you select Extras | Show from the View menu the form is expanded and displays controls that are used
to specify additional data to be displayed in the diagram.
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The following additional data may be added to the diagram:

Fail Safe limits
Restrictions
Checks
Monitor Limits
Control Parameters
Step Starts and Stops
To include any of the groups above in the trace check the corresponding checkbox. The respective limits
or parameters are displayed only if they are relevant with respect to the trace curves currently displayed.
Torque limits are displayed when Torque over Time curves are viewed, angle limits are displayed when
Angle over Time curves are viewed, monitoring limits and other checks that measure torque vs. angle are
displayed when Torque over Angle curves are viewed. The descriptions of Step – Control, Step –
Restriction, Step – Check and Bolt Monitoring describe if any limits are shown in trace and in what view
they are shown.
Note that limits and parameters are only shown for one trace at the time. Use the combo box "Show Limits
for trace" or use the buttons and under the Selected Trace heading to change the trace to show
limits for.
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Show Single Step
It is possible to view only one step at the time. Select Extras | Show from the View menu to bring forward
the Show Single Step frame.
Mark the checkbox "Show Single Step" and select which step number to show in the combo box.
If quantity Angle is used on either a vertical axis or the horizontal axis, you can select to show the step
angle instead of the cycle angle with the checkbox "Show Step Angle". The step angle starts at zero
degrees at the beginning of each step.
Note! The step is considered to begin at the step start time. The step angle is counted from this point also.
This may not be the same position as other parts of the system use for the start of the step. The positions
of limit curves may differ from what is expected.
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Show Cycle Data

If you select View | Extras | Show cycle data the lower part of the window is expanded and displays
more data. Press the Layout button to set up the layout of the cycle data. This will invoke the Trace
Reporter, see chapter: Edit reporter.
Match curves
When displaying several traces at the same time there are many reasons for the traces to differ on the
horizontal axis. Since this makes them difficult to compare it is possible to match the traces to each other.
Select View | Extras | Match conditions to display a frame where you can set up the match conditions.
If you select Torque, matching will be done where the traces have reached the same level of torque. The
level is specified in % in the field next to the alternative. If you e.g. specify 50% the traces will be matched
to where the individual traces have reached 50% of their maximum torque (for the first time).
For Time and Angle it is probably more interesting to set 100%, i.e. where they have reached their final
angle or time.
The scale of the horizontal axis will be set for the latest trace.
Use the sliders for minor positioning sideways.
With the buttons next to the sliders you can change color of the traces. Note that when two quantities on
the vertical axis are displayed, it is not possible to change the colors. You have to select one of the axis to
be Nothing.
By placing the mouse pointer over the button or the slider, a tool tip text is shown with identity information
about the trace. You can change the color by clicking on the color identifiers next to each slider.
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Identity of traces
Select View | Extras | Identify from the menu to display a list with identity information about each trace.
It is possible to change color of one or many traces at the same time. To change color of one trace, simply
click on the colored button to the left in the list. A color dialog is displayed where a new color can be
selected for the trace. To change color of many traces at the same time, hold down the CTRL key and
click on the traces to select them. Then click on one of the selected traces colored button to the left.
Note! It is only possible to change the color when only one curve is displayed for each trace, i.e. only one
quantity on the vertical axis is selected. If two quantities are selected, all curves for the quantity on
the left vertical axis will be displayed in red and all curves for the quantity on the right vertical axis
will be displayed in blue.
Print
Select Trace | Print from the menu to print the trace currently displayed.
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3.6.5.3 Select Trace

This dialogue is invoked from the View Trace form by selecting the Trace | Select from TC menu option
and is used for selecting one or several traces to display.
The list shows traces stored. By use of the Show traces for… frame you can select which traces to show.
In the ID field write as many characters you like. All traces that have an ID that contains the string of
characters will be displayed.
Hold down the CTRL key and select with the mouse the traces you are interested in. When you return to
the view window all the traces are presented in the same diagram, with different colors.
Normally traces are from the most recent cycles. Traces, which are tagged for save, will be saved
indefinitely. The save tag can be switched on and off by use of the Save/Unsave buttons for any trace.
Saved traces are marked by an S in the Save column on the left side of the window.
Due to the fact that traces consume quite a lot of memory only a limited number of traces can be saved.
When trace memory is full and new traces are produced the system will strive to keep the number of
stored OK and NOK according to the SRAM configuration (see chapter SRAM). This means that a new
OK trace will overwrite the oldest OK trace not marked for save, and vice versa for NOK traces.
Note! All traces, also the ones marked for “Save”, are deleted if the battery backed up memory is cleared,
for example when new System Software is loaded.
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3.6.6 View Tightening Path

The Tightening Path window displays how one or more bolts executed a cycle as a gantt chart. This layout
makes it easier to see how reject management procedures affected a cycle.
To display the tightening path for a cycle, either select a cycle data by pressing the Select Cycle Data
button or select one or more traces to compare.
In order to have the step type written for each step in the graph the Step Type cycle data variable must be
present in the Trace reporter.
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3.6.7 View Event Log

In the PowerMACS system events could happen that the operator should be informed of. These can be of
following types:
Event type Num. Id Example

General 0 Events that do not belong to any of the specific categories below.
Access 1 Operator log-in and log-out, failed log-in attempts
Power up 2 Restart of system
Emergency stop 3 Emergency or Machine stop of station
Checks 4 Tightening application errors, ”Torque high”, ”Angle low” etc.
System error 5 Abnormal situation, hardware breakdown etc.
Modifications 6 Changed parameter. Event contains additional information, like
parameter, station, spindle, program etc.
Hardware error 7 Hardware related errors, servo failure etc.
Software error 8 Internal communication errors, etc.
Ext. com. error 9 No response, too many retransmissions, etc., when communicating
with external equipment.
SPC 10 SPC events, "7 up", "7 down", etc.
Setup 11 Erroneous configuration detected during run mode, e.g. missing
parameters, etc.
All events are also classified by their Severity. Severity is one of the following:
Severity Num. Id Example

Info 0 Events that only informs the user of some activity, for example "Power
on".
Warning 1 Events that may indicate unexpected behavior, for example "Machine
stop".
Error 2 Severe errors in the system or events that indicate that cycle failed, the
error might be repairable.
Num. Id. above is the numerical identity of the respective Event Type. This value is used when events are
reported to binary devices. See Layout of Events for a complete description of the binary format of events.
All events are stored in an Event Log, which can be viewed using ToolsTalk PowerMACS.
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For each event the following information can be displayed (from left to right):
If the event is observed or not (a check mark if observed)
The severity of the event
The date and time when the event occurred
Number of the TC that generated the event (Optional)
The number of the station to which the event belongs (zero (0) if not connected to a particular
station) (Optional)
The number of the bolt (the user specified bolt number) to which the event belongs zero (0) if not
connected to a particular bolt) (Optional)
The Angle Channel if relevant (for restriction, check and monitoring events). Possible values are:
M Monitoring
C Control
1,2 Channel number
(Optional)
The Torque Channel if relevant (for restrictions, check and monitoring events). Possible values are:
M Monitoring
C Control
1,2,3 Channel Number (1-2 is torque transducers, 3 is Current As Torque)
(Optional)
The name of the program to which the event belongs (blank if not connected to a particular
program)
The type of the event
The event code of the event (Optional)
A textual description of the event
By default the Event Log window is docked on the bottom right half of the ToolsTalk PowerMACS main
window but can be placed freely.
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Events that have been dealt with can be marked as “Observed”. Select one or more events in the list and
press the Observed button. A single event can be marked by just double clicking it. An observed event
shows a red check mark in the leftmost column.
If you press the Setup button the Event Log Setup window is opened where you can specify which event
types and/or Severities to display. You can also include just events connected to a certain station, bolt, or
program.
Events may also be viewed and marked as observed per event type from PowerMACS PLC. See the
description of PLC Event handling in chapter: Advanced Station Settings for how this is enabled.
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3.6.8 View I/O signals
When ToolsTalk PowerMACS is connected you can display the current status of all digital inputs and
output connected to a particular TC. Use menu choice View-IO to open the IO Map form. (You can also
open it from the Hardware on the System Map form. Select the IO device for a TC and press
Advanced....)
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3.7 Reporter
The reporter is a very flexible and powerful tool that is used to configure which data to display and output
from a PowerMACS system. Reporters can be added, edited and removed from either the Reporter menu
item or the system map.
It can be seen as a function that helps you select various data from the system. It controls what data to
send to a particular device and how this data is formatted. The reporter itself is not able to output any
data; the device that the reporter is connected to does this.
Some devices, such as the ToolsTalk PowerMACS Screen, the ToolsTalk PowerMACS Printer, the
ToolsTalk PowerMACS File, and the Trace are considered to be logical devices that always exist,
meaning that you do not need to create reporters for these.
To output data via any other type of device, the device must first be added to the PowerMACS system.
See Add a device for how to do this. When the device exists you may create a new reporter, connect it to
the device and finally use the reporter to set up what data to report.
3.7.1 Predefined reporter settings

Files that describe predefined reporters are installed together with ToolsTalk PowerMACS. The files are
placed in special directories depending of the type of reporter. For example, API reporters are placed in
the directory "<ToolsTalk PowerMACS install dir>\Reporters\API" and screen reporters are placed in the
directory "<ToolsTalk PowerMACS install dir>\Reporters\Screen".
It is possible for users to make their own reporter files and place them in this directory structure. To do
this, simple export a reporter by using the Export Table form (invoked using the File - Export menu item,
see Table Export and Import). Place the exported file in the special directory for the Reporter type that
you want to use it for.
When adding a device in the File-New Wizard, the user is presented with a list of predefined reporters to
choose between. This list is built up by taking all file names of the files found in the special directory for
the type of device in question. The chosen reporter file will then be imported to the setup and used for the
device.
The list of predefined reporters is also available when adding a device from the System Map window. After
adding the device, the user gets the question if he wants to add a reporter. If the answer is yes, the list
described above is presented. Note that it is only reporters for the specific type of device that are
displayed. It is also possible to browse for and select a predefined reporter from the Reporters window.
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3.7.2 New reporter
To create a new reporter use menu item Reporter-New… or right click on the Reporters section of the
System Map and select Add Reporter. This will display a wizard that guides you through the creation of
the reporter.
From the list select which type of reporter you want to create:
Type Used for configuration of data…

ToolsTalk Printer to be printed on a printer using ToolsTalk PowerMACS (requires ToolsTalk PowerMACS
to be connected)
File sent to a file via ToolsTalk PowerMACS (requires ToolsTalk PowerMACS to be
connected)
Excel File sent to an Excel file via ToolsTalk PowerMACS (requires ToolsTalk PowerMACS to be
connected).
Printer to be printed on a (line) printer directly connected to a TC
PLC sent to inputs of PowerMACS internal PLC (defined in the CycleData_Var section of the
Global_Variables worksheet)
ID device sent to ID devices of type escort memory that are connected to the TC
Ext. Comm. Device available using external communication devices
Fieldbus available using fieldbus devices
API available using the PowerMACS API (Application Programmer Interface) for access by
other PC based computer applications via the network
ToolsNet sent to a Atlas Copco ToolsNet server
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You cannot create (or delete) reporters for the Screen, that is the ToolsTalk PowerMACS Cycle Data
window, or the Trace, that is the cycle data display in the Trace window. On the other hand, these
reporters are always available in the system.
If wanted, specify an additional name of the reporter. If you create a reporter of type Printer and you add
the name HP6P you can later find a menu item Reporter - Printer HP6P that corresponds to this reporter.
The additional name specified for a File or Excel File reporter is used as the name of the result file. For
each File reporter two files are created. The first have the character “1” appended to its name and the
second, which is created when the first file is full, the character “2”. When the second file is full then the
first will be overwritten. All files are created in the directory Log located in the directory where you to install
ToolsTalk PowerMACS.
The Excel File reporter can only be used if Microsoft Excel is installed on the PC that ToolsTalk
PowerMACS is running on. If Excel cannot be started the data is written to a text file with extension *.txt
instead. This text file is formatted in a format suitable for Excel. To import the text file from Excel follow do
as follows:
From inside Excel choose File/Open.
In the Open dialogue box select "Text files (*prn; *.txt; *.csv)" as "Files of types". Then select your
file and press Open.
In the Text Import Wizard - Step 1: Select "Delimited" in the frame marked "Original dat type" and
press Next.
In the Text Import Wizard - Step 2: Check "Tab" in the frame "Delimiters" and press "Finish".
Please note that if the destination Excel file is locked by another user ToolsTalk PowerMACS will fail to
write data to it. In these cases ToolsTalk PowerMACS will create a new file named
Name_DataWhenFileWasLocked_YYYYMMDD-HHMMSS".xls
where "Name" is the original name assigned to file and "YYYYMMDD-HHMMSS" is the current date and
time (example: "Excel1_DataWhenFileWasLocked_20020514-125932.xls"). The temporary file will be
used until the next time you go off-line.
When ready with the first page then press Next >> to display the next page of the wizard. If needed,
depending on the type of reporter, you will be asked for some additional information. For an API reporter it
looks like this:
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For most of the types you must select which device this reporter should connected to. The Device list box
displays all devices, of the relevant type, existing in the system. See Add a device for how to add new
devices if you need to that.
If predefined reporter settings files exists in the directory for the currently selected reporter type (see
Predefined reporter settings), you have the option to select predefined settings for the new reporter. If
you do not want this, leave the selection blank, which will create the reporter without any settings.
When ready, press Finish. A new window is displayed as if you had used the menu item Reporter-
Open… In this specify what data to collect and the layout.
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3.7.3 Remove reporter
You can remove a reporter by menu item Reporter-Remove…
Select a reporter and press Remove.

You can also delete reporters by right-clicking on them in the system map and select Remove Reporter.
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3.7.4 Edit reporter

The reporter is used to specify what data to collect for a device and the layout of the data when presented
on the device. All devices that should handle process data; Cycle Data, Events and Traces, must have a
reporter set up for it in order for any data to be output.
To edit a reporter select its name in the Reporter menu, e.g. Reporter – Printer 1... or double click on it in
the system map. This will open the following form:
Specify in the Station field, which specific station you want data from, or All stations if data generated by
all stations should go to the device. Use the Binary/Printable combo box to select if the data should be
formatted as binary or printable output.
The controls grouped under Collected data are used to configure what type of Process Data that should
be accessible for the device. Use them as follows:
Select if OK Cycles should be reported and for certain reporters the color to print them.
Select if NOK Cycles should be reported and for certain reporters the color to print them.
Select if Events should be included and optionally the color used for printing. More specific
filtering may be defined using the Reporter Preview
For binary reporters it is possible to preview how the generated data will be formatted.
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It is possible to adjust the preview according to a station and mode number. It is possible to hover with the
mouse above the individual fields in the address map to view the actual variable.
Advanced Event settings form.
Check OK Traces to include all traces with bolt status OK (only reporters capable of traces)
Check NOK Traces to include all traces with bolt status NOK (only reporters capable of traces)
Check Disconnected bolt included if you want such bolts to be included in the output.
For presentation on devices that can handle colors (the Screen and ToolsTalk Printer), you can also
specify the color you want the data to have. You may for example have events and NOK cycles shown in
red. (Traces can only be output in binary form therefore color is not relevant.)
For reporters of type File or Excel File the size, in Kbyte, of the resulting file is configured with the
parameter File Size.
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For the Screen, ToolsTalk Printer and Trace reporters you can specify which font to use. Please keep in
mind that you must use a font with fix width to make the variables be printed in columns (for example
when printing cycle data as table as described in chapter: Adding Cycle Data Variables.
Select Variables on the left side of the Reporter window to show the variables to include in the cycle data.
It is possible to select a predefined reporter by clicking the Load predefined settings… located under
Actions on the left side of the reporter window. The list with predefined reporters of the same type as the
currently configured reporter is displayed (see Predefined reporter settings), but it is also possible to
browse freely for any predefined reporter settings. If the chosen predefined reporter settings contain
parameters that are not available or configurable for the currently configured reporter the parameters are
omitted and fix parameters remain unchanged. An example is the trace reporter, which can never contain
station status. If predefined settings containing station status are applied station status will still not be
configured for the trace reporter.
3.7.4.1 Adding Cycle Data Variables

Select Variables on the left side of the Reporter window to show the variables to include in the cycle data.
Three list boxes with Station, Bolt and Step variables are presented here. To add a variable simply right
click on any of the list boxes and select Add variable from the menu – a list with possible variables will be
presented. It is possible to hold Ctrl and select more variables at the same time.
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Use the check boxes in the top of the form to select variables to present in the list. If e.g. the SPC
checkbox is marked the list will include SPC variables, otherwise not.
It is also possible to drag & drop variables from the Dynamic Tool to the three variable list boxes.
The Settings property grid shows the settings for the currently selected variable.
Setting Usage
Text Check this checkbox to include the variable name as a leading, or prompter, text. When using
table layout (Header text frequency > 0) then the variable name is always used as column header
regardless of the selection in this column.
No Of Specifies the number of decimals to print. Only valid for variables of numerical type and when
Decimals format is Printable (Data/Printable selected).
Width Defines the width of the field, in number of characters, in which the value of the variable is
printed. (left adjusted).
When using table layout (Header text frequency > 0) then the width must be big enough to cover
the variable name since it is used as column header.
When format is binary (Data/Binary selected) then Width normally should be left blank for all
numerical values variables. This will cause the selection in the Type column to control the width of
the field. However, specifying a value that is larger than the number of bytes implicated by the
Type selection will make the variable occupy the specified number of bytes. Data is then left
adjusted (the field is padded with NULL (0) characters).
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Type Controls the data type of the variable when printed. Valid only when format is binary (Data/Binary
selected). Takes the following values
I1 - Value is formatted as a one-byte integer. Any fractional part is truncated.
I2 - Data is formatted as a two-byte integer. Any fractional part is truncated.
I4 - Data is formatted as a four-byte integer. Any fractional part is truncated.
I8 and I12 - Data is formatted as 8 or 12-byte error/warning information. Only valid for the
bolt level result variables "Error", "RM Error" and "Warning". See also chapter: Errors and
Warnings.
F - Data is formatted as a four-byte Float (either as IEEE754, Fixed 2I2D, SPECIAL 1 or
SPECIAL 2).
Str - Data is formatted as a string. The setting of Width controls the number of bytes
occupied.
Step Specifies for which steps a variable will be printed. Only valid and visible for Step data variables.
Numbers Enter the step number of the step(s) for which the variables should be included. Leaving the value
blank will print the variable for all steps.
Note! Selecting a variable in the reporter will cause the variable to be included in the result. However, this
does not automatically mean that the variable will be measured. Most of the variables correspond to
values measured by bolt monitoring and step checks. Whether these checks are performed or not is
controlled by the Tightening program being executed. See Bolt Monitoring and Step – Check for
how to set up these.
3.7.4.2 Layout of Cycle Data

The controls grouped under Cycle Data Layout specify how the cycle data results should be presented.
The variables that can be included in the result are divided in three sections, Station data, Bolt data and
Step data. Station data variables are reported once for each cycle, Bolt Data variables once for each bolt
and Step data variables for each step in the program.
Normally the result is always laid out in a hierarchically manner, with the Station data at the top and the
Step data at the bottom, as below:
Station data
Bolt data for bolt 1
Step data for bolt 1, step 1
:
Step data for bolt 1, step n
Bolt data for bolt 2
:
Step data for bolt 2, step n
:
Variables that do not have a valid value, for example due to that the check that produces the value is not
executed or data from disconnected bolts, are said to have the value NOT_DEFINED. These are printed
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as “blank” (all spaces) when Data is set to Printable. With Data set to Binary all undefined numerical
variables are set to the value –32768 while text variables are set to an empty string, that is “”.
For a description of all variables see chapter: Result variables.
The parameter Type of layout controls how the printed result is formatted. Select one of the following
alternatives:
Standard. This generates a layout where the variables are formatted exactly as specified on the
Variables view (see Adding Cycle Data Variables).
Table. Formats the result as a table, that is, the variables are printed in columns with their
respective prompter texts as column headers.
Standard + Table. This layout is a mix of the previous ones where the station header is formatted
using the "Standard" layout, while bolt and step level result are formatted using the "Table" layout.
Fixed Positions This option gives you the possibility to have each of the variables at a fix position
in the result data. The output is similar to the Standard option with the following exceptions.
First the bolt level result variables are primarily ordered as defined in the variable view and then in
bolt number order. That is, the first bolt level result variable is printed for all bolts, then the second
bolt variable for all bolts.
Note that the bolts are ordered using the internal, ordinal, bolt number and not using the user
defined bolt number. A particular variable is always printed at the same position for a given bolt
regardless if the cycle result contains data for all bolts or only a few. Unused positions are filled
with zeros (0) if binary output selected and spaces if printable output is chosen. Should a cycle
result contain several data for the same bolt the most recently produced data is used.
Secondly, all step level result variables are disabled and cannot be included in the report.
Station level result variables are printed just as for the Standard option and all format options can
be used.
Since several stations in a system can use the same reporter the number of bolts per cycle data
can vary also if all bolts in the station are run. It is therefore possible to configure how many bolts,
or actually bolt positions, that should be used when the bolt result variables are laid out. The
Fixed pos. Layout parameter Report bolts on Advanced CD settings controls this.
This option is only available for the TC based reporters Fieldbus, Printer, API, ID device, Ext.
Comm., and PLC.
Static Offset. This format is similar to the “Standard” format but allows for offset specification of
where bolt and step data should begin. Configurations of offsets are displayed below Cycle Data
Layout when Static Offset is selected.
This format type makes it possible to divide a cycle data result into several blocks with areas
between where no data is written. Note that the offsets specified are relative to the start address
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of the targeted device output area.
It is possible to select where bolt data should start after the station data and how much each bolt
should occupy. Within each bolt it is possible to specify the same details for step data.
See Cycle Data layout example for examples of the different formats.
The parameter Header frequency controls when a header row is printed when the Layout option Table
th
or Std. + Table is used. The value 10 of Header frequency will generate a header for every 10 cycle data
printed.
Enter in the Additional new lines field the number of empty lines to print after that all cycle data has been
printed.
Using the Torque unit field you can specify the unit in which all torque results are to be presented. The
system will recalculate values before presentation. Set Standard if you want to keep the basic torque unit
set using the Options form invoked from the Set Up menu.
Using the Date format and Time format parameters you control how date/time variables should be
formatted when printed. Select "Standard" if you want to keep the format specified on the Options form.
For the ToolsTalk PowerMACS based reporters Screen, Trace, File, ExcelFile and ToolsTalk Printer, the
alternative "Reg. Settings" is available. Chose it if you want to use the date/time format configured using
Regional Options on your PC.
The effect of the selected date and time formats is displayed in the status bar at the bottom of the
Reporter form.
For reporters configured to format the result binary (Data/Binary selected) you can also:
Control byte order of all numerical variables. Set Byte Order to Normal to have the most
significant byte printed first, or at the lowest address. This is also known as Big Endian or Motorola
format. Select Intel to have the least significant byte printed first (Little Endian).
Control how real values are formatted. Set Float format to IEEE754 to print them as standard 32
bit floating point values according to IEEE 754.
Choose I2D2 to have them printed as a fixed-point value where the two most significant bytes
contains the integer part and the two least significant bytes the decimal part multiplied with 10000.
For the alternatives SPECIAL 1 and SPECIAL 2 the real value is first multiplied with 10 and then
rounded to an integral number before it is written. SPECIAL 1 prints the resulting value as a
Mitsubishi BCD value consisting of four consecutive bytes where the value 27.3 is written as 0x03,
0x07, 0x02, 0x00 with the first byte (0x03) at the lowest address. SPECIAL 2 prints the resulting
value as four ASCII decimal digits, that is, the value 27.3 is written as four bytes having the values
0x30, 0x32, 0x37, 0x33 ("0273") with the first byte (0x30) at the lowest address. Please note that
the value NOT_DEFINED is reported as the real value 999.9.
Control how the Station and Bolt level Status variables are reported using Status format. Choose
NORMAL to have them reported with values according to chapter: Statuses.
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Choose 1/0 (OK=1) to have an OK result, that is, OK and OKR, reported with value 1 (one) and a
NOK result, that is, NOK, NOKRM, and TERMNOK, reported with value 0 (zero).
Choose 0/1 ASCII (OK=0) to have the status using ASCII digits. An OK result is then reported as
the digit "0" (0x30) while a NOK result is reported as the digit "1" (0x31).
For all TC based devices you can control the order in which the step results are printed. This is done using
the Order steps by combo box on the Step data tab. Select Execution order to print the steps in the
order that they are executed and Step number to have them ordered in ascending step number order.
3.7.4.3 Cycle Data layout example
Standard layout
Configuring a reporter of type Printer with Type of layout set to "Standard", Additional new lines to 1
and the following result variables:
Station variables:
Variable Width No Of Text

Decimals
Station 8 Yes
Time 24 Yes
Status 9 Yes
<New Line>
Bolt variables:
Variable Width No Of Text

Decimals
Bolt No 8 Yes
Bolt T 7 1 Yes
Bolt A 7 Yes
Status 7 Yes
<New Line>
Step variables:
Variable Width No Of Text Step

Decimals Numbers
Step No 8 yes
Peak T 7 1 yes
A 3 yes
<New Line>
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Basic Functions
Will produce the following print out:
Station: Stn 01 Time: 011030 09:40:58 Status: OK
Bolt No: 1 Bolt T: 15.1 Bolt A: 435 Status: OK
Step No: 1 Peak T: 2.4 A: 125



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Table layout
Using the same variable settings but with Type of layout set to "Table" and Header frequency to 2 gives
the below printout:
Station Time Status Bolt No Bolt T Bolt A Status Step No Peak T A
----------------------------------------------------------------------------------------
Stn 01 011030 09:40:58 OK 1 15.1 435 OK 1 2.4 125
2 15.1 310
2 15.2 436 OK 1 2.5 124
2 15.2 312
Stn 01 011030 09:41:10 OK 1 15.1 435 OK 1 2.4 125

2 15.1 310
2 15.2 436 OK 1 2.5 124
2 15.2 312
Station Time Status Bolt No Bolt T Bolt A Status Step No Peak T A

----------------------------------------------------------------------------------------
Stn 01 011030 09:40:22 OK 1 15.1 435 OK 1 2.4 125
2 15.1 310
2 15.2 436 OK 1 2.5 124
2 15.2 312
Stn 01 011030 09:41:44 OK 1 15.1 435 OK 1 2.4 125

2 15.1 310
2 15.2 436 OK 1 2.5 124
2 15.2 312
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Basic Functions
Standard + Table layout
Using the same variable settings but with Type of layout set to "Standard + Table" and Header
frequency to 2 gives the below printout:
Bolt No Bolt T Bolt A Status Step No Peak T A
----------------------------------------------------------
1 15.1 435 OK 1 2.4 125
2 15.1 310
2 15.2 436 OK 1 2.5 124
2 15.2 312

1 15.1 435 OK 1 2.4 125
2 15.1 310
2 15.2 436 OK 1 2.5 124
2 15.2 312

Bolt No Bolt T Bolt A Status Step No Peak T A
-----------------------------------------------------------
1 15.1 435 OK 1 2.4 125
2 15.1 310
2 15.2 436 OK 1 2.5 124
2 15.2 312

1 15.1 435 OK 1 2.4 125
2 15.1 310
2 15.2 436 OK 1 2.5 124
2 15.2 312
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Basic Functions
Fixed Positions layout

Std. + TableSetting Type of layout to "Fixed Positions", the Bolts to report parameter to 5 (on the
Advanced CD settings form) and the following variable settings:
Station variables:
Variable Width Dec Text

Station 8 yes
Time 24 yes
Status 9 yes
<New Line>
Bolt variables:
Variable Width Dec Text

Bolt No 8 yes
<New Line>
Bolt T 7 1 yes
<New Line>
Bolt A 7 yes
<New Line>
Gives the following print out for a four-bolt station where only bolt 1, 2, and bolt 4 is executed when
printable format is selected:
Bolt No: 1
Bolt No: 2
Bolt No: 4
Bolt T: 15.1
Bolt T: 15.2
Bolt T: 15.4
Bolt A: 431
Bolt A: 432
Bolt A: 434
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Basic Functions
3.7.4.4 Reporter Preview
For binary reporters it is possible to preview how the generated data will be formatted.
It is possible to adjust the preview according to a station and mode number. It is possible to hover with the
mouse above the individual fields in the address map to view the actual variable.
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3.7.4.5 Advanced Event settings
Using the Advanced Event settings you can configure a filter for which events that should be sent to the
device and, for reporters configured to report data in binary format, how they should be formatted.
Events can be filtered on their type and their severity. In the Event types included frame, check the event
types you want to pass to the device controlled by this reporter. In the Severity included frame, check the
severities you want to pass to the device controlled by this reporter. See View Event Log for a description
of event types and severity.
In the Data included for event when printed binary frame, check the fields you want to include for each
event reported. See Layout of Events for a complete description of the binary format of events.
Include system events controls if events that do not belong to specific station should be reported or not.
3.7.4.6 Advanced CD settings

Given that you have specified a Header frequency in the Reporter form you can use this form to add a
header and footer to all pages of your cycle data.
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Basic Functions
Enter the text to be printed at the top of the document in the field Header on top of page/Text. For the
ToolsTalk Printer you may also use the Bitmap combo box to select a bitmap to be displayed as header.
Enter the text to be printed at the bottom of the document in the field Footer at bottom of page/Text. For
the ToolsTalk Printer you may also use the Bitmap combo box to select a bitmap to be displayed as
footer.
To be able to include your own bitmap you must first place the bitmap in the directory named Bmp located
in the directory where you to install ToolsTalk PowerMACS.
Using the fields Characters to be sent to the Reporter BEFORE the main data and Characters to be
sent to the Reporter AFTER the main data you can specify character strings that will surround each
cycle data result printed.
Here you may also include non-printable characters. Typing their ASCII code in hexadecimal format
enclosed by a "<" and a ">" does this. Example: To frame each cycle data with a start-of-text character
(STX), before the data, and an end-of-text character (ETX), after the cycle data then enter:
"<02>" in Characters to be sent to the Reporter BEFORE the main data
"<03>" in Characters to be sent to the Reporter AFTER the main data
Settings for Fixed pos. layout are only shown when the Layout option is set to Fixed pos. The
parameter Report Bolts controls how many bolts, or actually bolt positions, to use when the bolt result
variables are laid out when formatting the bolt variables. Leaving it empty will cause the number of bolts of
the station producing the result to be used instead.
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3.8 Security
PowerMACS contains a security system that prevents unauthorized access. All personnel must then be
registered as users with password and access level.
The access level makes it possible to allow personnel as a group or individuals to have access at these
levels:
No access at all
Read access
Read and write access
3.8.1 Registering groups

Use menu item File-Security-Groups to register a new group, to check or change data for an existing
group.
By default every setup contains one Administrators group that can not be modified or deleted. Users in
this group have read and write access to all ToolsTalk PowerMACS forms.
To remove a group, select the group in the list and press the Remove button. To change group data or
create a new group, press the New... or Change.. button. The following dialog box is opened
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Basic Functions
Enter the Group Name, use the controls located in the Set Access On All frame to set the access of all
forms to No Access, Read or Write. It is then possible to select access level for each ToolsTalk
PowerMACS window by selecting the access level in the Form Access list.
3.8.2 Registering users

Use menu item File-Security-Users to register a new user, or to check or change data for an existing
user.
The list contains current users.

To remove a user, select the name from the list and press Remove.
Press New… to add a new user.
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Basic Functions
The following dialog box is shown.
Enter Name, Password, and select Group. Press OK to register the user.
To change data for an existing user, select the name from the list and press Change…. The same dialog
box appears as for a new user. Change the data and press OK.
Recommendation: when security is used the group for user “Anonymous” must be changed from
Administrators to a group with lower access, preferable the group “No Access” should be used.
3.8.3 Login and Logout
When a new user is about to start to work with the system he should log in. This can be done in either of
the following ways:
Pressing button on the toolbar (if shown)
Using the menu item File-Login
At log in the following dialog box is displayed:
If the name and password is correct the user will be let in. The name of current user is presented on the
status bar, down to the right.
When the user is finished with his work he should log out to prevent other users from making any
unwanted changes. This can be done in the same way as for log in.
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Basic Functions
If no actions are made on the Console for ten minutes the system will make an automatic log out.
If you have made changes to the system and you log out you will automatically be asked to enter a
message in the Service Log. You will also be asked to save changes in the setup file.
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3.9 Printing
Use the menu item File-Print… to print the different tables in the setup.
First select the type of table you want to print in the combo labeled Table. This will display all tables of the
selected type in the Source frame.
Select one table by clicking on it.
If you want to print several consecutive tables, point on the first one, press left mouse button and hold
down. Drag the cursor over the table you want to print, and release the mouse button when on the last
one.
You can select several non-consecutive tables by clicking on these while holding down the CTRL key on
the keyboard.
Press Select all to select all tables of the selected type. Press Select changed to print all tables that have
been changed since last time they were printed.
When more than one table is printed each table is formatted and printed on a separate page.
Press Page Setup… to enter a dialog box where you can set up which printer to use, number of copies
etc.
When printing programs, you can also get a print preview or save the program as PDF.
Note! You can only print tables on a printer that is accessible from the console computer. Either directly
connected or via the network. It is not possible to reach a printer that is connected directly to the
tightening controllers in the PowerMACS system.
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Set Up and Maintenance
4 Set Up and Maintenance

4.1 Set Up and Maintenance - Overview
This part handles how to set up and maintain the system.
Note! Be careful when changing data in setups. If you are connected and your system is running, a
change will affect the system immediately when you press the Apply button in the current form.
Even though the change is activated in a controlled fashion between two cycles it might effect your
system in a way you did not intend.
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4.2 Setups and How to handle them

A setup is a group of data that completely describes how a system should work. The PowerMACS system
uses the information in the setup to know what to do. A setup can also be called a configuration. A setup
can be stored on the console computer in a file on a hard disk or on an usb memory stick. It can be
downloaded to the system, or uploaded for storing or modification.
Most items on the File menu handle setups.
Use the New item to create a completely new setup. This is described in chapter: Set up of a new
system.
With the Open item you open an existing setup, to alter or just to check. When you are ready with a setup
you can use Close to close the setup.
If you have opened a setup and made modifications to it you can save these to disk by selecting Save.
You can also rename it by using Save as. Then the original setup will be kept. This is also a fast way of
creating new setups by starting from a similar one.
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If you have a setup that is too old for the software in the TC, you can Convert it to a later version (see
section Backwards compatibility).
If you want to copy separate tables from one setup to another you can use the Export and Import
choices. This is described in chapter: Table Export and Import.
4.2.1 Backwards compatibility

Unless the setup version is identical to the version of the TC software, ToolsTalk will not connect to the
TC.
An old setup can be converted to a later version by clicking Convert in the File menu. Both the setup and
the PLC program can be converted to a later version. It is only possible to convert the PLC program if the
newer PLC environment is installed on the PC. Once a setup or PLC program have been converted it is
no longer possible to open it.
When running an old setup, ToolsTalk will emulate a ToolsTalk with the same version as the setup.
Functionality added after that version will be hidden and functionality removed after that version will be
shown. The versions of ToolsTalk and the setup are visible on the ToolsTalk title bar and in the About
form. It looks like the following images when a setup version 7.1.0 is opened with ToolsTalk 7.3.0.
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ToolsTalk is only able to emulate versions from 10.0.0 to the ToolsTalk version. Setups older than this
must be converted or an older version of ToolsTalk must be used.
4.2.1.1 PLC conversion

Note: When converting to a version older than 7.5.0, the PLC is not touched at all by the conversion
function.
When converting from a pre-7.5.0 setup to version 7.5.0 or newer, the following rules apply for moving
PLC variables from the shared area:
Inputs:
1. Variables mapped by any I/O device:
a. If name starts with “SI_”, variable is left in the shared area
b. else, variable is moved to the I/O area
Then, with the remaining variables in the shared area:
2. Variables mapped by fieldbus:
a. If mapped by any I/O device, variable is left in the shared area
b. else, variable is moved to the fieldbus area
Outputs:
1. Variables mapped by any I/O device:
a. If name starts with “SO_”, variable is left in the shared area
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b. else, variable is moved to the I/O area
Then, with the remaining variables in the shared area:
2. Variables mapped by fieldbus:
a. Variable is moved to the fieldbus area
Drivers for the I/O area and the fieldbus areas are added automatically if not already present in the PLC
program (the drivers are located in the “I/O Configuration” under “Physical Hardware” in the PLC)
Note 1: It is no longer possible to map an input to both I/O and Fieldbus at the same time. A signal
mapped to both I/O and Fieldbus will only be mapped to I/O after the conversion.
Note 2: It is only possible to map an output to both I/O and Fieldbus at the same time if the name starts
with SO_. A signal mapped to both I/O and Fieldbus with another name will be moved to the I/O area and
is thus no longer possible to map to the Fieldbus.
Note 3: It is no longer possible to remap the individual elements of an array to the Fieldbus, only the
whole array can be remapped. If an array is used and some elements have been remapped the whole
array will be moved to the Shared_Variables group and removed from the Fieldbus mapping. This means
none of the signals in the array will be available after the conversion. If wanted the whole array can be
moved back to the fieldbus, but it will NOT be possible to remap the individual elements to get back to the
old mapping used before the conversion.
4.2.1.2 Compatibility between PM4000 Tightening and Gauging

PM4000 Gauging can read a Tightening setup from file and convert it to a Gauging setup but not vice
versa. A setup converted to a Gauging setup is no longer possible to open with PM4000 Tightening.
4.2.1.3 Upgrade of PLC environment

The PLC part of a setup is handled by a separate program called Multiprog. This program is upgraded
much more seldom than the rest of PM4000 and it is also backwards compatible. A newer Multiprog can
read an older PLC program and convert it to the new version. An older Multiprog cannot read a PLC
program created by a newer Multiprog.
Two versions of Multiprog are currently included in the installation kit for PM4000. For Windows XP it is
recommended to use Multiprog 4.6. For Windows Vista or later Multiprog 5.3 must be used. To open a
setup that have a PLC program of version 5.3 Multiprog version 5.3 must be used also when running on
Windows XP.
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4.3 Set up of a new system

After you have decided what physical hardware you will have in your new system you should make a
setup. A setup is a file, which contains all information that is needed for the system to execute its task
properly.
You can create a new setup disconnected on any PC computer. Disconnected means that you are not
connected to the actual hardware. When you are ready to run you set up a PC as console computer (CC)
on the same network as the hardware and connect. Your PC gets in contact with the hardware and
downloads the setup.
Note! You should take as a rule to always create a new setup using the Wizard since it automatically
generates a setup that not only is valid but also contains a PLC program.
4.3.1 Creating a new system using the Set Up Wizard

A wizard will guide you through the creation of a completely new setup. Select menu item File-New…
A wizard is a set of dialog boxes that will lead you through the creation process. If you change your mind
you can always go back with use of the Previous button.
Enter a name for the system, the number of stations you will have in it, and for which version you want to
create it. You should choose the same version as the software in the TC you are going to send the setup
to.
Press Next >>. A new dialog box is presented.
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Enter the number of bolts and spindles you want to have in the first station using the fields No. of Bolts in
the Station and No. of Spindles in the Station.
Enter in Default Spindle type that you have in your system. If you have more than one type, select the
alternative you have most of. You can later individually change these values.
Press Next >>. This will display the following dialog:
Here you may change the names of the bolts.

Press Next >> to be displayed the dialog where you may alter the names given to the spindles:
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Here you may also change the type of the spindle and the TC corresponding to it.
Press Next >>. If you specified fewer spindles than bolts in the second wizard dialog you will be displayed
the following dialog:
Use the combo boxes in the Spindle column to select the spindle to be used to control each of the bolts.
Press Next >> to display the next wizard dialog.
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Enter the number of modes you want to have in the Mode table for the station (max is 50) and press
Next >>. This will present the following dialog:
Specify programs for the number of modes selected. You can select predefined programs located in the
installation directory for ToolsTalk PowerMACS under the subdirectory Programs.
Checking the Generate SPC Setup check box will configure the SPC function to calculate SPC data for
the variables Bolt T and Bolt A.
When done press Next >>. This will cause this dialog to be repeated once for each mode you specified in
the previous wizard dialog.
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If you specified more than one station in the system the wizard will repeat the sequence above from dialog
two for each station.
In the next step you can add and set up devices that you will have in your system. Devices are used to get
information in and out of the system, like printers, fieldbuses etc.
In the list box all stations and devices are presented.

If you want to change the name or any other parameter for a device, select the device and press Edit.
To remove a device, select the device and press Remove.
To add a device, select a station and press Add. A form is presented where you can select what type of
device you want to add.
Devices must be set up to work properly. When you press OK a form is presented where you can set up
various parameters.
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What data to enter depends on type of device. All parameters come up with default values. If you know
what exact values you will have, you can change the values now. You can also wait and change values
later, with use of the System Map.
A Reporter is used to format the output of cycle data. Mark the Include checkbox if you want a Reporter to
be automatically created for this device. Also specify if you want reporter data for just This station or for
All stations.
If predefined reporter settings files exists in the directory for the currently selected reporter type (see
Predefined reporter settings), you have the option to select predefined settings for the new reporter. If
you do not want this, leave the selection blank, which will create the reporter without any settings.
When you have specified all data for all stations included in your system, press Next >> to display the
next wizard dialog.
If you have more than one predefined reporter settings file for the Screen or Trace reporter (see
Predefined reporter settings), the following dialog will be displayed:
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Here you can select which predefined reporter settings that will be used for the Screen and Trace reporter.
Note that it is not possible to leave these selections blank.
Note that this dialog is only displayed if you have placed more than one file in the special directory for the
reporter in question. By default, this dialog is not displayed.
Press Next >> to display the last wizard dialog:
Mark boxes if you want a Checklist on printer or Checklist on file. In the latter case you can specify a
filename. The checklist will contain a list of activities that you should perform after that the initial setup is
created.
Pressing Finish will make the wizard create the new setup based on the information you have specified.
The following items will be included in the setup created:
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Spindle and bolt setup‟s, one for each item specified.
Specified programs.
A mode table for each station specifying the programs you have selected.
SPC configured for measuring the final torque and angle for each of the bolts.
A reporter for the ToolsTalk PowerMACS screen and a printer connected to the CC.
A PLC project containing one POU (Program Organization Unit) and one resource, with one task,
for each station defined in the system. All POU's are copies of a predefined POU template.
The setup is complete in the sense that it will be possible to execute. It will therefore be a good starting
point for your own application.
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4.4 System Map

The System Map by default docked on the left side of ToolsTalk PowerMACS main window is the place to
check and alter the system configuration (setup).
You can expand or collapse the tree structure by clicking on an item or clicking in the small squares with +
and -.
When you select an item in the tree the Details window is updated with relevant data for the selected
item, for more complicated items an Open... button is displayed that will open an item specific dialog. You
drag and resize/place the Details window as you feel most comfortable.
Data in fields with white background can be changed. Press Apply to save changes into the setup.
Note! If you are on-line the changes will affect the running system.
The items that make up a system are divided into two parts, the logical structure and the hardware
structure. The logical structure is displayed directly under the root node (System node), the hardware
structure is located under the Hardware item.
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To add or remove items simply right-click in the system map. However, even though it is possible to
add/remove logical items, such as stations and bolts, displayed on the System tab it is recommended that
you use the File-New Wizard (see chapter: Creating a new system using the Set Up Wizard) when doing
major structural changes to your system.
4.4.1 Logical view

The nodes under System, displays the logical items in the setup.
The System is displayed in a tree structure with the System node as the root element. The next level
contains all the Stations as well as the Program and Reporters folders.
Each Station contains the Mode table and all Bolts controlled by the Station.
The Programs and Reporters folders contain all programs and reporters that are defined in the setup,
these are available to all Stations within the system.
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4.4.1.1 System node

Select the System node by clicking on it using the mouse. This will make all properties of the System to be
displayed to in the Details window.
Use the Name field to change the name of the System. It identifies the system, and setup, and may be up
to 20 characters long. The name will be displayed when you scan for System TCs on a PowerMACS
network (see Select Target System).
When Unlock TC panel is checked it is possible to use the TC panel to make settings and changes,
otherwise the panel is locked and it is only possible to view information.
If Backlight auto off is checked the backlight of the TC display will go off after one minute of inactivity,
otherwise the light will always be on. If a button is pressed or if the information on the display changes the
light will always switch on.
The setting of Enable display settings and Backlight auto off effects all TCs in the system.
4.4.1.2 Station node

When selecting a Station node many of its properties are in the Details window.
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See chapter: Station Set Up for a description of the parameters.
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4.4.1.3 Bolt node

Select a Bolt node to display the most common properties of the Bolt.
Use the Name field to change the name of the Bolt. This name will identify the Bolt in cycle data reports,
etc. and may be up to 20 characters long.
The number entered in the Bolt number field may be used as a more compact identifier of bolt (in
addition to its name). This number may be included in the reports as the variable "Bolt No" (see Bolt level
result variables). The number must be unique within the station and within the range [1..9999].
With Bolt Status combo box you can control whether or not the bolt is connected, i.e. used by the system,
or disconnected. In the latter case you can also chose if it should be reported as OK or NOK.
Bolt type is a free text that identifies the type of the bolt. This information is used for the result variables
Total Type, Total Type OK and Total Type NOK, see chapter: Bolt level result variables.
Use the Spindle combo box to select the default spindle to use to tighten the bolt. Note that this is only
the default selection. A bolt may use different spindles in different modes. See chapter: The Mode Table
form for how to configure this.
Specify to which reject management group, or groups, the bolt belongs using the RM Group field. Enter
comma separated numbers (1, 3, 5), or intervals (1-5). See "Group" in chapter: Glossary for a definition
and Step – Rejects for how it is used.
4.4.1.4 Programs node

Clicking on the Programs node will in fold/unfold a list all programs defined in the system.
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A program can be opened in The Tightening Program form by double clicking it or right clicking and
selecting Open Program, to remove a program right click and select Remove Program.
4.4.1.5 Reporters node

Clicking on the Reporters node will in fold/unfold a list of all reporters defined in the system.
A reporter can be opened in the Reporter form by double clicking a reporter or right clicking and select
Open Reporter. To delete a reporter right click and select Remove Reporter.
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4.4.2 Hardware node

The Hardware node of the System Map contains all hardware in the system, this node is the primary
resource when configuring or monitoring the hardware configuration.
The tree level below Hardware contains a list of all TCs in the system.
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4.4.2.1 TC node
The TC node represent a TC in the system.
For each TC it is possible to change name and select which monitoring buffer to use for the TC HMI:s
Torque and Angle values.
By default the internal and external Ethernet ports are configured from the TC front panel. If Configure
external eth is checked the external Ethernet port will be configured based upon the IP Address, Net
mask and Gateway provided here.
Note 1: A setup with Configure external eth checked can only be downloaded to one specific TC in a
network. If downloaded to several TC‟s all will get the same external IP address, which will lead to an
address conflict in the network.
Note 2: There can only be one gateway specified in a TC. If a correct Gateway is specified (not 0.0.0.0)
the internal Ethernet gateway will be disabled (set to 0.0.0.0).
Under each TC all devices connected to it are displayed as leafs. Normally all TCs have a Spindle device.
To the right of each TC it says which station the TC is running under and whether it is a Station TC
(indicated by an asterix as prefix to the station name).
In addition to the spindle device you might add devices as you need them. The PowerMACS system
supports numerous types of devices. To add a device to TC first select the TC to which you want to add a
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device and then right click and select Add Device. This will bring up the Add Unit form in which you select
the type of device to add.
Most devices that should handle result data require a Reporter to function properly. The Reporter controls
what data that is reported over the device, and how it is formatted.
For devices that must have a Reporter, a Reporter is added automatically. For devices that can have a
Reporter you will be asked if one should be added. In both cases, if a predefined Reporter exists for the
device type added, you will be offered to choose one of them (see Predefined reporter settings for how to
add your own). If a reporter is added it must also be configured. See chapter: Edit reporter for how to do
this.
When ToolsTalk PowerMACS is online the TC popup menu contains a Manage Software alternative.
When this alternative is selected the Software Versions form is opened.
This form lists the running software versions for the Servo and Spindle and also the software versions
stored in the TC:s flash memory. The servo and spindle software is not automatically upgraded – you
should always verify with the release notes if it is necessary to upgrade the servo or spindle software.
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Note! Upgrading the spindle software might require re-programming of spindle parameters and motor
tuning.
4.4.2.2 Spindle node

Select a Spindle node to display the most common properties of the Spindle.
Use the Name field to change the name of the Spindle. This name will identify the Spindle in cycle data
reports, etc. and may be up to 20 characters long.
Use the Spindle type combo box to change the type of the used spindle.
Note! Changing spindle type will reset all spindle parameters to their default values. Any changes done
compared to the previous types default values are lost.
Press the Open… button or double click on the spindle node to access the Spindle Set Up form that
enables full access to all the spindle parameters.
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4.4.2.3 Other device nodes

Selecting any node of any other device type will display the parameters of the selected device type.
For most devices all parameters are displayed in the Details window.
Devices that have many parameters make use of a specific form to access these. For such devices an
Open… button is displayed. Press this button to open the device specific form.
The basics of these devices are described in the Peripheral Devices chapter.
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4.5 Station Set Up

Select a Station node object on the System tab and make sure the Details window is visible to display the
parameters available for a Station.
The name entered in the Name field defines the name of the Station. It will identify the Station in cycle
data reports, etc. The name may be up to 20 characters long.
The Advanced Reject Management if… settings are described in the functional description for
Tightening, see chapter: Advanced RM Actions.
Normally the Hold Torque step stop condition (see Tightening Program chapter: Ramps & Other – Other)
is automatically disabled for all bolts when a step fail on any of the bolts involved. This is done to avoid
overheating the motors. If it is absolutely necessary the torque may be maintained also during the reject
management phase. Check the Allow hold torque also during RM checkbox to do this.
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Note! Allowing hold torque during RM dramatically increases the risk of burning the motors!
Report Cycle Data at emerg. stop controls whether or not cycle data is reported for a cycle interrupted
by an emergency stop (caused by setting the PLC variables EMERGSTOP or MACHINESTOP, or if the
Station loses communication with one or more of its TCs). Uncheck it to automatically drop all result data
for such cycles.
With the Automatically restart TC on fatal errors parameter you can control whether or not the TCs
used by this Station should reset themselves if they run into an unrecoverable software error. If the TC
running the Station controller is automatically restarted it will always set its own status, and the status of
all its bolts, to NOK to make sure that a NOK cycle is not reported as OK by accident. This is done also if
the Station was not running a cycle when it restarted. All TCs that is restarted due to a fatal error will
generate an event in the event log when they do so. More detailed information on the error causing the
restart can be retrieved using the TC Crash Log.
With the Disconnect bolts that fail to start parameters the Station can be configured to automatically
disconnect bolts that cannot be started either due to a communication error (Ethernet) or a servo error.
Set Max no. of bolts to disconnect to the maximum number of bolts that may be disconnected
automatically due to communication or servo errors. Possible values are between from zero up to the
number of TCs in the Station minus one.
The radio buttons Select Disconnect with status OK and Disconnect with status NOK controls with
which status the bolts are reported if they are disconnected.
Note! It is not recommended to use the Select Disconnect with status OK choice since it will
cause non-tightened bolts to be reported as OK.
As long as the total number of automatically disconnected bolts is less than Max no. of bolts to
disconnect the event "Failed to reach TC. Bolt is disconnected (OK/NOK)" is generated for each TC that
cannot be contacted. When the maximum number of disconnects has been reached the event "Station
has no contact with spindle X" is generated for each additional failing bolt.
If at least one, and less then or equal the maximum number of allowed, bolt(s) have been disconnected
the event "Station starts the cycle even though X spindles could not be reached" is generated.
For each bolt that is disconnected due to servo failure during initialization the event "Failed to init servo.
Bolt is disconnected (OK/NOK)" is generated.
Press the Open… button to open the Advanced Station Settings form for additional settings, alternatively
you can right click on a station and select Advanced Station Settings from the popup menu.
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4.5.1 Advanced Station Settings

The Advanced Station Settings form is invoked by pressing the Open... button in the System Map when
the selected node is a Station, alternatively it is possible to right click on a station and select Advanced
Station Settings from the popup menu.
From this form you can set up which ID device to use as the Stations standard Work piece identifier
(Wp ID), configure the Multiple identifiers function, and control its PLC Event handling.
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4.5.1.1 Work piece identifier
The Work piece identifier (Wp ID) function makes it possible add an identifier string read from an ID
device, for example a barcode scanner, to the result data as the result variable "Wp ID" (see Station level
result variables).
Use the Device combo box to select the ID device this station should use as source for the Wp ID
function. The combo box lists only the devices that already exist in the system. See chapter: Add a device
for how to add a new one.
The identifier string read from the selected device is also available in the PowerMACS PLC as the input
CURRIDSTRING.
By adding a Conversion table... you may have the identifier string automatically translated to a numerical
value, or code. This code is then available to the PLC as the input IDCODE and can, for example, be used
for selection of which mode to run. See chapter: ID device variables for a description of the respective
PLC variables.
Note! The work piece identifier can not be used if the station has an AudiXML device attached.
4.5.1.2 Multiple identifiers

Using the Multiple identifiers function PowerMACS can handle up to six different types of identifier strings,
supplied from the same or different ID devices.
The Multiple identifiers function does not only add received strings to the result data, it can also be used to
differentiate strings supplied from one source depending on their data and/or control in which order they
are accepted.
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The Multiple identifier function can be monitored and controlled from the PowerMACS PLC using its
Multiple identifier variables.
Multiple identifiers are defined in two steps using Identifier types and Result variables.
Identifier types
An Identifier type is a string supplied by an identifier Source, that is, a device that supplies the identifier
data, and fulfills an optional match condition.
Any of the systems ID devices but the one configured for the Work piece identifier function can be used as
Source. In addition to the ID devices, the six PLC outputs PLCx_IDTYPE_STR (see chapter: Multiple
identifier variables) can be used. These make it possible to supply identification data from other device
types, for example fieldbus, API, etc.
It is not possible to use an id device or the six PLC outputs PLCx_IDTYPE_STR together with an
AudiXML device. If the station has an AudiXML device attached, possible input sources for the identifier
types will instead consist of AudiXML identifier tags TNR, PRT, PI1, PI2, STC and WID.
The match condition is specified using the Length parameter and the combination of the Significant
position and Significant string parameters. For a string to match it must fulfill all the following rules:
If a Length is specified then the incoming string must have exactly Length characters to pass.
Leave empty to accept strings of any length.
If Significant position and Significant string are non-empty then the specified character position
are first picked out from the incoming string. These must then match the regular expression
specified by the significant string (see chapter: Conversion table for a description of regular
expressions). Leave empty to accept all strings regardless of their content.
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For Identifier Type 1 up to twenty significant strings can be specified using a Conversion table. Aside from
that each of these strings are tested, one by one until a match is found, the same matching rules applies.
With the Conversion table it is also possible to have the matching identifier string automatically converted
to a numerical value available in the PLC as input IDTYPE_1_CODE (see PLC chapter: Multiple identifier
variables).
If the same source is used for more than one Identifier type and the respective match conditions does not
guarantee that an incoming string matches only one of the types then a rule must be set up for in which
order the Types are assigned. Press the Work Order... button to open a form where this can be done.
The Identifier type strings are not directly available in the result data produced by a cycle. They are
however available in the PLC for evaluation.
Work Order
A Work Order is useful when PowerMACS should receive the Identifiers in a given order and/or to resolve
in which order the received strings are assigned to the Types if they are ambiguously defined.
The Identifier types included in the Work Order must be received in the order that they are listed to be
accepted.
If there is at least one Type in the Work Order list the Multiple identifier function will always try to match
this Type before testing any type outside the Work Order.
The Work Order is said to be passive until its first Type is accepted. When this takes place the Work Order
becomes active.
While the Work Order is active then only an input string that matches the next, not already accepted, Type
in the Work Order list is accepted. All other strings are neglected even if they would have matched another
Identifier type.
When the last Type of the Work Order list is accepted the Work Order sequence is completed. This will
put the Work Order in passive mode, waiting for the first Type again.
Types that are not included in the Work Order may be received, and are accepted, in any order as long as
the Work Order is passive.
Types that are not uniquely defined, meaning that they use the same source and have match conditions
that does not ensure that only one of them match a given input string, should be included in the Work
Order. The Work Order then controls in which order received input strings are assigned to the respective
Type.
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Note Using ambiguous Types makes the operator, or overriding control system, responsible for
supplying the identifiers in the expected order.
The values of the Identifier Types included in the Work Order are not available to the Station as long as
the Work Order is active. On completion, all Identifier Types of the Work Order are sent to the Station and
its PLC.
Should the Work Order become active again after completion (by receiving the first Type in the list) then
all Identifier Types of the Work Order are reset.
The values of the Identifier Types which are not included in the Work Order are available to the Station
and PLC immediately when accepted.
The Multiple identifier function is reset, meaning that the values of all Identifier Types are cleared, when a
cycle is started from the PowerMACS PLC. That is, accepted identifiers can only be used once. To include
them in a following cycle their respective source must be initiated to generate the string again.
Result variables
To include the data of an Identifier Type string in the result data it must be mapped to one of the six
Result variables. Each of these result variables is represented in the cycle data by one of the for Station
level result variables "ID Res 1" to "ID Res 6" (all 40 character strings):
This is done by selecting the wanted Identifier Type as source for a particular result variable in the Result
variables frame. One Identifier Type can be used as source for more than one result variable.
Use the optional Significant position filter to select which character positions of the Identifier Type string
to transfer to the result variable.
The values of the result variables are sampled when the cycle is started from the PLC.
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4.5.1.3 PLC Event handling

The Advanced Station Settings form also enables you to configure which type of Events that should be
possible to mark as observed from the PowerMACS PLC using the outputs named ACKxxxEVENT.
Only the types checked in the Event types possible to mark as observed from the PLC frame will be
possible to acknowledge from the PLC.
From inside the PLC it is possible to see for which event types there exist unobserved events in the Event
Log. This information is available via the inputs xxxEVENT (SPCEVENT, ACCESSEVENT, etc.).
See View Event Log for a description of the different Event types and the PLC chapter: Station variables
for a description of the PLC inputs and outputs.
4.5.1.4 Conversion table

The Conversion table consists of a character mask name Significant positions and a list of up to 200
pairs of regular expressions, or Significant strings, and Code values.
The conversion table function starts by running the input string through the Significant position filter
resulting in a string consisting only of the characters at the specified positions of the input string.
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This string is then tested against the Significant strings one by one, starting from the top, until a match is
found.
If a match is found, and a Code is specified for the matching string, its value is returned. If there is no
match, or the Code column is empty, the result is set to NOT_DEFINED (-32768).
The resulting Code is available in the PLC as input IDCODE if the table is a part of the Work piece
identifier configuration, or as the input IDTYPE_1_CODE if it is a part of the Multiple identifiers setup. See
PLC chapters: Station variables and Multiple identifier variables for a description of the respective input.
The Significant strings may consist of all characters having an ASCII code between 31 and 126. The
exact number of entries (N) that can be entered depends on the length (L) of the Significant strings
according the following formula: N = MIN(200, 4500 / (L + 3)). Example: If all strings are 27 characters
long then 150 rows can be entered.
Significant string syntax

<Significant string> ::= <RegularExpr> <OptRangeCheck>
<RegularExpr> ::= <Expression> <OptExpression>
<OptExpression> ::= <Expression> <OptExpression> | NOTHING
<Expression> ::= See table below.
<OptRangeCheck> ::= ';' <TagRef> <RelOp> <IntegerValue> <OptRangeCheck> | NOTHING
<TagRef> ::= '\'N where N is a number from 1 to 9. Represents the value of
the Nth "tagged expression" found in <RegularExpr> from the left.
See the below table for a definition of a "tagged expression".
<RelOp> ::= '<' | '>' | '=' | '<=' | '>='
<IntegerValue> ::= A sequence of decimal digits representing an integer number in
the range [0..999 999 999]
Expression Syntax Description

Any one character ? Matches any one character.
Zero or more characters * Matches zero or more occurrences of any alphanumerical character.
One alphabetic character :c Matches one alphabetic character [a-zA-Z].
One decimal digit :d Matches one decimal digit [0-9].
One hexadecimal digit :h Matches one hexadecimal digit [0-9A-F].
Tagged expression Tags the text matched by the enclosed expression. The enclosed
expression must either be a sequence of decimal digits or a sequence
{} of hexadecimal digits. The value of the enclosed expression can be
referred to in a subsequent range check (see <OptRangeCheck>).
Example: {ddd} or {hhhh}
Escape Matches the character following the backslash (\). This allows you to
\
find characters used in the regular expression notation, such as { and :.
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Set of characters Matches any one of the characters enclosed within the [].
[] Example: [abc] matches any single occurrence of the characters 'a' 'b'
or 'c'.
Range check start ; Marks the start of a range check (see <OptRangeCheck>)
Example
A Conversion table with Significant positions set to 1-10, 24 and the following Significant string / Code
pairs:
Significant string Code

L?????????1 11
L?????????2 12
S?????????1 21
S?????????2 22
[AB]{ddd}?{ddd}???; \1 < 300; \2 < 700 1
[AB]{ddd}?{ddd}???; \1 >= 300; \2 >= 700 2
E* 100
will give the following result:
Input string tested Result

L123456789X00000X11111X2 12
L1234567892 -32768
S123456789X00000X1111111 21
E299X666AX12345678901234 100
A200Y666AX12345678901234 -32768
A500X888AX1 2
B200Z666AX1 1
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4.6 Spindle Set Up

There are many parameters that control the running of a spindle. During set up these parameters are
given default values. In some cases this is not enough. Therefore it is possible to change all parameters
with the Spindle Set Up form invoked by selecting the Spindle item in the Set Up menu or by double
clicking the spindle in the System Map.
The controls on the Spindle Set Up form is divided in several pages. Each of these is described in the
following subsections.
4.6.1 General page

The General page holds the most basic spindle parameters.
Use the Spindle Article No combo box to select the type of spindle to use. It will list the type name of all
spindle type files (extension .ttt) located in the directory SpindleType (a sub directory to the directory
where ToolsTalk PowerMACS is installed). It is necessary to have the same article number specified in
the setup as the actual hardware used.
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To use a conversion box for QMR/QMX spindles, see appendix Configuration of the Conversion Box.
The parameter Service interval is used to define the service interval, in number of cycles. To disable the
time for service event check the Disable time for service event checkbox.
4.6.2 Calibration page

The Calibration page is used to calibrate a spindle. All parameters on this page are stored to the physical
spindle. Note that only the available channels are visible.
The parameter Torque 1 Scale Factor and Gain controls the measuring on Torque Channel 1. Normally
a spindle with a 50Nm transducer should have a scalefactor of 50 at Gain 1.0. If the spindle has a second
torque channel equipped it is possible to calibrate that channel as well.
Note that if you change the Gain it is recommended to recalibrate the scale factor.
For the respective angle channel you may use the Wind Up to compensate for the torsion in the gears
and the shaft caused by the applied torque. They are expressed in the unit [degrees at maximum spindle
torque]. Please note that it is the torque transducer used for control that is used as input for the
compensation. See chapter Wind Up Coefficient in Calibration procedures in PowerMACS for how the
Wind Up value can be calculated.
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The T/C Correction Factor is used to calibrate the current measured as torque values.
4.6.3 Application page

To see this you have to enable the advanced mode by pressing the star “Advanced”.
The Application page contains application specific parameters, they are stored only in the setup and not
on the spindle.
Use the Direction field to select the basic direction for the spindle, normally Forward (clockwise). If the
spindle should use the inverse direction select Backward (counter clockwise). You can also control the
direction from the station PLC by selecting one of the items PLC P1 to PLC P5 which corresponds to the
PLCs Station variables output GENOUT_1 to GENOUT_5 respectively. If the selected PLC output is set to
1 then the spindle will run forward (clockwise), otherwise backwards (counter clockwise).
Zero Speed specifies how fast the spindle can rotate, in revolutions per minute, and still be considered
having zero speed.
If you run a JOG - Run until digital input goes high / low step, the spindle runs until a specified input goes
high or low. Specify in Dig input for JOG steps which digital input to supervise. Enter as
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<TC no.>.<channel>, e.g. 1.4. Leave blank if you do not have any input for this. See also the description
of I/O Device in chapter: Peripheral Devices.
Specify in Dig output for Gear Shift the digital output that is connected to the spindles gearshift unit. This
can be controlled using the GS - Run Gear Shift step. Enter as <TC no.>.<channel>, e.g. 1.4. Leave
blank if you do not have any output for this.
The Angle correction factor is used to calibrate the angle sensors, this is normally not necessary and
the value should be left as 1.0).
4.6.4 Application External Equipment

The Enable External Equipment checkbox should be checked when an external gearbox or similar
equipment is connected to the spindle. The following frame appears when external equipment is enabled:
Use the checkbox Equipment Inverses Direction if the connected equipment inverses the spindle
direction. A new Max Torque, Max Speed must be entered together with the External Gear Ratio.
The Torque Loss Factor is used to compensate from the torque measurement loss induced by the
external equipment.
It is also recommended to supply a new total Wind Up Angle that is valid for the complete construction
(spindle inclusive the external equipment). For instructions how to calculate this value see chapter Wind
Up Coefficient in Calibration procedures in PowerMACS.
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4.6.5 Angle Channels page

The Angle Channels page contains information about the equipped angle channels. It is also possible to
configure the double transducer check here.
This page shows basic properties for each equipped angle channel, it is possible to Disable the
secondary Angle channel (if equipped).
4.6.5.1 Angle Double Transducer Check

It is possible to configure a default double transducer check to run during cycles if two angle channels are
equipped on the spindle.
It is possible to select if the limits for the test should be read from the spindle (default provided) or if you
want to specify your own limits. The Spindle defined limits are only displayed when ToolsTalk
PowerMACS is connected to a system.
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It is possible to override the spindle configured transducer check for specific steps by using the Angle
Difference restriction.
Note The angle diff check is not executed while the spindle functional test is performed in the D -
Diagnostic Step.
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4.6.6 Torque Channels page

The Torque Channels page contains information about the equipped torque channels. It is also possible
to configure the double transducer check here. This page also shows information about the current
channel.
This page shows basic properties for each equipped torque channel (including the Current channel), it is
possible to disable any channel here by unchecking the Enabled checkbox.
Filter, Hz is the cut-off frequency of the low pass filter used to filter the torque and current inputs. Normally
this should be set to No Filter but can be specified if a certain application requires it.
4.6.6.1 Torque Double Transducer Check

It is possible to configure a default double transducer check to run during cycles.
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It is possible to select if the limits for the test should be read from the spindle (default provided) or if you
want to specify your own limits. The Spindle defined limits are only displayed when ToolsTalk
PowerMACS is connected to a system.
It is possible to override the spindle configured transducer check for specific steps by using the Torque
Difference restriction.
Note! The torque diff check is not executed while the spindle functional test is performed or zero offset is
being measured. Zero offset is normally measured during the execution of a D - Diagnostic Step
but can also be done during other steps if Flying zero offset is used (see chapter: Diagnostic ).
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4.6.7 Diagnostic page

The parameters located on the Diagnostic page specify the limits of the zero offset tests in the D -
Diagnostic Step.
Only the equipped channels are visible. It is also possible to specify if a cycle should continue to run after
a failed flying zero offset test.
In the Spindle Functional Test Limits frame it is possible to set the limits used in the spindle functional
test. These limits are stored in the physical spindle. To make a change enter wanted values and press
Store to spindle.
4.6.7.1 Static Zero Offset

To a large extent you can eliminate torque-measuring errors by performing zero offset check and
compensation. When such an operation is done is controlled by the execution of a D - Diagnostic Step.
Static zero offset is measured without turning the spindle. The static zero offset is the average torque
measured during Measuring time. The absolute value of the static zero offset must be below Maximum
Static Zero Offset. If not, step status is set to Fatal and the error flag STZODIAG is set.
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4.6.7.2 Dynamic Zero Offset and Angle Count
Dynamic zero offset is measured as the average torque while the spindle first runs the specified Target
angle degrees in forward direction and then in the reverse direction.
If an Angle count test is specified the motor will run exactly as when performing a Dynamic zero offset
test. The angle is measured separately in the forward and the backward direction. Both measured angles
must be greater than the specified Target angle – Angle limit and less then the specified Target angle +
Angle limit. If not then step status is set to Fatal and the error flag ANGDIAG is set. If Dynamic zero
offset is selected as well then it is measured at the same time as the Angle count test.
4.6.7.3 Flying Zero Offset

Flying zero offset is measured as the average torque while the spindle runs forward. The measurement
is not started immediately when the diagnostic step is started but first after that the Time from cycle start
to measuring has elapsed.
The average value is calculated during Measuring time. The absolute value of the measured offset
should be below Maximum Flying Zero Offset.
Whether or not the step is stopped when the offset exceeds this value depends on the value of Continue
to run on failed Flying Zero Offset. If checked then a too high value just generates a warning
(FLYZODIAG) and the bolt is not stopped. If not checked, then the occasion is considered to be an error
(FLYZODIAG) and step status is set to Fatal.
Since measuring does not necessarily start immediately when the diagnostic step does, both measuring
and evaluation may be done while during the execution of another step. If the cycle ends before
measuring is started, that is before Time from cycle start to measuring has elapsed, then the measuring
is cancelled and neither an error nor a warning is generated.
Note! The measured zero offset value is used to compensate all torque readings from that the next step
(compared to the step where the last zero offset measuring was taken) is started.
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4.6.7.4 Order of execution

The below text describes the sequence of actions that can occur:
IF (Static Zero Offset test) THEN

Measure the Static Zero Offset;
Save as Zero Offset compensation value if within limits;
ENDIF
IF (Dynamic Zero Offset test OR Angle test) THEN

First run in the forward direction and then in the backward direction;
Measure average torque and angle pulses in both directions;
IF (Dynamic Zero Offset test) THEN

Check the measured Dynamic Zero Offset;
ENDIF
IF (Angle test) THEN

Check that both the measured angles are within specified limits;
ENDIF
ENDIF
IF (Flying Zero Offset test) THEN

Run forward a programmable time from the start of the diagnostic step (do not measure);
Start measuring the torque and run another programmable time;
ENDIF
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4.6.8 Motortune page

If you have a service enabled ToolsTalk PowerMACS it is possible to Motortune a spindle.
Press Start Motortune to begin the motortune operation, note that the spindle will run at a very high
speed so it is absolutely critical it is running free. Motortune status can be observed through events.
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4.6.9 Automatic transducer protections

To protect the transducer from overload a number of non-configurable restrictions are continuously
executed. The errors produced by these tests are always considered Fatal.
Transducer overload protection (Spindle Protection)

This test supervises that the torque measured on the monitoring channel does not exceed the maximum
allowed torque for the spindle. The measured torque must be less than Max Torque + 5% and Max
Torque + 5 Nm otherwise a transducer protection event is generated and error bit TPROT is set in the
Bolt level result variables "Errors"/"RM Errors".
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4.7 I/O
The I/O form is invoked using menu item Setup – I/O…. or by double clicking an I/O device in the System
Map.
An I/O device is used to communicate with hardware modules for digital input and output signals. This can
be connected to all PTCs that run a station. The PTC communicates with the I/O using a local fieldbus (of
DeviceNet type) over its CAN channel.
S ta tio n P T C
I/O D ig ita l D ig ita l D ig ita l D ig ita l

in te rfa ce in p u t in p u t o u tp u t o u tp u t
node 1 m o d u le m o d u le m o d u le m o d u le
1 ... m ax 8 1 ... m ax 8
(8 ch a n) (8 ch a n) (8 ch a n) (8 ch a n)
The maximum configuration on the local I/O bus is six nodes. Each node can have a maximum of 64
inputs and 64 outputs. However, the total amount of I/O points must not exceed 192 inputs and 192
outputs per TC.
Currently the following I/O types are supported:
VIPA DeviceNet slave IM253DN
Allen-Bradley CompactBlock I/O Modules Series B (1791D)
Beckhoff BK5210
Wago DeviceNet I/O modules 750-346
An I/O device can be added to each PTC that has a PLC, i.e. the first PTC in each station.
You can add an I/O device to a station TC using the System Map. If you have used the Set up of a new
system it is automatically added.
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Press Add to add a new node. A new node is added with header but with no inputs or outputs. Press
Remove to remove the last node. Press Apply to make to the change immediately without leaving the
form. With the horizontal slider you can select which node you want to present.
Specify for each node how many inputs and outputs you have. Normally nodes are built with I/O blocks,
each having eight inputs or outputs. If you have one block, specify 1-8 signals. If you have two blocks
specify 9-16 signals, and so on.
Beside every input or output signal there is a combo box. With this you can select to which PLC signal you
want to connect the input or output. The I/O device, as well as Stacklight, Indicator Box, and Operator
Panel, can map all boolean signals located in the I/O area and in the shared area. Boolean outsignals
starting with “SO_” in the fieldbus area can also be mapped by these devices since they belong to the
shared signals. See I/O Device for more details on how to set up and program these signals.
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When a node is initially added it is set up with a default configuration.
Node PLC input signal PLC output signal

1 Name of signal 600..663, if there is one Name of signal 800..863, if there is one
2 Name of signal 664-727, if there is one Name of signal 864-827, if there is one
3 Name of signal 728..791, if there is one Name of signal 828..891, if there is one
4 No default is set up No default is set up
Note: The PLC signals presented in the combo box lists are those that existed when the form was
opened. If you open the PLC and change these names at the same time as an IO Setup or IO Map
form is open, the change will not be displayed until an IO form is opened the next time. The best
way is therefore to first create all names in the PLC, then configure the IO.
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4.7.1 Local I/O
Local I/O is visible as the first node of the I/O device. In order to map the local I/O, add an I/O device to
the setup and open the I/O form The Local I/O is mapped by selecting PLC signals in the combo boxes in
the form, like for the other I/O nodes.
As default, I/O node 1 is part of the I/O device. For users only needing the Local I/O, pressing the Remove
button will remove I/O node 1 from the setup.
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4.8 ID device Set Up

The ID device form is invoked using menu item Setup – ID device…. or by pressing the Open... button
displayed in the Details window when the selected node in the System Map is an ID device.
Select the ID device to view or configure using the ID device combo box.
ID devices are equipment that can read identification information from, and write result data to, the work
piece.
If the device is connected to a PowerMACS Station the information read from an ID device may be added
to the tightening data, as the station level result variable "Wp ID", or the Multiple identifier result variables
"ID Res x". See description of Work piece identifier and Multiple identifiers in chapter: Advanced Station
Settings for how to configure this.
The data read from an ID device is also available to the PowerMACS PLC making it possible to process it
as wished.
Note! To create a new ID device or to change the communication settings for a device you must use the
System Map.
Depending on the type of the ID device the frame Type specific parameters displays different controls.
For a detailed description of these see chapter: ID device.
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4.9 Assembly Overview Set Up

The Assembly Overview displays the current status of the system, its stations and bolts. Which data to
display in the different boxes, and their layout, are controlled by the Assembly Overview Set Up form. It
is invoked using the Set Up - Assembly Overview… menu item
When selecting the Set Up - Assembly Overview… item two forms are displayed. First the Assembly
Overview Set Up form and secondly the Assembly Overview form, now running in Set Up mode.
The first form is used to configure the basic settings for the Assembly Overview, which data and pictures
to display in the Assembly Overview window.
The second form is used to define the position and size of the different station and bolt boxes.
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The Assembly Overview Set Up form

Use the System Background Picture combo to select the JPG file to display as System View
background.
To include your own JPG files you must copy the files to the directory Bmp located in the directory you
installed the ToolsTalk PowerMACS application in. All files with extension JPG in this directory are listed in
the picture combo boxes when the form is opened the next time.
Note 1: The selected JPG files are not included as a part of the setup. In order to display the same
pictures on another computer then the one you created the setup with you must copy the files
manually.
Note 2: The JPG files are converted to bitmaps when used by ToolsTalk PowerMACS. The time it takes to
load a JPG file, and the amount of memory it occupies, therefore depends heavily on the resolution
and color depth of the picture. It is therefore important to keep these as low as possible if using a
low end PC.
In the Select Station to edit combo box choose the station to configure. Please note that it is possible to
have different settings for each station.
For each station you may select which station and bolt level variables to display in the corresponding
boxes. For a description of the variables see chapter: Result variables.
Use the combo boxes on the Station Box tab to define which result variables to display in the Station box.
The combo boxes on the Bolt Box tab controls which of the result variables that are displayed in the Bolt
boxes.
Use the combo boxes on the Bolt tab to define which result variables to display in the Bolt detailed view.
The variables selected are displayed in the same order as entered in the grid. Use the columns Font Size,
Text (whether to include the prompter text) and Dec to control the format of the each variable.
Check Expanded by default in system view if the Station box should be expanded, that is show its Bolt
boxes on top of the stations background picture (“Station detail view”), when the Assembly Overview form
is opened. If not checked, then the Station box is displayed in its collapsed form which means that it only
show the variables selected on the Station Box tab, which is no background and no Bolt boxes.
Check Show scrollbars when expanded in view mode if the “Station detail view” should display
scrollbars at the bottom and to the left of its frame when the Assembly Overview form is displayed in its
view mode (that is, when not opened from "Set Up - Assembly Overview"). The scrollbars are always
displayed when in set up mode to make it possible to position the picture within the “Station detail view”.
Check Maximized when selected if the “Station detail view” should occupy the whole Assembly Overview
picture when displayed (that is when the Station Box is clicked on in the System view).
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The above listed configurations are common for a given station regardless of which mode the station is
running (see The Mode Table form for a description of modes) . However, there are a number of aspects
that can be displayed differently depending on the currently selected mode: These are defined as a so
called Station View. Each station can have up to ten Station Views and for each of them you may specify
the following:
Which Background picture to use for the Station detail view.
The size and position of the Bolt boxes in the Station detail view (this is edited directly in the
Assembly Overview form).
For which Modes the Station View should be used. These are entered as a comma separated list
of mode numbers.
Click on Advanced… to open a new window with advanced settings:
All of these settings are used to change the Assembly Overview behavior in different aspects.
Note! It is not recommended to enable these settings. Do so only if you have problems to get an existing
set up to work as you want.
Enabling "Use Station View 1 for unmapped Mode numbers (including Mode number 0)" will cause Station
View 1 to be displayed when a Mode number that does not map to a station view is selected or Mode
number is set to zero. The default behavior is to keep the currently displayed Station View.
Enabling "Clear all data when changing station views" will cause all station and bolt boxes to be cleared of
its result information and the background color set to grey when the station view is changed. The default
behavior is to keep all result information and background color and use PLC station output variable
RESETSTATUS to clear the data.
Enabling "Do not show intermediate status when running stitching cycles" will cause all bolt boxes to
remain yellow until the complete tightening cycle is finished and the cycle data is produced. Default
behavior is that the bolt boxes background color is updated with the status of the sub cycle but no result
information is shown until the complete tightening cycle is finished.
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The Assembly Overview form in Set Up mode
This form is used to define the position and size of the different station and bolt boxes. The layout is
modified directly in the displayed picture by using the mouse.
To change the positions of a box move the mouse pointer to the upper left corner of the box. When the
mouse pointer changes to a vertical arrow pointing upwards, press the left mouse button and reposition
the box.
To change the sizes of a box move the mouse pointer to the lower right corner of the box. When the
mouse pointer changes to a diagonal arrow, press the left mouse button and resize the box.
All boxes of a given type will have the same size and display the same variables.
When you are satisfied with the settings press the Apply button in the Assembly Overview Set Up form to
save the settings of the current Station View.
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4.10 PLC Parameters Set Up

This form is invoked using the menu item Set Up - PLC Parameters.
The PLC Parameters Set Up form is used to define parameters that are available from inside the
PowerMACS PLC (see PLC - Overview).
Defining parameters for the PLC here is an alternative to defining them as a part of the PLC application
directly (using the Multiprog editor). This is useful if it is likely that the end user will need to adjust them
after delivery, or where one wants to make a PLC application that is generic to some extent.
The end user may change the value of the parameters defined here using the PLC Parameters form.
The form contains 190 rows on which either a parameter or label can be defined. Labels are used only to
make the layout of the form easier to read, they are not accessible from the PLC.
For each row you must define the following:
A Prompter: Used to describe the parameter. Max 20 characters long.
Data Type of the PLC variable: One of the following INT (16 bit signed integer), REAL (32 bit
floating point value), STRING40 (max 40 character long strings), Label, or blank.
Value. The default value of the parameters. Not valid if Type is blank or Label.
Min and Max: The min and max value of the parameter. Valid only if Type is INT or REAL.
PLC Variable: Defines to which variable in the PowerMACS PLC this parameter is connected. See
also chapter: Station variables).
The maximum numbers of parameters that can be used are:
130 of Type INT
20 of Type REAL
10 of Type STRING40
30 Labels.
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4.11 SRAM
This form is invoked using the menu item Set Up - SRAM.
Use this form to set up the configuration of the TC:s SRAM.
Change the size used for cycle data storage by dragging the slider Cycle data percentage. The digits
shown to the right of each slider is a guess of the minimum amount that can be stored given the selected
settings.
The checkbox Use only TC1 for CycleData Storage is used for backward compatibility, and disables the
distributed storage if checked.
Press the Default button to reset the settings to their default values.
It is also possible to configure the distribution of OK/NOK traces to store. The example below saves 70 %
of the memory for NOK traces and 30% for OK traces.
Please see chapter Cycle Data Storage for examples on the number of cycle data that can be stored on
each TC.
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4.12 Options
In the Options choice of the Set Up menu you can set up your main preferences.
Choose Language for presentation on screen. Change will take place when windows are closed and
reopened.
Note 1: All texts displayed by ToolsTalk PowerMACS are defined in a so-called Language file. To add
support for a new language you just have to copy a file supporting the language in the same
directory as your ToolsTalk PowerMACS is installed in. The file should have a name expressing
the language it supports and the extension “.LNG”, for example “English.LNG”.
Use the Torque unit combo box to select the unit you want all torque values expressed in. Possible
choices are Nm, kNm, FtLbs and InchLbs. This setting can be overridden for a particular device using its
reporter.
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Use Time Server to select from where the clock on the target system will be synchronized. Normally the
only option is ToolsTalk PowerMACS but if the system has an Ethernet Protocols device mounted on the
System TC then the following alternatives are available as well:
Open Protocol if the configured Ethernet type is Open Protocol
FSH if the configured Ethernet type is FSH
Note 3: If you only want to use the Open Protocol device as Time Server you must disable Collected
data (OK cycles, NOK cycles) in the reporter, otherwise there will be an overflow event as the
cycle data queues are never read.
Use Internal baud rate to set the communication speed with the AnyBus CC module, the following
speeds are possible to chose 19200 (default for setups created with versions prior to 7.4.1), 57600
(default speed for setups created from version 7.4.1) and 115200. The internal baud rate determines the
update speed for the connected fieldbus and in most cases the default speeds 19200 or 57600 should be
sufficient. Do not chose a higher value for the internal baud rate than necessary since it will affect the
overall load of the system, use 115200 only when absolute needed.
Use Max no. of trace samples to set up number of samples recorded for a trace. Possible values are
500..6000 with default 2000. Use higher values to get better resolution for long cycles, e.g. for gauging.
More samples will though decrease number of traces saved in the trace memory.
Use Date format and Time format to select the standard for how date/time variables should be formatted
when printed. The effect of the selected format is displayed in the Date/Time format settings field.
Check the checkbox Display disconnected bolts with blue color if you want the status of all
disconnected bolts to be indicated using blue color in the System Map and Assembly Overview forms. If
not checked, bolts that are disconnected OK are colored green while bolts that are disconnected NOK are
colored red.
Check the checkbox Automatically restore ToolsTalk-TC com. when broken if you want ToolsTalk
PowerMACS to automatically try to establish the communication to the System TC whenever it is lost due
to transmission errors.
Check the Use best-fit for trace storage checkbox to make the down sampling of traces try to include
peak- and low spot torque/current values at the expense of time resolution. When this option is enabled all
peak values and most low spots of torque and current channels are stored. Enabling this option on a 20
second long trace (max) adds up to 90 ms to the cycle time.
Check the Automatically backup setup every hour to have ToolsTalk PowerMACS automatically store
a backup copy of the currently loaded setup every hour.
Click on Set Customer error codes… to define or edit customer specific error codes, see Set Customer
error codes.
Click on Set Customer step name… to define or edit customer specific step name, see Set Customer
step names.
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Note 4: The parameters Language and Automatically restore ToolsTalk-TC com. when broken are
not part of the setup. Their values are only stored on the PC from which the parameters are
altered. However, since the values are stored in the PC's registry they are remembered between
different sessions, also if using different setups. Their respective default values are "English" and
"not checked".
4.12.1 Set Customer step names

Click on Set Customer step names… to display a window where customer specific step names can be
defined and edited:
In this window up to five different customers specific step names can be defined. In the tightening
program, under Ramps & Other – Other it is possible to select the customer step name to use for that
step. The selected customer specific step name is also used to select the customer error code to use for
that step, see also Set Customer error codes
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4.12.2 Set Customer error codes
Click on Set Customer error codes… to display a window where customer specific error codes can be
defined and edited:
The customer error code is a four (4) character string that can be included in the bolt level result data. Five
different series with customer error codes can be used. The name for each series is specified in the
window Set Customer step names.
The series to use is specified in each tightening step on the other tab. It is the series specified in the step
pointed to by the result variable Failing Step number that is used for the conversion. Only the errors that
occurred during that step are used, not any additional errors that happened during e.g. the termination
sequence. It is only the errors that happened during the last execution of the step that is used, each time a
step is started all errors for that step is cleared.
Each error code has a unique priority. If several error bits are set it is only the customer error code with
highest priority among these that is reported. Even if the customer error code being reported has been left
blank it will be reported as it is. The table can be sorted on each column to make it easier to edit.
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Customer error codes can also be specified for the two cases when the cycle ends without any error bit
set, that is, when the cycle ends with status OK, OKR or NOKRM (see chapter: Result variables -
Statuses for a description of statuses). Use Code to use when cycle ends OK or OKR and Code to use
when cycle ends NOKRM to specify these respectively.
To always be able to determine if the cycle ended OK or not a value must be specified for the OK/OKR
case if any error bit has a blank customer specific error code.
Note! Code to use when cycle ends NOKRM will be set to the default code used for NOKRM (NRM if
the English language file is used) when a setup created with a WinTC version earlier than 5.1.0 is
loaded and its Code to use when cycle ends OK is empty.
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4.13 Setup Problems

The Setup Problems function performs a number of tests on your setup. It will test all combinations of
programs against the bolt/spindles that you have setup using The Mode Table form. All target values will
be tested with respect to max values defined for the spindles used.
The window is by default docked on the left side of the ToolsTalk PowerMACS main window.
The list contains different categories. For each category a number of messages are displayed. Every
message is a classified as either an error or a warning.
If Show only errors is checked, only the messages classified as errors are displayed.
Note that the window is displayed even if the test succeeds. If so the text "No errors or warnings found" is
displayed.
You can configure the tests to be executed automatically when the setup is modified and/or when
connecting. This is controlled from the Set Up Options form.
If the checkbox Perform Setup problem detection when setup changes on the Set Up Options form is
not checked then setup problems will change appearance whenever the setup is changed to indicate that
the last test is no longer valid.
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4.14 Table Export and Import

A setup is a group of data that completely describes a PowerMACS system, how it looks and how it
should work. It can be handled and reused as a complete unit as described in the chapter: “Setups and
How to handle them”.
However, it is also possible re-use smaller parts of the setup. These parts are called tables and a table
normally represents one particular object in the setup, for example a bolt, a reporter, etc.
A table can be moved from one setup to another by using the Table Export and Import functions by first
exporting it from the first setup and then importing it into the second one.
The following tables are available for Export and Import:
Program
Sequence
Station
Reporter
Misc (Easy View and SPC configurations)
Bolt
Spindle
Servo
Device
The Export Table form is invoked using the File - Export menu item.
First select which type of table to export using the Table combo.
Depending on Table type you specify exactly which instance to export using the displayed controls
(Station, Program, Spindle etc.) in the Source frame.
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Use the Destination frame to specify to which file the table should be stored.
Finally press the Export >> button.
Repeat this for all tables you want to export.
Use the File - Export menu item to display the Import Table form.
First select the type of table to import using the Table combo.
Use the Source frame to specify which table file to import.
Specify in the Destination frame exactly to which instance you want to import the data. For some table
types you may also create a new instance using the imported data. In these cases the New field is
enabled.
Finally press the Import >> button.
Repeat this for all tables you want to import.
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4.15 Table Copy

This form is opened using the menu item Edit - Multi Copy.
It enables easy copying of a table instance to one or more other instances of the same type.
Use the Table combo box to select which type of table to copy. Depending on type of table you can then
in the Source frame specify which table you want to copy.
Use the fields in the Destination frame to specify where to copy the table data. For most table types you
may select multiple destinations (if displayed in the list). To do this, hold down the CTRL key and then
click on all items you want, or if they are contiguous, mark the first one, press the SHIFT key, and then
mark the last one
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4.16 Handling of the setup in the target system

The setup consists of all the configuration objects stored in the database along with the PLC program
including the PLC source code.
When downloaded to target system this setup data is stored on the System TC. It is from this TC all other
TCs in the system access the data they need. Any change made using ToolsTalk PowerMACS while the
system is on line directly notifies all dependent nodes about the change. This solution has the advantage
of making all TCs but the System TC directly replaceable, without updating them with the latest setup
manually.
A backup copy of the setup is always kept on TC 2 in a system in case the System TC needs to be
replaced.
4.16.1 Backup of the setup

The purpose of the backup function is to have a fresh copy of the setup available on another TC in the
system in case the System TC should need to be replaced. When the System TC is replaced it will then
read the backup copy from TC 2 and thereafter start as normally.
The backup function mirrors the setup stored in the System TC to TC 2. The function is automatically
enabled in all systems that consist of two or more TCs. Whenever a setup is modified, or completely
downloaded to TC1, either from ToolsTalk PowerMACS, or some other remote device (for example the
PowerMACS API) the data is automatically copied (mirrored) to TC2.
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During a cold start of the System TC checks the status of its own local database and the backup copy
stored on TC 2. Depending of their respective status the following cases can arise during system start-up:
Status of Status of the

Case setup in the backup in Action
System TC TC 2
1 Empty Empty Only the System TC is started. A setup must be
downloaded using ToolsTalk PowerMACS.
2 Empty Ok First the backup setup is copied from TC 2 to the System
TC.
Then the system starts using the copied setup.
3 Ok Empty First the setup is copied from the System TC to TC 2.
Then the system starts using setup originally stored on the
System TC.
4 OK OK and identical The system does a normal start.
to the setup in
the System TC
5 OK OK but not The system is not started. This situation is indicated to
identical to the the operator in the following two ways:
setup in the
On the System TC the display will say backup setup
System TC
differs.
When trying to go connect with ToolsTalk PowerMACS
it will refuse to connect and only display the "Resolve
Procedure" form describing the situation.
See chapter: Replacement of TCs below, for how to
resolve the ambiguity.
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4.16.2 Replacement of TCs

As described in the table in chapter: Backup of the setup there is only one case where it is not clear to the
system which setup to use. That is when both the System TC and TC 2 have valid but different setups
stored.
When this situation is detected the system will not start automatically. Instead the System TC will indicate
the situation by showing a message that the setups are different on the display.
To avoid this ambiguity you should make sure that the setup stored of the new TC is cleared
before it is inserted in the system, especially when replacing the System TC or TC 2.
Clearing the setup stored in a TC is done using the TC display.
It is also possible to resolve the setup ambiguity using ToolsTalk PowerMACS or the TC HMI.
Using ToolsTalk PowerMACS the following form will be displayed when an attempt to connect to the
system is made:
The form shows the system name and date and time for the last update of the individual setups and let
you choose which one to use. If the setup on ToolsTalk PowerMACS is selected then it will be
downloaded to the System TC and the backup will be updated to correspond to it.
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4.17 Maintenance
The Maintenance menu contains functions for maintenance, like checking the status of the system:
Test Bolts… opens a form from where you can run test passes for one or more bolts of a station. This is
an alternative to the PowerMACS PLC when it comes to start tightening cycles. It is also useful for
calibration of the torque, current, and angle measuring, see Calibration.
Event Statistics… gives you an overview of the most frequent alarms.
Service Log… opens a logbook. Use it to log all your service actions.
Replace ID String… displays a form from which you manually can enter ID strings. Useful if your ID
device does not work or just for testing.
Use Select Target System… to choose which PowerMACS system to connect to.
Configure Target System… opens a form from where you can configure the TCs of your PowerMACS
system. This involves function for upgrading the System Software, changing IP-address settings, etc.
Clear data… is used for clearing data stored in the non volatile RAM of the TCs.
Chose Compare programs… to compare the programs in your currently loaded setup with the
corresponding items in a setup stored on disk.
Check for Check for System Conflicts… to get an overview of TC set up errors, like mixed versions of
TC system software, missing TCs, etc.
TC Crash Log... opens a form that can be used to retrieve debug information from one or more TCs that
crashed due to internal, unrecoverable, software errors.
Maintain Spindle Parameters… opens a form that can be used to read/store all parameters from/to a
connected spindle. Spindle type files can also be opened and examined in this form.
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4.17.1 Select Target System

Selecting the Maintenance - Select Target System menu item or Select Target System... from the
Connect toolbar drop down menu opens this form that is used to select which target system ToolsTalk
PowerMACS should connect to when going online.
Click Browse... to select the PowerMACS Network Configuration file that best describes the network to
connect to.
A PowerMACS Network Configuration file describes the expected layout of a PowerMACS Network in the
sense that it lists a number of PowerMACS system nodes (System TCs), that for some reason are
logically grouped together. Each PowerMACS system in the network is identified with the IP-address of its
System TC and free textual description. The main purpose of this file is to document a configuration where
several PowerMACS systems are used, for example a complete assembly line.
The selected file will be opened automatically the next time you open this form, even between ToolsTalk
PowerMACS sessions. If no file has been selected, a default configuration is displayed.
How to create a Network Configuration file is described later in this chapter.
The network can also be scanned in order to automatically find all PowerMACS systems physically
connected to it. Click the Scan button to bring up a list of all System TCs on the network.
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All System TCs found during scan are compared to the contents of the currently selected Network
Configuration file. Depending on the differences the rows in the list is marked with a color.
Not scanned (Blue) – The TC in the list was not found on the net. When a network configuration
file is opened, all rows are marked blue.
New (Green) – A TC that was not in the list was found on the net.
Changed (Red) – The attributes of the found TC are different compared to the previously known.
Note that the Description field is not compared since it is not present in the TC it self.
Not changed (Black) – The attributes of the found TC is the same as the previously known.
Select the PowerMACS system to connect to by clicking one of the radio buttons in the Select column.
ToolsTalk PowerMACS does only communicate with the System TC (first TC in a system) so therefore
only one selection need to be made.
Choose TC-Simulator if you do not have a real target system to connect to but still want to demonstrate
the on-line functions of ToolsTalk PowerMACS.
TCs that are not possible to connect to due to network settings are indicated with a red exclamation mark.
The type of problem is not displayed in detail in this window. It is however possible to select such a TC in
this list but before ToolsTalk PowerMACS can connect to the system; the problem must be corrected.
Correcting such a problem can be done by using the “Configure Target Systems” window.
To create, or edit, a PowerMACS Network Configuration file use the Add..., Edit... and Remove buttons
to insert, change and remove entries in the list. When done editing, save the current configuration to file
using the Save button. Since the file name is used to identify the network you should give the file a
descriptive name. Editing the file can be done without being connected to the network.
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4.17.2 Test Bolts

The Test Bolt function gives you an alternative way to the execution of a tightening cycle, running all or
only one selected bolt for a station.
First chose which station to test using the Station combo box in the toolbar.
Depending on the status of the selected station the Test Bolt form may be disabled. The form is disabled
for this reason if:
The hardware Emergency input is inactive for the TC that executes the station (PLC station input
EMERGSTOPIN True).
The selected stations PLC output DISABLE_TESTBOLT is set True. See also the description of
the Station variables in the PLC section.
In either case an explanation of why the Test Bolt form is disabled is displayed at the top of the form.
With the Bolt combo box you may select a single bolt or All Bolts within the station. Note that if All Bolts
is chosen and some bolts use the same spindle only the first occurring bolt for that spindle will be run and
an error message will be generated.
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Should the Test Bolt form be closed, or ToolsTalk PowerMACS be disconnected from the TCs, while a
cycle is executing then the cycle is terminated using Machine stop.
Note! When running a station from the Test Bolt form the PowerMACS PLC outputs MODE and
BOLTCONTROL are overridden. This means that PLC inputs that depend on these, for example
BOLTSTATE, may have values that do not correspond to the values of MODE and/or
BOLTCONTROL. To detect these situations in the PLC use the input CURRMODE and
TESTBOLT_ACTIVE. The first one always reflects the mode currently known by the station and the
second one is set True whenever the Test Bolt form is opened against the station in questions.
Also, when the Test Bolt form is closed, or you switch to another station, the station is updated with
the value of the PLC outputs MODE and BOLTCONTROL.
You can run the test in Single Run mode, in Program mode or in Mode table mode. You select which by
activating the corresponding button.
Single Run mode

In Single Run the bolts are run once to a specified Target defined either by Torque, Angle or Current.
Use the controls in the Run conditions frame to define the direction and speed to use when executing the
step.
Speed can also be specified as target. If so, then the bolt(s) will run continuously with speed and direction
as set by the Run conditions.
When target is reached, or once a second if running speed, a number of measured values are displayed in
the Result frame. Except for the peak torque value all values are sampled at the switched off occasion.
Note! See chapter: Calibration for how to use Test Bolt to calibrate your system.
It is also possible to run a Spindle Functional Test or get the current Measurement values from the
transducers.
If you run a Spindle Functional Test the TC will run the same test that is done during the spindle
functional test in a diagnostic step. The results from the test are directly displayed in the Result frame.
With Measurement values the Result frame will continuously display the current measurement values for
torque and angle from all available transducers on the spindle. It is possible to let this run while a cycle is
started from the PLC, meaning you can follow the torque and angle measurements during the tightening in
(almost) real time.
Program mode
In Program mode you run the bolts by using one of the existing tightening programs.
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Here you can specify how many cycles you want to run, or for how long. If you want to run more than one
cycle you will probably need to specify a program to use for loosening (Program 2). How to create a new
program is described in chapter: Create a new Tightening Program.
Press the Start button to start executing the cycle, Program 1 will be used first and then if No. of cycles is
> 1 it will continue to alternate cycles between Program 1 and Program 2. Press Stop to stop any on-
going execution.
Running a program produces Cycle Data and Statistics just as if the bolts where executed by the
PowerMACS PLC. This means that data is reported over the normal channels, SPC is calculated, and so
on. However, none of the variables that depend on outputs from the PowerMACS PLC are updated. This
includes the following variables:
Station level variables Bolt level variables

Wp ID Total
Mode Total OK
Mode No Total NOK
Free Str Total Type
Free Str 2 Total Type OK
Free Str 3 Total Type NOK
Free No 1
Free No 2
Total
Total OK
Total NOK
188 9836 3521 01

Mode Table mode
In Mode Table mode you run the bolts by ordering the station to run a particular mode.
This means that which bolts that will run and which programs they will execute is decided by the current
Mode Table (see The Mode Table form).
Use the Mode 1 and Mode 2 combo boxes to select which Modes to run. If specifying more than once
cycle the station will alter between Mode 1 and Mode 2, starting with the first. Please note that the two
combo boxes are filled with the modes that are relevant with respect to the currently selected Bolt. If All is
selected they will include all modes, without Program from PLC, of the station. If a specific bolt is
selected they will only include the modes for which the bolt has a program.
Note! It is not possible to use Test Bolts to run modes that use dynamic program selection from PLC. This
means that for the selected mode no program may be Program from PLC for any bolt in the mode
table. Program from PLC requires BOLTCONTROL from PLC, which is overridden by Test Bolts.
Only modes without Program from PLC are selectable in Test Bolt.
All other functions are the same as for the Program mode.
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4.17.3 Calibration procedures in PowerMACS
4.17.3.1 General
It is strongly recommended to perform a calibration of the spindles after the system has been installed at
the production site. It is also recommended to make a new calibration periodically (for example one time a
year, every 6 months etc.) and this is normally specified in the customer quality control system.
There are at least four alternative ways to perform a calibration:
1. Run on the actual joint.
2. Using a test joint where the test joint should have similar characteristics as the actual one.
3. Using a dummy joint that always is pre-tightened.
4. The manual method.
Method 1: is recommended and is normally giving the most accurate results. One of the other methods
can be used, as it is not always possible to use method 1 due to mechanical or similar reasons.
Method 3: The joint is not a real screw joint. It could be a mechanical part with a welded bolt head or
similar.
Method 4.1: Program a torque x Nm and the speed 0 (zero) rpm.
Apply a torque wrench to the inline transducer on the spindle square drive.
Start the test.
Turn the torque wrench until the spindle shuts off (spindle torque is released).
Register the torque value.
Method 4.2: The same as for method 4.1 except that you don‟t use an inline transducer but only a torque
wrench. This method is NOT acceptable.
The easiest way to perform a calibration is to use the Test Bolts function. To be able to run spindles from
the "Test Bolts" the PLC output “DISABLE_TESTBOLT” must be set False. (In a system running in
production this output is normally True for safety reasons).
When running a spindle from the “Test Bolts” menu most PowerMACS PLC functions are not active.
There are three alternative ways to run a spindle from the Test Bolts menu:
Single run
Program
Mode
These are described in the following chapters.
Note! You should only run one bolt (spindle) at a time when calibrating.
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Single Run
When you use this function, you will automatically get some statistics directly on the screen. Do the
following:
Select a station.
Select a spindle.
Select a speed. The same speed as you have in the final tightening step in the normally used
program is a good choice.
Select the parameter you want to calibrate (Torque/Angle/Current) and a target value.
Reset the statistics.
Click on the Start button.
If you use the Stop function, the spindle will stop and a Machine Stop will be generated in the Event Log.
Note! When you use the “single run” function, there is no “zero-offset check and compensation” made.
This must be done manually by first running a tightening set that has a D - Diagnostic Step as a
first step. The “zero-offset” measured by it will automatically be stored and used until you either
run a new Diagnostic step, make a change in the Spindle Set Up form, or power off/on the TC.
Use the run “Program” alternative to do this.
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Program
You can either use an existing program or you can create a special tightening program called
“Calibration”. The tightening program shall have the following structure:
Step 1: “Diagnostic” step with spindle functional test enabled and Spindle Only selected as zero
offset compensation.
Step 2: Tightening step, e.g. torque xx Nm; speed yy rpm
Step 3: CE
It is practical to also create a loosening program to be used to loosen the tightened joint.
In the picture below is it defined one tightening and one loosening program.
With number of cycles set to the value 2, a loosening will first be done followed by a tightening.
Mode
Using the Mode option is similar to the Program one. The difference is that in the Mode option it is
possible to run different tightening programs for different spindles. As we normally recommend that you
shall only run one spindle at a time when you make a calibration is the mode alternative probably not a
real option.
4.17.3.2 Torque
All Atlas Copco torque transducers are factory calibrated to sensitivity within +/-0.3% of the nominal
torque. Due to component tolerances in the TC electronics a fine tune of the torque sensor is
recommended. Exchange of a torque transducer to an identical unit does not require a new calibration, but
for quality control reasons it is anyway normally done.
An inline slip-ring torque transducer and a peak hold monitoring amplifier shall be used for the torque
measurement, e.g. Atlas Copco IRTT transducer with ACTA.
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Single torque transducer
If you are using the “Single run” option, run a program with a “Diagnostic” step with spindle
functional test enabled to get a new zero offset reading and compensation from the spindle.
Make at least 10 tightenings to the desired final torque and record the results from the reference
transducer (Xref) and the reported final torque from the spindle (X)
Calculate the mean reference torque (Xmeanref) and the mean final torque (Xmean).
Xmeanref = SXrefn / n where “n” is the number of tightenings

Xmean = SXn / n where “n” is the number of tightenings
Adjust the spindle parameter Scale factor for channel Torque 1 (Ts) (see Spindle Set Up,
Calibration) with the calculated value. Increase the Scale factor in order to decrease the true torque
and vice verse.
Ts-new = Ts-old x Xmeanref / Xmean

If you are using the “Single run” option, run a program with a D - Diagnostic Step in order to get a
new zero offset reading and compensation.
Run a new test series in order to confirm the correction.
If a torque scatter test is required (Standard deviation, Cp, Cpk, Cmk, CAM……) a minimum of 20
tightenings are needed.
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Double torque transducer

Spindles are calibrated as follows:
Read the result from both transducers in the “Single run” window. The monitoring transducer is the one
that the torque results to the reporter(s) come from.
The monitoring transducer is the one that the torque results to the reporter(s) come from.
The control transducer is calibrated in the same way as a single transducer (see Single torque transducer
above).
The monitoring transducer can be calibrated at the same time by adjusting the scale factor for transducer
2.
4.17.3.3 Angle
The angle measurement is performed with the resolver signal and is normally not necessary to calibrate
(see “wind up” below) as all this is hardware.
The most reliable results are achieved with an inline Torque/Angle transducer and a Torque/Angle
amplifier with trace capability, for example an Atlas Copco IRTT transducer with ACTA.
There are two methods of checking the angle measuring.
1. Rotating the spindle in the air. Program a set angle value in the “Test Bolts”-“Single run” menu.
Connect your inline transducer and run. Compare the inline transducer angle result with the
PowerMACS one.
2. Running on a joint. With this method, a check of the tightening angle is difficult but not impossible
to make in a controlled way. Make a tightening on a joint and compare the trace curves, Torque vs.
angle, from the two systems.
Results from tests made with an external Torque/Angle recording unit where the angle from a torque level
to final torque is presented and then compared with the from PowerMACS reported value are normally not
giving an acceptable result.
The main reasons for the discrepancy in measured angles are:
The start point (torque level) does not occur simultaneously in the control and the monitoring
systems
The stop point is not defined in the same way in the control and the monitoring systems.
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4.17.3.4 Wind Up Coefficient

There is a spindle parameter, named Wind Up Coefficient (see Spindle Set Up, Calibration page), which
is used to compensate for the torsion in the mechanical parts (gears and shafts) between the electric
motor shaft and the square drive. The coefficient can be modified in order to fine tune systems where
external mechanics (like long thin extension shafts) affects the angle control.
The default value of the Wind Up Coefficient is 3 degrees at max spindle torque (that is, the value of
parameter Max Torque).
Note! The default Wind Up Coefficient is normally good enough and is in most cases not necessary to
change.
Calibration of the Wind Up Coefficient

It is fairly simple to check and to calibrate the Wind Up Coefficient.
Create a simple tightening program that has a Diagnostic step, a Torque step and a Cycle End.
Program a “high” torque in the T-step, the speed 5 rpm and the Speed Ramp 100 rpm/s. The “high”
torque shall be as much as the screw joint can stand without destroying it and that the spindle can
give.
Set the Wind Up Coefficient to the value 0.000 deg.
Run a number of times on the joint without loosening it between in order to have a test joint that is
not moving anymore.
Look at the trace showing Torque vs. Angle. Estimate the angle between two torque levels and
calculate the new Wind Up Coefficient. See the example below. The new value of the Wind Up
Coefficient will be: 3.5 / 45 * 50 (Spindle Max Torque) = 3,88 deg/Nm
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3.5 Deg
45 Nm
Program the new Wind Up Coefficient in the spindle interface and Apply.
Run a new tightening and look at the trace again. Now, the curve should look something like the
example shown below. As you can see now is there a lash in the socket of about 0.8 deg and then
the torque increases to 45 Nm without moving the bolt and this is the goal.
Note! When external equipment is connected on the spindle WindUp is likely to be calculated - but the
values should be entered using the External Equipment parameters, see Application External
Equipment on the Spindle Set Up form.
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4.17.3.5 Current (torque)

The step types TC - Run until Torque with Current Control, DT - Run until Dyna-TorkTM, DT2 - Run until
Dyna-TorkTM, method 2, and DT3 - Run until Dyna-TorkTM, method 3 are uses the servo current
measurement for step control. The programmed set torque value is converted to a current set value with
the T/C factor. The current set value is used in the servo and the servo shuts off itself.
The T/C factor

The spindle parameter T/C factor (Torque/Current) (see Spindle Set Up, Calibration page) is the scale
factor for all current control. The unit of the T/C factor is [<torque_unit>/A] and a theoretical value based
on the motor data is used as default setting. The value of the T/C Factor can not be changed since it is
written at spindle production and depends on the motor. Instead a T/C Correction Factor can be
specified to calibrate the torque/current conversions.
One way to calibrate the T/C Correction Factor is to select “Current” as control parameter under “Torque
usage” in the Spindle Set Up form (see General).
Use the “Single Run” function located of the Test Bolts form.
Run 10 cycles and register the torque values from an inline torque transducer. Calculate a mean torque
value and adjust the T/C-factor if necessary. Increased TC-factor decreases the true torque.
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4.17.4 Event Statistics

The Event Statistics form, invoked using the menu choice Maintenance - Event Statistics…, can give
you a good view on which events that are most frequent.
It displays a so-called Pareto diagram in which the most frequent event type is displayed to the far left. In
the diagram you can see both the percentage and the number of times each event has occurred.
One bar is displayed for each event code of which there is at least one error. For a list of possible event
codes see chapter: List of events.
The event statistics are stored in the system in accumulators. You can reset these by pressing the Reset
button. The last time this was done is shown to the right of this button.
Press the Reload button to first clear the accumulators and then reloaded them with all events currently
stored in the Event Log (see View Event Log).
To study only certain event types press the Selection button to expand the Event Types frame. Check
each event type you want to include in the display.
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4.17.5 Service Log

The Service Log is a useful tool to keep track of changes made to a system. It is invoked from the menu
Maintenance - Service Log…
Basically it functions as a notepad where you easily can write small notes. Use it to describe all the
changes you do to the system, and perhaps more importantly, why you have done them.
The log can contain up to approximately 10 messages and is a part of your setup and will therefore be
stored both on disk and in the target system.
When you open the Service Log the titles of all existing logs are listed in the top list box labeled Title while
the text box labeled Message displays contents of the currently selected title.
To create a new log entry press New. To change an existing message select its title and then press Edit.
In both cases a form is displayed in which you can enter a proper title and message texts.
To remove a log entry: select its title and press Remove.
If you have made changes to the system you will automatically be asked to enter a message in the
Service Log when you log out, closes the current setup, or exit ToolsTalk PowerMACS.
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4.17.6 Replace ID String

Using the Replace ID String form, opened from the menu Maintenance - Replace ID String…, you can
manually enter an ID string instead of actually input it using one of the ID-device devices in your system.
This is useful if when a barcode label is damaged, or when the ID device for some reason is not working.
The form is accessible only when on-line.

First select the device to operate on using the Choose ID device combo box. It is filled with all ID devices
defined in the system.
Depending on the type of the selected device the function is as follows:
For type Barcode: Enter the new string in the Replace with field and press the Apply button. The
new string is treated by the system just as if it was scanned using the barcode scanner. This
means that it is automatically sent to the Station and its PLC (visible as CURRIDSTRING, see
Station variables) and is stored in the device.
For type Escort AB, Escort P&F or Omron: Enter the new string in the Replace with edit field
and specify how many times the string should be valid in the No. of reads edit field. Press Apply
to send the string to the escort memory device. The next time the PLC orders reading of the device
(by generating a positive edge on the PLC ID device variables IDREAD, or one of the Multiple
identifier variables) IDTYPE_x_RD, the replacement string will be returned to the Station and PLC
instead of actually trying to read data from the escort memory. This will be repeated as many times
as set by the No. of reads parameter.
Any manually entered ID string sent to the device (by pressing Apply) can be cleared by pressing the
Clear button.
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4.17.7 Configure Target System

Selecting the Maintenance - Configure Target System menu item opens the Configure Target System
form.
This form is used for configuration of your PowerMACS 4000 TCs. This includes functions for downloading
new software and changing their IP-address data.
Press the Scan button to bring up a list of all available Tightening Controllers connected to the same
physically network as ToolsTalk PowerMACS. The scanning procedure uses network broadcast since this
gives the best possibility to find all connected TCs regardless of their IP-address and net mask settings.
The scan takes approximately 10 seconds and results in a list of TCs that where reached by ToolsTalk
PowerMACS. For each TC the following information is always displayed:
The current IP address on both interfaces
The current Status of the TC boot loader. Can be one of the following:
- No application – Means that the boot loader (the very first code executed by a TC when it
is powered on) did not find a valid TC System Software when it started. This indicates that
the System Software is either missing or is corrupt. To correct this try to download System
Software to the TC.
- Application Running – Means that the boot loader did find a valid System Software which
it started. It does not indicate that the TC has a setup loaded.
- Waiting for download – Means that the TC is set up to start download of new System
Software when it is restarted.
- Downloading: nn % – Indicates that download of System Software is progress.
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- Download Ok – Means that the boot loader has successfully downloaded System Software
to the TC. The TC must be restarted for the new software to take effect.
- Download failed or Download Aborted – Means that the boot loader failed to download
System Software to the TC. The cause of this may be network problems. Try to download
again.
4.17.7.1 Advanced mode

When not in advanced mode, the form shows only the most basic functions.
Advanced mode is reached by clicking the Advanced button on the toolbar. Advanced mode makes the
following available:
Restart button
Changes Load TC SW from a button to a button with a menu. The menu contains what was
earlier the Manage software function, to load spindle and servo SW.
View menu, where much more information to show can be chosen.
Context menu when right-clicking on either column headers or on a TC in the list.
Possibility to turn on/off telnet.
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4.17.7.2 Restart of TC’s after download

When all selected TC‟s have successfully downloaded new software, the user is prompted to restart them.
4.17.7.3 Information fields

The information fields are divided into groups Default, Spindle SW, Spindle Info, Servo, TC SW, TC
HW, and IP Addresses. When clicking on a group in the View menu, the list is refreshed to only show the
fields from the selected groups. The groups contain the following info fields:
Default
TC SW
System TC
Servo SW
Sp. SW
Sp. model
Sp. art. no
Spindle SW
Sp. model
Sp. SW
Sp. SW in TC
Sp. boot
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Spindle HW
Sp. model
Sp. serial no
Sp. art. no
Sp. HW serial no
Sp. HW ver
Sp. cycles
Sp. cycles since service
Sp. cycles to next service
Servo
Servo SW
Servo SW in TC
Servo boot
Servo HW ver
Servo serial no
TC SW
TC SW
TC boot
Telnet
IP addresses
Internal net mask
Gateway
Internal MAC
External net mask
External MAC
Com status
204 9836 3521 01

TC HW
TC model
TC serial no
TC art. no
PCB serial no
PCB type
PCB ver.
Fieldbus
If the TC is configured as a System TC. The System TC is the TC that controls all other TCs included in a
PowerMACS system. It is it that ToolsTalk PowerMACS is connected to and that holds the setup of the
system
TC boot is the version of the TC Boot loader. "(B1)" or "(B2)" indicates which of the dual boot loaders,
"Boot 1" or "Boot 2" that where active during start up. See chapter: Prepare TC for download of software
for a description of the dual boot loaders.
For a System TC, more data may be displayed if clicking Additional Info in the View menu. This
additional data includes the name of the System, the number of stations, the total number of bolts, and the
number of TCs used by the system. It is always the actually used values of the parameters that are
displayed in the list, this is important to understand when changing net data parameters.
Note! Since the scan procedure uses broadcasts it will detect all TCs that are connected to your network
regardless of their IP address configuration.
However, this does not mean that you can connect to, or send all configuration commands, to all
TCs displayed in the list. The reason for this is that the normal communication between ToolsTalk
PowerMACS and a TC is done using TCP and UDP which requires the communicating nodes to be
on the same IP network, or that a route between the networks is known. Therefore whether or not
you can connect to a TC depends on its IP-address, net mask, and default gateway.
To help you detect this situation an UDP message is sent to each TC found after the scan
procedure. If the TC does not bounce this message back the node is marked as erroneous and the
cause is displayed in the field under list, or in the Com status field.
Changing IP-address configuration, preparation of System Software download and changing service data
settings may be done to multiple TCs at the same time. Select the TCs of interest by marking them in the
list. To select a range click on the first row, hold down the Shift key and click on the last. To select multiple
single items, hold down the Control key and click on the wanted items.
To modify the network settings press the Set Int Eth or Set Ext Eth button. This will open the
9836 3521 01 205

Change Net Data form.
Press the Download button to prepare download of System Software using the form Prepare TC for
download of software.
To enable the telnet interface on a TC click the Telnet menu item.
Note The Telnet server is only used for advanced debugging purposes and should normally be
switched off during normal operations. You should not activate it unless directed by Atlas
Copco personal to do so.
The server is automatically disabled whenever the TC is restarted.
This command requires that the Console Computer is on the same network as the target system(s)
to modify, or there must exist a route between them.
For new net data, or a download to be effective, the TC must be restarted. Turning the power off and on
again is the normal way to do this. But if at least one TC accepts the request you will be offered the
possibility to restart those TCs remotely. You should only restart the TCs remotely if you are absolutely
sure that it is safe for the system to do so.
To overwrite spindle software with spindle software stored in TC flash, click Load spindle SW from TC.
This is only needed when wanting to downgrade the software in the spindle. TC automatically upgrades
the spindle upon start of communication if the spindle software in TC is newer than the software in the
spindle.
To overwrite servo software with servo software stored in TC flash, click Load servo SW from TC. This is
only needed when wanting to downgrade the software in the servo. TC automatically upgrades the servo
upon start of TC if the servo software in TC is newer than the software in the servo.
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4.17.7.4 Prepare TC for download of software

This form is used to select which software file to load to TCs selected for the operation.
To reduce the risk for non-repairable errors caused by failures during software download the application is
divided in two parts, the boot loader and the application.
The boot loader contains only the functions needed for starting and upgrading the application part while
the application contains the tightening functionality etc. Normally you need only to update the application.
Therefore the TC Software module is always delivered in two files, named as follows:
BOOT_x_y_z.MX: This file contains the boot loader image
APP_x_y_z.MX: This file contains the application image
x_y_z above is the version number of the respective file. Example: "APP_7_0_0.MX", BOOT_2_1_7.MX",
etc.
The boot loader is duplicated to increase the safety when updating the boot loader part. This gives each
TC dual boot loaders, named "Boot 1" and "Boot 2". At start up Boot 1 is responsible for checking that
Boot 2 is OK and if so start Boot 2. Boot 2 then performs the "everyday" work of the boot loader, that is,
starts the application, download new code etc. Should Boot 2 be found incorrect Boot 1 would instead
handle the work of the boot loader.
The boot loader file BOOT_x_y_z.MX contains both Boot 1 and Boot 2. If Boot 1 exists in the TC it is not
replaced when such a file is loaded since it is used only as a backup in case Boot 2 would be found
incorrect.
Note1 You should never downgrade the boot loader software. The latest boot loader version is
compatible with ALL applications.
Follow these steps to download new software:
1. Press Browse… to locate the file to load.
If boot must be downloaded, click on the Advanced >> button and check the Enable
downloading boot software check box that is displayed. Select the file named BOOT_x_y_z.MX.
Please note the warning.
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2. Click OK to prepare the selected TCs to download the specified file. This will cause a "Prepare TC
for download" command to be sent to the TCs. The success or failure of this command is displayed
in the Configure Target System dialog.
3. To start the actual download, you must restart the TCs. When restarted, each TC will request the
new file from ToolsTalk PowerMACS.
4. During download, TCs will indicate that they are downloading by flashing a text on the display.
5. When the download is finished the result of the download is displayed both by the TCs and
ToolsTalk PowerMACS. If successful the TC displays “Download OK” and if it failed “Download
Failed”. See chapter: Configure Target System for how ToolsTalk PowerMACS indicates the
result.
Note! It is important that you do not interrupt the download process when started. If that happens by
accident while downloading boot software you should not restart the TC. Restarting it may cause
the boot code to be erased, which will prohibit any further download. Instead try to download the
software again.
Restart the TCs after download to make the new software effective.
If you experience problems with spontaneously aborted download, it could be your network card that
has a cable hold off timeout set. For Windows 2000, look in Device Manager (open Control Panel, select
System, select tab Hardware and click on Device Manager). Find your network card under the heading
Network adapters and double click on it to view Properties. Select the tab Advanced and look for the
Property "Cable hold off timer" or similar. If this property has a value greater than zero, you could
experience the problem mentioned above. Set this property to zero. Note! Not all network cards have this
property.
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4.17.7.5 Change Net Data
This form is used for changing the network settings for one or more TCs.
Enter the new values in the field displayed

The Main Net Address determines the first three numbers in the IP address for the TC. The TC number
set on the TC display gives the last number of the address.
If you set a network mask with a nonzero value as the last number you must manually ensure that the
Default Gateway belongs to same network as all the TCs.
Click OK to send the new values to the TCs. The result of this request is displayed in the Configure Target
System form (see chapter: Configure Target System).
Keep in mind that the new values will not be displayed in the list until the TCs are restarted. The reason
for this is that the list always shows the currently used data and the TC will not use the new values until it
is restarted.
Note! This command requires that the Console Computer is on the same network as the target system(s)
to modify, or there must exist a route between them.
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4.17.8 Clear data
The Clear data form is invoked using the menu item Maintenance – Clear data….
The Clear Data form is accessible only when on-line and is used to clear process data stored in the non
volatile memory on the TCs. This includes the following:
SPC data, on all TCs or on an individual TC. The SPC data for a bolt is stored on the TC that
controls the spindle used to tighten the bolt.
Trace data, on all TCs or on an individual TC. The Trace data for a given bolt is stored on the TC
that controls the spindle used to tighten the bolt.
The Cycle data of the system. Only stored on the System TC, that is, the first TC in the system.
The Event log of the system. Only stored on the System TC.
To clear any of the above listen items first select the wanted TC, or TCs, and then press the Clear button.
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4.17.9 Compare programs

The Compare programs form, which is invoked using menu item Maintenance – Compare programs…,
is used to display the differences between the programs in two different setups.
Select two setups to compare, and then press the Compare button.
When the two setup files are read all programs that have the same name in the respective setups are
compared to each other. Programs that have different names are not compared to each other.
The differences are displayed using different colors and text style as follows (with item can be a step, a
check, or a parameter of these):
An item that exists in Setup 1 but not in Setup 2 is marked with blue underlined text, like this: Setup
1: Current.
An item that exists in the Setup 2 but not in Setup 1 is marked with green strikethrough text, like
this: Setup 2: File.
A changed item is marked with red text. The changed value of a parameter is indicated by having
the value from Setup 2 marked with green strikethrough text and the value Setup 1 is marked with
blue underlined text, like this: 5.00 s 4.00 s.
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By default, only the changes are displayed. To display the complete program, uncheck the checkbox
Show changes only.
Press the Print button to print the result and/or Save As… to save the result as a RTF file on disk.
Note! The algorithm used for comparing the two programs strives to find the smallest edit script needed to
change the program on disk to become equal to the program currently loaded. This means that the
result presented not necessarily correspond to the exact sequence of changes done by the
operator. For example, if the operator first have deleted a step of type A and then later inserted a
step of type B in the same location the result presented may be that the step type have been
changed.
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4.17.10 Check for System Conflicts

The Check for System Conflicts form, normally invoked using menu item Maintenance – Check for
System Conflicts…, is a tool for checking if the system contains conflicting TCs and/or TCs with different
versions of the TC System Software.
The frame Configuration conflicts lists all Spindle TCs that the System TC cannot connect properly to.
The list contains the Spindle TCs number with in the system (TC 1 is the System TC) and the reason for
the problem. This information is useful when trying to locate overlapping system layouts, that is, several
System TCs trying to use the same Spindle TC. The same information can also be found in the System
Map.
The data in the Configuration conflicts frame covers only the system that ToolsTalk PowerMACS is
currently connected to, and only when connected.
ToolsTalk PowerMACS continuously listens for telegrams (multicast) sent from a TC, System TC or
Spindle TC, that has detected a version conflict, that is, a System TC and a Spindle TC that does not use
the same version of the System Software. All errors of this type are presented in the Version conflicts
frame. This function is active also when ToolsTalk PowerMACS is not connected to any target system.
However, when on-line against a particular system the information received directly from it is used to
update the form with less delay.
Check the Include version errors from all systems to show version problems reported also for TCs
belonging to other systems then the currently selected target system.
Please note that the TCs do broadcasts the version conflict information with rather low frequency. This
leads to that the information in the Version conflicts frame may display an error even though it just has
been corrected. The information shown can be up to 30 seconds old.
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If any of the above conflicts are detected for the selected system when going on-line then a warning is
written on the caption bar of ToolsTalk PowerMACS and this form is displayed automatically. It is not
possible to close the form as long as there are errors in the system.
See also chapter: Tightening Controller for important information on System and Spindle TCs and The TC
HMI Menu System for how versions errors are displayed directly on the TCs. Chapter: Configure Target
System describes for how to download new TC System Software (Prepare TC for download of software)
and how to configure a TC as a System or a Spindle TC (The TC HMI Menu System).
4.17.11 TC Crash Log

The TC Crash Log form is invoked using menu item Maintenance – TC Crash Log…, is a tool that is
used to collect debug information from one or more TCs that crashed due to an internal software error.
Normally you should not run in to situations where this tool is needed but if you do the data it retrieves can
be of great help to Atlas Copco when analyzing the fault.
Use the Fetch log from TC combo box to select which TC to upload data from. Choosing the All
alternative will make all TCs be polled for data.
4.17.12 Maintain Spindle Parameters

The Maintain Spindle Parameters form is invoked by using the menu item Maintenance – Maintain
Spindle Parameters…, is used to both read and store all spindle parameters.
The operator must be connected to a TC in order to open the form.
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The operator can read any Spindle type file to the form by clicking the Open file button and select wanted
file of type *.ttt from the shown dialog box.
To read parameters from a connected spindle, the operator first selects wanted spindle from the combo
box in the upper left of the form. After that the operator clicks the Read from Spindle button. The Spindle
type is shown in the title of the form.
The operator can first open a Spindle type file and then read the parameters from a wanted spindle. Any
differences in parameter values will then be colored red.
When the operator wants to store parameters, the Store to Spindle button is clicked and the system will
check that the values seem reasonable. If not, the operator will be guided to the faulty value and given a
message of valid values to enter.
The operator can start all over again by clicking the Clear data button.
To access this form, the operator is urged to enter a password. Get in contact with Atlas Copco Tools
support in this matter.
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5 PLC
5.1 PLC - Overview
In every PowerMACS station there is a PLC (Programmable Logical Controller), called PowerMACS PLC.
This is programmed in a standardized, graphical, way according to the standard IEC 61131-3.
This part describes how to set up and use the PLC. A general description of the PLCs role in, and
interface to, the PowerMACS system is given in the next two chapters: General and System Globals.
The basics on how to write a program are given in the Programming the PLC chapter while a small, but
still powerful, user interface for the PLC is described in the PLC Console chapter.
Thorough information on how to use the Multiprog wt environment for editing PLC programs is given in
"The PowerMACS PLC Manual [2].
How to access parameters inside the PLC using the ToolsTalk PowerMACS is described in chapter: PLC
Parameters.
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5.2 General
PowerMACS PLC has a primary assignment to interface customer control system and peripheral devices
through different communication interfaces. It is used as ”glue” between various functions within the
system, as for example:
Start of tightening from digital inputs
Output of status to digital outputs
Controlling flow of data
Analyzing ID codes
The PLC has interfaces to several other units in the PowerMACS system.
Interfaces PLC-program Interfaces

System API and external
Globals serial comm.
devices
AND
PLC
Console
OR Cycle Data
Digital I/O
AND
Fieldbus
interface
The System Globals are inputs that represent the state of, and outputs that are used to control the
tightening process within PowerMACS. All these signals are described in chapter: System Globals.
The PLC Console interface is a simple, but still powerful, interface between the PLC program and the
ToolsTalk PowerMACS application running on the Console Computer. See chapter: PLC Console for a
detailed description of it.
From Digital I/O the PLC can read digital inputs (push buttons, switches etc.) and write digital outputs
(lamps, relays etc.) that have been configured in PowerMACS using an I/O device. See chapter: I/O
Device for how this is done.
The Fieldbus interface makes it possible to access signals in the PowerMACS PLC from a fieldbus
master. From the master it is then possible to write and read data in order to control the system and check
its status. See chapter: Fieldbus Interface for a description of this interfaces and how it is configured.
The API and external serial communication interface makes it possible to access signals in PLC from
external application from an external PC program or via some serial communication protocols. This is
handled much in the same way as the fieldbus interface. See chapter: API, Application Programmers
Interface and Serial Communication for a description of these interfaces and how they are configured.
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The Cycle Data interface makes it possible to read data produced as cycle data result. See the description
of PLC in chapter: Peripheral Devices, for how to enable this function.
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5.3 System Globals

The System Globals is the interface between the PLC and the tightening controller part of the system. By
setting global outputs from the PLC you can order ID devices to be read, start a tightening cycle and so
on. By reading inputs you can check the state of the system, for example if a cycle is ready.
These variables are all declared in the System_Globals section of the Global Variables worksheet found
in the project tree of the PowerMACS PLC.
5.3.1 Station variables

The following inputs reflect the status of the station, and to some extent, the system:
Variable Type Use

EMERGSTOPIN BOOL This signal is True if the TC hardware Emergency input is inactive.
CURRSYNCH INT Reflects the number of synchronization points that have been
passed. Initialized to 0 at cycle start.
CYCLEDATASTORED BOOL This input is set False when START is set True and is set to TRUE
when the Cycle Data result has been stored in the PowerMACS
internal cycle data queue. That is, when True an external device can
read the cycle data without delay.
This might be useful for external devices that need to know when
they can expect the result of the last cycle is available.
SYSTEMSTATUS INT Indicates system errors. The respective bits have the following
meaning (bit 0 is the least significant):
0: (value 1) Servo errors
1: (value 2) Spindle errors
2: (value 4) TC has lost contact with system TC
1-31: Reserved
TESTBOLT_ACTIVE BOOL This signal is True when the ToolsTalk PowerMACS Test Bolt form is
open and connected to this station. See also chapter: Test Bolts.
ACTA_ACTIVE BOOL This signal is True when an ACTA 3000 unit is connected to the
system and is active against a spindle belonging to this station.
TTPM_ACTIVE BOOL Indicates whether or not a ToolsTalk PowerMACS is connected to
the target system. True if a connection exists and False if not.
VALID_MODE BOOL This signal is True when a valid the mode is set using the PLC output
MODE.
A mode is valid if it is in the interval [1...50] and at least one bolt is
connected normally for the mode.
ACTA_MODE INT Reflects the mode number sent from the ACTA 3000 unit. Only valid
if ACTA_ACTIVE is True.
ACTA_SPINDLENO INT Reflects the spindle number sent from the ACTA 3000 unit. Only
valid if ACTA_ACTIVE is True.
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Variable Type Use

CD_OVERRUN_W1 BOOL This input is set True when there is room for less than 10 more cycle
data in the cycle data queue for any device. If set, it is automatically
reset when all devices have space for at least 10 more data, that is
when the failing device has read its queue
CD_OVERRUN_W2 BOOL Same function as CD_OVERRUN_W1 with the difference that it
indicates that at least one queue is full but not yet overrun. That is,
the next cycle data will be lost.
CD_OVERRUN_E1 BOOL This input is set True when a new a cycle data caused the queue for
at least one device to be overrun. If set, it remains set until a new
cycle can be added to the queue without causing it to be overrun.
This means the flag is not reset immediately when the failing device
read a cycle data from the queue (which frees one position in the
queue). The status is not checked with less than that a new cycle
data is generated.
CURRMODE INT This input always reflects the MODE value currently known by the
station.
EVENT BOOL System events. Is True when there are unobserved events of any
type (see View Event Log).
SPCEVENT BOOL This input is True when there is unobserved "SPC" events in the
event log (see View Event Log).
ACCESSEVENT BOOL This input is True when there is unobserved "Access" events in the
POWERUPEVENT BOOL This input is True when there is unobserved "Power up" events in the
CHKEVENT BOOL This input is True when there is unobserved "Check" events in the
SWEVENT BOOL This input is True when there is unobserved "Software" events in the
SYSERREVENT BOOL This input is True when there is unobserved "System error" events in
the event log (see View Event Log).
MODEVENT BOOL This input is True when there is unobserved "Modification" events in
the event log (see View Event Log).
HWEVENT BOOL This input is True when there is unobserved "Hardware" events in the
EMERGEVENT BOOL This input is True when there is unobserved "Emergency stop"
events in the event log (see View Event Log).
GENERALEVENT BOOL This input is True when there is unobserved "General" events in the
XCOMEVENT BOOL This input is True when there is unobserved "External
communication" events in the event log (see View Event Log).
SETUPEVENT BOOL This input is True when there is unobserved "Setup" events in the
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Variable Type Use

CONS_IN_1 BOOL Input connected to the ToolsTalk PowerMACS form PLC Console.
CONS_IN_4 STRING(40) Input connected to the ToolsTalk PowerMACS form PLC Console.
CONS_IN_5 STRING(40) Input connected to the ToolsTalk PowerMACS form PLC Console.
SERVOSTATUS ARRAY[1..50] Reports the current status of each servo (TC) in the system.
OF BYTE The respective bits have the following meaning (bit 0 is the least
significant):
0: (value 1) Servo NOK
1: (value 2) Communication NOK
2: (value 4) Over temperature
3: (value 8) Spindle not ready
4: (value 16) TC out of order
5: (value 32) Reserved
7: (value 128) Any Fault
See also the description of the PLC input RESET.
SPINDLESTATUS ARRAY [1..50] Reports the current status of each spindle (connected to TC) in the
OF BYTE system.
The respective bits have the following meaning (bit 0 is the least
significant):
0: (value 1) Spindle NOK
1: (value 2) Communication NOK
2: (value 4) Over temperature
3: (value 8) Servo not ready
7: (value 128) Any Fault
See also the description of the PLC input RESET.
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Variable Type Use

SPINDLECONTROL ARRAY[1..50] This output control which spindles to run when the station is started.
OF BYTE Takes one of the following values:
0: Connect normally. The bolts connected to the spindle will run
the tightening program specified in the mode table when
station is started.
1: Disconnected with OK status
2: Disconnected with NOK status
3: Do not run during next cycle
The difference between "Disconnected" and "Do not Run" is that in
the first case the bolt connected to the spindle will be reported with
the given status and in the latter nothing is reported for the bolt. In
neither case will the bolt start when the station is started.
MOTOR_TEMP ARRAY [1..50] Reports current motor temperature in centigrade for all spindles.
OF REAL Updated at cycle start and end.
CYC_TO_SERVICE ARRAY [1..50] Reports number of cycles before service should take place.
OF DINT
DEVICE_CTRL ARRAY [0..31] Controls device queue
OF DataHold DataDrop Result
{DATAHOLD,
DATADROP} False False Cycle data is saved for this device.
False True Cycle data is not saved for this
device.
True X Cycle data is saved for this device
but the wanted and unread bits are
not set (datahold bit is set instead).
True False Cycle data is dropped for this device
True when a positive edge is detected on
datadrop (latest or specific ID).
True X Cycle data is kept for this device
False when a negative edge is detected on
datahold (cycle data that have the
datahold bit set is marked as wanted
and unread).
DEVICE_ID ARRAY [0..31] CD and Trace ID for DataHold and DataDrop / Device.
OF {CDID, CDID - The cycle data id that should be dropped or zero if latest
reserved} should be dropped
reserved - The trace data id that should be dropped or zero if latest
should be dropped
STEP_OK BOOL Set when all bolts in the cycle have reached a synchronization
point and have status OK. It will stay set until next step start.
The minimum time is one PLC cycle.
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Variable Type Use

STEP_NOK BOOL Set when all bolts in the cycle have reached a synchronization
point and at least one bolt has status NOK. It will stay set until
next step start. The minimum time is one PLC cycle.
PLC_DI_1..10 BOOL These signals can be set at specific times directly from the tightening
programs, e.g. at step start or zone end. See Ramps & Other –
Signals at step start and end (only available for Gauging)
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Outputs used for controlling the station:
Variable Type Use

MODE INT Set to number of mode to use in next cycle. Sampled on the positive
edge of START.
RESET BOOL Reset servo errors on a positive edge. Should only be set True if the
station is idle.
Note! All servos connected to the station are reset.
START BOOL Starts cycle. A positive edge will start the first step in the cycle. This
signal is ignored if the station is not idle, or if STEPSTOP,
EMERGSTOP or MACHINESTOP is True.
LOOSENING BOOL Loosen cycle. When set to True mode 50 will be started and all
cycle data and trace data will be automatically dropped. See
detailed description below.
Note that the cycle and trace data that is produced while loosening
is active is dropped and will not be stored in the system.
STEPSTOP BOOL Step stop. Set to True to stop current step with status OK. Next
START will continue with next step in the cycle.
EMERGSTOP BOOL Emergency stop. Set to True to stop the cycle with status NOK.
Next START will start cycle from beginning.
MACHINESTOP BOOL Machine stop. Set to True to stop the cycle with status NOK. Next
positive edge on START will start a new cycle.
MONSTART BOOL Start monitoring. Set to True to start monitoring of the spindles. This
signal is ignored if the station is not idle.
MONEND BOOL End monitoring. Set to True to end monitoring of the spindles.
DATAHOLD BOOL Data hold. Set to True, before starting a cycle, to hold the
transmission of cycle data. The data is released when the input is
set to False if the station is idle (status < 4) and DATADROP is
False.
Note that the cycle data that is produced while hold is active will
contain only one station header, the one produced by the first start.
DATADROP BOOL Data drop. If True when a cycle data is to be reported then the data
is dropped, without any distribution.
Cycle data is normally reported when the cycle ends but if
HOLDDATA is active it is reported when DATAHOLD is set to False.
TRACEDROP BOOL Trace drop. If True when the cycle end the traces will not be
distributed to any device.
GENEVENT INT Set to a code 1-10 to generate an event. The code used will be
displayed together with the event.
STEPTYPE INT Control data used for the PLC - Run PLC step used in the tightening
program. Defines which control function the step should execute.
See the step description for valid values.
STEPVAL REAL Control data for the PLC - Run PLC step. Used as target value.
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Variable Type Use

GENOUT_1 ... INT General output. Can be used for selection of double encoders or
GENOUT_5 change of spindle direction. See chapter: Spindle Set Up.
FREESTRING STRING(40) The value of this output can be included in the cycle data result as
the station level result variable "Free Str". Sampled on the positive
edge of START.
FREESTRING2 STRING(40) The value of this output can be included in the cycle data result as
the station level result variable "Free Str 2". Sampled on the positive
edge of START.
FREESTRING3 STRING(40) The value of this output can be included in the cycle data result as
the station level result variable "Free Str 3". Sampled on the positive
edge of START.
FREENUM1 DINT The value of this output can be included in the cycle data result as
the station level result variable "Free No 1". Sampled on the positive
edge of START.
FREENUM2 DINT The value of this output can be included in the cycle data result as
the station level result variable "Free No 2". Sampled on the positive
edge of START.
DISABLE_TESTBOLT BOOL Set this output TRUE to disable the usage of the ToolsTalk
PowerMACS Test Bolt form for this station. See also chapter: Test
Bolts.
ACKACCESSEVENT BOOL Set this output True to mark all events of type "Access" as observed
(see View Event Log and PLC Event handling).
ACKPOWERUPEVENT BOOL Set this output True to mark all events of type "Power up" as
observed (see View Event Log and PLC Event handling).
ACKCHKEVENT BOOL Set this output True to mark all events of type "Check" as observed
ACKSWEVENT BOOL Set this output True to mark all events of type "Software" as
observed (see View Event Log).
ACKSYSERREVENT BOOL Set this output True to mark all events of type "System error" as
ACKMODEVENT BOOL Set this output True to mark all events of type "Modification" as
ACKHWEVENT BOOL Set this output True to mark all events of type "Hardware" as
ACKEMERGEVENT BOOL Set this output True to mark all events of type "Emergency stop" as
ACKGENERALEVENT BOOL Set this output True to mark all events of type "General" as
ACKXCOMEVENT BOOL Set this output True to mark all events of type "External
communication" as observed (see View Event Log).
ACKSETUPEVENT BOOL Set this output True to mark all events of type "Set up" as observed
(see View Event Log).
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Variable Type Use

ACKSPCEVENT BOOL Set this output True to mark all events of type "SPC" as observed
(see View Event Log).
CONS_OUT_1 ... STRING(40) Outputs connected to the ToolsTalk PowerMACS form PLC
CONS_OUT_5 Console.
RESETSTATUS BOOL Set this output True to reset the status of the station, and all bolts of
the station, in both the PLC and ToolsTalk PowerMACS. A positive
edge on this output will affect the following:
The PLC inputs STATIONSTATUS_EXT and
BOLTSTATUS_EXT[n] all flags are cleared
The status of the station and all bolts displayed by the ToolsTalk
PowerMACS forms “System Map” and “Assembly Overview” are
cleared by setting their background color to grey and removing
all result information being displayed
Note! A positive edge on RESETSTATUS while the station is not idle
is silently ignored.
DISABLE_ACTA BOOL Set this output True to disable the activation of an ACTA 3000 unit
for any spindle belonging to this station.
FILTER_SPINDLEEV BOOL Filter spindle events. When signal is high, spindle and servo events
are not generated.
INTERMEDSTART BOOL In each step it will be possible to select if the station shall continue
with the next step directly at step end or if it shall wait for the PLC to
continue. If the checkbox “Wait for PLC at step end” is checked for
at least one bolt in the cycle the station will stop and wait for the
signal INTERMEDSTART from the PLC to continue running the
cycle.
PLC_DO_1..10 BOOL These signals can be used as input to a JOG - Run until digital input
goes high / low or W - Wait step
Note! For the respective ACKxxxEVENT outputs to function they must first be enabled using the
Advanced Station Settings form. See chapter: PLC Event handling).
5.3.1.1 Loosening cycles

It is possible to run a loosening cycle with automatic data and trace drop by using the digital I/O signal that
has been designated for this purpose (LOOSEN). To use this function use the digital I/O signal named
DI_Loosening and mode 50 in the mode table in the following way:
In the mode table ensure that Mode 50 contains the loosening program that is to be run.
Activate the digital I/O signal DI_Loosening by setting it high.
Start the cycle using the digital I/O signal DI_Start.
Deactivate the digital I/O signal DI_Loosening by setting low.
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The loosening functionality is only activated if the tightening cycle is started from the PLC, it does not
affect cycles started from TESTBOLT, ACTA or GM-DEVICNET devices.
The standard PLC program that is generated by the wizard contains signals, outputs and functions to
support this. It is off course possible to alter the PLC program to use other means or input rather than the
digital I/O signal DI_Loosening by using the PLC output variable LOOSENING.
Note! Mode 50 in the mode table is acting as any other mode when the digital I/O signal DI_Loosening is
active low.
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The following shared memory variable also reflects the configuration and status of the station and system.
Even though they are defined as shared memory variables, which mean that the PLC application can write
to them, they should be used as inputs only.
Variable Type Use

NO_OF_BOLTS INT Indicates the number of bolts defined for this station.
NO_OF_SPINDLES INT Indicates the number of spindles (and TCs) defined for this
station.
IO_INCLUDED BOOL If True an I/O device is configured to be located on the
same TC as this station runs on.
FB_INCLUDED BOOL If True a Fieldbus device is configured to be located on the
same TC as this station runs on.
INT_PARAMS INT_PARAM_ARR This is an array of 130 parameters of type INT (16 bit
signed integer) defined and modified using the ToolsTalk
PowerMACS forms PLC Parameters Set Up and PLC
Parameters.
They can be used to make the PLC more generic in the
sense that minor parameter changes that earlier must be
done using the Multiprog wt editor now can be done by the
end user using the normal ToolsTalk PowerMACS
interface.
REAL_PARAMS REAL_PARAM_ARR This is an array of 20 parameters of type REAL (32 bit
floating point) defined and modified using the ToolsTalk
Parameters.
See also the description of INT_PARAMS.
STRING_PARAM_1 ... STRING40 These parameters of type STRING40 (max 40 character
STRING_PARAM_10 long strings) are defined and modified using the ToolsTalk
Parameters.
See also the description of INT_PARAMS.
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Variable Type Use

STATIONSTATUS_EXT STATION_STATUS_ This variable indicates the station status of the last
EXT_TYPE tightening.
It is a structure containing the following BOOL flags:
OK True if result is OK or OK after RM (OKR).
OKRM True if result is OK after RM.
NOK True if result is NOK or Stop and Terminate Not
OK (TERMNOK).
TERMNOK True if result is Stop and Terminate Not
OK (TERMNOK).
The value of this variable is only changed as a result of
running a cycle. When the station is started all flags are
reset and when the cycle is ready the relevant flags are
set.
Use this variable together with STATIONSTATE as an
alternative to the STATIONSTATUS input.
STATIONSTATE STATION_STATE_ This variable indicates the current state of the station.
TYPE It is a structure containing the following BOOL flags:
IDLE True if the station is idle, that is, it is not
executing a cycle.
RUNNING True if the station is running a cycle, that
is, it is not idle. This includes evaluating and waiting for
PLC as well.
EVALUATING True if the station is evaluating the
results from the bolts.
WAITING_FOR_PLC True if the station is waiting for
a new START signal due to that some bolt is executing
a step that requires a this to continue.
Use this variable together with STATIONSTATUS_EXT as
an alternative to the earlier STATIONSTATUS input.
DEVICE_ERR DEVICENO_ERR_ This variable indicates erroneous devices in the system
ARR per device number.
The variable is an array of BOOL where each element
represents the device with the number equal to the array
index number.
That is, if DEVICE_ERR[10] is True then the device with
device number 10 is erroneous.
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Variable Type Use

DEVICE_STATUS DEVICE_STATUS_ This variable indicates status of devices.
ARR The variable is an array of BYTE where each element
represents the device with the number equal to the array
index number.
That is, DEVICE_STATUS[10] shows the status of the
device with device number 10.
The status value corresponds to following:
0: NOSTATUS
1: WORKING
2: IDLE_OK
3: IDLE_NOK
4: OUTOFORDER
DEVICE_OVERRUN DEVICE_ OVERRUN This variable indicates device overrun error per device
_ARR number.
The variable is an array of elements that contain three
BOOL variables each where each element represents the
device with the number equal to the array index number.
That is, DEVICE_OVERRUN[10] shows the element of the
device with device number 10.
Each element includes:
WARNING1 : TRUE if less than PLC_W1_LEVEL queue
positions free
WARNING2: TRUE if there is no queue positions free
ERROR : TRUE if an unread item has been removed
when a new item was stored
The following shared memory variable can be used for handling of process data:
Variable Type Use

FB_PROCDATA_STORED BYTE The PowerMACS system will write True to it when it has written
anything to the Process Data output area of the fieldbus.
The System will never write False to it. In order to detect when it is
set you must clear it from inside the PLC.
IDDEV_PROCDATA_STORED BYTE Id Device handshake information.
The PowerMACS system will write True to it when it has written
anything to the escort memory.
The System will never write False to it. In order to detect when it is
set you must clear it from inside the PLC.
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CYCLDATA_VAR_UPDATED BYTE This input is set True when there are new cycle data available in
CycleData_Var.
It can be set False by the PLC program to be able to check when
new cycle data has arrived.
UPDATE_EXTCO_2 BYTE When this variable is written with a positive flank (0->1) all
variables controlled by the EXTCO2_out area will be updated. The
PLC program must reset it to 0 afterwards, not faster than one
execution loop. See sub chapter Access to PLC data of Serial
Communication.
A shared memory variable can be written to from the PowerMACS system as well as from the
PowerMACS PLC.
FB_PROCDATA_STORED may be used in many different ways depending on type of application. For
example: In a system where cycle data is generated after each cycle (also at emergency stop) and this
data is automatically loaded to the fieldbus device one way of using it is as follows:
1. Have the PowerMACS PLC write FALSE to the variable FB_PROCDATA_STORED just before or
simultaneously with, the start signal.
2. Wait for the PowerMACS system to write TRUE to the variable FB_PROCDATA_STORED before
indicating that the cycle is finished to the fieldbus master.
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5.3.2 Bolt variables

The following inputs can be used to monitor the status of each individual bolt:
Variable Type Use

COMPERRORS ARRAY[1..50] Reports the most commonly reported bolt errors for each of the
OF BYTE bolts.
The respective bits have the following meaning (bit 0 is the least
significant):
0: (value 1) THM (Torque High Monitoring)
1: (value 2) TLM (Torque Low Monitoring)
2: (value 4) AHM (Angle High Monitoring)
3: (value 8) ALM (Angle Low Monitoring)
4: (value 16) OK (Bolt status OK).
This bit is set if the bolts final status is
OK.
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Use the below output signals to control the behavior of the bolts:
Variable Type Use

BOLTCONTROL ARRAY[1..50] This output controls which bolt to run when the station is started.
OF BYTE Takes one of the following values:
0: Connect normally. The bolt will run the tightening program
specified in the mode table when station is started.
1: Disconnected with OK status
2: Disconnected with NOK status
3: Do not run during next cycle
100 + Pgm. No: The bolt will run the tightening program with
program number Pgm. No when station is started and mode
table value is “Program from PLC” for the bolt. PgmNo is a
number between 1 and 150.
The difference between "Disconnected" and "Do not Run" is that

in the first case the bolt will be reported with the given status and
in the latter nothing is reported for the bolt. In neither case will the
bolt start when the station is started.
The outputs BOLTCONTROL and DATAHOLD are useful when running a stitching application, i.e. when a
single spindle is used to tighten more than one bolt. To generate one cycle data result, including only one
station header, even though several starts are done follow the below scheme:
1. Set DATAHOLD = True
2. Set BOLTCONTROL = 0 or BOLTCONTROL = 100 + Pgm. No for all bolts to run in this cycle and
BOLTCONTROL = 3 for all bolts that should not.
3. Generate a START. This will start only the selected bolts.
4. Wait for the cycle to end (monitor for example STATIONSTATUS)
5. If not all bolts are tightened yet go to step 2
6. Set DATAHOLD = False to release the cycle data, complete with one record for the station and
one for each bolt tightened
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The following shared memory variable also reflects the state and status of the bolts. Even though they are
defined as shared memory variables, which mean that the PLC application can write to them, they should
be used as inputs only.
Variable Type Use

BOLTGROUPS BOLT_GROUPS_ARR This is an array of 50 WORDS (16 bit unsigned integers)
where each element represents the groups that a particular
bolt belongs to.
The respective bits in BOLTGROUPS[x] have the following
meaning (bit 0 is the least significant):
0: (value 1) Bolt x belongs to group 1
:
10 -15: Reserved
BOLTSTATUS_EXT BOLT_STATUS_EXT_ This variable is an array of 50 elements of type
ARR BOLT_STATUS_EXT_TYPE. Each element indicates the
status of the last tightening for a bolt.
The BOLT_STATUS_EXT_TYPE is a structure containing
the following BOOL flags:
OK True if result is OK or OK after RM (OKR).
OKRM True if result is OK after RM.
NOK True if result is Not OK (NOK), Not OK due to RM
(NOKRM) or Stop and Terminate Not OK (TERMNOK).
NOKRM True if result is Not OK due to RM (NOKRM).
TERMNOK True if result is Stop and Terminate Not OK
(TERMNOK).
The value of this variable is only changed as a result of
running a cycle. It is updated as follows:
When the station is started all bolts that are set to be
Disconnected OK/NOK, either using the PLC output
BOLTCONTROL or the ToolsTalk PowerMACS forms
"Mode Table" or "Bolt Set Up", the corresponding OK or
NOK flag is set immediately. For all other bolts all status
flags are cleared.
When the cycle is ready the relevant flags are set.
Use this variable together with BOLTSTATE as an
alternative to the earlier BOLTSTATUS input.
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Variable Type Use

BOLTSTATE BOLT_STATE_ARR This variable is an array of 50 elements of type
BOLT_STATE_TYPE. Each element indicates the current
state of a bolt.
The BOLT_STATE_TYPE is a structure containing the
following BOOL flags:
DONOTRUN True if the bolt is ordered not to run, either
using the PLC output BOLTCONTROL or the ToolsTalk
PowerMACS "Mode Table" form.
DISCON_OK True if the bolt is disconnected with OK
status, either using the PLC output BOLTCONTROL or
the ToolsTalk PowerMACS forms "Mode Table" or "Bolt
Set Up".
DISCON_NOK True if the bolt is disconnected with NOK
status, either using the PLC output BOLTCONTROL or
the ToolsTalk PowerMACS forms "Mode Table" or "Bolt
Set Up".
IDLE True if the bolt is connected normally and is idle,
that is, it is not disconnected or ordered not to run and is
not executing a cycle.
RUNNING True if the bolt is running a cycle, that is, it is
not idle. This includes running reject management,
evaluating and waiting for PLC as well.
RUNNING_RM True if the bolt is running reject
management.
EVALUATING True if the bolt is evaluating its
monitoring results.
WAITING_FOR_PLC True if the bolt is waiting for a new
START signal due to that it is executing a step that
requires a this to continue.
Note: Since the connect state (Do not run, Disconnected
OK, Disconnected NOK) of a bolt may depend on the MODE
(the Mode Table form), changing the value of the MODE
input may affect this variable.
This means that BOLTSTATE[x] always will reflect whether
or not bolt x is disconnected or not, regardless from where it
is disconnected.
Use this variable together with BOLTSTATUS_EXT as an
alternative to the earlier BOLTSTATUS input.
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5.3.3 ID device variables

The following input and outputs can be used to control and monitor the Stations Work piece identifier
function. See chapter: Advanced Station Settings for this is set up.
Inputs:
Variable Type Use

IDSTATUS INT Status for ID device read or write operation:
0: Idle and OK
1: Idle and NOK
2: Busy
Note that the read ID string is not valid until this signal is 0. After
issuing an IDREAD you should always wait one PLC scan before
evaluating IDSTATUS.
CURRIDSTRING STRING(40) This input always reflects the ID string known by the station. Will be
included in the cycle data as the station level variable "Wp ID".
IDCODE INT Code from conversion of read ID string. See chapters: Conversion
table for how the conversion is defined.
Outputs:
Variable Type Use

IDREAD BOOL Set to True to order reading of ID device connected to the station.
IDWRITE BOOL Set to True to replace the ID string currently known by the station with
the value of IDSTRING.
If the station is connected to an ID device this device will be used to
generate a corresponding IDCODE. The written value will be echoed
back to CURRIDSTRING.
IDSTRING STRING(40) String to replace the ID string currently known by the station.
Sampled on the positive edge of IDWRITE.
The station will only use an ID string once. When it starts a cycle it will clear its internal ID string, and
therefore also CURRIDSTRING, and then set the value of IDCODE to –32768.
Depending on which type of ID device that is used a read operation may take differently long time. For a
barcode reader the last string scanned by the operator is stored internally by PowerMACS system so
completing a read is done within less a few milliseconds. However, for devices of Escort memory, where
the external data tag is read using a communication protocol, a read operation may take much longer
time. You should therefore always check the input IDSTATUS to make sure that a read string is available
to the station before you issue a start order.
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Example: The below code issues an IDREAD order when the signal "Customer_Start_Signal" is set True,
waits for the string to be returned, and then starts the tightening cycle.
5.3.4 Multiple identifier variables

The following input and outputs can be used to control and monitor the Stations Multiple identifiers
function. See chapter: Advanced Station Settings for a description on how it is configured and works.
Inputs:
Variable Type Use

IDTYPE_1_STR ... STRING(40) The value of the last accepted string for the respective Identifier
IDTYPE_6_STR Type. Cleared when on a positive edge of START.
IDTYPE_1_CODE INT Code generated by the Conversion table defined for Identifier Type 1.
IDTYPE_WO_STATE BYTE Work Order State. A number between 0 and 4 indicating the latest
accepted item in the Work Order list.
One (1) means that the first Work Order condition is met, two (2) that
the second one was accepted, and so on.
Set zero (0) when the Work Order sequence is reset.
IDTYPE_WO_COMPL BOOL Work Order Complete. Set True when all Types of the Work Order
are accepted. Set False when a cycle is started or if the Work Order
sequence is restarted.
IDTYPE_1_STS... INT Status of the read operation of the ID device used as source for the
IDTYPE_6_STS respective Identifier Type:
0: Idle and OK
1: Idle and NOK
2: Busy – waiting for the device to respond
After issuing an IDTYPE_x_RD you should wait one PLC scan before
evaluating IDTYPE_x_STS.
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Outputs:
Variable Type Use

IDTYPE_1_RD ... BOOL Set to True to order a read of the ID device configured as Source for
IDTYPE_6_RD the respective Identifier Type.
Note! Issuing a read order using one of these outputs does not
automatically lead to that the returned string is assigned the
corresponding Identifier Type. This matching is controlled solely by
the Multiple identifiers function.
IDTYPE_LOCK BOOL While True all input to the Multiple identifiers function is locked. All
data received while lock is active is dropped.
IDTYPE_HOLD BOOL When the signal is high the state of the multiple id function and the
work order are kept between the cycles. This means that a half
finished work order can be completed after the cycle and the received
id string are used in the next cycle. It also means all received id string
are kept between the cycles and can be reused as many time as
wanted.
The other IDTYPE signals still work even though IDTYPE_HOLD is
high. If new strings are scanned they will also be used. To keep the id
strings totally fixed you should use IDTYPE_HOLD together with
IDTYPE_LOCK, this will stop new strings to be received from the
scanner and the strings already in will be kept between the cycles.
IDTYPE_RESET_ALL BOOL Resets the Multiple identifiers function on a positive edge.
This will clear all Identifier Type strings (IDTYPE_x_STR) and set the
Work Order sequence to its initial state (IDTYPE_WO_STATE = 0).
IDTYPE_RESET_LAST BOOL A positive edge resets the last accepted Identifier Type.
This will clear the string corresponding to the Identifier Type
(IDTYPE_x_STR).
If the Identifier Type is a part of a Work Order then the state of the
Work Order is backed one step. If the last accepted Type was made
the Work Order completed it will become active again, waiting for the
same Type.
IDTYPE_WO_BYPASS BOOL A positive edge will accept the Type currently monitored by the Work
Order.
The Type will be assigned an empty string and a warning event is
generated to indicate that a Work Order Type was bypassed.
PLC1_IDTYPE_STR ... STRING(40) String that can be used as Identifier Type Source. Sampled on the
PLC6_IDTYPE_STR positive edge of PLCx_IDTYPE_WR.
PLC1_IDTYPE_WR ... BOOL A positive edge samples a new value of the corresponding
PLC6_IDTYPE_WR PLCx_IDTYPE_STR variable.
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5.3.5 GM DeviceNet variables

The following shared memory variables serve as the discrete interface to the GM DeviceNet device. For a
more detailed description of the GM DeviceNet device see chapter: GM DeviceNet.
Even though the following variables are defined as shared memory type, which mean that the PLC
application can read and write to them, they should be used as outputs only (seen from the PLC):
Variable Type Use

GM_IN GM_INPUT_TYPE This variable represents the discrete inputs to the GM DeviceNet device.
GM_INPUT_TYPE is a structure containing the following BOOL flags:
PARSET1 Parameter set code (1-8) mapped to Mode bit 0 (value 1).
REVERSE Reverse tool cycle. Uses mode 9 for the reverse
program.
START A transition from FALSE to TRUE starts a tightening cycle.
Positive edges while a cycle is running or when STOPDISABLE is
True are ignored..
EPRIN TRUE indicates that a new cycle may be started. PARSETx
are sampled on a positive edge of this signal.
STOPDISABLE TRUE stops the current cycle and inactivate the
spindles from any future cycle. Must be low to permit a new cycle to
start.
DISABLEDNETINP When TRUE all inputs via DeviceNet except for
the PVI number are disabled.
Note! This input is always read, regardless of the value of the device
parameter Through discrete I/O (see chapter: GM DeviceNet).
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Even though the following variables are defined as shared memory type they should be used as inputs
only (seen from the PLC):
Variable Type Use

GM_OUT GM_OUTPUT_TYPE This variable represents the discrete outputs from the GM DeviceNet
device. GM_OUTPUT_TYPE is a structure containing the following
BOOL flags:
GREENLIGHT Pass through signal from the DeviceNet input
interface. (Green stack light).
YELLOWLIGHT Pass through signal from the DeviceNet input
interface. (Yellow stack light).
REDLIGHT Pass through signal from the DeviceNet input
interface. (Red stack light).
ALARMHORN Pass through signal from the DeviceNet input
interface. (Alarm Horn).
PARSET1 Parameter set code (1-8) confirmation. Mapped to
Mode bit 0 (value 1).
GLOBALACCEPT Global accept (Set to 1 if the cycle completed
OK).
INCYCLE Spindle in cycle, set to 1 when a cycle is running and to
0 when idle.
FAULTRELAY System fault relay (currently not used).
CYCLECOMP Rundown complete. Is TRUE when a cycle is
ended and FALSE when running.
EPROUT Reflects the current value of the input Error Proofing
Ready (EPR).
LIGHT(16) This is an array of 16 x 3 BOOL that indicates the
status of the tightening for each of the bolts in the station. The
status of each bolt is indicated using the following three BOOL
signals:
GREEN Good Rundown (Green light)

RED Remove, Inspect & Repair Fastener (Red light)
YELLOW Low Torque (Yellow light)
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5.3.6 DC PLUS variables

The following variables are used for control of a DC PLUS Ethernet device. For a more detailed
description of the DC PLUS Ethernet device see chapter: DC PLUS.
Inputs (seen from the PLC):
Variable Type Use

PLUS_CONNECTED BOOL TRUE if a connection to the PLUS server is established.
PLUS_DATAAVALIABLE BOOL TRUE if there are data available in the cycle data queue for the
PLUS device.
PLUS_MODE INT Mode number from conversion of TMU. The conversion table in the
PLUS device will be used for the conversion.
The string to convert is a TMU received from PLUS, if “Station Type”
on the PLUS device is SAW/WIS. Otherwise the string
PLUS_OVERRIDETMU will be used.
The value is updated when PLUS_GETTMU_OK is set to TRUE.
PLUS_GETTMU_CHECKED BOOL Reflects the selection of Station Type in the PLUS device in
ToolsTalk PowerMACS. Set to TRUE for station type SAW and to
FALSE for the other types.
Only available for backward compatibility reasons, it is
recommended to use PLUS_STATIONTYPE instead.
PLUS_STATIONTYPE INT Reflects the selection of Station Type in the PLUS device in
ToolsTalk PowerMACS.
Possible values are:
1 = SAW/WIS
2 = SPS
3 = VBA
4 = SSE
PLUS_SENDDATA_NOK BOOL Is set to NOK if a send of cycle data fails for some reason, e.g. bad
VIN number, bad QO, etc.
If there are more data in the cycle data queue they will be sent even
if one send failed.
PLUS_SENDDATA_NOK will be set until a positive edge is sent to
PLUS_RESETSENDDATA_NOK.
PLUS_BUSY BOOL The device is busy sending a request for TMU or a Test telegram.
Only tests started from the PowerMACS PLC, with
PLUS_CHECKCOM will affect PLUS_BUSY.
PLUS_GETTMU_OK BOOL TRUE if the latest request for TMU succeeded.
PLUS_GETTMU_NOK BOOL TRUE if the latest request for TMU failed.
PLUS_CHECKCOM_OK BOOL TRUE if the latest test of the communication, started from the
PowerMACS PLC with PLUS_CHECKCOM, succeeded.
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Variable Type Use

PLUS_CHECKCOM_NOK BOOL TRUE if the latest test of the communication, started from the
PowerMACS PLC with PLUS_CHECKCOM, failed.
Outputs seen from the PLC:
Variable Type Use

PLUS_CHECKCOM BOOL On a positive edge a test telegram “TSTS” is sent to the PLUS
server.
PLUS_BUSY will be set to TRUE and PLUS_CHECKCOM_OK
and NOK will be set to FALSE. Then the test has finished
PLUS_BUSY will be FALSE and PLUS_CHECKCOM_OK or
NOK will be TRUE, depending on the result of the test.
Has the same functionality as the Test button in ToolsTalk
PowerMACS.
PLUS_GETTMU BOOL On a positive edge the value in “PLUS_BARCODE” is sent to
PLUS in a request for a TMU and a PN or KN.
PLUS_BUSY will be TRUE during the transfer and
PLUS_GETTMU_OK will be TRUE when the result is ready for
usage.
The result of the request will be placed in CURRIDSTRING (the
PN or KN) and PLUS_MODE (mode number from conversion of
received TMU). CURRIDSTRING will have the letters „PN‟ or
„KN‟ added as a prefix to the string received from PLUS.
If “Station Type” in the PLUS device is different from SAW/WIS
nothing is sent to PLUS. Instead the string in PLUS_BARCODE
is copied directly to CURRIDSTRING with the letters „PN‟ or
„KN‟ added as prefix. The string in PLUS_OVERRIDETMU will
be sent to the conversion table to get PLUS_MODE.
In a VBA station nothing at all will happen when a positive edge
is sent to PLUS_GETTMU.
PLUS_BARCODE STRING Id string that is sent to PLUS to get a TMU and PN or KN. If the
(10) string is treated as a production number “PN”, a body number
“KN” or a carrier Id “LI” is controlled by the parameter “Barcode
scanned” in the PLUS device in ToolsTalk PowerMACS.
PLUS_BARCODE is sent on a positive edge on
PLUS_GETTMU and the result can be used when
PLUS_GETTMU_OK is set to TRUE.
The returned PN or KN will be copied to CURRIDSTRING with
the letters PN or KN added in the beginning. This string will be
included in the cycle data as "Wp ID". The TMU received from
PLUS will be converted to a mode number using the conversion
table in the PLUS device. The result will be placed in
PLUS_MODE.
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Variable Type Use

PLUS_DOKUENABLE BOOL Set high to send Cycle data to PLUS.
If the signal is high when a new Cycle data is produced it will be
sent immediately to PLUS.
If the signal is low when a new Cycle data is produced the new
data will be stored in the Cycle data queue for the PLUS device.
When the signal goes high the whole cycle data queue will be
sent to PLUS.
PLUS_DOKUENABLE is only used if “Send cycle data
automatically” is not checked in the PLUS device in ToolsTalk
PowerMACS. If “Send cycle data automatically” is checked all
new cycle data will be sent as soon as the cycle has ended.
PLUS_QO INT The value of PLUS_QO will be used as station identification QO
when sending requests for TMU to PLUS.
PLUS_QO will only be used if “Use QO from PLC” is checked in
the PLUS device; otherwise the value written in “QO for request
of TMU” in the PLUS device will be used instead.
When sending cycle data to PLUS the value in “Station QO” in
the result will be used as QO.
PLUS_DELETE BOOL On a positive edge the latest cycle data is removed from the
Cycle data queue for the PLUS device used for the station.
PLUS_DROP BOOL If PLUS_DROP is high when cycle data is stored for a cycle no
data is written in the Cycle data queue for the PLUS device.
The PLC variable CYCLEDATASTORED can be used to know
when the data has been stored.
PLUS_FLUSH BOOL On a positive edge the whole cycle data queue for the PLUS
device is deleted.
PLUS_RESETSENDDATA_NOK BOOL On a positive edge the variable PLUS_SENDDATA_NOK is set
to FALSE.
PLUS_SEND_SONL BOOL On a positive edge the telegram SONL is sent to PLUS.
PLUS_SEND_SOFF BOOL On a positive edge the telegram SOFF is sent to PLUS.
PLUS_MANUALMODE BOOL Set to TRUE to tell the TC that the station is operating in manual
mode. In manual mode the TC sends NNOT as answer to every
telegram received from PLUS. No cycle data is sent to PLUS
when PLUS_MANUALMODE is high.
Only used if the station type is VBA.
PLUS_OVERRIDETMU STRING String that will be sent to the conversion table in the PLUS
(25) device to get a mode number. The resulting mode number is
found in PLUS_MODE.
The string in PLUS_OVERRIDETMU will only be used if
“PowerMACS requests TMU” on the PLUS device is unchecked.
Otherwise the TMU received from PLUS will be used.
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5.3.7 Globals
These variables are used to transfer information from one station PLC to another station PLC. All stations
can reach these global variables.
Variable Type Use

SYSTEMGLOBALS_1 … INT For communication between PLCs on different stations.
SYSTEMGLOBALS_30
The variables are declared as a shared memory and can therefore both be read and written to both by the
PowerMACS System and the PowerMACS PLC.
You should see to that only one station write to a given variable but any number of stations can read it.
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5.3.8 Bolt specific commands

The bolt specific commands enable extended control of individual bolts using the following input and
outputs variables.
Outputs:
Variable Type Use

BOLTCTRL2_CMD INT The command to execute on the bolts selected using
BOLTCTRL2_BOLTSEL. See table below for supported command
codes.
The command is sent to the station when BOLTCTRL2_CMD
changes to a non zero value.
BOLTCTRL2_BOLTSEL ARRAY[1..50] Assign a non zero value for the bolts that should execute the
OF BYTE BOLTCTRL2_CMD command.
Note 1 The array index corresponds to the bolts ordinal number
within the station (not the user defined).
Note 2 The highest element (bolt) checked is NO_OF_BOLTS.
Currently the following command codes are supported:
Mnemonic Value Description

DROPLASTCD 1 Drop the last cycle data stored for the bolts selected.
The command may only be issued when the station is idle, that is, not executing a
cycle. The current cycle data must also include at least one result record for each of
the bolts selected.
In addition to the general result values the following may also be returned in
BOLTCTRL2_BOLTRES[x]:
5: NODATATODROP. There is no data to drop for the bolt.
6: CDCORRUPT. Cycle data is found to be corrupt.
Unless the command was executed OK for all bolts the cycle data is left untouched.
Note! The value of the station level result variable Status is always set according to
the status of all individual bolt results in the cycle data.
If used erroneously this function might cause NOK parts to be reported as OK
parts! Removing all NOK results from a cycle data produced by a station
causes it to be reported as OK. You should therefore not use this function
unless you are sure how to handle it.
Illegal commands, errors and successful drops are logged using events.
Note! New command codes may be added in future versions. To avoid unexpected behavior when
upgrading you should not make use of any other codes then the above listed and zero (0).
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Inputs:
Variable Type Use

BOLTCTRL2_STS INT Overall execution status of the BOLTCTRL2 command:
0: Idle and OK. Command completed OK for all bolts selected.
1: Idle and NOK. Command failed for at least one of the bolts
selected. Check BOLTCTRL2_BOLTRES for status of the
individual bolts.
2: Busy executing the command.
Note! The operation is not complete until this signal is 0 (or 1 if it
fails). After issuing a BOLTCTRL2 command you should wait one
PLC scan before evaluating BOLTCTRL2_STS.
BOLTCTRL2_BOLTRES ARRAY[1..50] Returns the result per individual bolts of the command executed.
OF BYTE The below values are common for all commands. See also the
description of the commands for additional command specific return
codes:
0: OK. Command executed OK.
1: ERROR. Command failed for unknown reason (that is,
anyone not listed here or per command).
2: NOBOLTSSEL. There where no bolts selected for the
command to execute on.
3: CMDNOTIMPL. Command not implemented (unknown value
of BOLTCTRL2_CMD).
4: STNNOTIDLE. Station is not idle (many commands may only
be executed when the station is not running a cycle).
Note! Values are only returned for the bolts selected using
BOLTCTRL2_BOLTSEL.
Using the BOLTCTRL2 variables in combination with the output DATAHOLD it is possible run reject
management from the PowerMACS PLC, or an external PLC, and still report one complete cycle data for
the tightening using PowerMACS standard reporting facilities.
Example: This example shows how reject management can be handled by the PowerMACS PLC for a
station having four bolts named "B1", "B2", "B3" and "B4". The scenario is that all four bolts starts by
running program "Tighten" (mode 1), bolt "B1" and "B2" fails and are loosened by program "Loosen"
(mode 2) and then retightened OK by running program "Tighten".
1. Set PLC output DATAHOLD to TRUE.
2. Set MODE to 1 and start a cycle. Wait for it to be completed. Say that bolt "B1" and "B2" finished
NOK.
3. To drop the NOK result of the failing bolts "B1" and "B2" do the following: First set up
BOLTCTRL2_BOLTSEL as below:
BOLTCTRL2_BOLTSEL[1] = 1
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Then order the station to remove the last result stored for the selected bolts by changing
BOLTCTRL2_CMD from 0 to 1.
Wait for BOLTCTRL2_STS to become 0 (idle OK). This indicates that the station has completed
the drop command.
4. To loose and retighten only the failing bolts the OK bolts must be inhibited. Therefore set up
BOLTCONTROL as below:
BOLTCONTROL[1] = 0 (* Connected normally *)
BOLTCONTROL[2] = 0 (* Connected normally *)
BOLTCONTROL[3] = 3 (* Do not run *)
BOLTCONTROL[4] = 3 (* Do not run *)
5. Loose the bolts by setting MODE to 2 and start the cycle. Wait for the cycle to be completed.
6. Remove the result of the loosening cycle by repeating step 3 above.
7. Retighten bolt "B1" and "B2" again using MODE 1 and starting the cycle. Wait for the cycle to be
completed.
8. Given that the complete tightening now is considered done, either since the retightening of bolt
"B1" and "B2" ended OK, or that no more attempts are allowed, releases the produced cycle data
by setting DATAHOLD to FALSE.
The cycle data produced using the above sequence will the be:
Time: 2005-07-08 13:00:00
Status: OK
Bolt: B3 Program: Tighten Status: OK
Bolt: B1 Program: Tighten Status: OK (the result from the retightening)
while the same operations without using the BOLTCTRL2 bolt data drop function would be:
Time: 2003-07-08 13:00:00
Status: NOK
Bolt: B1 Program: Tighten Status: NOK (the result from the first tightening)
Bolt: B2 Program: Tighten Status: NOK (the result from the first tightening)
Bolt: B1 Program: Loosen Status: OK (the result from the loosening)
Bolt: B2 Program: Loosen Status: OK (the result from the loosening)
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5.3.9 Device commands
Using the device command input and outputs it is possible to control individual devices directly from the
PLC.
Outputs:
Variable Type Use

DEVCMD_CMD INT The command to send to the device pointed out by
DEVCMD_DEVNAME. See table below for supported
commands.
The command is sent to the device when DEVCMD_CMD
changes to a non zero value.
DEVCMD_DEVNAME STRING(20) The name of the device, as defined in the ToolsTalk
PowerMACS, to send the command to. For example, "Printer
01".
DEVCMD_DEVID INT The Id of the device to send the command to (if
DEVCMD_DEVNAME is blank).
DEVCMD_CMDPARSIZE INT Size, in number of bytes, of additional command parameters
specified using DEVCMD_CMDPARDATA[].
Note! Only specific commands make use of addition command
parameters.
DEVCMD_CMDPARDATA ARRAY[1..1000] Additional command parameter data. Layout and usage
OF BYTE depends on the targeted device and command. See table
below for specification.
Currently only devices of type "Printer" are supported. For it the following command is available:
Mnemonic Value Description

PRINT 1 Prints DEVCMD_CMDPARSIZE bytes of the data supplied in the
DEVCMD_CMDPARDATA area.
The data is assumed to be binary and is printed without any additional formatting.
That is, to print the string "ABC" the following decimal data should be set as
parameters:
DEVCMD_CMDPARDATA[1] := 65
and DEVCMD_CMDPARSIZE := 3.
Illegal device types as targets and/or command codes are logged using events.
Note! Support for other device types and command codes may be added in future versions. To avoid
unexpected behavior when upgrading you should not make use of any other codes then the above
listed and zero (0).
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Inputs:
Variable Type Use

DEVCMD_STS INT Overall execution status of the DEVCMD command:
0: Idle and OK. Command completed OK.
1: Idle and NOK. Command failed.
2: Busy executing the command.
Note! The operation is not complete until this signal is 0 (or 1 if
it fails). After issuing a DEVCMD command you should wait
one PLC scan before evaluating DEVCMD_STS.
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5.4 Programming the PLC

To edit the PLC program select the item Program from the PLC menu.
For every PowerMACS setup there is a PLC project. This project is created by the setup wizard, see
Creating a new system using the Set Up Wizard, and is stored on disk together with the PowerMACS
setup file. It has the same name as the setup file but the extension ".ZWT2" instead of "PM4".
For a two station system the PLC project tree displayed when the PowerMACS PLC editor is opened will
look as follows:
Each station in the system is represented in the PLC project as a Resource. A Resource corresponds to a
physical unit that can execute a PLC program; in our case this is a station TC. They are named Stn01 for
the first station in the system, Stn02 for the second, and so on.
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To execute a program the Resource uses one or more tasks. A task controls the time scheduling of a
program. Tasks are typically cyclic which means that they are executed periodically with a given time
interval. The Setup Wizard creates one task named T10MS, which is executed every 100th millisecond,
for each of the resources.
The program that is executed by a task is called POU, or Program Organization Unit. The Setup Wizard
creates one POU for each station in the system. They are named Main01 for the first station, Main02 for
the second, and so on. When created all Main programs looks the same since they are copied from the
PowerMACS standard template. Normally you must adopt the program for each individual station. You do
that by double clicking on the icon representing the variable worksheet (MainNNV) and/or the icon
representing the logic worksheet (MainNN) of the program of interest.
Each resource has a number of variables that are global within the resource. These are defined on the
worksheet named Global_Variables and can be used in all your programs (POUs) executed by the
resource.
The variables defined on Global_Variables are divided in the following groups:

Default and Global_Variables: - Consists of a number of PLC internal variables that can be used
for advanced debugging of your PLC program.
System_Globals: - This group contains all variables interfacing the PLC with the tightening
controller part of the PowerMACS system. See System Globals for details.
ExtCom_API_Variables: - This group contains variables that are mapped to optional external
communication and/or API devices. See Serial Communication and API, Application
Programmers Interface for how this is configured and used.
CycleData_Variables: - This group contains variables that are mapped to the optional cycle data
interface. See the description of PLC in chapter: Peripheral Devices, for how this is done.
DC_PLUS_Variables: - This group contains all PLC variables used for interfacing a DC PLUS
server. See the description of DC PLUS in chapter: Peripheral Devices, for how this is done.
AUDI_XML_Variables: - This group contains all Audi XML device variables.
Shared_Variables: - This group contains variables that are shared between the optional fieldbus
interface and the digital I/O interface. See chapter: Fieldbus Interface for how this is done. See
I/O Device for a detailed description.
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Fieldbus_Variables: - This group contains the fieldbus mapping. See chapter: Fieldbus Interface.
Digital_In_Out: - This group contains variables only for digital I/O. Unlike the Shared_Variables
group, these signals are not shared with fieldbus.
The programming of the PLC logic can be done in two ways: - using functional blocks or ladder logic. In
both cases you use a graphical editor. Below is given two examples of this.
After editing the program you must compile it before it can be downloaded. This is done using the item
Make in the menu Build. If your program contains any errors you will be informed about them.
When the program is successfully compiled it is possible to download to the target system. This is
normally done as follows:
1. First close the PowerMACS PLC.
2. If the WinTC already is on-line download the PLC project by selecting the menu item PLC –
Synchronize. During synchronization a status form is shown se Display PLC Status.
3. If the WinTC is not on-line then just go on-line
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Downloading the PLC project this way ensures that the PLC program and the rest of the setup are kept
synchronized.
However, during the development phase, when you have to change the program often, and quickly want
to study the effect of your modifications you can download the program from inside the PLC. This is done
using the following sequence:
Open the Project Control dialog from the Online menu.
Stop the execution of the PLC by pressing the Stop button.

Reset the PLC by pressing the Reset button.
Open the Download dialog by pressing the button Download.
Press the Download button in the Bootproject frame

Open the Download dialog again by pressing the Download button in the Resource Control
dialog.
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Activate the Boot project by pressing the Activate button.
Start the execution of the PLC by pressing the button Cold in the Resource Control dialog.
When your program is downloaded you can study current status of all signals in the program by using the
Debug alternative in the PLC Online menu. If the program has not been compiled yet the PLC will
complain by saying, "Cannot switch to online mode because the project is not successfully compiled!" In
these cases just compile the program, and if there are errors, fix these. Then try to go on-line again.
Note 1: Saving the project from inside the PowerMACS PLC does not implicate cause the PLC project to
be saved together with your setup on disk. To do that you must you choose Save, or Save As,
from the WinTC File menu.
Note 2: It is the ZWT2 file that is regarded to be the source of the PLC project. It contains the project in
compressed form. Whenever you open a PowerMACS setup the PLC project is expanded to the
folder named CurrentSetup, which is located below the folder you installed PowerMACS in. Keep
in mind that this folder only is used as a temporary working folder. Whenever you save the setup
the PLC project is also compressed and saved to disk. When you go on-line and download a
setup to a system the ZWT2 is also downloaded.
For more details on how to program the PLC see the MULTIPROG wt manual.
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5.5 PLC Console

The PLC Console interface can be used as a simple operator‟s interface to your PLC application. It is
invoked using the PLC – Console… item.
Use this form to display internal data of your PLC program that you want the operator to be able to see or
modify.
Each of the controls in the frames PLC In and PLC Out are mapped to specific inputs and outputs in the
PLC as described in the tables below. See also the Station variables chapter.
PLC In: Type Connected to PLC Input

Cons In 1 BOOL CONS_IN_1
Cons In 4 STRING(40) CONS_IN_4
Cons In 5 STRING(40) CONS_IN_5
PLC Out: Type Connected to PLC output

Cons Out 1 STRING(40) CONS_OUT_1
The outputs will be displayed automatically for the selected station (given by the Station combo box).
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To set inputs do the following:
1. Enter the new values for one or more of the inputs. A checked check box corresponds to True, an
unchecked to False.
2. Press the button Set. This causes the new values to be sent to the PLC.
Note! The set values will remain in the PLC until next time they are changed, or the PLC is restarted.
Closing the PLC Console window will not clear any values.
If you, as an example, connect "Cons In 1" to the PLC output START then you can simulate the external
start signal that normally is input via some external device. Below the currently selected mode, which is
set using digital inputs in this case, is also displayed as the "Cons Out 1" variable.
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5.6 PLC Parameters

The PLC Parameters form, invoked using the PLC – Console… menu item, is similar to PLC Console
interface in the sense that they both can be used as a simple operator‟s interface to your PLC application.
The difference is that the PLC Parameters are stored in non-volatile memory, and therefore will survive a
restart of the PLC while all changes made using the PLC Console will vanish.
The parameters that are accessible using this form must first have been defined using the PLC
Parameters Set Up form.
To change the value of a parameter just enter the new value in the Value column and press the Apply
button.
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5.7 Display PLC Status

The Display PLC status form, normally invoked using menu item PLC – Display Status…, is a tool for
checking the status of the PLC runtime kernels when online.
This form is displayed automatically when the system is online and menu item PLC – Synchronize … is
used.
The frame PLC status lists all PLC runtime kernels in the system. The list contains the name of the
station and the state of the PLC runtime kernel.
Possible state for the PLC is:
Synchronizing new PLC program (Blue), synchronization has begun and the PLC is in an
undefined state.
PLC is running (Green), the PLC is in state running.
PLC is stopped (Red), the PLC is stopped and waiting to start.
When the form is invoked by the PLC – Synchronize command it is only possible to close the form when
the state of all PLC:s is PLC is running. During synchronization a progress bar is shown.
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6 Tightening
6.1 Tightening - Overview
Most functions needed for to create and edit tightening programs are found in the Tightening menu
Select New Program… to Create a new Tightening Program.

To edit an existing program or sequence select Open Program… or Open Sequence…. Both open The
Tightening Program form
Select Mode… to configure the mode table using The Mode Table form.
This chapter describes most things about the tightening process, for example
How it works
How to create a new program
How to edit an existing program
To understand how the tightening process is actually performed within a PowerMACS system you should
be familiar with all parts that make up the tightening process.
1. The PLC starts the tightening by setting outputs for start of tightening, for selection of which bolts to
execute, and which tightening mode to run.
2. The Mode Table, set up using The Mode Table form, is used by the system to figure out which
tightening program each bolt should run for the chosen mode.
3. The Tightening Program chapter describes how the tightening should be done for each bolt. A
program is built using steps and sequences.
4. The spindles perform the actual tightening according to the information in the tightening program.
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6.2 Create a new Tightening Program

The New Program wizard is opened using the Tightening - New Program menu or by right clicking on
the Programs folder in the System Map and selecting Add Program.
Start by entering a proper name for the new program in the Program name field. If you want to create a
new program based on another program check the Build a new tightening program by combining
existing programs checkbox.
When you are ready, press OK to create the program. This adds the program to the System Map tree.
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6.3 The Tightening Program form

Tightening Program form is opened using the Tightening - Open Program… or by double clicking a
program in the System Map. It is used for creation and editing on or several programs. A detailed
description of programs is given in the Tightening Program chapter.
You can edit more than one program simultaneously by opening more programs using the System Map, it
is also possible to drag & drop steps between programs.
Programs are displayed on the left side of the Tightening Program form, to the right are the Settings for
the currently selected item shown (this can be general program settings or details for a selected step).
Programs are made up of steps which you insert and remove by right clicking on a program or by dragging
items from the dynamic tool.
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Maximize/Minimize Program
Close Program
Program Setting Block

Select this block to view program settings
in the Detail window.
Collapsed step block

Select a step block to view the settings in
the Detail window.
Number of Number of
Restrictions Checks in
in step step
Expanded step block

Lists more information about the step
configuration
Number of Monitoring
checks in CE Step
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6.3.1 Tightening Program step operations
To add a step you can drag the step from the Dynamic Tool window and drop the step on the desired
location in the program. It is also possible to right click between two steps and select Add steps from the
popup menu.
It is also possible to hold the Ctrl button while dragging an existing step from the same (or another)
program to a new location – this will create an identical copy of the step. A copy operation is indicated by
a small “plus sign” when the mouse is over the drop location.
When you right click on a step a popup menu is opened, here it is possible to Cut, Copy or Delete the
step.
Select Add checks to add checks to the step and Add restrictions to add restrictions to the step. Note
that it is also possible to drag & drop checks and restrictions to a step from the dynamic tool.
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The Settings window displays parameters for the currently selected item (step or program). The default
location is on the right side in the Tightening Program window but it can be placed freely.
The information for programs is divided in the following groups. To show program properties click on the
topmost rectangle in the program.
Group Use
Common Basic properties for the program
User Variables Definition of program user variables and values.
Settings Trace, monitoring and report limit settings for the program.
The information for steps is divided in the following groups. To show step properties click on a step in the
program.
Group Use
Control What task the step performs. See Step – Control.
Restrictions What restriction to run during the step. See Step – Restriction.
Checks What checks to execute after the step. See Step – Check.
Rejects Reject management in case anything goes wrong. See Step – Rejects.
Ramps & Other Other configuration parameters for the step. See Step – Ramps & Other.
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6.4 The Mode Table form

The Mode Table form is opened using the Tightening - Mode… menu item or by right clicking on the
Mode Table for a station in the System Map and selecting Open Mode Table. The Mode Table form is
used to set up which tightening program each bolt in a station should execute for a given mode.
Each station has its own Mode Table. Use the Station combo box to select the station for which the mode
table should be edited.
The Mode Table has one column for each mode (up to 50) and a row for each bolt in the station. On the
top row, labeled Name, you can specify a symbolic name for each mode. This name may be included in
the cycle data as the station level result variable Mode.
The remaining rows are labeled with the names of the respective bolts. On these you should specify the
tightening program to use for each mode. You may also specify which spindle to use to tighten the bolt in
each mode. If no spindle is specified, the default spindle for the bolt is used (default spindle is defined in
Bolt Setup).
The list labeled Tightening Program to the right lists all programs available in the system. In addition to
these it also include the following entries which have special meaning:
“Disconnected OK”
“Disconnected NOK”
“” (empty)
“Program from PLC”
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Bolts marked with Disconnected OK/NOK will be treated as disconnected for the corresponding mode.
That is, they will not be executed but return a result, either OK or NOK depending on the selection.
Disconnecting bolts here is equivalent to disconnecting them using the Bolt Status parameter of the Bolt
with the difference that the selecting is only valid for specific modes.
Leaving a cell empty will have the effect that the bolt is not run when the station is started in the given
mode. This corresponds to setting the PLC out BOLTCONTROL to the value 3, that is "Do not run", for the
bolt. This may be very useful for so called stitching applications where the same spindle is used to tighten
several bolts. See also the description of the PLC Bolt variables.
Bolts marked with Program from PLC will get the program to run from the PLC when the station is started
in the given mode. The station will use the PLC out BOLTCONTROL to find the program for the bolt. It is
essential that all programs used by Program from PLC have PgmNo between 1 and 150. Program from
PLC may be very useful when the combinations of programs to run on different bolts are many and you
want the PLC logic to determine what tightening program to run on different bolts. It is possible to combine
program numbers with “Do not run” if stitching or reject management is to be handled. See also the
description of the PLC Bolt variables.
You may type the program name directly in the cells, but it is probably easier to use the copy function to
the right. It is used as follows:
1. Mark the program you want to copy in the Tightening Program list.
2. Mark the cells in the mode table you want the name copied to.
3. Press the button next to the Tightening Program list.
To clear the selected Tightening Program from a number of cells mark them and press the Clear button
next to the Tightening Program list.
If you want to Create a new Tightening Program, press New….to open the New Program wizard.
To edit or view a program, mark it in the Tightening program list and press Open…. This will open The
Tightening Program form.
The list labeled Spindle to the left lists all spindles available for the current station. The default spindle of
all the bolts in a station belongs to the station. In addition to that, a secondary spindle on TCs for the
default spindles also belongs to the station.
Use the copy function to select a spindle.
1. Mark the spindle you want to copy in the Spindle list.
2. Mark the cells in the mode table you want the name copied to.
3. Press the button next to the Spindle list.
To clear the selected Spindle from a number of cells mark them and press the Clear button next to the
Spindle list.
If a spindle is not explicitly selected the default spindle of the bolt will be used (set up using System /Bolt
node). This means that if the default spindle is changed for the bolt, the new spindle will automatically be
used to tighten the bolt.
Press Print to print the current Mode Table configuration. The document printed on your systems default
printer includes the settings for all used modes, that is, all modes for which a name is specified.
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6.5 Tightening Program

The Tightening Program defines the algorithm to use for tightening a bolt. This includes evaluating the
result of the tightening, during execution as well as the final result, and fault handling.
A Tightening Program consists of the following parts:
Common settings like name, program number, etc.
User variables and their values
Steps, the basic blocks to build a program with. The parameters of each step is divided in the
following parts:
- Control – Defines function of the step, i.e. when to switch off, in what direction to run, etc.
- Restrictions – Used for supervision of the control function. All the restriction tests are
executed in parallel with the control function and if any limit is exceeded it will interrupt the
execution of the step.
- Checks – Defines variables that are measured during the execution of the step but are not
evaluated until the step has finished. Checks never interrupt the execution of the step.
- Reject Management – Defines how to do an automatic repair in case of a step failure.
- Speed – Defines which speed to use during the step.
- Other – Used for setting up start delays, stop conditions, etc.
Bolt monitoring. Defines how the complete tightening cycle should be evaluated. It is configured on
the Checks tab for the CE-steps. Bolt monitoring differs depending on at which CE-step the
program execution ends.
Trace settings
Synchronization
You can choose if the execution of the steps should be synchronized between different spindles or not.
When a station starts a tightening cycle the individual bolts may run freely as long as the steps are not
synchronized. When the spindle encounters a synchronized step it will wait for all other spindles to reach
their synchronization steps. Spindles may run different number of steps between the synchronization
points.
This function is best used in in-homogenous stations with spindles that do individual jobs, e.g. a marriage
point in a car assembly.
It is possible to compare how programs will run in relation to each other by having two or more programs
open in the Tightening Program form and clicking the Match Sync. lines toolbar button.
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6.5.1 Program Properties

A tightening program has a number of general properties, they are shown in the Details window when the
Program Settings box is selected.
6.5.1.1 Program Common properties

The most basic settings for a program are located in the Common group.
Pgm No.: A tightening program is identified by its name. However, using this property you may
optionally specify a Program number as an alternative identifier. This number can be used for
reporting and is mandatory when program from PLC is used, as the PLC configures which program
to run using the Pgm. No.
Program Name: The name of the program.
Comment: Any comment about the program.
6.5.1.2 Program User variables

This group contains the defined user variables for a program.
Name: The name of the variable.
Description: Variable description.
Value: The value of the variable when the program is run.
Unit: The unit of the variable (for information only).
User Variables are used to make programs more flexible and more easy to manage. If a user variable is
defined in the program you can later refer to that variable when entering parameters for a step, check,
restriction instead of hard coding actual values.
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Suppose we want to make two programs, one with target torque 50 Nm and one with target torque 75 Nm
and we want to make sure the monitoring Peak Torque check is within 3 % of the target torque in order to
have an OK cycle.
Then we can create one program with user defined variables, we call this program Tighten. One variable
is defined TargetTorque and we set this to 50 Nm (our first program).
Then we add a Peak Torque to the CE monitoring and enter the high and low limits using the
TargetTorque user variable.
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In order to create or second program with target torque 75 Nm we copy the Tighten program and change
the TargetTorque variable value to 75 Nm. The advantage with user variables is that each program
needs only to expose a set of variables that are sufficient to change to adapt the program to other
requirements.
Note! Complex expressions are not supported for user variables, one operation (+, -, *, /) and one
parameter is allowed. Examples:
TargetTorque * 1,3
Target1 + 3
6.5.1.3 Program Settings

Trace Settings
Trace Start: When trace collection should start, the options are Cycle Start or at a specific
step. In many cases you are not interested in the first part of the tightening, but want more
details in the latter parts
Trace Start Quantity: Makes it possible to start trace collection when a specific condition has
occurred, for example a torque value has been reached.
nd
Include 2 Torque: Check this to include the second torque channel in the trace if equipped
(takes more memory).
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nd
Include 2 Angle: Check this to include the second angle channel in the trace if equipped
(takes more memory).
Monitoring Settings
Stop monitoring when NOK: Check this checkbox to have the monitoring function stop
recording data whenever a step is found NOK when evaluated. This, together with the step
control parameter Start/restart monitoring (see chapter: Step – Control), is used to select
which parts of the cycle that is evaluated by he monitoring checks set up using the Cycle End
step(s). See also chapter: Bolt Monitoring.
nd
Use 2 monitoring buffer: Check this checkbox to enable the second monitoring buffer. The
buffer will use the same settings as the monitoring buffer. Only Final torque and Threshold
angle checks are run and reported for the second buffer. See also chapter: Bolt Monitoring.
Monitoring Start and Monitoring End: Are used to specify the condition when monitoring
function should be started and stopped.
Auto scale Mon Buffer: If Auto scale is checked then the buffer is automatically rescaled if the
traveled angle exceeds the maximum angle of the buffer. When every element started covers 1
encoder increment and whenever the buffer limit is reached this value is doubled causing a
lower resolution. Already recorded data is kept (compressed) when the buffer is rescaled. If
you leave Auto scale unchecked you must manually enter the resolution of the buffer in the edit
field to the right of it. In this case the oldest recorded data will be overwritten when buffer limit
is reached resulting in that the last part of the cycle is kept in the buffer. When using a fix buffer
the checkbox Allow monitoring buffer overrun controls whether or not a buffer overrun
should be regarded as an error or not. If checked then an overrun will generate an event and
cause the cycle to end NOK. If not checked then only a warning is generated.
Limits
Report threshold torque limit: Each bolt for which the highest measured torque does not
exceed the Report threshold torque limit will have the "Warnings" bit REPLIMIT (REPort
LIMIT) set.
The highest measured torque is defined as the highest value of the two result variables “Bolt
Max T” and “Bolt Min T”. If “Bolt Min T” is negative the absolute value of “Bolt Min T” is used
instead, that is,. the warning bit is set if Report threshold torque limit > MAX (ABS (Max T),
ABS (Min T)).
If none of the bolts executed for a cycle (disconnected bolts excluded) exceeded the value of
the Report threshold torque limit parameter then the corresponding cycle data will be
automatically dropped.
Normally this parameter is used to avoid reporting tightening made "in the air". Leave the
parameter empty to disable the function.
Remove fastener torque limit: This is a "program global" restriction, that is, a restriction that
is checked over all steps executed in the cycle. When the measured torque exceeds the
entered value the current step is immediately stopped.
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An event and the error bit RFTLIMRE (Remove Fastener Torque Limit REeached) indicate the
condition.
Backlash compensation (only available for Gauging)
All steps will do backlash compensation, if the direction is different from the previous step and a measured
backlash correction exists (measured with step BCT – Backlash correction (only available for Gauging)
During the backlash correction nothing in the steps will be run. This means that all checks will start after
the backlash correction is finished. The same is true for the step. They will not start to execute the control
function before the backlash is finished. This means that a step will not end even if the target torque is
reached during the backlash. It also means that all angle measurements will start when the backlash is
finished.
Reset backlash: If checked the stored backlash value (from an earlier cycle) will be reset at
cycle start.
Default value is checked
Speed: The speed used for the backlash compensation. All steps in the program will use the
same speed.
Angle channel: Channel for Backlash and Position measurements. The backlash
compensation and the position measurements are made on the same angle channel.
The stored backlash compensation and positions (Null, Half, Peak and Low) will be cleared on cycle start
if the program uses a different channel compared to the previous program that was run.
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6.5.2 Step – Control

The Control part describes what main task to perform during the step.
The settings available for the Control part depend on the selected step. It is possible to change step by the
parameter Step type.
The checkbox Synchronize is used to select if the step should synchronize or not.
The check box Start/restart monitoring can be used in conjunction with the monitoring settings for the
program (Program Settings) in order to start or restart the recording into the monitor buffer. If restarted
everything recorded before this step is erased. See also the description of Bolt Monitoring.
Most step that run the spindle have a Speed parameter and a step Direction that can be set, note that the
direction is relative to the desired spindle direction.
It is also possible to select the torque and angle channel to use for step control with the Torque channel
and Angle channel properties. The default value is Auto which is the first channel (Torque 1 or Angle 1) if
not disabled on the Spindle Set Up form.
Below the common properties follows the step specific properties, the following sub chapters list all
available step types and describe the parameters.
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6.5.2.1 DT - Run until Dyna-TorkTM

Step type Id: 1
Parameters: T (Torque), TI1 (Time1), TI2 (Time2), PERC (Current percentage), DIR (Direction).
Function: Run spindle, in DIR direction, until torque is T using current control. When the target is
reached a new torque, DT, is calculated as
DT = T * PERC / 100
The torque DT is then retained during the next TI1 + TI2 seconds using current control.
TM
The PERC parameter makes it is possible to Dyna-Tork at a lower level than the target.
Before the step is started both torques, T and DT, are converted to corresponding motor
currents using the spindle parameters T/C Factor, T/C Correction Factor and Gear ratio.
When the step starts the current that corresponds to T is set as current reference to the
motor servo. When the servo reaches this current the step immediately switches the current
reference to the current that corresponds to DT which then is maintained for TI1 + TI2
seconds.
Note: To avoid overheating of the spindle it is strongly recommended to never run Dyna-
TM
Tork to more than 40% of the maximum torque of the spindle.
Diagram:
DT (PERC = 100%)
Torque
T DT (PERC = 80%)
TI2 Time
TI1
Step
T Torque TI1 DynaTork Time 1

PERC Percent of T TI2 DynaTork Time 2
DT Torque level retained during TI1 and TI2
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Result var.: This step produces the step level result variables “DT T”, "DT Mean T" and "Relax A".
"DT T" is the torque measured when the torque set point is switched to DT.
"DT Mean T" is the mean torque measured during the second time interval (TI2).
"Relax A" (relaxation angle) is the angle that the bolt moves during the time interval
TI1 + TI2.
Trace: Torque T is shown as a horizontal line from step start to step stop in trace when Torque vs.
Time is selected. Control parameters must be enabled in the trace form (see View of
trace curves).
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6.5.2.2 DT2 - Run until Dyna-TorkTM, method 2

Step type Id: 34
Function: Run spindle, in DIR direction, until torque is T using transducer control. When the target is
reached the current measured on the current input channel at this point is sampled and a
new current set point is calculated as
Current Set point = Measured current * PERC / 100
The current is then retained during the next TI1 + TI2 seconds using current control.
TM
TM
TI1 + TI2
trace curves).
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6.5.2.3 DT3 - Run until Dyna-TorkTM, method 3

Step type Id: 35
Function: Run spindle, in DIR direction, until torque is T using transducer control. When the target is
reached a new torque, DT, is calculated as
DT = T * PERC / 100
The torque DT is then retained during the next TI1 + TI2 seconds using current control.
TM
Before the step starts the torque DT is converted to a corresponding motor current using the
spindle parameters T/C Factor, T/C Correction Factor and Gear ratio. The first part of the
step runs using transducer control. When the torque measured on the torque transducer
used for control reaches T the step switches to current control using the current that
corresponds to DT as set point for the motor servo. This current is then maintained for TI1 +
TI2 seconds.
TM
TI1 + TI2.
trace curves).
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6.5.2.4 T - Run until Torque

Step type Id: 2
Parameters: T (Torque), DIR (Direction).
Function: Run spindle, in DIR direction, until torque is T.
Diagram:
Torque
T
Step Angle
T Target Torque
trace curves).
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6.5.2.5 TC - Run until Torque with Current Control

Step type Id: 3
Parameters: T (Torque), DIR (Direction).
Function: Run spindle, in DIR direction, until torque is T using current control.
The target torque T is converted to a corresponding motor current using the spindle
parameters T/C Factor, T/C Correction Factor and Gear ratio. This current is then set as
reference to the motor servo. The step is stopped when the servo reaches its set point.
Diagram:
Torque
T
Step Angle
T Target Torque
trace curves).
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6.5.2.6 AO - Run until Angle with overshoot compensation

Step type Id: 5
Parameters: A (Angle), DIR (Direction).
Function: Run spindle, in DIR direction, an angle of A degrees. The angle is measured from where the
previous step was stopped, that is from its shut off.
Any overshoot will be included in this step. If the overshoot is larger than A the step will be
signaled ready immediately. Overshoot is defined as the angle measured between shut off
point in the previous step and the current angle when this step starts.
Diagram 1:
Torque
Previous
step
A Angle
+OS
AStop A2
Step x-1 Step x
Astop Shut-off point A Target Angle

A2 A - OS actual angle movement in this step
OS Overshoot in previous step
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Diagram 2:
Previous
step
A Angle
-OS
AStop A2
Step x-1 Step x
Astop Shut-off point A Target Angle

A2 A - OS actual angle movement in this step
OS Overshoot in previous step
Trace: Angle A is shown as a horizontal line from step start to step stop in trace when Angle vs.
trace curves).
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6.5.2.7 A - Run until Angle

Step type Id: 6
Parameters: A (Angle), DIR (Direction), Start condition.
Function: Run spindle, in DIR direction, until angle A has passed.
Diagram :
Torque
A Angle
Step
A Angle
trace curves).
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6.5.2.8 Y1 - Run until Yield point, method 1

Step type Id: 7
Parameters: TC (Torque TC), INC (Increment), NOS (No degrees), TDIFF (Torque difference),
DIR (Direction).
Function: Run spindle, in DIR direction, until yield point. Search for yield point starts when the torque
has reached TC. The average of the torque (T n) over NOS angle degrees is calculated. This
procedure is repeated after INC angle degrees. The difference in average torque values
(Tn - Tn-2) are continuously calculated and the max difference is stored.
The yield point is considered reached when the calculated difference is less than TDIFF %
of the current max difference.
Diagram:
TDIFF
Torque 1
TDIFF 1
1
TDIFF
TDIFF 1
NOS
TDIFF NOS
1
NOS
TDIFF 1
NOS
TDIFF 1
1 NOS 1: INC
TC 1 NOS
NOS
NOS Angle
NOS
NOS
Step
TC Torque TC INC Increment

NOS No. degrees TDIFF Difference in average torque
Trace: Torque TC is shown as a horizontal line from step start to step stop in trace when Torque
vs. Time is selected. Control parameters must be enabled in the trace form (see View of
trace curves).
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6.5.2.9 Y2 - Run until Yield point, method 2
Step type Id: 8
Parameters: TC (Torque TC), NOS (No degrees), NNOS (No of points), TDIFF (Torque difference),
RNOS (No of points ref), DIR (Direction).
Function: Run spindle, in DIR direction, until the yield point. Search for the yield point starts when the
torque has reached TC. The average of the torque over NOS angle degrees is calculated.
This procedure is repeated RNOS times. A reference slope is calculated with linear
regression over the RNOS points. After that, new average values are continuously
calculated over NOS degrees. The actual slope is calculated with linear regression over the
last NNOS average points. The yield point is reached when the actual slope is less than
TDIFF % of the reference slope.
Diagram:
Torque Actual slope
1
1
1
RNOS 1
1 1
NNOS
Reference slope
1: NOS
TC
Angle
1
1 1
1
1
1
Step
TC Torque, TC NNOS TDIFF

NOS No. degrees RNOS
trace curves).
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6.5.2.10 LT - Loosen until torque

Step type Id: 11
Parameters: T (Torque), Mask1, Mask2, DIR (Direction).
Function: Run until torque decreases below the threshold level T.
First run for Mask1 seconds in the DIR direction, then measure the torque. Should the
measured torque be less than T the step is stopped with status OK.
Continue to run for Mask2 seconds in the DIR direction. During this time the step is not shut
off regardless of the measured torque.
From this point continue to run in the DIR direction until the measured torque is less than, or
equal to, the parameter T.
The Release angle can be reported from this step. It is measured from the point where the
torque reaches its highest value to the point where the projected torque vs. angle curve
should have crossed the angle axis if not shut off. Please note that the peak torque is not
checked for during Mask1.
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Diagram:
Torque
Peak T
Mask1 Release Angle Angle

(time)
Mask2
(time)
Step
T Torque Peak T Peak Torque

Mask1 Time 1
Mask2 Time 2
trace curves).
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6.5.2.11 RA - Release angle

Step type Id: 12
Parameters: T (Torque), Mask1, Mask2, DIR (Direction).
Function: Run until torque decreases below 0.3 * peak torque (measured during the step).
First run for Mask1 seconds in the DIR direction then measure the torque. Should the
measured torque be less than T the step is stopped with status OK.
Start monitoring of peak torque and continue to run for Mask2 seconds in the DIR direction.
During this time the step is not shut off regardless of the measured torque.
From this point continue to run in the DIR direction until the measured torque is less than
0.3 * the peak torque (measured from that the timer Mask2 was started).
The Release angle can be reported from this step. It is measured from the point where the
torque reaches its highest value to the point where the projected torque vs. angle curve
should have crossed the angle axis if not shut off. Please note that the peak torque is not
checked for during Mask1.
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Diagram:
Torque
Peak T
Peak T * 0.3
Mask1 Angle
(time) Mask2 Release Angle
(time)
Step
T Torque Peak T
Mask1 Time 1 Peak T * 0.3 Shut off point
Mask2 Time 2
trace curves).
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6.5.2.12 PA - Run until Projected angle

Step type Id: 9
Parameters: A (Angle), TC (Torque, TC), INC (Increment), NOS (No degrees), DIR (Direction).
Function: Run spindle, in DIR direction, until projected angle A. Search starts when torque has
reached TC. The average of the torque over NOS angle degrees is calculated. This
procedure is repeated after INC angle degrees. A straight line is calculated through the two
calculated torque average values and down to the x-axis. The projected angle starts from
this intersection.
Diagram:
Torque
TC INC
NOS
NOS
A Angle
Step
TC Torque INC Increment

NOS No. degrees A Projected Angle
trace curves).
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6.5.2.13 TD - Run until Torque has decreased

Step type Id: 10
Parameters: T (Torque), A (Angle), DIR (Direction)
Function: Run spindle, in DIR direction, until angle A is reached. The rotation continues but from that
point the torque is measured. The step stops when the measured torque is less than, or
equal to, T.
Diagram:
Torque
A Angle
Step
A Angle
T Torque
trace curves).
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6.5.2.14 TI - Run until Time

Step type Id: 13
Parameters: TI (Time), DIR (Direction).
Function: Run spindle, in DIR direction, for TI seconds.
Trace: Time TI is shown as a vertical line in trace when Torque, Angle, Current or Current as
torque vs. Time is selected. Control parameters must be enabled in the trace form (see
View of trace curves).
6.5.2.15 E1 - Run Engage method 1

Step type Id: 14
Parameters: TI (Time), T (Torque), TC (Current as Torque).
Function: Engage spindle, method 1. Run spindle reverse for TI seconds and then forward for TI
seconds or until torque T or current TC is reached.
Time is selected. Current C is shown as a horizontal line from step start to step stop in trace
when Current vs. Time is selected. Control parameters must be enabled in the trace form
(see View of trace curves).
6.5.2.16 E2 - Run Engage method 2

Step type Id: 15
Parameters: TC (Current As Torque), TI (Time), DIR (Direction).
Function: Engage spindle, method 2. Run spindle, in DIR direction, with maximum TC torque, until no
increase in angle for TI seconds.
Trace: TC is shown as a horizontal line from step start to step stop in trace when Torque vs. Time
is selected. Control parameters must be enabled in the trace form (see View of trace
curves).
6.5.2.17 NS - Run until next step

Step type Id: 17
Parameters: DIR (Direction).
Function: Run spindle, in DIR direction, until next step starts. Next step starts when all the other
spindles reach their next synchronization point. That is, this step is meaningful only if there
are other spindles executing normal steps at the same time.
Trace: There are no control parameters for this step type in trace.
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6.5.2.18 GS - Run Gear Shift
Step type Id: 16
Parameters: GS (Gear Shift), TI1 (Time1), TI2 (Time2).
Function: Controls the digital output used for shifting the gear for the currently executed spindle. GS
equal to 1 (one) will cause gearshift output go high when this step is executed. GS equal to
0 (zero) will make the gearshift output go low.
When changing speed from high to low (normal tightening), the spindle will first run reverse
for TI1 seconds, then wait for TI2 seconds before the gear is changed.
When changing speed from low to high the spindle will first run forward for TI1 seconds, and
then wait for TI2 seconds before the gear is changed.
6.5.2.19 PLC - Run PLC step

Step type Id: 18
Parameters: DIR, PLC output STEPTYPE, PLC output STEPVAL
Function: This step is configurable during run-time using the PLC. When the PLC sets the start signal
high the PLC Station variables STEPTYPE and STEPVAL are sampled. The first output,
STEPTYPE, controls the type of step that will be executed and the STEPVAL is used as
target value. DIR is the only parameter that is defined in the tightening program and it
controls the direction of the step.
STEPTYPE can take the following values:
STEPTYPE Type of Step

1 T - Run until Torque
2 A - Run until Angle with Start condition = AS1
3 TI - Run until Time
STEPVAL should be set to a target value of corresponding type, that is, a torque, an angle,
or a time.
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6.5.2.20 JOG - Run until digital input goes high / low

Step type Id: 19
Parameters: Stop Condition, DIR (Direction), Digital Input.
Function: This step runs the current spindle, in the direction defined by parameter DIR, until the input
specified by Digital Input goes high or low depending on the value of Stop Condition.
The parameter Stop Condition can take the following values:
Stop Condition Function

Falling Edge – The step runs until a falling edge is detected
FE
after step start.
Rising Edge – The step runs until a rising edge is detected
RE
after step start.
Any Edge – The step runs until a falling or a rising edge is
AE
detected after step start.
The step runs until low value is detected. Should the digital
Low
input be low at step start the step is finished immediately.
The step runs until high value is detected. Should the digital
High
input be high at step start the step is finished immediately.
The parameter Digital Input can take the following values:
Digital Input Digital input monitored

The digital input specified by the parameter Dig input for
DI def. by Spindle JOG steps on the Spindle setup form (see Spindle Setup
Application page).
PLC_DI_1, … Can be accessed in the PLC
PLC_DI_10
Local DI 1
Local DI 2 One of the four local digital inputs available on TCs of type
Local DI 3 'PTC', that is, a System or Station TC.
Local DI 4
6.5.2.21 W - Wait
Step type Id: 20
Parameters: Type (Time, PLC, Digital Input, Continue)
Time, Digital Input, Stop Condition, Hold Position
Trace: Not available
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Function: Waits until the specified stop condition is fulfilled. Does not run the spindle while waiting.
Type Parameter Function
Time Time The step waits the specified time

PLC The step waits until a positive edge of one
of the PLC Station Variables START or
INTERMEDSTART is detected
Digital Digital input. The step waits until the selected digital
Input Local DI 1, … Local DI 4 signal fulfils the condition selected in Stop
PLC_DI_1, … PLC_DI_10 Condition
DI Spindle def.
Stop Condition:
Falling Edge, Rising Edge,
Any Edge, Low or High
Continue The step waits until all other bolts running in
parallel have reached the next
synchronization point.
If the check box Hold Position is checked, the spindle tries to hold the position of the bolt
during the wait. The position will be held until the next step starts, if there are any delays
between the steps due to synchronization the position will still be kept.
6.5.2.22 TA – Run Torque-Angle with no stop

Step type Id: 28
Parameters: Torque TC, Angle, TA step type, Falling edge,
A start cond, Angle torque start, DIR (Direction).
Function: Depending on the value of parameter TA step type four different functions are possible.
The TA program is considered to be one step, as there is no step change where the
spindles can be synchronized. The Angle parameter may be reported using an angle check.
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T plus A
Function Run spindle, in DIR direction, until the Torque TC is reached. Measured from this point,
continue to run spindle until Angle is reached. The switch from torque to angle control is done
"On-The-Fly", that is, without stopping in-between.
The two parts can be programmed with different speeds and if so the speed will be changed
on the fly without stopping.
By default the search for the TC threshold is done on rising torque.

TC on rising edge:
TC
A Angle
Step
TC Torque TC
A Target angle
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If parameter Falling edge is marked the search for the TC threshold is done on falling
torque.
TC on falling edge:
TC
A Angle
Step
TC Torque TC
A Target angle
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T and A
Run spindle, in DIR direction, until torque has been larger than Torque TC and the angle
has been larger than Angle. Parameter A start cond. controls from where Angle is
measured. See description on following page for possible values.
Diagram:
Torque
TC
A Angle
Step
TC Torque TC
A Target angle
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T or A
Run spindle, in DIR direction, until the first of either Torque TC or Angle is reached.
Parameter A start cond. controls from where Angle is measured. See description on
following page for possible values.
Diagram:
Torque
TC
Angle
Step A
TC Torque TC
A Target Angle
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A plus T
Run spindle, in DIR direction, until the Angle is reached. Measured from this point, continue
to run spindle until Torque TC is reached. The switch from angle to torque control is done
"On-The-Fly", that is, without stopping in-between. Parameter A start cond. controls from
where Angle is measured. See description on following page for possible values.
Diagram:
Torque
TC
A Angle
Step
TC Torque TC
A Target angle
Parameters A start cond. and Angle torque start controls from which point the angle
Angle is measured. Possible values are:
Start condition Description

AS1 (Normal) Angle measurement starts at the angle of the current position when the
step is started.
T Angle measurement starts when the torque passes the level specified
using parameter Angle torque start.
vs. Time is selected. Angle A is shown as a horizontal line from step start to step stop in
trace when Angle vs. Time is selected. Control parameters must be enabled in the trace
form (see View of trace curves).
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6.5.2.23 SR – Socket Release

Step type Id: 29
Parameters: A (Angle), DIR (Direction).
Function: Run spindle, in DIR direction, until angle A has passed.. Angle is zero at start of step.
This step performs the same function as an “A - Run until Angle” step with Start condition
set to AS1 except from that nothing that this step does is recorded by the Bolt Monitoring
function.
Diagram:
Torque
A Angle
Step
A Target Angle
trace curves).
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6.5.2.24 ADT-Angle Delta Torque

Step type Id: 31
Parameters: Delta Torque, Angle, DIR (Direction).
Function: 1. Run Angle degrees in the reverse direction.
2. Measure the torque when the Angle is reached and store this value as Tl ast.
3. Stop the spindle and wait until zero speed is reached.
4. Run in the forward direction until the torque Tlast + Delta Torque is reached.
5. Shut off the step.
The same speed and speed ramps are used both when running in the backward and the
forward directions.
If Check angle is used it will report the total angle without compensation of the lash.
The step is intended to be used in an injector pump setting application and the proposed
tightening sequence is:
Step 1: T = 25 [Nm]; Direction = Forward

Step 2: T = 3 [Nm]; Direction = Backward (to deal with the lash in the transmission).
Step 3: ADT = 5 [Nm] / 60 [deg]
Step 4: A = 30 [deg]; Direction = Backward
Step 5: CE
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Diagram:
Torque
T
Delta T
Tlast
A Angle
Step x-1
Step x
Delta T Delta Torque

A Angle
trace curves).
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6.5.2.25 SG - Snug Gradient

Step type Id: 32
Parameters: DeltaA (Delta Angle), TcMIN (Min Torque), TcMAX (Max Torque), TSLOPE (Torque Slope),
ASG (Angle run), DIR (Direction).
Function: 1. The spindle is started with the programmed speed in direction DIR.
2. The search for the Snug-point is started as soon as the torque passes TcMIN.
3. The average slope over DeltaA deg is calculated.
4. This is repeated for every DeltaA deg.
5. As soon as two slopes after each other are larger than TSLOPE the Snug-point is found.
6. From this point, the Snug-point, the spindle runs another ASG deg.
7. If the torque level TcMAX is passed without finding the Snug-point the step is aborted
and an event is generated.
Diagram:
Torque
TcMax
Snug-point
TcMin
DeltaA
DeltaA
DeltaA
TSLOPE
ASG Angle
Step
TcMax Max Torque ASG Angle run

TcMin Min Torque DeltaA Delta angle
TSLOPE Torque slope
Result var.: After the step has finished the angle from the Snug-point to the end of the step can be
checked using the normal angle check (see Check angle) if using the special start condition
"SGP" (Snug Point). If so, the result is reported as the step level result variable "A".
Trace: Angle when ASG has been run from the detected Snug-point is shown as a horizontal line
from step start to step stop in trace when Angle vs. Time is selected. Control parameters
must be enabled in the trace form (see View of trace curves).
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6.5.2.26 D - Diagnostic Step

Step type Id: 22
Parameters:
Function: Defines the diagnostic checks to perform in a tightening program.
Normally the diagnostic step is the first step in a program but it can be a later step in the
program (e.g. when Flying Zero Offset is used).
The diagnostic step can also be performed in a special program, which can be run between
normal cycle programs. The normal programs will hence be faster.
The limits for PowerMACS zero offset compensation are configured using the Spindle Set
Up form.
Select if you want a Spindle Functional Test to be performed. This test verifies the spindle
is working correctly and adjusts the spindle‟s measuring system. This test is performed
automatically at startup but it is recommended to run a Diagnostic step with the spindle
functional test as the first step in every tightening program to compensate torque
measurements.
The spindle takes care of zero offset compensation, if this is not sufficient you can select to
let PowerMACS also compensate for zero offsets using the Static, Dynamic or Flying
method.
Check Angle count test to execute a test of the angle measurement channels. Chapter:
Dynamic Zero Offset and Angle Count describes how this is done.
Errors detected in a diagnostic step are reported as Fatal errors except for one case. If the
Flying Zero Offset parameter Continue to run after failed check is checked (see Spindle
Set Up), a flying zero offset error is reported as a warning instead of as an error.
Note! The double torque transducer test is not executed while the spindle functional test is
performed or zero offset is being measured. The double angle encoder test is not executed
while the spindle functional test is performed.
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6.5.2.27 BCT – Backlash correction (only available for Gauging)
Step type Id: 36
Parameters: T (Torque), TI (Delay time between directional change, DIR (direction to run),
Function: This step measures the lash between the angle transducer on the spindle and the external
load (a bolt or another object that shall be rotated). It does so by running in both directions
until a specified torque is reached and measures the angle between the end points. The
angle measurements in all following steps are compensated with the measured angle every
time the spindle changes direction.
The measurement is done on the angle channel specified as angle channel for Backlash
correction in Program Settings.
1. Run spindle, in opposite direction of DIR until torque is T.

2. Wait time TI.
3. Run spindle in direction DIR until torque is T and measure the angle.
Note: The position registers used by the step Run to Position will be reset by the BCT step.
Result var: This step produces the step level result variable “BCT A” which is the angle from the end of
the wait time to torque TC. This angle is used for backlash transportation in following steps.
6.5.2.28 POS - Run to Position (only available for Gauging)

Step type Id: 37
Parameters: Type (1 or 2),
Reference position (Null, Half, Peak, Low)
Position correction (relative to selected position reference, positive or negative)
Auto slow down,
Slow down position (Angle to reduce speed at, if not Automatic slow down)
Low speed (Speed used for last part of movement)
Type 2 parameters:
Adjust to (360 or 720 deg), Min Angle (Minimum angle to run)
Function, type 1:
Run the spindle to an absolute position stored in an earlier step. The target position of the
step is the selected Reference position adjusted with the specified Position correction.
The Position correction can be both positive or negative, meaning after or before the stored
reference position.
Depending on the current position and the calculated target the spindle may run forward or
reverse to reach the target position.
Function, type 2:
Run spindle in direction of previous step. The step calculates the necessary movement to
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transport to the closest multiple (determined by Adjust to) of the distance to target position.
This position is then adjusted with the Position correction parameter to get the final target
of the step.
If the total movement is less than Min Angle another 360 or 720 degrees are added to the
target position.
Slow down at step end:
When the spindle has reached an angle of Slow down position before the target position,
the speed is reduced to Low speed, using the speed ramp programmed as “Speed ramp
up” on the “Ramps & Other” tab.
If Automatic slow down is used the slow down angle is automatically calculated so the
speed reaches 1 rpm just before the target position.
Example, type 2:
Reference position = Null position
Adjust to = 720 deg
Position correction = -100 deg
Min Angle = 50 deg
Null position is at 324 deg (from cycle start)

Current angle is 843 deg, i.e. 519 deg from Null position
Adjust to = 720 deg, i.e. the target position is 324 + 720 = 1044 deg
Position correction = -100 deg, i.e. the compensated target is 1044 – 100 deg = 944 deg
The total movement in the step is thus 944 – 843 = 101 deg. If this had been less than Min
Angle (50 deg) another 720 deg had been added to the target.
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6.5.2.29 MS4 – Measurement step method 4 (only available for Gauging)
Step type Id: 41
Parameters:
MeasZ (Measurement zone, specifies the length of the measurement zone)
Max Adjust (Maximum number adjustments that are allowed)
First Mean High Limit (High limit for the first measured average torque)
First Mean Low Limit (Low limit for the first measured average torque)
Meas High (High limit for the measured average torque)
Meas Low (Low limit for the measured average torque)
Direction (Direction, set the direction of the step)
Delay 1 (Delay time before the first measurement)
Delay 2 (Delay time for the remaining measurements)
Function: The Measurement step, MS, normally runs together with an Adjust step, AD. The AD step
configures the master TC (TC number 1 to 50) for the control and this TC must run a MS
step.
If MaxAdjust is 0 (zero), no AD step is needed. The measurement will be made once and
the result will be evaluated.
The step starts to rotate the spindle in the selected direction. The rotation will continue for
the whole step, also when the Adjust step, AD, is running. The time needed to accelerate to
the target speed is calculated and as soon as the target speed is reached the timer Delay 1
starts to count.
When Delay 1 have passed the first measurement is started, the mean torque and the peak
torque are measured for MeasZ degrees. The results are stored as CW Mean T and CW
Peak T
When the measurement is finished the result variables will be calculated as:
Mean Load = CW Mean T
CW Mean T = The measured mean torque in CW direction
CW Peak T = The measured peak torque in CW direction
If the step is run in the CCW direction the result variables CCW Mean T and CCW Peak T
will be used instead.
The measured Mean Load is compared with the limits MeasH and MeasL. If the value is
between the limits, the step is finished, with status OK. If the value is over MeasH the step
end with status NOK
If the value is below the limit MeasL the value is sent to the AD step. The MS continues the
rotation while the AD step is executed. When the AD step is finished, the MS step waits for
the time set in Delay 2, to pass and then makes another measurement and compares the
new Mean Load with the limits.
This is repeated until the Mean Load is inside the limits or the Max Adjust tries has been
reach.
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In the first case the MS step and the AD step is ended with status OK, in the latter both
steps are ended with the fatal error TRIES. The process will also end if Mean Load is above
MeasH, with the error TRIES.
Check: First Mean Load High and First Mean Load Low
It checks that the first measured Mean Load in the MS step is between the limits Mean Load
High and Mean Load Low. For a description of the measurement and the Mean Load value,
see the description of the respective MS steps.
Alarms: Mean Load outside limits (MEAS_LOAD), MS or AD step failed and aborted (MEAS_ADJ),
First Mean Load high alarm (FMLH), First Mean Load Low alarm (FMLL)
Trace: Torque vs. Time (start and stop for one try zone, maximum the last 5 tries).
Angle vs. Time
Result var: This step produces the step level result variables shown below:
First Mean Load
Mean Load 1, …, Mean Load 5
CW Mean T 1, …, CW Mean T 5
CW Peak T 1, …, CW Peak T 5
6.5.2.30 AD2 – Adjust step method 2 (only available for Gauging)

Step type Id: 43
Parameters:
Torque, TC (Threshold torque for the angle measurement.)
Master TC (Master TC Id number, 1 to 5)
Target (Unit Nm)
Torque Rate (Unit Nm/deg)
Offset (Offset compensation, unit deg)
CCWComp (CCW Compensation, unit %)
InitialOffset (Angle to run the adjustment)
Function: The Adjust step, AD, is always run together with a Measurement step, MS. The AD step
configures the master TC (TC number 1 to 5) for the control and this TC must run a MS
step. The MS and AD step of different types may be combined freely.
The AD waits while the MS step makes the first measurement. If the step make hold
position or not is controlled by the settings in the previous step. When the MS step is
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finished the measured Mean Load is transferred to the AD step. The AD step calculates an
angle target and direction with the following formulas
T arg et MeanLoad
Angle
TorqueRate
If Angle > 0 the direction is CW and the Angle target is
AngleT arg et Angle Offset
If Angle < 0 the direction is CCW and the Angle target is
AngleT arg et Angle CCWComp Offset
The calculated value is not used for the first adjustment. Instead, the angle InitialOffset is
used as Angle Target. If InitialOffset is positive the direction is CW, otherwise it is CCW.
When the target and direction has been calculated, the step run to the torque TC in that
direction.
Measured from the point there the torque passes TC the spindle runs another Angle Target
degrees in the same direction.
After this, the AD step waits again, while the MS step makes another measurement. If the
step make hold position or not is controlled by the settings in this step.
The total movement during the step is measured and reported in the result variable Adj
Total Movement. It is the sum of all the measured angles during the adjustments made.
Trace: Not available.
Result var: This step produces the step level result variables shown below:
Angle Target 1, …, Angle Target 4

Angle Measured 1, …, Angle Measured 4
Adj Total Movement
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6.5.3 Step – Restriction

You can set up restrictions that decide when a step shall be interrupted. A restriction stops a running step
immediately. A restriction can be considered repairable or fatal.
All restriction checks except for the Fail Safe Torque limit starts when torque spike elimination has ended
and stops after the step overshoot time has ended.
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6.5.3.1 Fail Safe Torque

Parameters: Torque
Function: Supervises the fail-safe limits for Torque, The fail safe limits are active also during the
step overshoot time.
The absolute value of the measured torque must be lower than the fail-safe torque limit
during the entire step, including the post step check time. Note! The torque restriction is
supervised also during the Torque Spike Elimination phase.
Diagram:
Torque
FsTorque
FsAngle Angle
FsTime
(time)
Step
FsTorque Fail safe torque Angle Fail safe angle

FsTime Fail safe time
Alarms: Torque restriction (TR)

Trace: Torque is shown as a horizontal line from step start to step stop in trace when Torque vs.
Time is selected. Fail safe limits parameters must be enabled in the trace form (see
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6.5.3.2 Fail Safe Time

Parameters: Time
Function: Supervises the fail-safe limits for Time, The fail safe limits are active also during the step
overshoot time.
Time measurement starts at step start (after start delay for step) and end when the step has
ended and post step check time has elapsed. The measured time must be less than the fail-
safe time limit.
Diagram: See Fail Safe Torque
Alarms: Time restriction (TIR)
Trace: Fail safe limits parameters must be enabled in the trace form (see View of trace curves).
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6.5.3.3 Fail Safe Angle

Parameters: Angle
Function: Supervises the fail-safe limits for Angle, The fail safe limits are active also during the step
overshoot time.
The angle is measured either from the current position where the step is started (AS1) or
from the point where the configured Torque start level has been reached. The measured
angle must be less than the fail-safe angle limit. No check is made until the selected start
condition has been achieved.
Diagram: See Fail Safe Torque
Alarms: Angle restriction (AR)
Trace: Angle is shown as a horizontal line from step start to step stop in trace when Angle vs. Time
is selected. Fail safe limits parameters must be enabled in the trace form (see View of
trace curves).
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6.5.3.4 Min Torque Restriction

Parameters: Threshold torque TStart, Min torque limit MinT
Function: The restriction starts when the measured torque passes TStart. After this the step is
stopped immediately if the measured torque falls below the level MinT. The restriction is
only active until the control function of the step has shut off, since the torque normally drops
when the spindle is stopped.
Note that the restriction is not active during the torque spike elimination phase in the
beginning of the step. The search for TStart starts then the torque spike elimination is
finished.
Diagram 1:
Torque
TStart
MinT
Restriction active Angle

Step
TStart Threshold Torque

MinT Min Torque Limit
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Diagram 2:
Torque
TStart
MinT
Restriction active Angle

Step
TStart Threshold Torque

MinT Min Torque Limit
Alarms: Min Torque Restriction (MTR) if the torque drops below MinT
Trace: MinT is showed in trace as a horizontal line from TStart to step stop when Torque vs. Angle
is selected. Restriction limits must be enabled in the trace form (see View of trace
curves).
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6.5.3.5 Gradient
Parameters: Threshold Torque, Angle distance, No degrees, Gradient Low, Gradient High
Function: Calculates and checks the gradient of the torque curve, that is, the ratio of torque vs. angle.
The gradient is calculated as the difference in torque Angle distance apart divided by the
Angle distance. The first gradient is calculated Angle distance after Threshold torque has
been reached. A new gradient is calculated every time a new torque and angle sample is
available, that is, normally once every millisecond.
The calculated gradient is compared against the limits and stored in trace as a gradient
curve. One or both of the gradient limits can be left empty. If both are empty no restriction
check is active, but the calculated gradient is still stored in the trace.
The torque samples used for the gradient calculation are filtered using a sliding window
average filter. The No degrees parameter defines the sliding window angle over which
mean values are calculated.
In case the step runs backwards compared to the step direction the restriction ends the step
if limit is specified. If no limit is configured the gradient calculation is restarted and there is a
gap in the trace curve until the first new gradient can be calculated.
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Diagram:
Torque Gradient
GradHigh
Reported Grad value
Gradient
GradLow
Shut off point
A dist Torque
ThreshT
Angle
A dist
Step
GradHigh Gradient high ThreshT Threshold Torque

GradLow Gradient low A dist Angle distance
Result var.: This restriction produces the step level result variable "Grad” which is the lowest gradient
measured during the restriction or the gradient that violated the high limit of the restriction.
Alarms: Gradient high restriction (GHR) and Gradient low restriction (GLR).
Trace: Gradient High and Gradient Low are shown in trace as horizontal lines from the point where
the first gradient was calculated to shut off when Gradient vs. Angle is selected. Restriction
limits must be enabled in the trace form (see View of trace curves).
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6.5.3.6 Cross Thread and Gradient

Parameters: Torque level T1, Torque level T2, Min angle, Max angle
Function: Measures the angle from the point where torque passes Torque level T1 to the point where
torque passes Torque level T2. Checks that the measured angle, A, is between Min angle
and Max angle.
Min angle or Max angle can be left empty meaning that the respective test is disabled. Note
that at least one of them must be configured.
Diagram:
Torque
T2
T1
Amin
A
Amax
Angle
Step
T1 Torque Level T1 Amin Angle min
T2 Torque Level T2 Amax Angle max
A Measured angle from T1 to T2
Result var.: This restriction produces the step level result variable "Cross thr. A” which is the measured
angle from T1 to T2.
Alarms: Cross thread restriction (CROSSTR) if A > Max angle. Cross gradient too high restriction
(CROSSGR) if A < Min angle.
Trace: Two lines are shown in Torque vs. Angle view. The horizontal line represents the T2 level
and it starts when T1 is passed and ends after Amin degrees. The vertical line represents
the point where Amax degrees are passed after T1. The step fails if any of the lines is
crossed. Restriction limits must be enabled in the trace form (see View of trace curves).
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6.5.3.7 Torque Profile

Parameters: TnStart, AnStart, AnStop, TnHigh, TnLow, where n is in the range [1..3].
Function: Checks that the torque in the three angle windows defined by TnStart and the pairs AnStart
and AnStop, is within the unique limits TnHigh and TnLow. The angles are measured from
the start point according to the step angle definition if TnStart isn‟t configured and from
TnStart if the parameter is used.
TnStart, AnStart and/or AnStop may be left empty. Leaving AnStart empty corresponds to
the beginning of the step while an empty AnStop corresponds to the end of the step.
TnHigh and/or TnLow may be left empty. Leaving them empty disables the test against the
limit in question. Note that if none of the torque limits is specified then TnStart, AnStart and
AnStop must also be empty and the restriction is not used.
Diagram 1:
Torque Tp3 Peak T
T3High
T3Low
T2High
T2Low
T1High
T1Low
A1start A1stop A2start A2stop A3start A3stop Angle

Step
TnLow Torque Low AnStart Angle start

TnHigh Torque High AnStop Angle stop
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Diagram 2:
Shut off due to high torque T3HR

Torque
T3High
T3Low
T2High
T2Low
T1High
T1Low
A1start A1stop A2start A2stop A3start A3stop Angle

Step
TnLow Torque Low AnStart Angle start

TnHigh Torque High AnStop Angle stop
Result var.: This restriction produces the step level result variables "Tp1 Peak T", "Tp2 Peak T" and
"Tp3 Peak T" which is the highest torque measured in the respective interval.
Alarms: Torque in window n too high (TnHR) and/or Torque in window n too low (TnLR).
Trace: TnHigh and TnLow are shown in trace as horizontal lines from AnStart to AnStop when
Torque vs. Angle is selected. The step fails if any of the lines is crossed. Restriction limits
must be enabled in the trace form (see View of trace curves).
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6.5.3.8 Angle Difference

Parameters: Use spindle limits, Max difference, Number of samples
Function: Supervises Angle channel 1 readings compared to Angle channel 2 readings. The
restriction requires two angle channels to be equipped on the spindle.
Select if you want to use the spindle‟s stored limits or configure your own limits (Max
difference – Maximum difference in degrees, Number of samples – For how many
samples (milliseconds) Max difference is allowed).
If an angle double transducer protection is configured on the spindle this restriction will
replace that during the step, see Angle Double Transducer Check.
Diagram: None
Alarms: Double Angle Transducer Error (ADIFF)
Trace: -
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6.5.3.9 Torque Difference

Parameters: Use spindle limits, Channels, Max difference, Number of samples
Function: Supervises two torque channels compared to each other.
Select if you want to use the spindle‟s stored limits or configure your own limits (Max
difference -- Maximum difference in Nm and Number of samples – For how many
samples (milliseconds) Max difference is allowed).
If a torque double transducer protection is configured on the spindle this restriction will
replace that during the step, see Torque Double Transducer Check.
Diagram: None
Alarms: Double Torque Transducer Error (TDIFF)
Trace: -
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6.5.4 Step – Check

Checks are used to define which step level variables to measure and optionally test against
programmable limits.
Note! If a check of a specific variable is not defined the variable will not be measured and therefore not
available for reporting. This also goes for the corresponding SPC values.
The Overshoot time is configured for each step (see Ramps & Other – Other). This parameter decides
for how long the measuring should continue after that the control function for the step has shut off.
All checks can be set to repairable (R, default) or fatal (F). If repairable the Reject Management can try to
re-tighten the joint (see Step – Rejects). Select the Fatal box if you want the fault to be considered Fatal.
All found check errors in a step are reported when the step has finished. Checks do not interrupt a running
step.
The limits of the most checks are optional. A check having no limit defined will always generate an OK
result. This might be useful if its only purpose is to produce a result variable to be reported. Check limits
are available for display in trace for many of the checks. Check limits must be enabled in the trace form
Note! If the conditions required for evaluation of a check for some reason are not fulfilled an event saying
so is generated. Should the check have one or more limits defined then the corresponding error bits
are set as well and the status of the checks is set to Fatal independent of the configuration. An
example of such conditions is that the start condition for a Check angle check is not met.
In the following sub chapters all checks are described in detail together with their parameters.
With the parameter Operate on (only available in Gauging) it is possible to select if the check shall work
on the Step or Zone level. It is a combo box that has the selections „Step‟ and all available zones for the
step. E.g. if you have specified 3 zones for the step the selections will be „Step‟, „Zone 1‟, „Zone 2‟, „Zone
3‟. Some of the checks can only work on the step level, see the table below.
With the parameter Start condition it is possible to select the start condition for the check. The available
choices vary between the different check types and if the check operates on step or zone level, see the
table below (if a check only have one possible start or stop condition the parameter will not be shown).
A check not running in a zone will start as soon as the backlash correction is finished (if the step run
backlash correction, otherwise the check start directly at step start).
Check Type Operate on Start condition Start condition Condition for OK

(operate on Step) (operate on Zone) (operate on Zone)
Check Peak T Step or Zone Step start Zone start Zone started
Speed reached
Torque in Angle Step or Zone Step start Zone start Zone started
window
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Torque in Time Step or Zone Step start Zone start Zone started
window
Check Mean T Step or Zone Angle Angle Zone ended
Torque Torque
Time Time
Step start Zone start
Check Angle Step or Zone Start condition: Start condition: Zone started
Torque Torque
Step start (AS1) Zone start
Shut off previous (AS2)
Peak angle previous
(AS3)
Stop condition: Stop condition: Zone ended (if stop
Shut off Zone end condition is Zone
Shut off previous Torque End)
Peak Angle
Final Angle
Torque
Check Post view Step Step start
Torque
Check T/T3 Step or Zone Step start Zone start Zone ended
Check shut off Step or Zone Step start Zone start Zone ended
Torque
Check torque rate Step or Zone Step start Zone start Zone started
Check Time Step or Zone Step start Zone start Zone started
Check Yield point Step Step start
Check Stick Slip Step Step start
Check Delta T Step or Zone Step start Zone start Zone started
Low Spot T Step or Zone Step start Zone start Zone started
Angle Angle
Check Position Step Step start
6.5.4.1 Result values from checks

For each check it is possible to select the cycle data variable it shall use to store the result. Each check
type has its own specialized variables that can only be used for that check type (e.g. Peak T, Peak T1,
Peak T2 and Peak T3 for a peak torque check). There are also general variables available that can be
used for all check types.
The specialized variables can only be used in the correct check type with the correct channel selection for
torque or angle. For example Peak T can only be used in a peak torque check with the torque channel set
to Auto. A2 can only be used by an angle check with the angle channel set to Angle 2, etc.
Two sets of general variables are available, one on step level and one on bolt level, with 80 variables in
each set. The variables on step level are named Step var. 01, Step var. 02, etc, and the variables on bolt
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level are named Bolt var. 01, Bolt var. 02, etc. The first 40 variables of each type are marked with a T, to
indicate that these are scaled according to the torque unit selection in the reporters.
It is also possible to select Not reported, which mean that no value will be reported for the check.
Checks that run in a zone, i.e. have Operate on set to Zone, can not use the Specialized variable for
reporting, only the Step var and Bolt var are available.
Note: It is only possible to use the same variable once in each step. For example, with two Peak Torque
checks on the same step with channel selection Torque 1, only one can use the specialized variable Peak
T1, the other one must use one of the general variables (or not reported). Setup problems will detect any
errors and generate warnings if needed.
6.5.4.2 Check peak torque

Parameters: TH (Torque high), TL (Torque low),
Set null position (Store peak position to Null position register) (only available for Gauging)
Set peak position (Store peak position to Peak position register) (only available for
Gauging)
Function: The peak torque from check start to check stop is checked to be between the high limit TH
and the low limit TL.
Both limits are optional. Leaving them blank disables the check but the result value is still
calculated and reported.
If the check operates on step it starts at step start. It ends when the step ends, including
overshoot time. If the check operates on zone the check starts when the selected zone
starts and ends when the zone ends.
If Set null position or Set peak position is set the peak position, that is the angle where
the peak torque was found, is stored in the corresponding position register. It is possible to
return to this position later with the step POS - Run to Position (only available for Gauging).
This check requires that at least one sample is collected after the torque spike elimination
phase. If not, and at least one limit is specified, the steps status is set to Fatal and the error
bit of the respective limit is set.
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Diagram:
Peak
Torque
Torque Shut-off point
TH
TL
Angle
Step OSHT
TH Torque High OSHT Overshoot time

TL Torque Low
Result var.: Peak T, Peak T1, Peak T2, Peak T3 (Peak torque).
Alarms: Step peak torque high (PTH) and step peak torque low (PTL).
Trace: TH and TL are shown in trace as horizontal lines from step start to step stop when post step
check time has elapsed. The lines are only shown when Torque vs. Time is selected.
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6.5.4.3 Check torque in angle window
Parameters: TH (Torque high), TL (Torque low), Astart, Astop
Function: Astart and Astop are both measured from the start of the step and define an angle window.
All torque values measured in this window are checked to be between the high limit TH and
the low limit TL.
Both limits are optional. Leaving them blank disables the check but the result values are still
phase and that angle Astop is reached. If not, and at least one limit is specified, the steps
status is set to Fatal and the error bit of respective limit is set.
Diagram:
Torque
A Win Hi T
TH
TL
A Win Lo T
Angle
AStart AStop
Step
TH Torque High AStart Angle start

TL Torque Low AStop Angel stop
Result var.: "A Win Hi T" (angle window high torque) and "A Win Lo T" (angle window low torque).
Alarms: Step torque high in angle window (THAWIN) and step torque low in angle window
(TLAWIN).
Trace: TH and TL are shown in trace as horizontal lines from AStart to AStop. The lines are only
shown when Torque vs. Angle is selected and Check limits are enabled in the trace form
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6.5.4.4 Check torque in time window
Parameters: TH (Torque high), TL (Torque low), Start time, Stop time
Function: Start time and Stop time are both measured from the start of the step and define a time
window. All torque values within this window are checked to be between the high limit TH
and the low limit TL.
phase and that time Stop time is reached. If not, and at least one limit is specified, the steps
status is set to Fatal and the error bit of the respective limit is set.
Diagram:
Torque
Ti Win Hi T
TH
TL
Ti Win Lo T
Time
Start time Stop time
Step
TH Torque High Start time

TL Torque Low Stop time
Result var.: "Ti Win Hi T" (time window high torque) and "Ti Win Lo T" (time window low torque).
Alarms: Step torque high in time window (THTIWIN) and step torque low in time window (TLTIWIN).
Trace: TH and TL are shown in trace as horizontal lines from Start time to Stop time. The lines are
only shown when Torque vs. Time is selected and Check limits are enabled in the trace
form (see View of trace curves).
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6.5.4.5 Check mean torque
Parameters: MTH (Mean torque high), MTL (Mean torque Low), Start condition, TI (Time), Tstart
(Torque start), Astart (Angle start)
Function: Measures the average torque during the step. The calculated value is checked to be
between the high limit MTH and the low limit MTL.
Depending on the Start condition the measurement starts at different points during the step:
Start condition Measurement range

Step start From step start to Shut-off point
Time The last TI seconds of the step
Torque From the point there the toque pass Tstart to Shut-off point
Angle From the point there the angle pass Astart to Shut-off point
The parameters Start condition, Tstart and Astart are only available for Gauging. In
Tightening the start condition Time is always used.
Diagram 1 (Start condition Time):
Shut-off point
Torque
MTH
Mean Torque
MTL
Time
TI
Step OSHT
MTH Mean Torque High OSHT Overshoot time

MTL Mean Torque Low
TI Time
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Diagram 2 (Start condition Torque):
Shut-off point
Torque
MTH
Mean Torque
MTL
TStart
Time
Step OSHT
MTH Mean Torque High OSHT Overshoot time

MTL Mean Torque Low
Tstart Torque start
Diagram 3 (Start condition Angle):

Shut-off point
MTH
Mean Torque
MTL
Angle
Astart
Step
MTH Mean Torque High Astart Angle start

MTL Mean Torque Low
Result var.: "Mean T" (mean torque).

Alarms: Step mean torque high (MTH) and Step mean torque low (MTL).
Trace: There are no limits in trace for this check.
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6.5.4.6 Check angle
Parameters: AH (Angle high), AL (Angle low), Start condition, Tstart (Torque start), Stop condition,
Tstop (Torque stop), Operate on (Step or Zone),
Torque channel (Auto, Torque 1, Torque 2 or Torque 3 (Current as Torque)),
Angle channel (Auto, Angle 1 or Angle 2), Result variable
Function: Measures the angle movement made during a step and checks that it is between the high
limit AH and the low limit AL. When to start and stop the measuring is controlled using
parameters Start condition and Stop condition as follows:
Start condition Value used as start angle

T The angle, A_Tstart, measured when torque reaches the value Tstart.
AS1 The angle of the current position when the step is started.
AS2 The angle measured at shut of the previous step.
AS3 The peak angle reached during the execution of the previous step.
SGP The "Snug Point "of a SG step. See SG - Snug Gradient for a description.
Zone start Angle at zone start
Stop condition Value used as end angle

F - "Final" The final angle (AE1, measured when the "Overshoot time" has passed
after shut off).
SO - "Shut Off" The angle measured at the shut of point (AE2).
P - "Peak" The largest angle measured from shut off until the "Overshoot time" has
passed (AE3).
SOP - "Shut Off The angle measured when the torque falls under the shut off torque
Previous" measured during the previous step (AE4).
T - "Torque" The angle, A_Tstop, measured when torque drops below the value of
Tstop after the shut off point.
Zone end Angle at zone end
Note! The "Overshoot time" (which is measured from that the step is shut off, see chapter:
Step – Check) has to be programmed long enough to monitor the requested end condition.
The check is only evaluated if both the Start condition and the Stop condition are met. If
not, and at least one limit is specified, the steps status is set to Fatal and the error bit of the
respective limit is set.
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Diagram:
Torque
Shut-off point
TStop
TStart
Shut-off point
Previous step
AS3 P AH Angle
AS1 A_Snug AL F
A_Tstart SO A_Tstop
AS2
SOP
Step x-1 Step x
TStart Torque Start A_Tstart Start cond. - Angle at Tstart F Stop cond. - Final angle
TStop Torque Stop AS1 Start cond. - Angle at step start SO Stop cond. - Shut-off angle
AL Angle Low AS2 Start cond. - Angle at prev. shut off P Stop cond. - Peak angle
AH Angle High AS3 Start cond. - Peak angle prev. SOP Stop cond. - Shut-off angle prev.
A_Snug Start cond. - Snug point A_Tstop Stop cond. - Angle at Tstop
Result var.: A (step angle)

Alarms: Step angle high (AH) and Step angle low (AL).
Trace: AH and AL are shown in trace as horizontal lines from check start to stop, which vary
according to selected start and stop conditions. The lines are only shown when Angle vs.
Time is selected and Check limits are enabled in the trace form (see View of trace curves).
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6.5.4.7 Check Post view Torque

Parameters: TC (Torque check level),
TL (Torque low), AdistL (Low angle distance), AwinL (Low angle window),
NOSL (No samples low)
TH (Torque high), AdistH (High angle distance), AwinH (High angle window),
NOSH (No samples high)
Function: This function checks that the filtered torque in the angle window AwinL is higher than the
torque limit TL. It also checks that the filtered torque in the angle window AwinH is less than
the torque limit TH. Both limits are optional but at least one of them must be specified.
Angle window AwinL is located AdistL before the point where the torque reaches level TC
and AwinH is located AdistH before the torque reaches level TC. The torque level is allowed
to reach level TC several times during a step. The angle windows are measured from the
last point where the torque reached TC.
The torque values used in the check are filtered using a sliding window average algorithm.
The mean torque value is calculated over NOSL for the TL check and over NOSH for the
TH check. The filter can be disabled by leaving the respective number of samples
parameter empty.
The filter starts after the torque spike elimination phase and runs throughout the check. The
check does not start until the filter is full. The filtered torque value is recalculated on every
new sample; that is, normally every millisecond.
The angle used for crossings over the limits is the filter‟s median angle value (angle at
sample NOSL/2 or NOSH/2 in the filter).
This check requires that torque TC is reached after the torque spike elimination phase and
that the angle MAX(AwinL + AdistL; AwinH + AdistH) has been reached at that point. If not,
the steps status is set to Fatal and the error bit of the respective limit is set.
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Diagram:
Torque
TC
AwinL AdistL
AwinH AdistH
TL
TH
Angle
Step
AwinL Low Angle Window TL Torque Low

AwinH High Angle Window TH Torque High
AdistL Low Angle Distance
AdistH High Angle Distance TC Torque Check Level
Result var.: None.

Alarms: Post view torque too high (PVTH) and post view torque too low (PVTL).
Trace: TH and TL are shown in trace as horizontal lines displaying the angle window for each limit.
The lines are only shown when Torque vs. Angle is selected and Check limits are enabled
in the trace form (see View of trace curves).
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6.5.4.8 Check T/T3 (Current as Torque)

Parameters: T/IH (Torque/T3 high), T/IL (Torque/T3 low), TI (Time)
Function: The average torque vs. the average current measured during the last TI seconds of the step
is measured and checked to be between the high limit T/IH and the low limit T/IL.
Diagram:
Shut-off point
Torque /
Current
T/IH
T/IL
Torque
Current
Time
TI
Step OSHT
T/IL Torque/Current Low OSHT Overshoot time

T/IH Torque/Current High
TI Time
Result var.: "T/T3"

Alarms: “T/T3 high” and “T/T3 low”.
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6.5.4.9 Check shut off torque
Parameters: SOTH (Shut off torque high), SOTL (Shut off torque low)
Function: The torque measured at the shut off point of the step is checked to be between the high
limit SOTH and the low limit SOTL.
Diagram:
Shut-off point
SOTH
SO T
SOTL
Step OSHT Time
SOTH Shut-Off Torque High SO T Shut-Off Torque

SOTL Shut-Off Torque Low OSHT Overshoot time
Result var.: "ShutOff T" (shut off torque).

Alarms: Step shut off torque high (SOTH) and step shut off torque low (SOTL).
Trace: TH and TL are shown in trace as horizontal lines from step start to step stop after post step
check time. The lines are only shown when Torque vs. Time is selected and Check limits
are enabled in the trace form (see View of trace curves).
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6.5.4.10 Check torque rate

Parameters: T Start (Torque Start), T Stop (Torque Stop), A Start, A Stop, TRL (Torque rate low), TRH
(Torque rate high) , Dev (Deviation), Falling Edge , Type
Function: Measures and checks the Torque Rate (TR), that is, the ratio of torque vs. angle during a
single step or zone.
Measuring is started when the angle Astart has elapsed from that torque reached the value
Torque Start. If Falling Edge is checked the measurement of Astart is started when the
torque falls below Torque Start. This is point (A1, T1).
Point (A2, T2) is the point where measuring is stopped, that is, when any of the following
conditions first is met:
- when the torque reaches the value Torque Stop
- when the angle measured from Torque Start reaches Astop
- when the torque reaches final torque, that is, the end of the step. This point is used only if
both Torque Stop and Astop are empty.
Torque Start, Torque Stop, Astart, and Astop are all optional. If Torque Start is left
empty, then Astart is measured from the start of the step. Leaving Astart empty is equal to
setting Astart to zero. Leaving Torque Stop and/or Astop empty deactivates the
respective check as stop conditions.
Depending on the setting of Type, different methods are used to calculate the Torque Rate:
Type ‘Least Square’:

The check calculates a straight line with least square method using 15 points evenly spread
between the angles A1 and A2, the points A1 and A2 are always included. The minimum
distance between two points is 2 deg, so if the total angle between A1 and A2 is less than
28 degrees fewer points are used.
Type ‘Two point’:

The Torque Rate is calculated as: TR = (T2 – T1) / (A2 – A1)
The formula for the calculated line is:

T = TR * A + m, there T is the torque, A the angle and TR the calculated Torque Rate.
The calculated TR is checked to be within the limits TRH and TRL.
This function also checks that the torque does not deviate more than Dev from a straight
line between the points (A1, T1) and (A2, T2). The Deviation in sample k, DEV(k), is
calculated as:
DEV(k) = ABS[T(k) – (A(k) * TR + m)]
The highest found deviation is reported in the result variable TorqueRate Dev.
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This check requires that the start condition and, if specified, the stop condition are met. In
addition, the angle measured between these two points must be larger than the angle
corresponding to one (1) encoder increment. If not, and at least one limit is specified, the
steps status is set to Fatal and the error bit of the respective limit is set.
The parameters Falling Edge, Type is only available for Gauging. In Tightening rising edge
and type „Two point‟ is always used.
Diagram 1:
Torque
Tstop
TRH
T2
Dev
TRL
T1
Tstart
Astart
Angle
A1
Astop
A2
Step
Tstart Torque Start Astart Angle Start Dev Deviation

Tstop Torque Stop Astop Angel Stop TRL Torque Rate Low
TRH Torque Rate High
T1 Torque at the end of Astart
T2 Torque at Astop
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Diagram 2:
Torque
TRH
T2 = Tstop
Dev
TRL
T1
Tstart
Astart
Angle
A1 A2
Astop
Step

A2 Angle at Tstop
Result var.: "TR" (step torque rate) and "TR Dev" (step torque rate deviation).
Alarms: Torque rate too low (TRL), Torque rate too high (TRH) and Too big deviation (DEV)
Trace: The calculated torque rate line and the Dev lines are shown as in the diagram above. The
lines are only shown when Torque vs. Angle is selected and Check limits are enabled in the
trace form (see View of trace curves).
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6.5.4.11 Check Zero Crossing (only available for Gauging)

Parameters: Zero Crossing high, Zero Crossing low, Torque Rate Check, Set null position
Function: This check is not possible to run by itself, it use the data collected by a Check Toque Rate
check. The torque rate check to use is selected with the parameter Torque Rate Check.
The Zero crossing check use the calculated torque rate line in the torque rate check (T = TR
* A + m) to calculate the zero crossing point, i.e. the angle there the toque is zero.
The zero crossing ZC is calculated as: ZC = -m / TR
The angle used is the cycle angle, so the result will be angle from cycle start and not angle
from step start. The check will use the angle channel selected in the torque rate check.
The calculated ZC is compared with the limits Zero Crossing High and Zero Crossing
Low. If Set Null position is checked this position will also be stored to make it possible to
return to that point with the step Run to Position
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Diagram:
Check Zero Crossing

Torque
Angle
ZCL ZC ZCH A1 A2
Step x-1 Step x
ZCL Zero Crossing low ZC Measured Zero crossing

ZCH Zero Crossing high
A1 Start point for the torque rate calculation in the torque rate check
A2 End point for the torque rate calculation in the torque rate check
Result var.: "Zero Cr. A", "Zero Cr. A1", "Zero Cr. A2 " (measured zero crossing)
Alarms: Zero Crossing high (ZCH), Zero crossing low (ZCL)
Trace: ZCH and ZCL are shown in trace as vertical lines. The calculated line is shown as a straight
line, from the end of the step and down to the torque axis. The lines are only shown when
Torque vs. Angle is selected.
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6.5.4.12 Check time

Parameters: TIH (Time high), TIL (Time low)
Function: The time from when the step starts until it ends is measured and checked to be between the
high limit TIH and the low limit TIL.
Diagram:
Torque
Shut-off point
TIL Time
Step time TIH
Step OSHT
TIL Time Low OSHT Overshoot time

TIH Time High
Result var.: "Time" (step time).

Alarms: Step time high (TIH) and Step time low (TIL).
6.5.4.13 Check Yield Point Angle

Parameters: Yield Angle high, Yield Angle low, Torque start, No degrees, Angle distance, DIFF, Stop
condition
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Function: This check measures the angle from the yield point to the end of the step. The measured
angle, YP Angle, is checked to be within the limits Yield Angle low and Yield Angle high. If
the value is outside an error is reported.
The search for the yield point starts then the torque has reached the level Torque start.
From this point the gradient, i.e. the ratio of torque vs. angle, is calculated. During the step
the maximum gradient value is stored. The yield point is found then the calculated gradient
is less than DIFF * Maximum gradient. The DIFF value is specified as a percentage of the
maximum gradient.
The angle to use as end angle is controlled by the parameter Stop condition. There are
three different angles that can be used. Final angle, F, is the last measured angle in the
step. Shut off angle, SO, is the angle at the shut off point and Peak angle, P, is the highest
angle reached during the step. For more details see Check Angle.
The gradient calculation is done in the same way as in the Gradient Restriction. The check
compares the filtered torque values Angle distance apart to find the gradient. The torque is
filtered with a sliding average over the angle No degrees. See also the Gradient Restriction
for more details.
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Diagram: (with Stop condition SO)
Torque Gradient
Max gradient DIFF * Max gradient Gradient
Shut off point
Yield point
A dist
Torque
T Start
Angle
A dist YAL YAH
YP Angle
Step
T Start Torque start A dist Angle distance

YAH Yield point angle high DIFF Difference %
YAL Yield point angle low
Result var.: "YP Angle" (Yield Point Angle), the angle between the Yield point and the end angle.
Alarms: Yield Point Angle High (YAH) and Yield Point Angle Low (YAL)
Trace: No limits are shown in trace.
6.5.4.14 Check Stick Slip

Parameters: Trigger mode, Max drops, Trigger level, and Threshold torque.
Function: This check detects and reports stick slip effects during a step. The detection is done by
counting the times the torque falls below the level TTrig and if the number of times is larger
than Max drops the stick slip error is reported.
The check operates in two different modes, Dynamic or Fix. The difference between the
modes is the way TTrig is calculated.
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Dynamic mode: TTrig is dynamically calculated as percentage of the current max torque
that has been reached so far during the step. The user specifies the percentage to use. The
check is started as soon as the torque passes the threshold torque level.
Fixed Mode: TTrig is a fixed torque level specified by the user. In this mode the Threshold
torque is not needed.
To prevent false detections of stick slip the counter of the drops below TTrig is reset if a too
long angle has been run since the last drop. The counter is reset if the angle since the latest
drop is larger than the angle between the first and latest drop, i.e. if
a – ai > ai – a1; a = current angle, a1 = angle at first drop, ai = angle at last drop
Note 1: Since this is a check the step will continue to run to the final target even after a
stick-slip has been detected.
Note 2: Since the sample frequency of the torque transducer normally is 1 kHz the check
can have problems to detect a stick slip with a frequency higher than 500 Hz.
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Diagram:
Torque
Shut off point
TTrig 4
1 3
2
TC
Step Angle
TC Threshold torque 1–4 Drops below trigger level

TTrig Trigger level
Result var.: none

Alarms: Stick slip detected (SS)
Trace: The torque trigger level is shown as a horizontal line from the first drop to the last. In
dynamic mode the line represents the maximum trigger level that was used. The line is only
shown when Torque vs. Angle is selected.
6.5.4.15 Delta T (only available for Gauging)

Parameters: TH (Maximum delta torque), TL (Minimum delta torque).
Function: The difference between the peak torque and the low spot torque, measured from check
start to check end is compared to the limits. TH is the high limit and TL is the low limit. Both
or only one of the limits can be programmed.
If the check operates on step it starts at step start. It ends when the step end, the last
sample is taken at the shut off point of the step. If the check operates on zone the check
start when the selected zone starts and ends when the zone ends.
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Result var: Delta T
Alarms: Delta torque high (DTH) and Delta torque low (DTL).
6.5.4.16 Low Spot Torque (only available for Gauging)

Parameters: TH (Maximum low spot torque), TL (Minimum low spot torque),
Start condition, Astart (for Start condition Angle)
Set null position (Store low position to Null position register)
Set low position (Store low position to Low position register)
Function: The lowest torque during the check is measured and compared to the limits (TH, TL). The
measurement starts when the angle Astart (measured from check start) has been passed.
If Start condition is Step start or Zone start the measurement starts directly when the
check starts.
The measurement ends then the step or zone ends. If it is running on step level the last
sample is taken at the shut off point of the step.
If Set null position or Set low position is set the low position, that is the angle where the
low spot torque was found, is stored in the corresponding position register. It is possible to
return to this position later with the step Run to Position.
Result var: Low Spot T
Alarms: Low spot torque high (LTH) and Low spot torque low (LTL).
Trace: Torque vs. Angle
6.5.4.17 Check Position (only available for Gauging)

Parameters: PH (Maximum distance to selected position),
PL (Minimum distance to selected position),
Reference position (Null, Half, Peak or Low position),
Function: The distance to the selected position at the shut off point of the step is compared to the
limits PH and PL. Both limits are optional.
The distance is calculated as Distance = Reference Position – Current Position, the result
can be both negative and positive.
Result var: Position A
Alarms: Position high (PH) and Position low (PL).
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6.5.4.18 Check Backlash angle (only available for Gauging)
Parameters: Backlash angle high, Backlash angle low
Function: The backlash angle used in the step (measured by the last BCT step ran) is compared to
the limits Backlash angle high and Backlash angle low. Both or only one of the limits can
be programmed.
Result var: "BCT A", "BCT A1", "BCT A2" (Backlash angle)
Alarms: Backlash angle high (BAH) and Backlash angle low (BAL).
6.5.4.19 Check external input (only available for Gauging)

Parameters: Digital Input, Signal Value
Function: The selected Digital Input is compared to the Signal Value at the end of the step, after the
over shoot time has passed.
The following digital signals are available for Digital Input:

Local DI 1, … Local DI 4 (the digital outputs directly on the TC)
PLC_DO_1, … PLC_DO_10 (available as outputs in the PLC)
Possible Signal Value are Low or High

Result var: None
Alarms: Step input not OK (NOKINPUT).
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6.5.5 Step – Rejects
The Reject Management (RM) function is used for automatic repair of failed steps. Most of the RM
settings for a step can be found in the Rejects group.
When a failed step is detected the RM performs the following:

1. Checks bolt status
2. Decides what to do
3. Starts repair
4. If problem was correctable, continues with status OKR
5. If not correctable, terminates or continues with status NOK
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6.5.5.1 Checking the bolt status
The first thing that the Reject Management function does when a step fails is to figure out whether or not
the step can be repaired. This is decided by the bolts current statuses.
At each synchronized step all bolts will be assigned a status. This status is the result of all checks made in
the step, comprising the restriction tests, the step checks, hardware checks, etc. The resulting overall
status for a bolt will be one of the following:
Status of all restrictions, checks, etc. of the step Bolt status
All checks are Acceptable Acceptable
At least one check is Repairable and none is Fatal Repairable
At least one check is Fatal Fatal
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6.5.5.2 Deciding what to do

Whenever a reject management action is considered the following concepts are important:
Bolt Categories
All bolts executing are divided into one of three groups
Reject bolts: All Bolts that have other status than Acceptable, that is have failed them self
(Repairable or Fatal).
Reject group: All Bolts that have status Acceptable but belong to a group in which at least one
bolt is not Acceptable.
Others: All Bolts that have status Acceptable and do not belong to a group where one or more
bolts are not Acceptable.
Possible RM Actions
There are four different RM Actions to choose between:
Terminate: The bolts should execute their Terminate sequence.
Continue: The bolts should continue with the next step. The bolt will first wait for any Terminate
and Repair sequences to finish.
Retry: The bolts should execute their Retry action(s). The bolt will first wait for any Terminate
sequences to finish.
Wait: The bolts should wait at the step they currently are at while other bolts are being terminated
or repaired.
Selecting RM Action
You can specify different action for each bolt category depending on what kind of error that is at hand, and
when it occurred. This is configured using the First Failure, Failure during repair and Fatal failure
settings specified for the steps.
The First failure alternatives are used when the station is in its Running Normal state and for cycle
RM. It offers the following alternatives and combinations:
Failing bolts Failing group Other bolts

Terminate Terminate Terminate
Terminate Terminate Wait
Terminate Wait Wait
Continue Continue Continue
Retry Retry Retry
Retry Retry Wait
Retry Wait Wait
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The Failure during repair alternatives is used when the station is in its Running Repair state, that
is when an error occurs during the repair.
Please note that the Retry alternative is not available for the steps located in the repair part of the
program. The steps in the repair part of the program are only intended for preparation of a repair.
CE steps do not have Failure during repair since all CE steps finish the cycle (and thereby ends
any on-going repair).
The Failure during repair action only affects bolts that are active running repair. Bolts that are
waiting, or have finished their repair, are not affected. The following Failure during repair
alternatives is available in the main program:

Terminate Wait Wait
Continue Continue Continue
Retry Retry Retry
Note! No Retry is allowed as Failure during repair action when steps in the repair part are run.
The Fatal failure alternatives are used when a fatal error occurs for the bolt. It offers the following
alternatives:

Terminate Wait Wait
The Fatal failure action affects all bolts that are not already terminated. That is, also the bolts that are
waiting while other bolts are being repaired may be ordered to Terminate.
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Depending on the overall status of all bolts that have executed the station will choose Reject Management
actions as follows:
Status of all Bolts Reject Management Action

All bolts are Acceptable Continue with next step
At least one bolt is Repairable and none is Fatal Depends on the state of the station:
If it is Running Normal (that is not currently repairing)
then the First failure settings of all bolts in the Failing
bolts category are evaluated in order to decide the next
action.
If it is already Running Repair then the Failure during
repair settings of all bolts in the Failing bolts category
are evaluated in order to decide the next action to take for
the bolts running repair.
At least one bolt is Fatal First the actions according to the Fatal failure settings of all
bolts with status Fatal are executed. Note that also bolts that
are waiting for other bolts to be repaired can be ordered to
terminate using the Fatal try settings.
If there are any bolts remaining with Repairable errors after
running the terminate sequence they will be executed
according to the First failure or Failure during repair
settings as above.
Since the First failure, Failure during repair and Fatal failure settings are defined per bolt the station can
meet contradictory actions. Should this happen the ambiguity is resolved by choosing the action in the
following order: Terminate, Retry, Wait, and Continue.
When the station has decided what action each bolt should take it will order the bolts to either run the
Terminate sequence, the Retry sequence, to continue with next step, or do nothing (wait).
The Retry and Terminate sequences are defined individually for each step and bolt. This means that if a
bolt is ordered to execute a Retry action while at step 5, it is the Retry settings (see Configuring Reject
Management) on step 5 that controls at which step the repair will start.
Note 1 If no Repair action is configured for a reject bolt the bolt will get status NOK instead of OKR after
the repair. All other bolts will get status OKR as best after repair, independent of if any repair
action was done or not.
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Note 2 When a bolt is ordered to terminate the following rules are used to decide its status:
A bolt that has a termination sequence defined, that is, the parameter Terminate with step is
non-empty, for the last step it executed (in its current state) will get status NOKRM (NOK if it
belongs to the Failing group).
A bolt that ends its cycle before reaching a CE step due to a termination order will get status
NOKRM (NOK if it belongs to the Reject bolts group).
Remaining bolts, that is, those that have reached a CE step and does not have a termination
sequence defined for the last step executed, will keep the status they have before they are
ordered to terminate since the termination order will not cause any action.
Emergency stopped bolts that do not have a termination sequence defined get status OK if all
steps were run successfully and NOK if not.
Emergency stopped bolts that have a termination sequence defined get status TERMNOK
since the termination steps were not run.
All bolts that fail during the termination sequence will get status TERMNOK.
Note 3 If a bolt is ready with initial repair, and has no repair step, it waits for the other bolts to finish their
repair. If any of these other bolts fail when running the “Failing synchronization interval” the failing
bolt will cause a repairable error treated as a First failure as the repair is ready. The waiting bolt
will do Repair or Terminate according to the Retry in the step from which the repair was started.
Note 4 Bolts that end their cycle at a CE step in the repair part of the program reenters state Running
Normal when the CE step is reached. The repair is finished when all bolts running repair have
reached CE or the Failing synchronization interval. At this point the bolts go back to state Running
Normal. If any bolt still running steps fails while a bolt waits after last step before CE, the waiting
bolt will do Repair or Terminate according to the Retry in the step it is waiting at.
Please note that the above rules controls the status a bolt will have after executing the normal steps but
before evaluating the monitoring checks configured for the CE step. See chapter: Cycle RM for a
description of how monitoring affects the resulting status.
See also chapter: Reject management states for a description of the states of the station and its bolts with
respect to reject management.
Synchronization marks
The usage of synchronization marks is very important for the execution of reject management. The station
will only make decision on reject management action when all bolts have stopped either due to that they
have failed executing a step or that they have reached a synchronization mark. They are also important
with respect to when a bolt is considered done with any repair (see chapter: Reject management states).
In addition to the explicit synchronization marks there are also a number implicit ones, namely:
All Cycle End (CE) and Return from Repair (RE) steps.
6.5.5.3 Configuring Reject Management

Most reject management settings are defined per step using the Rejects group.
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The parameters grouped under Retry controls how this bolt should be repaired on the selected step when
ordered so by the station:
Loosen with step. The number of the step to jump to in order to prepare the repair action. Any
step in the repair part of the program (that is, any of the steps after the first CE step) is allowed as
target. Typically this sequence is used to loosen the bolt before the repair is started.
If initiate repair steps end with a Cycle End step the cycle ends and the retry is considered ready. If
left blank then no initial repair is done. That is, if a Cycle End step is reached while executing in the
repair part of a program the cycle is ended for the bolt. Monitoring and cycle reject management is
done according to the Cycle End step in the program.
Restart from step. Points to the step in the main part of the program or sequence where the repair
should be started when the optional initial repair is finished. Any step in the main part of the
program up to, and including, the current step is allowed. If left blank execution resumes at the next
step after the step where the Retry was ordered and repair is ready.
Terminate with step. The number of the step to jump to when ordered by the station to Terminate.
Any step in the repair part of the program is allowed as target.
If the sequence started with the Terminate with step end with a CE step then monitoring will be
performed as configured in this Cycle End step. If a RE step ends the sequence then monitoring is
performed according to the CE step that should have been reached if the execution had not been
transferred to the Terminate sequence.
Whether to use a RE or a CE step should be based on if you want to use different Monitoring
check settings for the Terminate sequence compared to the main sequence.
Max no. of retries. Defines how many times this step may be repaired when it has failed. When
this number is exceeded the error is considered Fatal. Max number of retries is 9.
If both Loosen with step and Restart from step are specified then Loosen with step sequence is
executed first. If none of them are specified when ordered to do a repair the reject bolt will get status
NOK instead of OKR as no repair has been done. All other bolts that are ordered to do a repair will get
status OKR as best.
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6.5.5.4 Advanced RM Actions
The RM actions specified above do not take into consideration any ”history” of the cycle. Decisions are
made for each sequence separately, without looking back on what has happened earlier in the cycle.
With the Advanced RM you can have an alternative RM dependent on what has happened earlier, in
terms of number of sequences, spindles, and groups that have failed.
The conditions for when to start Advanced RM are set up for a Station using the System Map, see chapter
Station Set Up.
You may choose one or more of the following alternatives (with step is here meant all steps between two
synchronization points):
When more than No. of reject steps in cycle erroneous steps have been detected during the
cycle. The function counts the number of times steps fail (regardless of which bolt(s) that failed and
which step number that failed) while the station is running in state "Normal". That is, whenever the
First failure alternative is at hand.
When more than No. of reject groups in step erroneous groups have been detected in the
current synchronization interval. This function counts the number of groups that includes one or
more failing bolts. The check is done after each synchronization point and involves only the bolts
that executed the step(s). This means that bolts that where ordered to "Wait", "Continue" or
"Terminate" in a previous step (or synchronization point) are not counted.
When more than No. of reject bolts in step erroneous bolts have been detected in the current
synchronization interval. This function counts the number of bolts that failed. The check is done
after each synchronization point and involves only the bolts that executed the step(s). This means
that bolts that where ordered to "Wait", "Continue" or "Terminate" in a previous step (or
synchronization point) are not counted.
The Advanced RM will be used if any of the selected conditions has been met. The conditions are
common to all steps in the cycle, independent of which is the current step.
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6.5.5.5 Cycle RM
To enable Reject Management also on Monitoring errors all Monitoring checks can be configured as either
Fatal or Repairable.
When all bolts have reported Cycle End to the station and nothing is to be repaired the station orders the
bolts to do monitoring of the cycle. Then the bolt starts evaluation of the Monitoring conditions. The
spindles will report the result of the Monitoring checks to the station and if at least one not already
terminated spindle reports Repairable or Fatal reject management will be executed. The station uses the
status and RM settings of all not terminated rejected bolts to determine the reject action. The station
change state to Evaluating when monitoring starts, but re-enters state Running if Reject Management is
started.
Note 1 For configuration of Reject Action on a CE step only the First failure and Fatal failure settings
are available.
Note 2 No terminated spindles are involved in reject action for the cycle. This includes OK spindles that
are terminated after the last step before CE without termination step and thus keeps status OK.
Monitoring check results always affect the status of the individual bolt. OK or OKR bolts become
NOK if monitoring fails and no reject management is done.
Bolts that have been terminated before they reach the CE step will not participate in Reject Management
executed on the CE step. Bolts that have status NOK before the Monitoring checks are evaluated are
considered Repairable. There are only two possibilities for a bolt to reach the CE step with status NOK.
The first is that it as a reject bolt has been ordered to Continue (failing step was not repaired). The second
is that it as reject bolt has been ordered to Retry, but had no retry configured (failing step was not
repaired).
The status reported to the station after monitoring is constructed using the bolt status after executing the
ordinary steps and the result from evaluating monitoring. A cycle that is NOK before monitoring cannot
become OK due to correct monitoring checks.
However, a bolt that has status NOKRM before monitoring is evaluated will keep the NOKRM status also if
one or more monitoring checks fail.
The below table shows the possible outcome for the bolts involved in RM on the CE step (that is, all not
already terminated bolts):
Status before Result of Reject Management action Best possible status after
evaluation of Monitoring taken repair
Monitoring checks
checks
OK Acceptable None OK
Repairable According to First failure settings OKR
Fatal According to Fatal failure settings NOK
OKR Acceptable None OKR
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NOKRM Acceptable According to First failure settings OKR
Fatal According to Fatal failure settings NOKRM
NOK Acceptable According to First failure settings OKR
Bolts that never reach a CE step, for example due to that it is terminated, will use the Monitoring checks
defined on the CE step it would have reached if the execution should have continued normally. As an
example of this see the program outlined below. If the bolt is ordered to terminate in step 2 the Monitoring
settings of the first CE step (step 8) will be used. If terminated at step 10 the settings of the second CE
step (step 12) is used.
F a ilin g
S yn ch syn ch ro n iza tio n S yn ch
M a rk in te rva l M a rk
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
CE CE CE CE RE
-/-/- -/-/- 9 /-/- 1 3 /-/- -/-/- -/-/- -/-/- -/-/- -/-/- -/-/-
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6.5.5.6 Reject management states
The states of the Station

With respect to reject management the station is always in one of the following states:
State Description
Running Normal All bolts are running steps in the main part of their programs. No error has occurred.
When all bolts have stopped, either because they reached a synchronization mark or that
they failed, the station decides what reject action to take by evaluating the
Fatal failure settings for all bolts with Fatal errors
First failure settings for all bolts with Repairable errors
Should the settings lead to different actions for a given bolt the “hardest” action is taken
Running Repair Some bolts are running their repair sequence. When all bolts have stopped, either
because they reached a synchronization mark or that they failed, the station decides what
reject action to take by evaluating the following conditions for all bolts that are not yet
ready with their repair:
Failure during repair settings for all bolts with Repairable errors
Note 1: Only the bolts that currently are running repair are affected by any Failure
during repair actions. Bolts that never entered the repair sequence, for example
due to that they had Wait or Continue as reject action, and bolts that are already
ready with the repair sequence are not involved.
Note 2: The Fatal failure action affects all bolts, that is, also the bolts not currently
Running Repair.
Should the settings lead to different actions for a given bolt the “hardest” action is taken
Repair Ready All bolts that once started their repair sequence have finished it. In this state the station
does not execute any steps; it only evaluates the outcome of the repair in order to decide
the next action.
The station evaluates the reject settings of all bolts that started repair and was not
terminated while executing it using the
First failure settings for all bolts with Repairable errors
The action decided is taken for all bolts that are not terminated, this means that not only
the bolts that have done repair but also all bolts that had Wait or Continue as reject action
when the station entered the Running Repair state may have new actions ordered here.
Running Terminate One or more bolts are running their terminate action. Synchronization is maintained for
these bolts as long as the steps end OK. Should a step fail then the bolt is considered
ready with status TERMNOK (Terminated NOK) while the remaining bolts continue the
terminate sequences.
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A n e rro r h a s o cc u rre d a n d th e re
is at le as t o n e b o lt to te rm in a te
R U N N IN G
NORMAL
T h e te rm in ate ac tio n is
re a d y a n d th e re is n o b o lt
A n e rro r h a s o cc u rre d a n d th e re to re p a ir
is n o b o lt to te rm in ate b u t a t le a st
o n e b o lt to re p a ir A n e w e rro r o c c u rre d a n d
th e F a ilu re d u rin g re p a ir
o r F a ta l fa ilu re s e ttin gs
A n e w e rro r o c c u rre d s a ys th e re is at le as t o n e
a n d th e F a ilu re d u rin g R U N N IN G b o lt to te rm in a te R U N N IN G
re p a ir s e ttin g s s a ys
R E P A IR T E R M IN A T E
th e re is n o b o lt to
T h e te rm in ate ac tio n is
te rm in a te b u t at le as t
re a d y a n d th e re is a t le a st
o n e to re p a ir
o n e b o lt to re p a ir
A ll b o lts
re a d y w ith E va lu a tio n of a ll b o lts
re p a ir u s in g F irs t a n d F ata l
fa ilu re g ive s th at th e re is
n o b o lt to te rm in a te b u t a t
le a s t o n e b o lt to re p a ir
E va lu a tio n of a ll b o lts us in g
F irs t a n d F ata l fa ilu re g ives R E P A IR E va lu a tio n of a ll b o lts us in g F irst
th a t n e xt ste p in th e m a in READY o r F a ta l fa ilu re g ives th a t th e re is
p ro g ra m s h o u ld b e sta rte d a t le as t o n e b o lt to te rm in ate
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The states of the Bolt

With respect to reject management a bolt is always in one of the following states:
State Description
Idle The bolt is done with any previous cycle and is just waiting for a new cycle to start.
Running Normal The bolt is executing steps in the main part of its program. When it receives a “Start Step”
command from the station it executes all steps until the next synchronization mark or that
a step fails. “Start Step” with Retry or Terminate order causes a state switch if Retry or
Terminate steps are defined.
Running Repair The bolt is running its repair sequence. The bolt enters this state when it is ordered to
start repair.
It will then remember the synchronization interval from which it entered this state as the
"Failing synchronization interval" (see the picture of the below example). This information
is used when the bolt determines if it is ready with the repair
The bolt will stay in this state until it again stops in this interval, either due to that it failed
to execute one of the steps in the interval or due to that it reached the ending
synchronization mark of the interval.
Note! Reaching any CE step in a program will end the "Failing synchronization interval"
and thereby end the repair phase. This regardless if the execution has reached the
same CE step that the repair was started from or not.
Should the bolt be ordered to enter repair again while already in this state it will remain in
this state, without changing the "Failing synchronization interval".
Running Terminate The bolt is running steps in its terminate sequence.
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ID L E
T h e te rm in a te
T h e re is n o m o re to s e q u e n c e is
T h e c yc le is s ta rte d
e xe c u te a n d th e s ta tio n done
o rd e rs th e b o lt to fin is h
T h e b o lt is o rd e re d to
te rm in a te
R U N N IN G R U N N IN G
NORMAL T E R M IN A T E
T h e b o lt is o rd e re d to
s ta rt re p a ir T h e b o lt is re a d y w ith re p a ir
R U N N IN G
R E P A IR T h e b o lt is o rd e re d to
te rm in a te
The bolt is ready with repair when:
The bolt reaches CE step.
The bolt reaches RE step and no Repair with step is configured.
All steps from Repair with step to the last step in the failing synchronization interval has been run.
The bolt failed running one of the steps in the failing synchronization interval. This causes an immediate
First try evaluation that affects all not terminated bolts in the station. If the evaluated reject action is Retry
the bolt reenters Running Repair.
If an initial repair ends with RE step and no repair step is configured cycle execution resumes at the step
where the Retry was ordered. Next step when running normal is the step after the step where Retry was
ordered. When another bolt fails in its Failing synchronization interval and the action determined by the
station is Retry or Terminate the steps run by the OK bolt is configured in the step where the retry was
ordered.
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See the following example with Bolt 1 and Bolt 2. Bolt 1 fails in step 3 and 4. First failure Retry runs on
both steps for all bolts:
F a ilin g
s yn c h ro n iz a tio n
S yn c h S yn c h
in te rv a l
M a rk M a rk
1 2 3 4 5 6 7 8 9 10 11 12
CE RE
-/-/- -/-/- 9 /1 /- 9 /1 /- -/-/- -/-/- -/-/- -/-/- -/-/- -/-/- -/-/-
1 B o lt tra n s fe r fro m s ta te 2 B o lt tra n s fe r fro m s ta te 3 B o lt tra n s fe r fro m s ta te

R U N N IN G N O R M A L to R U N N IN G R E P A IR to R U N N IN G R U N N IN G R E P A IR to
R U N N IN G R E P A IR N O R M A L to R U N N IN G R E P A IR R U N N IN G N O R M A L
Bolt 2 runs OK, but is ordered to Retry when bolt 1 fails:
S yn ch S yn ch
M a rk M a rk
1 2 3 4 5 6 7 8 9 10 11 12
CE RE
-/-/- -/-/- 9 /-/- -/-/- -/-/- -/-/- -/-/- -/-/- -/-/- -/-/- -/-/-
1 B o lt tra n sfe r fro m sta te 3 B o lt 2 w a its fo r b o lt 1 to fin ish re p a ir. R u n N e xt 2 B o lt 2 w a its fo r b o lt 1 to fin ish re p a ir.
R U N N IN G N O R M A L to o rd e re d w h e n re p a ir re a d y. C h a n g e sta te fro m R e try o rd e re d w h e n re p a ir re a d y. R u n R e try
R U N N IN G R E P A IR R U N N IN G R E P A IR to R U N N IN G N O R M A L . a s co n fig u re d in ste p 3
When a bolt has reported that repair is ready, due to a CE step, the bolt will reenter state Running Normal
while waiting for the other bolts to finish. If any other bolt fails when running normal, reject management
will affect the bolt at CE. Retry and Terminate steps will be run as configured in the last step before the CE
step.
See the following example with Bolt 1 and Bolt 2. Bolt 1 fails in step 3 and 7. In step 3 First failure action is
Retry for all bolts. In step 7 First try action is Terminate for all bolts:
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F a ilin g
S yn c h S yn c h
in te rv a l
M a rk M a rk
1 2 3 4 5 6 7 8 9 10 11 12
CE RE
-/-/- -/-/- 9 /1 /- 9 /1 /- -/-/- -/-/- -/-/1 0 -/-/- -/-/- -/-/- -/-/-
1 B o lt tra n s fe r fro m s ta te 2 B o lt tra n s fe r fro m s ta te 4 E n d o f c yc le a t R E .

R U N N IN G N O R M A L to R U N N IN G R E P A IR to 3 B o lt tra n s fe r fro m s ta te M o n ito rin g c h e c k s a c c o rd in g to
R U N N IN G R E P A IR R U N N IN G N O R M A L R U N N IN G N O R M A L to s te p 8 . B o lt d o e s n ‟t p a rtic ip a te
R U N N IN G T E R M IN A T E in c yc le R M a s it is T e rm in a te d
Bolt 2 runs OK, but is ordered to Retry and Terminate when bolt 1 fails:
S yn c h S yn c h
M a rk M a rk
1 2 3 4 5 6 7 8 9 10 11 12
CE CE
-/-/- -/-/- 9 /-/- -/-/- -/-/- -/-/- -/-/- -/-/- -/-/- -/-/- -/-/- -/-/-
1 B o lt tra n s fe r fro m s ta te 2 B o lt tra n s fe r fro m s ta te R U N N IN G 3 B o lt o rd e re d to T e rm in a te , n o

R U N N IN G N O R M A L to R E P A IR to R U N N IN G N O R M A L w h e n T e rm in a te s te p d e fin e d in s te p 1 1 . R e a d y
R U N N IN G R E P A IR s ta tio n s ta rts s te p 6 o n B o lt 1 . im m e d ia te ly a n d k e e p s s ta tu s O K R .
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6.5.5.7 Reject management examples

F a ilin g
S yn c h S yn c h
in te rv a l
M a rk M a rk
1 2 3 4 5 6 7 8 9 10 11 12
CE RE
-/-/- -/-/- 9 /1 /- -/-/- -/-/- -/-/- -/-/- -/-/- -/-/- -/-/- -/-/-
H e re th e b o lt tra n s fe r fro m H e re th e b o lt tra n s fe r fro m

s ta te R U N N IN G N O R M A L s ta te R U N N IN G R E P A IR
to R U N N IN G R E P A IR to R U N N IN G N O R M A L
When the bolt fails the first time in step 3 the station will use the First failure settings of this step when
computing the reject management action.
In this case a Loosen with step sequence is defined (step 9 to 11) so when the station orders the bolt to
start repair the bolt will
Enter the Running Repair state
And jump to step 9
It will continue to execute without interaction with the station until it reaches a synchronization mark. Here
the bolt will stop after step 11 since step 12 is a Return from Repair (which is an implicit synchronization
mark). This ends the Loosen with step sequence.
Since Restart from step is set to 1 for the step 3 the bolt will jump to step 1 when it receives the next start
order from the station. Since step 1 has a synchronization mark the bolt will stop here and wait for a new
order from the station.
When the station sends the next start order the bolt will run until step 5 is finished. Since the bolt now
have reached its "Failing synchronization interval" it transfers from state Running Repair to the Running
Normal. The station will not order the bolt to start the next step until all other bolts that also are running
repair are finished.
When the next start order is received from the station the bolt will run until it reaches step 7 and at this
point report to the station that has finished the program.
When all bolts have finished their cycles the station will order the bolt to do monitoring checks. Monitoring
checks will be performed as configured in step 8.
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Alternative sequences:
Should the bolt fail while executing step 1 the second time (that is, while Running Repair) it would cause a
new reject management action according to the Failure during repair settings of step 1. This since it has
not yet reached its "Failing synchronization interval".
Should the bolt fail to execute one of the steps 2, 3, 4 or 5 the second time it will immediately return to the
Running Normal state since it reached its "Failing synchronization interval". The station would then wait
until all bolts is in the Running Normal state and then compute a new reject action according to the First
failure settings of the failing step (2, 3, 4 or 5).
Should the Initiate repair steps end by a CE step the cycle ends at step 11 and monitoring and cycle RM is
performed according to step 12. If some monitoring check fails repairable First failure settings for the step
are used to determine the action. Fatal errors cause Fatal failure settings to be used.
When step 11 has been run the bolt reports step status and that it has reached cycle end and RM end. If
there was an error when running step 11 it is handled with Failure during repair settings. If there are other
bolts still running when the repair is ready the station will order the bolt at CE too to run next step, upon
which the bolt repeats that cycle end is reached and changes state to Running Normal. After this the bolt
might be ordered to retry or to terminate, due to other reject bolts.
If some of the bolts in the system run longer cycles, with more synchronization points, than other bolts it is
recommended to add a last step before the CE step in the shorter programs. This extra step does not
contain any repair steps or terminate steps. It could be for example a “Run until next step” (NS) or a “Wait”
(W) step. This saves the shorter cycles from getting involved in reject management actions when they
have finished.
F a ilin g
S yn c h S yn c h
in te rv a l
M a rk M a rk
1 2 3 4 5 6 7 8 9 10 11 12
CE CE
-/-/- -/-/- 9 /-/- -/-/- -/-/- -/-/- -/-/- -/-/- -/-/- -/-/- -/-/- -/-/-
H e re th e b o lt tra n s fe r fro m H e re th e b o lt tra n s fe r fro m s ta te R U N N IN G R E P A IR to

s ta te R U N N IN G N O R M A L R U N N IN G N O R M A L w h e n m o n ito rin g is o rd e re d o r w h e n n e xt
to R U N N IN G R E P A IR s te p is o rd e re d w h e n th e b o lt h a s ru n s te p 1 1 a n d re p o rte d C E .
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6.5.6 Step – Ramps & Other

The Ramps & Other group contains parameters related both to speed ramping of the step (Ramps) and
other options (Other).
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6.5.6.1 Ramps & Other – Ramps
The Speed ramp up parameter controls the ramp of the step start and is important to tune to the process
in order to avoid unnecessary damage and wear of equipment.
The speed ramps defined on a step can be smooth or straight. Straight ramps are defined by a linear
equation while smooth follows an S-function. The type of ramp to use is selected in the parameter Ramps.
If needed, you can control every aspect of a step‟s speed curve by use of Ramp data parameters.
Speed
Down ramp start point
Target
speed
Speed Down
ramp up ramp
Smoothened ramps
Straight ramps
New
Target
speed
Time
Up to five speed changes can be made during a step. These are defined as Ramp data entries.
When to change speed can be triggered by one of the following conditions:
Angle reaches a specified value
Torque reaches a specified value
Current reaches a specified value
A specified time from step start
Chose type by selecting the wanted type in the Start column and specify the trig value in the Level
property. Enter the new target speed in Speed and the acceleration/deceleration to use in Ramp [rpm/s].
Only one of the start conditions is monitored at the time. The second condition will not be checked until the
first condition has been met, and so on. However, there is no check done that the speed has reached the
final value of the first condition before the second is activated.
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Speed
Down ramp start point 1

Down ramp 1
Speed 1
Down ramp 2
Speed 2
Down ramp 3
Speed 3
Time
6.5.6.2 Ramps & Other – Other

The Other group holds parameters that do not belong to the earlier parts.
Specify in Start delay for step if you want a delay first in the step, before the main function starts.
If the checkbox Wait for PLC at step end is checked for at least bolt in the cycle the station will stop and
wait for the signal INTERMEDSTART from the PLC to continue running the cycle. This works like an
implicit synchronization point. Even if the step is lacking the synchronization point it will still report to the
station and wait for all other spindles.
In Torque Spike Elimination specify the angle for which all torque readings should be disregarded for
control.
Note! The torque restriction (see chapter: Fail Safe Torque) is active also during the Torque Spike
Elimination phase.
Use the Customer step name combo to select the customer error code series that shall be used in this
step. See Set Customer step names and Set Customer error codes for more information about this
function.
By checking Hold position when stopped the bolt will be held in the position it has when zero speed is
detected. This option cannot be used together with the Hold torque stop condition.
Using the Stop method property you can set up how you want to stop the spindle when the target for the
step has been reached:
Inertia brake. Choose this alternative if you want to stop as quickly as possible. This is the
recommended stop alternative for fastening.
Ramp down the current. First lower the current to X % of the current value at target (Initial
value), and after that ramp down the current with the Slope [A/s]. Use this alternative to relax any
torsion built up in a controlled manner.
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Hold torque. This alternative does not stop any ongoing motion. The servo will maintain the torque
it has when the step is stopped. Note! This means that if there is not contradicting force the spindle
TM
will continue to run. This stop condition is used for step types DT - Run until Dyna-Tork , DT2 -
TM TM
Run until Dyna-Tork , method 2, and DT3 - Run until Dyna-Tork , method 3.
Continue rotation (only available for Gauging)
With this stop condition the spindle will not stop between steps, but instead continue to rotate.
During the time between the steps the restrictions Torque, Remove fastener torque limit and
Transducer Protection will still be active. The same limits as in the step before will be used.
There will also be a time restriction of 60 seconds for the continue rotation. If any of the limits are
exceeded the spindle will be stopped directly and the fatal error CROT will be set, together with
error-code for the error that stopped the spindle. Failing Step No will be set to the step before and
the reject settings in this step will be used.
When the next step starts the speed will be ramped to the target speed of that step with the ramp
programmed in this step. If the next step has a different direction compared to the previous step
the direction change will be made with a speed ramp. An event will also be generated to warn the
user that this has happened.
If the evaluation of any checks fails for a spindle that run Continue rotation the motor will be
switched off and the spindle will roll out to a stop. The same will also happen if another spindle fails
and starts to run reject management. However, if Allow hold torque also during RM is checked
in the Station Set Up the spindle will continue to rotate in both these cases.
6.5.6.3 Ramps & Other – Store Position (only available for Gauging)
It is possible to store the current position at the end of each step and later return to this position with the
step Run to Position.
Set Null position is a combo box with following choices:
Keep old value (default): The null position is not changed
Half pos: The null position is set to the position half way through the step.
Full pos: The null position is set to the current position at the end of the step (after the over shoot
time has passed)
Set Half position is a checkbox. If checked the half position will be set to the position half way through
the step, otherwise the half position will not be changed. Default value is not checked.
Half position is defined as half the angle from step start (after backlash is done) to step stop (the angle
there the braking of the spindle begins).
In Program Settings-Settings there is a checkbox Reset Position. If checked all four position registers
(Null, Half, Peak and Low) will be cleared at cycle start, otherwise the positions stored in a previous cycle
will be kept.
Any movement between the programs will be measured and the distance to the position registers will be
updated accordingly.
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6.5.6.4 Ramps & Other – Signals at step start and end (only available for Gauging)
It is possible to set and reset digital outputs directly from the tightening program. At cycle start all the
signals will be cleared, i.e. set low. If a signal is already high and are supposed to be set high from a step,
nothing at all will happen, and vice versa if it is already low. A signal used for step start or step end is not
allowed to be used in the zones in the same step.
Digital signal at step start:
Output signal specifies the signal to use. With the combo box Change at it is possible to select if the
signal shall be set directly at step start or when a specific angle has been reached. If the signal shall be
set high or low is specified with the combo box Value.
Digital signal at step end:
The signal to use is specified with the combo box Output signal. The signal is set to the selected Value
(high or low) when the step ends.
For both step start and step end the following digital signals are available:
Local DO 1, … Local DO 4 (the digital outputs directly on the TC)
PLC_DI_1, … PLC_DI_10 (available as inputs in the PLC)
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6.5.7 Zones (only available for Gauging)
It is possible to divide a tightening step into several zones. Each zone is specified with a Start angle and
a Stop angle, measured from step start (after the backlash correction is ready). It is possible to have up to
10 zones in one step.
The zones can be used to make a measurement of some kind during only a part of the step. Each check
added to the step can be run during the whole step or only during one specific zone, see Step – Check for
more information.
All zones within one step use the same Angle channel, as selected in the Common parameters for the
zones.
It is possible to set a digital signal high at zone start and low at zone end. The signal to use is set with
Output signal. If High at start is checked the signal is set high as soon as the zone starts and if Low at
end is checked the signal is set low when the zone ends.
The following digital signals are available:
Local DO 1, … Local DO 4 (the digital outputs directly on the TC)
PLC_DI_1, … PLC_DI_10 (available as inputs in the PLC)
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6.6 Bolt Monitoring
The Monitoring function is used to examine the result of a whole tightening cycle.
This is done using a buffer, called the Monitoring buffer, in which each element represents a given angle
interval measured from when monitoring is started. The buffer has a fix length of 8192 elements but its
resolution, i.e. the length that each element represents, can be configured by editing the settings for a
program.
Note! It is possible to use a second monitoring buffer. To enable the second monitoring buffer check the
nd
Use 2 monitoring buffer check box located in general program settings, see chapter: Program
Settings. The second monitoring buffer is sampled on the secondary angle and torque channels if
equipped.
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The monitoring function can be started and stopped at any point during the cycle. When to start and stop
monitoring is configured for each program. The following alternatives are available as start conditions:
At cycle start (default)
When a specific step is started
When torque reaches a specified level
The following stop conditions are available:
At cycle end (default)
When torque reaches a specified level
Monitoring is performed when a CE-step is reached and the station orders the bolt to do monitoring. If the
CE-step has RM defined the cycle might continue after the first monitoring. If so, monitoring is waiting for a
new start. The only way to start monitoring after the first CE is to run a step with the Start/restart
monitoring parameter checked (see Step – Control). When such a step is started monitoring is reset and
started. The next time a CE-step is reached monitoring is performed as specified in that step.
Monitoring evaluation is always performed as specified in the different monitoring checks. Should
monitoring not have been restarted and the bolt has terminated the monitoring reevaluates the checks
using the same measurement values as last evaluation. Thus the reported results will remain and events
will be generated if any errors are found. Check Ignore monitoring errors when step ends NOK if
events and error bits are not wanted during monitoring evaluation after Terminate.
If monitoring was never started or restarted and any step was started (and the bolt is not terminated) the
evaluation is done on reset monitoring measurement values, which causes Fatal errors for all checks that
have configured limits.
Monitoring can also be stopped when a step fails. To enable this check the Stop monitoring when step
ends NOK check box on The Tightening Program form, see chapter; : Program Settings. This, together
with the use of the Start/restart monitoring parameter for the steps (see Step – Control) can be useful if
you want to report the result from the failing tightening.
Normally the first torque and angle transducers are recorded on the first monitoring buffer and the
secondary transducers recorded on the second monitoring buffer. If there is only one channel available it
is used for both buffers.
Example: The spindle set up contains two enabled torque channels and one enabled angle channel the
second monitoring buffer will use torque channel two and angle channel one.
When monitoring is running and the bolt is run in its forward direction, the maximum torque value
measured in each angle interval will be stored in the corresponding buffer position.
When the bolt is run in its backward direction (and monitoring is running), the buffer is backed to the
position that corresponds to minimum angle reached during the step. The buffer adjustment is done when
the next step or monitoring evaluation starts. All values that correspond to the backed distance are
erased. Should you pass the point (that is, angle) where monitoring was started, the monitoring buffer will
be restarted the next time the bolt is run in its forward direction. This means that you cannot measure a
negative angle using the monitoring buffer. (Should you need to measure a negative cycle angle there is
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an alternative method that does not use the monitoring buffer. See description of the Angle monitoring
check in chapter: Monitoring Check – Angle .
If the bolt runs forward again the recording is started from the current position.
Steps of the following types are handled specially:
D - Diagnostic Step. Is always considered running backward.
E1 - Run Engage method 1. Is always considered running backward.
GS - Run Gear Shift. Is always considered running backward.
SR – Socket Release. Nothing is recorded for this step, neither in the forward, nor backward
direction.
When monitoring ends two things are done. First, the "Cycle End Torque", used by the Monitoring Check –
Monitoring Yield point torque and angle check, is stored. It is normally set to the torque measured at the
shut off point of the last step, or if this step is a SR – Socket Release, the step prior to it. However, if the
shut off point (target) is not reached for the last step executed, or if it did run in reverse direction and
thereby deleted values from the buffer, then the last torque value stored in the buffer is used as "Cycle
End Torque".
Secondly, the complete buffer is filtered for maximum torque for increasing angle, i.e. the following
algorithm is applied on the buffer
Torque(k) = MAX(Torque(k), Torque(k – 1)), where k = [2..8192]
It is the filtered buffer that is used for all monitoring checks.
The monitoring checks are added as regular checks on any CE step. The checks are described in detail in
the following sub chapters.
If the parameter Ignore monitoring errors when step ends NOK (located under Monitoring on the CE
step) is checked then the active checks will not cause any events or set any error bits, only calculate and
report the corresponding result variables, when the cycle is already NOK. It is wise to check this setting to
avoid resulting events and error bits caused by the original error.
Note! All limits of the checks are optional. A check having no limit defined will always generate an OK result.
This might be useful if its only purpose is to produce a result variable to be reported.
All Monitoring checks can be configured as Fatal or Repairable. This controls which RM action that will be
taken.
Note! If the conditions required for evaluation of a check for some reason are not fulfilled an event saying
so is generated. Should the check have one or more limits defined then the corresponding error bits
are set as well and the status of the checks is set to Fatal independent of the configuration.
Examples of such conditions are that the buffer is empty, that T start, T stop or threshold torques was
not reached, that no yield point was found, etc.
When a monitoring error is found the error is reported as RM Errors in cycle data and if not repaired by
Cycle RM also as Errors. See Cycle RM for details on reject management for monitoring checks.
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6.6.1 Monitoring Check – Final Peak Torque
User Interface:
Parameters: Fatal, Monitoring buffer, FTH (High level), FTL (Low level)
Function: This function checks that the Peak Torque is within limits FTH and FTL. The final torque is
the highest torque value found in the monitor buffer. The limits FTH and FTL are both
optional. Leaving them blank disables the check but the result value is still calculated and
reported.
Unless Fatal is checked a value outside the specified limits is considered to be a repairable
error. If a value cannot be calculated and at least one limit is specified the check is always
considered Fatal. This is for example the case if the buffer is empty when evaluating.
Monitoring buffer selects which monitoring buffer the check should use.
Diagram:
Bolt T
Torque
FTH
FTL
Angle
FTH Final Peak Torque High level

FTL Final Peak Torque Low level
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Result var.: "Bolt T" and ”Bolt T2nd” (measured on the second monitoring buffer)
Alarms: Final torque too high (FTHM, FTHM2), Final torque too low (FTLM, FRLM2). FTHM2 and
FTLM2 are used for check errors on the second monitoring buffer. If Bolt T is less than the
value specified by the Program Settings parameter Report threshold torque limit then the
warning bit REPLIMIT is set. This does not generate an event unless all bolts that where
run during a cycle sets REPLIMIT. If so, the station issues an event (event code 628) to
inform that the cycle data was dropped.
Trace: FTH and FTL are shown in trace as horizontal lines from monitoring start to monitoring stop.
The lines are only shown when Torque vs. Angle is selected and Monitoring limits are
enabled in the trace form (see View of trace curves).
6.6.2 Monitoring Check – Angle

User Interface:
Parameters: Fatal, Monitoring buffer, AH (High level), AL (Low level), Tstart (Torque Level, Tstart),
Tstop (Torque Level, Tstop), Torque falling below Tstop.
Function: This function checks that the angle A is within the specified limits AH and AL. Angle A is
measured from the point where the torque has reached Tstart (Astart) until the point where
the torque reaches Tstop (Astop).
Depending on the configuration of Tstart, Tstop and Torque falling below Tstop one of
two basically different methods for data collection is used. If Tstart and Tstop both are left
empty, or Tstop is specified and Torque falling below Tstop is checked, then Astart and
Astop are continuously searched for during the cycle. This is the Runtime method. For all
other settings the buffer method is used, which means that Astart and Astop are searched
for in the buffer.
The Buffer method:

Astart is defined as the angle in the buffer where the torque first exceeds Tstart. If Tstart is
empty Astart is defined as the angle at buffer start. Astop is defined as the angle in the
buffer where the torque first exceeds Tstop (this is Astop1 in the below picture). If Tstop is
left empty Astop is defined as the maximum angle reached (Aend 1 in the picture).
The Runtime method:
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Astart is defined as the angle where Tstart is reached for the first time when monitoring is
running and values are added to the buffer. If Tstart is empty Astart is the cycle angle when
monitoring is started (hence it is possible to measure negative angles).
Astop is defined as the angle where torque decreases below Tstop (Astop2 in the picture)
during the overshoot time. When torque exceeds Tstop, Astop is always reset to an
undefined value and a new Astop has to be found for the check to evaluate correctly. An
AStop found is valid as long as the torque does not exceed Tstop later during the cycle.
Found positions are erased and reset if the buffer is cleared passed the found positions
(when a step is run in backward direction).
If both Tstart and Tstop are empty the angle will be measured from monitoring start to
monitoring end. That is, Astart is defined as the cycle angle when monitoring is started and
Astop is the last measured cycle angle while monitoring is running (Aend 2 in the picture).
Astop is measured during all steps except for the SR step.
Both limits, that is, AH and AL, are optional. Leaving them blank disables the check but the
result values are still calculated and reported.
If Fatal is not checked a value outside the specified limits is considered to be a repairable
error. If a value cannot be calculated and at least one limit is specified the check is always
considered Fatal. This is for example the case if Astart or Astop are not found or if the
buffer is empty.
Monitoring buffer selects which monitoring buffer the check should use.
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Diagram:
AL
AH
Tstop
Tstart
Astop1 Angle
Astart Aend2 Aend1
Astop2
Tstart Torque Start Astart Start cond. – Angle at Tstart

Tstop Torque Stop Astop1 Stop cond. – Angle at Tstop (torque falling below Tstop unchecked)
AL Angle Low limit Astop2 Stop cond. – Angle at Tstop (torque falling below Tstop checked)
AH Angle High limit Aend1 Stop cond. – Peak angle
Aend2 Stop cond. – Last measured angle
Result var.: "Bolt A", “Bolt A2nd” (measured on the second monitoring buffer) and "Bolt A Thresh T" (the
programmed value of Tstart)
Alarms: Angle too high (AHM, AHM2), Angle too low (ALM, ALM2) and Threshold torque not
reached for angle monitoring (TTNOTRM). AHM2 and ALM2 are used for the second
monitoring buffer. TTNOTRM is generated if Tstart is specified but not reached during the
cycle.
Trace: AH and AL are shown in trace as vertical infinite lines. The lines are only shown when
Torque vs. Angle is selected and Monitoring limits are enabled in the trace form (see
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6.6.3 Monitoring Check – Torque Rate
User Interface:
Parameters: Fatal, Monitoring buffer, T Start, T Stop, A Start, A Stop, TRL, TRH, Dev
Function: This function checks the Torque Rate (TR), i.e. the ratio of torque vs. angle.
Measuring is started when the angle A Start has elapsed from that torque reached the
value T Start. This is point (A1, T1).
Point (A2, T2) is the point where measuring is stopped, that is, when any of the following
conditions first is met:
- when the torque reaches the value T Stop

- when the angle measured from T Start reaches A Stop
- when the torque reaches final torque, that is, the end of the monitoring buffer.
This point is used only if both T Stop and A Stop are empty.
T Start, T Stop, A Start, and A Stop are all optional. If T Start is left blank, then A Start is
measured from the start of the monitoring buffer. Leaving A Start empty is equal to setting
A Start to zero. Leaving T Stop and/or A Stop empty deactivates the respective check as
stop conditions.
The Torque Rate is calculated as:
TR = (T2 – T1) / (A2 – A1)
where T1, T2, A1, and A2 are defined as in the diagrams below.
The measured TR is checked to be within the limits TRH and TRL.
This function also checks that the torque does not deviate more than Dev from a straight
line between the points (A1, T1) and (A2, T2). The Deviation in sample k, DEV(k), is
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calculated as:
DEV(k) = ABS[T(k) – (A(k) * TR + m)]
where
m = T1 – TR * A1
You may specify one or two intervals, which may overlap.
All limits, that is, TRH, TRL and Dev, are optional. Leaving them blank disables the
respective check but the values are still calculated and reported.
error. If a value cannot be calculated and at least one limit is specified for the check in
question it is always considered Fatal. This is the case if T Start, A Start, T Stop or Astop
are not found or if the buffer is empty.
Diagram 1:
Torque
Tstop
TRH
T2
Dev
TRL
T1
Tstart
Astart
Angle
A1
Astop
A2

T2 Torque at Astop
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Diagram 2:
Torque
TRH
Tstop
Dev
TRL
T1
Tstart
Astart
Angle
A1 A2
Astop

A2 Angle at Tstop
Result var.: "Bolt TR 1", "Bolt TR 2", "Bolt TR Dev 1", and "Bolt TR Dev2".
Alarms: Torque rate in interval 1 too high (TR1HM),
Torque rate in interval 1 too low (TR1LM)
Torque rate in interval 2 too high (TR2HM)
Torque rate in interval 2 too low (TR2LM)
Too big deviation in interval 1 (DEV1M)
Too big deviation in interval 2 (DEV2M)
Trace: TRH and TRL are shown in trace as lines originating from T1 showing the selected torque
rate. The TRH and TRL lines end where either T2 or A2 should have been reached using
the specified torque rates (see above diagrams). The deviation limit lines are drawn the
distance Dev from, and parallel to, the line between (A1, T1) and (A2, T2). The lines are
only shown when Torque vs. Angle is selected and Monitoring limits are enabled in the
trace form (see View of trace curves).
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6.6.4 Monitoring Check – Monitoring Yield point torque and angle

The monitoring checks Angle from Yieldpoint and Torque from Yieldpoint are described as one item since
their configuration is very similar.
User Interface:
Parameters: TC, NOS, INC, DIFF, Fatal, YTH, YTL, YAH, YAL
Function: Search for Yield point starts when the torque value has reached the trig level TC. From this
point the average torque is measured over NOS degrees (TNOS). This procedure is repeated
after each INC degrees.
When three or more TNOS values have been measure (that is after 3 NOS + 2 INC) the
difference in average torque, TDIFF(k), is calculated as
TDIFF(k) = TNOS(k) - TNOS(k – 2 )
This value corresponds to the current torque rate. Also, every time T DIFF is calculated its
maximum value, MaxTDIFF, is updated
MaxTDIFF(k) = MAX(TDIFF(k), MaxTDIFF(k – 1))
The yield point is considered reached when T DIFF(k) < MaxTDIFF(k) * DIFF / 100
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Two result variables are produced. "Bolt YP T", which is how much the torque increases
after the yield point, is calculated as
"Bolt YP T" = TCycle End – TYP
where TCycle End is the Cycle End Torque (as described by Bolt Monitoring).
The second variable, "Bolt YP A" represents how much the angle is increased from the yield
point to the cycle end. It is calculated as:
"Bolt YP A" = ACycle End – AYP
The function checks that "Bolt YP T" is within the limits YTH and YTL and that "Bolt YP A" is
within the limits YAH and YAL. Note that YTH and YTL can be negative.
All limits, that is, YTH, YTL, YAH and YAL, are optional. Leaving them blank disables the
respective check but the values are still calculated and reported.
error. If a value cannot be calculated and at least one limit is specified for the check in
question it is always considered Fatal. This is for example the case if the yield points are
not found or if the buffer is empty.
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Diagram:
Yield point Cycle End

Torque
YTH
Bolt YP T
YTL
YAL
INC
TDIFF Bolt YP A
TDIFF INC
NOS
NOS
TDIFF INC
TC INC
NOS
NOS Angle
NOS
TC Torque TC INC Increment

NOS No. degrees TDIFF Difference in average torque
Result var.: "Bolt YP T" and "Bolt YP A".

Alarms: Yield torque high (YTHM). If "Bolt YP T" > YTH
Yield torque low (YTLM). If "Bolt YP T" < YTL
Yield angle high (YAHM). If "Bolt YP A" > YAH
Yield angle low (YALM). If "Bolt YP A" < YAL
Trace: YAH and YAL are shown in trace as vertical infinite lines. YTH and YTL are shown in trace
as horizontal lines from monitoring stat to monitoring stop. The lines are only shown when
Torque vs. Angle is selected and Monitoring limits are enabled in the trace form (see
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6.6.5 Monitoring Check – Follow the Curve

User Interface:
Parameters: Fatal, Monitoring buffer, Start torque, High curve limit (angle, torque) pairs, Low curve
limit (angle, torque) pairs
Function: This function checks that the torque values are within High and Low curve limits. A curve
limit consists of a series of (angle, torque) pairs. A valid curve limit must contain at least 2
(angle, torque) pairs (Ax, Tx) to make up a straight line. Maximum 10 (angle, torque) pairs
can be entered for a curve limit. The (angle, torque) pairs (A1, T1) (A2, T2) .. (Ax, Tx) are
connected with straight lines to resemble a curve. If any measured torque value is outside
the curve limits an event will be generated and an error code will be included in the cycle
data.
error. Monitoring buffer selects which monitoring buffer the check should use. If no Start
torque is entered, the angle positions are measured from the beginning of the monitoring
buffer. If a Start torque value is entered, the stroke positions are measured from the point
where the force passes the level ST, see Diagram. To enter (angle, torque) pairs, mark
High curve limit or Low curve limit and push the expand button to open its input form, see
User Interface above.
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(A5, T5)
Torque
(A4, T4)
High curve limit
(A5, T5)
(A4, T4)
(A3, T3)
(A2, T2)
(A3, T3) Low curve limit

(A2, T2)
(A1, T1)
(A1, T1)
ST = 0
Angle
Diagram:
Torque
(A5, T5)
(A4, T4)
T2 Low curve limit

(A3, T3)
T1
ST
A1 Angle
A2
ST Start Torque (A2, T2) Point 2

A1 Stroke level A1 … ...
T1 Torque level T1 (A5, T5) Point 5
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Result var.: None.
Alarms: For High curve limit – if the torque in any position is above these lines, the step is
considered NOK and the error FTCH is reported. For Low curve limit – if the torque in any
position is below these lines, the step is considered NOK and the error FTCL is reported.
Trace: High and low curve limits are shown in trace as connected lines from monitoring start to
monitoring stop. The lines are only shown when Torque vs. Angle is selected and
Monitoring limits are enabled in the trace form (see View of trace curves).
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6.7 Result variables

This chapter describes which system data and tightening results that are available for reporting to the
different devices in the system.
What data to report to a particular device is configured using a Reporter. How to create and configure
reporters is described in the chapter: Reporter.
The result data is divided in the following sections
Station level data
Bolt level data
Step level data
If a result variable for some reason does not have a value, e.g. due to that the check that produces the
value is not included in the program, then the value NOT_DEFINED is reported for it.
A NOT_DEFINED value is printed as blanks (spaces) when reported as text and the value –32768 when
reported in binary format.
6.7.1 Statuses
Stations and bolts have a variable named "Status" that indicates their resulting status.
The Station Status variable can take one of the following values:
Mnemonic Num. Id Description

OK 0 Successful. No repairs have been made.
OKR 1 Successful. Errors have occurred but have been repaired
NOK 2 Not successful. Either a fatal error has occurred or a bolt failed to repair a
repairable error.
TERMNOK 3 Not successful. An error occurred while running a terminate sequence (i.e. the
steps specified using “Terminate with step” on the Reject tab for a step). The
execution of steps was terminated when the error was found
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Bolt Status variables can take one of the following values:
Mnemonic Num. Id Description

OK 0 Successful. No repairs have been made.
OKR 1 Successful. Errors have occurred but have been repaired
NOK 2 Not successful. This bolt failed to execute a step either due to a restriction, a
check or that any other fatal error occurred.
TERMNOK 3 Not successful. An error occurred while running a terminate sequence (i.e. the
steps specified using “Terminate with step” on the Reject tab for a step). The
execution of steps was terminated when the error was found
NOKRM 4 Not successful only due to reject management. The bolt did not fail to execute a
step but was ordered to terminate, or not to finish the program, as a reject
management action.
6.7.2 Station level result variables

The Station level contains information concerning the station that runs the tightening.
Variable name Description

Data No A device unique sequence number. This number is incremented by one for each cycle
data reported over the device in question. This number can be used to detect missing
cycles.
Station The name of the station. See System for how to set or change the name of a station. Max.
20 ASCII characters.
Station No The number of the station. The first station in the system is 1.
Time The date and time when the cycle was started.
Wp ID Work piece Identity. Supplied to station from an ID device (see ID device Set Up) or set by
the PLC using the IDSTRING output (Station variables). Max. 40 ASCII characters.
Mode The name of the mode that was executed. Set using The Mode Table form. Max. 20 ASCII
characters.
Mode No The number of the mode that was executed.
Status Total status for the station: See chapter: Statuses for possible values.
Total Total number of cycles executed during the current shift. See Shift Reports and Shift Set
Up for a description of shifts.
Total OK Total number of cycles that ended OK or OKR during the current shift. See Shift Reports
and Shift Set Up for a description of shifts.
Total NOK Total number of cycles that ended NOK or TERMNOK during the current shift. See Shift
Reports and Shift Set Up for a description of shifts.
Free Str The value of the PLC output FREESTRING when the cycle was started (see Station
variables).
Free No 1 The value of the PLC output FREENUM1 when the cycle was started (see Station
variables).
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Free No 2 The value of the PLC output FREENUM2 when the cycle was started (see Station
variables).
Free Str 2 The value of the PLC output FREESTRING2 when the cycle was started (see Station
variables).
Free Str 3 The value of the PLC output FREESTRING3 when the cycle was started (see Station
variables).
Data No Station A tightening unique sequence number. This number is incremented by one for each cycle
produced by the station.
Data No System A tightening unique sequence number. This number is incremented by one for each cycle
produced by the system.
Station QO A variable specific for the PLUS protocol. The variable will only have a valid value if a
PLUS device is defined. The value is taken from the QO/SA Table in the PLUS device.
Station SA A variable specific for the PLUS protocol. The variable will only have a valid value if a
PLUS device is defined. The value is taken from the QO/SA Table in the PLUS device.
Station AB A variable specific for the PLUS protocol. The variable will only have a valid value if a
PLUS device is defined. The value is taken from Station AB in the PLUS device.
ID Res 1 Multiple identifiers result variable 1. Max. 40 ASCII characters.
No Bolts Number of bolts in the Cycle Data
Audi PRT Tag A variable specific for the Audi XML protocol. The variable will only have a valid value if an
Audi XML device is defined.
Audi PI1 Tag A variable specific for the Audi XML protocol. The variable will only have a valid value if an
Audi PI2 Tag A variable specific for the Audi XML protocol. The variable will only have a valid value if an
Audi STC Tag A variable specific for the Audi XML protocol. The variable will only have a valid value if an
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6.7.3 Bolt level result variables

Bolt level data is divided in two parts, Common data and Monitoring data where the latter consists of all
variables that are produced by the Bolt Monitoring functions.
Common data
The Common data consists of the following variables:

Bolt The name of the bolt. Set System for how to set or change the name of a bolt. Max. 20
ASCII characters.
Bolt No The number of the bolt as configured.
Spindle No The number of the TC used to tighten the bolt as configured.
Program The name of the program used to tighten the bolt. Max. 20 ASCII characters.
OP mode Operational mode of the bolt. Takes one of the following values:
0: Connect normally. The bolt was executed during the cycle.
1: Disconnected with OK status. The bolt was not executed during the cycle.
2: Disconnected with NOK status. The bolt was not executed during the cycle.
Status Overall status for the bolt including monitoring. See chapter: Statuses for possible values.
Total Total number of cycles that this bolt has run during the current shift. See Shift Reports and
Shift Set Up for a description of shifts.
Total OK Total number of OK and OKR cycles that this bolt has run during the current shift. See
Shift Reports and Shift Set Up for a description of shifts..
Total NOK Total number of NOK and TERMNOK cycles that this bolt has run during the current shift.
See Shift Reports and Shift Set Up for a description of shifts.
Total Type The total number of cycles that all bolts, which is of the same type as this bolt, have run
during the current shift. The bolt type is a property that can be accessed from the System
Map. See Shift Reports and Shift Set Up for a description of shifts.
Total Type OK The total number of OK and OKR cycles that all bolts, which is of the same type as this
bolt, have run during the current shift. The bolt type is defined using the System Map. See
Shift Reports and Shift Set Up for a description of shifts.
Total Type NOK The total number of NOK and TERMNOK cycles that all bolts, which is of the same type
as this bolt, have run during the current shift. The bolt type is defined using System Map.
See Shift Reports and Shift Set Up for a description of shifts.
Errors Lists all errors that have occurred during the cycle and is not repaired. See Errors for
possible values.
RM Errors Lists all errors that have occurred during the cycle including all that have been repaired.
See Errors for possible values.
Warnings Lists all warnings that have occurred during the cycle. See Warnings for possible values.
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Compact Errors This is a compact version of the "Errors" result variable It may list the following errors:
THM -Torque High Monitoring (bit 0, value 1)
TLM -Torque Low Monitoring (bit 1, value 2)
AHM -Angle High Monitoring (bit 2, value 4)
ALM -Angle Low Monitoring (bit 3, value 8)
OK – Bolt status is OK (bit 4, value 16). This bit is set if the bolts final status is OK. It
means that there where no errors at all.
When reported binary, each error is represented by the bit written within parentheses
above (bit 0 is the least significant).
Failing Step No The number of the last step that failed in the main part of a program. Only valid if bolt
status is NOK, or TERMNOK.
Pgm No The optional number assigned to the program that was used to tighten the bolt. Set using
The Tightening Program form.
Ordinal No Ordinal Bolt Number. This is always an enumeration of the bolt‟s position within the
station.
Bolt A Thresh T The threshold torque level Tstart for measuring of Bolt A.
Spindle Serial No The serial number of the spindle that tightened the bolt.
Compact Errors 2 This is a compact version of the "Errors" result variable It may list the following errors:
TLM -Torque Low Monitoring (bit 0, value 1)
THM -Torque High Monitoring (bit 1, value 2)
ALM -Angle Low Monitoring (bit 2, value 4)
AHM -Angle High Monitoring (bit 3, value 8)
TR1LM - Torque rate in interval 1 too low during monitoring (bit 4, value 16).
TR1HM - Torque rate in interval 1 too high during monitoring (bit 5, value 32).
TR2LM - Torque rate in interval 2 too low during monitoring (bit 6, value 64).
TR2HM - Torque rate in interval 2 too high during monitoring (bit 7, value 128).
When reported binary, each error is represented by the bit written within parentheses
above (bit 0 is the least significant).
Bolt Pgm Time The time when the program was last changed or setup downloaded to TC.
Bolt Pgm Strategy The control strategy of the program. This value is set according to the strategy type of the
last step in the program according to rules outlined in chapter: GM DeviceNet/Indication
schema. Possible values are:
2: If the control strategy is Torque Control.
6: If the control strategy is Angle Control.
NOT_DEFINED (-32768 if report format is Binary and blank if Binary): If the control
strategy is Undefined
Spindle Name Name of the spindle that was used to tighten the bolt.
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Customer Error A four (4) character string with a customer configurable error code. The mapping of
Code PowerMACS errors to customer error codes are done in the Options window, click on
button "Set Customer error codes…"
Mon A Chan Angle channel used for monitoring.
Mon T Chan Torque channel used for monitoring.
Con A Chan Angle channel used for control.
Con T Chan Torque channel used for control.
Mon Buf 1 A Angle channel used for first monitoring buffer.
Mon Buf 1 T Torque channel used for first monitoring buffer.
Mon Buf 2 A Angle channel used for second monitoring buffer.
Mon Buf 2 T Torque channel used for second monitoring buffer.
No. Steps Number of steps stored in the Cycle Data.
Spindle Art. No Spindle article number
Sp. total cycles Spindle Total cycles produced by the spindle
Sp. cycles since Spindle Cycles since last service
serv.
Sp. cycl. to serv. Spindle Cycles to next service
Spindle type Spindle type
Data missing Is 1 if data for a specific bolt is missing and 0 if not.
Bolt Id Bolt ID
Program version A unique program version string. Can be used to check if two programs are equal or not.
Audi FAP Tag A variable specific for the Audi XML protocol. The variable will only have a valid value if an
Audi FNR Tag A variable specific for the Audi XML protocol. The variable will only have a valid value if an
Audi COM Tag A variable specific for the Audi XML protocol. The variable will only have a valid value if an
Audi CNR Tag A variable specific for the Audi XML protocol. The variable will only have a valid value if an
Audi WID Tag A variable specific for the Audi XML protocol. The variable will only have a valid value if an
Audi SIO Tag A variable specific for the Audi XML protocol. The variable will only have a valid value if an
Audi GNR Tag A variable specific for the Audi XML protocol. The variable will only have a valid value if an
Audi GAP Tag A variable specific for the Audi XML protocol. The variable will only have a valid value if an
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Audi TAP Tag A variable specific for the Audi XML protocol. The variable will only have a valid value if an
Audi TNR Tag A variable specific for the Audi XML protocol. The variable will only have a valid value if an
Audi VAR Tag A variable specific for the Audi XML protocol. The variable will only have a valid value if an
Audi NUT Tag A variable specific for the Audi XML protocol. The variable will only have a valid value if an
Monitoring data
The Monitoring data contains variables that correspond to the result of the Bolt Monitoring functions.
In addition to the variables listed below the high and low limit set up for it, as well as the Cp, Cpk, and
Cam SPC values calculated for them, are also available as result variables.
When including the limits of a variable both the high and the low limit will be included in the report. If you
choose to include the SPC values all three values are reported together.
All monitoring data variables are defined once for each monitoring buffer. The variable referring to the
”
second monitoring buffer is appended with “2nd

Bolt T Peak Torque for the cycle. See Monitoring Check – Final Peak Torque for how it is
nd
Bolt T 2 defined.
Bolt A, Cycle Angle. Either measured from monitoring start or from when the threshold level Tstart
nd
Bolt A 2 is reached. See Monitoring Check – Angle for how it is defined.
Bolt TR1 Torque Rate in interval 1. See Monitoring Check – for how it is defined.
nd
Bolt TR1 2
Bolt TR2 Torque Rate in interval 2. See Monitoring Check – for how it is defined.
nd
Bolt TR2 2
Bolt TR Dev 1 Maximum torque rate deviation in interval 1. See Monitoring Check – for how it is defined.
Bolt TR Dev 1 2nd
Bolt TR Dev 2 Maximum torque rate deviation in interval 2. See Monitoring Check – for how it is defined.
Bolt TR Dev 2 2nd
Bolt YP T Yield Point Torque. See Monitoring Check – Monitoring Yield point torque and angle for
Bolt YP T 2nd how it is defined.
Bolt YP A Yield Point Angle. See Monitoring Check – Monitoring Yield point torque and angle for
nd
Bolt YP A 2 how it is defined.
Bolt Max T The highest measured torque during the cycle. This value does not use the monitoring
buffer and is totally independent from all steps and check, etc. There are no limits for this
variable.
Bolt Min T The lowest measured torque during the cycle. If any loosening takes place during the
cycle, this will be a negative value. The value does not use the monitoring buffer and is
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totally independent from all steps and check, etc. There are no limits for this variable.
Bolt T try 1 Bolt T for each evaluation of the monitoring. "Bolt T try 1" is from the first evaluation, "Bolt T
Bolt T try 2 try 2" from the second evaluation and so on. Can be useful together with reject
Bolt T try 3 management to see the original measurement value that caused the cycle to repair. The
Bolt T try 4 value in Bolt T will always correspond to the last used of these variables.
Bolt T try 5
Bolt A try 1 Bolt A for each evaluation of the monitoring. "Bolt A try 1" is from the first evaluation, "Bolt
Bolt A try 2 A try 2" from the second evaluation and so on. Can be useful together with reject
Bolt A try 3 management to see the original measurement value that caused the cycle to repair. The
Bolt A try 4 value in Bolt A will always correspond to the last used of these variables.
Bolt A try 5
Bolt var. 01..40 T General cycle data variables for the checks, scaled as Torque if different torque units are
selected in reporters.
Bolt var. 41..80 General cycle data variables for the checks
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6.7.3.1 Errors
The Bolt result variables Errors and RM Errors can hold the errors listed below.
When reported in binary format the respective error variable occupies 16 bytes (128 bits) where each bit
represent an error. The bits are numbered 0 to 127 and are laid out as below:
Byte Offset 0 1 2 3
Error bit no. 31 24 23 16 15 8 7 0
Byte Offset 4 5 6 7
Error bit no 63 56 55 48 47 40 39 32
Byte Offset 8 9 10 11
Error bit no. 95 88 87 80 79 72 71 64
Byte Offset 12 13 14 15
Error bit no 127 120 119 112 111 104 103 96
Note! If Type is set to "I8" then only first 8 bytes are included, that is errors 0 to 63.
Possible errors:
Mnemonic Bit Description
no.
ANGDIAG 0 Angle count test failed during a diagnostic step
SPFUNCTEST 1 Spindle functional test failed during a diagnostic step
STZODIAG 2 Static zero offset failed during a diagnostic step
DYNZODIAG 3 Dynamic zero offset failed during a diagnostic step
FLYZODIAG 4 Flying zero offset failed during a diagnostic step
TR 5 Fail safe Torque restriction exceeded
AR 6 Fail safe Angle restriction exceeded
TIR 7 Fail safe Time restriction exceeded
TCR 8 Torque – Current restriction exceeded
CROSSTR 9 Cross thread restriction exceeded
CROSSGR 10 Cross gradient restriction exceeded
T1HR 11 Torque in window 1 too high from check
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no.
T1LR 14 Torque in window 1 too low from check
PTH 17 Peak torque high alarm from check
PTL 18 Peak torque low alarm from check
AWINTH 19 Torque high in angle window alarm from check
AWINTL 20 Torque low in angle window alarm from check
TIWINTH 21 Torque high in time window alarm from check
TIWINTL 22 Torque low in time window alarm from check
MTH 23 Mean torque high alarm from check
MTL 24 Mean torque low alarm from check
AH 25 Angle high alarm from check
AL 26 Angle low alarm from check
TIH 27 Time high alarm from check
TIL 28 Time low alarm from check
CH 29 Current high alarm from check
CL 30 Current low alarm from check
SOTH 31 Shut off torque high from check
SOTL 32 Shut off torque low from check
T/CH 33 Torque/T3 (Current as Torque) too high from check
T/CL 34 Torque/T3 (Current as Torque) too low from check
PVTH 35 Post view torque too high from check
PVTL 36 Post view torque too low from check
THM 37 Final torque too high during monitoring
TLM 38 Final torque too low during monitoring
AHM 39 Angle too high during monitoring
ALM 40 Angle too low during monitoring
TR1HM 41 Torque rate in interval 1 too high during monitoring
TR1LM 42 Torque rate in interval 1 too low during monitoring
TR2HM 43 Torque rate in interval 2 too high during monitoring
TR2LM 44 Torque rate in interval 2 too low during monitoring
DEV1M 45 Deviation in interval 1 too high during monitoring
DEV2M 46 Deviation in interval 2 too high during monitoring
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no.
YTHM 47 Yield point torque high during monitoring
YTLM 48 Yield point torque low during monitoring
YAHM 49 Yield point angle high during monitoring
YALM 50 Yield point angle low during monitoring
TDIFF 51 Double Torque transducer error
ADIFF 52 Double Angle encoder error
BUFOVFLM 53 Monitoring: Overflow in recording buffer. See description of parameter "Allow
monitoring buffer overrun" in Program Settings.
– 54 – Reserved
61
SAT 62 A/D converter used for torque measurement saturated
OTHER 63 This is bit is set if any error bit(s) in the range 64. 95 are set and only the first 8
bytes are included. That is, Type in the reporter is set to "I8".
LOOSEN 64 The automatic loosening, defined using the "Run reverse before retry" parameters
on the Step – Rejects tab, failed.
TRH 65 Torque rate too high from check
TRL 66 Torque rate too low from check
DEV 67 Deviation too high from check
TTNOTRM 68 Threshold torque not reached for angle monitoring (see also chapter: Monitoring
Check – Angle )
RFTLIMRE 69 Remove fastener torque limit reached (see also chapter: Program )
– 70 – Reserved
71
FTCH 72 Follow the Curve high limit exceeded
FTCL 73 Follow the Curve low limit exceeded
PH 74 Absolute Position check high limit
PL 75 Absolute Position check low limit
MAXFP 76 Maximum forward position exceeded
MAXBP 77 Maximum backward position exceeded
ESTOP 78 Emergency stop
MSTOP 79 Machine stop
SSTOP 80 Station stop (Disconnect, problem reported from station to all bolts, connected bolts
get Station stop)
DETACH 81 Detach, TC detach detected and reported by station
SERVO 82 Servo problem
DISNOK 83 Bolt is in operational mode Disconnected NOK
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no.
SPROT 84 Spindle protection, none configurable restriction active during all steps in cycle
THM2 85 Final torque too high during monitoring on second buffer
TLM2 86 Final torque too low during monitoring on second buffer
AHM2 87 Angle too high during monitoring on second buffer
ALM2 88 Angle too low during monitoring on second buffer
BUFOVFLM2 89 Monitoring: Overflow in second recording buffer. See description of parameter
"Allow monitoring buffer overrun" in Program Settings.
MTR 90 Min Torque restriction exceeded
GHR 91 Gradient restriction, high limit exceeded
GLR 92 Gradient restriction, low limit exceeded
YAH 93 Yield angle, high limit exceeded
YAL 94 Yield angle, low limit exceeded
OTHER2 95 This is bit is set if any error bit(s) in the range 96. 127 are set and only the first 12
bytes are included. That is, Type in the reporter is set to "I12".
SS 96 Slip Stick Error
SPINDLE 97 Spindle Error
CONFIG 98 Configuration error
DTH 99 Delta torque high alarm from check
DTL 100 Delta torque low alarm from check
CROT 101 Continue rotation
LTH 102 Low spot torque high alarm from check
LTL 103 Low spot torque low alarm from check
BAH 104 Backlash angle high alarm from check
BAL 105 Backlash angle low alarm from check
ZCH 106 Zero crossing high alarm from check
ZCL 107 Zero crossing low alarm from check
NOKINPUT 108 External Input Not OK alarm from check
TRIES 109 Max number of retries exceeded (for a MS step)
MEAS_LOAD 110 MS step failed, measured Mean Load outside limits
MEAS_ADJ 111 MS or AD step failed and aborted.
FMLH 112 First Mean Load high alarm from MS step
FMLL 113 First Mean Load low alarm from MS Step
POSCALIB 114 Absolute position is not calibrated
PETHM 115 Pre end torque is outside high limit
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no.
PETLM 116 Pre end torque is outside low limit
PHM 117 Measured absolute position is outside high limit
PLM 118 Measured absolute position is outside low limit
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6.7.3.2 Warnings
The warning codes displayed in the bolt data table are listed and explained below:
The Bolt result variables Warnings can hold the warnings listed below.
When reported in binary format the respective error variable occupies 8 bytes (64 bits) where each bit
represent a warning. The bits are numbered 0 to 63 and are laid out as below:
Byte Offset 0 1 2 3
Error bit no. 31 24 23 16 15 8 7 0
Byte Offset 4 5 6 7
Error bit no 63 56 55 48 47 40 39 32
Possible warnings:
Warning Bit no. Description
NZS 0 Not zero speed
FLYZODIAG 1 Flying zero offset failed during a diagnostic step
BUFOVFLM 2 Monitoring: Overflow in recording buffer. See description of parameter "Allow
REPLIMIT 3 Report limit not reached. Monitoring torque (Bolt T) is less than the value specified by
the parameter Report threshold torque limit (see chapter: Program ).
BUFOVFLM2 4 Monitoring: Overflow in second recording buffer. See description of parameter "Allow
SPSERV 5 Time to service spindle
- 5 - 63 Reserved.
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6.7.4 Step level result variables

The Step level data is the data that can be reported for each individual step in a tightening cycle. It is
divided in two parts, Common data and Check data, where the first covers all variables that available for
all steps and the latter all variables produced by checks executed for the step.
Common data
This section lists all variables that are available for all steps without any specific configuration.

Step No The step number. This is the order of the step within the program. First step is one (1).
Steps within a sequence are given the step number P * 100 + S where P is the step number
of the SE step that calls the sequence and S is the step number within the sequence.
Step Type The numerical representation of the type of step. See the definition of the respective step
for valid values (Step – Control).
Par The parameters of the steps control part. See the definition of the respective step type
(Step – Control) for which parameters that are printed, and in which order.
Note This variable always prints 10 values. If fewer parameters are used for a step then the
unused will have the value NOT_DEFINED.
Speed The target Speed for the step.
A Chan Con The angle channel used for step control
T Chan Con The torque channel used for step control
Errors Step errors that have occurred, see Errors.
Step Name Step name
Check data
The check data consists of the variables that are produced as a result of running a check, a restriction or
produced by the steps control function.
In addition to the variables listed below the high and how limit set up for it, as well as the Cp, Cpk, and
Cam SPC values calculated for them, are also available as result variables.
Each check data variable is defined once for each possible choice for check channel. The first variable is
reported when the default check channel is used (Monitoring).

Peak T The highest torque reached during the step. Produced by the "Check peak torque"
Peak T1 check.
Peak T2
Peak T3
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Mean T Mean torque during end of step. Produced by the "Check mean torque" check.
Mean T1
Mean T2
Mean T3
DT Mean T The mean torque measured during the time interval TI2 of the DT - Run until Dyna-
TM TM TM
Tork , DT2 - Run until Dyna-Tork , method 2, and DT3 - Run until Dyna-Tork ,
method 3 steps.
Value is based on control channel used for step.
TM TM
DT T The torque measured when a DT - Run until Dyna-Tork , DT2 - Run until Dyna-Tork ,
TM
method 2, or a DT3 - Run until Dyna-Tork , method 3 step switches to using the DT
torque as target.
A Win Hi T The highest torque measured in the angle window. Produced by the "Check torque in
A Win Hi T1 angle window" check.
A Win Hi T2
A Win Hi T3
A Win Lo T The lowest torque measured in the angle window. Produced by the "Check torque in
A Win Lo T1 angle window" check.
A Win Lo T2
A Win Lo T3
Ti Win Hi T The highest torque measured in the time window. Produced by the "Check torque in
Ti Win Hi T1 time window" check.
Ti Win Hi T2
Ti Win Hi T3
Ti Win Lo T The lowest torque measured during time window. Measured by “Check torque in time
Ti Win Lo T1 window”.
Ti Win Lo T2
Ti Win Lo T3
A The step angle. Produced by the "Check angle" check.
A1
A2
Time The time that the step was run. Measured from that the servo is started until it is
stopped. Produced by the "Check time" check.
T / T3 The mean value of torque vs. the mean value of current both measured during the last T
T1 / T3 s of the step. Produced by the "Check T/T3 (Current as Torque)" check.
T2 / T3
Relax A The angle measured from that target is reached until the step is shut off. Only produced
TM TM
by the DT - Run until Dyna-Tork , DT2 - Run until Dyna-Tork , method 2, and DT3 -
TM
Run until Dyna-Tork , method 3 steps. This value is based on the control channel used
for the step.
Release A The release angle measured from the negative peak torque until the point where the
line, trough the peak torque point and the shut off point, cuts the angle axis.
Is produced by the “LT - Loosen until torque” and the “”RA - Release angle steps. This
value is based on the control channel used for the step.
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Tp1 Peak T The peak torque measured in angle window 1 of the restriction Torque Profile.
Tp1 Peak T1
Tp1 Peak T2
Tp1 Peak T3
Tp2 Peak T1
Tp2 Peak T2
Tp2 Peak T3
Tp3 Peak T1
Tp3 Peak T2
Tp3 Peak T3
Yieldpoint A The Yield point angle measured by the Check Yield Point Angle check.
Yieldpoint A1
Yieldpoint A2
ShutOff T The torque measured at the shut off point of the step. Produced by the "Check shut off
ShutOff T1 torque" check.
ShutOff T2
ShutOff T3
TorqueRate T Torque Rate. Produced by the "Check torque rate" check.
TorqueRate T1
TorqueRate T2
TorqueRate T3
TorqueRate Dev Maximum torque rate deviation. Produced by the "Check torque rate" check.
TorqueRate Dev T1
TorqueRate Dev T2
TorqueRate Dev T3
Gradient The gradient measured by the Gradient restriction.
Gradient T1
Gradient T2
Gradient T3
Delta T The difference between the lowest and the highest torque. Produced by the Check delta
Delta T1 torque check. (Only available for Gauging)
Delta T2
Delta T3
BCT A Reports measured backlash angle for BCT – Backlash correction (only available for
BCT A1 Gauging). (Only available for Gauging)
BCT A2
Zero Offset T1 Reports the last measured Zero Offset of the torque transducer. Measured by the
Zero Offset T2 spindle during Spindle functional test in a D - Diagnostic Step.
ZO Drift T1 Reports the Zero offset drift for the torque transducer, that is the difference between the
ZO Drift T2 Zero offset measurement and the previous one. Measured by the spindle during Spindle
functional test in a D - Diagnostic Step.
Shunt Calib T1 Reports the last measured Shunt calibration value of the torque transducer. Measured
Shunt Calib T2 by the spindle during Spindle functional test in a D - Diagnostic Step.
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Shunt Drift T1 Reports the Shunt calibration drift for the torque transducer that is the difference
Shunt Drift T2 between the Shunt calibration measurement and the previous one. Measured by the
spindle during Spindle functional test in a D - Diagnostic Step.
Position A The result of the check Check Position (only available for Gauging)
Low Spot T The lowest torque. Produced by the Check low spot torque check (only available for
Low Spot T1 Gauging)
Low Spot T2
Low Spot T3
Null Pos A The distance to the Null position after the current step (only available for Gauging).
Half Pos A The distance to the Half position after the current step (only available for Gauging).
Peak Pos A The distance to the Peak position after the current step (only available for Gauging).
Low Pos A The distance to the Low position after the current step (only available for Gauging).
Zero Cr. A The Zero crossing measured by the Zero Crossing check
Zero Cr. A1
Zero Cr. A2
Fail Safe T The Fail Safe Torque Limit used in the step.
Fail Safe T1
Fail Safe T2
Fail Safe T3
Fail Safe A The Fail Safe Angle Limit used in the step.
Fail Safe A1
Fail Safe A2
Min T Rest The Min. Torque restriction limit used in the step.
Min T1 Rest
Min T2 Rest
Min T3 Rest
Angle A TStart The Torque start used in the angle check, i.e. the torque value there the angle
Angle A1 TStart measurement is started. Only used if start condition of the check is Torque.
Angle A2 TStart
MeanLoad 1… 5 Mean load (1 to 5) measured during a MS step. (only available for Gauging).
CW Mean T1 … T5 Measured mean torque in CW direction in a MS step (T1-T5 = Try 1-5). (only available
for Gauging).
CCW Mean T1… T5 Measured mean torque in CCW direction in a MS step (Tries 1-5). (only available for
Gauging)
CW Peak T1 … T5 Measured peak torque in CW direction in a MS step (Tries 1-5). (only available for
Gauging)
CCW Peak T1 … T5 Measured peak torque in CCW direction in a MS step (Tries 1-5). (only available for
Gauging)
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Diff Peak T1 CW Peak T 1 - CCW Peak T 1, measured in a MS step
… …
Diff Peak T5 CW Peak T 5 - CCW Peak T 5, measured in a MS step
(only available for Gauging)
Diff Mean T 1 CW Mean T 1 - CCW Mean T 1, measured in a MS step
… …
Diff Mean T 5 CW Mean T 5 - CCW Mean T 5, measured in a MS step
CW Peak Pre 1 CW Peak T 1 - Preload, measured in a MS step
… …
CW Peak Pre 5 CW Peak T 5 - Preload, measured in a MS step
CCW Peak Pre 1 CCW Peak T 1 - Preload, measured in a MS step
… …
CCW Peak Pre 5 CCW Peak T 5 - Preload, measured in a MS step
(only available for Gauging).
Angle Target 1 The calculated angle target 1 in an AD step
… …
Angle Target 4 The calculated angle target 4 in an AD step
Angle Measured 1 The actual run angle 1 in an AD step
… …
Angle Measured 4 The actual run angle 4 in an AD step
First Mean Load First Mean load measured during a MS step, it is reported by the check First Mean Load
Adj Total Movement The total movement made during an AD step. It is the sum of all the measured angles
during all the adjustments.
Cross thr. A The angle measured from T1 to T2 in the Cross Thread and Gradient restriction
Step var. 1..40 T General cycle data variables for the checks, scaled as Torque if different torque units are
selected in reporters.
Step var. 41..80 General cycle data variables for the checks
When including the limits of a variable both the high and the low limit will be included in the report. If you
choose to include the SPC values all three values are reported together.
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6.8 Servo and spindle protections

To avoid servo and spindle breakdowns there are a number of protections implemented in the servo
software. These protections aim to protect the servo and spindle from overheating and over current
failures.
6.8.1 Stall protection

The stall protection protects the servo and the spindle if the spindle for some reason gets stuck and don‟t
have enough power to continue the rotation. The speed of the motor is constantly monitored and if it is too
low the servo shuts down the motor to protect from excessive heating due to high currents.
The speed limit is 274 rpm, measured on the motor. The spindle speed this corresponds to depends on
the gear ratio of the spindle, for some examples see the table below. If the motor run slower than this the
stall protection is activated.
Depending on the current level the protection works in different ways:
Below 20 A => No protection is active
Between 20 A and 42 A => It is allowed to stall for a maximum time of 5 s
Above 42 A => It is only allowed to stall 3 ms.
If the stall protection is activated the event “TC %d, Servo Driver Stalled“ is reported. In the cycle data the
error code “SERVO“ will be set.
Spindle type Stall speed limit

[rpm]
QST42-20CT 37
QST42-50CT 13
QST50-90CT 15
QST50-150CT 9
QST62-350CT 10
QST80-450CT 12
6.8.2 How to avoid the problems

It is normally best for the spindle and the servo to run with medium speeds. With low speeds the
tightenings will take a long time and thus a lot of heat will have time to build up. With very low speeds the
stall protection will also be activated and cause problems.
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7 SPC and Statistics

7.1 SPC - Overview
This part describes how to set up the SPC, Statistical Process Control, and other statistics.
A first introduction to SPC is given in the next chapter:, SPC, Statistical Process Control.
SPC Set Up… opens the SPC set up form with which the SPC is configured.
Shift Set Up… opens Shift Set Up form. Use it to configure shifts.
The other alternatives on the SPC menu are used for printing so-called shift reports. See Shift Reports
and Shift Set Up for a description of these.
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7.2 SPC, Statistical Process Control

The purpose of the built-in SPC function is to provide the operator or quality control staff with data that will
enable them to judge the stability and capability of the assembly process according to standard SPC rules.
By automating the SPC function within the PowerMACS the work will be simplified and carried out without
the necessity of external SPC charts.
Since any assembly parameter within PowerMACS can be used as a SPC variable, it is necessary to
understand that only variables controlled by the PowerMACS reflect the performance of the PowerMACS
system. Other variables will mainly reflect results from other processes. If e.g. a torque value is applied to
a joint, then obviously SPC of the final torque value and conclusions from that, such as Cp and Cpk will
reflect the performance of the tool and the controller. A SPC study of the angle from some torque level will
in the same case reflect mainly other aspects outside the PowerMACS sphere of influence, such as
friction of the threaded surfaces, machining of thread and mating surfaces etc. even though it is reported
by PowerMACS.
The built-in SPC is very flexible and it is possible to tailor data collection, calculations, and checks to suit
most needs.
7.2.1 Data Collection

Data is collected only for those variables that have been set up for collection. Data are collected in two
main ways:
As subgroups for the SPC and TDA
As latest results, or Short Term Trend
For the SPC and TDA function data is collected into subgroups. Only data with bolt status OK are
calculated on, results from NOK cycles are ignored. The Subgroup size defines how many samples a
subgroup is calculated from.
When Subgroup size values have been collected they are used to calculate the Average value and the
Range or Standard deviation. These values are saved for the subgroup while the original values are lost.
This is repeated with a selectable frequency, either specified in number of samples (Samples), or in time
between start of subgroups (Minutes). Note that the selected frequency only controls when collection of
data for a subgroup should be started. When started, the result of each OK cycle is taken until the
subgroup is filled.
If frequency is specified as Samples, say N, then the collection of a new subgroup is started N samples
after that the previous subgroup was started. When started, the result of each OK cycle is taken until the
subgroup is filled.
If frequency is specified as Minutes, say T, then the collection of a new subgroup is started T minutes
after that the collection of the previous subgroup was started. Also, if a subgroup is not complete within 30
minutes it is discarded.
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The SPC and TDA function will store and calculate data on No. of subgroups to save subgroups. It will
not display any values until at least No. of subgroups to calculate has been collected. However, from
that point it will use all subgroups stored in memory in the calculations.
The short Term Trend function is used to give a detailed view of the latest recorded samples. It uses a
buffer where the last (Subgroup size * No. of subgroups to save) samples are stored. Here are values
from both OK and NOK cycles collected.
When the Short Term Trend is to be displayed then average and the range or deviation values are
calculated for subgroups built from the data in the short Term trend buffer, starting with most resent value.
Which variables to collect are set up uniquely for each bolt/spindle and program.
7.2.2 Calculations for subgroups

Data in a subgroup is calculated as:
Xi
A verage X ;i 1.. n
n
R ange R m ax( X i ) m in( X i ) ; i 1.. n
2
( Xi X )
S tan dard devia tion S ;i 1.. n
n 1
2
2
( Xi )
X i
n
S is a p p ro xim a ted w ith ;i 1.. n
n 1
where n = size of subgroup
7.2.3 Calculations and checks

When specified number of subgroups to use for calculations has been collected, the SPC function will
start calculations to determine the statistical stability. This will be repeated every time a new subgroup is
ready.
Calculations are performed in following steps: (m = number of subgroups)
Calculation of Average of Average values:
X i
X ;i 1.. m
m
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SPC and Statistics
Calculation of Average of Range or Standard deviation:
Ri
R ;i 1.. m
m
and
Si
S ;i 1.. m
m
Calculation of Control levels (if enabled):
UCL X X A2 * R
LCL X X A2 * R
UCLR D4 * R
LCLR D3 * R
or
UCL X X A3 * S
LCL X X A3 * S
UCLS B4 * S
LCLS B3 * S
A 2 , D 4 , D 3 and A 3 , B 4 , B 3 : see table
Check and alarm (if enabled) if following happens with Average or Range or Standard deviation:
one value outside control levels (One out)
points consecutively increasing (Seven up)
7 points consecutively decreasing (Seven down)
7 points consecutively above average (Seven above)
7 points consecutively below average (Seven below)
>90% in mid third (Mid gather)
<40 in mid third (End gather)
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Calculation of the process capabilities Cp and Cpk:
R
i
d 5*
0 ,864
d 5* d5 1, 645
k
' R
s ;i 1 .. m ( d 2 : see table )
d2
or
' S
s ;i 1 .. m ( c 4 : see table )
c4
UTL LTL
Cp '
su sl * s
UTL X X LTL
Cpk min '
, '
su * s sl * s
UTL LTL
Cam
su sl * i
where
for a normal distribution su = sl = 3
d5 = 2.326 for subgroup size = 5
k = no of subgroups to calculate
Cam is only calculated for subgroup size = 5, and requires range to be collected. Cam is not applicable to
standard deviation.
An error event is generated if the value of Cam, Cp or Cpk is out of limit.
When SPC is wanted for a station, not for its individual bolts, the calculations are made on those variables
that happen to be set up for data collection on that station.
Station, Program, Step and Variable are still defined, so only variables matching those criteria are used.
It is not possible to specify alarm limits or control limits for SPC calculated on a station. The weighing
together of values for the separate bolts are done for each subgroup according to the following rules:
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SPC and Statistics
NoBolt The number of bolts in this station for which SPC - collection is set up.
X ij The mean value for subgroup j for bolt i.
XStn j The average for the station for subgroup j

Var ij The varians for subgroup j for bolt i
VarStn j
The varians for the station for subgroup j
StdDevStn j
The standard deviation for the station for subgroup j
NoBolts
X ij
i 1
XStn j
NoBolts
NoBolts
2
VarStn j
X ij XStn j Var ij
i 1
StdDevStn j
VarStn j
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7.2.4 SPC constants

The table below gives the constants to use in the mathematical formulas.
Sub- Divisors for Factors for Control Limits

group estimate of
size standard dev.
n d2 c4 A2 D3 D4 A3 B3 B4
2 1.13 0.798 1.88 - 3.27 2.66 - 3.27
3 1.69 0.886 1.02 - 2.57 1.95 - 2.57
4 2.06 0.921 0.73 - 2.28 1.63 - 2.27
5 2.33 0.940 0.58 - 2.11 1.43 - 2.09
6 2.53 0.952 0.48 - 2.00 1.29 0.03 1.97
7 2.70 0.959 0.42 0.08 1.92 1.18 0.12 1.88
8 2.85 0.965 0.37 0.14 1.86 1.10 0.19 1.82
9 2.97 0.969 0.34 0.18 1.82 1.03 0.24 1.76
10 3.08 0.973 0.31 0.22 1.78 0.98 0.28 1.72
11 3.17 0.975 0.29 0.26 1.74 0.93 0.32 1.68
12 3.26 0.978 0.27 0.28 1.72 0.89 0.35 1.65
13 3.34 0.979 0.25 0.31 1.69 0.85 0.38 1.62
14 3.41 0.981 0.24 0.33 1.67 0.82 0.41 1.59
15 3.47 0.982 0.22 0.35 1.65 0.79 0.43 1.57
16 3.53 0.984 0.21 0.36 1.63 0.76 0.45 1.55
17 3.59 0.985 0.20 0.38 1.62 0.74 0.47 1.53
18 3.64 0.985 0.19 0.39 1.61 0.72 0.48 1.52
19 3.69 0.986 0.19 0.40 1.60 0.69 0.50 1.50
20 3.74 0.987 0.18 0.42 1.59 0.68 0.51 1.49
21 3.78 0.988 0.17 0.42 1.58 0.66 0.52 1.48
22 3.82 0.988 0.17 0.43 1.57 0.65 0.53 1.47
23 3.86 0.989 0.16 0.44 1.56 0.63 0.55 1.46
24 3.90 0.989 0.16 0.45 1.55 0.62 0.56 1.45
25 3.93 0.990 0.15 0.46 1.54 0.61 0.57 1.44
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SPC and Statistics
7.3 SPC set up

This form is used for configuration of the SPC, Statistical Process Control function. It is opened using the
Statistics SPC - Set Up menu item.
Specify Subgroup size and if you want to use Range or Standard Deviation.
In the SPC and TDA frame, set up values for normal SPC and Trend Deviation Alarms.
Do the same for the Short Term Trend frame. These values will be used for calculations of all variables
you choose to calculate on. See chapter: Data Collection for a description of the parameters.
In the Variables to collect frame, add those variables you want to check. Select Station, Bolt and/or
Spindle, Program, Variable and Step. For Bolt and/or Spindle you may specify All, this will add the
variable for all bolts in the station. Press . The variable shows up in the list box.
If more than one spindle can be used to tighten a bolt (defined in the Mode Table) you must define which
spindle for the bolt to collect data for.
A PowerMACS system may contain up to 200 SPC variables and max 20 per TC/spindle.
To remove a variable from the list, select it and press the remove button .
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If you press the Information button a dialog box is presented where you can enter various check values
for the selected variable.
If you have marked Auto recalculation of limits on the first page, the UCLX, LCLX, UCLR/S and LCLR/S,
fields will show current value of the control limits. If you disable automatic recalculation you can manually
enter control limits in these fields.
Cam limit is only applicable if cam can be calculated.
Check one or more of the check boxes in the Trend Deviation Alarms frame to have the SPC and TDA
data monitored for any of the following deviations:
One out: One point outside control levels
Seven up: Seven points consecutively increasing
Seven down: Seven points consecutively decreasing
Seven above: Seven points consecutively above average
Seven below: Seven points consecutively below average
Mid gather: More than 90% of the points in mid third
End gather: Less than 40% of the points in mid third
If a deviation is detected an event of type SPC is generated and stored in the Event Log (see also View
Event Log).
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7.4 Shift Reports and Shift Set Up

It is possible to define automatic end of shift reports summarizing deviations and exceptions during the
last shift. To use this function you must first define the shifts. This is done using the Shift Set Up form.
The report is produced automatically after each shift but can also be printed ”so far” during the current
shift. The report can be previewed on the ToolsTalk PowerMACS screen or sent to a printer connected to
it. Preview and print are invoked from the Statistics menu.
The report contains the following information per station:
Total No. of cycles executed, No. of OK and No. of NOK.
Total No. of cycles executed for each mode, No. of OK and No. of NOK.
For each combination of program and bolt the following SPC data are listed for the bolt level result
variables "Bolt T" and "Bolt A": Mean value, +3*Sdev, -3*Sdev, Cp, Cpk and Cam. To be included
in the report the variables must first have been included using the SPC set up form.
Some statistics can be automatically reported on a shift base.
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7.4.1 Shift Set Up
The Shift Set Up form is used for to define shifts. It is invoked using the Statistics - Shifts Set Up… menu
item.
Up to 21 shift periods can be defined. Each row in the above form represents a shift. Enter the day and
time for when the shift starts and when it stops.
The days are expressed as numbers where 1 corresponds to Monday and 7 to Sunday. A shift may have
different start and stop days.
The start and stop times must be entered using 24 h notation, i.e. as 00:00 to 23:59.
Check Automatic clear at shift start to have all shift statistics variables erased when a new shift starts.
Clearing the shift statistics will reset the following:
All counters (No. of cycles, No. of OK cycles, No. of NOK cycles) for each combination of station
and mode used for the Shift Report.
The Station level result variables "Total", "Total OK", and "Total NOK"
The Bolt level result variables "Total", "Total OK", "Total NOK", "Total Type", "Total Type OK", and
"Total Type NOK"
Check Automatic printout at shift end to automatically have the shift report printed when the shift ends.
See chapter: Shift Reports and Shift Set Up for an example on a typical shift report.
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Note! In order to have the information on number of cycles executed in the report (OK as well as NOK)
the following Station level result variables must be included in at least one reporter in the system
(see chapter: Edit reporter for how to configure a reporter).
Total
Total OK
Total NOK
To have the SPC data included in the shift report the following Bolt level result variables must be
included in at least one reporter in the system:
Bolt T
Bolt A
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8 Peripheral Devices
8.1 Peripheral Devices - Overview
Peripheral devices are used to get information in and out of a PowerMACS system. The devices can be
both of simple type, like printers, and of more complex type like a fieldbus, a serial communication
protocol and the PowerMACS API interface.
C C P rin te r
PC
C C , C o n so le C o m p u te r A p p lic a tio n
F ie ld b u s M a s te r API
E th e rn e t
T C , T ig h te n in g C o n tro lle r
E x t. C o m .
D e vic e
I/O P rin te r ID D e vic e
D ig ita l in p u ts a n d
o u tp u ts
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PowerMACS can handle the following devices:
Device Usage Signal Interface

Printer or File on CC Printout of cycle data, events, traces, SPC, etc. Printer port on CC.
File on CC Storage of cycle data end events in file. File system on CC.
Printer on TC Printout of cycle data and events. Serial port on TC.
Stacklight (part of Show status information. Serial port on TC.
Standard Accessory
Device)
Indicator Box (part of Show status information and control a station. Serial port on TC.
Standard Accessory
Device)
Operator Panel (part of Show status information and control a station. Serial port on TC.
Standard Accessory
Device)
I/O Device Binary data to/from the PLC. Internal fieldbus port on TC.
ID device Input for identification data and/or output of cycle Serial port on TC.
data and events.
Serial Communication Data to/from PLC, output of cycle data, events and Serial port on TC.
Protocol Information traces, read/write Setups.
Fieldbus Interface Data to/from PLC, output of cycle data, events and Fieldbus interface board.
traces, read/write Setups.
ToolsNet Reporting cycle data and traces to Atlas Copco's Ethernet, TCP/IP.
ToolsNet server.
PLC Reporting cycle data to the PowerMACS PLC (see Internal
chapter: PLC).
API, Application Data to/from PLC, output of cycle data, events and Software package on a PC
Programmers Interface traces, read/write Setups, read/write Setup items. computer.
Ethernet Protocols Receiving control and sending result from/to Ethernet, TCP/IP.
specialized servers like Open Protocol,
DaimlerChrysler PFCS, FSH, DC PLUS etc.
GM DeviceNet Receiving control and sending result from/to a an DeviceNet fieldbus and/or
overriding controller according to GM's specification local I/O via the internal
"GAE Electric Nutrunner Controller Design Criteria" fieldbus port on TC.
ACTA 3000 Calibration of spindle torque transducer. Serial port on TC.
The following chapters will describe how these devices are added and used.
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8.2 Add a device

You can have a total of 21 devices in a PowerMACS system and up to 6 can be connected to each TC.
To add a device, select a TC in the System Map, right click and select Add Device from the popup menu.
This will bring up a list of devices that can be added
You will be asked to give the new device a name. This name will later be referred to when you create a
Reporter, which will be used to select and format the data sent to the device.
When you have added a device you should configure it. Which parameters that is available depends on
the type of device.
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Example for an ID device:
For it you must specify Type, which is one of Barcode, Escort P&F and Escort AB.
Select a suitable port. There are several ports on a Tightening Controller that can be used for in and
output of data.
Port Usage Signal Interface

Serial 1 General serial communication RS-232, RS-485
Serial 2 General serial communication RS-232, RS-422, ST-Bus
CAN I/O port I/O Device communication CAN with DeviceNet
For the selected port you must also specify its characteristics: Baud Rate (300-115 200), Parity (None,
Even or Odd) and Data Bits (7 or 8). Number of Stop Bits is always 1.
Note! Due to technical reasons you can only use two different baud rates on each TC.
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8.3 Status of a device

During performing its task each device checks for errors or malfunction. The result is shown in the System
Map.
Devices not working OK are shown with a red cross.
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8.4 Standard Accessory Devices

The standard accessory devices consist of Stacklight, Indicator Box and the Operator Panel. They are all
communicating using the DeviceNet protocol and can essentially be considered to be specialized I/O
devices.
8.4.1 Stacklight
To access the stacklight configuration window, add a stacklight device and double-click on it in the system
map.
Select the correct MAC Id for the Stacklight. When a new Stacklight device is added a simple default
configuration is provided.
Configure the Stacklight by selecting the component you wish to edit (lamp, buzzer or button) in the
property grid on the right side or by clicking on the actual component in the Stacklight image (this will
cause the correct property to be selected).
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Once a component is selected configure the digital IO signal to connect to the component and additional
properties (flashing, duration etc.).
It is possible to select the number of lamps on the indicator box by selecting the “None” value as
Component type.
When connected to a system the form will show the signal values in real-time and no editing is possible.
8.4.2 Indicator Box

To access the indicator box configuration window, add an indicator box device and double-click on it in the
system map.
Select the correct MAC Id for the Indicator Box. Select the correct Indicator box software version.
Software versions up to 0.12 have a configuration in the Indicator box which specifies ten lamps to be
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used. Later software versions allow the user do decide exactly which of the lamps should have a specific
function.
Configure the Indicator Box by selecting the component you wish to edit (lamp or digital input) in the
property grid on the right side or by clicking on the component in the indicator box image or LED signal
list.
When connected to a system the form will show the signal values in real-time.
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8.4.3 Operator Panel
To access the operator panel configuration window, add an operator panel device and double-click on it in
the system map.
Select the correct MAC Id for the Operator Panel. When a new Operator Panel device is added a simple
default configuration is provided.
Configure the Operator Panel by selecting the component you wish to edit (lamp, buzzer or button) in the
property grid on the right side or by clicking on the component in the operator panel image.
A special integer Mode signal is provided to use with LED displays to show the actual mode number
selected. Use the DI_Manual signal to override other devices mode selection.
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When connected to a system the form will show the signal values in real-time.
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8.5 I/O Device

An I/O device is used to communicate with hardware modules for digital input and output signals. For
description on I/O devices and how to set up, see chapter: I/O.
The I/O device, as well as Stacklight, Indicator Box, and Operator Panel, can map all boolean signals
located in the Digital_In_Out group and in the Shared_Variables group. Boolean outsignals starting with
“SO_” in the Fieldbus_Variables group can also be mapped by these devices since they belong to the
shared signals. Se PLC Areas for more information about these areas in the PLC.
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8.6 Printer on TC
A Printer device connected to a TC can be used to print cycle data and events via a serial port.
Most printers will work as long as they are made for printout of normal ASCII characters. There is no
handshake protocol or modem signaling needed.
Add a Printer device as described in previous chapter. Set up which port to use and the port
characteristics.
Now you have added a printer device. To get data on it you must also create a Printer Reporter. How to
do this, and connect it to your Printer device, is described in the New reporter chapter. How to make the
Reporter format the result as you wish is described in chapter: Edit reporter
8.7 Printer or File on CC

A Printer device connected to a CC can be used to print cycle data and events, but also for printout of
graphical traces and SPC charts.
To get data to the printer it you must create a ToolsTalk Printer Reporter. How to do this is described in
the New reporter chapter. How to make the Reporter format the result as you wish is described in chapter:
Edit reporter
Note! The ToolsTalk PowerMACS program must be running if order to be able to print on a printer
connected to the CC.
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8.8 PLC
Using the PLC device it is possible to read cycle data from inside the PowerMACS PLC (see chapter:
PLC).
To enable this function you must first add a PLC device, as described in chapter: Add a device, to TC that
runs the PLC, i.e. the first TC in a station. Note that the PLC device is only a logical device, it requires no
additional hardware to be connected to the system.
Secondly you must create New reporter and connect it to the PLC device.
Use the reporter to select what result variables to include in the cycle data, see Edit reporter for how to do
that.
Finally you must declare variables within the PLC that corresponds to the layout of the Reporter.
Configuring a reporter with Type of layout set to "Standard", Additional new lines to 0 (or empty), Byte
order and Status format to "Normal", Float format to IEEE754, and the following result variables:
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Station variables:
Variable Order Width Dec Type Text Lines

Data No 1 I2
Station No 2 I2
Time 3 I4
Mode No 4 I2
Bolt variables:
Variable Order Width Dec Type Text Lines

Bolt No 1 I2
Bolt T 2 F
Bolt A 3 F
Status 4 I2
You must also enable and configure the drivers used for accessing the PLC data. This is done using the
IO_Configuration worksheet for station in question.
The above setup (for a station containing one bolt) corresponds to the declaration of the following PLC
variables in the CycleData_Var section of the Global_Variables worksheet for the station in question:
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You must also configure the PLC drivers used for accessing the PLC data. This is done using the I/O
Configuration dialogue which is invoked by double-clicking on the icon for IO_Configuration worksheet of
station in question in the Project Tree.
In the /O Configuration dialogue select the I/O Group CYCLE_in located on the tab marked INPUT and
press the Properties button.
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Change the value of Logical addresses – Length so that it corresponds to the size of your cycle data, in
this case 22.
The Start and End addresses shown (here 4000 and 4021) are logical, meaning that a PLC variable later
mapped to the logical address 4000 will correspond to the first byte of the cycle data.
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8.9 ID device
ID devices come in two forms: input only and both input and output. An input device could be used to get
identification of a work piece. The read data could include information on how the tightening should be
performed. The identification could also be used to identify the result data.
An ID device, which can be written, can be used to store crucial data (status, final torque etc.) along with
the work piece. This can then later be read in, for example, a repair station.
See chapter: Add a device for how to add an ID device.
Use Type to specify the type of ID device to use. Currently the following ID device types are supported:
Barcode - Barcode scanner, any brand that uses a serial input.
Escort P+F - Escort memory of type Pepperl+Fuchs, MVI-D2-2HRX
Escort AB - Escort memory of type Allen Bradley, Intelligent Antenna 2750-ASP* together with
code tag 2750-TAU40
Omron - Escort memory of type Omron V600 RFID system (V600-CA1A-V and V600-CA2A-V)
Euchner - Euchner Electronic-Key-System reader of type EKS-A-ASX
A Barcode scanner is an input only device. It can be used to read bar codes attached to a work piece. An
Escort Memory is an ID device that can be used both for input and output.
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All ID device types are connected to the PowerMACS TC using a serial communication interface. Use Port
to specify of PowerMACS communication ports the device is connected to and Baud Rate, Parity and
Data Bits to configure its characteristics.
Press the Advanced… button to open the ID device Set Up form from where you can set all type specific
parameters, like at which addresses to read/write from/to for an escort memory device. See Type specific
parameters below for a description of these.
To make use of the data read from an ID device it must be transferred to a Station. This connection is
configured using the Advanced Station Settings form, see chapters: Work piece identifier and Multiple
identifiers. Note that it is possible for several Stations to read from the same ID device.
The data read from an ID device is also available to the PowerMACS PLC making it possible to process it
as wished.
When the device is connected to a Station the data read from it is also available to the Stations PLC for
processing. The PLC can also be used to control and supervise reading of the data. The PLC functions
available are described in chapter: ID device variables and Multiple identifier variables.
If result data should be written to the ID device (an escort memory) you must set up how the data should
be formatted. This is done by connecting a Reporter to the device. See chapter: New reporter for how to
create a new Reporter and/or chapter: Edit reporter for how to configure it. Remember to specify if data
should be written as readable characters or in binary format. The writing of the escort memory is done as
soon as the cycle is ready.
8.9.1 Type specific parameters

Type specific parameters are opened by clicking the Open... button located on the Details form.
8.9.1.1 Barcode scanner
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An ID device of type Barcode normally handles a barcode scanner. Since PowerMACS allows you to
freely choose which characters that are used to frame the scanned ID string it supports most types of
scanners.
The character entered as Start character, if any, must be the first character returned from the device. If
not the device is marked erroneous until a correct string is scanned.
Enter as End character the character that marks the end of returned string. Non-printable characters are
entered using their hexadecimal code enclosed between a pair of "<" and ">", for example "<09>" for a
horizontal tab.
8.9.1.2 Pepperl + Fuchs escort memory
For an ID device of type Escort P&F, that is, a Pepperl+Fuchs escort memory, you must specify where in
the data tag to read the ID string from and where to write cycle data to.
Use the two pairs of Start address and Stop address to do this. The first address in the tag has address
zero (0). For reading you can specify up to 40 cells and for writing up to 500.
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8.9.1.3 Allen Bradley escort memory
The ID device type Escort AB corresponds to Allen Bradley's Intelligent Antenna 2750-ASP* together with
code tag 2750-TAU40.
For the Allen Bradley Intelligent Antenna escort memory, you must specify where in the data tag to read
the ID string from and where to write cycle data to. Use the two pairs of Start address and Stop address
to do this. The first address in the tag has address zero (0)
RF field strength controls the power of the signal transmitted by the antenna and may need to be
adjusted depending on the distance between the antenna and data tags.
The parameters Delay before resp, Delay between char and Sensor timeout should normally be kept
at their default values.
For more information on these parameters see Allen Bradley's User Manual for the Intelligent Antenna.
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8.9.1.4 Omron escort memory
The ID device type Omron corresponds to Omron V600 RFID system. Currently the two models
V600-CA1A-V (RS-232C interface) and V600-CA2A-V (RS-422 interface) are supported.
Note! V600-CA2A-V (RS-422) can only be connected to port X104 since it is the only port that supports
RS-422. For other ports an external converter must be used.
For an Omron ID device you must specify where in the data tag to read the ID string from and where to
write cycle data. See Reading an ID string and Writing result data below for how to do this.
Parameter Antenna controls which of the two antennas supported by the V600 serial interface controller
to use. Currently only 1 (one) is supported.
Reading an ID string:
For Omron devices the ID String may consist of two different parts, the main part and an optional number
part.
Parameters Start address and Stop address defines the address area on the tag where the main part is
located. The main part must be an ASCII string. The first address in the tag has address zero (0) and up
to 40 bytes can be read.
Parameters Start address 2 and Stop address 2 defines the address area on the tag where the optional
number part is located. The parameter ID string conversion controls how this data is converted to a
numerical value and it takes one of the following values:
Mitsubishi: The optional number part is interpreted as a four byte integer having a special
Mitsubishi BCD format where the decimal value 1234 is formatted as four consecutive bytes having
the values 0x04, 0x03, 0x02, 0x01 with the first byte (0x04) is located at lowest address.
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ASCII: The optional number part is assumed to be a four character string consisting of decimal
digits only. That is, the decimal value 1234 is formatted as four consecutive bytes having the
values 0x31, 0x32, 0x33, 0x34 with the first byte (0x31) is located at lowest address.
The value read from the tag is converted to a four character decimal number (example: value 47 gives the
string "0047"). Leaving either Start address 2 or Stop address 2 blank disables reading of the optional
number part.
If the optional number part is used it is concatenated to end of the main part before the resulting ID string
is sent to the station and the PowerMACS PLC.
Example: If the main part is the string "ABCDE" and decimal value 47 is read as optional number part the
resulting ID String is "ABCDE0047". This string is sent to the station and PLC as a response
to an IDREAD (PLC output) request.
Writing result data:

Start address and Stop address defines the address area of the tag where result data is written if a
reporter is assigned to the device. The offsets are relative to Start address.
Limitations:
A V600 controller cannot be shared between different ID devices. Every TC that should write to a tag must
have a separate V600 controller.
Only one of the V600 controllers' antennas can be used. Which antenna to use is configurable.
The system configuration for 1 to N connections (available only for V600-CA2A) is not supported.
The command used for reading and writing data in the EM is Read (RD) and Write (WT), which means
that there is no support for Auto Read (AR), Auto Write (AW), Polling Auto Read (PR) or Polling Auto
Write (PW).
Since auto reading is not supported an external signal has to be used to inform the PLC that the tag is in
place for reading or writing.
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8.9.1.5 Euchner card reader
An ID device of type Euchner, that is, a Euchner Electronic-Key-System reader of type EKS-A-ASX, is
equipped with a 24V output signal (data carrier active) that is used by PowerMACS to know when the
reader has a card. When a card is inserted in the reader, the 24V signal goes high. This triggers
PowerMACS to start communicating with the card reader and fetch the data from the card. Whenever the
signal is set low PowerMACS clears the read data.
Use DI for Euchner card reader to specify which PowerMACS I/O input that the "data carrier active"
signal is connected to.
Note! The Euchner device must be configured to use Baud Rate 9600, Parity = Odd and Data Bits = 8.
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8.10 ToolsNet
Using a ToolsNet device you may report cycle data and/or traces to an Atlas Copco ToolsNet server over
the Ethernet.
To enable this function you must first add a ToolsNet device, as described in chapter: Add a device.
Select the created device and adjust its parameters if necessary.
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Use Name to specify the name of the device. This name should be referred to when you create a reporter
for the new ToolsNet device using the New reporter form.
Server IP-address should be set to IP-address of the computer on which the ToolsNet server is installed.
The value of Server Port No depends on the configuration of ToolsNet and should only be changed after
consultation with your network manager. Default values for the port number are suggested by the system
when the protocol version is changed.
Trace – no of samples controls how many samples of a PowerMACS trace that are sent to the ToolsNet
server. It can be set to a value in the range [100…2000] and the default value is 752.
Use Select Protocol to select which version to use: Auto detect or specific version.
When ToolsNet is used together with DC PLUS it is possible to have the "PN" or "KN" prefix of the
"Wp. Id" result variable removed when it is sent to the ToolsNet server. This filter is activated by checking
the Filter PN/KN checkbox (displayed only if the system contains a DC Plus device).
The ToolsNet device does not require any additional hardware to be connected to the TC since it uses the
TCs standard Ethernet connector. However, you must make sure that the network between your
PowerMACS system and the ToolsNet server is correctly configured. See PowerMACS Ethernet Manual
[3] for how to do this.
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Create a new Reporter for the ToolsNet device and use it to set up what data to report to ToolsNet. The
ToolsNet reporter is somewhat different from reporters used for other devices since you can only select
what variables to include, not format them. Certain variables can not be removed from the reporter, they
are marked as gray in the reporter window.
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8.11 Ethernet Protocols

Today most factories have a local area network, LAN, for distribution of data. These networks are often
based on Ethernet and with TCP/IP as link protocol. PowerMACS is capable of using such LAN for
communication to and from a central server. What functions possible to use differs between protocols but
may include things like:
Reporting cycle data
Control of tightening
Reporting alarms
To enable this function you must first add an Ethernet protocol device, as described in chapter: Add a
device.
Add the device to a TC that has a PLC, i.e. the first TC in a station.
With the exception of DC PLUS and Audi XML it is possible to set up multiple Ethernet devices on any TC
in the system. The Audi XML device is limited to one per system and must be on the System TC. For DC
PLUS there can be one device per station and they must be located on the respective station TC.
However, Ethernet devices of other types can coexist on the same TC as the Audi XML and DC PLUS
devices.
Select the created device and adjust its parameters if necessary.
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Example:
Use Name to specify the name of the device. This name should be referred to when you create a reporter
for the new ToolsNet device using the New reporter form.
Set up which Ethernet Type of protocol to use, and which IP-address the server has.
A new Reporter is created automatically for the Ethernet protocol device. The reporter is different from
other reporters in that sense that what variables to include are predefined and cannot be changed.
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In chapters below is described how to configure the different Ethernet protocol devices. The protocols are
standard protocols, which are defined by major car manufacturers. It is also described what functions are
included and how they are mapped on PowerMACS functions.
The Ethernet protocol device does not require any additional hardware to be connected to the TC since it
uses the TCs standard Ethernet connector. However, you must make sure that the network between your
PowerMACS system and the Ethernet server is correctly configured. See PowerMACS Ethernet Manual
[3] for how to do this.
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8.11.1 Open Protocol

Note! This protocol has been renamed it was earlier called FFCCP and supported revision 4.7 of FFCCP,
the Ford Fastening Controller Common Protocol. The FFCCP functionality still exists in this protocol.
PowerMACS supports a subset of Open Protocol described in the document 9836 4415 01 Open Protocol
(se Supported message types below).
Port No specifies the port on which PowerMACS listens for incoming requests for Open Protocol.
Retries specifies how many retries should be done in case a telegram has not been able to send. Retry
Timeout specifies the timeout between retries.
Keep Alive Timeout is the timeout used to detect the absence of a client. If no telegram has been
received within the timeout period, the TC closes the connection.
OKs to disable station specifies the number of cycles with status OK or OKR that may be run while in
Automatic mode before the station is automatically disabled. NOK cycles are not counted. If OKs to
disable station is greater than zero then the station is disabled at power up and whenever a connection
to Open Protocol is established. If left empty, or zero, then the station is only disabled if explicitly ordered
so by Open Protocol. All tightening made during a batch will have the same VIN number, sampled at the
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first start. The actual value of the OK, or batch, counter is reset when a "Select Parameter set" message
(MID 0018) is received from Open Protocol but is unaffected by Enable/Disable commands.
Allow Client control specifies how control messages (see below for a listing which these are) from the
Open Protocol client should be treated by the tightening controller. Choose one of the following
alternatives:
Always: Select this alternative if control messages should be accepted regardless if the station is
in Automatic or Manual mode.
In Automatic mode: (Default). Select this alternative if control messages only should be accepted
when the station PLC output MODE is equal to zero.
Never: Select this alternative if control messages never should be accepted.
See Automatic/manual mode for a description on the differences between Automatic and Manual mode.
The following messages from the Open Protocol client are regarded as control messages:
MID 0018, "Select Parameter set"
MID 0042, "Disable tool"
MID 0043, "Enable tool "
MID 0050, "Vehicle Id Number download request"
When these are received in a state when they are not wanted according to the value of the Allow Client
control parameter PowerMACS will respond with a “Command Error" (MID 0004) message with the field
"Error" set to 95 (Reject request, PowerMACS is in manual mode).
Station Controller specifies if this device is allowed to read/write user data to/from the PLC. If this is
checked the following messages from the Open Protocol Client are allowed.
MID 240, “User data download”
MID 241, “User data subscribe”
MID 242, “User data upload”
MID 243, “User data upload acknowledge”
MID 244, “User Data upload unsubscribe”
8.11.1.1 Automatic/manual mode

The station controlled by the Open Protocol device is always in either Manual or Automatic mode
depending on the current value of the PLC output MODE. If MODE is zero the station is in Automatic
mode and if it is non-zero the station is in Manual mode.
The following messages can be used by Open Protocol to supervise the stations with respect to its
Manual/Automatic state:
MID 0400, “Automatic/Manual mode subscribe”
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MID 0401, “Automatic/Manual mode upload”
MID 0402, “Automatic/Manual mode upload acknowledge”
MID 0403, “Automatic/Manual mode unsubscribe”
MID 0410, “AutoDisable settings request”
MID 0411, “AutoDisable settings reply”
In addition to the “Automatic/Manual mode" messages the "Parameter set selected" (MID 0015) message
can be used to keep track of the stations Automatic/Manual mode state. PowerMACS sends this message
when the stations mode selection is changed, also when it changes to/from zero.
When entering Manual mode the following the following actions are executed internally by the
PowerMACS station:
The Open Protocol mode selection is zeroed.
The VIN number is cleared.
The station is enabled.
The OK, or batch, counter is zeroed and turned off (not used in Manual mode).
If the connection to Open Protocol is lost while in Automatic mode then the following actions are executed:
The Open Protocol mode selection is zeroed.
The station is disabled.
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8.11.1.2 Supported message types
MID Name Implementation description

0001 Communication start Enables communication
0002 Communication start acknowledge
0003 Communication stop Disables communication
0004 Command error
0005 Command accepted
0010 Parameter set numbers upload request Modes are used for parameter sets in PowerMACS.
0011 Parameter set numbers upload reply
0014 Parameter set “selected” subscribe
0015 Parameter set “selected” Creation/download time for program run by first bolt in
selected mode. Mode number not 0 in start signal gives that
mode no according to start signal is used. Mode number 0
in start signal makes the station use the mode number it has
stored. When testbolt is run mode number is reset to the
mode number used before testbolt, when the testbolt cycle
is ready.
0016 Parameter set “selected” acknowledge
0017 Parameter set “selected” unsubscribe
0018 Select Parameter set Selection of Mode. Mode number is sent to station. ModeNo
NOT_DEFINED (-32768) (test bolt not mode view) is not
reported as parameter set change and mode is reset to
original mode in station when the test bolt cycle has run.
0040 Tool data upload request
0041 Tool data upload reply Tool serial number (Id 01) is reported as spaces ' '.
As Tool number of tightening (Id 02) is reported the number
of cycles run on the spindle controller of the TC holding the
epHan device (max value is 2147483647).
As Last calibration date (Id 03) is reported the time for when
the service flag was last reset (cycle count changes).
Controller serial number (Id 04) is reported as spaces ' '.
0042 Disable tool Disables START signal in PLC. When the station controller
receives a START signal (from PLC or testbolt) a info event
is issued to report that the station is disabled if a Disable
tool signal has been received from the epHan device. When
a Disable tool signal is received during a cycle an
emergency stop is issued and the cycle stops. Emergency
stop event is reported.
0043 Enable tool Enables START signal in PLC. Station controller is enabled
at startup. To enable the station controller when disabled an
Enable tool signal must be sent.
9836 3521 01 457

Peripheral Devices

0050 Vehicle Id Number download request Selection of Wp Id. Wp Id is sent to PLC and
CurrentIdString is updated the CurrentIdString is also
reported to the station, which reports the Id to ephan device.
When TestBolt is run Id is reset to the prior value after the
cycle.
0051 Vehicle Id Number upload subscribe
0052 Vehicle Id Number upload
0053 Vehicle Id Number upload acknowledge
0054 Vehicle Id Number upload unsubscribe
0070 Alarm subscribe Events mapped on 3-digit numbers. All events for the station
and all general events are reported.
0071 Alarm Upload There is no Controller ready status and Tool ready status
available in the PowerMACS events. Status is always
reported as OK.
0072 Alarm Upload acknowledge
0073 Alarm Unsubscribe
0074 Alarm Acknowledged on torque Acknowledges all events in PM regardless of specified error
controller number.
TC sends this message when an event (subscribed on) has
been marked observed in PM. If command "mark all as
observed" is used event code 0 is reported.
0075 Alarm Acknowledged Ack
0076 Alarm Status Alarm status reports the oldest not already reported event.
After alarm status Alarm Upload is done automatically until
there are no not reported events in the queue. Alarm status
1 if any not observed events exist.
0077 Alarm Status acknowledge
0080 Read time upload request
0081 Time upload reply
0082 Set Time in the Torque Controller Only possible to perform on devices on the System TC.
0090 Multi spindle status subscribe
0091 Multi spindle status upload See TC Status Record Formats for message structure.
0092 Multi spindle status upload acknowledge
0093 Multi spindle status unsubscribe
0100 Multi spindle result subscribe
0101 Multi spindle result upload See TC Result Record Formats for message structure.
0102 Multi spindle result upload acknowledge
0103 Multi spindle result unsubscribe
458 9836 3521 01

Peripheral Devices

0105 Last PowerMACS tightening result data See document Open Protocol MID for PowerMACS data for
subscribe more information
0106 Last PowerMACS tightening result See document Open Protocol MID for PowerMACS data for
Station data upload reply more information
0107 Last PowerMACS tightening result Bolt See document Open Protocol MID for PowerMACS data for
data upload reply more information
acknowledge more information
unsubscribe more information
0240 User data download See document Open Protocol MID for PowerMACS data for
more information
0241 User data subscribe See document Open Protocol MID for PowerMACS data for
more information
0242 User data upload See document Open Protocol MID for PowerMACS data for
more information
0243 User data upload acknowledge See document Open Protocol MID for PowerMACS data for
more information
0244 User data upload unsubscribe See document Open Protocol MID for PowerMACS data for
more information
0400 Automatic/Manual mode subscribe
0401 Automatic/Manual mode upload
0402 Automatic/Manual mode upload
acknowledge
0403 Automatic/Manual mode unsubscribe
0410 AutoDisable settings request
0411 AutoDisable settings reply
9999 Keep alive message
9836 3521 01 459

Peripheral Devices
8.11.1.3 TC Status Record Formats
Parameter Id Bytes Implementation

Number of 01 2 The number of spindles is two bytes long and specified by 2 ASCII digits.
spindles Reports number of bolts in the cycledata. For PowerMACS 0 and 1 are
possible numbers. In the case of 0 bolts in the cycledata the spindle specific
part is omitted (18 x 0 = 0).
Sync 02 5 The sync tightening Id is a unique Id for each sync tightening result.
tightening Id Each individual result of each spindle is stamped with this Id.
The tightening Id is incremented after each sync tightening. 5 ASCII digits.
Max 65 535. Reports Station DataNo, created when cycle is ready.
Time 03 19 YYYY-MM-DD:HH:MM:SS
Sync overall 04 1 Reports station status. The sync overall status is specified by one ASCII digit
status 1 = OK or OKR, 0 = NOK, TERMNOK or NOKRM.
Spindle 05 5 Bytes 1-2: Ordinal bolt number (01 –99)
status Bytes 3-4: Spindle number (01-99)
Number Byte 5: Reports 0 when bolt status is NOK, NOKRM or TERMNOK . Reports
of 1 when bolt status is OK or OKR.
spindles
460 9836 3521 01

Peripheral Devices
8.11.1.4 TC Result Record Formats

Number of 01 2 The number of spindles is two bytes long and specified by 2 ASCII digits.
spindles Reports number of bolts in the cycledata. For PowerMACS 0 and 1 are
possible numbers. In the case of 0 bolts in the cycledata the spindle specific
part is omitted (18 x 0 = 0).
VIN Number 02 25 The VIN number is 25 byte long and is specified by 25 ASCII characters
taken between 0x20 and 0x7F Hex. Reports Id string (CD_ST_IDDEV).
Job Number 03 2 The job number is two bytes long and always 00 as no such number is
available in PowerMACS.
Pset number 04 3 This is the pset number that is run (psetId). The pset number is three byte
long specifying a range of 000 to 999 and is specified by three ASCII digits
(„0‟….‟9‟). Reports mode number.
Batch Size 05 4 The batch size is four byte long and always 0000 as no such number is
available in PowerMACS.
Batch 06 4 The batch counter number is four byte long and always 0000 as no such
counter number is available in PowerMACS.
Batch status 07 1 The batch status is specified by one ASCII character. Always 0 as no such
number is available in PowerMACS.
Torque Min 08 6 The torque min limit is multiplied by 100 and sent as an integer (2 decimals
limit truncated). The torque min limit is six byte long and is specified by six ASCII
digits („0‟….‟9‟).
Bolt T, Min limit, from the Monitor function.
Value retrieved from the first bolt reported in the cycle data. Reports
measured value in global torque unit times 100.
Torque Max 09 6 Reports Bolt T, Max limit, from the Monitor function. Same format as Torque
limit Min limit is reported in.
Torque final 10 6 Bolt T from the Monitor function, which is the measured final torque in the
target monitor function. Same format as Torque Min limit is reported in.
Angle Min 11 5 The angle min value has a specified range between 0 and 99999. The angle
min value is five byte long and is specified by five ASCII digits („0‟….‟9‟). Bolt
A, Min limit, from the Monitor function. The value is retrieved from the first bolt
reported in the cycle data
Angle Max 12 5 Bolt A, Max limit, from the Monitor function. Same format as Angle Min limit is
reported in.
Final Angle 13 5 Bolt A from the Monitor function, which is the measured angle in the
Target monitoring function. Same format as Angle Min limit is reported in.
Date/time of 14 19 Time stamp for the last change in the current program or time for latest
last change complete download. The time stamp is 19 byte long and is specified by 19
in Pset ASCII characters (YYYY-MM-DD:HH:MM:SS).
settings
9836 3521 01 461

Peripheral Devices

Time 15 19 YYYY-MM-DD:HH:MM:SS
Sync 16 5 The sync tightening Id is a unique Id for each sync tightening result.
tightening Id Each individual result of each spindle is stamped with this Id.
The tightening Id is incremented after each sync tightening. 5 ASCII digits.
Max 65 535. Reports Station DataNo, created when cycle is ready.
Sync overall 17 1 Reports 1 when station status is OK or OKR. Reports 0 when station status
status is NOK, TERMNOK or NOKRM.
Spindle 18 18 Bytes 1-2: Ordinal bolt number (01 –99)
status Bytes 3-4: Spindle number (01-99)
Number Byte 5: Reports 0 when bolt status is NOK, NOKRM or TERMNOK. Reports 1
of when bolt status is OK or OKR.
spindles Byte 6: Reports 0 if bit CD_ERR_FTLM set for ErrorCode. Equally 2 is
reported if FTHM set. If neither FTLM nor FTHM is set 1 is reported
Bytes 7-12: Bolt T from the Monitor function for current bolt. Same format as
Torque Min limit is reported in.
Byte 13: Equal to Byte 6, but looks at bit ALM and AHM.
Byte 14-18: Bolt A from the Monitor function for current bolt. Same format as
Angle Min limit is reported in.
462 9836 3521 01

Peripheral Devices
8.11.2 DaimlerChrysler PFCS
Specify in Port No which port to use in the server.

Retries specifies how many retries should be done in case a telegram has not been able to send. Retry
Timeout specifies the timeout between retries.
The Machine ID is the identification that is sent first in all telegrams to the server and which identifies the
source of all telegrams.
Vehicle Data Timeout is the timeout used when transmitting Vehicle Data from the server to
PowerMACS.
In the text blow the server is described as PFCS (Plant Floor Communication System) and the
PowerMACS as PFD (Plant Floor Device),
The protocol is implemented according to the Daimler Chrysler document "PFCS Vendor Specifications",
revision no 4.
9836 3521 01 463

Peripheral Devices

Following message types are supported:
 0002: Test Results to PFCS from PFD
 9999: Keep alive message from PFD
PFCS can also send a 0003 message, unsolicited vehicle data, to PFD. PFD will accept the message and
return an ACK message but will currently not perform any actions.
Please see chapter Cycle Data Storage for more information about saving cycle data.
8.11.2.2 PFD Result Record Formats

The tightening results are reported to PFCS according to the specification, with following additional
information.
Field Implementation
VIN Last 6 characters of the ID string
Track Seq No Always 000000
Spindle Number Bolt number
Bolt Count Bolt number
Torque High Limit Torque high limit from the Monitor function
Torque Low Limit Torque low limit from the Monitor function
Torque Reading Torque value the Monitor function
Angle High Limit Angle high limit from the Monitor function
Angle Low Limit Angle low limit from the Monitor function
Angle Reading Angle value the Monitor function
464 9836 3521 01

Peripheral Devices
8.11.3 FSH
FSH is a protocol specified by General Motors used to communicate between the PowerMACS and the
Fastening System Host (FSH)
Specify in IP address the TCP/IP address of the Fastening system Host (FSH).
Specify in Port No which port to use in the FSH. (default is 4242)
The Station No is the identification of the TC in the FSH, this is sent in all telegrams and identifies the
source of all telegrams.
In the following text the server is described as FSH (Fastening system Host) and the PowerMACS as TC
(Torque controller),
The protocol is implemented according to the General Motors document "GAE Electric Nutrunner
Controller Design Criteria", GAEc-03 6-9-03Revision.doc.
9836 3521 01 465

Peripheral Devices

The following message types are supported:
Packet Messages
number
1 FSH Station ID No Request
2 TC Station ID No Acknowledge
3 FSH Rundown Packet Request
4 TC Rundown Packet
5 FSH Rundown Packet Acknowledge
6 TC No Rundown Packet
7 FSH Reset Buffer Request
8 TC Reset Buffer Acknowledge
15 FSH Communication Parameters Packet
16 TC Communication Parameters Packet Acknowledge
17 FSH Set Date and Time Packet
18 TC Set Date and Time Packet Acknowledge
Please see chapter Cycle Data Storage for more information about saving cycle data.
466 9836 3521 01

Peripheral Devices
8.11.3.2 TC Result Record Formats

The tightening results are reported to FSH according to the specification, with following additional
information.
Network Id IP address of TC.
Station Number Configurable via ToolsTalk PowerMACS.
Cycle Number Data Number.
Number of Spindles Reports number of bolts in the cycle data.
Parameter Set Mode number
Supplier Code "ACS".
Vehicle ID code. (PVI No) ID device string converted to a number.
Spindle Ordinal bolt number within the station.
Torque Bolt Torque from the Monitor function.
Torque Low Limit Bolt Torque, Min limit, from the Monitor function.
Torque High Limit Bolt Torque, Max limit, from the Monitor function.
Angle Bolt Angle from the Monitor function.
Angle Low Limit Bolt Angle, Min limit, from the Monitor function.
Angle High Limit Bolt Angle, Max limit, from the Monitor function.
Status Bits Completion, Torque Status, Torque Spec, Angle Status, and Angle Spec
are set in accordance to the corresponding bits in the Bolt level result
variables "Compact Errors".
The Time Status and Time Spec bits are set according to the status of the
bits TIR, TIL, TIH in the Bolt level result variables "Errors". The following
rules are used::
If neither TIR, TIL nor TIH are set then Time Status and Time
Spec are set to 0.
If at least one of TIR, TIL or TIH is set then Time Status is set to 1.
If TIL is set then Time Spec is set to 0 (regardless if TIR and/or TIH
are set as well). If only TIR and/or TIH are set then Time Spec is set to
1.
Tool Serial Number The value of the Spindle Set Up/General parameter "Spindle Serial
Number" for the spindle that was used to tighten the bolt in
question.
9836 3521 01 467

Peripheral Devices
8.11.4 DC PLUS
The PLC variables used to control this device are described in chapter DC PLUS variables.
PowerMACS supports two different versions of the DC PLUS, PDT and PQD
The PLC variables used to control this device are described in chapter DC PLUS variables.
Press the Open... button on the Details form to open the Advanced DC PLUS settings form.
The different parameters and their function are described below.
Protocol Version – There are two different versions of the protocol, PDT and PQD. The parameters
needed for the device vary a little depending on the selected version.
468 9836 3521 01

Peripheral Devices
8.11.4.1 Parameters for PDT
Station Type - There are four different station types, SAW/WIS, SPS, VBA and SSE. Controls the
behavior of the device. See the description of the different types below.
Barcode scanned - Possible choices are LI, PN and KN. Specifies the type of the scanned barcode.
VIN number type -Possible choices are PN or KN. Controls how "Wp ID" shall be treated when sending
cycle data to PLUS. Only possible to select if “Barcode scanned” is LI, otherwise the value is the same as
“Barcode scanned”.
Station ET -Possible choices are E and G. The value selected here is used as “Einzelergennis Typ Kz”
when sending tightening results to PLUS.
Station AB -The value to use as AB “Anlagen betreiber” for all bolts when sending cycle data to PLUS.
Will also be included in the cycle data as the result variable Station AB.
Use QO from PLC -Controls which value to use as QO when sending requests for TMU. If checked the
value is taken from the PLC, otherwise the value “QO for request of TMU” will be used.
QO for request of TMU -The value to use as QO when sending a request for a TMU to the PLUS server.
Only enabled if “Use QO from PLC” is unchecked and “Station Type” is SAW/WIS.
Listen Port -The port that PM listen to for PLUS connections. Valid port numbers are 20 000 – 32 767
PLUS IP Address -The IP address of the PLUS server to communicate with.
PLUS Port -The port in the PLUS server that PowerMACS connects to. Valid port numbers are 0 –
32 767.
9836 3521 01 469

Peripheral Devices
Send cycle data automatically -Controls the sending of cycle data. If checked the result from a
tightening will be sent to PLUS immediately after the cycle has finished.
If the connection to the PLUS server is broken when the cycle is finished the data will be sent when the
connection is established again.
If unchecked the sending of data is controlled by the PLC variable PLUS_DOKUENABLE instead.
Conversion table -Converts the received TMUs to a mode number. Has the same functionality as the
conversion tables used for the Stations Work piece identifier and Multiple identifiers functions.
QO/SA table -The value to use as QO, “Qualitätsaussage Orts Nr”, and SA, “Soll anzahl
Einzelergebnisse” when sending cycle data to PLUS is dependent on the mode used for the tightening.
The QO and SA to use are specified in this table with one row for each mode. If no values are specified for
a mode, cycle data produced when running this mode will not be sent to the PLUS server.
The values specified will also be included in the cycle data as the result variables Station QO and Station
SA.
The value specified as QO will also be used as AO, “Anlagen Orts Nr”, for all bolts in the cycle data.
Strings entered in the columns US if OK, US if OKR and US if NOK for a specific mode are used in the
cycle data US field. US is part of the bolt data. The bolt status is used to select the correct field in the
table.
Bolt Status Field used
OK US if OK
OKR US if OKR
NOK US if NOK
TERMNOK US if NOK
NOKRM US if NOK
If no string is entered the value in result variable Id Res 4 is used instead.

Test PLUS -When this button is pressed the connection to the PLUS server is tested. The result of the
test will be indicated as OK or NOK. The test button is only available if the advanced form is opened
connected to the target system.
470 9836 3521 01

Peripheral Devices
8.11.4.2 Parameters for PQD
Station Type - There are four different station types, SAW/WIS, SPS, VBA and SSE. Controls the
behavior of the device. See the description of the different types below.
Barcode scanned - Specifies the type of the scanned barcode.
VIN number type - Controls how "Wp ID" shall be treated when sending cycle data to PLUS. Only
possible to select if “Station Type” is SAW/WIS, otherwise the value is the same as “Barcode scanned”.
Station ET -Possible choices are E and G. Controls how OK bolts in cycles that are NOK shall be
reported to PLUS. With the selection E all bolts keep there original status, the NOK bolts are reported as
NOK and the OK bolts as OK. With the selection G ALL bolts are reported as NOK, even the bolts that
were really OK. For the originally OK bolts the string specified in Group NOK error code will be used in
the field FE, “Fehlercode Anlage”, to indicate that the bolt status was changed.
Use FP from PLC -Controls which value to use as FP when sending requests for TMU. If checked the
value is taken from the PLC, otherwise the value “FP for request of TMU” will be used.
FP for request of TMU -The value to use as FP when sending a request for a TMU to the PLUS server.
Only enabled if “Use FP from PLC” is unchecked and “Station Type” is SAW/WIS.
Listen Port -The port that PM listen to for PLUS connections. Valid port numbers are 4950 – 5050 and
20 000 – 32 767
Send cycle data automatically -Controls the sending of cycle data. If checked the result from a
tightening will be sent to PLUS immediately after the cycle has finished.
9836 3521 01 471

Peripheral Devices
If the connection to the PLUS server is broken when the cycle is finished the data will be sent when the
connection is established again.
If unchecked the sending of data is controlled by the PLC variable PLUS_DOKUENABLE instead.
Conversion table -Converts the received TMUs to a mode number. Has the same functionality as the
conversion tables used for the Stations Work piece identifier and Multiple identifiers functions.
FP table -The value to use as FP, “Fertigungspunkt” when sending cycle data to PLUS is dependent on
the mode used for the tightening. The FP to use is specified in this table with one row for each mode. If no
values are specified for a mode, cycle data produced when running this mode will not be sent to the PLUS
server.
The values specified will also be included in the cycle data as the result variables Station QO
Strings entered in the columns US if ok, US if OKR and US if NOK for a specific mode are used in the
cycle data US field. US is part of the bolt data. US is selected according the table below.
Bolt Status Station ET Station Status Field used
OK E - US if OK
OKR E - US if OKR
NOK E - US if NOK
TERMNOK E - US if NOK
NOKRM E - US if NOK
OK G OK or OKR US if OK
OKR G OK or OKR US if OKR
NOK G OK or OKR US if NOK
TERMNOK G OK or OKR US if NOK
NOKRM G OK or OKR US if NOK
OK G NOK or TERMNOK US if NOK
OKR G NOK or TERMNOK US if NOK
NOK G NOK or TERMNOK US if NOK
TERMNOK G NOK or TERMNOK US if NOK
NOKRM G NOK or TERMNOK US if NOK
If no string is entered the result variable Id Res 4 is used. If Id Res 4 is also empty eight zeros are sent
(i.e. 00000000)
Test PLUS - When this button is pressed the connection to the PLUS server is tested. The result of the
test will be indicated as OK or NOK. The test button is only available if the advanced form is opened
connected to the target system.
472 9836 3521 01

Peripheral Devices
8.11.4.3 Handling of PN, KN and LI, in protocol version PDT
The handling of PN, KN and LI are controlled by the two parameters Barcode scanned and VIN number
type.
Request for TMU

When PowerMACS requests a TMU from the PLUS server the value to use for PN, KN or LI is sampled
from the PLC variable PLUS_BARCODE. If the value shall be treated as a PN, KN or LI is controlled by
Barcode scanned, see table below.
Barcode VIN number PLUS_BARCODE Telegram sent

scanned type is treated as to PLUS
PN PN PN NSR ADAA
KN KN KN NSR KDAA
LI PN LI NSR ALAA
LI KN LI NSR KLAA
Sending results
When PowerMACS sends result data to the PLUS server the value to use for PN or KN is sampled from
the Wp ID field in the result. VIN number type controls if Wp ID shall be treated as PN or KN, see also the
table below.
Barcode VIN number Wp ID is treated Telegram sent

scanned type as: to PLUS
PN PN PN ISR ADEA
KN KN KN ISR KDEA
LI PN PN ISR ALEA
LI KN KN ISR KLEA
The Wp ID shall always begin with the letters “PN” or “KN” if everything is correct. These letters are
removed before the result is sent to PLUS.
Before the cycle data is sent Wp ID is checked for consistency. If it begins with “PN” and “VIN number
type” is KN or vice versa an event is generated. The same will also happen if the letters “PN” or “KN” is
completely missing or if the length of Wp ID is not correct. If the layout of Wp ID is wrong no data will be
sent to PLUS.
9836 3521 01 473

Peripheral Devices
8.11.4.4 Handling of QO and FP
QO and FP is the same thing, it is only the name that differs, and they are handled in the same way in
both protocol versions. In protocol version PDT the name is QO and in PQD the name is FP.
The value that PowerMACS uses as QO “Qualitätsaussage Orts Nr” is controlled by the parameters
QO for request of TMU, Use QO from PLC and the QO/SA table. The PLC system global PLUS_QO is
also used.
Request for TMU

When PowerMACS asks for a TMU the value written in QO for request of TMU is used as QO if
Use QO from PLC is unchecked.
If Use QO from PLC is checked the value of the PLC system global PLUS_QO is used instead. If the
value of PLUS_QO is not a valid QO an event is generated to inform the user and no request for TMU is
sent.
Use QO from PLC Value used as QO

Checked PLUS_QO in the PLC
Unchecked QO for request of TMU
Sending results
When PowerMACS send tightening results to PLUS the value to use as QO is taken from result variable
Station QO stored in the cycle data.
The value to store in Station QO is determined by the mode number, according to the QO/SA table. The
first mode that was started will decide the QO. In the case of stitching different modes can be used for one
tightening, but the value will always be from the first mode.
474 9836 3521 01

Peripheral Devices
8.11.4.5 SAW / WIS

In this station type, a barcode scanner is connected directly to the Station TC.
PLUS
5) Cycle data
Ethernet
3) PN or KN
Switch
and TMU
2) PN, KN
or LI
TC TC TC
1 2 3
1) PN, KN or LI
Barcode
scanner
Workflow
1. The PN, KN or LI number is read by the barcode scanner, or automatic scanner, and sent to the
TC.
2. The TC sends a request for TMU to PLUS with the PN, KN or LI that was scanned.
3. PLUS sends the TMU and PN or KN to use for the tightening to the TC.
4. The TC converts the TMU to a mode number and makes the tightening.
5. When the tightening is finished the cycle data is sent to PLUS.
9836 3521 01 475

Peripheral Devices
PLC program
The PowerMACS PLC must handle the string read from the barcode and request a TMU from PLUS.
1. The barcode is scanned and the value is put in CURRIDSTRING in the PowerMACS PLC.
2. The PowerMACS PLC copies the value in CURRIDSTRING to PLUS_BARCODE and sends a
positive edge to PLUS_GETTMU.
3. When the PLUS server has sent an answer PLUS_GETTMU_OK will be set to TRUE.
PLUS_MODE contains the mode number to use for the tightening. The received TMU is converted
to the mode number using the conversion table for the device. CURRIDSTRING contain the PN or
KN sent by PLUS with the letters “PN” or “KN” added as prefix.
4. PLUS_MODE is copied to MODE by the PowerMACS PLC. This mode is started and
CURRIDSTRING will be included as Wp. Id in the cycle data.
476 9836 3521 01

Peripheral Devices
8.11.4.6 SPS
In this station type, an external PLC controls the station. The TC gets the VIN number and mode number
from the external PLC over a field bus connection.
PLUS
Ethernet
Switch
3) Cycle data
TC TC TC
1 2 3
1) PN or KN
and Mode
Fieldbus
Line PLC
Workflow
1. The external PLC sends a PN or KN and a mode number over the field bus.
2. The TC makes the tightening with the selected mode.
PLC program
The PowerMACS PLC program will be very similar to the program used in the SAW station.
1. The line PLC sends mode number and PN or KN to PowerMACS PLC through a field bus
connection.
2. The PowerMACS PLC copies the value of PN or KN to PLUS_BARCODE and sends a positive
edge to PLUS_GETTMU.
3. Since Station type is SPS nothing is sent to PLUS. Instead the value written in PLUS_BARCODE
is directly copied to CURRIDSTRING with a “PN” or “KN” added as prefix.
4. The mode number received from the line PLC is copied to MODE, by the PowerMACS PLC. This
mode is started and CURRIDSTRING will be included as Wp. Id in the cycle data.
9836 3521 01 477

Peripheral Devices
8.11.4.7 VBA
In this station type the VIN number and TMU are sent directly from PLUS, without a request from the TC.
PLUS
3) Cycle data
Ethernet
Switch
1) PN or KN
and TMU TC TC TC
1 2 3
Workflow
1. PLUS sends PN or KN and a TMU to the TC.
2. The TC converts the TMU to a mode number and makes the tightening.
PLC program
Normal workflow:
1. PLUS sends a PN or KN and a TMU to the TC. The PN or KN is automatically copied to
CURRIDSTRING with a “PN” or “KN” added as prefix. The TMU is automatically converted to a
mode number and the result is placed in PLUS_MODE.
NSCR:
If PLUS sends the telegram NSCR it means that no tightening shall be made for the PN or KN and
TMU that was just received. This is indicated to the PLC by clearing the CURRIDSTRING and
PLUS_MODE. If this happens the PLC program must recognize this and not start a tightening.
Automatic and Manual mode:
The VBA station can operate in Automatic or Manual mode. Automatic mode is the normal case and is
the one that is describe in the picture above. In manual mode no connection to PLUS is needed, the
PLC receives the mode number from some other device and no cycle data shall be sent to PLUS. The
PowerMACS PLC must inform the TC that the station is running in manual mode with the PLC variable
PLUS_MANUALMODE to make sure no data is sent.
478 9836 3521 01

Peripheral Devices
8.11.4.8 SSE
In this station type there are no TMU, instead the PN or KN is decoded to get the mode number.
PLUS
Ethernet Switch
3) Cycle data
TC TC TC
1 2 3
1) PN or KN
Barcode
scanner
Workflow
1. The PN or KN number is read by the barcode scanner and sent to the TC.
2. The TC converts the PN or KN to a mode number and makes the tightening.
PLC program
The PowerMACS PLC program will be very similar to the program used in the SAW station.
1. The barcode is scanned and the value is put in CURRIDSTRING in the PowerMACS PLC.
2. The PowerMACS PLC copies the value in CURRIDSTRING to PLUS_BARCODE and sends a
positive edge to PLUS_GETTMU.
3. Since Station type is SSE nothing is sent to PLUS. Instead the value written in PLUS_BARCODE
is directly copied to CURRIDSTRING with a “PN” or “KN” added as prefix.
The string in PLUS_BARCODE is also sent to the conversion table for the device and the result is
placed in PLUS_MODE.
9836 3521 01 479

Peripheral Devices
8.11.4.9 TC Result Formats for PDT
The tightening results are reported to PLUS according to the specification.
Station data:
QUALITÄTSAUSSAGE-ORTS-NR QO Station QO in the cycle data.
JOB-NR JN Mode number for the tightening.
GESAMT-Q-AUSSAGE GQ Station status of a tightening.
1 = OK is sent for status OK and OKR (OK after repair)
0 = NOK is sent for status NOK and TERMNOK (failed
during termination).
GESAMT-STATUS GS Always 0
SOLL-ANZAHL-EINZELERGEBNISSE SA Station SA in the cycle data.
EINZELERGEBNIS-TYP-KZ ET The value in Station ET.
Bolt data:
EINZELERGEBNIS-NR EN Bolt number from ToolsTalk PowerMACS setup.
EINZELERGEBNIS-IDENT EI Bolt name from ToolsTalk PowerMACS setup. The bolt
number will be added at the end of the bolt name to reach 24
characters.
EINZELERGEBNIS-Q-AUSSAGE EQ Bolt status for this tightening
1 = OK is sent for status OK and OKR (OK after repair)
0 = NOK is sent for status NOK, TERMNOK (failed during
termination) and NOKRM (not successful due to reject
management)
EINZELERGEBNIS-STATUS ES Always 0
EINZELERGEBNIS-QA-DETAIL ED Customer Error Code in the cycle data.
ANLAGEN-ORTS-NR AO Will always be the same as QO for all bolts.
ANLAGEN-BETREIBER AB Station AB in the cycle data, always the same for all bolts.
USER-ID US Id Res 4 in the cycle data, always the same for all bolts.
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Result data:
Bolt level data
This table describes the data sent to PLUS if Bolt level data is reported
PI Description Value sent, PW Comment

001 Torque Bolt T The value reported from “Final Torque at cycle end”
monitoring.
The torque is multiplied by 100 and is sent as an integer (2
decimals rounded).
002 Angle of rotation Bolt A The value reported from “Angle from threshold to Cycle
End” monitoring.
Are always sent as an integer with unit degrees. The value
is rounded to nearest integer.
003 Step number 0 The step number will always be 0 to indicate that it is bolt
data
Step level data

This table describes the data sent to PLUS if step level data is reported. All the step data will come from
the same step.

001 Torque SO T, The value reported from a “Check shut off torque” check.
“Shut off torque” The torque is multiplied by 100 and is sent as an integer (2
decimals rounded).
002 Angle of rotation A The value reported by a “Check angle” check.
Are always sent as an integer with unit degrees. The value
003 Step number Step No The number of the step that produced the other data.
004 Current Peak C The highest current reached during the step. Reported by a
“Check peak torque” check running on channel T3.
The current is converted to torque, which is then multiplied
by 100 and sent as an integer (2 decimals rounded).
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8.11.4.10 TC Result Format for PQD

The tightening results are reported to PLUS according to the specification.
Station data:
Fertigungspunkt FP Station QO in the cycle data
Id-Typ IT The string specified as VIN number type
Id-Wert IW Wp. Id. In the cycle data
Q-AUSSAGE-ART AA Always „SC‟
Bolt data:
Q-AUSSAGE-IDENT QI Bolt Id from WinTC setup
Q-AUSSAGE QA Bolt status for this tightening
IO = OK is sent for status OK and OKR (OK after repair)
NIO = NOK is sent for status NOK, TERMNOK (failed during
termination) and NOKRM (not successful due to reject
management)
FEHLERCODE-ANLAGE FE Customer Error Code in the cycle data
Q-AUSSAGE-STATUS QS Always 00
USER-ID US Id Res 4 in the cycle data, always the same for all bolts.
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Result data:
The following data is possible to report to DC PLUS. By default only the Torque, Angle, Redundancy
Torque and the Step number is included. The other data can be selected in the reporter if wanted.
Bolt level data
This table describes the data sent to PLUS if the Bolt level data is reported

DM Torque Bolt T
MO Torque high limit Bolt T, high limit Only sent if limits for Bolt T is selected in the reporter
MU Torque low limit Bolt T, low limit Only sent if limits for Bolt T is selected in the reporter
RM Redundancy - No value is sent
torque
DW Angle Bolt A Are always sent as an integer with unit degrees. The value
WO Angle high limit Bolt A, high limit Only sent if limits for Bolt A is selected in the reporter
WU Angle low limit Bolt A, low limit Only sent if limits for Bolt T is selected in the reporter
RW Redundancy - This value is not possible to send.
angle
ZW Time - No value is sent
PH Step number 0 The step number will always be 0 to indicate that it is bolt
data
ST Current - No value is sent
GD Gradient - No value is sent
Step level data

This table describes the data sent to PLUS if step level data is reported. All the step data will come from
the same step.

DM Torque SO T, The value reported from a “Check shut off torque” check.
“Shut off torque” The torque is multiplied by 100 and is sent as an integer (2
decimals rounded).
MO Torque high limit SO T, high limit Only sent if limits for SO T is selected in the reporter
MU Torque low limit SO T, low limit Only sent if limits for SO T is selected in the reporter
RM Redundancy Peak C The current is converted to torque.
torque
DW Angle A Are always sent as an integer with unit degrees. The value
WO Angle high limit A, high limit Only sent if limits for A is selected in the reporter
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WU Angle low limit A, low limit Only sent if limits for SO T is selected in the reporter
RW Redundancy - This value is not possible to send.
angle
ZW Time Time The time that the step was run, measured by the Check
time check. Only sent if Time is selected in the reporter
PH Step number Step No The step number for the step that produced the other data
ST Current - Not sent, the current is used as redundancy torque, RM,
instead.
GD Gradient Grad The value produced by the Gradient Restriction. Only sent if
Grad is selected in the reporter
8.11.4.11 Selecting the data to report

Only one angle value and one torque value can be sent for each tightening. Bolt T and Bolt A are reported
in OK cycles and SO T and A (from the failing step) in NOK cycles.
If Bolt level data is reported but both Bolt T and Bolt A are empty the step data for the last step with both
SO T and A is reported instead.
8.11.4.12 Selecting the data to report

Only one angle value and one torque value can be sent for each tightening. Bolt T and Bolt A are reported
in OK cycles and SO T and A (from the failing step) in NOK cycles.
If Bolt level data is reported but both Bolt T and Bolt A are empty the step data for the last step with both
SO T and A is reported instead.
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8.11.5 I-P.M.
Specify in IP address the TCP/IP address of the I-P.M. server.

Specify in Port No which port to use in the I-P.M. (default is 5501)
Station No specifies the station number this station use to identify itself in telegrams sent to I-P.M.
Set I-P.M. Server No to the server number of the I-P.M. server (shall normally be 1).
8.11.5.1 Mapping of data

The I-P.M. implementation is done following version 3.1.11 of the I-P.M. specification with the following
additional information.
Telegram Header
Field Bytes Value sent
“AC.0001 “, the number is the station, number selected in the device in
Source 8
WinTC, numbers between 1 and 9999 are possible to use
“IPM.0001”, the number is the IPM number selected in the device in
Destination 8
WinTC, numbers between 1 and 9999 are possible to use
Identification 8 “IPM-DATA”
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Version 2 “3 “
Character Code 20 “ISO-8859-1 “
Sequence Number 4
Length of User Data 6
Byte Order 1 Always 0 = Intel byte order
Maintenance Sequence User Data

Manufacturer
5 “AC “
Identification
1 if Facility type = “Fastening” and 4 if = “Adjustment,
Facility Type 2
for the moment always 1
Date 10 Cycle start time
Time 8 Cycle start time
Maintenance Sequence,
30 See description below.
AFU-number
Event Number 15 Empty
Maintenance Sequence “Bolt name” + “-“ + “Program name”
50
Text e.g. “Bolt 01-Test run”, “Left bolt-Tighten left bolt”
Tool-ID 10 Spindle serial number from the spindle setup, if it is specified.
Unit Carrier ID 10 Result variable Id res 2, only the 10 first characters are used.
Type 10 Result variable Id res 3, only the 10 first characters are used.
Result variable Id res 1 or Wp ID, depending on the selection in the
Identification 30
I-P.M. reporter, only the 30 first characters are used.
Additional ID 10 Result variable Id res 4, only the 10 first characters are used.
0 = without trace
Curve 1
1 = with trace
0 = OK or OKR
1 = NOK, TERMNOK or NOKRM
Status 2
This is always the bolt status; a bolt can be OK even if the station is
NOK.
Mode 1 Always 0 = automatic mode
Loosen 1 “ “ = not available.
Number of additional
2 Always “0 “, no additional information is available
information
Number of Error Codes 2
Error Code (for every
5 See table below for possible error codes
error)
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Number of
2
Characteristics
Characteristic Data
Identification 5 See table below for possible values
Unit 10
Length 1
Factor 2
Algebraic Sign 1
Increment 8
Start Value 8
Actual Value 8 The result variable
Step 2 Always 1
Number of Parameters 2
For every Id 6 See table below for possible values
parameter Value 8 The value
8.11.5.2 Value sent as Maintenance Sequence (AFO-number)

The value sent in the field Maintenance Sequence is built up using the following result variables:
Station name
Spindle number
Bolt number
Program number
The layout of the maintenance sequence is controlled by the settings in the I-P.M. reporter.
The station name is put first in the maintenance sequence; the value of the field width in the reporter sets
the number of characters to use. If width is empty the whole station name is used as it is.
After the station name the spindle number and bolt number are sent if they are selected in the reporter.
The one that has the lowest order value selected in the reporter are sent first. They are added directly
after the station name without any additional characters in-between
Last in the maintenance sequence the program number is sent, if it is selected in the reporter. Between
the spindle number/bolt number and the program number the character „-„ is added. This character is only
added if a program number is sent. If the program that was used didn‟t have a program number specified,
the number 0 is used.
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For the values spindle number, bolt number and program number the setting in the field width in the
reporter sets the number of digits to use, it is padded with 0‟s to the left to reach this number of digits. If
width is empty the actual number of digits in the result value is used.
The string sent as Maintenance Sequence is left aligned and padded with spaces to reach 30 characters.
If the total numbers of characters selected are more than 30 only the first 30 (counted from left) will be
sent. In this case an event will be issued to inform the user of the occurrence.
Example: With the following settings in the reporter:
Result variable Order: Width:
Station name 1 6
Spindle number 2 3
Bolt number
Program number 4 2
Station name = Test1234

Spindle Number = 12
Bolt Number = 17
Program Number = 21
The maintenance sequence will be “Test12012-21”
8.11.5.3 Possible error codes

Value sent Meaning Corresponding PowerMACS error
1 MD-max THM, torque high monitoring
2 MD-min TLM, torque low monitoring
3 WI-max AHM, angle high monitoring
4 WI-min ALM, angle low monitoring
DEV1M, DEV2M or DEV, Deviation in interval 1 or 2 to high during
5 Angle different monitoring or Deviation to high from check. Set if any of these errors are
present.
6 Gradient max TRH, Torque rate to high from check.
7 Gradient min TRL, Torque rate to low from check.
8 Draft1 max TR1HM, torque rate 1 high monitoring
9 Draft1 min TR1LM, torque rate 1 low monitoring
10 Draft2 max TR2HM, torque rate 2 high monitoring
11 Draft2 min TR2LM, torque rate 2 low monitoring
TIH or TIL, time high or low from check
13 Not OK-Time
Also TIR, time restriction
18 Not enough WI AL, angle low from check
19 Self tap max PVTH, post view torque too high from check
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Value sent Meaning Corresponding PowerMACS error

20 Current max CH, current high from check
21 Current min CL, current low from check
22 Security, MD TR, torque restriction
23 Security, WI AR, angle restriction
499 Other error If any other error code is set.
8.11.5.4 Characteristic Identifications

Identification Meaning Value sent Unit
WI Actual value angle Bolt A Grad
MI Actual value torque Bolt T Nm
GI Actual values gradient Bolt TR1 Nm/Gr
TI Actual value time Only sent as trace data S
nd
MR Redundancy Torque Bolt A 2 Grad
nd
WR Redundancy angle Bolt T 2 Nm
8.11.5.5 Parameter Identifications

Identification Meaning Value sent
W- Lower tolerance angle Bolt A low limit
W+ Upper tolerance angle Bolt A high limit
M- Lower tolerance torque Bolt T low limit
M+ Upper tolerance torque Bolt T high limit
G- Lower tolerance gradient Bolt TR1 low limit
G+ Upper tolerance gradient Bolt TR1 high limit
MS Threshold Bolt A Thresh T
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8.11.6 Audi XML
Specify in Port No the port number to use for Port A.

Use Retry Timeout and Keep Alive Timeout to set protocol timeouts.
Specify in Port B the port number to use for Port B.
If Manual start enabled is checked it is possible to run cycles from the PLC.
If Master PC enabled is checked cycle data is sent to the Master PC.
If VW Variant is checked the VW version of the protocol is used, otherwise it is the Audi version. The Audi
XML device use an Audi/VW specific XML protocol to send cycle data to a central server called Master
PC. There are two versions of the protocol, the Audi Variant and the VW Variant.
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In the Audi Variant the Master PC controls the tightening process and sends program number and start
signal to the TC over Ethernet with the XML protocol.
In the VW Variant the control of the tightening process is done over a Fieldbus interface through the
PowerMACS PLC.
If Reset MID Always is checked the MID number is always reset when an RST telegram is received from
the Master PC, otherwise it is only reset if the MID in the RST telegram is 0.
If Use only Port B is checked the Port A connection is not used. In this case the IP address of the
Application server must be set.
With No of cycle data in queue it is possible to get a queue with cycle data stored in the Audi XML device,
for cycles ran without a connection to the Master PC / Application server. The data in the queue is sent
when the connection is established. The timer Send delay for queue sets the time to wait between each
cycle data telegram. Set No of cycle data in queue to 0 if no queue is wanted.
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8.12 Fieldbus Interface

On a tightening controller it is possible to have a fieldbus slave interface module mounted. This makes it
possible to interact with your PowerMACS system from a fieldbus master. A fieldbus device handles
access via fieldbus.
Currently the following fieldbuses are supported:
Profibus-DP and DP-V1
DeviceNet
Modbus TCP
EtherNet/IP
ProfiNet IO
Using a fieldbus device you can access the following PowerMACS functions:
Read and write PLC signals
Read cycle data
Read events
Read traces
Read and write complete setups
From PowerMACS point of view most fieldbus types looks the same.
To access the PowerMACS system via a fieldbus you first have to add a fieldbus device, as described in
chapter: Add a device, to TC that has a PLC, i.e. the first TC in a station.
A PowerMACS PLC can only access a fieldbus interface that is mounted on the same TC as the PLC is
running on.
Note! The DeviceNet GM is a special case in the sense that its input and output maps are predefined and
fixed. The inputs and outputs of the interface is not accessible from the PowerMACS PLC but are
handled by the PowerMACS station controller it self. This means that the contents of the following
chapters: Access to PLC data and Access to Process data are not valid for the DeviceNet GM
alternative.
Regardless of which type of fieldbus interface you use the following model describes how it is interfaced
with the PowerMACS system.
Note! In PLC programs generated with the setup wizard from version 7.2.0 the PLC In area starts at
address 30000 instead of 3300 and the PLC Out area starts at address 30000 instead of 3000.
On the fieldbus interface there is a memory area that is accessible from the fieldbus master as well as the
PowerMACS.
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Each fieldbus has its own characteristics regarding the amount of data it could transfer over the bus. The
data on the bus is divided in cyclic and acyclic transfer.
Cyclic transfer occurs on a regular basis between the master and the PowerMACS 4000 fieldbus. Cyclic
data is typically PLC data.
Acyclic transfer occurs only on a request from the master to the PowerMACS 4000 fieldbus. Acyclic data
is typically cycle data, traces etc.
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A summary of the features offered by the different fieldbus modules are presented in the table below. All
numbers are in bytes.
The maximum available size of the IN and OUT areas varies with the type of fieldbus as listed in the
comparison table below, all numbers are in bytes:
Profibus DP-V1
Modbus/TCP
EtherNet/IP
ProfiNet IO
DeviceNet
Item
a c d
Max. Cyclic Data (Read + Write) 512 152(400) 504 512 512
Min. Cyclic Data (Read + Write) 0 1 0 0 0
a c d
Max. Write Cyclic Data 256 152(244) 256 256 256
Min. Write Cyclic Data 0 0 0 0 0
a c d
Max. Read Cyclic Data 256 152(244) 256 256 256
Min. Read Cyclic Data 0 0 0 0 0
b
Max. Acyclic Data (Read + Write) 7680 8192 8192 8192 8192
Min. Acyclic Data (Read + Write) 0 0 0 0 0
b
Max. Write Acyclic Data 7680 8192 8192 8192 8192
Min. Write Acyclic Data 0 0 0 0 0
b
Max. Read Acyclic Data 7680 8192 8192 8192 8192
Min. Read Acyclic Data 0 0 0 0 0
a. The numbers in parenthesis are valid if the checkbox “Extended Mode” is checked.
b. Only available for DP-V1 protocol.
c. This has to be a multiple of 2 bytes.
d. This has to be a multiple of 8 bytes.
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Because the size of the areas is limited you must specify the size of each area individually using the
parameters PLC bytes In, PLC bytes Out, Data bytes In, Data bytes Out, Fast bytes In and Fast bytes
Out of the fieldbus device.
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The below picture shows how the input and output areas are divided using the parameters:
Input area Output area

0 PLC byte AT 3000 0 0 PLC byte AT 3300 0
Inputs to the
PowerMACS PLC 1 PLC byte AT 3001 1 1 PLC byte AT 3301 1
Outputs from the
2 PLC byte AT 3002 2 PowerMACS PLC 2 PLC byte AT 3302 2
Size =
: : : : : :
Fast bytes In Size =
7 PLC byte AT 3007 7 Fast bytes Out 7
Filedbus side
0 Data byte In 1 8 Filedbus side 8 : :
1 Data byte In 2 9 9 PLC byte AT 3309 9
2 Data byte In 3 10 0 Data byte Out 1 10
: : : 1 Data byte Out 2 11
Used as Process 2 Data byte Out 3 12
Data input, e.g. Used as Process : : :
to request next Data output, e.g.
cycle data. the requested
cycle data.
Size =
Data bytes In Size =
Data bytes Out
: : : : : :
29 Data byte In 30 37 99 Data byte Out 100 109
Note! You should not configure the respective input and output areas bigger then what really needed. The
reason for this is that all bytes you set up here will be transferred over the fieldbus, regardless if
they are used by the application or not.
If you want to transfer Process data over the fieldbus then you must create a Fieldbus-Reporter. How to
do this, and connect it to your fieldbus device, is described in the New reporter chapter. How to make the
Reporter format the result as you wish is described in chapter: Edit reporter.
Indication of the fieldbus status

When connected to a target system you can study the current status of the module using the
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System Map form. Select the Fieldbus device, at the bottom of the Details window Status Leds are
shown that indicate the current status of the node.
Press the button View for 30 sec to start updating the LED's. These will then show the same information
as the LED's mounted on the AnyBus board.
The function of the respective LED is specific to the fieldbus type being used. See chapter: Fieldbus
specific Information for a description.
8.12.1 Access to PLC data

For ToolsTalk to be able to move around variables in the PLC, Fieldbus variables should be placed in a
group called Fieldbus_Variables and shared variables in a group called Shared_Variables. Placing
variables in other groups will result in them not being possible to map for a fieldbus in ToolsTalk. Shared
variables must also carry the prefixes “SI_” or “SO_” in order to be mapped by the fieldbus form.
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8.12.1.1 PLC Areas
Fieldbus input signals
Address: 3000-3299
Can in ToolsTalk be mapped for fieldbus when having prefix “SI_”.
Fieldbus output signals
Address: 3300-3599
Can in ToolsTalk be mapped for fieldbus and I/O when having prefix “SO_”.
Digital input signals
Address: 1600- 1791
Can in ToolsTalk be mapped only for I/O.
Digital output signals
Address: 1600- 1791
Can in ToolsTalk be mapped only for I/O.
Shared input signals
Address: 30000-30999
Can in ToolsTalk be mapped for fieldbus and I/O when having prefix “SI_”.
Shared output signals
Address: 30000-30999
Can in ToolsTalk be mapped for fieldbus and I/O when having prefix “SO_”.
NOTE: Only boolean signals can be mapped by I/O.
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8.12.1.2 Complex data types
PM4000 has support for user-defined data types and arrays defined in SHARED_MEMORY_TYPE.
Both a complex data type and each element in the complex data type can be declared in the
Global_Variables sheet. PM4000 calculates the size of the complex type to find out how much of the area
is occupied by that variable.
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When selecting a variable for mapping to a fieldbus in TTPM, all variables declared on addresses
occupied by the complex variable are hidden from the user. When a complex variable is moved in TTPM,
all variables declared on addresses occupied by the complex variable are moved as well.
When mapping an I/O device in TTPM, only boolean variables are available to choose from. Complex data
types are hidden from the user.
Example
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The variable SO_Bolt_Status_Overall has a complex data type and is declared on address 30003. For this
example, the size of mBOLT_DATA_ARRAY_SHORT is 50 bytes. The following variables represent the
elements within mBOLT_DATA_ARRAY_SHORT and are therefore also declared on addresses starting
with 30003. These variables (SO_Running_Bolt_1, SO_OK_Bolt_1, SO_NOK_Bolt_1,
SO_Running_Bolt_2 etc.) are not available when mapping a fieldbus in TTPM. They are instead used
when mapping I/O devices, while SO_Bolt_Status_Overall is not.
If SO_Bolt_Status_Overall is mapped from the fieldbus form in TTPM, all variables between 30003 and
30052 are moved to the fieldbus area.
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8.12.1.3 Set up shared variables
A number of signals are predefined in the PLC, but signals can be added, delete, or get a changed
functionality. Signals under the group Shared_Variables in the Global variables sheet in the PLC can be
shared between I/O and fieldbus. Signals under the group Fieldbus_Variables represent the fieldbus
mapping.
When converting a setup older than version 7.5.0, the PLC will not have the same signals defined. Access
to the PLC part of the fieldbus data area from the PowerMACS PLC is configured in two steps. First you
must configure how the respective area should be used by defining variables. Secondly must configure
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the SHARED driver to correctly map the total sizes of the respective input and output data areas defined
in the first step.
The addresses for inputs and outputs starts at 30000 and are logical only. Signals added here must also
have the prefixes “SI_” or “SO_” to be able to map to fieldbus and I/O devices.
Note! All numerical values are written and read as Big Endian values, commonly referred to as Motorola
format.
When the variables are declared you are free to refer them from any POU (Program Organization Unit)
you have, or will, declare in the PLC project.
After mapping the input and outputs variables the next step is to configure the SHARED driver to copy the
input and output data from the fieldbus to the PLC and vice versa. This is done using the I/O Configuration
dialogue which is invoked by double-clicking on the icon for IO_Configuration worksheet of station that has
the fieldbus interface mounted.
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In the I/O Configuration dialogue first select the INPUT tab, select the I/O Group SHARED_in and press
the Properties button. The group name has no functionality, therefore the group can be named anything.
Change the value of Logical addresses – Length so that it corresponds to the size of your fieldbus data
declared as inputs, in this case 24.
Then select User defined Input and click the Driver Parameter-button to set up the driver information.
Name the driver SHARED.
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Then select the OUTPUT tab in the I/O Configuration dialogue, select the I/O Group SHARED_out and
press the Properties button. The group name has no functionality, therefore the group can be named
anything.
Set up address, length and driver parameter the same way as for the input driver. For both input and
output driver, the address should be 30000, driver name should be SHARED. The length can differ based
on how much data is needed for input and output variables.
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8.12.1.4 Fieldbus form
The fieldbus form is reached by pressing the "Open" button in the system map, or by double-clicking the
fieldbus directly in the map.
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The form shows a listview and a memory grid each for data in and data out. The form represent the
signals in the Fieldbus_Variables group in the PLC.
When clicking on a cell in the grid, the mapped signal is highlighted in the listview and the whole signal is
highlighted in the grid. When clicking on a signal in the listview, the signal is highlighted in the grid.
Mapping of PLC signals can only be done when not connected to a TC. Monitoring and forcing of PLC
signals can only be done when connected.
Data bytes can not be set up in this form. A link to the reporter form is available on the command bar. Only
monitoring is available for the data bytes.
Mapping of signals
When not connected to a TC, PLC signals is added either by dragging them from the dynamic tool, which
will have one list of the available insignals and one list of the available outsignals, or by right-clicking one
of the listviews.
By right-clicking a signal in any of the lists, the user can choose to edit the offset, delete signal, clear all
signals in that list, or add new signals. The alternative Pack signals in the context menu will fill holes in the
map by moving all signals towards offset 0. Signals can also be dragged and dropped if the user wants to
change the order of the signals.
The "data" part of the grids will show nothing during the mapping phase.
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Only shared signals can be mapped in the fieldbus form. A shared signal is defined by having its name
start with “SI_” or “SO_”.
Complex data types can be mapped even if their size exceeds the declared fieldbus size. Regular data
types will not be added if their size exceeds the declared fieldbus size.
When pressing the Apply button, the mapped signal in the fieldbus are being moved to the defined
address in the fieldbus area in the PLC.
A signal being deleted in the fieldbus form is moved back to the first free address in the shared area in the
PLC when pressing Apply.
Monitoring
When connected to a TC, fieldbus data is monitored in the form. A snapshot of the fieldbus data is taken
once a second and sent to TTPM from the TC. The monitored values of the PLC signals are based on the
fieldbus data and not taken directly from the PLC. This means that if the user connects to a TC without
having pressed Apply in the fieldbus form, the signal values in the fieldbus form might not be the same as
in the PLC.
Values for signals and variables will be shown in the listview. The "value" column in the listview is empty
when not connected.
Since the refreshing of values in this form is slower than then PLC, very quick data changes in the PLC
can occur without being noticed in this form.
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Force values
When connected to a TC, a signal can be forced from the fieldbus form by right-clicking the signal and
selecting Force in the context menu. The values of forced signals are marked by a star in the form. The
data is forced onto the fieldbus data map and not directly into the PLC. This means that if the user
connects to a TC without having pressed Apply in the fieldbus form, the forced values in the fieldbus form
might not force the same signal in the PLC.
The force list can be reset from the command bar. Values can only be forced when connected to a TC and
when the fieldbus form is open. On disconnection from the TC, the TC will reset the force list
automatically.
Only the PLC bytes can be forced.
8.12.2 Access to Process data

Accesses to the Process data, i.e. Cycle data, events, trace and setup, by the fieldbus master are done by
read and write accesses to the Process data areas.
Because Process data normally is bigger than would fit into the areas available they are read by use of a
special handshake sequence. This is described in chapter: Process data.
Also, since the same area (address) is used for accesses to all kinds of process data the input and output
areas are prefixed with a command and a status word respectively. These are used to specify what to do,
and with what kind of data. The Process data areas are therefore used as follows:
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Peripheral Devices
P ro c e s s d a ta P ro c e s s d a ta
B yte B yte
IN a re a O U T a re a
0 C M D (M o st S ig n ific a n t B yte ) 0 S T S (M o st S ig n ifica n t B yte )
1 C M D (L e a st S ig n ific a n t B yte ) 1 S T S (L e a st S ig n ific a n t B yte )
2 2
3 D a ta : D a ta
: TO FROM
P o w e rM A C S P o w e rM A C S
: :
D a ta b yte s In – 1 D a ta b yte s O u t – 1
The first word in the IN area is used as Command (CMD). The fieldbus master writes commands in this to
request PowerMACS perform a task.
The first word in the OUT area is used as Status (STS) in which PowerMACS writes information to
indicate the result of the command issued.
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Peripheral Devices
The CMD word is laid out as follows:
Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
Name R W F S X d2 d1 d0 - - - - - - - -
The respective bits have the following meaning:
Name Meaning Usage

R Read Set one (1) to read the process data selected with DataType.
W Write Set one (1) to write the process data selected with DataType.
F Flush Set one (1) to flush the data queue selected with DataType. Flushing will delete all
items in the specified process data queue. However, a data item currently being read
will not be deleted. It can safely be read also after that this command has been issued.
S Skip Set one (1) to skip reading of the current data item in the data queue selected with
DataType. Next reading will return next data item (or the first part of it) in the queue.
X Extended This bit is normally 0.
format If this bit is set then which process data queue to read is not specified using the d2..d0.
Instead the queue is specified using an address following the CMD byte. See Using the
extended format for a detailed description. This can be used for to access more data to
the PLC then the particular fieldbus allows.
d2..d0 DataType Specifies which process data queue the command is issued for.
d2 d1 d0
DataType = 4 + 2 + 1 d. Allowed values of DataType are:
1: Cycle data queue
2: Event queue
3: Trace queue
4: Setup
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The STS word is used as follows:
Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
Name R W F S X d2 d1 d0 s7 s6 s5 s4 s3 s2 s1 s0
Bit 15 to 8 just mirrors the corresponding bits in the CMD word.

The bits named s7 to s0 represents the status code that PowerMACS returns after executing the
command. They should be interpreted as a signed 8 bit value where a value greater or equal to zero
indicates a positive result, and negative values a failure. Currently the following status codes are defined:
Status code Description

0 Success
-1 Illegal process data specified
-2 Illegal size of the process data area
-3 Device is not properly connected
-4 Error in sequence number
-5 Received setup is too big
-15 Unknown error
-16 Size of Data bytes In to small for the requested service
-17 Size of Data bytes Out to small for the requested service
-18 The specified Process Data type cannot be flushed/skipped
-19 Ambiguous Command (more than one of the R, W, F & S bits are set)
-20 Invalid Extended format
-21 Invalid Address
-22 Fieldbus read error
-23 Fieldbus write error
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Peripheral Devices
When the Fieldbus master wants to read or write anything via the PowerMACS process data interface it
has to follow the following basic rules:
1. Read the STS word to ensure that it is zero.
2. If not zero then write zero to the CMD word to acknowledge that the previous data/result has been
read.
3. Wait for the STS word to become zero. This is PowerMACS way to indicate that it is ready to
receive a new command.
4. Write the wanted command to the CMD word.
5. Wait for the high byte (bit 15...8) of the STS word to become equal to the written in the CMD word.
This is PowerMACS way to acknowledge that the command is received and executed.
6. Check that the low byte (bit 7...0) of the STS word is zero. This indicates that the command was
executed successfully. If reading, the output data is now valid.
7. When finished, with reading of data and/or the STS word, write zero to the CMD word to
acknowledge that the result is read.
Example on how to read process data:

To read Process data the fieldbus master should use the following handshake sequence:
Fieldbus master PowerMACS

1 Sets CMD = R + DataType
2 Loads data in the OUT area
Sets STS = R + DataType + Status
3 Reads data from the OUT area
Sets CMD = 0
4 Sets STS = 0
5 Waits until STS = 0
Example on how to write process data:

To write Process data the fieldbus master should use the following handshake sequence:
Fieldbus master PowerMACS

1 Writes data in the IN area
Sets CMD = W + DataType
2 Reads data from the IN area
Sets STS = W + DataType + Status
3 Sets CMD = 0
4 Sets STS = 0
5 Waits until STS = 0
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Whenever one of these sequences is executed a new package of data is transferred to, or from, the
PowerMACS system.
Since most types of Process data are too big to fit into the available area it is split up into packages. Each
access will transfer a new package. The data part of the IN and the OUT areas are therefore further dived
into several fields in order to handle transferring sequence of packages.
See chapter: Process data for a detailed description of this. There is also described how the respective
Process data is formatted.
Normally no data is written to the Process Data out area unless the client first has requested so. However,
by checking the Load Cycle Data automatically check box for the fieldbus device (see System ) the
PowerMACS system will automatically load the first package of a cycle data when the cycle is finished.
The data will only be written if the Process Data out area is free for PowerMACS to write to. The area is
considered free as long as the fieldbus master do not already have a read or write transaction ongoing
(i.e. it have issued a command but not yet written zero (0) to the CMD word to indicate that it has read the
response). If a Cycle Data is generated when the output area is not free then it will be lost. It will not be
written automatically when the area becomes free again.
An automatically written cycle data is formatted exactly the same way as if the fieldbus master had used
the CMD to request it. That is, in addition to the result data, the STS, SEQ, and LEN fields are also
properly assigned.
After reading automatically loaded data the fieldbus master do not need to indicate that he is done
reading by writing zero (0) to the CMD word.
All normal Process Data functions over the fieldbus are supported in parallel. This means that the fieldbus
master may request Events, Traces as well as Cycle Data's (from the FIFO queue) if so wanted. However,
the master must be aware of that doing so may interfere with the automatic loading of Cycle Data.
Typically the master should issue such commands only in-between cycles and after the last generated
Cycle Data have been read.
Note 1: It is only the first package of a cycle data that is written automatically to the board. This means
that if the cycle data is bigger then the Process data output area, i.e. Data bytes Out, then the
client must request the remaining packages by using normal read request. See chapter: Process
data for a description detailed description of how a cycle data is divided in packages.
Note 2: When using Load Cycle Data automatically the fieldbus master must ensure that it is done
reading data before starting a new cycle.
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8.12.2.1 Using the extended format

The Extended format gives you an alternative method of specifying the targeted type of process data.
When using this method you specify what to read or write to using an address instead of the bits d2..d0 in
the command word. The address is the same as used for the Serial Communication (see its sub chapter:
Accesses from External communication device).
An advantage of using this method is that you in addition of accessing the traditional process data, i.e.
cycle data, trace, and events, also can read and write to the PLC input/output area normally used for the
External communication devices and the API.
The address is specified in the first word of the Process data, i.e. the word following next after the
command word. I.e. Process data should be laid out as below:
P ro c e s s D a ta
0 T a rg e t A d d r (M S B )
1 T a rg e t A d d r (L S B )
2
3 M essage
D a ta
: (m b yte s )
m + 1
The layout of Message Data depends on whether the targeted data is of type "Process Data" (i.e. Cycle
Data, Event Data, Trace Data and Setup Data) or "PLC Data".
M e s s a g e D a ta M e s s a g e D a ta a s
to /fro m th e P L C P ro c e s s D a ta
0 L E N (M S B ) 0 S E Q (M S B )
1 L E N (L S B ) 1 S E Q (L S B )
2 D a ta b yte 1 2 L E N (M S B )
3 D a ta b yte 2 3 L E N (L S B )
LEN LEN
: 4 D a ta b yte 1
n + 1 D a ta b yte n 5 D a ta b yte 2
:
n + 3 D a ta b yte n
The format of Process Data is the very same as used the External communication devices, but the format
of PLC Data is slightly different. For the fieldbus device the first word of the Message Data specifies the
length of data to be read or written. If writing, this is then followed with as many bytes of PLC data that is
specified.
Also, note that if the extended format is used for the command then the target address of the command
will be included in the response as well.
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See chapter: Process data for a description of how the Process Data is laid out and how SEQ and LEN is
used.
Example: To write the ten characters ID code "ABCDEFGHIJ" to the PLC input starting at address
2010 the following should be written to the fieldbus process data input:
0 0 x4 8 C M D (M S B )
1 0 x0 0 C M D (L S B )
2 0 x0 0 T a rg e t A d d r. (M S B )
3 0 x0 A T a rg e t A d d r. (L S B )
4 0 x0 0 L E N (M S B )
5 0 x0 A L E N (L S B )
6 0 x4 1 A
7 0 x4 2 B
8 0 x4 3 C
9 0 x4 4 D
10 0 x4 5 E
11 0 x4 6 F
12 0 x4 7 G
13 0 x4 8 H
14 0 x4 9 I
15 0 x4 A J
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8.12.3 Fieldbus specific Information

Most field buses are handled the same way by the PowerMACS system but some of them have a number
of extra parameters. These are described in the following sub chapters.
8.12.3.1 DeviceNet
The Anybus-CC DeviceNet communication module provides instant DeviceNet Real Time connectivity via
the host interface and supports the following features:
DeviceNet communication, with baud rates 125, 250 and 500kbps
Up to 256 bytes of Real Time I/O
Up to 7060 bytes of acyclic data such as cycle data, trace etc.
Generic EDS-file.
Use Name to specify the name of the device. This name should be
referred to when you create a reporter for the fieldbus using the New
reporter form.
Fieldbus Type should be set to DeviceNet.
Use Node addr. field to set the node address. Node address can be
set to [0..63]. Use the Baud Rate to set the baud rate to 125, 250 or
500 Kbit/s.
See chapter: Fieldbus Interface for a description on PLC bytes In,
PLC bytes Out, Data bytes In, and Data bytes Out.
The parameter Fast bytes In defines the size (in bytes) of the input
data that is transferred as cyclic, or real time, IO data on the DeviceNet
network. Max value is PLC bytes In + Data bytes In. Leaving the
parameter "blank" will make all input data transferred as IO data.
Fast bytes Out defines the size (in bytes) of the output data that is
transferred as cyclic IO data on the DeviceNet network. Max value is
PLC bytes Out + Data bytes Out. Leaving the parameter “blank" will
make all output data transferred as IO data.
Note: The max size of Fast byte In/ Out is depended on the fieldbus
type and could be found in the table in chapter Fieldbus Interface.
The "fast" areas always start at offset zero (0) of the respective input or
output area. The remaining part of the respective areas is transferred
as acyclic data.
The input as well as the output area of the DeviceNet module is divided
in data blocks. The maximum size of each block is 64 bytes. For
example, if 400 bytes output is configured it will be available as seven
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blocks, the first six contains 64 * 6 = 384 bytes and the seventh 16 bytes.
Inputs to PowerMACS (that is, the AnyBus OUT area) are mapped as follows:
Class Id Acyclic block No (bytes) Instance Id Attribute Id
0xA2 - Acyclic Data Input 1 (0 .. 63) 0x05 0x05
2 (64 .. 127) 0x06 0x05
3 (128 .. 191) 0x07 0x05
: : : :
118 (7488 .. 7551) 0x7B 0x05
119 (7552 .. 7615) 0x7C 0x05
120 (7616 .. 7679) 0x7D 0x05
Outputs from PowerMACS (that is, the AnyBus IN area) are mapped as follows:
Class Id Acyclic block No (bytes) Instance Id Attribute Id

0xA2 - Acyclic Data Output 1 (0 .. 63) 0x81 0x05
2 (64 .. 127) 0x82 0x05
3 (128 .. 191) 0x83 0x05
: : : :
118 (7488 .. 7551) 0xF7 0x05
119 (7552 .. 7615) 0xF8 0x05
120 (7616 .. 7679) 0xF9 0x05
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With parameters set as in the above example the input and output areas are mapped as below:
Input to Fieldbus side Output from Fieldbus side

PowerMACS PowerMACS
0 PLC byte AT 3000 0 0 0 PLC byte AT 3300 0 0
Fast bytes In = 16
Fast bytes Out = 22

2 PLC byte AT 3002 2 REAL TIME 2 2 PLC byte AT 3302 2 2
IO Data
: : : 16 bytes : : : : :
14 PLC byte AT 3014 14 14 14 PLC byte AT 3314 14 REAL TIME 14
15 PLC byte AT 3015 15 15 15 PLC byte AT 3315 15 IO Data 15
22 bytes
0 Data byte In 1 16 Acyclic data 0 0 Data byte Out 1 16 16
block 1
1 Data byte In 2 17 64 bytes 1 1 Data byte Out 2 17 17
: : : : : : :
Class id=A2
62 Data byte In 63 78 Inst id=05 62 4 Data byte Out 5 20 20
Attrib id=05
63 Data byte In 64 79 63 5 Data byte Out 6 21 21
64 Data byte In 65 80 Acyclic data 0 6 Data byte Out 7 22 Acyclic data 0
65 Data byte In 66 81 block 1 1 7 Data byte Out 8 23 block 1 1
64 bytes 64 bytes
: : : : : : : :
Class id=A2 Class id=A2
126 Data byte In 127 142 Inst id=06 62 68 Data byte Out 69 84 Inst id=81 62
Attrib id=05 Attrib id=05
64 bytes 64 bytes
: : : : : : : :
190 Data byte In 191 206 Inst id=07 62 132 Data byte Out 133 148 Inst id=82 62
: : : : : : : : : :
64 bytes 10 bytes
: : : : : : : :
398 Data byte In 399 414 Inst id=0B 14 398 Data byte Out 399 414 Inst id=87 8
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Peripheral Devices
Three LED‟s on the AnyBus module indicate the status of the DeviceNet. These LED:s can also be
displayed from the System Map form, see Indication of the fieldbus node’s for how to do this.
The function of the respective LED is as follows:
LED Function Indicates

1 Network status Steady off – Not Online / No Power.
Steady Green – On-line, one or more connections established.
Steady Green (1 Hz) – On-line, no connections established.
Steady Red – Critical Link Failure.
Flashing Red (1 Hz) – One or more connections timed-out.
2 Module status Steady off –No Power.
Steady Green – Operating in normal condition.
Flashing Green (1 Hz) – Missing or incomplete configuration.
Steady Red –Major Fault(s).
Flashing Red (1 Hz) – Minor Faults(s).
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8.12.3.2 Profibus DP and DP-V1

The Anybus-CC Profibus communication module provides instant
Profibus Real Time connectivity via the host interface and supports the
following features:
Profibus communication, with baud rates 12 Mbps (auto detect by
the module)
Up to 152/244 bytes of Real Time I/O
Acyclic data can be accessed from the network using DP-V1
read/write services.
Generic GSD-file.
Use Name to specify the name of the device. This name should be
referred to when you create a reporter for the fieldbus using the New
reporter form.
Fieldbus Type should be set to DeviceNet.
Use Node addr. field to set the node address. Node address can be set
to [0..125].
See chapter: Fieldbus Interface for a description on PLC bytes In, PLC
bytes Out, Data bytes In, and Data bytes Out.
The parameter Fast bytes In defines the size (in bytes) of the input data
that is transferred as cyclic, or real time, IO data on the ProfiNet IO
network. Max value is PLC bytes In + Data bytes In. Leaving the
parameter "blank" will make all input data transferred as cyclic IO data.
Fast bytes Out defines the size (in bytes) of the output data that is
transferred as cyclic IO data on Profibus network. Max value is PLC
bytes Out + Data bytes Out. Leaving the parameter “blank" will make all output data transferred as cyclic
IO data.
The "fast" areas always start at offset zero (0) of the respective input or output area. The remaining part of
the respective areas is transferred as acyclic data.
The input as well as the output area of the Profibus module is divided in data blocks. The maximum size of
each block is 64 bytes. For example, if 400 bytes output is configured it will be available as seven blocks,
the first six contains 64 * 6 = 384 bytes and the seventh 16 bytes.
The parameter Extended Mode is a checkbox that chooses between the 152 bytes data mode and the
368 bytes data mode. When this checkbox is unchecked the backward compatible 152 bytes data mode is
chosen, and when checked the new 368 bytes data mode is chosen.
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A GSD-file for the different data modes are included in the installation kit and are named 321-2932-
HMS_1811.gsd for the 152 bytes data mode and Ext_321-2932-HMS_1811.gsd for the 368 bytes data
mode.
Note! The 368 bytes data mode requires that the AnyBus module has at least software and hardware
versions greater than or equal to 2.0. It is likely that Profibus modules already delivered with systems are
too old and cannot be used for this mode. If the 368 bytes data mode is used on an old module the
following event will be generated ANYBUS: TC %d: Error! Module version (%x) does not support
Extended Mode, and the module has to be replaced. When using the 368 bytes data mode there is a
limitation of max 244 bytes input or output. Do not use extended mode if 152 bytes of fast data is
enough for your application.
Inputs to PowerMACS (that is, the AnyBus OUT area) are mapped as follows:
Command Acyclic block No (bytes) Slot No Index
DP-V1 / write services 1 (0 .. 63) 4 3
2 (64 .. 127) 4 4
3 (128 .. 191) 4 5
: : : :
126 (8000 .. 8063) 4 128
127 (8064 .. 8127) 4 129
128 (8128 .. 8191) 4 130
Command Acyclic block No (bytes) Slot No Index
DP-V1 / read services 1 (0 .. 63) 8 7
2 (64 .. 127) 8 8
3 (128 .. 191) 8 9
: : : :
126 (8000 .. 8063) 8 132
127 (8064 .. 8127) 8 133
128 (8128 .. 8191) 8 134
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Fast bytes In = 16
Fast bytes Out = 22

2 PLC byte AT 3002 2 REAL TIME 2 2 PLC byte AT 3302 2 2
IO Data
: : : 16 bytes : : : : :
14 PLC byte AT 3014 14 14 14 PLC byte AT 3314 14 REAL TIME 14
15 PLC byte AT 3015 15 15 15 PLC byte AT 3315 15 IO Data 15
22 bytes
0 Data byte In 1 16 Acyclic data 0 0 Data byte Out 1 16 16
block 1
1 Data byte In 2 17 64 bytes 1 1 Data byte Out 2 17 17
: : : : : : :
Slot No=4
62 Data byte In 63 78 Index=3 62 4 Data byte Out 5 20 20
block 1 block 1
64 bytes 64 bytes
: : : : : : : :
Slot No=4 Slot No=8
126 Data byte In 127 142 Index=4 62 68 Data byte Out 69 84 Index=7 62
block 1 block 1
64 bytes 64 bytes
: : : : : : : :
Slot No=4 Slot No=8
: : : : : : : : : :
block 1 block 1
16 bytes 10 bytes
: : : : : : : :
Slot No=4 Slot No=8
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Three LED‟s on the AnyBus module indicate the status of the Profibus. These LED:s can also be

1 Operation Mode Steady off – Not online / No Power.
Steady Green – On-line, data exchange.
Flashing Green – On-line, clear.
Flashing Red (1 flash)- Error in "Set Prm service".
Flashing Red (2 flashes)- Error in "Chk_Cfg service".
2 Status Steady off – No power or not initialized.
Steady Green – Initialized.
Flasing Green – Initialized, diagnostic event(s) present.
Steady Red - Exception Error.
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Peripheral Devices
8.12.3.3 ProfiNet IO
The Anybus-CC PROFINET IO communication module provides instant PROFINET Real Time
connectivity via the host interface and supports the following features:
ProfiNet IO communication, up to 100Mbps full duplex
Generic GSD-file.
Use Name to specify the name of the device. This name should
be referred to when you create a reporter for the fieldbus using
the New reporter form.
Fieldbus Type should be set to ProfiNet IO.
Specify with IP address the address the AnyBus-CC module
initially should have on the network. Also specify the Subnet
mask and the IP address of an optional Gateway. These data can
be changed by the ProfiNet IO Master when connected.
Alignment defines the size (in bytes) of the individual input and
output modules that are used when the I/O area is configured on
the ProfiNet master. The size of the used modules must be equal
to the value of Alignment. Since max 64 modules can be used
Alignment also controls the maximum size of data that can be
transferred as cyclic IO data, see table below.
See chapter: Fieldbus Interface for a description on PLC bytes
In, PLC bytes Out, Data bytes In, and Data bytes Out.
The parameter Fast bytes In defines the size (in bytes) of the
input data that is transferred as cyclic, or real time, IO data on the
ProfiNet IO network. Max value is PLC bytes In + Data bytes In.
Leaving the parameter "blank" will make all input data transferred
as cyclic IO data.
Fast bytes Out defines the size of the output data that is
transferred as cyclic IO data on the ProfiNet IO network. Max
value is PLC bytes Out + Data bytes Out. Leaving the parameter
“blank" will make all output data transferred as cyclic IO data.
The "fast" areas always start at offset zero (0) of the respective
input or output area. The remaining part of the areas are
transferred as acyclic data on the ProfiNet IO network.
The input as well as the output area of the Profinet IO module is divided in data blocks. The maximum size
of each block is 64 bytes. For example, if 600 bytes output is configured it will be available as ten blocks,
the first nine contains 64 * 9 = 576 bytes and the tenth 24 bytes.
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The AnyBus-CC IN and OUT areas can be configured to a maximum size according to the following table:
Alignment Max fast bytes In/Out Max Acyclic bytes In/Out

Note
(Total) (Total)
64/64 8192/8192 Mapped as an 8 bit byte
1
(64) (8192) array.
128/128 8192/8192 Mapped as a 16 bit word
2
(128) (8192) array.
256/256 8192/8192 Mapped as a 32 bit double
4
(256) (8192) word array.
256/256 8192/8192 Mapped as a 64 bit quad
8
(512) (8192) word array.
Note: When the cyclic IO data is configured on the ProfiNet IO master side it must be done in the following
order:
1. All data sent from the master to PowerMACS
2. All data sent from PowerMACS to the master
Acyclic data Inputs to PowerMACS are sent with “Write record” commands and acyclic data Outputs from
PowerMACS are sent with “Read record” commands and are mapped to parameter data as follows:
Index
API Slot Subslot Parameter block address
Input Output
0 0 1 1024 2048 0 – 63
0 0 1 1025 2049 63 – 127
0 0 1 1026 2050 128 – 191
0 0 1 1027 2051 192 – 255
0 0 1 1028 2052 256 – 319
0 0 1 1029 2053 320 – 383
0 0 1 1030 2054 384 – 447
: : : : :
0 0 1 1145 2169 7744 – 7807
0 0 1 1146 2170 7808 – 7871
0 0 1 1147 2171 7872 – 7935
0 0 1 1148 2172 7936 – 7999
0 0 1 1149 2173 8000 – 8063
0 0 1 1150 2174 8064 – 8127
0 0 1 1151 2175 8128 – 8191
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Peripheral Devices
Note: Each index represents a parameter block that is 64 byte long but depending of the configured size
of the acyclic data the last block could be less than 64 bytes.
Fast bytes Out = 22

0 PLC byte AT 3000 0 Fast bytes In = "Empty" 0 0 PLC byte AT 3300 0 0
: : : : : : : :
REAL
15 PLC byte AT 3015 15 15 15 PLC byte AT 3315 15 TIME 15
IO Data
: : : : : : :
REAL API 0
TIME Slot 0
: : : IO Data : : : : SubSlot 1 :
Index 2048
88 Data byte In 89 104 104 68 Data byte Out 69 84 Length 64 62
API 0
Slot 0
: : : : : : : SubSlot 1 :
Index 2049
154 Data byte In 155 170 170 : : : : :
API 0
: : : : 263 Data byte Out 264 279 1
Slot 0
175 Data byte In 176 191 191 : : : SubSlot 1 :
Index 2052
299 Data byte Out 300 315 37
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Peripheral Devices
Three LED‟s on the AnyBus module indicate the status of the ProfiNet IO. These LED:s can also be

1 Network status Steady off – No power applied to module or no connection established
Steady Green – Connection with IO Controller established.
– IO Controller in RUN State.
Flashing Green – Connection with IO Controller established.
– IO Controller in STOP State.
2 Module status Steady off – No power applied to module or module I SETUP state
Steady Green – Normal operation.
Green, 1 flash – Diagnostic event present.
Green, 2 flashes – Used by engineering tools to identify the node on the
network.
Steady Red – Major internal error detected
Red, 1 flash – Expected Identification differs from Read Identification.
Red, 2 flashes – IP address not set.
Red, 3 flashes – Station name not set.
Red, 4 flashes – Module has encountered a major internal error.
4 Link/Activity Steady off – No link, no communication present.
Steady Green – Ethernet link established no communication present.
Flashing Green – Ethernet link established communication present.
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8.12.3.4 Modbus TCP

The Anybus-CC Modbus TCP communication module provides instant Modbus TCP communication via
Modbus TCP communication, with 10/100Mbit, full/half duplex operation
Acyclic data can be accessed from the network.
the New reporter form.
Fieldbus Type should be set to Modbus TCP.
Specify with IP address the address the Modbus TCP module

should have on the network. Also specify the Subnet mask and
the IP address of an optional Gateway.
The parameter Fast bytes In defines the size (in bytes) of the
input data that is transferred as cyclic, or real time, IO data on the
ProfiNet IO network. Max value is PLC bytes In + Data bytes In.
Leaving the parameter "blank" will make all input data transferred
as cyclic IO data.
Fast bytes Out defines the size (in bytes) of the output data that
is transferred as cyclic IO data on the Modbus TCP network. Max
value is PLC bytes Out + Data bytes Out. Leaving the
parameter “blank" will make all output data transferred as I/O
data.
The "fast" areas always start at offset zero (0) of the respective
input or output area. The remaining part of the respective areas is
transferred as acyclic data.
The input as well as the output area of the Modbus TCP module
is divided in data blocks. The maximum size of each block is 32
bytes. For example, if 400 bytes output is configured it will be
available as thirteen blocks, the first twelve contains 32 * 12 =
384 bytes and the thirteenth 16 bytes.
Special address map is used to get a different address map
seen from the fieldbus. See chapter below.
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The AnyBus-S Modbus TCP communication module acts as a server and supports the following Modbus
TCP commands:
Function Sub Function Name Register Affects Area Addressing

code code type See note 1 method
1 - Read coils 0 IN/OUT Bit
2 - Read Input discrete 1 IN/OUT Bit
3 - Read multiple registers 4 IN/OUT Word
4 - Read input registers 3 IN/OUT Word
5 - Write coil 0 OUT Bit
6 - Write single register 4 OUT Word
15 - Write multiple coils 0 OUT Bit
16 - Write multiple registers 4 OUT Word
23 - Read/Write multiple 4 IN/OUT Word
registers
43 14 Read Device Identification - - -
Note 1: IN/OUT here refer to the client side. That is, IN is input to the client (output from PowerMACS)
and OUT is output from the client (input to the PowerMACS).
The Modbus TCP IN and OUT areas can be configured to a maximum size of 8192 bytes. The input and
output areas of the PowerMACS fieldbus device are available from the Modbus TCP network side as
registers. Each register represents a word of data on the fieldbus device.
The Fast bytes IN area (output from PowerMACS) using 04: Input Register:
Word addr Bit address

0x000 0x0000 0x0001 0x0002 0x0003 0x0004 … 0x000E 0x000F
0x001 0x0010 0x0011 0x0012 0x0013 0x0014 … 0x001E 0x001F
... ... ... ... ... ... … ... ...
0x1FFF 0x1FFF0 0x1FFF1 0x1FFF2 0x1FFF3 0x1FFF4 … 0x1FFFE 0x1FFFF
The Fast bytes OUT area (input to PowerMACS) using 03: Holding Register:

0x000 0x0000 0x0001 0x0002 0x0003 0x0004 … 0x000E 0x000F
0x001 0x0010 0x0011 0x0012 0x0013 0x0014 … 0x001E 0x001F
... ... ... ... ... ... … ... ...
0x1FFF 0x1FFF0 0x1FFF1 0x1FFF2 0x1FFF3 0x1FFF4 … 0x1FFFE 0x1FFFF
The Acyclic IN area (output from PowerMACS) using 03: Holding Register:
9836 3521 01 531

Peripheral Devices

0x8200 0x82000 0x82001 0x82002 0x82003 0x82004 … 0x8200E 0x8200F
0x8201 0x82010 0x82011 0x82012 0x82013 0x82014 … 0x8201E 0x8201F
... ... ... ... ... ... … ... ...
0xA1FF 0xA1FF0 0xA1FF1 0xA1FF2 0xA1FF3 0xA1FF4 … 0xA1FFE 0xA1FFF
The Acyclic OUT area (input to PowerMACS) using 03: Holding Register:

0x4200 0x42000 0x42001 0x42002 0x42003 0x42004 … 0x4200E 0x4200F
0x4201 0x42010 0x42011 0x42012 0x42013 0x42014 … 0x4201E 0x4201F
... ... ... ... ... ... … ... ...
0x61FF 0x61FF0 0x61FF1 0x61FF2 0x61FF3 0x61FF4 … 0x61FFE 0x61FFF
Special address map

PM4000 uses Anybus-CC modules as fieldbus interfaces. The address map for this, seen from the
fieldbus, is different from the predecessor Anybus-S, which is used in PM Classic and PowerFocus.
It is possible to get a form of compatibility by marking the Special address map checkbox. The address
map will then resemble the one in Anybus-S for function 23, the combined Read/Write Multiple registers.
Address map, PM4000 (Anybus-CC) PM4000 (Anybus-CC) PM Classic, PowerFocus

Func 23 Standard address map Special address map
Read 256..511 0..255 0..2047
Write 0..255 1024..1279 1024..2047
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Peripheral Devices
With parameters set as in the example above the input and output areas will be mapped as below (note
that he offsets are in words):
Input to Fieldbus side Output from Fieldbus side

PowerMACS PowerMACS
0 PLC word AT 3000 0 Fast bytes In = 16 0 0 PLC word AT 3300 0 0
Fast bytes Out = 22

1 PLC word AT 3002 1 FAST 1 1 PLC word AT 3302 1 1
IO Data
2 PLC word AT 3004 2 8 words 2 2 PLC word AT 3304 2 2
FAST
: : : Addr.= 000
: : : : IO Data :
Reg. = 3 11 words
6 PLC word AT 3012 6 6 6 PLC word AT 3312 6 6
7 PLC word AT 3014 7 7 7 PLC word AT 3314 7 Addr.= 000 7
Reg. = 4
0 Data word In 1 8 0 0 Data word Out 1 8 8
Acyclic data
1 Data word In 2 9 block 1 1 1 Data word Out 2 9 9
16 words
: : : : 2 Data word Out 3 10 10
Addr.= 4200
14 Data word In 15 22 Reg.= 3 14 3 Data word Out 4 11 0
Acyclic data
15 Data word In 16 23 15 4 Data word Out 5 12 block 1 1
16 Data word In 17 24 0 : : : 16 words :
Acyclic data
17 Data word In 18 25 block 2 1 17 Data word Out 18 25 Addr.= 8200 14
16 words Reg.= 3
: : : : 18 Data word Out 19 26 15
Addr.= 4210
Reg.= 3
Acyclic data
31 Data word In 32 39 15 20 Data word Out 21 28 block 2 1
16 words
32 Data word In 33 40 0 : : : :
Acyclic data Addr.= 8210
33 Data word In 34 41 block 3 1 33 Data word Out 34 41 14
Reg.= 3
16 words
: : : : 34 Data word Out 35 42 15
Addr.= 4220
46 Data word In 47 54 14 : : : : :
Reg.= 3
:
: : : : : 192 Data word Out 193 200 Acyclic data 1
block 13
191 Data word In 192 199 0 : : : 16 words :
Acyclic data
192 Data word In 193 200 block 13 1 198 Data word Out 199 206 Addr.= 82C0 6
8 words Reg.= 3
: : : : 199 Data word Out 200 207 7
198 Data word In 199 206 Addr.= 42C0 6
Reg.= 3
199 Data word In 200 207 7
9836 3521 01 533

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Three LED‟s on the AnyBus module indicate the status of the Modbus TCP. These LED:s can also be

1 Network Status Off - No power or no IP address
Green - Module is in Process Active or Idle state
Flashing Green - Waiting for connections
Red - Duplicate IP address, or FATAl event
Flashing Red - Process Active Timeout
2 Module Status Off – No power
Green - Normal operation
Red - Major fault; module is in state EXCEPTION(or FATAL event)
Flashing Red - Minor fault
3 Link/Activity Off – No link, no activity
Green - Link established
Flickering Green - Activity
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8.12.3.5 Ethernet/IP
The System Map looks as below for an Ethernet/IP fieldbus device.
The AnyBus-CC Ethernet/IP module acts as a server and
supports the Assembly Object (class id = 0x04) for I/O data input
and output.
the New Reporter form.
Fieldbus Type should be set to EtherNet/IP.
Specify with IP address the address the AnyBus-CC board
should have on the network, seen from a client. Also specify the
Subnet mask and the IP address of an optional Gateway.
The AnyBus-CC IN and OUT areas can be configured to a
maximum size of 256 bytes each.
Inputs to PowerMACS (that is, the AnyBus OUT area) are
mapped as follows:
Class Id I/O or Param block No Instance Id Attribute Id

0x04 – Assembly Object I/O block No 1 0x96
I/O block No 2 0x97
0x03
I/O block No 3 0x98
I/O block No 4 0x99
9836 3521 01 535

Peripheral Devices
Class Id I/O or Param block No Instance Id Attribute Id

0x04 – Assembly Object I/O block No 1 0x64
I/O block No 2 0x65
0x03
I/O block No 3 0x66
I/O block No 4 0x67
The AnyBus-CC module (from version 2.05) has instances for Input only and Listen only. There are two
versions for both: normal and extended. The numbering of these instances can be changed by marking
Use extended instances.
Instance Default Use extended instances
Input Only 3 6
Listen Only 4 7
Input Only Extended 6 3
Listen Only Extended 7 4
This way it is possible to switch between normal and extended mode without having to change instance
numbering in other equipment.
The version of the AnyBus board is presented in the System Map. If the extended numbering is wanted,
and the version is 2.03 or older, please contact Atlas Copco to get a description on how to upgrade the
AnyBus board firmware to a newer version.
Three LED‟s on the AnyBus-CC board indicate the status of the EtherNet/IP and the AnyBus card. These
LED:s can also be displayed from the System Map form, see Indication of the fieldbus node's status in
the manual for how to do this.

1 Network Status Steady off – No power or no IP address
Flashing Green – On-line, no connections established
Steady Green – On-line, one or more connections established (CIP Class 1 or 3)
Flashing Red – One or more connections timed out (CIP Class 1 or 3)
Steady Red – Duplicate IP address or FATAL error
2 Module Status Steady off – No power
Flashing Green – Not configured or Scanner in Idle state
Steady Green – Controlled by a scanner in Run state
Flashing Red – Recoverable fault(s)
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Steady Red – Major fault (EXCEPTION-state, FATAL error)
3 Link/Activity Off – No link, no activity
Steady Green – Link established
Flickering Green – Activity
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8.12.3.6 CC-Link
The Anybus-CC CC-Link IO communication module provides instant CC-Link Real Time connectivity via
All profiles for a Remove Device (default PLC profile)
Selectable baud rates from 156 Kbit/S to 10 Mbit/S
Number of occupied stations: 1-4
Support for CC.Link version 2.0 with extended data
The interface for CC-Link provides data areas for PLC Data only. It is not possible to read or write Process
Data directly. Reporting result data via CC-Link can be accomplished by adding a PLC device that makes
the data available in the PLC. This data can then be forwarded to the CC-Link master as normal PLC
Data.
Use Name to specify the name of the device.
Fieldbus Type should be set to CC-Link.
The PLC bytes In and PLC bytes Out are read only and calculated
automatically depending on the specified configuration. See chapter:
Fieldbus Interface for a description on PLC bytes In and PLC bytes
Out.
Use the Baud Rate to set the baud rate to 156 Kbit/S, 625 Kbit/S, 2.5
Mbit/S, 5 Mbit/S or 10 Mbit/S
Station No defines the number that identifies this station on the CC-
Link network. The highest number depends on the number of stations
that this node occupies.
No. of stations controls how many CC-Link stations that this node
occupies on the CC-Link net. The sum of Station No and No. of
stations can not exceed 65.
No. of extension cycles is available for CC-Link version 2.0 and
enables the use of extended data.
VersionNo is used to set the desired CC-Link version.
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The following table shows the available sizes for PLC bytes In and PLC bytes Out.
CC-Link version 1:
No. of Points Total, in bytes PLC bytes
stations in/Out
1 32 bits / 12 12/12
4 words
2 64 bits / 24 24/24
8 words
3 96 bits / 36 36/36
12 words
4 128 bits / 48 48/48
16 words
CC-Link version 2.0 :

1 Extension Cycle 2 Extension Cycles 4 Extension Cycles 8 Extension Cycles
PLC bytes
PLC bytes
PLC bytes
PLC bytes
stations
Points
Points
Points
Points
in/Out
in/Out
in/Out
in/Out
No. of
1 32 bits / 12/12 32 bits / 20/20 64 bits / 40/40 128 bits / 80/80

4 words 8 words 16 words 32 words
1
1
16 words 32 words 64 words 128
words
1
When using this configuration the PLC bytes In and PLC bytes Out are limited to 256 each.
The PLC bytes In and Out data areas is mapped so that all data bits (bit points) are placed first (beginning
at offset zero) then followed by the data words (word points). See chapter: Fieldbus Interface for more
information on how the input and outputs are accessed by the PLC.
Since this fieldbus type does not handle Process Data directly it is not possible to connect a Reporter to it.
With parameters set as in the above example the input and output areas is mapped as below:
9836 3521 01 539

Peripheral Devices
P o w e rM A C S C C -L in k m a s te r P o w e rM A C S C C -L in k m a s te r
b yte In p u t a re a O u tp u t b yte O u tp u t a re a In p u t
0 P L C b o o l A T 30 0 0 .0 Y 0 (b it 0 ) 0 P L C b o o l A T 33 0 0 .0 X 0 (b it 0 )
: P L C b o o l A T 30 0 0 .1 Y 1 (b it 1 ) : P L C b o o l A T 33 0 0 .1 X 1 (b it 1 )
: : Y : : : X :
0 P L C b o o l A T 30 0 0 .7 Y 7 (b it 7 ) 0 P L C b o o l A T 33 0 0 .7 X 7 (b it 7 )
D a ta D a ta
1 P L C b o o l A T 30 0 1 .0 b its Y 8 (b it 8 ) 1 P L C b o o l A T 33 0 1 .0 b its X 8 (b it 8 )
: : : : : :
7 P L C b o o l A T 30 0 7 .7 Y 6 3 (b it 6 3 ) 7 P L C b o o l A T 33 0 7 .7 X 6 3 (b it 6 3 )
8+9 P L C w o rd A T 30 0 8 RWw W o rd 1 8+9 P L C w o rd A T 33 0 8 RW r W o rd 1
10+11 P L C w o rd A T 30 1 0 W o rd 2 10+11 P L C w o rd A T 33 1 0 W o rd 2
D a ta D a ta
: : w o rd : : : w o rd :
22+23 P L C w o rd A T 30 2 2 re g iste rs W o rd 8 22+23 P L C w o rd A T 33 2 2 re g iste rs W o rd 8
Two LED‟s on the AnyBus module indicate the status of the CC-Link. These LED:s can also be displayed
from the System Map form, see Indication of the fieldbus node’s for how to do this.

1 Run Steady off – No network participation, timeout status (no power).
Steady Green – Participating, normal operation.
Steady Red – Major fault (FATAL error).
2 Error Steady off – No error detected (no power).
Steady Red – Major fault (Exception or FATAL event).
Red, flickering – CRC error (temporary flickering).
Red, flashing – Station Number or Baud rate has changed since startup
(flashing)
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8.13 Serial Communication

The serial communication devices support the following protocols:
Siemens 3964R
Telemechanique UNI-TE
SATT Comli
Allen-Bradley Data Highway (Plus)
JBUS
Via an external communication device you can access the following PowerMACS functions:
Read and write PLC signals
Read cycle data, events and traces
Read and write complete setups
E xte rn a l C o m m u n ica tio n D e vic e
W rite R ead
IN E xt. co m m . d e vice
0 -4 9 9 6 0 0 0 -9 9 9 9 (1 0 0 0 -4 0 0 0 ) 5 0 0 -9 9 9 6 0 0 0 -9 9 9 9 (1 0 0 0 -4 0 0 0 )
PLC PLC P ro ce ss PLC PLC P ro ce ss

2499 2499
a re a 1 a re a 2 d a ta a re a 1 a re a 2 d a ta
2 0 0 0 -2 4 9 9 8 0 0 0 -1 1 9 9 9 2 5 0 0-2 9 9 9 8 0 0 0-1 1 9 9 9 OUT
PLC P ro ce ss D a ta
R e p o rte r
Q ueues
C yc le
T ig h te n in g C o n tro lle r d a ta E ve n ts T ra ce s S e tu p
9836 3521 01 541

Peripheral Devices
To enable access to PowerMACS via a serial protocol add an external communication device as
described in previous chapter. Add it to a TC that has a PLC, i.e. the first TC in a station. Set up which
Type of protocol to use, which port to use and port characteristics.
If you want to transfer Process data over the external communication device then you must first create a –
Reporter for it. How this is done is described in the chapter: New reporter and Edit reporter.
8.13.1 Accesses from External communication device

To access data in PowerMACS external devices should perform normal read and write operations.
Depending on address different data is available:
Address Data Length Read/Write

0..999 Variables in PLC area 1 Length of area as defined by drivers EXTCOM_in R/W
and EXTCOM_out on the IO_Configuration
worksheet
1000 Cycle data 2..Max R/W
2000 Events 2..Max R/W
3000 Traces 2..Max R/W
4000 Setup 2..Max R/W
6000-9999 Variables in PLC area 2 Length of area as defined by drivers EXTCO2_in and R/W
EXTCO2_out on the IO_Configuration worksheet
Max depends on which serial protocol that is used.

A read or write to an address between 0 and 999 will access a memory that the PLC on that TC can
access, thereby providing a way to communicate with the PLC. See the chapter: Access to PLC data for
how to enable this.
The PLC area 2 at address 6000-9999 can be used for transfer of large data, e.g. formatted cycle data.
The PLC must set a positive flank (0->1) in the system global UPDATE_EXTCO2 to get this area updated.
By accessing address 1000-4000 the external device can get access to Process data.
542 9836 3521 01

Peripheral Devices
It might seem odd to write to the Cycle Data, Event and Trace queues but by writing a two-byte integer to
one of the corresponding address you can control the queues as follows:
Value Action
-2 Skips reading of the current data item in the data queue. Next read will return next data item (or the
first part of it) in the queue.
-1 Flush the data queue. All items in the specified process data queue are deleted. However, the data
item currently being read will not be deleted. It can safely be read also after that this command has
been issued. To remove the current data item you have to issue a skip command.
0 Rewind the data queue to the oldest value data item available in the central SRAM storage.
1..32767 Here value is interpreted as an earlier received device specific sequence number (DataNo) to which
the queue should be re-winded.
When the queue is read the next time the item that corresponds to DataNo = Value + 1 will be
returned, if it exists in the queue.
If it no longer exists in the queue then the item returned will have DataNo set to Value + 2 to indicate
this.
For Event and Trace the DataNo is always included in the item read. For Cycle data you must
include it manual using the reporter for this.
Note! If the external communication device is added to a TC that also has an API device then the PLC
data area will be shared with corresponding area used by the API, Application Programmers
Interface. If you use these simultaneously you must co-ordinate the use of the cells to avoid
unwanted collisions.
9836 3521 01 543

Peripheral Devices
8.13.2 Access to PLC data

The external devices accesses the PLC data by simple read and write accesses to address 0..999 and/or
8000-11999. How these respective areas are used internally is configured using the PowerMACS PLC by
defining variables and connecting them with logic written using, for example, function blocks. This way the
PLC programmer can set up exactly which signals to transfer via the serial protocol.
Access to the PLC part of the External communication device data area from the PowerMACS PLC is
configured in two steps. First you must configure how the respective area should be used by defining
variables. Secondly must configure the EXTCOM and/or EXTCO2 driver(s) to correctly map the total sizes
of the respective input and output data areas defined in the first step.
The input and output areas of the fieldbus are mapped to PLC variables by declaring them in the
ExtCom_API_Var section of the Global_Variables worksheet for the station that the device is connected
to:
The addresses above are logical, meaning that a PLC variable declared at the logical address 2000 will
correspond to address 0, that is, the first byte in the PLC input area of the external communication device.
544 9836 3521 01

Peripheral Devices
Likewise a variable declared at the logical address 2500 is mapped to address 0 of the output area of the
device. For best performance you should not define bigger areas than necessary.
When the variables are declared you are free to refer them from any POU (Program Organization Unit)
you have, or will, declare in the project.
After mapping the input and outputs variables the next step is to configure the EXTCOM and/or EXTCO2
driver(s) to copy the input and output data from the external communication device to the PLC and vice
versa. This is done using the I/O Configuration dialogue which is invoked by double-clicking on the icon for
IO_Configuration worksheet of station to which the device is connected.
In the I/O Configuration dialogue first select the INPUT tab, mark the I/O Group EXTCOM_in or
EXTCO2_in and press the Properties button.
Change the value of Logical addresses – Length so that it corresponds to your needs. See How to map
input and outputs below for a description of the possible choices.
Then configure the copying of output data by selecting the EXTCOM_out or EXTCO2_out I/O Group on
the OUTPUT tab of the I/O Configuration dialogue and pressing the Properties button.
9836 3521 01 545

Peripheral Devices
How to map input and outputs
The mapping between the areas inside the PowerMACS PLC and the external communication device
addresses are as follows:
For the EXTCOM_in/out driver
PLC address XCOM device address

2000..2999 0..999
For the EXTCO2_in/out driver
PLC address XCOM device address

8000..11999 6000..9999
How much of the respective areas to use for inputs and/or outputs is set up using the drivers as explained
below. Please note that if an area is used for both inputs and outputs the outputs must be located directly
after the inputs.
Example:
Correct Erroneous
Inputs 8000..8999 8000..8999
Outputs 9000..9999 10000..10999
Note! All numerical values are written and read as Big Endian values (commonly referred to as Motorola
format).
8.13.3 Access to Process data

The external device accesses the Process Data areas by normal read and writes accesses.
Since Process Data quite often is bigger than what can be transferred using a single read or write
operation all process data handling are done by splitting up each process data item into smaller parts
called packages. Each access will transfer a new package. The external device must then put the
packages together to recreate the original data. How to do this is described in chapter: Process data.
8.13.4 Serial Communication Protocol Information

Serial communication devices use serial protocols to communicate with PowerMACS. Chapters below do
not describe the protocols in full detail but gives a brief description of major characteristics and how they
are used with PowerMACS.
The communication is for all protocols based on simple read and write operations. Examples of character
flow are included for two types of communication:
Read five integers at address 500..509, i.e. PLC outputs area, address 2500..2509
546 9836 3521 01

Peripheral Devices
Write five integers at address 0..9, i.e. PLC input area, address 2000..2009
External device is indicated with XD, PowerMACS with PM. Data that are irrelevant for PowerMACS are
indicated with „*‟.
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Peripheral Devices
8.13.4.1 JBUS
Two types of commands are used:
Word read (function 3) to read data from PowerMACS
Multiple word write (function 16) to write data in PowerMACS
Checksum is calculated as CRC-16 for all bytes from the first byte (slave no) up until the checksum.
PowerMACS will respond to all telegrams independent of Slave no from XD.
R e a d in g 5 in te g e rs a t a d d re s s 5 0 0 W ritin g 5 in te g e rs a t a d d re s s 0
XD PM Com m ent XD PM Com m ent
0 x0 0 * S la ve n o 0 x0 0 * S la ve n o
0 x0 3 R e a d co m m a n d 0 x1 0 W rite co m m a n d
0 x0 1 A d d re ss, M S B 0 x0 0 A d d re ss, M S B
0 xF 4 A d d re ss, L S B 0 x0 0 A d d re ss, L S B
0 x0 0 S ize in w o rd s, M S B 0 x0 0 S ize in w o rd s, M S B
0 x0 5 S ize in w o rd s, L S B 0 x0 5 S ize in w o rd s, L S B
0 xC 4 C h e cks u m , L S B 0 x0 A S ize in b yte s
0 x1 6 C h e cks u m , M S B xx D a ta
: 5 x (M S B -L S B )
0 x0 0 S la ve n o xx C h e cks u m , L S B
0 x0 3 R e a d co m m a n d xx C h e cks u m , M S B
0 x0 A N u m b e r o f b yte s
xx D a ta 0 x0 0 S la ve n o
: 5 x (M S B -L S B ) 0 x1 0 W rite co m m a n d
xx C h e cks u m , L S B 0 x0 0 A d d re ss, M S B
xx C h e cks u m , M S B 0 x0 0 A d d re ss, L S B
0 x0 0 S ize in w o rd s, M S B
0 x0 5 S ize in w o rd s, L S B
0 x0 1 C h e cks u m , L S B
0 xD B C h e cks u m , M S B
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Peripheral Devices
8.13.4.2 Siemens 3964R

Two types of commands are used:
A-telegram for writing data to PowerMACS
E-telegram for reading data from PowerMACS
Checksum is calculated as XOR for all bytes from the first byte after STX up until and including ETX.
0 x0 2 STX 0 x0 2 STX
0 x1 0 DLE 0 x1 0 DLE
0 x0 0 * 0 x0 0 *
0 x0 0 * 0 x0 0 *
0 x4 5 „E ‟ 0 x4 1 „A ‟
0 x4 4 „D ‟ 0 x4 4 „D ‟
0 x0 1 A d d re ss, M S B 0 x0 0 A d d re s s, M S B
0 x0 0 S ize in w o rd s, M S B 0 x0 0 S ize in w o rd s, M S B
0 x0 5 S ize in w o rd s, L S B 0 x0 5 S ize in w o rd s, L S B
0 x0 0 * 0 x0 0 *
0 x0 0 * 0 x0 0 *
0 x1 0 DLE xx D a ta ,
0 x0 3 ETX : 5 x (M S B + L S B )
0 xE 2 C h e cks u m 0 x1 0 DLE
0 x1 0 DLE 0 x0 3 ETX
xx C h e cks u m
0 x0 2 STX 0 x1 0 DLE
0 x1 0 DLE
0 x0 0 0 x0 2 STX
0 x0 0 0 x1 0 DLE
0 x0 0 0 x0 0
0 x0 0 E rro r n u m b e r 0 x0 0
xx D a ta 0 x0 0
: 5 x (M S B -L S B ) 0 x0 0 E rro r n u m b e r
0 x1 0 DLE 0 x1 0 DLE
0 x0 3 ETX 0 x0 3 ETX
xx C h e cks u m 0 x1 3 C h e cks u m
0 x1 0 DLE 0 x1 0 DLE
9836 3521 01 549

Peripheral Devices
8.13.4.3 Telemechanique UNI-TE
Five types of commands are used:
Read object (command 0x36) reading data from PowerMACS.
Write object (command 0x37) for writing data to PowerMACS
Identification (command 0x0F) for identification of PowerMACS
Protocol Version (command 0x30) for protocol version used in PowerMACS
Mirror (command 0xFA) for performance measurement between the master and PowerMACS
For Read and Write object the supported segments and types are:
Segment 0x68, Type 0x07 (internal word number)
Segment 0x68, Type 0x08 (internal double word number)
Checksum is calculated as the modulo-256 sum of all bytes from and including DLE-STX up until and
including the last character before the checksum.
If PowerMACS is configured with slave number = 1..255 it will respond only if Slave no from XD is the
correct one. If slave number = 0 PowerMACS will respond to any Slave no from XD.
See next page for an example of using the Read object and Write object command
550 9836 3521 01

Peripheral Devices
Reading 5 words at address 500 Writing 5 words at address 0

XD PM Comment XD PM Comment
0x10 DLE 0x10 DLE
0x02 STX 0x02 STX
0x00 Slave no 0x00 Slave no
0x0E Length of rest of data 0x18 Length of rest of data
0x14 * Type of addressing 0x14 * Type of addressing
0x01 * Network 0x01 * Network
0x02 * Station 0x02 * Station
0x03 * Gate 0x03 * Gate
0x04 * Module 0x04 * Module
0x05 * Channel 0x05 * Channel
0x36 Read command 0x37 Write command
0x00 * Category 0x00 * Category
0x68 * Segment 0x68 * Segment
0x07 * Type 0x07 * Type
0xF4 Address LSB 0x00 Address LSB
0x01 Address MSB 0x00 Address MSB
0x05 Length LSB 0x05 Length LSB
0x00 Length MSB 0x00 Length MSB
0xD2 Checksum xx Data,
0x06 ACK : 5 x (MSB+LSB)
xx Checksum
0x10 DLE 0x06 ACK
0x05 ENQ
0x00 Slave no 0x10 DLE
0x10 DLE 0x05 ENQ
0x02 STX 0x00 Slave no
0x00 Slave no 0x10 DLE
0x0A Length 0x02 STX
0x14 Type of address 0x00 Slave no
0x01 * Network 0x07 Length
0x02 * Station 0x14 Type of address
0x03 * Gate 0x01 * Network
0x04 * Module 0x02 * Station
0x05 * Channel 0x03 * Gate
0x66 Confirm 0x04 * Module
0x07 * (Type) 0x05 * Channel
xx Data, 0xFE Confirm
: 5 x (MSB+LSB) 0x3A Checksum
xx Checksum 0x06 ACK
0x06 ACK
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8.13.4.4 SATT Comli
Checksum is calculated as XOR for all bytes from the first byte after STX up until and including ETX.
Data bytes have reverse bit order, i.e. bit7 = bit0, bit6 = bit1 etc. PowerMACS will respond to all telegrams
independent of Destination from XD.
0 x0 2 STX 0 x0 2 STX
0 x3 0 * D e stin a tio n , M S B , „0 ‟ 0 x3 0 * D e stin a tio n , M S B , „0 ‟
0 x3 1 * D e stin a tio n , M S B , „1 ‟ 0 x3 1 * D e stin a tio n , M S B , „1 ‟
0 x3 1 S ta m p , „1 ‟ 0 x3 1 S ta m p , „1 ‟
0 x3 2 R e a d co m m a n d , „2 ‟ 0 x3 0 W rite co m m a n d , „0 ‟
0 x3 0 A d d re ss, d ig it 1 , „0 ‟ 0 x3 0 A d d re ss, d ig it 1 , „0 ‟
0 x4 6 A d d re ss, d ig it 3 , „F ‟ 0 x3 0 A d d re ss, d ig it 3 , „0 ‟
0 x3 0 S ize , d ig it 1 , „0 ‟ 0 x3 0 S ize , d ig it 1 , „0 ‟
0 x4 1 S ize , d ig it 2 , „A ‟ 0 x4 1 S ize , d ig it 2 , „A ‟
0 x0 3 ETX xx D a ta ,
0 x0 3 C h e cks u m : 5 x (M S B + L S B )
0 x0 3 ETX
0 x0 2 STX xx C h e cks u m
0 x3 0 D e stin a tio n , M S B , „0 ‟
0 x3 0 D e stin a tio n , M S B , „0 ‟ 0 x0 2 STX
0 x3 1 S ta m p , „1 ‟ 0 x3 0 D e stin a tio n , M S B , „0 ‟
0 x3 0 „W rite ‟ co m m a n d 0 x3 0 D e stin a tio n , M S B , „0 ‟
0 x3 0 A d d re ss, d ig it 1 , „0 ‟ 0 x3 1 S ta m p , „1 ‟
0 x3 1 A d d re ss, d ig it 2 , „1 ‟ 0 x3 1 W rite co n firm , „1 ‟
0 x4 6 A d d re ss, d ig it 3 , „F ‟ 0 x0 6 ACK
0 x3 4 A d d re ss, d ig it 4 , „4 ‟ 0 x0 3 ETX
0 x3 0 S ize , d ig it 1 , „0 ‟ 0 x0 6 C h e cks u m
0 x4 1 S ize , d ig it 2 , „A ‟
xx D a ta ,
: 5 x (M S B + L S B )
0 x0 3 ETX
xx C h e cks u m
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8.13.4.5 Allen-Bradley Data Highway (Plus)

Two types of commands are supported, unprotected read for reading data from PowerMACS and
unprotected write for writing data to PowerMACS. Checksum is calculated as the 2‟s complement of the
modulo-256 sum of all bytes from the first byte after DLE-STX up until but not including DLE-ETX.
PowerMACS will respond to all telegrams independent of destination DST from XD.
XD PM C om m ent XD PM C om m ent
0 x1 0 D LE 0 x1 0 D LE
0 x0 2 STX 0 x0 2 STX
0 x0 2 * DST 0 x0 2 * DST
0 x0 1 * SRC 0 x0 1 * SRC
0 x0 1 CMD 0 x0 8 CMD
0 x0 0 * STS 0 x0 0 * STS
0 x0 5 * TN S, LSB 0 x0 5 * TN S, LSB
0 x0 0 * TNS, MSB 0 x0 0 * TNS, MSB
0 x0 1 A d d re ss, M S B 0 x0 0 A d d re ss, M S B
0 x0 A S ize in b yte s 0 x0 A S ize in b yte s
0 x1 0 D LE xx D a ta ,
0 x0 3 ETX : 5 x (L S B + M S B )
0 xF 8 C h e cks u m 0 x1 0 D LE
0 x1 0 D LE 0 x0 3 ETX
0 x0 6 ACK xx C h e cks u m
0 x1 0 D LE
0 x1 0 D LE 0 x0 6 ACK
0 x0 2 STX
0 x0 1 DST 0 x1 0 D LE
0 x0 2 SRC 0 x0 2 STX
0 x4 1 CMD 0 x0 1 DST
0 x0 0 STS 0 x0 2 SRC
0 x0 5 TN S, LSB 0 x4 8 CMD
0 x0 0 TNS, MSB 0 x0 0 STS
xx D a ta , 0 x0 5 TN S, LSB
: 5 x (L S B + M S B ) 0 x0 0 TNS, MSB
0 x1 0 D LE 0 x1 0 D LE
0 x0 3 ETX 0 x0 3 ETX
xx C h e cks u m 0 xB 0 C h e cks u m
0 x1 0 D LE 0 x1 0 D LE
0 x0 6 ACK 0 x0 6 ACK
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8.14 API, Application Programmers Interface

The API, Application Programmers Interface, is an interface to the PowerMACS TC system that makes it
possible to access data in the PowerMACS TC from, externally written, custom applications.
The PowerMACS API is a software library that serves as the interface between the custom application and
the PowerMACS TC. This means that it exports a number of functions that the custom application can call
in order to access the PowerMACS target system without needing to know the details on how they are
performed. Today the PowerMACS API exports functions for performing the following tasks:
Read and write PLC signals from/to the PowerMACS station PLC
Read cycle data from the PowerMACS system
Read events from the PowerMACS system
Read traces from the PowerMACS system
Read and write complete setups from/to PowerMACS system
Read or write individual parameters in a setup stored in a PowerMACS system
Any PC
C u s to m A p p lic a tio n
T h is is a n a p p lica tio n w ritte n b y yo u F ile S ys te m

u s in g e .g . V is u a l B a s ic , V is u a l C + + ,
E xc e l (V B m a c ro s ), o r a n y o th e r
e n v iro n m e n t s u p p o rtin g A c tiv e X .
p o w e rM A C S O ra c le D a ta b a s e
G e tC yc le D a ta
API
G e tE v e n t
E xc e l
G e tT ra c e
M S A ccess
T C P /IP
S ta c k
E th e rn e t
TC1 TC2 TCn

(S ys te m
Node) ...
554 9836 3521 01

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The PowerMACS API handles all communication needed between the PC, on which the custom
application resides, and the PowerMACS TC targets involved. The developer of the custom application
needs only to know which function(s) to call, and in some cases how the returned data is formatted.
When the custom application invokes one of the API functions the API first translates the request to
commands understood by the target TC. These are then sent to the target TC via the TCP/IP connection.
Thereafter the API waits for the answer to be returned. When the answer is received it is interpreted and
in some cases translated to a more easily understood format before the API returns the answer to the
custom application.
Custom applications using the API can be run on any PC that is connected to a PowerMACS TC via
TCP/IP. It need not be the Console Computer, that is, the PC running ToolsTalk PowerMACS. However,
only one custom application may use a specific API instance of a specific TC system at the time. The only
information needed in order to establish a connection between the API and the specific target system is
the IP-address and Port No (Primary/Secondary instance) of a TC in the system executing a station
function.
Technically the PowerMACS API is implemented as a Microsoft ActiveX component. The main advantage
with having the API implemented as an ActiveX component is that it provides a standardized way of
describing its public interface. This makes it possible for a developer to use more or less any of the
existing development environments that runs on a Windows machine when creating applications.
Before using the PowerMACS API you must install the component on the PC you are going to use it from.
Executing the PowerMACS API install kit distributed on the same CD as the ToolsTalk PowerMACS install
kit does this.
The install kit will copy the component to the computer in question and make all necessary registrations. It
also installs two small custom application examples, one written in Visual Basic and one written as a VBA
macro in Excel, which shows you how to use the API. Given that you have access to a running
PowerMACS TC you can also use it to verify that the component was correctly installed.
After installing the PowerMACS API you can start to develop applications performing tasks not covered by
the standard PowerMACS system. Typical cases are:
Storing cycle data on disk, or in a data base, in any customer specific format
Sending cycle data to an external SPC program
Sending or receiving data via any serial protocol
Backing up setups on a central server
Etc.
To access a PowerMACS system via the API the target system in question must be set up to allow access
via the API. Adding an API device to the first TC, or any other TC executing a station function, in the
system enables this access. See chapter: Add a device for how to do this.
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An API device can be located on the TCs running a station controller. Each of these TCs may have up to
two API devices making it possible for two clients to access the same cycle data, traces, etc. If more than
one device is configured on a particular TC the value of the parameter Port No must be used by the client
software to distinguish between them. This is done using the property DeviceInstance of the Api object.
Before being able to access signals in one of the PowerMACS station PLCs via the API you must enable
the input and output areas in the PLC. How this is done is described in the chapter: Access to PLC data.
Note! The PLC input and output data areas are shared with the areas used by the external
communication devices. This means that if an external communication device is located on TC 1
then the PLC data areas that this device accesses is the same as the area accessed via the API
interface. If you use these simultaneously you must co-ordinate the use of the cells to avoid
unwanted collisions.
If you want to fetch Process data, that is cycle data, events, traces, etc., then you must also add a
Reporter that refers to the API device. Use the Reporter to configure if you want cycle data, events and/or
traces to be accessible from the API. Also, define how cycle data should be formatted, if data is sent in
readable format, i.e. as characters, or in binary format. It is important to understand that it is the
configuration of this reporter that controls the layout and format of the cycle data returned by the API
methods GetCycleData and GetCycleDataBin.
Note! When your client application first instantiate an Api object it can take some time for the
PowerMACS API ActiveX server to start up. If you are experience any problems accessing a
property/method of the newly created Api instance you should make your application wait some
time for the server to be started.
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C o n s o l C o m p u te r
E xte rn a l
SPC
P a cka g e
R e m o te C lie n t
S to rin g
A p p lica tio n
IF d a ta
W rite API R ead API
E th e rn e t
A P I d e v ic e (s e rv e r)
0 499 (1 0 0 0 -4 0 0 0 ) 500 999 (1 0 0 0 -4 0 0 0 )
PLC P ro c e ss PLC P ro c e ss
IN OUT
a re a d a ta a re a d a ta
2000 2499 2500 2999
PLC P ro ce ss D a ta
R e p o rte r
Q ueues
C yc le E ve n ts T ra ce s S e tu p
T ig h te n in g C o n tro lle r d a ta
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8.14.1 Subscriptions
This function requires API version 10.1.0 or later and TC software version 7.2.3 or later.
Process data can be fetched by cyclically calling read functions. It is also possible to set up subscriptions
that will automatically call application functions when new data has arrived. This will make the response
fast without increasing the load.
To handle subscriptions the application should define specific ActiveX event functions. When new data
arrives the API will raise an ActiveX event which calls these functions. Inside these functions the
application can take care of the received data.
The parameters of the ActiveX event functions vary depending on type of subscribed data.
Subscribed Data Parameters

Cycle Data Station, Id
Event EventData object
Trace Station, Bolt, Spindle, ID, Status
Station Status Station, Station status, Mode, Workpiece ID, Number of bolts, Bolt status
The application should call subscribe methods to switch subscriptions on or off.

Note! The event functions are called on the API communication thread. This will not continue execution
until the event function is finished. Therefore, do not do any lengthy handling inside the event function.
Also beware that the GUI is executed on a different thread. Trying to update any GUI control directly from
within the event function can cause unpredictable results.
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8.14.2 Object model

The below picture describes how the objects of the PowerMACS API are related to each other:
Api
S yste m
S ta tio n s S ta tio n
T ra ce D a ta B o lts B o lt
C h a n n e ls C hannel
S te p B o u n d s S te p B o u n d
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8.14.3 Enumerators exported by the API

The PowerMACS API exports a number of enumerated types representing return values, possible control
strategies and statuses.
RetCodeEnum
This enumerator lists the codes being returned by the functions of the API
Constant Description
eRetOk = 0 Function executed OK
eRetCmdNotAllowed = -20 Command not allowed
eRetNotOk = -51 Function did not execute OK for reasons other then listed below
eRetTimeout = -52 No answer was received from the TC within 4 seconds
eRetBufferToSmall = -53 The buffer supplied is not big enough for the returned data
eRetIpAddress = -54 IP–address is invalid
eRetConnectError = -55 A TCP/IP connection cannot be established to the specified IP-address
eRetWrongPlcAddress = -56 Incorrect PLC address (check parameters Address and/or Bit)
eRetNoData = -57 The data requested (Cycle data, Event, Trace or Setup) is not available.
eRetNotSupported = -58 Command not supported by the current version of TC SW
eRetWrongDataType = -59 Supplied data type not supported
eRetBufferToBig = -60 Write buffer is too big
eKeyNecessary = -61 Necessary USB key not found
SeverityEnum
This enumerator lists the possible Severities of an event (see View Event Log for a description of
Severity).
eSevInfo = 0 The event is classified as information only.
eSevWarning = 1 The event is classified as a warning.
eSevError = 2 The event is classified as an error.
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DeviceInstanceEnum
This enumerator is used to select which of the API devices to access if more than one device is defined on
a TC.
eDevPrimary = 0 Communicate with target TC's primary API device
eDevSecondary = 1 Communicate with target TC's secondary API device
CDStatusEnum
This enumerator is used to indicate status of Cycle Data or Trace.
eStatusNOK = 0 Not OK
eStatusOK = 1 OK
eStatusOKRepaired = 2 OK but Repaired
eStatusStopTerminateNOK = 3 Stop and Terminate, not OK
eStatusNOKRM = 4 Not OK by Reject Management
RunStatusEnum
This enumerator is used to indicate the status for a station or bolt when it is running
eRunNoStatus = 0 No status
eRunWorking = 1 Working
eRunIdleOK = 2 Idle and OK
eRunIdleNOK = 3 Idle and not OK
eRunOutOfOrder = 4 Out of order
eRunIdleNOKRM = 5 Idle and not OK by Reject Management
eRunDisconOK = 6 Disconnected and OK
eRunDisconNOK = 7 Disconnected and not OK
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TorqueUnitEnum
This enumerator is used to indicate the torque unit used in trace data
eTorqUnitNone = 0 No unit
eTorqUnitNm = 1 Nm
eTorqUnitKNm = 2 kNm
eTorqUnitFTLBS = 3 Ft. Lbs
eTorqUnitINCHLBS = 4 Inch Lbs
eTorqUnitMNm = 5 MNm
ForceUnitEnum
This enumerator is used to indicate the force unit used in trace data
eForcUnitNone = 0 No unit
eForcUnitN = 1 N
eForcUnitKN = 2 kN
eForcUnitMN = 3 MN
eForcUnitLBS = 4 Lbf
StrokeUnitEnum
This enumerator is used to indicate the stroke unit used in trace data
eStrokeUnitNone = 0 No unit
eStrokeUnitMM = 1 mm
eStrokeUnitINCH = 2 Inch
eStrokeUnitM = 3 m
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8.14.4 Api object

The Api object represents the root of the PowerMACS API and is the only object in the interface that can
be created, or instantiated, by your client application.
Using the Api object your application get a description of the PowerMACS system that the Api currently is
connected to, read and write PLC data and access Process data, such as Cycle data, Trace and Events.
For any method of the Api object to function you must be connected to a PowerMACS target system.
Which TC to connect to is controlled using the property IpAddress. Normally you connect to the system
node, that is, the System TC. However, in order to access the PLC of another station but the first (which
always executes on the System TC) you must connect to the TC on which the station in question runs.
The following methods do only function if connected to the System TC:
If called when not connected to a System TC they will return eRetCmdNotAllowed.
GetSetup
SetSetup
GetSetupItem
SetSetupItem
8.14.4.1 Properties
The following table lists all properties on the Api object:
Property Name Return Type Description

IpAddress String This is the IP-address of the target that the Api will communicate to.
It should be the IP-address of the System TC a Station TC.
Must be set prior to any other call to an API-method.
DeviceInstance DeviceInstanceEnum This property points out which API device on the target that the API
should communicate with. Should correspond to the value of the
parameter "Port No" on the targets API device. Its default value is
eDevPrimary.
The syntax for accessing the properties of the Api object is as follows:
object.PropertyName
where object is an expression that evaluates to an object of type Api.
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8.14.4.2 GetPLCBoolEx
Description: This method reads a Boolean value from the PLC output data area for ExtCom_API.
Return type: A RetCodeEnum value.
Syntax: object.GetPLCBoolEx(Station, Address, Bit, Value)
Obj./Arg. Type Dir Description

object Api The Api object to operate on.
Station Integer In Specifies which stations PLC to access. Range 0 – 15 where 0
correspond to the station connected to the API device.
Address Integer In Specifies the offset in the PLC area of the Byte to read. Range
0 – 999.
Bit Integer In Specifies which bit to read within the byte. Range 0 – 7 where
0 is the Least significant bit and 7 is the Most significant bit.
Value Boolean Out Returns the result. True if the read bit is 1, False otherwise.
8.14.4.3 SetPLCBoolEx
Description: This method writes a Boolean value to the PLC input data area for ExtCom_API.
Syntax: object.SetPLCBoolEx (Address, Bit, Value)

Address Integer In Specifies the offset in the PLC area of the Byte to write. Range
0 – 999.
Bit Integer In Specifies which bit to write within the byte. Range 0 – 7 where
Value Boolean In If True then the bit is set to 1. If False then it is set to 0.
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8.14.4.4 GetPLCByteEx
Description: This method reads a BYTE value from the PLC output data area for ExtCom_API.
Syntax: object.GetPLCByteEx(Station, Address, Value)

0 – 999.
Value Byte Out Returns the result. Range 0 to 255.
8.14.4.5 SetPLCByteEx
Description: This method writes a BYTE value to the PLC input data area for ExtCom_API.
Syntax: object.SetPLCByteEx(Station, Address, Value)

0 – 999.
Value Byte In The data to write. Range 0 to 255.
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8.14.4.6 GetPLCIntEx
Description: This method reads an Integer value from the PLC output data area for ExtCom_API.
Syntax: object.GetPLCIntEx(Station, Address, Value)

Address Integer In Specifies the offset in the PLC area of the first byte of the
Integer to read. Range 0 – 999.
Value Integer Out The read data interpreted as an Integer. Range –32768 to
32767.
8.14.4.7 SetPLCIntEx
Description: This method writes an Integer value to the PLC input data area for ExtCom_API.
Syntax: object.SetPLCIntEx(Station, Address, Value)

Station Integer In Specifies which stations PLC to access. Range 0 – 15 where
0 correspond to the station connected to the API device.
Integer to write. Range 0 – 999.
Value Integer In The data to write. Range –32768 to 32767.
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8.14.4.8 GetPLCRealEx
Description: This method reads a Real value from the PLC output data area for ExtCom_API.
Syntax: object.GetPLCRealEx(Station, Address, Value)

Address Integer In Specifies the offset in the PLC area of the first byte of the Real
to read. Range 0 – 999.
38
Value Single Out The read data interpreted as a Real. Range +/- 1.18 * 10 .
8.14.4.9 SetPLCRealEx
Description: This method writes a Real value to the PLC input data area for ExtCom_API.
Syntax: object.SetPLCRealEx(Station, Address, Value)

Station Integer In Specifies which stations PLC to access. Range 0 – 15
where 0 correspond to the station connected to the API
device.
Real to write. Range 0 – 999.
38
Value Single In The data to write. Range +/- 1.18 * 10 .
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8.14.4.10 GetPLCStringEx
Description: This method reads 40 consecutive bytes from the PLC output data area for ExtCom_API.
The read data is returned as an ASCII string.
Note! Variables declared as STRING in the PLC are prefixed by two Short integers (four
bytes) where the first short specifies max possible length of the string calculated as Max
length – 80. The second short defines the strings current length. That is, the first character
of the string is located at offset 4 (fourth byte). All PLC strings are also terminated with a
NULL (0) character. This method does not handle the four leading bytes.
Example: To read the string declared as below from PowerMACS station 1
MyString AT %QB 2600 : STRING40;
you should call: MyApi.GetPLCStringEx(1, 2604, Value)

Syntax: object.GetPLCStringEx(Station, Address, Value)

Address Integer In Specifies the offset in the PLC area of the first byte to read.
Range 0 – 999.
Value String Out The read data interpreted as a string.
8.14.4.11 SetPLCStringEx
Description: This method writes the specified string to the PLC input data area for ExtCom_API as 40
consecutive bytes. Each byte will be set to the ASCII value of the respective character. See
also the note for SetPLCString.
Syntax: object.SetPLCStringEx(Station, Address, Value)

Address Integer In Specifies the offset in the PLC area of the first byte to write to.
Range 0 – 999.
Value String In The data to write.
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8.14.4.12 GetPLCBool
Description: This method is replaced with the GetPLCBoolEx method and should not be used in new
applications. It is here only for backward compatibility reasons.
This method reads a Boolean value from the PLC output data area for ExtCom_API (see
Access to PLC data).
Syntax: object.GetPLCBool(Address, Bit, Value)

0 – 999.
Bit Integer In Specifies which bit to read within the byte. Range 0 – 7 where
Value Boolean Out Returns the result. True if the read bit is 1, False otherwise.
8.14.4.13 SetPLCBool
Description: This method is replaced with the SetPLCBoolEx method and should not be used in new
This method writes a Boolean value to the PLC input data area for ExtCom_API (see
Syntax: object.SetPLCBool(Address, Bit, Value)

0 – 999.
Bit Integer In Specifies which bit to write within the byte. Range 0 – 7 where
Value Boolean In If True then the bit is set to 1. If False then it is set to 0.
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Peripheral Devices
8.14.4.14 GetPLCByte
Description: This method is replaced with the GetPLCByteEx method and should not be used in new
This method reads a BYTE value from the PLC output data area for ExtCom_API (see
Syntax: object.GetPLCByte(Address, Value)

0 – 999.
Value Byte Out Returns the result. Range 0 to 255.
8.14.4.15 SetPLCByte
Description: This method is replaced with the SetPLCByteEx method and should not be used in new
This method writes a BYTE value to the PLC input data area for ExtCom_API (see Access
to PLC data).
Syntax: object.SetPLCByte(Address, Value)

0 – 999.
Value Byte In The data to write. Range 0 to 255.
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8.14.4.16 GetPLCInt
Description: This method is replaced with the GetPLCIntEx method and should not be used in new
This method reads an Integer value from the PLC output data area for ExtCom_API (see
Syntax: object.GetPLCInt(Address, Value)

Integer to read. Range 0 – 999.
Value Integer Out The read data interpreted as an Integer. Range –32768 to
32767.
8.14.4.17 SetPLCInt
Description: This method is replaced with the SetPLCIntEx method and should not be used in new
This method writes an Integer value to the PLC input data area for ExtCom_API (see
Syntax: object.SetPLCInt(Address, Value)

Integer to write. Range 0 – 999.
Value Integer In The data to write. Range –32768 to 32767.
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Peripheral Devices
8.14.4.18 GetPLCReal
Description: This method is replaced with the GetPLCRealEx method and should not be used in new
This method reads a Real value from the PLC output data area for ExtCom_API (see
Syntax: object.GetPLCReal(Address, Value)

Address Integer In Specifies the offset in the PLC area of the first byte of the Real
to read. Range 0 – 999.
38
Value Single Out The read data interpreted as a Real. Range +/- 1.18 * 10 .
8.14.4.19 SetPLCReal
Description: This method is replaced with the SetPLCRealEx method and should not be used in new
This method writes a Real value to the PLC input data area for ExtCom_API (see Access to
PLC data).
Syntax: object.SetPLCReal(Address, Value)

Real to write. Range 0 – 999.
38
Value Single In The data to write. Range +/- 1.18 * 10 .
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Peripheral Devices
8.14.4.20 GetPLCString
Description: This method is replaced with the GetPLCStringEx method and should not be used in new
This method reads 40 consecutive bytes from the PLC output data area for ExtCom_API
(see Access to PLC data). The read data is returned as an ASCII string.
See note in the description of GetPLCStringEx for limitations and an example on how to
call.
Syntax: object.GetPLCString(Address, Value)

Address Integer In Specifies the offset in the PLC area of the first byte to read.
Range 0 – 999.
Value String Out The read data interpreted as a string.
8.14.4.21 SetPLCString
Description: This method is replaced with the SetPLCStringEx method and should not be used in new
This method writes the specified string to the PLC input data area for ExtCom_API (see
Access to PLC data) as 40 consecutive bytes. Each byte will be set to the ASCII value of
the respective character. See also the note for SetPLCString.
Syntax: object.SetPLCString(Address, Value)

Address Integer In Specifies the offset in the PLC area of the first byte to write to.
Range 0 – 999.
Value String In The data to write.
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Peripheral Devices
8.14.4.22 GetCycleData
Description: Call this method to read the next Cycle data from the FIFO queue for the API device. The
data returned is interpreted as a string. Therefore this method should be used together with
a Reporter configured to format data Printable.
Note 1: The prompter text, or variable name, included for a variable by checking the "Text"
column in the Reporter is language dependent.
Note 2: The reporter executes on the TC and that it can only be configured using ToolsTalk
PowerMACS.
The FIFO queue can hold max 500 cycle data. If overflowed then the oldest data is
overwritten. Once a cycle data has been read by a call to this method it cannot be read
again. If the queue is empty when called then Buf is set to an empty string and eRetNoData
is returned. If Buf is too small to receive the read cycle data then Size is set to 0 and
eRetBufferToSmall is returned.
Syntax: object.GetCycleData(Buf, Size)

Buf String Out The string to receive the read cycle data.
Size Long In/Out At call: Max length of Buf, At return: The length of the returned
string in Buf.
8.14.4.23 GetCycleDataBin
Description: GetCycleDataBin performs the same function as GetCycleData with the difference that the
data returned is the raw binary data received from the TC. It is not interpreted in any way.
Therefore this method should be used together with a Reporter configured to format data
Binary. See chapter: GetCycleData for details.
Syntax: object.GetCycleDataBin(Buf, Size)

Buf Byte array Out The byte array to receive the read cycle data.
Size Long In/Out At call: Max length of Buf, At return: The length of the
returned data in Buf.
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8.14.4.24 GetLastCycleData
Description: Get last cycle data in the queue in the same way as GetCycleData but data is returned even
if it has already been read.
Syntax: object.GetLastCycleData(Buf, Size)

string in Buf.
8.14.4.25 GetLastCycleDataBin
Description: Get last cycle data in the queue in raw binary format in the same way as GetCycleDataBin
but data is returned even if it has already been read.
Syntax: object.GetLastCycleDataBin(Buf, Size)

Buf Byte array Out The byte array to receive the read cycle data.
Size Long In/Out At call: Max length of Buf, At return: The length of the
returned data in Buf.
8.14.4.26 GetCycleDataById
Description: Get a specific cycle data in the queue in similar way as GetCycleData.
Syntax: object.GetCycleDataById(Buf, Size, Id)

string in Buf.
id Long In Identity of cycle data to get.
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Peripheral Devices
8.14.4.27 SubscribeCD
Description: Subscribe for cycle data. When new cycle data arrives an ActiveX event is raised. Any
registered functions of type RecNewCD will be called.
Syntax: object.SubscribeCD(OnOff)

OnOff Integer In Set 1 to switch subscription on. Set 0 to switch off.
8.14.4.28 RecNewCD
Description: Format for ActiveX event function that will be called when new cycle data arrives and
subscription is switched on.
Return type: -.
Syntax: Event RecNewCD(Station, Id)

Station Integer In Station number.
Id Long In Cycle data identity. Can be used with GetCycleDataById.
8.14.4.29 FlushCDQueue
Description: Flush the Cycle Data queue.
Syntax: object.FlushCDQueue()

8.14.4.30 RewindCDQueue
Description: Rewind the Cycle Data queue.
Syntax: object.RewindCDQueue()

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8.14.4.31 GetEvent
Description: This method is replaced with the GetEventEx method and should not be used in new
GetEvent performs the same function as GetEventEx with the difference that it does not
return the Severity of the event.
Syntax: object.GetEvent(DataNo, SeqNo, Ts, Code, Typ, Stn, Blt, Pgm, Str)

DataNo Integer Out A device unique sequence number. This number is
incremented by one for each event reported over this device.
SeqNo Long Out A global sequence number. This number is incremented by
one for each event generated by the system.
Ts Long Out Date and time for event. Expressed as no of seconds since
1970-01-01 00:00:00
Code Integer Out Event code, see List of events for possible values.
Typ Integer Out Event type, see View Event Log.
Stn Integer Out Station on which the event occurred, 0 if not relevant
Blt Integer Out Bolt for which the event occurred, 0 if not relevant
Pgm String Out Tightening program connected to the event, 0 if not relevant
Str String Out Event string in the language configured using ToolsTalk
PowerMACS.
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Peripheral Devices
8.14.4.32 GetEventEx
Description: Call this method to read the next Event from the FIFO queue for the API device.
The FIFO queue can hold max 200 events. If overflowed then the oldest event is
overwritten. Once an event has been read by a call to this method it cannot be read again.
If the queue is empty when called then eRetNoData is returned.
Syntax: object.GetEvent(DataNo, SeqNo, Ts, Code, Typ, Stn, Blt, Pgm, Str)

DataNo Integer Out A device unique sequence number. This number is
incremented by one for each event reported over this
device.
SeqNo Long Out A global sequence number. This number is incremented
by one for each event generated by the system.
Ts Long Out Date and time for event. Expressed as no of seconds
since 1970-01-01 00:00:00
Code Integer Out Event code, see List of events for possible values.
Typ Integer Out Event type, see View Event Log.
Stn Integer Out Station on which the event occurred, 0 if not relevant
Blt Integer Out Bolt for which the event occurred, 0 if not relevant
Pgm String Out Tightening program connected to the event, 0 if not
relevant
Str String Out Event string in the language configured using ToolsTalk
PowerMACS.
Sev SeverityEnum Out The Severity of the event.
8.14.4.33 GetEventObj
Description: This method is similar to GetEventEx but returns data packed in an object.
Syntax: object.GetEventObj(EventObj)

EventObj EventData Out Object which contains all event data.
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8.14.4.34 SubscribeEvent
Description: Subscribe for TC Events. When new TC Event arrives an ActiveX event is raised. Any
registered functions of type RecNewEvent will be called.
Syntax: object.SubscribeEvent(OnOff)

8.14.4.35 RecNewEvent
Description: Format for ActiveX event function that will be called when TC Event arrives and subscription
is switched on..
Return type: -.
Syntax: Event RecNewEvent(EventObj)

EventObj Event In Event data object containing all event information.
Data
8.14.4.36 FlushEventQueue
Description: Flush the Event queue.
Syntax: object.FlushEventQueue()

8.14.4.37 RewindEventQueue
Description: Rewind the Event queue.
Syntax: object.RewindEventQueue()

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Peripheral Devices
8.14.4.38 GetTrace
Description: Call this method to read the next Trace from the FIFO queue for the API device. See
chapter: Layout of Traces for the returned data is formatted.
The FIFO queue can hold max 100 traces. If overflowed then the oldest trace is overwritten.
Once a trace has been read by a call to this method it cannot be read again. If the queue is
empty when called then eRetNoData is returned.
Syntax: object.GetTrace(Buf, Size)

Buf Byte array Out The byte array to receive the read trace.
data in Buf.
8.14.4.39 GetTraceEx and GetTraceEx_v2

Description: Call one of these methods to read the next Trace from the FIFO queue for the API device.
The data is returned as a TraceData object. If the call GetTraceEx_v2 is used some
additional information is available in the object. GetTraceEx_v2 is supported from 10.5.0.
The FIFO queue can hold max 100 traces. If overflowed then the oldest trace is overwritten.
Once a trace has been read by a call to this method it cannot be read again. If the queue is
empty when called then eRetNoData is returned.
Syntax: object.GetTraceEx(TraceData) or object.GetTraceEx_v2(TraceData)

TraceData System Out A reference that can hold the returned TraceData object. Is set
to Nothing (null) if error.
8.14.4.40 GetLastTrace and GetLastTrace_v2

Description: Get last trace for a specific station and bolt in similar way as GetTraceEx but data is
returned even if it has already been read. With the call GetLastTrace_v2 some additional
information is available in the TraceData object returned.
Syntax: object.GetLastTrace(Stn, Blt, TraceData) or object.GetLastTrace_v2(Stn, Blt, TraceData)
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Stn Integer In Station
Blt Integer In Bolt
TraceData System Out A reference that can hold the returned TraceData object. Is set
to Nothing (null) if error.
8.14.4.41 SubscribeTrace
Description: Subscribe for Trace. When new Trace arrives an ActiveX event is raised. Any registered
functions of type RecNewTrace will be called.
Syntax: object.SubscribeTrace(OnOff)

8.14.4.42 RecNewTrace
Description: Format for ActiveX event function that will be called when Trace arrives and subscription is
switched on..
Return type: -.
Syntax: Event RecNewTrace(Station, Bolt, Spindle, Id, Status)

Station Integer In Station number
Bolt Integer In Bolt number
Spindle Integer In Spindle number
Id Long In Trace identity
Status Integer In Status according to CDStatusEnum
8.14.4.43 FlushTraceQueue
Description: Flush the Trace queue.
Syntax: object.FlushTraceQueue()

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8.14.4.44 RewindTraceQueue
Description: Rewind the Trace queue.
Syntax: object.RewindTraceQueue()

8.14.4.45 SubscribeStStatus
Description: Subscribe for Station Status. When there is a change in Station Stauts an ActiveX event is
raised. Any registered functions of type RecNewStStatus will be called.
Syntax: object.SubscribeStStatus(OnOff)

8.14.4.46 RecNewStStatus
Description: Format for ActiveX event function that will be called when new Station Status arrives and
subscription is switched on..
Return type: -.
Syntax: Event RecNewStStatus(Station, StnStatus, ModeNo, WpId, NoBolt, BoltStatus)

Station Integer In Station number
StnStatus Integer In Station status according to RunStatusEnum
ModeNo Integer In Mode number
WpId String In Workpiece ID
NoBolt Integer In Number of bolts
BoltStatus Integer In Bolt status according to RunStatusEnum
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8.14.4.47 GetSetup
Description: This method uploads the setup from the PowerMACS system in binary form. Such a setup
can be used by the SetSetup method. If there is no setup to read when called then
eRetNoData is returned. If not connected to a System TC then eRetCmdNotAllowed is
returned.
Syntax: object.GetSetup(Buf, Size)

Buf Byte array Out The byte array to receive the uploaded setup.
data in Buf.
8.14.4.48 SetSetup
Description: This method downloads a setup in binary form to the PowerMACS system. The setup must
have been created by an earlier call to GetSetup. The setup must have been uploaded from
a system with the same version as the one it is downloaded to. If not connected to a System
TC then eRetCmdNotAllowed is returned.
Syntax: object.SetSetup(Buf, Size)

Buf Byte array In The byte array containing the setup to download.
Size Long In The size of the setup to download.
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8.14.4.49 GetSetupItem
Description: This method returns the value of the setup item specified by the Item string. The Item string
uses a specific syntax (see Layout of Setup Item Descriptions for a description) to point out
which parameter to read the value of. The value is always returned as a floating-point
number. Boolean parameters are converted to a Single such that zero (0) represents False
and one (1) represents True. If not connected to a System TC then eRetCmdNotAllowed is
returned.
Return type: A RetCodeEnum value, or if in the interval [-101..-260] syntax errors in the Item string. In
case of syntax error then ABS(return value) - 100 is equal to the position in the string of the
first error. Example: Return value -120 corresponds to a syntax error near character 20.
Syntax: object.GetSetupItem(Item, Value)

Item String In The string specifying which parameter to read, see Layout of
Setup Item Descriptions.
Value Single Out The value of the read parameter.
8.14.4.50 SetSetupItem
Description: This method sets the value of the setup item specified by the Item string. The Item string
uses a specific syntax (see Layout of Setup Item Descriptions for a description) to point out
which parameter to write to. The value must be a floating-point number. For Boolean
parameters - set zero (0) if False and one (1) if True. If not connected to a System TC then
eRetCmdNotAllowed is returned.
Return type: A RetCodeEnum value, or if in the interval [-101..-260] syntax errors in the Item string. In
case of syntax error then ABS(return value) - 100 is equal to the position in the string of the
first error. Example: Return value -120 corresponds to a syntax error near character 20.
Syntax: object.SetSetupItem(Item, Value)

Item String In The string specifying which parameter to write, see Layout of
Setup Item Descriptions.
Value Single In The value to write.
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8.14.4.51 GetSystemDesc
Description: This method returns a System object that describes the PowerMACS system currently
connected to.
Syntax: object.GetSystemDesc(SysDesc)

SysDesc System Out A reference that can hold the returned System object. Is set to
Nothing (null) if error.
8.14.4.52 GetStationDesc
Description: This method returns a Station object that describes the PowerMACS station currently
connected to.
Syntax: object.GetStationDesc(StnDesc)

StnDesc Station Out A reference that can hold the returned Station object. Is set to
Nothing (null) if error.
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8.14.4.53 GetDateAndTime
Description: This method returns the current date and time of the target system. (Not compatible with
VisualStudio .NET)
Return type: A RetCodeEnum value. If an unsupported data type is used for the DateAndTime argument
then eRetWrongDataType is returned. If the method is not supported by the connected
target eRetNotSupported is returned. If not connected to a System TC then
eRetCmdNotAllowed is returned.
Syntax: object.GetDatyAndTime(DateAndTime)

DateAndTime VARIANT Out The variable to receive the current date and time of the target.
Since the type is VARIANT variables of different data type can
be passed to the method. Currently the following are
supported:
Date. (IDL data type DATE).
Long. Will return the date and time as number of seconds
since 1970-01-01 00:00:00.
8.14.4.54 SetDateAndTime
Description: This method sets the current date and time of the target system. (Not compatible with
VisualStudio .NET)
Return type: A RetCodeEnum value. If an unsupported data type is used for the DateAndTime argument
then eRetWrongDataType is returned. If the method is not supported by the connected
target eRetNotSupported is returned. If not connected to a System TC, or if the API device
is not configured as Time Server, then eRetCmdNotAllowed is returned.
Syntax: object.GetDatyAndTime(DateAndTime)

DateAndTime VARIANT In The date and time to set.
Since the type is VARIANT variables of different data type can
be passed to the method. Currently the following are
supported:
Date. (IDL data type DATE).
Long. Will return the date and time as number of seconds
since 1970-01-01 00:00:00.
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8.14.4.55 GetTime
Description: This method returns the current date and time of the target system as a long integer.
(Compatible with VisualStudio .NET)
Return type: A RetCodeEnum value. If not connected to a System TC then eRetCmdNotAllowed is
returned.
Syntax: object.GetTime(Time)

Time Long Out Will return the date and time as number of seconds since
1970-01-01 00:00:00.
8.14.4.56 SetTime
Description: This method sets the current date and time of the target system. (Compatible with
VisualStudio .NET)
Return type: A RetCodeEnum value. If the method is not supported by the connected target
eRetNotSupported is returned. If not connected to a System TC, or if the API device is not
configured as Time Server, then eRetCmdNotAllowed is returned.
Syntax: object.SetTime(Time)

Time Long In The time to set as number of seconds since 1970-01-01
00:00:00.
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8.14.5 System object

The System object represents the PowerMACS system currently connected to.
8.14.5.1 Properties
The following table lists all properties on the System object:

Name String The name of the system as entered for the System object using the System
form.
Stations Stations The collection of all Station objects that exists in the PowerMACS system.
The syntax for accessing the properties of the System object is as follows:
object.PropertyName
where object is an expression that evaluates to an object of type System.
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8.14.6 Stations object (collection)

The Stations object is a collection of Station object. It represents all station included in the PowerMACS
system connect to.
8.14.6.1 Properties
The following table lists all properties on the Stations object:

Count Long Returns the number of objects in the collection. Read only.
The syntax for accessing the properties of the Stations object is as follows:
object.PropertyName
8.14.6.2 Item
Description: Returns a specific Station object in the collection either by position or by the Name property
of the Station object. If the value provided as IndexKey does not match any existing
member of the collection, then Nothing (null) is returned.
Return type: A Station object.
Syntax: object.Item(IndexKey)

object Stations The Stations object to operate on.
IndexKey Variant In An expression that specifies the position of a member of the
collection.
If a numeric expression, IndexKey must be a number from 1 to
the value of the collection's Count property.
If a string expression, IndexKey must correspond to the Name
property of a Station object.
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8.14.6.3 Exists
Description: Checks if a specific Station object exists in the collection either by position or by the Name
Return type: A Boolean value. True if the object exists, else False.
Syntax: object.Exists(IndexKey)

object Stations The Stations object to operate on.
collection.
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8.14.7 Station object

The Station object represents a PowerMACS station.
8.14.7.1 Properties
The following table lists all properties on the Station object:

Name String The name of the Station as entered for the Station object using the
System form.
Number Integer The number of the station within the system [1..15].
IpAddress String The IP-address of the station (as dotted decimal).
Bolts Bolts The collection of all Bolt objects that exists within the station.
The syntax for accessing the properties of the Station object is as follows:
object.PropertyName
where object is an expression that evaluates to an object of type Station.
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8.14.8 Bolts object (collection)

The Bolts object is a collection of Bolt objects. It represents all bolts in a particular station.
8.14.8.1 Properties
The following table lists all properties on the Bolts object:

The syntax for accessing the properties of the Bolts object is as follows:
object.PropertyName
where object is an expression that evaluates to an object of type Bolts.
8.14.8.2 Item
Description: Returns a specific Bolt object in the collection either by position or by the Name property of
the Station object. If the value provided as IndexKey does not match any existing member
of the collection, then Nothing (null) is returned.
Return type: A Bolt object.

object Bolts The Stations object to operate on.
collection.
If a numeric expression, IndexKey must be a number from 1 to the
value of the collection's Count property.
property of a Bolt object.
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8.14.8.3 Exists
Description: Checks if a specific Bolt object exists in the collection either by position or by the Name

object Bolts The Bolts object to operate on.
collection.
If a numeric expression, IndexKey must be a number from 1 to the
value of the collection's Count property.
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Peripheral Devices
8.14.9 Bolt object

The Bolt object represents a bolt within a Station.
8.14.9.1 Properties
The following table lists all properties on the Bolt object:

Name String The name of the Bolt as entered using the System Map.
Number Integer The number of the bolt within the station [1..100]. First bolt is always 1.
UserBoltNo Integer The bolt number assigned to the bolt using parameter Bolt Number on
the System Map. [1..9999].
The syntax for accessing the properties of the Bolt object is as follows:
object.PropertyName
where object is an expression that evaluates to an object of type Bolt.
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8.14.10 TraceData object

The TraceData object contains a requested trace.
8.14.10.1 Properties
The following table lists all properties on the TraceData object:

BoltId Long Bolt
Channels Channels The collection of all Channel objects that exists in the trace.
DataNo Integer A device unique sequence number. This number is incremented by one for
each trace reported over the device.
DateAndTime Data Timestamp of trace in Data format
PgmName String Name of program used at the occasion
StationId Long Station
StepBounds StepBounds The collection of all StepBound objects that exists in the trace.
Ts Long Timestamp of trace
If one of the calls GetTraceEx_v2 or GetLastTrace_v2 was used to retrieve the trace it will contain some
additional properties as well:

FormatVersion Integer The format version of the trace. Traces received with GetTraceEx
and GetLastTrace have format version 4, the _v2 functions return
traces with format version 9. The other properties in this table are
only available if FormatVersion is 9 or above
TorqueUnit TorqueUnitEnum The torque unit used for the torque channel
ForceUnit ForceUnitEnum The force unit used for the torque channel (in PowerMACS Press
the torque channel is used for force values)
StrokeUnit StrokeUnitEnum The stroke unit used for the angle channel (in PowerMACS Press
the angle channel is used for stroke values)
TorqCurrScaleFact Single The scale factor to convert the current channel to torque values
SpindleId Long The idenity of the spindle used to produce the trace
The syntax for accessing the properties of the TraceData object is as follows:
object.PropertyName
where object is an expression that evaluates to an object of type TraceData.
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Peripheral Devices
8.14.10.2 Press traces
In a trace from a press system the torque channel is used for the force measurement values and the angle
channel is used for the stroke measurements.
8.14.11 Channels object (collection)

The Channels object is a collection of Channel object. It represents all channels included in the requested
trace.
The following table lists all properties on the Channels object:

The syntax for accessing the properties of the Channels object is as follows:
object.PropertyName
8.14.11.2 Item
Description: Returns a specific Channel object in the collection either by position or by the Name
property of the Channel object. If the value provided as IndexKey does not match any
existing member of the collection, then Nothing (null) is returned.
Return type: A Channel object.

object Channels The Channels object to operate on.
collection.
property of a Channel object.
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Peripheral Devices
8.14.11.3 Exists
Description: Checks if a specific Channel object exists in the collection either by position or by the Name
property of a Channel object.

object Channels The Channels object to operate on.
collection.
If a numeric expression, IndexKey must be a number from 1
to the value of the collection's Count property.
If a string expression, IndexKey must correspond to the
Name property of a Channel object.
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Peripheral Devices
8.14.12 Channel object

The Channel object represents a channel in the trace.
The following table lists all properties on the Channel object:

Name String The name of the Channel.
NoOfSamples Long The number of stored samples.
SampleTime Single The Sample time at which the stored samples were collected.
TimeOffset Single The time offset for the first stored sample, where Ts is 0.
The syntax for accessing the properties of the Channel object is as follows:
object.PropertyName
where object is an expression that evaluates to an object of type Channel.
8.14.12.2 GetSampleValueNo
Description: Give sample time as parameter and get sample number as reply.
Return type: A Long value. Sample number possible values are 1 to 6000.
Syntax: object.GetSampleValueNo(SampleValueTime)

object Channel The Channel object to operate on.
SampleValueTime Single In Time from Ts to when the current sample was taken.
8.14.12.3 GetSampleValueTime
Description: Give sample number as parameter and get sample time as reply.
Return type: A Single value. Time from Ts to when current sample was taken.
Syntax: object.GetSampleValueTime(SampleValueNo)

SampleValueNo Long In Sample number that corresponds to entered sample
time.
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8.14.12.4 GetSampleValues
Description: Get buffer with all sample values collected for the channel.
Syntax: object.GetSampleValues(Buf(), Size)

Buf() Single Out Array of Single, contains all sample values.
Size Long In/Out Available array size in and stored number of samples
out.
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8.14.13 StepBounds object (collection)

The StepBounds object is a collection of StepBound object. It represents all StepBounds included in the
requested trace.
The following table lists all properties on the StepBounds object:

The syntax for accessing the properties of the StepBounds object is as follows:
object.PropertyName
8.14.13.2 Item
Description: Returns a specific StepBound object in the collection by position. If the value provided as
IndexKey does not match any existing member of the collection, then Nothing (null) is
returned.
Return type: A StepBound object.

object StepBounds The StepBounds object to operate on.
IndexKey Variant In An expression that specifies the position of a member of
the collection.
If a numeric expression, IndexKey must be a number
from 1 to the value of the collection's Count property.
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8.14.13.3 Exists
Description: Checks if a specific StepBound object exists in the collection by position.

object StepBounds The StepBounds object to operate on.
IndexKey Variant In An expression that specifies the position of a member of
the collection.
If a numeric expression, IndexKey must be a number
from 1 to the value of the collection's Count property.
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8.14.14 StepBound object

The StepBound object contains start and stop times for one step or zone in the trace.
The following table lists all properties on the StepBound object:

StepNo Long The step number that the start and stop times apply to.
StartTime Single The time difference from Ts to when the step started.
StopTime Single The time difference from Ts to when the step started.
The syntax for accessing the properties of the StepBond object is as follows:
object.PropertyName
where object is an expression that evaluates to an object of type StepBound.
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8.14.15 EventData object

The EventData object represents a PowerMACS event.
The following table lists all properties on the EventData object:

DataNo Integer A device unique sequence number. This number is incremented by one
for each event reported over this device.
SeqNo Long A global sequence number. This number is incremented by one for each
event generated by the system.
Time Long Date and time for event (number of seconds since 1970-01-01 00:00:00)
Code Integer Event code, see List of events for possible values.
Typ Integer Event type, see View Event Log.
Station Integer Station on which the event occurred, 0 if not relevant
Bolt Integer Bolt for which the event occurred, 0 if not relevant
Observed Boolean TRUE if event is observed
Pgm String Tightening program connected to the event, 0 if not relevant
EventStr String Event string in the language configured using ToolsTalk PowerMACS.
Severity SeverityEnum The Severity of the event.
Param[ix] Variant Array of parameters, ix = 1..5.
ParamType[ix] String Array of parameter types, ix=1..5. Indicates how parameter should be
interpreted.
d: decimal integer
x, X: hexadecimal integer
f': float
c: ASCII character
s: string with up to 4 characters
The syntax for accessing the properties of the EventData object is as follows:
object.PropertyName
where object is an expression that evaluates to an object of type EventData.
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8.14.16 How to use the API

The API is developed in Visual Basic 6 as an ActiveX object and is as such callable from other languages
as well. Below are some examples on how to call the API from Visual basic.
Environment
Set up your Visual Basic environment according to the following
PowerMACSAPI must be installed on the computer
PowerMACSAPI must be checked in the project references dialog.
Do not create more than instance of the PowerMACSAPI.Api object in your application.
Declare a variable at module level

Private WithEvents mPowApi As PowerMACSApi.Api
Put some initiating code in the form load event

Set mPowAPi = New PowerMACSApi.APi
mPowApi.IpAddress = ”192.168.0.1”
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Reading cycle data from the target system

This example assumes that there is a label where you can put the cycle data result if there is one.
Normally you would loop and save the cycle data to disc or showing them continuously. Here we just do
one call to see if there are any cycle data waiting for us.
Private Sub cmdGetCd_Click()

'
' Abstract: Get cycle data from API-server and display it
'
On Error GoTo ErrorHandler
Dim Size As Long
Dim Ret As RetCodeEnum
Dim Buf As String
Size = 10000
Ret = mPowApi.GetCycleData(Buf, Size)
If Ret = eRetOk Then
lblResult = Buf
ElseIf Ret <> eRetNoData Then
MsgBox "GetCycleData returned: " & Ret
End if
Exit Sub
ErrorHandler:
libCleanTerminate "cmdGetCd_Click"
Stop
Resume
End Sub
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Peripheral Devices
Receiving cycle data from the target system using subscription

This example assumes that there is a label where you can put the cycle data result if there is one.
Note! The API object should have been declared With Events.
Private Sub mPowApi_RecNewCd(Station As Integer, Id As Long)

'
' Abstract: New Cycle data notification received from the API
'
Dim Size As Long
Dim Buf As String
Size = 10000
Ret = mPowApi.GetCycleDatabyId(Buf, Size, Id)
If Ret = eRetOk Then
lblResult = Buf ' Take care of cycle data
ElseIf Ret <> eRetNoData Then
MsgBox "GetCycleData returned: " & Ret ' Something wrong
End if
Exit Sub
ErrorHandler:
libCleanTerminate "mPowApi_RecNewCd"
Stop
Resume
End SubEnd Sub
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Setting a Boolean value in the target system

This example assumes that there are textboxes for address and value, and a dropdown list for the bit
value.
Private Sub cmdSetBool_Click()

'
' Abstract: Set PLC Bool from API-server and display it
'
Dim Address As Integer
Dim Value As Boolean
If Val(txtAddress) < 1 Or Val(txtAddress) > 999 Then

MsgBox "Address must be between 1 and 999"
txtAddress.SetFocus
Exit Sub
End If
Address = CInt(txtAddress)
Value = CBool(txtValue)
Ret = mPowApi.SetPLCBool(Address, Val(cboBit), Value)

if Ret <> eRetOk then msgBox "SetPLCBool returned: " & Ret
Exit Sub
ErrorHandler:
If Err.Number = 13 Then
MsgBox "Value must be a valid boolean"
txtAddress.SetFocus
Exit Sub
End If
MsgBox err.description
exit sub
End Sub
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Reading an Integer PLC value from the target system

This example assumes that there are textboxes for address and value.
Private Sub cmdSetBool_Click()

'
' Abstract: Get PLC Integer from API-server and display it
'
Dim Address As Integer
Dim Value As Boolean
If Val(txtAddress) < 1 Or Val(txtAddress) > 999 Then

MsgBox "Address must be between 1 and 999"
txtAddress.SetFocus
Exit Sub
End If
Address = CInt(txtAddress)
Ret = mPowApi.GetPLCInt(Address, Value)
if Ret <> eRetOk Then
msgBox "GetPLCInt returned: " & Ret
else
txtValue = CStr(Value)
end if
Exit Sub
ErrorHandler:
MsgBox err.description
exit sub
End Sub
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8.15 GM DeviceNet
This device type is used to interface a PowerMACS station to an overriding control system according to
GM's specification the General Motors document "GAE Electric Nutrunner Controller Design Criteria",
GAEc-03 6-9-03Revision.doc. Using it the control system start and stop the tightening cycles and receive
result.
The device offers the following two interfaces:
A special configuration of the standard DeviceNet fieldbus (the input and output maps are
predefined and fixed).
A discrete I/O using digital signals.
By default the discrete I/O interface is mapped to PowerMACS local I/O system (see chapter: I/O) but is
also available in the PowerMACS PLC and can therefore be mapped to other kind of interfaces if so
wanted. See chapter: GM DeviceNet variables for a description of the PLC interface.
The device is configured using the following form:
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Enter the Node addr. (Can be [0..63]) and Baud Rate (can be 125, 250 or 500 Kbit/s).
Specify in Bytes In the number of input bytes, this could be either 4 or 8 depending on if the PVI number
should be read from the fieldbus or not.
Depending on the number of spindles in the system set Bytes Out to 4 for a station with 1 to 5 spindles,
and 8 for a station with 6 to16 spindles.
Specify in Turn of light timeout how many seconds the external tool lights should present the result of
the rundown (max 60 seconds). Specify 0 if the tool lights should remain on to the next rundown cycle.
The checkbox Flash tool light on rising EPR signal controls whether or not the green tool lights should
start to flash when a positive edge is detected on the Error Proofing Ready input signal. If checked the
tools will flash.
Use the checkboxes in the Rundown control signals frame to select which interface that should be
active. It is possible to have both interfaces active at the same time. If both are active then the
corresponding input signals will be OR:ed together.
Note 1: To ensure Operator Safety it is possible to disable all of the input bits from the DeviceNet interface
as well as the discrete I/O interface. Uncheck the checkbox in the Rundown control signals
frame that corresponds to the interface you want to disable.
It is also possible to disable all DeviceNet inputs except for the PVI number using the PLC output
GM_IN.DISABLEDNETINP (normally mapped to the digital input DI_GM_DisableDNetInp). This
signal is read by the GM Device regardless of the value of the Through discrete I/O. See also
chapter: GM DeviceNet variables.
Note 2: When using this device type you must ensure that the ANYBUS_in and ANYBUS_out drivers of
the PowerMACS PLC are disabled. This is done using the I/O Configuration dialogue opened by
double-clicking on the IO_Configuration worksheet of the Station that has the fieldbus interface
mounted. See chapter: Access to PLC data for details.
Also, since the interface layout is fixed it is not possible to create a reporter for a device of this
type.
For more information on the DeviceNet fieldbus, for example the meaning of the status indication LED's,
see chapter: Fieldbus Interface.
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8.15.1 Interface definition input

The input map definition for signals to PowerMACS is according to the following table:
Word Byte Bit Name in DeviceNet map Name of Pass through
IO signal IO signal
0 Green Light (Pass through to IO) DO_GM_GreenLight
1 Yellow Light (Pass through to DO_GM_YellowLight
IO)
0 2 Red Light (Pass through to IO) DO_GM_RedLight
3 Alarm Horn (Pass through to IO) DO_GM_AlarmHorn
4-6 Spindle – Mode Set Code (1-8) DI_GM_ParSet1 - 4 DO_GM_ParSet1 - 4
0
7 Spare
0 Start Cycle DI_GM_Start
1 Reverse DI_GM_Reverse
1 2 Error Proofing Ready (EPR) DI_GM_EprIn DO_GM_EprOut
3 Spindle – Stop/Disable DI_GM_StopDisable
4-7 Spare
1 0-1 N/A Spare
2-3 0-3 N/A PVI number
The inputs are used as follows (all signals have positive logic where active is 1 and passive is 0):
Green Light: This signal is just passed through to PowerMACS discrete I/O interface (local I/O).
Yellow Light: This signal is just passed through to PowerMACS discrete I/O interface (local I/O).
Red Light: This signal is just passed through to PowerMACS discrete I/O interface (local I/O).
Alarm Horn: This signal is just passed through to PowerMACS discrete I/O interface (local I/O).
Spindle – Mode Set Code: Used to choose the mode that should be run when Start Cycle goes high
(could be 0 to 7 witch will correspond to Mode 1 to 8 in the stations Mode Table). This
signal is sampled continuously as long as no cycle is running and is echoed to the output
signal Spindle – Mode Set Code.
Reverse: When this signal is 1 it will override the value of Mode Set Code and force mode to the
value 9 for a reverse program. This signal is sampled continuously as long as no cycle is
running.
Start Cycle: Starts the tightening cycle if the Error Proofing Ready signal has switch from 0 to 1 since
the last cycle and Spindle - Stop/Disable is low. The cycle is started using the current
value of Spindle – Mode Set Code or Reverse. Immediately when starting the cycle all
green, yellow and read indication lamps are turned off (for the DeviceNet and as well as the
I/O interface).
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Error Proofing Ready: This signal indicates that a new cycle can begin and enables the station to start a
cycle. It is also passed through to the output Spindle Error proofing Ready (EPR), see
Interface definition output. If enabled by the parameter Flash tool light on rising EPR
signal (see chapter: GM DeviceNet) the green tool lights will start to flash when this signal
changes state from low to high. The lights will flash with an interval of 750 ms until the cycle
is completed and the result is presented.
Spindle Stop/Disable: Is used to stop the current cycle and to inactivate the spindles from any future
cycle. Must be 0 to permit a new cycle to start.
PVI number: The value of this input is added to the cycle data produced when running a cycle as the
station level result variable "Wp ID". Sampled when the Start Cycle changes from 0 to 1.
DI_GM_DisableDNetInp: This input is only available via the discrete I/O. When set to 1 all inputs via
the DeviceNet interface, except for the PVI number, are disabled.
Note! This input is always read, regardless of the value of the device parameter Through
discrete I/O (see chapter: GM DeviceNet).
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8.15.2 Interface definition output

Two output maps are defined in the PowerMACS, one for systems with up to five (5) spindles and one for
systems with up to sixteen (16) spindles. Only one of the maps can be enabled at a given time. The maps
are enabled/disabled manually by changing the PLC bytes Out parameter. All outputs are stable for at
least 500 ms. The output map definition for signals from PowerMACS is according to the following table:
Word Byte Bit Name in DeviceNet map Name of I/O signal
0 Spare
1 Spare
0 2-3 Spare
4-6 Spindle – Mode Set Code (0-7) DO_GM_ParSet1 - 4
7 Global Accept DO_GM_GlobalAccept
0 0 Spindle – In Cycle DO_GM_InCycle
1 Spare
2 Fault Relay DO_GM_FaultRelay
1
3 Spindle – Cycle Complete DO_GM_CycleComp
4 Spindle – Error Proofing Ready (EPR) DO_GM_EprOut
5-7 Spare
0 Spindle – 1 Good Rundown (Green Light) DO_GM_Green_Sp1
1 Spindle – 1 Remove (Red Light) DO_GM_Red_Sp1
2 Spindle – 1 Low Torque (Yellow Light) DO_GM_Yellow_Sp1
0
1
1
7 Spare
Note! The above shows the output for a system with up to 5 spindles. For a system with up to 16
spindles just continue the table with spindle 6, and so on.
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The outputs are set as follows:
Spindle – Mode Set Code: This signal echoes back the current value of the input Spindle – Mode Set
Code as long as the station is idle, that is, while the output Spindle – In Cycle is 0.
Global Accept: This signal is set to 0 when a cycle starts. When the cycle is finished it is set according to
the resulting status of the station. It is set to 1 if the cycle completed successfully and 0 if
not.
Spindle – In Cycle: This signal is set to 1 when the station is running a cycle, and it is set to 0 when the
cycle is finish.
Fault Relay: This signal is currently not used. Always 0.
Spindle – Cycle Complete: This signal is set to 1 when the station has finished a cycle. It is set to 0
when a new cycle starts
Spindle – Error Proofing Ready: This signal is passed through from the input, see Interface definition
input.
Spindle – x Good Rundown: See Indication schema below for a description of how this output is set.
Spindle – x Remove: See Indication schema below for a description of how this output is set.
Spindle – x Low Torque: See Indication schema below for a description of how this output is set.
Note! All Outputs have a 500-millisec transition from ON/OFF states to enable sufficient dwell time for
PLC‟s to scan/read the change of state of all Inputs and Outputs.
8.15.2.1 Indication schema

Indication of the bolt result is done differently depending on if the strategy used for the tightening.
Whether or not a tightening is classified as using Torque or Angle control is based on the type of the last
step in the main part of the tightening program used, that is, the step before the first CE step in the
program.
However, some steps are not classified to be of Torque or Angle control type. A typical example of this is
the SR – Socket Release step. To ignore these steps when deciding the control strategy of the program
the program is traversed backward, starting at the last step, until one of the steps in the below table is
found.
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The first found step defines the control strategy of the program.
Step type Defines Control Strategy as

DT - Run until Dyna-TorkTM
DT2 - Run until Dyna-TorkTM, method 2
DT3 - Run until Dyna-TorkTM, method 3 Torque Control.
T - Run until Torque
TC - Run until Torque with Current Control
AO - Run until Angle with overshoot compensation
A - Run until Angle
Angle Control.
PA - Run until Projected angle
TA – Run Torque-Angle with no stop
All other step types Undefined
Depending on the outcome of the Monitoring result and the Control strategy of the used program the result
for each bolt is indicated according to the following schemas:
Torque Control strategy:

TORQUE (Bolt T)
< ZDR Low OK High > Remove limit
Low Yellow Yellow Yellow + Red Yellow + Red Red

(Bolt A)
ANGLE
OK Yellow Green Yellow + Red Red
High Red Red Red Red
If a REHIT is detected (see below for how) then the Yellow + Red outputs are set.
Angle Control strategy:
TORQUE (Bolt T)
< ZDR Low OK High > Remove limit
Low Yellow Yellow + Red Yellow + Red Yellow + Red Red

(Bolt A)
ANGLE
OK Yellow + Red Green Yellow + Red Red
High Red Red Red Red
If a REHIT is detected (see below for how) then the Yellow + Red outputs are set.
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Whether torque and angle are considered OK or not for a bolt is decided by the data in the corresponding
Bolt level result variables "Errors". The below tables shows which error bits that are used, and for what
purpose.
TORQUE status Bit in "Errors"

< ZDR TTNOTRM (Threshold torque not reached for angle monitoring, see chapter: Monitoring
Check – Angle )
REHIT CROSSGR (Cross gradient restriction exceeded, see chapter: Cross Thread and Gradient)
> Remove limit RFTLIMRE (Remove Fastener Torque Limit REeached, see chapter: Program )
Low TLM (Final torque too low during monitoring, see chapter: Monitoring Check – Final Peak
Torque)
High THM (Final torque too high during monitoring, see chapterMonitoring Check – Final Peak
Torque)
OK True only if the status of the bolt is OK
ANGLE status Bit in "Errors"

Low ALM (Angle too low during monitoring, see chapter: Monitoring Check – Angle )
High AHM (Angle too high during monitoring, see chapterMonitoring Check – Angle )
OK True only if the status of the bolt is OK
If several of the above errors occur during a cycle they are prioritised so that the worse, or most "red",
error wins. That is, the priority order is (most significant error has lowest number):
1. The Red lamp only
2. The Yellow + Red lamps
3. The Yellow lamp
4. The Green lamp.
Note! If a bolt ends with status NOK and none of the errors listed above are at hand, or the control
strategy is undefined, then none of the lamps will be switched on.
This situation can occur if the monitoring checks and restrictions listed above are not used, or if the
program does not include any step defining a control strategy.
The monitoring checks must always be evaluated, thus Ignore monitoring errors when step ends
NOK cannot be checked.
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8.16 ACTA 3000

The ACTA 3000 device enables calibration of the torque transducer for the spindles of your system using
the ACTA test equipment from Atlas Copco. One device enables calibration of all spindles in the station.
Add the device to the Station TC and make the physical connection of the ACTA unit to this TC.

Port specifies which physical communication port that should be used. Port 2 is default and should be
used for the standard cables.
You can control whether or not cycles can be started from the PowerMACS PLC or the Test Bolts form
using the PLC System Globals Station variables ACTA_ACTIVE and DISBALE_ACTA.
The PLC program created by default (when no GM DeviceNet device is used) blocks out starts from the
PowerMACS PLC and the Test Bolts form.
The calibration can be run in two different modes, controlled by the ACTA or controlled by the TC.
Controlled by ACTA
If the calibration is controlled by the ACTA the cycles are started from the ACTA unit. In the ACTA unit you
have to specify the spindle and the mode number that shall be used. It is only this spindle that will run.
If mode 0 is selected a special program adapted to the QRTT equipment is used for the calibration. With
this program both the torque and angles can be verified and calibrated.
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If a mode between 1 and 50 is selected the program that is specified for that mode in the mode table is
used for the calibration. This can be any tightening program that is included in the setup. In this case there
is only possible to calibrate the torque.
Controlled by TC
If the calibration is controlled by the TC the cycles are started from the TC as all normal tightenings. The
start can come from a digital I/O, a fieldbus or some other external equipment. It is still possible to select
the mode number from the ACTA if wanted. The PLC system global ACTAMODE will reflect the mode
selected from the ACTA and it is possible to connect this to the output MODE.
Calculation of Torque Scale Factor

The ACTA unit can calculate a new torque scale factor, based on the torque measurements that were
made in the TC and in the ACTA. It is also possible to save this value in the TC if the difference from the
old scale factor is less than 10%.
Requirements on the tightening program used for calibration

Any normal tightening program can be used for the calibration, but it is important to consider how the
ACTA detects cycle start and cycle end to make sure the values sent from the TC really correspond to the
values measured in the ACTA
See Atlas Copco Tools document No. 9836 2086 00 [4] for how to operate the ACTA test equipment.
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8.17 Process data

Process data comprises following types of data:
Cycle data
Traces
Events
Setup
Process data is accessed from external devices using fieldbus, external communication protocols, the
API, etc.
Cycle data, Events, and Traces generated by PowerMACS are put into a number of FIFO queues. Each
device has their own queues, one for cycle data, one for traces, and one for events. This means that they
can read data at their own speed without interfering with each other.
All access to Process data is done on the client's request. When requested for, the PowerMACS system
will return the next data from the queue in question. Should the queue be empty then the client will receive
an empty data package. It is the client's responsibility to request new data. PowerMACS will not
spontaneously indicate to him that new data is available.
Since a process data item, e.g. one cycle data, often are bigger than what can be handled by a single
read or write access, it is accessed through successive reads or writes where each access returns a part
of the complete data item. These parts are called packages. In other words, one data item consists of one
or more data packages.
A Process data package has the following format:
B yte
0 S E Q (M o s t S ig n ific a n t B yte )
1 S E Q (L e a s t S ig n ific a n t B yte )
2 L E N (M o s t S ig n ifica n t B yte )
3 L E N (L e a s t S ig n ifica n t B yte )
4 D a ta b yte 1
5 D a ta b yte 2
: :
N + 4 D a ta b yte N
First in the package there is a sequence number named SEQ and a length field named LEN. Both are
Short Integers, which means that they occupy two bytes each (see Data types).
SEQ is the sequence number of the package within a particular data item (e.g. a cycle data). The first
package has SEQ = 1, the second has SEQ = 2, and so on. To indicate the last package of a data item
SEQ is negated. This means that a data item that is divided in three packages will have the following
values of SEQ: 1, 2, -3.
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Peripheral Devices
LEN is the length of the complete package, including both SEQ and LEN. LEN is therefore always equal
to N + 4 where N is the number of data bytes contained in the package.
To reconstruct the Data item being read you just have to concatenate the Data part (Data byte 1, …) of
each package, from first package (SEQ = 1) to the last package (SEQ = -K).
Example: Assuming that a complete cycle data consists of the 10-character string "ABCEDFGHIJ"
should be read using an 8-byte buffer then the below data transfer will occur when the cycle
data is requested (all data is written in Hexadecimal notation):
A C y c le d a ta P a c k a g e re tu rn e d b y th e firs t re a d re q u e s t
0 0 x4 1 („A ‟) 0 0 x0 0
SEQ = 1
1 0 x4 2 („B ‟) 1 0 x0 1
2 0 x4 3 („C ‟) 2 0 x0 0
LEN = 8
3 0 x4 4 („D ‟) 3 0 x0 8
4 0 x4 5 („E ‟) 4 0 x4 1 („A ‟) Ite m d a ta b yte 0

5 0 x4 6 („F ‟) 5 0 x4 2 („B ‟) Ite m d a ta b yte 1
6 0 x4 7 („G ‟) 6 0 x4 3 („C ‟) Ite m d a ta b yte 2
7 0 x4 8 („H ‟) 7 0 x4 4 („D ‟) Ite m d a ta b yte 3
8 0 x4 9 („I‟)
9 0 x5 0 („J‟)
P a c k a g e re tu rn e d b y th e s e c o n d re a d re q u e s t
0 0 x0 0
SEQ = 2
1 0 x0 2
2 0 x0 0
LEN = 8
3 0 x0 8
4 0 x4 5 („E ‟) Ite m d a ta b yte 4

5 0 x4 6 („F ‟) Ite m d a ta b yte 5
6 0 x4 7 („G ‟) Ite m d a ta b yte 6
7 0 x4 8 („H ‟) Ite m d a ta b yte 7
P a c k a g e re tu rn e d b y th e th ird re a d re q u e s t
0 0 xF F
S E Q = --3
1 0 xF D
2 0 x0 0
LEN = 6
3 0 x0 6
4 0 x4 9 („I‟) Ite m d a ta b yte 8

5 0 x5 0 („J‟) Ite m d a ta b yte 9
6 xx n o t se t
7 xx n o t se t
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If this was the last available cycle data in the queue then another read would give the following result
(indicating that the queue is empty):
E m p ty p a c k a g e re tu rn e d s in c e q u e u e is e m p ty
0 0 xF F
S E Q = --1
1 0 xF F
2 0 x0 0
LEN = 4
3 0 x0 4
4 xx n o t se t
5 xx n o t se t
6 xx n o t se t
7 xx n o t se t
8.17.1 Data types

The following data types are used in the following sections:
Data type Description Values

Boolean 2 bytes, 16 bit unsigned binary Zero (0) represent False and non-zero True
Short integer 2 bytes, 16 bit, 2-complement signed -32768, …, +32767
binary
Long integer 4 bytes, 32 bit, 2-complement signed -2 147 483 648, …, +2 147 483 647
binary
Time 4 bytes, 32 bit long integer Number of seconds since January 1, 1970
38
Float or Real 4 bytes, 32 bit, IEEE-754 standard +/- 1.18 * 10
char[] Array of bytes containing ASCII- Null-terminated i.e. the byte after last relevant
character character contains null, 0.
For data occupying more than one byte the order is that most significant byte comes first, at the lowest
address. This is also known as Big Endian or Motorola format.
8.17.2 Layout of Cycle data in Process data

The layout of Cycle data is set up by use of a Reporter.
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8.17.3 Layout of Events in Process data

An Event contains data as described in the table below.
Offset Item Data type Description

0 DataNo Short integer A device unique sequence number. This number is incremented by
one for each event reported over the device.
2 SeqNo Long integer A global sequence number. This number is incremented by one for
each event generated by the system.
6 Time Time Date and time for event.
10 Code Short integer Event code, see List of events for possible values.
12 Type Short integer Event type, see View Event Log for possible values.
14 Station Short integer Station on which the event occurred, 0 if not relevant
16 Bolt Short integer Bolt for which the event occurred, 0 if not relevant
18 Observed Short integer <> 0 if event is observed
20 Pgm char[21] Tightening program connected to the event, 0 if not relevant
41 EventStr char[81] Event string in the language configured using ToolsTalk
PowerMACS.
122 Severity Short integer The severity of the event, see View Event Log for possible values.
124 Par 1 char[4] First parameter for the EventStr, see below for a description.
128 Par 2 char[4] Second parameter for the EventStr, see below for a description.
132 Par 3 char[4] Third parameter for the EventStr, see below for a description.
136 Par 4 char[4] Fourth parameter for the EventStr, see below for a description.
140 Par 5 char[4] Fifth parameter for the EventStr, see below for a description
Par1 to Par5 represents values that should replace the parameter placeholders in the event strings
defined for each event code (%d, %x, %f, and %c). See List of events for a listing of all events with their
place holders. Par1 represents the leftmost placeholder, Par2 the second leftmost, and so on. The
respective placeholder has the following meaning:
Placeholder Meaning
%d Interpret the four bytes of ParX as a long and display it as a decimal integer
%x Interpret the four bytes of ParX as a long and display it as a hexadecimal integer
%f Interpret the four bytes of ParX as a float and display it as a float with two (2) decimals
Interpret the four bytes of ParX as ASCII values of four single characters and display them as
%c
characters.
Which items that is included for an event when it is read by a particular device is controlled by the
Reporter connected to the device.
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If all items are included then the size of an event is 144 bytes.
8.17.4 Layout of Traces in Process data

A Trace contains data as described in the table below.
Offset Item Data type Description

0 DataNo Short integer A device unique sequence number. This number is
incremented by one for each trace reported over the
device.
2 FmtVer Long integer Format version on the TC when the trace was created
6 Station Long integer Station
10 Bolt Long integer Bolt
14 Time Time Timestamp of trace
18 Freq Float Sampling frequency in Hz
22 TimeOffset Long integer Offset to first sample in milliseconds
26 NoTsamples Long integer Number of torque samples [0..2000]
30 NoAsamples Long integer Number of angle samples [0..2000]
34 NoCsamples Long integer Number of current samples [0..2000]
38 Not used Long integer Always zero (0)
42 PgmName char[21] Name of program used at the occasion
st
63 1 T sample Float The first Torque sample
63 + 4 * ( Last T sample Float The last Torque Sample (sample NoTsamples)
NoTsamples – 1)
st
63 + 4 * ( 1 A sample Float The first Angle sample
NoTsamples)
63 + 4 * ( Last A sample Float The last Angle Sample (sample NoAsamples)
NoTsamples +
NoAsamples – 1)
st
63 + 4 * ( 1 C sample Float The first Current sample
NoTsamples +
NoAsamples)
63 + 4 * ( Last C sample Float The last Current Sample (sample NoCsamples)
NoTsamples +
NoAsamples +
NoCsamples – 1)
The trace will only contain the samples that are recorded. This means that only data for used channels are
recorded. The number of samples included for each channel is given by the variable NoTsamples,
NoAsamples, NoCsamples and NoGsamples respectively.
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8.17.5 Layout of Setup Item Descriptions
Using the API interface it is possible to read or write individual items within a setup. Items that can be
accessed are parameters for which alteration would be meaningful and which can be handled by the
system.
The following parts of a setup may be modified individually:
Bolt
Spindle – Parameters
Spindle – Channel data
Programs – General data
Programs – Monitoring data
Sequences and programs – Step Control data
Sequences and programs – Step Speed data
Sequences and programs – Step Speed ramp down data
Sequences and programs – Step Surveillance data
To access an individual item a description must be provided which points to the item. This description
should be according to the syntax described in the following.
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8.17.5.1 Bolt
Syntax: Bolt[<station no>,<bolt no>].<parameter>
<station no> = 1..Max station no

<bolt no> = 1..Max bolt no in that station
<parameter> = See table below
<parameter> Data type Description

OpMode Short integer Operation mode:
0: Connected
1: Disconnected OK
2: Disconnected NOK
ExternalBoltNo Short integer The bolt number used in cycle data reports.
Example: Bolt[1,1].OpMode
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8.17.5.2 Spindle, Parameters

Syntax: Spindle[<spindle no>].<parameter>
<spindle no> = 1..Max spindle no

<parameter> = See table below (and Spindle Set Up for a description)

NoCyclMaint Long integer Service interval in no. of cycles (>= 0)
Direction Short integer Direction in which the spindle should rotate. Allowed
values are:
0. Forward (clockwise)
1. Backward (counter clockwise)
ZeroSpeed Float The maximum speed that counts as zero speed
ADiffEnabled Boolean If angle channel difference test should be enabled
ADiffUseSpindle Boolean If spindle‟s limits should be used
ADiffMaxDiff Float Maximum allowed difference
ADiffSamples Short integer Maximum number of samples tolerated above
ADiffMaxDiff
TDiffEnabled Boolean If torque channel difference test should be enabled
TDiffUseSpindle Boolean If spindle‟s limits should be used
TDiffChannels Short integer Channels to compare
1 : Current compared to Torque Channel 1
2 : Current compared to Torque Channel 2 *(
3 : Torque Channel 1 compared to Torque Channel 2 (*
*) Requires two torque channels

TDiffMaxDiff Float Maximum allowed difference
TDiffSamples Short integer Maximum number of samples tolerated above
TDiffMaxDiff
ContFailedFzo Boolean True if spindle should continue to run after failed flying
zero offset check.
SzoMax1 Float Max allowed static zero offset for transducer 1.
SzoMax2 Float Max allowed static zero offset for transducer 2.
DzoMax1 Float Max allowed dynamic zero offset for Torque 1.
DzoMax2 Float Max allowed dynamic zero offset for Torque 2.
FzoMax1 Float Max allowed flying zero offset for Torque 1.
FzoMax2 Float Max allowed flying zero offset for Torque 2.
ExtEnabled Boolean True when external equipment enabled.
626 9836 3521 01

Peripheral Devices

ExtInverse Boolean True if external equipment inverses direction.
ExtGearRatio Float External Equipment GearRatio
ExtTorqueLossF Float Torque Measurement Loss factor for transducers, < 1.0
ExtWindUp1 Float External Equipment Replacement WindUp for Angle
Channel 1.
ExtWindUp2 Float External Equipment Replacement WindUp for Angle
Channel 2.
Example: Spindle[1].Direction
8.17.5.3 Spindle, Channel data

Syntax: Spindle[<spindle no>].Chan[<channel no>].<parameter>
<spindle no> = 1..Max spindle no

<channel no> = Channel number, 1..6 (number is given by the order in the form)
<parameter> = See table below (and Spindle Set Up for a description)

Filter Short integer Filter frequency (for the torque and current channels)
Example: Spindle[1].Chan[1].Filter
9836 3521 01 627

Peripheral Devices
8.17.5.4 Program, General data

Syntax: Program[<pgm name>].General.<parameter>
<pgm name> = The name of the program

description)

StopMonAtNokStep Boolean If True then monitoring is stopped when a step have a
NOK status when it ends.
Use2ndMonBuf Boolean If true then 2nd monitoring buffer is used if there is more
than one used torque or angle channel.
ReportTqLimit Float Report threshold torque limit.
If none of the bolts executed for a cycle (disconnected
bolts excluded) exceeded this value then the
corresponding cycle data will be automatically dropped
RemFastTqLimit Float Remove fastener torque limit.
When the measured torque exceeds the entered value
the current step is immediately stopped.
Example: Program[Pgm01].General.StopMonAtNokStep
628 9836 3521 01

Peripheral Devices
8.17.5.5 Program, Trace data

Syntax: Program[<pgm name>].Trace.<parameter>

description)

TraceStart Short integer The main condition for when to start recording a Trace.
Takes the following values:
1: At cycle start
3: When the step with number <TraceStartStep> is
started.
TraceStartStep Short integer The number of the step where trace will start
TraceStartQty Short integer Specifies an addition condition for when to start recording
a trace. Takes one of the following values:
0: None
1: When the measured angle reaches the value
<TraceStartMin>
2: When the measured torque reaches the value
<TraceStartMin>
3: When the measured current reaches the value
<TraceStartMin>
TraceStartMin Float The minimum value to reach before trace starts. Valid
only if <TraceStartQty> has the value 1, 2 or 3.
Inc2ndTorque Boolean If true both torque channels will be recorded to trace.
Inc2ndAngle Boolean If true both angle channels will be recorded to trace.
Example: Program[Pgm01].General.StopMonAtNokStep
9836 3521 01 629

Peripheral Devices
8.17.5.6 Program, Monitoring data

Syntax: Program[<pgm name>].Mon.<parameter>

<parameter> = See table below (and Bolt Monitoring for a description)

MonStart Short integer Defines when to start monitoring. Takes the following
values:
0: Disabled
1: At cycle start
3: When a step that has the Start/restart monitoring flag
set is started (see Step – Control).
<MonStartTorqueVal>.
MonEnd Short integer Defines when to end monitoring. Takes the following values:
1: At cycle end
<MonEndTorqueVal>.
MonStartTorqueVal Float The torque value to reach before starting monitoring. Only
valid if <MonStart> is 4.
MonEndTorqueVal Float The torque value to reach before ending monitoring. Only
valid if <MonEndt> is 3.
MonBufAutoScale Boolean If True then the resolution of the monitoring buffer is auto
scaled.
MonResolution Short integer No of angle increment per buffer element in the monitoring
buffer. Valid only if <MonBufAutoScale> is False.
MonBufOverrunAllowed Boolean If True then monitoring buffer overrun is not regarded as an
error. Valid only if <MonBufAutoScale> is False.
Example: Program[Pgm01].Mon.MonStart
630 9836 3521 01

Peripheral Devices
8.17.5.7 Sequence and Program, Step, Control data

Syntax: Program[<pgm name>].Step[<step no>].Control.<parameter>
Sequence[<seq name>].Step[<step no>]. Control.<parameter>

<step no> = Step number, 1..50
<parameter> = See table below (and Step – Control for a description)

Sync Boolean If True then the step is synchronized.
StartMon Boolean If True then monitoring will be cleared and restarted when
the step is started.
Par[<par no>] Float The control function parameter (allowed values are 1..7).
The number of each parameter is given by the order they
are listed in chapter: Step – Control.
Example: Program[Pgm01].Step[1].Control.Sync
Program[Pgm01].Step[1].Control.Par[1]
8.17.5.8 Sequence and Program, Step, Speed data

Syntax: Program[<pgm name>].Step[<step no>].Speed.<parameter>
Sequence[<seq name>].Step[<step no>].Speed.<parameter>

<parameter> = See table below (and Step – for a description)

Speed Float Target Speed
Zsd Boolean If True then Zero Speed detection is active
Sru Float Speed ramp up
Tru Float Torque ramp up
RampType Short integer Ramp type. Possible values: Straight / Smoothened
1. Straight
2. Smoothened
NoSrds Short integer No of Speed ramp downs case used, [0..5]. See
Sequence and Program, Step, Speed, Ramp down data.
Example: Program[Pgm01].Step[1].Speed.Speed
9836 3521 01 631

Peripheral Devices
8.17.5.9 Sequence and Program, Step, Speed, Ramp down data

Syntax: Program[<pgm name>].Step[<step no>].Speed.RampDown[<ramp>].<parameter>
Sequence[<seq name>].Step[<step no>].Speed.RampDown[<ramp>].<parameter>

<ramp> = Ramp number, 1..5
<parameter> = See table below (and Step – for a description)

Start Short integer Defines the quantity to monitor as start condition.
Allowed values:
1. Torque
2. Angle
3. Current
4. Time
Level Float The trig level of the measured quantity.
Speed Float The new target speed.
Ramp Float The ramp to use when changing the speed.
Example: Program[Pgm01].Step[1].Speed.RampDown[1].Start
632 9836 3521 01

Peripheral Devices
8.17.5.10 Sequence and Program, Step, Other data

Syntax: Program[<pgm name>].Step[<step no>].Other.<parameter>
Sequence[<seq name>].Step[<step no>].Other.<parameter>

<seq name> = The name of the sequence

StartDelay Float Start delay of step
TorqueSpikeAngle Float Torque spike elimination angle
StopMethod Short integer How to stop. Allowed values:
1. Inertia break
2. Ramp down current
3. Hold Torque
InitialStopValue Float The start level of the amperage ramp expressed in % of
the amperage at shut off. Used only if <StopMethod> is
"Ramp down current".
DownRamp Float The amperage down ramp. Used only if <StopMethod>
is "Ramp down current".
HoldWhenStopped Boolean If True then the position should be maintained when
stopped. Can only be used if <StopMethod> is "Inertia
break" or "Ramp down current".
Example: Program[Pgm01].Step[1].Other.StartDelay
9836 3521 01 633

Peripheral Devices
8.17.5.11 Sequence and Program, Step, Surveillance data

Syntax: Program[<pgm name>].Step[<step no>].Surveillance [<id no>].Par[<par no>]
Sequence[<seq name>].Step[<step no>].Surveillance [<id no>].Par[<par no>]

<id no> = Identity number of check/restriction/monitoring function.
<par no> = Parameter number, 1..12, as listed in the description.
Example: Program[Pgm01].Step[1].Surveillance[1].Par[1]
8.17.6 Layout of Setups

A Setup is a complete package of data containing all information necessary to configure a complete
PowerMACS system. It is stored in a proprietary compressed format, safeguarded by Checksums to keep
its integrity. The main purpose for handling setups this way is for storage of backup copies, or for
exchange of setups between systems. It is not possible with normal software tools to read or write
information within a setup.
634 9836 3521 01

Peripheral Devices
9836 3521 01 635

Specification
9 Specification
9.1 Specification
This part is the specification of the system. It describes general performances of a complete system:
Topic Performance
Max. time from start signal until all spindles are running 50 msec.
Max. time from last spindle stops a step until all are running in the next step: 50 msec. + monitoring
time.
Max. time from last spindle stops last step until OK/NOK status on digital output, per 0.1 sec. + monitoring
spindle and total: time.
Max. time between cycles 0.5 sec at limited data
reporting.
Position accuracy 0.5 degrees.
Sampling frequency 1000 Hz
Stations per system. 1 – 15
Spindles per system 1 – 50
Delays in set values to servo 2 x sampling time
Maximum time for a loop in the PLC program 5
Maximum number of cycle data stored in the system Depends on number of
bolts and variables
included.
Traces per spindle. Each trace with 2000 values for angle, torque and current. Up to 300 (depends on
length of trace and curve
form)
Max time to change a device 3 min
The Performance values can be seen as a realistic estimate of performance for the finalized system, but
the design of the system is focused on reaching the Target values.
Traces will be stored in two circular buffers with equal size, one for OK cycles, the other for NOK cycles. A
new trace will overwrite the oldest stored trace, independent of tightening program.
636 9836 3521 01

Specification
9.2 Requirements ToolsTalk PC

Requirements for a ToolsTalk computer:
Windows XP or Windows 7
CPU clock frequency min 1 GHz
Memory min 1 GB
Disc with min 200 MB free
Monitor resolution min 1024x768
9836 3521 01 637

Appendix
10 Appendix
10.1 List of events
The below table lists the Code, Compact code, Type, Severity and Event string for most events that can
be generated by the system. The compact event code is only used when events are reported from an
Ethernet Open Protocol device.
Comp
Code Type Severity Event string
Code
1 1 Ext. com Error Unexpected signal: %d %d %d
2 2 System Error DB Get error %d, Proc %d, Case %d
3 3 Hardware Error Spurious interrupt %d, %d, %d
4 4 System Error Internal error on line %d in class base no %d, ret %d
6 40 Access Info Operator login
7 41 Access Info Operator logout
8 43 Access Info Illegal login
101 9 Power up Info Power on
102 10 Hardware Error System: Lost connection to TC %d
103 11 Hardware Info System: Established connection to TC %d
104 12 Hardware Error System: TC %d is of wrong type
105 13 Hardware Error System: Spindle TC %d is configured as system TC
106 442 Hardware Error System: TC %d is of wrong version
107 443 Hardware Error System: TC %d participates in another system
108 444 Hardware Error System: TC %d needs coldstart
201 14 Setup Error Easy View parameter %d fails in pos %d
202 15 System Error Error when reading/writing ODB image (err=%d)
203 16 System Error Error when reading ODB image (ODB seq.=%d, my seq.=%d)
204 431 System Error Error when receiving (type=%d, d1=%d, d2=%d)
205 432 System Error PLC ZIP file access error (access=%d, info=%d)
207 625 Setup Info New setup loaded
208 626 Setup Info Program changed
638 9836 3521 01

Appendix
Comp
Code
501 901 System Error Trying to read event that no longer exists (missing %d)
601 18 System Warning Start is impossible since there are no active spindles
603 20 System Error Bolt %d is connected to invalid spindle %d
604 21 System Error Bolt %d is connected to invalid spindle %d
605 22 System Error ST: signal from undefined spindle
606 23 System Error ST: signal from undefined bolt
607 24 System Error ST: Data structures inconsistent
608 25 System Error ST: Telegram %d received in wrong state %d from proc %d
609 26 System Error Start is impossible since station has no contact with spindle %d
610 27 System Error Start is impossible since station has no contact with PLC
611 28 System Error Start is impossible since station has no contact with Test Bolts
612 29 System Error Unexpected Cycle End when running RM
613 30 System Error Invalid Bolt number from spindle
614 31 System Error ST: DB read error %d for bolt %d
615 32 Emergency stop Warning ST: emergency stopped
616 33 Emergency stop Warning ST: machine stopped
617 34 System Error Start is impossible since stations has no contact with syinit
618 35 Setup Error Cycle data too big, bolt %d not stored
619 419 General Info Cycle start disabled
620 425 Setup Error Start is impossible since bolt %d and %d both uses TC %d
621 434 System Error Station failed to reach TC. Bolt is disconnected (OK)
622 435 System Error Station failed to reach TC. Bolt is disconnected (NOK)
623 436 System Error Station starts the cycle even though %d spindles could not be
reached
624 437 System Error Station failed to init servo. Bolt is disconnected (OK)
625 438 System Error Station failed to init servo. Bolt is disconnected (NOK)
626 439 System Error Station failed to read which cycle data that is wanted
627 445 System Error Start is impossible since there are conflicting TCs in the station
628 477 Setup Info Cycle data dropped since no bolt reached report threshold torque
limit
629 544 Setup Error ST: BoltControl from PLC has bad value (%d) in mode %d
9836 3521 01 639

Appendix
Comp
Code
630 545 Setup Error ST: Found no program for mode %d in mode table to run for the
bolt
631 552 System Error Start is impossible since station has no contact with Station
service
632 560 General Warning PLC BOLTCTRL2 cmd %d ignored since no bolts are selected
633 561 General Error PLC BOLTCTRL2 cmd %d ignored since station is not idle
634 562 General Error PLC BOLTCTRL2 cmd %d ignored since there is no cycle data
635 563 General Error PLC BOLTCTRL2 cmd %d ignored since bolt (ordinal no %d) has
no cycle data
636 564 General Info PLC BOLTCTRL2 cmd %d is ignored since command code is
unknown
637 565 General Info Cycle data with status %d dropped for bolt (ordinal no %d)
638 566 System Error Cycle data does not contain any bolt records
639 889 General Info Cycle start is only allowed from Audi XML device
640 19 General Info Cycle start is not allowed while FILTER_SPINDLEEV signal in
PLC is high.
700 36 System Error SP: DB read error %d, object %d
701 37 Setup Error No current channel configured
703 39 System Error SP: Internal error line %d, file %d (%d)
706 42 Setup Error Incorrect Sampling frequency
708 44 System Error Spindle initialization failed
709 45 System Error SP: Hunt for ipc process %d failed
711 47 Setup Error Incorrect Direction
712 48 Setup Error Step %d, Incorrect Torque spike elimination setup
713 49 Setup Error Step %d, Incorrect Pre step time
714 50 Setup Error Step %d, Incorrect Post step time
720 56 Check Error Step %d, Monitoring: Final torque. %f > %f
721 57 Check Error Step %d, Monitoring: Threshold angle. %f > %f
722 58 Check Error Step %d, Monitoring: Torque rate in interval 1. %.4f > %.4f
723 59 Check Error Step %d, Monitoring: Torque rate in interval 1. %.4f < %.4f
724 60 Check Error Step %d, Monitoring: Deviation in interval 1. %.4f > %.4f
725 61 Check Error Step %d, Monitoring: Yield point torque diff. %f > %f
640 9836 3521 01

Appendix
Comp
Code
726 62 Check Error Step %d, Monitoring: Yield point angle diff. %f > %f
727 63 Setup Error Monitoring: Incorrect configuration
728 64 Setup Error Step %d, Monitoring: Incorrect Final torque
729 65 Setup Error Step %d, Monitoring: Incorrect Threshold angle
730 66 Setup Error Step %d, Monitoring: Incorrect Torque rate deviation (interval %d)
731 67 Setup Error Step %d, Monitoring: Incorrect Yield point torque
732 68 Setup Error Step %d, Monitoring: Incorrect Yield point angle
733 69 Setup Error Trace: Incorrect configuration
734 70 Setup Error Step %d, Control: Incorrect Torque
735 71 Setup Error Step %d, Control: Incorrect Angle
736 72 Setup Error Step %d, Control: Incorrect Time
737 73 Setup Error Step %d, Control: Incorrect Current
739 75 Setup Error Step %d, Control: Incorrect Percent
740 76 Setup Error Step %d, Control: Incorrect No degrees
741 77 Setup Error Step %d, Control: Incorrect No of points (NNOS or RNOS)
742 78 Setup Error Step %d, Control: Incorrect Increment
743 79 Setup Error Step %d, Control: Incorrect Direction
744 80 Setup Error Step %d, Control: Incorrect Stop Condition
745 81 Setup Error Step %d, Control: Incorrect Digital Input
746 82 Setup Error Step %d, Control: Incorrect Digital Output
747 83 Setup Error Step %d, Control: Incorrect Step type from PLC
748 84 Setup Error Step %d, Restriction: Incorrect FS Angle
749 85 Setup Error Step %d, Restriction: Incorrect FS Torque
750 86 Setup Error Step %d, Restriction: Incorrect FS Time
752 88 Setup Error Step %d, Restriction: Incorrect Cross thread and gradient
753 89 Setup Error Step %d, Restriction: Incorrect Torque profile
754 90 Check Error Step %d, Check: Peak torque. %f > %f
755 91 Check Error Step %d, Check: Torque in angle window. %f > %f
756 92 Check Error Step %d, Check: Torque in time window. %f > %f
757 93 Check Error Step %d, Check: Mean torque. %f > %f
9836 3521 01 641

Appendix
Comp
Code
758 94 Check Error Step %d, Check: Angle. %f > %f
759 95 Check Error Step %d, Check: Time. %f > %f
760 96 Check Error Step %d, Check: Current as Torque. %f > %f
762 98 Check Error Step %d, Check: T/T3. %f > %f
763 99 Check Error Step %d, Check: Post view torque high.
764 100 Check Error Step %d, Check: Post view torque low.
765 101 Check Error Step %d, Diagnostic: Static Zero Offset high on T1. abs(%f) > %f
766 102 Check Error Step %d, Diagnostic: Dynamic Zero Offset high on T1. abs(%f) >
%f
767 103 Check Error Step %d, Diagnostic: Flying Zero Offset high on T1. abs(%f) > %f
768 104 Check Warning Step %d, Diagnostic: Flying Zero Offset high warning on T1.
abs(%f) > %f
769 105 Check Error Step %d, Diagnostic: Angle count high on A1. %f > %f
770 106 Check Error Step %d, Diagnostic: Calib. failed on T1. Meas. %f, expected %f
771 107 Setup Error Step %d, Diagnostic: Incorrect configuration
772 108 Setup Error Step %d, Check: Incorrect Peak torque
773 109 Setup Error Step %d, Check: Incorrect Torque in angle window
774 110 Check Error Step %d, Check: Torque in angle window failed
775 111 Setup Error Step %d, Check: Incorrect Torque in time window
776 112 Check Error Step %d, Check: Torque in time window failed
777 113 Setup Error Step %d, Check: Incorrect Mean torque
778 114 Check Error Step %d, Check: Mean torque failed
779 115 Setup Error Step %d, Check: Incorrect T/T3
780 116 Check Error Step %d, Check: T/T3 failed
781 117 Setup Error Step %d, Check: Incorrect Angle
782 118 Check Error Step %d, Check: Angle failed
783 119 Setup Error Step %d, Check: Incorrect Current
784 120 Setup Error Step %d, Check: Incorrect Clamp Load
785 121 Setup Error Step %d, Check: Incorrect Time
786 122 Setup Error Step %d, Check: Incorrect Post view
787 123 Check Error Step %d, Check: Post view Torque failed
642 9836 3521 01

Appendix
Comp
Code
788 504 Check Error Step %d, Check: Post view Torque failed (Buffer overflow)
793 128 General Warning Spindle %d: Time for service. %d cycles since service (%d to
many)
794 129 Setup Error Spindle: No program for mode %d
795 130 Setup Error Cycle data too big, step %d not stored
796 131 Check Error Step %d, Monitoring: Final torque could not be evaluated
797 132 Check Error Step %d, Monitoring: Threshold angle could not be evaluated
798 133 Check Error Step %d, Monitoring: Torque rate could not be evaluated (interval
%d)
799 134 Check Error Step %d, Monitoring: Yield point torque could not be evaluated
800 135 Check Error Step %d, Monitoring: Yield point angle could not be evaluated
801 136 Check Error Step %d, Check: Peak torque. %f < %f
802 137 Check Error Step %d, Check: Torque in angle window. %f < %f
803 138 Check Error Step %d, Check: Torque in time window. %f < %f
804 139 Check Error Step %d, Check: Mean torque. %f < %f
805 140 Check Error Step %d, Check: Angle. %f < %f
806 141 Check Error Step %d, Check: Time. %f < %f
807 142 Check Error Step %d, Check: Current as Torque. %f < %f
809 144 Check Error Step %d, Check: T/T3. %f < %f
810 145 Check Error Step %d, Diagnostic: Angle count low on A1. %f < %f
811 146 Check Error Step %d, Diagnostic: Angle count high on A2. %f > %f
812 147 Check Error Step %d, Diagnostic: Angle count low on A2. %f < %f
813 148 Setup Error Step %d, Speed is not defined
814 149 Setup Error Step %d, Control: Slope has bad configuration
815 150 Setup Error Step %d, Check: Wrong step type for Check
816 151 Check Error Step %d, Check: Angle at the corner failed
817 152 Check Error Step %d, Check: Angle at the corner %f < %f
818 153 Check Error Step %d, Check: Angle at the corner %f > %f
819 154 Setup Error Step %d, Check: Torque has bad configuration
820 155 Check Error Step %d, Check: Torque at the corner failed
821 156 Check Error Step %d, Check: Torque at the corner %f < %f
9836 3521 01 643

Appendix
Comp
Code
822 157 Check Error Step %d, Check: Torque at the corner %f > %f
829 164 Setup Error Step %d, Check: Shut Off Torque has bad configuration
830 165 Check Error Step %d, Check: Shut Off Torque %f < %f
831 166 Check Error Step %d, Check: Shut Off Torque %f > %f
832 167 Check Error Step %d, Check: Shut Off Torque failed
833 168 Setup Error Step %d, Restriction: Torque-Current has bad configuration
834 169 System Error Step %d, Received unexpected SP_RUN_STEPS from station.
835 170 General Error Step %d, Run reverse before retry failed (max time was
exceeded)
836 171 General Error Step %d, Run reverse before retry failed (max torque was
exceeded)
837 172 General Error Step %d, Run reverse before retry failed
838 173 Setup Error Step %d, Spindle %d has incorrect Gear ratio
839 174 Check Error Step %d, Monitoring: Final torque. %f < %f
840 175 Check Error Step %d, Monitoring: Threshold angle. %f < %f
841 176 Check Error Step %d, Monitoring: Torque rate in interval 2. %.4f > %.4f
842 177 Check Error Step %d, Monitoring: Torque rate in interval 2. %.4f < %.4f
843 178 Check Error Step %d, Monitoring: Deviation in interval 2. %.4f > %.4f
844 179 Check Error Step %d, Monitoring: Yield point torque diff. %f < %f
845 180 Check Error Step %d, Monitoring: Yield point angle diff. %f < %f
846 181 Check Error Step %d, Check: Torque rate %.4f > %.4f
847 182 Check Error Step %d, Check: Torque rate %.4f < %.4f
848 183 Check Error Step %d, Check: Deviation %f > %f
849 184 Check Error Step %d, Check: Torque Rate calculation failed
850 185 Check Error Step %d, Check: Overflow in Torque Rate recording buffer
851 186 Setup Error Step %d, Check: Torque rate/deviation has bad configuration
852 423 Setup Info Step %d, Retry is ordered but this step has no retry step
programmed
853 426 Check Error Step %d, Check: Angle failed because Torque stop was never
reached
854 427 Check Error Step %d, Monitoring: Torque level stop for Threshold angle was
never reached
644 9836 3521 01

Appendix
Comp
Code
863 460 Setup Error Step %d, Control: Start cond. "Sync Pulse" requires Angle 2 as
control channel
864 424 Setup Error Step %d, Control: Maximum Position has bad configuration
871 446 Check Error Step %d, Abs. Pos. not referenced. Speed ramp down abs. pos.
mode not possible.
872 447 Check Error Step %d, Speed ramp down has bad configuration
873 448 Check Error Step %d, Check: Absolute Position failed because position is not
referenced
874 449 Check Error Step %d, Digital Output for control of the brake is not configured
875 478 System Error Step %d, Received illegal Retry order in SP_RUN_STEPS from
station. (Spindle running %d.)
876 479 Check Error Step %d, Check: Peak torque failed.
878 481 Check Error Step %d, Diagnostic: Static Zero Offset high on T2. abs(%f) > %f
879 482 Check Error Step %d, Diagnostic: Dynamic Zero Offset high on T2. abs(%f) >
%f
880 483 Check Error Step %d, Diagnostic: Flying Zero Offset high on T2. abs(%f) > %f
881 484 Check Warning Step %d, Diagnostic: Flying Zero Offset high warning on T2.
abs(%f) > %f
883 531 Setup Error Step %d, Control: Torque-Angle step has bad configuration
884 532 Setup Error Step %d, Restriction: Start torque for FS Angle has bad
configuration
885 533 Setup Error Step %d, Restriction: Start condition for FS Angle has bad
configuration
887 535 Check Error Step %d, Monitoring 2nd: Final torque could not be evaluated
888 536 Check Error Step %d, Monitoring 2nd: Threshold angle could not be evaluated
889 537 Check Error Step %d, Monitoring 2nd: Final torque. %f > %f
890 538 Check Error Step %d, Monitoring 2nd: Threshold angle. %f > %f
891 539 Check Error Step %d, Monitoring 2nd: Final torque. %f < %f
892 540 Check Error Step %d, Monitoring 2nd: Threshold angle. %f < %f
893 541 Check Error Step %d, Monitoring 2nd: Torque level stop for Threshold angle
was never reached
894 542 Setup Info Monitoring 2nd buffer: No second channels. 2nd buffer used in
check %d, step %d.
895 549 Setup Error Step %d, Restriction: Incorrect FS Min torque configuration
9836 3521 01 645

Appendix
Comp
Code
897 555 Setup Error Step %d, Restriction: Incorrect Gradient restriction configuration
898 683 Setup Error Step %d, Check: Incorrect Yield Point Check configuration
899 690 Check Error Step %d, Diagnostic: Spindle shunt test failed on channel %d
901 187 Check Error Step %d, Restriction: Fail-safe torque
902 188 Check Error Step %d, Restriction: Fail-safe angle
903 189 Check Error Step %d, Restriction: Fail-safe time
905 191 Check Error Step %d, Restriction: Cross thread and gradient
906 192 Check Error Step %d, Restriction: Torque profile
907 193 Check Error Double transducer: torque diff high
908 194 Check Error Double transducer: angle diff high
909 195 System Error Monitoring: Overflow in recording buffer %d
910 196 Hardware Error Step %d, Servo hardware failure, Id %d
911 197 Setup Error Incorrect Servo configuration
917 203 System Error No Snug point was found
918 440 Check Error Step %d, Restriction: Remove fastener torque limit
920 455 Check Error Step %d, Spindle protection: Maximum backward load exceeded
921 414 Check Error Step %d, Maximum forward position exceeded
922 415 Check Error Step %d, Maximum backward position exceeded
923 529 Check Error Spindle protection: Max allowed torque for spindle exceeded
924 550 Check Error Step %d, Restriction: Min Torque
925 556 Check Error Step %d, Restriction: Gradient too high
926 557 Check Error Step %d, Restriction: Gradient too low
927 558 Check Error Step %d, Restriction: Gradient error as angle decreased
929 684 Check Warning Step %d, Check YP: Gradient calculation restarted as angle
decreased
930 934 Check Error Step %d, Fatal continue rotation error, was not handled by reject
management
931 935 Check Error Step %d, Restriction error during continue rotation
932 936 Setup Warning Step %d, Continue rotation is not allowed at step start, spindle
was stopped
933 937 Setup Warning Step %d, Direction changed during Continue rotation
646 9836 3521 01

Appendix
Comp
Code
939 461 Setup Error Step %d, Control ADJ step, no contact with TC running MEAS
step
946 462 Check Error Step %d, Max number of retries exceeded
947 463 Check Error Step %d, Control MEAS step, no contact with TC running ADJ
step
948 464 Check Error Step %d, Control ADJ step, no contact with TC running MEAS
step
949 465 Check Error Step %d, Control MEAS or ADJ step was aborted
950 466 Setup Error Step %d, Control: MEAS step has bad configuration
951 467 Setup Error Step %d, Control: ADJ step has bad configuration
952 468 Check Error Step %d, Check: First Mean Load measurement failed.
953 469 Check Error Step %d, Check: First Mean Load measurement. %f > %f
954 470 Check Error Step %d, Check: First Mean Load measurement. %f < %f
955 471 Setup Error Step %d, Check: Bad First Mean Load measurement
configuration.
956 472 Setup Error Step %d, Control: Not possible to get value for Baseline/Preload
957 472 Check Error Step %d, Meas step failed, measured Mean Load outside limits
958 474 Check Error Step %d, Set direction in ADJ3 step failed. T Err. = %f, A Target =
%f
959 475 Check Error Step %d, Control ADJ step was aborted
960 480 Check Info Step %d, Signal between MEAS and ADJ step was droped and
not executed
961 959 Check Warning TC %d, Inertia brake was not allowed. Ramp down current was
used instead
1001 553 System Error Trace: Unable to store new trace on TC %d, too many saved
traces
1102 205 Hardware Error Low battery voltage on TC %d
1106 209 System Error System TC on addr 0x%x received setup from other system TC
with addr 0x%x
1107 210 System Error TC %d received setup from 2 system TCs: 0x%x and 0x%x
1108 890 System Error TC %d Device type %d uses a serial channel, this is only allowed
on PTC
1150 441 System Error TC %d restarted due to fatal SW error (code: %s, sub code: 0x%x)
9836 3521 01 647

Appendix
Comp
Code
1401 211 General Warning Printer on TC %d (port %d) does not support Device Command =
%d
1500 212 Ext. com Error ID write error %d on TC %d, port %d
1501 213 Ext. com Error ID read error %d on TC %d, port %d
1502 214 Ext. com Error ID read error on TC %d, port %d. Invalid start char. ASCII = 0x%x
1503 215 Ext. com Error ID read error on TC %d, port %d. Unable to read tag, Data = %d
1504 216 Ext. com Error ID write error on TC %d, port %d. Unable to write tag, Data = %d
1506 530 Ext. com Error ID device on TC %d, failed to write process data
1507 886 Ext. com Error ID read error on TC %d, port %d. Tot. length of string was more
than %d chars
1508 887 Ext. com Error ID read error TC %d, port %d. Start char was never received,
must be ASCII=0x%x
1601 218 System Error Device init. error (TC %d, device %d, info %d)
1602 219 Ext. com Error Illegal link message received (TC %d, device %d, info %d)
1603 220 Ext. com Error Device is not on a PLC TC (TC %d, device %d)
1604 221 Ext. com Error Missing sequence number (TC %d, device %d, expected seq. no
%d)
1605 222 Ext. com Error Received setup is too big (TC %d, device %d)
1606 891 Ext. com Error Device is not on the System TC (TC %d, device %d)
1701 223 System Error Fieldbus on TC %d has no contact with PLC
1702 224 System Error Fieldbus on TC %d can not read process data (err %d)
1703 225 System Error Fieldbus on TC %d can not write process data (err %d)
1704 226 Ext. com Error Fieldbus on TC %d can not read from board (err %d)
1705 227 Ext. com Error Fieldbus on TC %d can not write to board (err %d)
1706 228 Ext. com Error Fieldbus on TC %d rec. a req. (0x%x) that requires Data bytes In
>= %d
1707 229 Ext. com Error Fieldbus on TC %d rec. a req. (0x%x) that requires Data bytes Out
>= %d
1708 230 Setup Error Fieldbus on TC %d requires Data bytes Out > %d to auto load
cycle data
1709 231 Ext. com Error Fieldbus on TC %d rec. a Flush/Skip req. (0x%x) for an invalid
address %d
648 9836 3521 01

Appendix
Comp
Code
1710 232 Ext. com Error Fieldbus on TC %d rec. an ambig. req. (0x%x) (>1 of R, W, F & S
are set)
1711 233 Ext. com Error Fieldbus on TC %d rec. a req. (0x%x) having an invalid extended
format
1712 234 Ext. com Error Fieldbus on TC %d rec. a req. (0x%x) having an invalid address
(%d)
1713 235 System Error Fieldbus on TC %d is not licensed
1901 237 System Error API on TC %d rec. an illegal message (err %d, info %d)
1902 238 System Error API on TC %d rec. a Read Setup req. Only allowed on TC 1
1903 239 System Error API on TC %d rec. a Write Setup req. Only allowed on TC 1
1904 240 System Error API on TC %d rec. a Read Setup Item req. Only allowed on TC 1
1905 241 System Error API on TC %d rec. a Write Setup Item req. Only allowed on TC 1
1906 242 System Info API on TC %d failed to send answer (cmd=%d, ret=%d)
2001 243 System Error CCH: Error when receiving (type=%d, d1=%d, d2=%d)
2005 247 System Error CCH: Unable to delete trace (first failing TC=%d)
2006 248 System Error CCH: Unable to delete events (first failing TC=%d)
2007 249 System Error CCH: Unable to delete cycle data (first failing TC=%d)
2008 250 System Error CCH: Unable to delete SPC data (first failing TC=%d)
2009 251 System Error CCH: Link message is too big (sock=%d, size=%d)
2010 252 System Error CCH: Link message has no header (sock=%d)
2011 892 General Error CCH: Function GetSetupObject() used
2100 253 System Error REP: Calculated size wrong (value=%f, width=%d, ndec=%d)
2101 433 Setup Error REP: Invalid date/time format selected
2201 254 System Error IO: two units with same address
2202 255 System Error IO: Illegal channel
2203 256 System Error IO: No CAN driver found
2204 257 Hardware Error IO: TC %d, chan %d. Subscriber not found
2205 258 Ext. com Error IO: Error communicating with I/O device (TC %d, identity %d)
2206 893 Ext. com Error IO: Error when configurating I/O signal (TC %d, MacId %d, Err
%d)
2207 902 Hardware Error IO: Node %d, Sig %d, referring address %d on fieldbus
9836 3521 01 649

Appendix
Comp
Code
2400 260 System Error Zip expand failed. Error %d, size in %d, size out: %d
2401 261 System Error Zip compress failed. Error %d, size in %d, size out: %d
2701 681 Hardware Error No angle channel found
2702 682 Hardware Error No torque channel found
2802 345 System Error Invalid communication port %d for device
2900 347 System Error Unexpected signal
3100 348 System Error Hunt for station failed
3101 349 System Error TestBolt: DB read error, code %d
3102 350 Setup Error TestBolt: No station defined in the setup
3103 351 General Error TestBolt: Disabled by PLC for station %d
3201 352 System Error PLC: Run time system error (code 0x%x, info 0x%x)
3202 353 System Error PLC: Bootfile access error (error %d)
3203 354 System Error PLC: Only one input and one output 'EXTCOM' driver allowed
(now %d and %d)
3204 355 System Error PLC: 'EXTCOM' area (input %d + output %d) is too big (max %d
bytes)
3205 356 Setup Error PLC: 'ANYBUS' variables defined but no Fieldbus device exists
3206 357 Setup Error PLC: Only one 'ANYBUS' input/output driver is allowed (now %d
and %d)
3208 359 General Error PLC: User event %d generated
3210 567 General Error PLC: The target device for DEVCMD does not exist
3211 568 General Error PLC: Device %d on TC %d is not allowed as target for DEVCMD
(wrong type %d)
3212 569 General Error PLC: Failed to send DEVCMD %d to device %d on TC %d
3215 896 Setup Error PLC: LIO driver will not be used. Use I/O device instead.
3216 958 System Error PLC: Illegal channel no %d.
3303 364 Setup Error Fieldbus on TC %d: Config. error. Max output size=%d, max input
size=%d
3305 366 Setup Error Fieldbus on TC %d: Board type mismatch, type connected=%d,
type configured=%d
3307 368 Setup Error Fieldbus on TC %d: Configured Node addr.(%d) is out of range
3308 369 Setup Error Fieldbus on TC %d: Setting Node addr. by SW is not supported
650 9836 3521 01

Appendix
Comp
Code
3309 370 Setup Error Fieldbus on TC %d: Setting Baude Rate by SW is not supported
3310 371 Setup Error Fieldbus on TC %d: Configured Baude Rate (%d) is not supported
3311 372 Setup Error Fieldbus on TC %d: Configured Source Node addr. (%d) is out of
range
3312 373 Setup Error Fieldbus on TC %d: Source no. of words (%d) is > Fast bytes In /
2 (%d)
3313 374 Setup Error Fieldbus on TC %d: Source Offset + Source no. of words (=%d)
must be <= 32
3314 375 Setup Error Fieldbus on TC %d: Unsupported param used (Modbus specific)
3315 543 Setup Error Fieldbus on TC %d: Configured Number of Stations (%d) is not
supported
3316 897 Setup Error Fieldbus on TC %d: Config error. PLC bytes in/out must be over 0.
3317 898 Ext. com Error Fieldbus on TC %d: Error! Fieldbus could not be initialized!
3318 910 Setup Error Fieldbus on TC %d: Configuration error. (%d)!
3402 377 System Error ToolsNet: Illegal message received (error type %d, info %d)
3403 378 Ext. com Info Toolsnet: Connection to server established using protocol ver. %f
3404 379 Ext. com Error Toolsnet: Connection to server lost
3405 380 Setup Error ToolsNet: Bad Data IP address (%X)
3406 381 Setup Error ToolsNet: Bad Status IP address (%d)
3407 428 Ext. com Info ToolsNet: Wrong TgmId received for Ack, Exp.=%d, Rec.=%d
3408 429 Ext. Com Info ToolsNet: Wrong SeqNo received for Ack, Exp.=%d, Rec.=%d
3409 430 Ext. com Error ToolsNet: Timeout when waiting for Acknowledge
3410 456 Ext. com Error ToolsNet: Wrong message ver., TgmId: %d, TgmVer: %d (exp.),
%d (rec.)
3411 457 Ext. com Error ToolsNet: ToolsNet rejected protocol version %f
3412 458 Ext. com Warning ToolsNet: Telegram Id %d is not supported in protocol version %f
3413 459 Setup Error ToolsNet: Entered protocol version %f is not supported in
PowerMACS
3414 622 Ext. com Error ToolsNet: Link closed by server (state %d)
3415 623 Ext. com Error ToolsNet: Link closed due to error %d (state %d)
3416 624 Ext. com Error ToolsNet: Link closed due to send congestion (error %d, state %d)
3450 601 System Error ToolsNet: Station number is missing in Cycle data
9836 3521 01 651

Appendix
Comp
Code
3451 602 System Error ToolsNet: Start time is missing in Cycle data
3452 603 System Error ToolsNet: Station status is missing in Cycle data
3453 604 System Error ToolsNet: Bolt number is missing in Cycle data
3454 605 System Error ToolsNet: Bolt status is missing in Cycle data
3455 606 System Error ToolsNet: Bolt data for bolt no: %d is missing in Cycle data
3456 607 System Error ToolsNet: Operation mode for bolt no: %d is missing in Cycle data
3457 608 System Error ToolsNet: Wrong format for torque and/or angle factors
3458 609 System Error ToolsNet: Reported data for %d of %d optional variables for Bolt:
%d
3459 610 System Error ToolsNet: Reported data for %d of %d Bolts
3460 611 System Error ToolsNet: Cycle data is corrupt, not possible to send, Info = %d
3500 382 System Error SPC: DB read error (%d)
3501 383 System Error SPC: Out of memory
3503 384 System Error SPC: Variable does not exist (Bolt: %d, StepNo: %d, Var: %d)
3504 385 SPC Error SPC: One out check failed
3505 386 SPC Error SPC: End gather check failed
3506 387 SPC Error SPC: Mid gather check failed
3507 388 SPC Error SPC: Seven above check failed
3508 389 SPC Error SPC: Seven below check failed
3509 390 SPC Error SPC: Seven up check failed
3510 391 SPC Error SPC: Seven down check failed
3511 392 SPC Error SPC: Cp limit check failed
3512 393 SPC Error SPC: Cpk limit check failed
3513 394 SPC Error SPC: Cam limit check failed
3514 395 System Error SPC: Sub group size must be > 0 (NoSttSgSave=%d Sgsize=%d
NoSubSgSave=%d)
3515 396 System Error SPC: Ref. to free area is corrupt (FreeMem=%d SubgrpBase=%d
NoSubSgSave=%d)
3516 397 SPC Error SPC: SPC data structure corrupt, pos %d, idx: %d, %d
3517 398 Setup Error SPC: Too many variables for spindle %d
3601 399 Ext. com Error Illegal link message rec. (device %d, type %d, info %d)
652 9836 3521 01

Appendix
Comp
Code
3700 400 Ext. com Error Send failed. Not possible to correct with retransm. (port %d, info
%d)
3701 401 Ext. com Error Received failed (port %d, info %d)
3702 402 Ext. com Error State machine error for send (port %d, state %d)
3703 403 Ext. com Error State machine error for receive (port %d, state %d)
3704 404 Ext. com Error Status from sio not OK (port %d, retcode %d)
3705 405 Ext. com Error Unknown protocol selected (port %d, protocol type %d)
3706 406 Ext. com Error Bad checksum received (port %d, checksum in tgm %d, calc.
checksum %d)
3707 407 Ext. Com Error Read telegram failed (TELWAY protocol, info %d)
3801 408 System Error Error when receiving (type=%d, d1=%d, d2=%d)
3802 409 System Error Error when sending (type=%d, d1=%d, d2=%d)
3811 420 Ext. Com Info Device %d, Connection established
3812 421 Ext. com Error Device %d, Connection lost
3813 422 Setup Error Bad Data IP address, %d
3814 505 Ext. com Error Bad configuration of Barcode and VIN number
3815 506 Ext. com Error Station QO has not correct value: %d
3816 546 Ext. com Error Bad length of received TMU, (actual = %d, expected = %d)
3817 508 Ext. com Error No response from PLUS server
3818 509 Ext. com Error Send data failed, Wp ID must be 10 char and start with PN or KN
(len. = %d)
3819 510 Ext. Com Info Device %d, Connection to PLUS established as server
3820 511 Ext. Com Info Device %d, Connection to PLUS established as client
3821 519 Ext. com Error No TMU received from PLUS, NNEG received
3822 520 Ext. Com Info No TMU received from PLUS, No tightening shall be made for
sent barcode
3823 521 Ext. com Warning No TMU received from PLUS, Barcode already used
3824 522 Ext. com Error No TMU received from PLUS, telegram sent from TC inconsistent
3825 523 Ext. com Warning Problem in PLUS server, NNEG received in state Idle
3826 524 Ext. com Warning No matching mode number for received TMU
3827 525 Ext. com Error No SA found for mode number: %d
9836 3521 01 653

Appendix
Comp
Code
3828 526 Ext. com Error SA has not correct value: %d
3829 529 Ext. com Warning No TMU received from PLUS, Double tightening not allowed
3830 530 Ext. com Error No TMU received from PLUS, Id No unknown in PLUS server
3831 547 Ext. com Error No TMU received from PLUS, Bad layout of telegram
3832 548 Ext. com Error No TMU received, no connection to PLUS
3833 507 Ext. com Error Request of TMU failed, barcode has bad length (actual = %d,
expected = %d)
3834 570 Ext. com Error Data could not be sent, NACK received from I-P.M.
3835 571 Ext. com Error Data could not be sent, no answer from I-P.M.
3836 572 System Info Received TMU from PLUS not accepted, device already busy
3837 573 System Info Received TMU from PLUS not accepted, device busy sending
cycledata
3838 574 System Error A non VBA station received a TMU without a request from the TC
3839 589 Ext. com Warning No program number defined, used PgmNo = 0 when sending data
to I-P.M.
3840 590 Ext. com Warning The AFO no was too long, %d chars, only %d sent to I-P.M.
3841 614 Ext. com Error No TMU received from PLUS, wrong IT type in received telegram
3842 559 Ext. com Error EPH: OpenProtocol, revision %d of MID%d is not supported
3843 616 Ext. com Info Total length of IT and IW is %d chars. Truncated after %d chars
3845 618 Ext. com Error Send data failed, Wp ID must start with specified VIN number type
3846 619 Ext. com Error Send data failed, not possible to store data in PLUS (TC received
I*NQ)
3847 620 Ext. com Error Unknown or corrupt tgm received from PLUS (Error=%d, tgm
id=%d, state=%d)
3848 621 Ext. com Error Error when sending telegram to PLUS (Error=%d, tgm id=%d,
state=%d)
3849 591 System Error Device %d. No ACK (MID %d) received from Integrator, closing
connection
3850 719 System Error No connection to station %d
3851 720 System Error Group %d cannot be selected/deselected since it does not exist
3852 721 System Error Chan. %d cannot be selected since it does not exist
3853 722 System Error Group %d cannot be deselected since it is not selected
3854 723 System Error Group %d is not valid for the operation
654 9836 3521 01

Appendix
Comp
Code
3855 724 System Error TAP/TNR cannot be added to chan. %d since it is not part of
group %d
3856 725 System Error Cannot enable group %d since it is not selected (no GRS.GRP
received)
3857 726 System Error Cannot enable chan. %d since it is not selected (no PRS received)
3858 727 General Info Start failed since no groups or channels are specified
3859 728 Ext. com Error Too large XML message
3860 729 System Warning Master PC PNR %d not supported. PNR of Audi XML device is
%d
3861 730 System Error Cannot disable group %d since it is not enabled
3862 731 System Error Cannot disable chan. %d since it is not enabled
3863 732 System Error Cannot disable chan. %d of group %d since it is not part of the
group
3864 733 System Error Group %d cannot be started since it is not enabled
3865 734 System Error Channel %d cannot be started since it is not enabled
3866 735 System Error Start failed since group %d is already running
3867 736 System Error Start failed since chan. %d is already running
3868 737 System Error Start failed since station %d used by group %d already is
occupied
3869 738 System Error Start failed since station %d used by chan. %d already is occupied
3871 739 System Error Start failed since groups does not have the same batch
parameters
3872 740 System Error Start failed since chan. %d of group %d already is occupied
3873 741 System Error Start failed since chan. %d already is occupied
3874 742 System Error Start/stop of station %d failed due to connection problem
3875 743 System Error Group %d cannot be selected since it does not have ny channels
3876 744 System Info Manual start ignored since device is not configured for manual
control
3877 745 System Info Manual loosen ignored since it is not enabled by the Master PC
3878 746 System Error Chan. %d cannot be selected since there is no program with no.
%d
3879 747 System Error %s without KNR is not supported
3880 748 System Error %s without GRS and KNR is not supported
9836 3521 01 655

Appendix
Comp
Code
3881 749 System Error %s with both GRS and KNR is not supported
3882 750 System Error Start of station %d failed. Machine stopping all stations
3883 911 System Error VW Variant not allowed on systems with more then one TC
3901 416 Setup Error GMH: DeviceNet: Input area (%d) is wrong size. Fieldbus declares
only (%d) bytes
3902 417 Setup Error GMH: DeviceNet: Output area (%d) is wrong size. Fieldbus
declares only (%d) bytes
3903 418 System Error GMH: Hunt for station failed
4002 575 Check Error Step %d, Monitoring: Follow the Curve could not be evaluated for
buffer %d
4004 593 Check Error Step %d, Monitoring: Absolute Position high. %f > %f
4005 594 Check Error Step %d, Monitoring: Absolute Position low. %f < %f
4006 551 Check Error Step %d, Monitoring: Abs Pos not referenced. Pos check could
not be evaluated
4007 358 Check Error Step %d, Monitoring: Pre End Torque could not be evaluated
4008 360 Check Error Step %d, Monitoring: Pre End Torque high limit failed. %f > %f
4009 361 Check Error Step %d, Monitoring: Pre End Torque low limit failed. %f < %f
4010 362 Setup Error Step %d, Monitoring: Absolute Position has bad configuration
4011 363 Setup Error Step %d, Monitoring: Pre End Torque has bad configuration
4012 376 Setup Error Step %d, Speed ramp down has to high value %f > %f
4013 685 Check Error Step %d, Check: Yield Point check failed, no yield point found
4015 686 Check Error Step %d, Check: Yield Point Angle high, %f > %f
4016 687 Check Error Step %d, Check: Yield Point Angle low, %f < %f
4017 688 Setup Error Step %d, Check: Stick-Slip has bad configuration
4018 689 Check Error Step %d, Check: Stick Slip Error
4020 262 Check Error Step %d, Monitoring: FtC, Start torque was never reached
4021 263 Check Error Step %d, Monitoring: Abs Pos not referenced. FtC check could not
be evaluated
4022 264 Check Error Step %d, Monitoring: FtC, high limit, Start angle is not in buffer
4023 265 Check Error Step %d, Monitoring: FtC, low limit, Start angle is not in buffer
4024 266 Check Error Step %d, Monitoring: Follow the Curve High limit failed, (interval
%d)
656 9836 3521 01

Appendix
Comp
Code
4025 267 Check Error Step %d, Monitoring: Follow the Curve Low limit failed, (interval
%d)
4101 476 Ext. com Info ACTA: Batch result received. (torque flags=%d, angle flags=%d,
pulses flags=%d)
4103 595 Ext. com Warning ACTA: Set Torq SF failed for sp %d, too high diff (old = %f, new =
%f)
4104 596 Ext. com Error ACTA: Set Torq Scale Factor failed for sp %d
4105 597 Ext. com Info ACTA: Torq SF changed for T1 on spindle %d, old = %f, new = %f
4106 598 Ext. com Info ACTA: DATAHOLD or DATADROP used, no cycle data will be
avaliable for ACTA
4107 599 Ext. com Warning ACTA: Set Torq SF failed for spindle %d, it is used more than
once in the cycle
4108 600 Ext. com Info ACTA: Not possible to start tightening, spindle %d is not used in
mode %d
4201 650 Ext. com Error DASP: TC %d: Message receiving error (0x%x)
4203 651 Ext. com Error DASP: TC %d: Received wrong DLP task (task=%d), (key=%d)
4206 654 Ext. com Error DASP: Servo on TC:%d has wrong LLP version (0x%x)
4207 655 Ext. com Error DASP: Spindle on TC:%d has wrong LLP version (0x%x)
4208 656 Ext. com Error DASP: TC %d: No servo connected
4209 657 Ext. com Error TC %d: No spindle detected, check cable and connections
4210 658 Ext. com Error DASP: TC %d: Stream %d resend max time
4211 659 Ext. com Info DASP: TC %d: New software has been downloaded to the servo
4212 660 Ext. com Info DASP: TC %d: New software has been downloaded to the spindle
4213 661 System Error DASP: TC %d: Update EEPROM in servo, command has already
been sent
4214 662 System Error DASP: TC %d: Bank select failed
4215 663 System Error DASP: TC %d: Failed to read from device boot
4216 664 System Error DASP: TC %d: Application do not match this device (Model %d,
App %d)
4217 665 System Error DASP: TC %d: Device HW version too low (Variant %d, LowLim
%d)
4218 666 System Error DASP: TC %d: Device HW version too high (Variant %d, HighLim
%d)
9836 3521 01 657

Appendix
Comp
Code
4219 667 Ext. com Error DASP: TC %d: Servo ALP version too high (Servo %d, Supported
up to %d)
4220 668 Ext. com Error DASP: TC %d: Spindle ALP version too high (Spindle %d,
Supported up to %d)
4223 671 Ext. com Error DASP: TC %d: Update EEPROM in spindle, command has
already been sent
4224 648 Ext. com Info DASP: TC %d: Restarting servo and TC.
4225 649 Ext. com Info DASP: TC %d: Restarting spindle.
4227 677 General Error TC %d: Incorrect spindle article number
4228 678 General Warning TC %d: Any Spindle article number in use
4229 679 General Error TC %d: Simulated Spindle and Servo in use
4230 680 System Info TC %d, Replaced ramp down with i. brake (too short time between
start/stop)
4231 903 General Info Conv. Box: TC %d, New box detected
4232 904 General Error Conv. Box: TC %d, Failed to program box with reference values
from setup
4233 905 General Error Conv. Box: TC %d, Motortune is required and calibration is
recommended
4234 906 General Info Conv. Box: TC %d, Box programmed successfully
4235 907 General Warning Conv. Box: TC %d, Checksum faults detected. Verify spindle
calibration values
4401 554 General Warning Multiple ID: Bypassed Work Order position %d, which uses
Identifier Type %d
4501 703 Ext. com Error ANYBUS: TC %d: Unable to initialize the serial channel
4502 704 Ext. com Error ANYBUS: TC %d: Unable to configure the serial channel
4503 705 Ext. com Error ANYBUS: TC %d: Driver Error! Severity (%d) Code (%d)
4504 706 Ext. com Warning ANYBUS: TC %d: Connection to ABCC Recovered.
4505 707 Ext. com Info ANYBUS: TC %d: Connection to ABCC lost!
4507 708 Ext. com Error ANYBUS: TC %d: Error! No module connected!
4508 709 Ext. com Error ANYBUS: TC %d: Error! Module not supported!
4509 710 Ext. com Error ANYBUS: TC %d: Error! Wrong anybus network module mounted!
4510 711 Ext. com Error ANYBUS: TC %d: Error! Attached module is not an AnyBusCC
module!
658 9836 3521 01

Appendix
Comp
Code
4511 712 Ext. com Error ANYBUS: TC %d: Error! Exception (%d) in AnyBus module!
4512 713 Ext. com Error ANYBUS: TC %d: Error! Read request offset (%d) is out of range!
4513 714 Ext. com Error ANYBUS: TC %d: Error! Write request offset (%d) is out of range!
4514 715 Ext. com Error ANYBUS: TC %d: Error! Failed to set up read map!
4515 716 Ext. com Error ANYBUS: TC %d: Error! Failed to set up write map!
4516 717 Ext. com Error ANYBUS: TC %d: Setup done!
4517 718 Ext. com Error ANYBUS: TC %d: Error! Module version (%x) does not support
Extended Mode!
5001 751 Hardware Error TC %d, Servo Overtemp: Power Stage %f deg
5002 752 Hardware Error TC %d, Servo EEPROM Version Error
5003 753 Hardware Error TC %d, Servo Motor parameters invalid
5004 754 Hardware Error TC %d, Servo Motortune parameters invalid
5005 755 Hardware Error TC %d, Servo software error Id %d Code %d
5006 756 Hardware Error TC %d, Servo software warning Id %d Code %d
5007 757 Hardware Error TC %d, Servo Ref21 Error 0x%x
5020 758 Hardware Error TC %d, Spindle Overtemp: Motor %f deg, Chip %f deg
5021 759 Hardware Error TC %d, Spindle 5V Digital Torque Off
5022 760 Hardware Error TC %d, T1 Voltage Off
5023 761 Hardware Error TC %d, Spindle EEPROM Error. New spindle parameters needed.
5024 762 Hardware Error TC %d, Torque 1 Low. Torque Value outside transducer range
(transducer failure)
5025 763 Hardware Error TC %d, Torque 1 High. Torque Value outside transducer range
5026 764 Hardware Error TC %d, Torque 2 Low. Torque Value outside transducer range
5027 765 Hardware Error TC %d, Torque 2 High. Torque Value outside transducer range
5028 766 Hardware Error TC %d, Torque 2 Voltage Off
5029 767 Hardware Error TC %d, Spindle Chassis ground error
5030 768 Hardware Error TC %d, Spindle Ref21 Error 0x%x
5040 769 System Error TC %d, Could not read ref %d from spindle
5041 770 System Error TC %d, Could not read ref %d from servo
9836 3521 01 659

Appendix
Comp
Code
5042 771 Hardware Error Step %d, Diagnostic: Shunt values T1 Offset %d, Gain %d
5043 772 Hardware Error Step %d, Diagnostic: Shunt values T2 Offset %d, Gain %d
5044 773 System Error TC %d, Could not write ref %d to spindle, bytes %d
5045 774 System Error TC %d, Could not write ref %d to servo, bytes %d
5046 775 System Error TC %d, Failed to update checksum group %d on spindle
5047 776 System Error TC %d, Failed to update checksum group %d on servo
5048 777 System Error TC %d, Channel %d Hardware Error %x
5049 778 General Info TC %d, Motortune Started
5050 779 General Info TC %d, Motortune Complete
5051 780 General Info TC %d, Motortune Aborted
5052 781 General Info TC %d, Motortune Failed, Progress %x, Status %x
5053 782 Hardware Error TC %d, Drive parameters invalid
5054 783 System Error TC %d, Channel error %x
5055 784 Check Error Diagnostic: Torque/Current calibration finished due to time
5056 785 System Error Servo Communication Error (WD %d)
5057 615 General Info TC %d, Not possible to start motortune, cycle running or TC is
emergency stopped
5070 786 Hardware Error TC %d, Spindle Software Warning
5071 787 Hardware Error TC %d, Spindle Software Error
5080 788 Hardware Error TC %d, Servo Current Control Error
5081 789 Hardware Error TC %d, Servo Driver Stalled
5082 790 Hardware Error TC %d, Servo Missed angle
5083 791 Power up Error TC %d, Gate Driver Voltage Low
5090 792 Hardware Error TC %d, Servo Current High
5091 793 Hardware Error TC %d, Servo Offset Error
5092 794 Hardware Error TC %d, Servo HW Trip
5093 795 Hardware Error TC %d, Servo I2R Integrator High
5094 796 Hardware Error TC %d, Servo DC Bus Low
5095 797 Hardware Error TC %d, Servo DC Bus High
5096 798 Setup Warning Negative spindle windup.
660 9836 3521 01

Appendix
Comp
Code
5101 799 System Error TC %d, Spindle Functional Test Required (Diagnostic Step)
5102 800 System Info TC %d, FPGA ERROR Isr & Imr 0x%x Usr 0x%x
5103 801 System Info TC %d, FPGA OVERFLOW Count %d Usr 0x%x
5104 802 Hardware Error TC %d, Sensor Error on Angle Channel %d
5105 803 Hardware Error TC %d, Sensor Error on Torque Channel %d
5201 804 System Error TC %d, Error writing serial number to spindle. Ref %d, Status %d
5202 805 System Error TC %d, Error reading serial number from spindle. Ref %d, Status
%d
5203 806 System Error TC %d, Error writing model to spindle. Ref %d, Status %d
5204 807 System Error TC %d, Error reading model from spindle. Ref %d, Status %d
5205 808 System Error TC %d, Error writing type to spindle. Ref %d, Status %d
5206 809 System Error TC %d, Error reading type from spindle. Ref %d, Status %d
5207 810 System Error TC %d, Error writing max torque to spindle. Ref %d, Status %d
5208 811 System Error TC %d, Error reading max torque from spindle. Ref %d, Status %d
5209 812 System Error TC %d, Error writing gear ratio to spindle. Ref %d, Status %d
5210 813 System Error TC %d, Error reading gear ratio from spindle. Ref %d, Status %d
5211 814 System Error TC %d, Error writing motor temp to spindle. Ref %d, Status %d
5212 815 System Error TC %d, Error reading motor temp from spindle. Ref %d, Status %d
5213 816 System Error TC %d, Error writing electronics temp to spindle. Ref %d, Status
%d
5214 817 System Error TC %d, Error reading electronics temp from spindle. Ref %d,
Status %d
5215 818 System Error TC %d, Error writing units per lap to spindle. Ref %d, Status %d
5216 819 System Error TC %d, Error reading units per lap from spindle. Ref %d, Status
%d
5217 820 System Error TC %d, Error writing torque transducer config to spindle. Ref %d,
Status %d
5218 821 System Error TC %d, Error writing angle transducer config to spindle. Ref %d,
Status %d
5219 822 System Error TC %d, Error reading torque transducer config from spindle. Ref
%d, Status %d
5220 823 System Error TC %d, Error reading angle transducer config from spindle. Ref
%d, Status %d
9836 3521 01 661

Appendix
Comp
Code
5221 824 System Error TC %d, Error writing angle diff config to spindle. Ref %d, Status
%d
5222 825 System Error TC %d, Error reading angle diff config from spindle. Ref %d,
Status %d
5223 826 System Error TC %d, Error writing torque diff config to spindle. Ref %d, Status
%d
5224 827 System Error TC %d, Error reading torque diff config from spindle. Ref %d,
Status %d
5225 828 System Error TC %d, Error writing t/c factor to spindle. Ref %d, Status %d
5226 829 System Error TC %d, Error reading t/c factor from spindle. Ref %d, Status %d
5227 830 System Error TC %d, Error writing torque amplification to spindle. Ref %d,
Status %d
5228 831 System Error TC %d, Error reading torque amplification from spindle. Ref %d,
Status %d
5229 832 System Error TC %d, Error writing calibration value to spindle. Ref %d, Status
%d
5230 833 System Error TC %d, Error reading calibration value from spindle. Ref %d,
Status %d
5231 834 System Error TC %d, Error writing calibration date to spindle. Ref %d, Status
%d
5232 835 System Error TC %d, Error reading calibration date from spindle. Ref %d, Status
%d
5233 836 System Error TC %d, Error writing motortune params to spindle. Ref %d, Status
%d
5234 837 System Error TC %d, Error reading motortune params from spindle. Ref %d,
Status %d
5235 838 System Error TC %d, Error writing motor params to spindle. Ref %d, Status %d
5236 839 System Error TC %d, Error reading motor params from spindle. Ref %d, Status
%d
5237 840 System Error TC %d, Error writing commutation offset to spindle. Ref %d,
Status %d
5238 841 System Error TC %d, Error reading commutation offset from spindle. Ref %d,
Status %d
5239 842 System Error TC %d, Error writing date and time to spindle. Ref %d, Status %d
5240 843 System Error TC %d, Error reading date and time from spindle. Ref %d, Status
%d
662 9836 3521 01

Appendix
Comp
Code
5241 844 System Error TC %d, Error writing service date to spindle. Ref %d, Status %d
5242 845 System Error TC %d, Error reading service date from spindle. Ref %d, Status
%d
5243 846 System Error TC %d, Error writing service interval to spindle. Ref %d, Status %d
5244 847 System Error TC %d, Error reading service interval from spindle. Ref %d, Status
%d
5245 848 System Error TC %d, Error writing cycles since service to spindle. Ref %d,
Status %d
5246 849 System Error TC %d, Error reading cycles since service from spindle. Ref %d,
Status %d
5247 850 System Error TC %d, Error writing cycle counter to spindle. Ref %d, Status %d
5248 851 System Error TC %d, Error reading cycle counter from spindle. Ref %d, Status
%d
5249 852 System Error TC %d, Error writing last shunt calibration to spindle. Ref %d,
Status %d
5250 853 System Error TC %d, Error reading last shunt calibration from spindle. Ref %d,
Status %d
5251 854 System Error TC %d, Error writing wind up to spindle. Ref %d, Status %d
5252 855 System Error TC %d, Error reading wind up from spindle. Ref %d, Status %d
5253 856 System Error TC %d, Error writing hardware revision to spindle. Ref %d, Status
%d
5254 857 System Error TC %d, Error reading hardware revision from spindle. Ref %d,
Status %d
5255 858 System Error TC %d, Error writing bootloader to spindle. Ref %d, Status %d
5256 859 System Error TC %d, Error reading bootloader from spindle. Ref %d, Status %d
5257 860 System Error TC %d, Error writing application to spindle. Ref %d, Status %d
5258 861 System Error TC %d, Error reading application from spindle. Ref %d, Status %d
5259 862 System Error TC %d, Error writing chip serial no to spindle. Ref %d, Status %d
5260 863 System Error TC %d, Error reading chip serial no from spindle. Ref %d, Status
%d
5261 908 System Error TC %d, Error writing reference to spindle. Ref %d, Status %d
5262 909 System Error TC %d, Error reading reference from spindle. Ref %d, Status %d
5301 864 System Error TC %d, Error writing power stage temperature to servo. Ref %d,
Status %d
9836 3521 01 663

Appendix
Comp
Code
5302 865 System Error TC %d, Error reading power stage temperature from servo. Ref
%d, Status %d
5303 866 System Error TC %d, Error writing torque constant to servo. Ref %d, Status %d
5304 867 System Error TC %d, Error reading torque constant from servo. Ref %d, Status
%d
5305 868 System Error TC %d, Error writing conversion constants to servo. Ref %d,
Status %d
5306 869 System Error TC %d, Error reading conversion constants from servo. Ref %d,
Status %d
5307 870 System Error TC %d, Error writing motortune parameters to servo. Ref %d,
Status %d
5308 871 System Error TC %d, Error reading motortune parameters from servo. Ref %d,
Status %d
5309 872 System Error TC %d, Error writing motortune status to servo. Ref %d, Status
%d
5310 873 System Error TC %d, Error reading motortune status from servo. Ref %d, Status
%d
5311 874 System Error TC %d, Error writing motor parameters to servo. Ref %d, Status
%d
5312 875 System Error TC %d, Error reading motor parameters from servo. Ref %d,
Status %d
5313 876 System Error TC %d, Error writing date and time to servo. Ref %d, Status %d
5314 877 System Error TC %d, Error reading date and time from servo. Ref %d, Status
%d
5315 878 System Error TC %d, Error writing hardware revision to servo. Ref %d, Status
%d
5316 879 System Error TC %d, Error reading hardware revision from servo. Ref %d,
Status %d
5317 880 System Error TC %d, Error writing bootloader to servo. Ref %d, Status %d
5318 881 System Error TC %d, Error reading bootloader from servo. Ref %d, Status %d
5319 882 System Error TC %d, Error writing application to servo. Ref %d, Status %d
5320 883 System Error TC %d, Error reading application from servo. Ref %d, Status %d
5321 884 System Error TC %d, Error writing serial number to servo. Ref %d, Status %d
5322 885 System Error TC %d, Error reading serial number from servo. Ref %d, Status
%d
664 9836 3521 01

Appendix
Comp
Code
5700 691 Setup Error Step %d, Angle channel for check (%d) has bad configuration
(%d)
5701 692 Setup Error Step %d, Channel Angle %d for check (%d) does not exists in
spindle
5702 693 Setup Error Step %d, Torque channel for check (%d) has bad configuration
(%d)
5703 694 Setup Error Step %d, Channel Torque %d for check (%d) does not exists in
spindle
5704 695 Setup Error Step %d, Angle channel for restriction (%d) has bad configuration
(%d)
5705 696 Setup Error Step %d, Channel Angle %d for restriction (%d) does not exists in
spindle
5706 697 Setup Error Step %d, Torque channel for restriction (%d) has bad
configuration (%d)
5707 698 Setup Error Step %d, Channel Torque %d for restriction (%d) does not exists
in spindle
5708 699 Setup Error Step %d, Angle channel for steptype (%d) has bad configuration
(%d)
5709 700 Setup Error Step %d, Channel Angle %d for steptype (%d) does not exists in
spindle
5710 701 Setup Error Step %d, Torque channel for steptype (%d) has bad configuration
(%d)
5711 702 Setup Error Step %d, Channel Torque %d for steptype (%d) does not exists in
spindle
5712 592 Setup Error Cust. error series bad config. Step %d, Series %d, BoltStatus %d.
Series 1 used
5713 612 Setup Error Customer Error: No step errors found for step %d, used the bolt
errors instead
5714 613 Setup Error No step failed, used customer step name in first CE step (step
%d) instead
5715 888 Setup Error Step %d, Control: Local DI %d cannot be used since TC type is
not 'PTC'
5716 912 Check Error Step %d, BCT measutement failed, old values are cleared
5717 913 Setup Info Backlash Angle Chan %d differ from stored chan %d, backlash
values are cleared
5718 914 Setup Error Step %d, Control: Speed or speed ramp has bad configuration
5719 915 Setup Error Step %d, Control: The selected position target has no stored value
9836 3521 01 665

Appendix
Comp
Code
5720 916 Setup Error Step %d, Control: No prev. step direction stored, not possibel to
run POS step
5721 918 Setup Error Step %d, Zone has bad configuration
5722 919 Check Error Step %d, Check: Peak torque failed, Zone %d was never started
5723 920 Check Error Step %d, Check: Torque in angle window failed, Zone %d was
never started
5724 921 Check Error Step %d, Check: Torque in time window failed, Zone %d was
never started
5725 922 Check Error Step %d, Check: Mean torque failed, Zone %d was was not
finished
5726 923 Check Error Step %d, Check: Angle failed, Zone %d was was not finished
5727 924 Check Error Step %d, Check: Time failed, Zone %d was never started
5728 925 Check Error Step %d, Check: T/T3 failed, Zone %d was was not finished
5729 926 Check Error Step %d, Check: Torque Rate calculation failed, Zone %d was
never started
5730 927 Setup Error Step %d, Res var have bad configuration. %d is not a valid cycle
data variable
5731 928 Setup Error Step %d, Check with identity %d has bad configuration
5732 929 Check Error Step %d, Check: Delta torque failed, Zone %d was never started
5733 930 Check Error Step %d, Check: Delta torque failed
5734 931 Check Error Step %d, Check: Delta torque. %f > %f
5735 932 Check Error Step %d, Check: Delta torque. %f < %f
5736 933 Setup Error Step %d has bad configuration, one or more paramters are faulty,
Step Type = %d
5737 938 Setup Warning Step %d, The step is syncronized since Wait for PLC to continue
is checked.
5738 939 Check Error Step %d, PosValid %d, Stored External Postion = %f
5739 940 Check Error Actual Internal position = %d, Actual External position = %f
5740 941 Setup Error Step %d, Store of position register not possible, Angle channel
does not exist
5741 942 Emergency stop Error The e-stop chain is broken somewhere between TC %d and the
primary TC (TC %d)
5742 943 Emergency stop Error E-stop is faulty. TC %d (station TC) is e-stopped, some other TCs
isn't
666 9836 3521 01

Appendix
Comp
Code
5743 944 Check Error Step %d, Check: Shut Off Torque failed, Zone %d was was not
finished
5744 945 Check Error Step %d, T1 Shunt Cal NOK. Shunt drift from last cal too high, %f
> %f
5745 946 Check Error Step %d, T2 Shunt Cal NOK. Shunt drift from last cal too high, %f
> %f
5746 947 Check Error Step %d, T1 Zero Offset comp NOK. Drift from last cal too high %f
> %f
5747 948 Check Error Step %d, T2 Zero Offset comp NOK. Drift from last cal too high %f
> %f
5748 949 Check Error Step %d, T1 Shunt Calibration NOK. Measured Shunt too low %f
< %f
5749 950 Check Error Step %d, T2 Shunt Calibration NOK. Measured Shunt too low %f
< %f
5750 951 Check Error Step %d, T1 Shunt Calibration NOK. Measured Shunt too high %f
> %f
5751 952 Check Error Step %d, T2 Shunt Calibration NOK. Measured Shunt too high %f
> %f
5752 953 Check Error Step %d, T1 Zero Offset compensation NOK. Measured offset too
low %f < %f
low %f < %f
high %f > %f
high %f > %f
5756 957 Setup Error Step %d, RampsAndOther: Digital signals for step start or step
end has bad configuration
5757 917 Check Error Step %d, Check Position: The selected position target has no
stored value
5758 894 Check Error Step %d, Check: Distance to abs position high. %f > %f
5759 895 Check Error Step %d, Check: Distance to abs position low. %f < %f
5760 410 Check Error Step %d, Check: Low spot torque failed, Zone %d was never
started
5761 411 Check Error Step %d, Check: Low spot torque failed, start angle was never
reached
5762 412 Check Error Step %d, Check: Low Spot Torque High %f > %f
9836 3521 01 667

Appendix
Comp
Code
5763 413 Check Error Step %d, Check: Low Spot Torque Low %f < %f
5764 198 Check Error Step %d, Zero Crossing failed. Not possible to find Torque Rate
check with id %d
5765 199 Check Error Step %d, Zero Crossing failed. Torque Rate check %d didn't
produced any data
5766 200 Check Error Step %d, Zero Crossing failed. Not possible to calculate the zero
crossing value
5767 201 Check Error Step %d, Check: Zero Crossing Angle high, %f > %f
5768 202 Check Error Step %d, Check: Zero Crossing Angle low, %f < %f
5769 206 Check Error Step %d, Backlash check failed. No backlash value was found
5770 207 Check Error Step %d, Check: Backlash angle High %f > %f
5771 208 Check Error Step %d, Check: Backlash angle Low %f < %f
5772 244 Check Error Step %d, External input check failed. Not possible to read input
value
5773 245 Check Error Step %d, Check: External input high, actual value High, Target
value Low
5774 246 Check Error Step %d, Check: External input low, actual value Low, Target
value High
5775 217 Hardware Warning Step %d, Check: The speed is too high(%d). Speed = %d is used
instead
5776 617 Setup Error The settings for Brake control are not correct(Loc DO = %d Delay
time = %f)
5777 365 Setup Error Brake control not possible since TC type is not 'PTC'
5778 367 Setup Error Brake signal (Local DO %d) is also used as output in the
tightening program
8001 899 General Info TFTP: Software update of TC %d, failed
668 9836 3521 01

Appendix
10.2 ToolsTalk PowerMACS command line

ToolsTalk PowerMACS supports the following command line arguments:
PowerMACS_4000.exe [/t=<ip_address>]
[/g=online | /g=offline]
[/o=backoff | /o=override]
[/c=target | /c=file]
[<setup>]
The arguments have the following meaning:
Argument Usage
<setup> Specifies the setup to open.
<setup> may include a path. The directory of the PowerMACS application is
used as default directory.
If the file pointed out by <setup> cannot be located or read ToolsTalk
PowerMACS will stop and display an error message.
/t=<ip_address> Sets <ip_address> as the IP-address of the selected target system for
ToolsTalk PowerMACS in the system register.
If not specified the IP-address of the system most recently connected to is
used.
/g=online Specifies if ToolsTalk PowerMACS should connect or not against the target
/g=offline system known by ToolsTalk PowerMACS.
If not specified the same on-line state as ToolsTalk PowerMACS had when it
was last closed is assumed.
If ToolsTalk PowerMACS should go on-line but fails to connect to the target it
will stop and display an error message.
/o=backoff Specifies how to handle the situation that another ToolsTalk PowerMACS
/o=override already is connected to the target system when going on-line.
Only used if ToolsTalk PowerMACS is configured to go on-line.
/c=target Specifies how to handle conflicting setups, that is, the case when the setup
/c=file read from file is different compared to the one in the target system.
It is only used if ToolsTalk PowerMACS is configured to go on-line.
Choose "target" to ToolsTalk PowerMACS fetch the setup from the target
system.
Choose "file" to ToolsTalk PowerMACS to overwrite the setup read from
file to the target system.
If not specified "target" is assumed.
9836 3521 01 669

Appendix
10.3 Cycle Data Storage

This scenario exemplifies the number of cycle data possible to store given a typical reporter configuration.
The setup includes a ToolsNet device and an Ethernet device of type DC PLUS.
Station Data Bolt Data Step Data

Station number Op Mode Failing Step No Step No
Cycle Start Time Bolt No Bolt Pgm Strategy Peak T
Status Status Spindle No A
Data no station Program Name Bolt T Shut Off T
Wp. Id Ordinal No Bolt A Peak T3
Mode No Errors Bolt Name
Station Name RM Errors Program number
Mode Name Warnings Limits (Bolt T)
Station QO Compact Errors Limits (Bolt A)
Station SA Bolt Name
Station AB Cust Error
Id Res 4
Amount of SRAM used System with 2 bolts System with 8 bolts System with 16 bolts
for Cycle Data
30 % (Default) 900 cycles 280 cycles 140 cycles
75 % 2400 cycles 700 cycles 360 cycles
10.3.1 Store 5000 Cycle Data
It is possible to store more than 5000 cycle data by distribute the storage to all TCs included in a system.
The cycle data for each bolt is stored locally on the TC the bolt was run on. To be able to store more than
5000 cycle data the size of the cycle data storage has to be increased on the expense of trace data
storage (there will still be room for more than 20+ trace).
Please see chapter SRAMfor more information.
670 9836 3521 01

Appendix
10.3.1.1 Storing and retrieving cycle data
Since the cycle data for each bolt is stored locally on the TC it was run on the amount of cycle data that
could be stored depends only on the size of the cycle data storage and on how many variables that is
included in the configured reporters.
To minimize the need for fetching bolt cycle data from each TC when a device is requesting it a complete
cycle data is stored in a volatile memory cache on TC1. This cache is filled with cycle data when a cycle is
run or when a requested cycle data has been retrieved from each TC. After a power up the cache is empty
an all requested cycle data has to be retrieved from each bolt.
It is possible to change TCs within a system and still be able to retrieve cycle data from them.
If however any TC should be missing or disconnected when a cycle data is fetched the data for the bolt
that belong to that TC is reconstructed using status information that is saved in the cycle data header for
each bolt in the cycle data. Since this data is saved together with station data and data for bolt 1 on TC1 it
is kept to a minimum, the data saved for each bolt is:
Ordinal bolt number

Status (OK,NOK etc.)
Failing step number (if status NOK)
A new bolt variable “Data missing” has been added to make it possible to detect if data was missing for a
particular bolt. This variable is 1 if data is missing and 0 if not.
9836 3521 01 671

Appendix
Example of cycle data with all bolt data and with bolt data 5 missing:
Data No Station: 1 Station: Stn 01 2008-03-04 09:34:07 Status: OK No Bolts: 7

Ordinal No Bolt Data Missing Status Bolt T Bolt A Failing Step No
1 Bolt 01 0 OK 0,75 362,37

2 Bolt 02 0 OK 0,75 362,37
3 Bolt 03 0 OK 0,75 362,37
4 Bolt 04 0 OK 0,75 362,37
5 Bolt 05 0 OK 0,75 362,37
6 Bolt 06 0 OK 0,75 362,37
7 Bolt 07 0 OK 0,75 362,37
Data No Station: 2 Station: Stn 01 2008-03-04 09:34:08 Status: OK No Bolts: 7

Ordinal No Bolt Data Missing Status Bolt T Bolt A Failing Step No
1 Bolt 01 0 OK 0,75 362,37

2 Bolt 02 0 OK 0,75 362,37
3 Bolt 03 0 OK 0,75 362,37
4 Bolt 04 0 OK 0,75 362,37
5 1 OK
6 Bolt 06 0 OK 0,75 362,37
7 Bolt 07 0 OK 0,75 362,37
672 9836 3521 01

Appendix
10.4 Configuration of the Conversion Box

The Conversion Box, which allows QMR and QMX spindles to be used together with PowerMACS 4000,
have had to be configured for a particular spindle type using the tool ToolsTalk Service. From
PowerMACS 4000 version 7.5.0 it is automatically configured by the PowerMACS system for the type of
spindle that is specified by the setup.
The programming of the Box is handled by the TC and takes place when any of the following two
situations occur:
The setup loaded to the TC specifies another spindle article number than the one that the Box
currently is configured for.
The TC detects that the value of one or more of a number of crucial parameters differs between
the Box and the PowerMACS setup (the calibration parameters are not included in the
comparison).
The TC indicates that it has programmed the Conversion Box by issuing one of the following events
depending on the outcome:
4234, Conv. Box: TC n, Box programmed successfully
4232, Conv. Box: TC n, Failed to program box with reference values from setup
Whenever the Box is programmed by the TC, or the TC detects that the Box has been replaced, it
requires that a Motortune is run for the spindle before it allows a cycle to be started. This is indicated by
the following events:
4231, Conv. Box: TC n, New box detected
4233, Conv. Box: TC n, Motortune is required and calibration is recommended
If Motortune is required the TC will remember that also if the power supply is cycled.
The only exception to this is the first time a TC connected to a correctly programmed Box is updated to
version 7.4.2. If all important parameters have the same values as stated by the latest spindle type
definition files, then Motortune is not required.
If the Box has been calibrated using an earlier TTPM version its checksum is most likely incorrect even
though all values are correct. This problem is also checked for and corrected the first time the TC is
upgraded to version 7.4.2 if a Box is connected at that time. When corrected the following warning event is
issued:
4235, Conv. Box: TC n, Checksum faults detected. Verify spindle calibration values
Please note that even if the checksum is automatically corrected you should verify that the calibration
values are correct.
Should a Box calibrated with an old TTPM version be connected to an upgraded TC at a later time then
the following events will be issued:
5262, TC 1, Error reading reference from spindle. Ref 1, Status 50
9836 3521 01 673

Appendix
5262, TC 1, Error writing reference to spindle. Ref 62, Status 21
after which the Box is programmed with default values.
When the Box is programmed all parameters that are important for controlling the spindle, including the
calibration parameters, are set. However, the following parameters are left unchanged:
The serial number of the spindle
The total number of cycles run
The total number of cycles run at last service
The date when the last service was made
The value of these parameters can be set, at any time, using the new "Service Data" page of the TTPM
Spindle Set Up form when on-line to a spindle of Conversion Box type.
674 9836 3521 01

Appendix
The configuration parameters for a spindle are defined in the spindle type file accompanying the spindle.
From version 7.5.0 PowerMACS uses the same version of these files as ToolsTalk Service does
(extension .TTT, instead of .TTS).
These latest version of these files are installed in the folder "SpindleType" which is located in the folder
that TTPM was installed to (normally "C:\ PM4000 7.4.2"). By default this folder only contains files for QST
spindles. The files corresponding to QMR and QMX spindles are located in subfolders named "QMR" and
"QMX" respectively and must be copied to the "SpindleType" folder before they can be seen and used by
TTPM.
TTPM will refuse to convert an old setup to version 7.4.2 unless it can find the spindle type files of all used
spindles of QMR and QMX type.
9836 3521 01 675

Appendix
10.5 Fatal Software Errors

If a fatal software error occurs in the TC software an error code is generated by the real time operating
system (called OSE) and it is shown on the display of the TC, e.g.
OSE Error 0x103
Most of the fatal software errors indicate some kind of bug in the TC software. Normally you can just
restart the TC and it will work fine again, at least for a while. If you get a fatal software error you should
always try to get the TC Crash log from the TC, to help debugging.
The errors 0x01, 0x02, 0x03, 0x11, 0x20, 0x21 and 0x24 indicate insufficient memory. This might be
cause by running too many, memory consuming, and devices on the failing TC. Try to move one or more
of the devices from the failing TC to another TC in the system. Especially devices used for reporting of
Trace and Cycle data may consume much memory.
This list show possible OSE error codes.
Code Description
0x01 Too large stack buffer requested.
0x02 Out of space in user stack pool.
0x03 Too many processes were created.
0x11 Too large signal buffer requested.
0x12 Out of space in kernel pool.
0x1d An attempt to kill a static semaphore was made.
0x1e An attempt to kill a semaphore that is still in use was made.
0x1f An illegal semaphore pointer was presented to the kernel.
0x20 Out of space in user signal pool.
0x21 Pool extension failed.
0x22 The create_pool system call was used on a block that contains processes.
0x23 The create_pool system call was presented a signal size table or a stack size table that contains
an unreasonable number in the first location.
0x24 Too many signals were attached.
0x25 Vector already in use.
0x26 Illegal system call from an interrupt process.
0x27 Illegal intersegment send to an interrupt or timer-interrupt process.
0x28 Illegal wakeup priority for an interrupt process.
0x29 An error was encountered while an error handler was executing.
0x2a An error was encountered while an error handler was executing.
0x2b A semaphore with a negative initial value was found or created.
0x2c A semaphore in use was implicitly killed, but processes are still waiting for it.
676 9836 3521 01

Appendix
0x2d An attempt to detach from an already detached process was made.
0x2e An attempt was made to detach from a process long after the death of that process.
0x2f An attempt was made to detach from a process when the attached signal has already been
received.
0x30 An attempt was made to create a process of an invalid type.
0x31 The caller tried to operate on the NIL pointer.
0x32 An illegal block or process ID was presented to the kernel.
0x47 An invalid process ID was encountered in the flush system call.
0x48 A static process was killed. Killing a static process is illegal.
0x49 An invalid redirection table was presented to the kernel.
0x4a Kernel data was damaged.
0x52 An interrupt occurred from an unused interrupt vector.
0x53 An attempt was made to attach to the current process, this is illegal.
0x54 The current receive (or similar) system call failed because the pool attached to the current
process does not support the size of the signal received.
0x55 A too large interrupt stack was requested.
0x56 An attempt was made to kill a system daemon, this is illegal.
0x57 Restore was attempted on a signal buffer that has already been freed or is otherwise not owned
by any process.
0x58 An attempt was made to install an unreasonably small pool fragment.
0x59 The tick system call was called concurrently by several processes.
0x5b An attempt was made to start a process that is not stopped.
0x5c A linkhandler deadlock was detected.
0x5d An illegal environment variable name was detected.
0x5e An illegal pool id was presented to the kernel.
0x5f The calling process is not the owner of the specified signal buffer.
0x70 An invalid signal pointer was presented to the kernel.
0x71 An invalid parameter was used in a system call.
0x72 An attempt was made to create a pool with a memory area that is already used in another pool.
0x73 An unrecognized signal was received by one of the system daemon processes.
0x74 An unrecognized signal was received by one of the system daemon processes.
0x75 An attempt was made to install an unreasonably large pool or pool fragment.
0x76 An attempt was made to stop a process an unreasonable number of times.
0x77 An attempt was made to signal a semaphore or a fast semaphore beyond the maximum value.
0x78 The huntd priority is too low. The ose_huntd process must have a priority higher than the
ose_sysd process.
0x79 An illegal system call was made from interrupt or background process.
0x7a One or more entries in the kernel configuration file have an illegal value.
9836 3521 01 677

Appendix
0xa5 A valid end mark could not be found in the signal buffer presented to the kernel.
0xa6 A damaged signal buffer was presented to the kernel.
0x101 A user stack overflow was encountered.
0x102 A supervisor stack overflow was encountered.
0x103 An interrupt stack overflow was encountered.
0x104 An unknown breakpoint was encountered.
0x105 An unknown interrupt was encountered.
0x107 A prioritized or background process ended.
0x108 Startup stack overflow.
0x109 The CPU model is not recognized. The kernel configuration file needs to contain a known CPU
model.
0x110 An undefined function code has been used for a system call.
0x111 An unexpected exception occurred.
0x112 An interrupt has occurred with equal or less priority than the currently running interrupt process.
0x113 An unexpected exception occurred. A register dump is provided.
678 9836 3521 01

References
11 References
11.1 References to external documents
1. “Functional and Technical Description PowerMACS 4000 TCs”
2. "Calibration with ACTA", Atlas Copco Tools document No. 9836 2086 00
3. “Specification Open Protocol” , Atlas Copco Tools document No. 9836 4415 01
9836 3521 01 679

References
680 9836 3521 01

Glossary of Terms
12 Glossary of Terms
12.1 Glossary
This part describes some basic concepts that are used throughout the complete document and have very
specific meanings.
System
A system comprises one or more Tightening Controllers linked together. A system works autonomously,
performing a tightening task.
Station
Within a system there are one or more stations. A station controls the tightening of one or more bolts. It
has a PLC to control the tightening cycles.
Bolt
A bolt is the object that will be tightened by the system.
Spindle
A spindle performs the actual tightening of a bolt. It normally comprises:
Motor
Torque sensor
Angle sensor
Often one bolt is tightened with one spindle, but it is possible to configure the system so several bolts are
tightened with one spindle.
Program, steps and sequences

How the tightening of the bolt should be done is described in a tightening program. The program
comprises steps, each describing how a part of the tightening cycle should be performed.
A number of steps can be saved as a sequence. When building a new tightening program, or altering an
existing one, it is possible to insert sequences.
Mode
When a tightening cycle is started, the choice of tightening program is done using the Mode signal in the
PLC. With use of a mode table it is defined which tightening program that should be used for each of the
specific bolts in each mode. Each station in a system has its own unique Mode table.
Cycle
9836 3521 01 681

Glossary of Terms
A tightening cycle is all operations from a start signal until ready to start next cycle.
Reject Management
Reject management is an alternative sequence to be followed, in the event of a NOK situation with the
purpose to achieve an OK condition by doing a second try.
Shift
A shift is a time period. It is programmable when shifts starts and stops during a day (weekends may be
different). Some results/reports are related to shifts.
Console Computer
The console or console computer is the PC computer used to set up a PowerMACS system. It is not
needed for automatic running, but it can optionally be used to monitor the system and to collect and
present various data using ToolsTalk PowerMACS.
One console computer can be used for several systems, if these are hooked up on the same computer
network, but only one system at a time.
ToolsTalk PowerMACS
ToolsTalk PowerMACS is the graphical user interface of the PowerMACS 4000 system. It is a Windows
based program that executes on the console computer (or any PC). It is used to set up a PowerMACS
4000 system and can be used to monitor the system and to collect and present various data.
Setup and Tables

A setup is a group of data that completely describes the system. The system uses the information in the
setup to know what to do. A setup could also be called a configuration. A setup can be stored on the
console computer in a file on a hard disk or on a floppy. It can be downloaded to the system, or uploaded
for storing or alteration.
A setup is made up of tables, each containing data for a specific topic, e.g. tightening program, SPC setup
etc.
Setups are manipulated with the ToolsTalk PowerMACS application program on the console computer. It
is possible to export and import certain tables, but the setup itself is a complete package.
<system torque unit>

<system torque unit> is the torque unit selected for the system, or setup. This is selected using the Set Up
Options form.
PLC
In every PowerMACS station there is a PLC (Programmable Logic Controller). The PLC is used as ”glue”
between various functions within the system like:
682 9836 3521 01

Glossary of Terms
Start of tightening from digital inputs
Output of status to digital outputs
Controlling flow of data
Analyzing ID codes
Group
In many cases, when there is a problem with one bolt, reject actions must be performed not only on this
bolt but with others within the station. In PowerMACS it is therefore possible to put bolts together in
groups.
A group is a set of bolts, which are run completely separate from each other, but have some form of
relationship. In case of reject management, they are considered to belong to the same group, and special
actions can be specified for bolts within the group.
The bolts in a station can be divided into groups of bolts as in following figure:
s ta tio n g ro u p s
St 1
Gr 1 Gr 2 Gr 3
B o lt 1 B o lt 3 B o lt 5
b o lt
B o lt 2 B o lt 4 B o lt 6
All bolts belong to the station St 1. Bolts 1 and 2 belongs to group Gr 1, bolt 3 and 4 to group Gr 2, bolt 5
and 6 to group Gr 3. A special case is bolt 3 and 5, which both belongs to two groups at the same time.
9836 3521 01 683

9836 3521 01
2011-12
Edition 10.5.0
www.atlascopco.com

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User guide

1.1.2 Intelligent tightening controllers, TCs

1.2 Tightening and Gauging

1.2.1 Gauging Functions

Step Run to Position

Step MS (Measurement step method) and AD (Adjust step method)

Step Wait, PLC signal addition

Check Low Spot

Check Peak T, additions

Zones (within step)

1.2.2 Gauging Applications

1.2.2.1 Torque To Turn Gauging Application

1.3 Installing ToolsTalk PowerMACS

1.3.1 Settings needed when running on Windows 7

Click Allow a program through Windows Firewall.

2.2 System Structure

A o n e sta tio n P o w e rM A C S S yste m A th re e sta tio n P o w e rM A C S S yste m

S ta tio n S ta tio n S ta tio n S ta tio n

2.3 Hardware Structure

TC 1 (primary) TC 2 (secondary) ...... TC n (secondary)

Digital I/O Sp 1 Sp 2.. ..Sp n

Item Function Use

2.3.1.1 PTC Description

Sockets on the PTC

M A C S I/O : 9 p ole P ow er c on n ector

2.3.1.3 The TC HMI Menu System

T: 120.32 Torque view

Setup Menu – Basic Setup

TC Number Edit Settings Example

TC Number Edit Settings Example

The following options can be set in Basic Setup.

Sys info System Information

Select Back Shows Information about TC

Info Menu – Events

Press Up/Down buttons to

Info Menu – Sys info

Information Menu Description

2.3.2 Version conflict message

Ver. Conflict Version conflict.

2.3.3 Console Computer (CC)

2.3.5 Peripheral Devices

2.4 Automatic update of TC, Servo and Spindle

The TC application software

The Servo application software

The Spindle application software

2.4.2 General function

Ver. Conflict Version conflict.

Ver. Conflict Version conflict

2.4.4 Replacement of TC3 – TCn

2.4.5 Updating a system with new software

2.4.8 Automatic Update of Spindle software

This is used by the system to show (from left to right):

Frame – Groups a number of controls that belongs together

Button – Carries out a command when pressed

Spread – An Excel style control used to display table oriented data

Property grid – A list of properties for an object

Automatic Help Window

3.4 The File menu