Power Focus 4000A new level of tightening intelligence

Presenting the Power Focus 4000 – smarter than ever before

With your productivity in mind, we present the next generation of control systems for Tensor tools. The Power Focus 4000 is smarter and more intuitive than ever. Two versions, Graph and Compact, have all the functions you need to control Tensor electric nutrun-ners. The PF 4000 Graph offers a full user-interface with easy- to-read colour display. The PF 4000 software includes a built-in Logic Confi gurator with PLC functions.

One model is all you need

The Power Focus 4000 is a new generation of control sys-tems suitable for Tensor S, ST, DS and ETX models. Unlike its predecessor, the PF 3100, the PF 4000 is available in one model with two versions, Compact and Graph, that can handle all torque levels. This favours your maintenance budget, since fewer back-up units are required.

PF 4000 Graph – full-colour display,more compact design

Once you start working with the new PF 4000 Graph, you won’t want to work with any other controller. The easy-to-read LCD colour display gives you all the information you need. Statistical data is collected, analyzed and presented on the screen. Changes and trends in the assembly process are indi-cated by diagnostics and statistical alarms, such as SPC moni-

tor charts and capability (Cpk) alarms. Alpha-numeric keys allow on-unit set-up and easy checking of traces and statistics.

After listening to our customers, we made the PF 4000 much more compact as well. A standardized mounting plate ensures easy installation at every workstation.

PF 4000 Compact – a handy alternative

Completing the range, the PF 4000 Compact has a basic opera-tor interface with a six-button keyboard and LED display. Pre-programmed using ToolsTalk PF and with a PC as the interface, it offers the same functions as the Graph.

Traceable, zero-fault process control

Advanced control functions built into the Power Focus 4000 prevent the operator deviating from the required process. When it receives assembly information, the programmed “Job” func-tion automatically selects the correct tightening sequence and parameters. When combined with barcode scanning for com-ponent identifi cation, the “Job” function offers traceable, zero-fault process control.

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Presenting the Power Focus 4000 – smarter than ever before

PF 4000 can handle all Tensor toolsbetween 1 and 4000 NmThe Tensor range of hand-held and fi xtured electric assembly tools defi ne the global benchmark in smart, cost-effi cient and error-proof assembly management. Whichever tools you are running, Tensor S/SII/ST, DS or ETX, the PF 4000, with Unidrive, can handle them all.

When you want toconnect a laptop…

No problem! The Power Focus 4000 is equipped with a handy USB connector for laptop access. It is located on the front of the unit for maximum accessibility.

Communication is also possible over serial RS232, Ethernet TCP/IP and various fi eld bus types. Networking is simple, both with external equipment and plant staff, or within the Power Focus production cell.

Plug & Play software functionality

Why pay for more functionality than you need? You decide how much functionality the Power Focus 4000 will contain, and you can infl uence the system cost correspondingly.

There are four standard software levels: DS, Bronze, Silver and Gold. With Atlas Copco’s patented Rapid Back-up Unit, RBU, a combined program back-up unit and functionality key, you can tailor a hardware/software combination to your spe-cifi c application using a “plug and play” approach.

RBU concept minimizes downtime

Atlas Copco’s RBU concept transfers functionality to the PF 4000 hardware and ensures the controller can easily be upgrad-ed should functionality requirements change.

It also acts as a back-up for programming and confi guration. If a change of hardware is required, just fi t the RBU to the new hardware, switch on the unit and you’re ready. This cuts down-time to a minimum.

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Logic Confi gurator cuts costs and makes life simple

Workpiecein place?

Activate cylinder,clamp workpiece

Cylinderactivated?

Enable tool,yellow light on

Job OK?

Manual release?

Green light on,release workpiece

Yes

Yes

Yes

No

Yes

No

Built-in PLC functions eliminate problems

It couldn’t be more convenient! The advanced Power Focus 4000 has an integrated Logic Confi gurator. This provides lim-ited PLC functionality as an integrated part of the controller, without additional hardware components. You can now confi g-ure your “PLC style” signal fl ow between the line or the fi xture, and the PF 4000, thus the need for an interface PLC is eliminated in most cases.

It saves you time and money

The integrated Logic Confi guarator cuts purchase, set-up and installation costs and simplifi es system maintenance. It also saves you time and trouble.

Recognize this situation?

Your tool controller needs to talk to the production process, but the controller doesn’t quite fi t the I/O signal specifi cation. So you would be forced to acquire a PLC.

Logic Confi gurator eliminatesPLCs in pre-assembly station

Motor vehicle industry discoversthe benefi ts of PF 4000

At a large automotive plant, to assure the tightening quality, a new pre-assembly station required communication between the Atlas Copco tightening system and the mechanical fi xture. This would normally have required a PLC. The PF 4000, with its integrated Logic Confi gurator, solved the problem by offering basic PLC functions.

Process description

When a workpiece is positioned, a proximity switch in the fi x-ture detects its presence. The workpiece is held in position by an air cylinder. The position “workpiece fi xtured” is detected by a second proximity switch.

When the two proximity switches “workpiece in place” and “workpiece fi xtured” are active, the tightening operation can begin.

After fi nalizing the tightening operation, a green lamp lights and stays alight to indicate the OK result to the operator. If the job can’t be fi nalized the operator can release the workpiece from the fi xture manually.

Releaseworkpiece

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Improved ToolsTalk PF simplifi es QIF confi guration

StackLight

Operator Panel

Socket Selector

I/O Expander

ToolsTalk PF – intuitive and user-friendly

Atlas Copco’s new, upgraded ToolsTalk PF software with im-proved graphics is more intuitive than ever before – and thus highly user friendly.

Using your PC as the interface, you can easily connect and confi gure the Quality Integrated Fastening (QIF) accessories below. All accessories are linked to the controller via a single cable using the built-in I/O bus.

• StackLight Designed to provide continuous operator feedback on the tightening process.

• Operator Panel Equipped with command buttons and in-tegrated lamps for operator feedback. A selector switch ena-bles manual selection of programs, and the program number is displayed on the small, integrated screen.

• Socket Selector Determines the correct fastening parameter program (P-set) for the specifi c application.

• I/O Expander Connected to the Power Focus, the I/O Expander provides eight additional Inputs and Outputs for increased communication possibilities.

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New tightening strategies enhance production quality

At last, SynchroTork for up to six spindles!

Available in the Power Focus 4000, SynchroTork allows continuous synchronization of up to six spindles during fi nal tightening. This will improve assembly quality in the joints where an even clamp force build-up is critical, such as in U-bolt applications. The torque difference between the spindles, is minimized during the tightening stage by adjusting the individual speeds.

Synchronization of the tools is assured through high-speed communication via the proprietary Power Focus accessory bus. It should be noted that this function does not eliminate the need for a reaction bar, or similar, in higher-torque applications.

Yield control – get more from your fasteners

With the Power Focus 4000, it is possible to apply a Yield Control strategy for the cases where you need to get the most out of your fasteners.

Torque

Angle

Elasticzone

Plasticzone

Shut-off level,yield control

Shut-off level,torque control

While maintaining productivity, you can now make the fi xtured tool shut off where each individual bolt yields, and not based on a fi rm torque or angle value. You can achieve substantial savings by always purchasing the correct sized fast eners for the application.

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DS

Controller hardwareModelPF 4000-G-HW PF 4000-C-HWPF 4000-G-DN-HWPF 4000-C-DN-HW PF 4000-G-FLN-HW PF 4000-C-FLN-HWPF 4000-G-PB-HW PF 4000-C-PB-HWPF 4000-G-IB-HW PF 4000-C-IB-HWPF 4000-G-MB-HWPF 4000-C-MB-HW PF 4000-G-EIP-HWPF 4000-C-EIP-HW

Ordering No.8433 6100 00 8433 6100 05 8433 6140 008433 6140 05 8433 6141 00 8433 6141 05 8433 6142 008433 6142 058433 6145 00 8433 6145 058433 6147 008433 6147 058433 6149 008433 6149 05

Hardware and software ordering numbers

Controller functionality keysModelRBU-BronzeRBU-SilverRBU-GoldRBU-DS/DL

Ordering No. 8433 0010 108433 0015 208433 0020 208433 0005 10

Programming software (for PC)ModelToolsTalk PF licence 1 userToolsTalk PF licence 5 userToolsTalk PF licence 10 userToolsTalk PF licence PlantToolsTalk PF 1 user upgrade, W05 to W07ToolsTalk PF 5 user upgrade, W05 to W07ToolsTalk PF 10 user upgrade, W05 to W07ToolsTalk PF Plant upgrade, W05 to W07

Ordering No. 8092 1183 018092 1183 058092 1183 10 8092 1183 99 8092 1183 31 8092 1183 35 8092 1183 40 8092 1183 49

Version Field busGraphCompactGraph DeviceNetCompact DeviceNetGraph FL-Net Compact FL-NetGraph Profi BusCompact Profi BusGraph InterbusCompact InterbusGraph ModBusCompact ModBusGraph Ethernet IPCompact Ethernet IP

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