Introduction

• General Data Protection Regulation (GDPR)
• Conventions
• Liabilities and Warnings
  • Liability
  • Safety Signal Words
• System description
  • FlexSystem general functionality
  • FlexSystem description
    • FlexSystem components
    • FlexCarrier
    • FlexController
    • FlexDrive
    • FlexDrive blank
    • Cables
    • FlexIAM
  • FlexSystem capability
    • Maximum number of channels/spindles
  • FlexSystem compatible tools
  • Control cable for FlexSystem
    • Control cable
  • Power cable for FlexSystem
    • Power cable for FlexSystem product data
    • Power cable, straight entry (SE)
    • Power cable, right entry (RE)
    • Power cable, left entry (LE)
    • Power cable, straight to right entry (SRE)
    • Power cable, right entry to straight (RES)
    • Power cable, open end (OE)
  • Tool cable for FlexSystem
  • QST tool cable
  • Cables connected to the front of the FlexController
  • IP54
  • Voltage supply for FlexSystem
  • FlexSystem supervision
  • Flex Fusing
    • Power distribution cable
    • Power supply to mains switch box
  • Placement of FlexSystem
    • Distances between FlexSystem parts
    • Placement of fastening holes
    • Distance from thermal insulating wall
    • Daisy chain
  • Placement of modules in FlexCarrier
  • Emergency stop for FlexSystem
    • E-stop rules
    • E-stop configuration plug
    • E-stop entry plug
    • Bypass plug
    • ASM plug
    • Emergency stop modes
    • E-stop source from button connected to first FlexCarrier
    • E-stop source safety PLC connected FlexController
    • E-stop cable length
  • Protective earth connection for FlexSystem
  • Supported fieldbus module
• License Introduction
• Licenses Overview
• License Sources

General Data Protection Regulation (GDPR)

This product offers the possibility to process personal identifiable information such as system user name, role and IP-address. The purpose of this processing capability could be to enhance quality control through traceability and proper access management.

If you decide to process personal data you need to be aware of and comply with relevant personal data protection rules, including, in the EU the GDPR as well as other applicable laws, directives and regulations. Atlas Copco can in no way be held liable for any use made by you of the product.

Conventions

To enhance user understanding, certain formatting conventions are used throughout this document. The formatting conventions used are listed below.

Liabilities and Warnings

• Liability
• Safety Signal Words

Liability

Many events in the operating environment may affect the tightening process and shall require a validation of results. In compliance with applicable standards and/or regulations, we hereby require you to check the installed torque and rotational direction after any event that can influence the tightening result. Examples of such events include but are not limited to:

• initial installation of the tooling system

• change of part batch, bolt, screw batch, tool, software, configuration or environment

• change of air- or electrical connections

• change in line ergonomics, process, quality procedures or practices

• changing of operator

• any other change that influences the result of the tightening process

The check should:

• Ensure that the joint conditions have not changed due to events of influence.

• Be done after initial installation, maintenance or repair of the equipment.

• Occur at least once per shift or at another suitable frequency.

Safety Signal Words

System description

• FlexSystem general functionality
• FlexSystem description
  • FlexSystem components
  • FlexCarrier
  • FlexController
  • FlexDrive
  • FlexDrive blank
  • Cables
  • FlexIAM
• FlexSystem capability
  • Maximum number of channels/spindles
• FlexSystem compatible tools
• Control cable for FlexSystem
  • Control cable
• Power cable for FlexSystem
  • Power cable for FlexSystem product data
  • Power cable, straight entry (SE)
  • Power cable, right entry (RE)
  • Power cable, left entry (LE)
  • Power cable, straight to right entry (SRE)
  • Power cable, right entry to straight (RES)
  • Power cable, open end (OE)
• Tool cable for FlexSystem
• QST tool cable
• Cables connected to the front of the FlexController
• IP54
• Voltage supply for FlexSystem
• FlexSystem supervision
• Flex Fusing
  • Power distribution cable
  • Power supply to mains switch box
• Placement of FlexSystem
  • Distances between FlexSystem parts
  • Placement of fastening holes
  • Distance from thermal insulating wall
  • Daisy chain
• Placement of modules in FlexCarrier
• Emergency stop for FlexSystem
  • E-stop rules
  • E-stop configuration plug
  • E-stop entry plug
  • Bypass plug
  • ASM plug
  • Emergency stop modes
  • E-stop source from button connected to first FlexCarrier
  • E-stop source safety PLC connected FlexController
  • E-stop cable length
• Protective earth connection for FlexSystem
• Supported fieldbus module

FlexSystem general functionality

Main features

• Flexible system building possibilities

• Easy to mount off the floor which saves floor space

• Compact

• Line and process flexibility

• Serviceability

ToolsTalk 2

The FlexSystem is configured with ToolsTalk 2. For information on how to configure the FlexSystem, refer to ToolsTalk 2 User Guide.

FlexSystem description

• FlexSystem components
• FlexCarrier
• FlexController
• FlexDrive
• FlexDrive blank
• Cables
• FlexIAM

FlexSystem components

The FlexSystem must consist of the following parts:

A	FlexCarrier
B	FlexController
C	FlexDrive
D	FlexIAM (Flex Intelligent Application Module)
E	Tools
F	FlexSystem cables

The FlexSystem can also include of the following parts:

G	FlexDrive blank (required if there is an empty slot in the FlexCarrier)
H	FlexFan module

FlexCarrier

The FlexCarrier is available in two versions: 3 slot and 6 slot. The FlexController and the FlexDrives connects into device slots in the FlexCarrier. The FlexCarrier distributes power, interconnection, emergency stop (e-stop) and cooling. It also connects to accessories.

It is possible to connect one FlexCarrier to other FlexCarriers in a daisy chain.

The FlexCarrier module has the following functions:

• AC-power, with fuse and distribution

• DC 24V power generation, monitoring/control

• Emergency stop functions

• Supervision and fan control.

Flexible mounting

It is possible to mount the FlexCarrier on a:

• Station

• Power head frame

• Robot arm

• Manual station post

• Suspended tool stations

• Floor stations.

FlexController

The FlexController contains the central processing logic for internal and external communication.

One FlexController can control several FlexDrives.

The FlexController has the following functions:

• USB 2.0

• Ethernet communication (factory network, service and industrial port) 100BaseTX (100Mbit, 3 ports), full duplex

• Communication with fieldbus module

• PROFIsafe capability (only valid for 8436 1500 01)

• Real Time Clock (RTC) with backup (10 years)

• External fully isolated IO ports.

FlexDrive

The FlexDrive connects to the 3-phase tool.

The FlexDrive has the following functions:

• Power supply for the motor

• Inrush and DC-bus monitoring

• 3-phase power stage and current measurement

• Tool interface driver and tool power supply

• Temperature sensor, power stage and analysis

• Class III emergency stop channel

• AC input-, DC bus- and Current-control

• Tool control

• Servo

• Power rectification

• Control board

• Tool cable port to spindle.

FlexDrive blank

Each slot on the FlexCarrier must be filled. If there is no need of a FlexController or FlexDrive, a FlexDrive blank module must be added.

The FlexDrive blank module includes functions for IP, cooling and e-stop.

Cables

The FlexSystem has the following cables:

FlexIAM

The Flex Intelligent Application Module (FlexIAM) is a memory card for application software and result storage.

The FlexIAM may store:

• Necessary software for the FlexController

• Configuration data

• Working tasks

• Working data logs

• Past event and data logs

FlexSystem capability

The maximum number of FlexCarriers in a FlexSystem is limited to the number of tools and the size of the tools in the system. This is due to ampere rating of the 3-phase power cable.

Maximum number of channels/spindles

* For fully synchronized spindles, 64 spindles is the limit.

However, up to 64 bolts can be set up in the system. That is to say, for example, a system with 60 bolts and 30 spindles can be set up and each bolt has a unique number. The 30 spindles can tighten first 30 bolts and then the rest 30 bolts.

Conditions

• Simultaneous tightenings on all channels.

• Angular speed at final tightening: 20% of tool maximum speed for QST50 - QST80, 30% speed for QST34 - QST42

• Final torque: 60% of tool maximum torque for QST50 - QST80, 70% torque for QST34 - QST42

• Tightening interval 30 s (two per minute)

• Environment: sea level, room temperature and without cooling fans

• Tightening angle 360 degrees.

• Power factor: PF=0.6

• For higher torques, speeds and shorter tightening intervals it may be necessary to use more mains connection cables and mains switch boxes than stated in this table. In this case, contact your service center for advice.

Available power based on fuse

• At 30 A, output: 12.5 kW (PF=0.6, U=400Vac), 41.8 kW peak @ 1 second.

• At 2x30 A, output: 2x12,5 kW=25 kW (PF=0.6, U=400Vac), 83.6 kW peak @ 1 second.

• At FlexCarrier internal 16 A circuit breaker: 6.7 kW, 13 kW peak @ 1 second.

FlexSystem compatible tools

FlexSystem is compatible with all QST tools, including dual transducer tools.

Control cable for FlexSystem

The ethernet, e-stop and 24 VDC between FlexCarriers in a daisy chain goes through the control cables.

The control cable from FlexCarrier to FlexCarrier is designed to work with a control cable length of maximum 30 m.

Control cable

The following cables are provided when the FlexCarriers are mounted far from each other:

Power cable for FlexSystem

The 400/480 VAC between FlexCarriers in a daisy chain goes through the power cables.

Power cables are designed for cable carriers.

Cable to third party mains switch must be an Atlas Copco open end power cable.

The power cable is available in the following versions:

• Straight Entry (SE)

• Right Entry (RE)

• Left Entry (LE)

• Open End (OE)

• Straight to Right Entry (SRE)

• Right Entry to Straight (RES)

Power cable for FlexSystem product data

Power cable, straight entry (SE)

Power cable, right entry (RE)

Right entry (RE) power cables are used when the FlexCarriers are mounted horizontally.

Power cable, left entry (LE)

Left entry (LE) power cables are used when the FlexCarriers are mounted horizontally.

Power cable, straight to right entry (SRE)

Use straight to entry (SRE) power cables when the FlexCarriers are mounted vertically top down, that is, the first FlexCarrier mounted above second the FlexCarrier.

Power cable, right entry to straight (RES)

Use straight to entry (RES) power cables when the FlexCarriers are mounted vertically bottom up, that is, the first FlexCarrier mounted below second the FlexCarrier.

Power cable, open end (OE)

Use 4222 1887 xx for fixed installations in EU.
Use 4222 3147 xx for fixed installations in the USA and Canada.
Use 4222 3189 xx for non-fixed installations.
All installations must follow local laws and regulations.

Tool cable for FlexSystem

The FlexTool cable connects the tool with the FlexDrive.

The maximum length of the FlexTool cable is 60 m. Up to 8 cables (9 connections) are supported.

QST tool cable

The QST tool cable can used to extend the PF6 FlexTool cable from the tool to the FlexDrive.

The maximum length of the combined FlexTool and QST tool cable is 60 m. Up to 8 cables (9 connections) are supported.

Cables connected to the front of the FlexController

The Ethernet cable connected to the front of the FlexController must be a shielded category 5 cable. The maximum length of the cable is 100 m.

IP54

The FlexSystem is IP54 certified.

Make sure that every external connector point on the FlexSystem is mated with either a cable connector or a protection plug.

Voltage supply for FlexSystem

24 V FlexCarrier power

The 24 V power has two operation modes:

• Normal

• Backup.

Normal mode

In normal mode the power comes from a semi-floating 24 VDC power inside the FlexCarrier that is generated from the 3-phase AC. The fuses for the 24VDC is placed inside the FlexCarrier which means that it does not rely on the main circuit breakers placed on the front of the FlexCarrier.

Backup mode

In backup mode the power comes from an external 24V source.

Backup mode is when the 3-phase AC is missing to one or more FlexDrives connected to a FlexCarrier. The tool connected to the FlexDrive will not have any power and cannot be monitored, that is, it will not be visible in the controlling software, for example, ToolsTalk 2. All other communication in the FlexSystem works as normal.

The external power supply must be current limited to 8A, double insulation. It shall be certified according to EN 61010-1 or according to another standard compatible with the requirements in EN 61010-1 (for example EN 60950 or EN 60601).

24V Output

There is a floating 1.8 A, 24 VDC output for external equipment in the front of each FlexCarrier.

Current output with faulty units in daisy chained FlexCarriers

Even if the power supply function are broken in one or more of the FlexCarriers in a daisy chain it will still be possible to connect external equipment to all FlexCarriers in the FlexSystem. For available current see the table below:

Example

If one the FlexSystem consists of 2 FlexCarriers and 1 FlexCarrier is broken, the total available max current is 1.1 A. This means that 0.55 A is available from each FlexCarrier if an external equipment is connected to both FlexCarriers.

If one the FlexSystem consists of 6 FlexCarriers and 1 FlexCarrier is broken, the total available max current is 10.5 A. This means that 1.75 A is available from each FlexCarrier if an external equipment is connected to all 6 FlexCarriers. If external equipment is connected to 5 of the FlexCarriers the available current for each external equipment will be 1.8 A.

Backup mode

If an external 24 VDC power supply is connected to the FlexSystem this will distribute differently. A FlexSystem with 1 FlexCarrier can have a load of 1.8 A

Maximum input current can be 8 A. Each FlexCarrier need 1.25 A.

For available current see the table below:

Power loss in control cables

It is recommended that the remaining voltage is at least 20 V in the last FlexCarrier in a daisy chain.

The power loss in long control cables limits the usage of long cables.

If running the system in backup mode the length of the IO-bus must be considered.

FlexSystem supervision

The AC/24 VDC power supply voltage supervision measures the 3-phase voltages.

The FlexCarrier network contains:

• Temperature sensors

• Fan controllers

• Voltage monitors

• Drive network

The device in the first slot is responsible for:

• Collecting all the information from all local networks of the FlexDrives

• Controlling the fans (optional).

Example

If a temperature sensor registers a temperature that is too high, a signal is sent through the supervision network to increase the fan speed.

Flex Fusing

The Flex System input power distribution is designed for daisy chaining a current of 32 A maximum. The system is approved with the Atlas Copco 32 A power cable only. This sets the maximum allowed fusing for one chain to 32 A. When using external fuse it is recommended to use a slow blow, Class CC.

In both the fusing tables it is assumed that all channels/tools are set up to do a synchronized simultaneous tightening. If this is not the case, like for some kind of stitching operation, then go with a fuse value according to the actual number of simultaneous tightenings.

The fusing tables presents the recommended values for one daisy chained mains power supply (one fuse) with normal performance.

* Simultaneous tightening with 14 tools of QST50 type on a soft joint with 75 Nm final tightening torque.

Tool count for a given fuse value (one power chain) with approximately 75% of maximum performance

It is highly recommended that the mains supply chain is split if the number of tools exceed numbers in the table above.

The EMC certification is for one FlexCarrier.

The first mains power cable in one chain must be the Atlas Copco approved 32A cable. It is a critical part in the Safety certification.

Third party mains power supply

When a third party mains power supply is used it is required that another safety approved (UL 61010-1 or equivalent) mains switch is used. In that case it is recommended that the external fuse has the same value as for one power outlet, that is, a 30-32A slow blow fuse. However, if a smaller system is installed a 20A external fuse should be used.

The fuses in the FlexCarrier should always blow before any fuse installed before the FlexSystem.

Example

A 6-channel FlexSystem can be installed with a 20A external fuse.

If the Atlas Copco 32A mains cable is connected from the mains switch to the FlexCarrier, you do not necessarily need to have the same current rating for the cables feeding the factory installation system mains switch. The cable size should comply with the chosen fuse value.

Power distribution cable

The power distribution cable is the cable that connects the mains switch box with the power supply system.

Power supply to mains switch box

TN or TT mains are to be preferred

If the power supply system isn’t as shown above an isolation transformer is needed. Below are shown some examples of additional power supply system types using up to 480 VAC (phase to phase) where an isolation transformer is required

Examples

Examples 1:

Examples 2:

Examples 3:

Examples 4:

Examples 5:

Placement of FlexSystem

The FlexCarrier should be mounted vertically for optimal system functionality. This will allow for best air flow and heat transfer.

The FlexSystem and the mains switch box can be mounted in any normal industrial environment without any extra enclosure, if local regulations do not require otherwise.

The FlexSystem should not be exposed to excessive amount of vibrations. The vibration should be less than 10 g (98 m/s²) and between 1000 to 2000 Hz.

Distances between FlexSystem parts

Placement of fastening holes

When fastening the units, use:

• Screw: M6

• Torque: 9.8 Nm

FlexCarrier

FlexMSB 60

FlexMSB 30

Mount the mains switch box in a convenient place where it is easily accessible. It shall be possible to open the mains switch box in order to get access to the fuses.

Distance from thermal insulating wall

The FlexSystem must be placed 20 mm from a thermal insulating wall.

Daisy chain

It is possible to connect one FlexCarrier to other FlexCarriers in a daisy chain. Then it is possible for one FlexController to control more FlexDrives than fits in one FlexCarrier.

FlexCarrier address setting

Set the addresses in sequential order. The first FlexCarrier has address set to 1, set the second to 2, the third to 3 etc.

The default factory setting is 0. It is not allowed to have 0 as an address in an installed application.

Placement of modules in FlexCarrier

The following rules apply to the placement of modules in a FlexCarrier:

• The FlexController must be placed in the first device slot on the first FlexCarrier in a daisy chain.

• Every device slot must contain a module (FlexController, FlexDrive or a FlexDrive blank module).

Emergency stop for FlexSystem

The FlexSystem makes it possible to connect emergency stops (e-stops) in different configurations with up to 15 FlexCarriers.

For the e-stop button and reset button there is a protected 24VDC input via the e-stop terminals on the front of the first FlexCarrier in the system.

Test the e-stop function every time the power supply chain is changed, to make sure the e-stop function is still intact.

E-stop rules

The e-stop works according to the rules below:

• The first FlexCarrier controls the e-stop functions.

• The first FlexCarrier must have address 1.

• Place the FlexController in the first FlexCarrier.

• An e-stop configuration plug must be inserted in each FlexCarrier. If not, the e-stop will not work.

• The first FlexCarrier must have either an entry plug or an ASM plug.

• If an e-stop entry plug is placed in another FlexCarrier than the first one the e-stop will not work.

• If a control cable is missing in between FlexCarriers, the next FlexCarrier will not start.

• If the control cables have swapped positions, parts of the system will not be started.

  Do not connect any daisy chained FlexCarriers to the controller input inter-com port on the first FlexCarrier.

• In ASM mode the e-stop and reset buttons are only sensed and the safety PLC is controlling the system.

• FlexCarriers in the daisy chain with higher address than 1 may be connected in any order.

E-stop configuration plug

The following plugs are available:

• E-stop entry plug

• Bypass plug

• Advanced Security Module (ASM) plug.

E-stop entry plug

The e-stop entry plug is used in the first FlexCarrier in an e-stop chain. It has four connectors for the e-stop button and power feed and two connectors for the reset button.

Bypass plug

The bypass plug is used in the second FlexCarrier and each of the following FlexCarriers in an e-stop chain. The bypass plug does not have any connections and the plug covers the 24VDC in.

ASM plug

If an external safety PLC will control the e-stop, use an ASM plug in the first FlexCarrier in the e-stop chain.

Emergency stop modes

The e-stop can be configured in different modes:

• E-stop source from button connected to the first FlexCarrier

• E-stop source safety PLC connected to FlexController.

E-stop source from button connected to first FlexCarrier

In this mode the first FlexCarrier in the daisy chain is used as a primary FlexCarrier. Connect an e-stop entry plug in the first FlexCarrier. If more FlexCarriers are connected in a daisy chain, connect a bypass plug in each of the following FlexCarriers. The bypass plug is used to signal that the chain is correct.

All FlexCarrier must have a plug otherwise the e-stop function will prevent the FlexSystem to start

For the system to work, an e-stop and a reset button needs to be connected to the entry plug.

E-stop source safety PLC connected FlexController

In this mode an external safety PLC controls the e-stop. The safety PLC is connected to a PROFINET fieldbus module on the FlexController. Use an ASM plug on the FlexCarrier.

Error-Bits reported by the FlexController via PROFIsafe shall not be used to trigger the safety function of a device or system.

GSD-file

Atlas Copco delivers a GSD-file that includes a description of the FlexSystem as an IO device in PROFINET. Use this GSD-file when configuring the PROFINET system.

Logical ports of PROFISafe module

Logical illustration - PROFISafe implementation in the FlexSystem

Input process image

The input process image contains the data and status collected from the local digital inputs of the PROFISafe module as well as the PROFIsafe frame elements which are to be transported via PROFINET from the PROFISafe module to the PROFIsafe PLC.

The qualifier bits QDI_X indicate whether a fail-safe error was detected at the corresponding input or output channel of the ProfiSafe module. If set to 0, the input or output state is “fail-safe”, that is, the input data contains the fail-safe values or the output is locally set to the fail-safe value by the ProfiSafe module. A qualifier with the value 1 indicates that the input or output is operated without any fail-safe errors.

The input- and output channel qualifiers are operated individually, that is, the qualifiers show the error state only for the corresponding channel or channel group. Other channels may still operate correctly.

Output process image

The output process image of the PROFISafe module contains all the safety-relevant data sent from the F-Host to the PROFISafe module. The data of the output process image is used on the one hand to control the safe digital output states of the PROFISafe module and on the other hand to send the fail-safe error acknowledge data for the digital inputs and outputs of the PROFISafe module.

E-stop cable length

The maximum allowed resistance for the e-stop chain is 200Ω. To calculate the maximum allowed cable length the following formula should be used:

2,7N_carriers + 0,22L_10-cabletotL + R_{Estop cable per m} • L_{Estop cable} • 6 ≤ 200Ω

N_Carriers = Number of FlexCarriers

L_IO-cabletot =Total length of control cable

R_{Estop cable per m} = Resistance per meter of e-stop cable

L_{Estop cable} = Length of e-stop cable

Maximum and minimum wire size

AWG: 16, 18, 20, 22, 24, 26, 28

mm²: 0,2 - 1

Example:

A 14 channel system with two 6 slot and one 3 slot FlexCarriers. The system has got a normal e-stop solution with three e-stop buttons and one restart button. The e-stop cable length is 150 m and the control cables are 2 m and 5 m.

The e-stop cable is a 6 wire AWG 22 (0.64 mm² 0.11 Ω/m).

2.7·3 + 0.22(2+5) + 0.11·150·6 = 108.64 ≤ 200

For power distribution reasons the control cable length must not exceed 30 m in any segment.

Protective earth connection for FlexSystem

The FlexSystem is connected to protective earth through the power cables (the power cable and the tool cable). The power cables must be connected even if they are not powered.

Never connect two FlexCarriers without the power cable. Always use both control cable and power cable.

The FlexSystem is still connected to protective earth if the mains switch board is switched off or a fuse is blown.

Supported fieldbus module

The following fieldbus modules types are supported:

• DeviceNet

• EtherNet IP

• Profinet IO

• Profibus

• CC Link

• CC Link IE

• EtherNet IP M40

License Introduction

Licenses for controller features are managed through the Functionality Management System (FMS). This allows customers to tailor controller functions to their specific needs through a dynamic licensing scheme.

Licenses can be obtained for individual features or collections of features and can be deployed across multiple Virtual Stations. The licenses can be returned to the pool when they are no longer required. Licenses can be obtained through the Atlas Copco License Portal (ACLP). Licenses can be downloaded from the ACLP and managed/distributed through ToolsTalk, or can be stored on a FMS Portable (USB drive) to be inserted into the controller.

Note that the creation and management of a customer account in the ACLP is not covered in this documentation. Contact your local Atlas Copco representative for more information.

Licenses Overview

Configuration of features governed by licenses can be done even in the absence of an installed license. For example configuration of tightening programs and configuration of Multistep programs. Assigning these features to a tool or virtual station is also possible. Running the feature without a valid license, however, will require the installation of the appropriate license.

License enforcement is performed at two stages: assignment and runtime (trigger pressed). If a feature for which no license is installed is assigned to a Virtual Station, a red exclamation mark will appear at the Virtual Station View in ToolsTalk 2. The controller GUI will also show a warning triangle at the tool or task section (depending on what is missing). If a feature for which no license is installed is started (i.e. trigger pressed), an event will be presented to the user informing the user of which license is missing. It will not be possible to proceed without a correct license installed.

Running an unlicensed feature will, in most cases, result in a locked tool.

Many features and functions in the controller require a license in order to be assigned and used by a virtual station. There are four types of licenses:

Virtual Station Type

Fixed collection of features bundled together in a single package. The Virtual Station Type determines, among other things, what tools can be run, how many programs and sequences can be used, which tightening strategies are available, and the type of reporting that can be done. The features contained in each Virtual Station Type are features that often are used in conjunction with each other, or which have internal dependencies that require the presence of other features in the package. Virtual Station Types are assigned in their entirety to a virtual station. The virtual station can then make use of all features contained in the Virtual Station Type. In order to be able to perform tightenings, a Virtual Station has to be assigned a Virtual Station Type license. Depending on the license type, various tightening options will be enabled or blocked.

Sync Functionality Type

Works in the same way as described in Virtual Station Type but used for fixtured systems. To be able to run several tools on a virtual station each tool need a sync functionality license.

Virtual Station Feature

Individual features which can complement Virtual Station Types. A lot of features can be purchased as a single license.

Controller Feature

Features that are controller-wide. These are features which are assigned to a controller and once assigned can be used by all virtual stations on that controller.

License Sources

Licenses used on a controller can be pulled from several different sources. The number of simultaneous sources is limited to 10 (either 10 FMS Portable sources, or one License Server (TT2) in addition to 9 FMS Portable sources). If you would like to add licenses from a source when the source limit (10) has been reached, all licenses from one source need to be removed from the controller to make room for licenses from the other source.

Source Overview

The Source Overview tab (License assignment > Source Overview) provides the user with an overview of the licenses installed on the controller, as well as where they were installed from. A maximum number of 10 different sources can be displayed here, and each will be designated with FMS P (for FMS Portable, or dongle), or License Server (TT2).

Clicking on any license source will present that source's detailed license source information. It lists the source name and type, as well as the number and type of licenses in each category (Virtual Station Type, Virtual Station Feature and Controller Feature).

Installation and Upgrade

• Installation overview
  • FlexSystem components
• Hardware installation
  • Preparations
  • Tools
  • Mounting FlexSystem
    • Placement of FlexSystem
  • Cable planning
    • Recommended cables for minimum footprint
    • Recommended cables for general positioning
  • Installation instructions
  • Install first FlexCarrier
  • Install daisy chained FlexCarriers
  • Install FlexController
  • Install FlexDrive
  • Install FlexBlank
  • Tighten module to FlexCarrier
  • Mount FlexFan
  • Route and install power- and control cables to FlexCarrier
  • Install tool
  • Turn on the system
  • Test e-stop function
• Software installation
  • Configure the system
  • Installing Licenses on the Controller
  • Removing Licenses from the Controller
• Test and validate installation
  • Test and validate installation
  • Test and validation of PROFISafe controlled e-stop
  • Prerequisites for test and validation of PROFISafe
  • Power on
  • Reset of stop condition
  • Test e-stop sources
  • Test loss of PROFINET cable
  • Test loss of FlexCarrier e-stop plug
  • Stop functionality test during tightening
  • Check configuration parameters
  • Configuration parameters
  • Test and validate entry plug controlled e-stop
  • Prerequisites for test and validation of FlexSystem
  • Power on
  • Reset of stop condition
  • Test e-stop source
  • Test loss of FlexCarrier e-stop plug
  • Stop functionality test
  • Test loss of input stop
• Software upgrade
  • Installation of upgrade
  • Software configuration

Installation overview

• FlexSystem components

FlexSystem components

The FlexSystem must consist of the following parts:

A	FlexCarrier
B	FlexController
C	FlexDrive
D	FlexIAM (Flex Intelligent Application Module)
E	Tools
F	FlexSystem cables

The FlexSystem can also include of the following parts:

G	FlexDrive blank (required if there is an empty slot in the FlexCarrier)
H	FlexFan module

Hardware installation

• Preparations
• Tools
• Mounting FlexSystem
  • Placement of FlexSystem
• Cable planning
  • Recommended cables for minimum footprint
  • Recommended cables for general positioning
• Installation instructions
• Install first FlexCarrier
• Install daisy chained FlexCarriers
• Install FlexController
• Install FlexDrive
• Install FlexBlank
• Tighten module to FlexCarrier
• Mount FlexFan
• Route and install power- and control cables to FlexCarrier
• Install tool
• Turn on the system
• Test e-stop function

Preparations

WARNING

Read all safety warnings, instructions, illustrations and specifications provided with this power tool.

Failure to follow all instructions listed below may result in electric shock, fire, and/or serious injury.

Save all warnings and instructions for future reference.

Make sure that every external connector point on the FlexSystem is mated with either a cable connector or a protection plug.

Tools

Mounting FlexSystem

For minimal footprint select power cables and mount the FlexSystem according to the specified distances.

The FlexCarrier should be mounted vertically for optimal system functionality. This will allow for best air flow and heat transfer. Mounting FlexCarrier horizontally can affect the lifetime of the system.

The FlexSystem and the main switch box can be mounted in any normal industrial environment without any extra enclosure, if local regulations do not require otherwise.

The FlexSystem should not be exposed to excessive amount of vibrations. The vibration should be less than 10 g (98 m/s²) and between 1000 to 2000 Hz.

Screw: M6, Torque: 9.8 Nm

Distances between FlexSystem parts for minimal footprint (with FlexFan)

Distances between FlexSystem parts for minimal footprint (without FlexFan)

Placement of FlexSystem

Placement of fastening holes

Distance from thermal insulating wall

The FlexSystem must be placed at least 20 mm from a thermal insulating wall.

Cable planning

• Recommended cables for minimum footprint

• Recommended cables for general positioning

Recommended cables for minimum footprint

For information of dimensions for minimal footprint installation, see Mounting FlexSystem.

Power cables

To connect a FlexCarrier to mains switch board, use the power cable:

To connect a FlexCarrier to a 3 slot FlexCarrier, use these power cables:

To connect a FlexCarrier to a 6 slot FlexCarrier, use these power cables:

Control cables

Use these control cables:

Recommended cables for general positioning

FlexCarriers can be positioned freely, with more spacing or with FlexCarriers not placed in the same plane.

Power cables

The selection is based on the routed length between cable ends from A to B. Select a FlexPower cable with the closest longer length to the measurement.

The minimum bending radius (0.12 m) must be followed.

Control cables

The selection is based on the routed length between cable ends from A to B. Select a FlexControl cable with the closest longer length to the measurement.

The minimum bending radius (0.1 m) must be followed.

Installation instructions

WARNING

Only qualified and trained operators should install, adjust or use this equipment.

Install the FlexSystem in the following order:

Each step is explained in detail in the following section.

Install first FlexCarrier

Install daisy chained FlexCarriers

Install FlexController

Install FlexDrive

Install FlexBlank

Each slot on the FlexCarrier must be filled. If there is no need of a FlexDrive in the last FlexCarrier in a daisy chain, add a FlexBlank module to the device slot.

Tighten module to FlexCarrier

Use torque 5.7 Nm. Screw head TX25.

For each module in the FlexCarrier:

Mount FlexFan

Power must be turned off when mounting a FlexFan.

This step is optional.

For 3 slot FlexCarrier:

For 6-slot FlexCarrier, repeat for second FlexFan.

Route and install power- and control cables to FlexCarrier

Make sure that the cables are in good condition before connecting them to the system. Check that

• Cables are not damaged

• Connectors are not damaged.

If these conditions are not fulfilled the system must not be connected to mains or switched on.

Systems where damages to connections or cables are found must be disconnected and repaired immediately.

WARNING

It is dangerous to use systems, cables or units that are not in good condition or not connected according to electrical regulations and system requirements, whether manufactured by Atlas Copco or third party.

Install tool

Turn on the system

When turning on the system the power residual current device may switch off the power.

Before you power up the system make sure it is installed the same way as it was planned and configured. Otherwise it will not work.

The FlexSystem is now potentially dangerous since the e-stop functionality is not tested yet.

Test e-stop function

See Test and validate installation.

Test the e-stop function every time the power supply chain is changed, to make sure the e-stop function is still intact.

Wait at least 30 seconds between power off and power on when you restart the FlexSystem.

Software installation

• Configure the system
• Installing Licenses on the Controller
• Removing Licenses from the Controller

Configure the system

The FlexSystem is configured with ToolsTalk 2 and with the web graphical user interface (web GUI).

Installing Licenses on the Controller

Note that licenses sources are limited to 1 License Server (TT2) and 9 FMS Portables (dongles) simultaneously. Licenses are installed either through the server (ToolsTalk 2) or FMS Portable. If the license source limit is reached, all licenses from one source need to be removed from the controller in order to add licenses from another source.

Before installing licenses through the server (ToolsTalk 2), make sure that the controller time is synced with the server time.

Installing from the Server

Distributing server-based licenses is done through ToolsTalk 2. Please refer to the ToolsTalk 2 User Guide for instructions on installing licenses.

In order to be able to install licenses using ToolsTalk 2, the correct license server needs to be configured:

Installing from FMS Portable (USB)

The Functionality Management System (FMS) uses a special FMS Portable device to transfer functionality to and from a controller. The USB flash drive contains both a general purpose memory area and a trusted storage area that is only accessible by the License manager in a controller. The purchased feature items are downloaded from Atlas Copco to the general purpose area. The first time the FMS Portable is inserted into a controller with a License manager, the file is detected and decoded and the feature items are transferred to the trusted storage area that is only accessible from a License manager.

If you have a USB drive with the licenses installed, perform the following steps to install them on the controller.

The user will be presented with events on the controller for both license transfer start and end.

License sync

Existing licenses are checked against the license server every two hours. If no response from the license server is obtained within a 14 day period, the affected licenses will be revoked. The user will also be warned when licenses are about to expire. When a license is within 7 days of expiration, the user will be presented with a warning once every two hours. If licenses are not renewed, they will expire and the affected functions will no longer be available.

Removing Licenses from the Controller

One way of removing an FMS Portable-installed licenses are described, for instructions how to remove server-installed licenses, please refer to the ToolsTalk 2 User Guide.

Removing FMS Portable-Installed Licenses

Test and validate installation

• Test and validate installation
• Test and validation of PROFISafe controlled e-stop
• Prerequisites for test and validation of PROFISafe
• Power on
• Reset of stop condition
• Test e-stop sources
• Test loss of PROFINET cable
• Test loss of FlexCarrier e-stop plug
• Stop functionality test during tightening
• Check configuration parameters
• Configuration parameters
• Test and validate entry plug controlled e-stop
• Prerequisites for test and validation of FlexSystem
• Power on
• Reset of stop condition
• Test e-stop source
• Test loss of FlexCarrier e-stop plug
• Stop functionality test
• Test loss of input stop

Test and validate installation

Verify that the FlexSystem is possible to stop in a safe way, and that a loss of a safety function will put the FlexSystem in a safe state

Wait at least 30 seconds between power off and power on when you restart the FlexSystem.

Test and validation of PROFISafe controlled e-stop

Example

This is a PROFISafe controlled FlexSystem with two FlexCarriers. In this configuration there is one e-stop button and one reset button attached to the safety PLC.

The e-stop button, the reset button and the safety PLC are not considered to be a part of the FlexSystem. These sources must be verified by the machine tool builder (MTB).

Prerequisites for test and validation of PROFISafe

Make sure that all equipment is in place. Pay special attention to the following:

• The first FlexCarrier has an ASM plug connected.

• The daisy chained FlexCarriers have a bypass plug connected.

• That a PROFINET cable is connected between the FlexController and the safety PLC.

• All FlexCarriers are fully populated, no empty slots are allowed. If there is an empty slot, equip it with a FlexBlank module.

• Connect all FlexCarriers together with FlexControl cables, pay attention to the IN and OUT markings on the FlexCarriers.

• The first and the last FlexCarrier in the daisy chain must only have one FlexControl cable connected.

• That you have access to the FlexSystem web GUI, Reports > Events > View all events. All alarms are shown in the Events list.

• PROFINET IO Controller with PROFIsafe (Safety PLC) must be parameterized with configuration parameters as shown in table. PROFIsafe destination addresses must be unique within the station and the network.

• Safety PLC must be programmed to activate safe output DO1 (bit 0) and monitor feedback of digital input DI4 (bit 3).

Power on

Power on the FlexSystem and wait for the FlexSystem to come online, verify that:

• No tightening can be made.

• An alarm stating that the FlexSystem is stopped.

Reset of stop condition

Reset the stop condition and verify that:

• The alarm regarding the stop is removed and that it is possible to perform a tightening.

The FlexSystem is now potentially dangerous since the stop functionality is not tested yet.

Test e-stop sources

Trigger all possible stop safety PLC input sources individually, for example, e-stop buttons. Verify that:

• An alarm stating that the FlexSystem is stopped is triggered.

Between every stop a reset has to be made.

Test loss of PROFINET cable

Test loss of FlexCarrier e-stop plug

Stop functionality test during tightening

Start a tightening and trigger one e-stop source, for example, an e-stop button. Verify that:

• The tightening is stopped.

• The tightening does not continue when the stop condition is removed. An automatic restart can be made if it can be implemented in a way that guaranties that no injury can occur.

• The tightening is not restarting if reset is pressed and stop condition remains.

• A new tightening is possible when stop condition is removed and reset function is activated.

Check configuration parameters

The configuration parameters for the safety module are included in the GSD-file provided by Atlas Copco. The parameters shall not be altered.

Check that the parameters are correct by verifying that the checksum is:

• 0x4DC13CF8.

Configuration parameters

Test and validate entry plug controlled e-stop

Example

This is a FlexSystem using e-stop entry plug to control the e-stop, a discrete e-stop solution. The stop input source can be buttons, light curtains or other sensors, however they need to be able to break two signal paths in a safe manner. One or more stop sources can be connected in series.

Prerequisites for test and validation of FlexSystem

Make sure that all equipment is in place. Pay special attention to the following:

• The first FlexCarrier have an e-stop entry plug connected.

• The daisy chained FlexCarriers have a bypass plug connected.

• The e-stop button is a breaking model (N.C. Contacts) and that it is connected to the e-stop entry plug

• The reset button is of a closing model (N.O. Contacts) and that it is connected to the e-stop entry plug.

• Make sure that the screws on the terminal block are securely tightened, to prevent cables from disconnecting.

• All FlexCarriers are fully populated, no empty slots are allowed. If there is an empty slot equip it with a FlexBlank module.

• Connect all FlexCarriers together with FlexControl cables, pay attention to the IN and OUT markings on the FlexCarriers.

• The first and last FlexCarrier in the daisy chain should only have one FlexControl cable connected.

• That you have access to the FlexSystem web GUI, Reports > Events > View all events. All alarms are shown in the Events list.

Power on

Power on the FlexSystem and wait for the FlexSystem to come online, verify that:

• No tightening can be made.

• An alarm stating that the FlexSystem is stopped is triggered.

Reset of stop condition

Reset the stop condition and verify that:

• The alarm regarding the stop is removed and that it is possible to perform a tightening.

The FlexSystem is now potentially dangerous since the stop functionality is not tested yet.

Test e-stop source

Trigger one stop condition with all possible stop sources, for example, e-stop button, and for each input observe the following:

• An alarm stating that the FlexSystem is stopped is triggered.

Between every stop a reset has to be made.

Test loss of FlexCarrier e-stop plug

Stop functionality test

Start a tightening and trigger one e-stop source, for example, an e-stop button. Verify that:

• The tightening is stopped.

• The tightening doesn’t continue when the stop condition is removed. (An automatic restart can be made if it can be implemented in a way that guaranties that no injury can occur.)

• The tightening is not restarting if reset is pressed and stop condition remains.

• A new tightening is possible when stop condition is removed and reset function is activated.

Test loss of input stop

Start a tightening and disconnect the wires to the stop input source, for example, e-stop button. Verify that:

• The tightening is halted.

• An alarm stating that the FlexSystem is stopped is triggered.

Software upgrade

• Installation of upgrade
• Software configuration

Installation of upgrade

To update the software perform the following steps:

If the software is upgraded from version 1.2.X and the tightening program has errors in conversion after restart, do the following for all the programs in the Tightening Program list:

Software configuration

For information on how to configure the FlexSystem, see ToolsTalk 2 Configuration Manual.

Configuration

• Configuration overview
  • Configuration alternatives
  • Connect to web GUI
• Getting started
  • Liability
  • Connecting to web GUI via service ethernet port when ToolsTalk server is connected to factory ethernet port
  • Setting up connection to ToolsTalk 2 server
  • Set PIN protection on the FlexSystem
  • Configuring ToolsTalk 2 when ToolsTalk server is connected to service ethernet port
  • Connecting to web GUI via factory network when ToolsTalk server is connected to factory ethernet port
  • Connecting to web GUI through the service ethernet port
• Features
  • Batch sequence menu
    • Batch Sequence Settings
  • Sources menu
  • Tool menu
  • Virtual station menu
    • Creating a Virtual Station
    • Assigning licenses to a Virtual Station
    • Unassigning licenses from a Virtual Station
    • Configuring Task Window in a Virtual Station
    • Configuring Protocols Window in a Virtual Station
    • Configuring Fieldbus Window in a Virtual Station
  • Configurations menu
    • Internal I/O
      • Digital input
      • Digital output
    • I/O Expander
      • Relays
      • Digital input
    • Operator panel
    • Stacklight
    • Indicatorbox
    • Scanner
    • General Virtual Station
  • PF6 FlexSystem menu
    • Automated Backup
  • Reports menu
  • Settings menu
    • Setting up the Firewall
  • License assignment
  • Live results
    • Result View - Numbers
    • Result View - Identifier Strings

Configuration overview

• Configuration alternatives
• Connect to web GUI

Configuration alternatives

All components connected directly to factory network

In this alternative all components are connected directly to the factory network. The service ethernet port is used to connect to each separate FlexSystem.

Components connected via a switch to a local ToolsTalk server

In this alternative the FlexSystems are connected to a switch. The ToolsTalk server is installed on an Industrial PC (IPC) that is connected to the same switch. The service ethernet port is used to connect to each separate FlexSystem.

ToolsTalk server connect locally to service ethernet port

In this alternative the ToolsTalk server is installed on an IPC connected to the service ethernet port. The FlexSystem is connected to the factory network through the factory ethernet port.

More than one FlexSystem connected locally to one ToolsTalk server via service ethernet port

This alternative is not possible since the service ethernet port has a fixed IP-address.

Connect to web GUI

There are two ways to connect to the FlexController’s web GUI:

• Through the service ethernet port (primary).

• Through the factory ethernet port (secondary).

Getting started

• Liability
• Connecting to web GUI via service ethernet port when ToolsTalk server is connected to factory ethernet port
• Setting up connection to ToolsTalk 2 server
• Set PIN protection on the FlexSystem
• Configuring ToolsTalk 2 when ToolsTalk server is connected to service ethernet port
• Connecting to web GUI via factory network when ToolsTalk server is connected to factory ethernet port
• Connecting to web GUI through the service ethernet port

Liability

Many events in the operating environment may affect the tightening process and shall require a validation of results. In compliance with applicable standards and/or regulations, we hereby require you to check the installed torque and rotational direction after any event that can influence the tightening result. Examples of such events include but are not limited to:

• initial installation of the tooling system

• change of part batch, bolt, screw batch, tool, software, configuration or environment

• change of air- or electrical connections

• change in line ergonomics, process, quality procedures or practices

• changing of operator

• any other change that influences the result of the tightening process

The check should:

• Ensure that the joint conditions have not changed due to events of influence.

• Be done after initial installation, maintenance or repair of the equipment.

• Occur at least once per shift or at another suitable frequency.

Connecting to web GUI via service ethernet port when ToolsTalk server is connected to factory ethernet port

Make sure the DHCP settings are enabled on the computer.

When the ToolsTalk server is connected to the factory ethernet port, perform the following steps to connect to the web GUI:

Setting up connection to ToolsTalk 2 server

Table Title

A	Factory network
B	ToolsTalk server
C	Factory ethernet port.

To set the IP address for the factory ethernet port and point out the ToolsTalk server, perform the following steps:

Set PIN protection on the FlexSystem

PIN protection can be set in ToolsTalk 2 > Settings > Preferences.

PIN protection can also be set in the web GUI > Settings > PIN > Configure.

It is possible to have one or many different PIN configurations. Users can decide whether or not to activate one or several PIN configurations at the same time.

Each PIN configuration has a PIN code, a user name, a switch for enabling or disabling the user/PIN, and a list of available configurations that the user can access.

When PIN is enabled and the screen is locked, a locked padlock icon is shown at the upper-right corner of the GUI. The user can access and make changes only to the selected configuration(s) without entering any PIN code, and browse the unselected configurations with read-only access only. The unselected configurations are greyed out or disabled.

The screen lock goes automatically on after a certain time of inactivity, configurable by the user.
The minimum value of the inactivity time is 20 sec and the maximum value is 600 sec. The inactivity time is configurable and applies to all PIN configurations.

After a system startup, the controller is locked if the PIN is turned on, regardless of the current inactivity time.

The users and PIN configured apply also to the Service Port (169.254.1.1).
To enable PIN protection on the Service Port, in the PIN windows, set Use PIN for Service Port to On.

Each controller can configure up to 10 users.
The PIN of each configuration has to be unique. It is required to have at least one configuration to enable the PIN functionality on the controller.

The PIN can be configured from the Embedded controller-GUI, Web-based controller-GUI or Tools Talk 2.

Adding New Users

Enabling Users

Activating the PIN configuration

Deleting Users

Configuring ToolsTalk 2 when ToolsTalk server is connected to service ethernet port

Connecting to web GUI via factory network when ToolsTalk server is connected to factory ethernet port

ToolsTalk 2 server must have been set up before you can connect to the web GUI.

To connect to the web GUI via the factory network, perform the following steps:

Connecting to web GUI through the service ethernet port

Table Title

A	ToolsTalk server
B	Service ethernet port.

When the ToolsTalk server is connected to the service ethernet port, perform the following steps to connect to the web GUI:

Features

• Batch sequence menu
  • Batch Sequence Settings
• Sources menu
• Tool menu
• Virtual station menu
  • Creating a Virtual Station
  • Assigning licenses to a Virtual Station
  • Unassigning licenses from a Virtual Station
  • Configuring Task Window in a Virtual Station
  • Configuring Protocols Window in a Virtual Station
  • Configuring Fieldbus Window in a Virtual Station
• Configurations menu
  • Internal I/O
    • Digital input
    • Digital output
  • I/O Expander
    • Relays
    • Digital input
  • Operator panel
  • Stacklight
  • Indicatorbox
  • Scanner
  • General Virtual Station
• PF6 FlexSystem menu
  • Automated Backup
• Reports menu
• Settings menu
  • Setting up the Firewall
• License assignment
• Live results
  • Result View - Numbers
  • Result View - Identifier Strings

Batch sequence menu

Batch Sequence Settings

A batch sequence can consist of up to 99 batches, with a batch size of up to 250 tightenings. The batches in a batch sequence are carried out in the order listed, or by using a Socket selector to choose which batch to run.

Sources menu

Controller features, such as the Low Reaction Tightening Strategies and controller-wide functions among others, require licenses distributed through the Functionality Management System (FMS). Whereas configuration of features is possible without specific licenses, the assignment and use of those features will require the correct license to be installed on the controller. Please refer to Licenses (FMS) for more detailed information on licenses.

External signals used as tasks for tightenings are configured in the Sources menu. Sources are accessories or similar connected to a virtual station. Two types of source tasks are available:

• Tightening

• Batch sequence

Tightening is used to select a single tightening program.

Batch sequence is used to select a batch sequence, a series of tightening programs.

For more information about selection of tasks, see Assigning a Task to a Virtual Station.

Tool menu

Tool information

The Tool information view contains information used for giving service personnel accurate information about the tool connected to the controller, so that they can give adequate help and support, or for operators to see what tool is connected to the controller.

Connection

The Connection pane displays what FlexDrive the tool is connected to.

Health

Maintenance

The tool stores a service interval number and counts how many tightenings can be performed before a tool maintenance or service should be performed.

Calibration

Preparing the calibration

Make sure the tool and controller are set up to perform tightening. Set up the tool with a torque reference transducer such as an STanalyser, ACTA or BLM Bench. Refer to the torque reference transducer’s product information for set-up instructions.

Choose a tightening program with a target torque corresponding to a tightening normally used with your tool.

Calibrating the tool

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

Tool diagnostics

To diagnose a tool, the angle or torque sensor, it is possible to start Sensor tracking in the Tool menu. A Sensor tracking session has a time out of 20 minutes. A warning is shown 5 minutes before timeout and it is then possible to extend the session or to stop it.

Sensor tracking is only possible for cable tools.

It is only possible to start one Sensor tracking session for each controller at a time.

Start a sensor tracking session

Zero position

This configuration makes a system always return to the original start position for each tightening or sequence. Zero Position is set for each tool separately for both handheld and fixtured. Zero position sets the current position of the tool. It is not possible to set Zero Position during an ongoing tightening or sequence.

Set a zero position:

Motor tuning

A motor tuning adjusts the tool’s motor control unit to optimize the performance and minimize loss

Always do a motor tuning when a tool is moved from a Power MAC 4000 system to a PF6 FlexSystem.

Starting the motor tuning

The motor tuning will take approximately 1 minute to perform and will rotate the tool in high speed in both clockwise and counterclockwise directions before it is finished.

Zero offset and shunt

Transducer information

Virtual station menu

Virtual stations are configured in the Virtual Station menu.

A virtual station is a software abstraction of a physical station and can be set up to use a specific tool and remotely execute different tasks using the tool.

It is possible to set up a number of virtual stations per controller. Each virtual station can be connected to:

• one or more tools

• one or more accessories

By using virtual stations, the operator can operate multiple tools and run different tasks using the same controller.

When configuring different tools, make sure the selected start signal in Start source matches the selected tool and that the selected task can be run on the specific tool.

Before any tightening can begin a task must be selected in the virtual stations menu. A task is of one of three types:

• Sync Modes

• Batch sequence

• Sources

The selection can be made manually by the operator or by external signals.

Product Essentials Tutorials

https://www.youtube.com/watch?v=Ay0zO5fGSD8

Creating a Virtual Station

Controller features, such as the Low Reaction Tightening Strategies and controller-wide functions among others, require licenses distributed through the Functionality Management System (FMS). Whereas configuration of features is possible without specific licenses, the assignment and use of those features will require the correct license to be installed on the controller. Please refer to Licenses (FMS) for more detailed information on licenses.

To create a new virtual station:

To remove a virtual station: Tap on delete at the bottom of the list of parameters.

The list of virtual stations created is presented in the order of creation.

Assigning licenses to a Virtual Station

To make virtual stations working, it is needed to assign them a Sync functionality license.

Unassigning licenses from a Virtual Station

Configuring Task Window in a Virtual Station

The Task menu enables users to change task and do test tightening. The test tightening is used for easier fault finding and testing of the system.

Configuring Protocols Window in a Virtual Station

Under the tab Protocols, in the Virtual Station menu, you will find a list of available communication protocols depending on the current license in use. The Open Protocol is available for all licenses.

To gain access to ILM Protocol functionality, refer to the ILM Adapter User Guide.

To gain access to functionality through Open Protocol, a unique port for each Virtual Station needs to be defined.

As the default value for SoftPLC Index is always 1 and no checks are made to see if it is in use, there is a possibility that you may have configured the system so that the same index is configured several times when adding Virtual Stations. In this case, the Soft PLC will not be able to determine from which Virtual Station the incoming MID is originating from.

Configuring Fieldbus Window in a Virtual Station

The Fieldbus entry in the GUI shows the fieldbus mapping assigned to the controller.

To analyze the fieldbus configuration click on perform in the diagnostics field for the fieldbus mapping. Read more about the diagnostics tool in the Virtual station - Accessories section of this chapter.

To configure Fieldbus mappings, ToolsTalk 2 is required.

Configurations menu

A list of accessory configurations are given in the Configurations menu. Digital I/O signals are mapped to buttons, lamps, switches and connectors.

Internal I/O

Input signals are system commands that are carried out by using for example buttons or switches on an accessory or by connecting the signal to an I/O input plug.

Output signals are states or events of the system.

Digital input

Nominal input: 24V ± 10%.

Digital output

The digital output consists of four individually isolated relay outputs. The relays are rated to 500 VACrms input to output isolation. The output pins comes in groups of three:

• One relay have a center pin (Out X common)

• Normally Closed pin (Out X NC)

• Normally Open pin (Out x NO)

The Out X common pin should be connected to the equipment which is to be controlled and the two other pins to a suitable High or Low level for the equipment to be controlled

• Max relay switch current is 2 A at 24VDC.

• If the output is connected to an inductive load a fly back diode is required, to prevent the relay tongue from welding towards a pole when opening the circuit.

• Max output cable length is 3 m.

I/O Expander

The I/O-expander is designed to extend I/O with 8 digital inputs and 8 relay outputs.

Relays

Relays Relay out

There are 8 relayoutputs. Normally open or normally closed depending on the connection.

Connector

24-pin detachable screw terminal. Mating connector Phoenix MCVR 1.5/12-ST.3.81 or compatible.

Function

Two way dry contact relays. Isolated outputs. Logical function is set in the configuration of the PowerFocus or DS-drive.

Electrical data

Max 50VDC/AC. Switching load: min 1mA, max 500 mA resistive load.

Screw terminal

External output

Digital input

There are 8 optically isolated inputs. The internal supply and ground are galvanic isolated, providing a possibility to use for instance a pushbutton as signal.

Connector

20-pin detachable screw terminal. Mating connector Phoenix MCVR 1.5/10-ST-3.81 or compatible.

Function

Isolated optocoupled digital inputs. Logical function is set in the configuration of the PowerFocus.

Electrical data

According to IEC 61131-2.

Operator panel

The operator panel is connected to the I/O bus and provides a configurable digital communication link between an operator and the controller. Lamps, buttons, buzzer, and switches are used in the communication. Read the operator panel documentation for address configuration and specifications of connections.

Stacklight

The stacklight can be configured to display the I/O signals from the controller.

The stacklight can be customized as follows:

• A stack of four lights. One optional light can be added to this stack. You can also customize the order and the color of lights.

• Two positions, A and B, which can be customized with indicator lamps or switches.

• A buzzer placed on the side of the box that has a fixed frequency of 3000 Hz. The buzzer can be configured to activate on any tightening controller signal.

• Two external outputs, two external inputs and a connector for external power.

• Two I/O bus connectors. A termination plug, should be applied to the second I/O bus connector if it is at the end of the I/O bus line. The I/O bus termination plug is listed in the accessory list.

Indicatorbox

The Indicatorbox is a flexible display indicator used to display status signals from the controller. The display is equipped with 20 dual color LEDs, these are mounted in a square with five LEDs at each side.

Scanner

In this menu, scanner configurations can be added. Scanners can be configured to either have scanned strings handled by the controller, or passed through to a an external system. When the scanned string is passed through, the controller does not select a task based on the string, but instead passes the string to an external device via an output signal.

Adding a scanner and enabling pass through

General Virtual Station

In General Virtual Station, different specific result reporting and tightening settings can be saved. Different filters can be created, filtering out specific results. In the tightening settings, characteristics like the tool unlocking behavior can be set. These configurations can then be assigned to virtual stations.

Adding and editing a configuration

Disable loosening settings

To ensure that a bolt cannot be loosened by mistake, use the disable loosening function. There are four disable loosening settings:

These settings are valid during the execution of a task. Loosening enables and disables depending on the setting and the status of the last tightening. For a new task the start state for disable loosening is set as follows:

The start state applies whenever a new task is assigned to a Virtual station or when a task starts again. The start state can differ depending on the type of task, described as follows.

The start state applies whenever a new task is assigned to a Virtual station or when a task starts again. The start state can differ depending on the type of task, described as follows.

Tightening program and Sync mode

Enable and disable of loosening follows the disable loosening setting and is set to the status of the last tightening.

Batch Sequence

During a batch sequence the enable or disable of loosening follows the disable loosening setting and is set to the status of the last tightening. This also applies when a batch goes to the next one within a batch sequence. If a batch sequence starts again, the loosening is enabled or disabled according to the start state for a new task.

Source Batch

Enable and disable of loosening follow the same procedure as described in Batch sequence. If an ongoing source batch starts again or if a new one is selected, the loosening is enabled or disabled according to the start state for new task.

Source Tightening (No batch control)

During a batch, enable and disable is set according to the status of the last tightening. If another program is selected, enable and disable is set according to the start state for new task. If any change of program, tool or socket is done, enable and disable is set according to the start state for new task.

Multispindle tightening

Enable and disable of loosening always follows the status of the last tightening. This is also applicable for a new sync mode.

Disable tightening settings

To make sure that an operator does not tighten a bolt by mistake there is a function called disable tightening. There are four disable tightening settings:

These settings are valid during the execution of a task. Tightening enables and disables depending on the setting and the status of the last tightening. For a new task the start state for disable tightening is set as follows:

The start state applies whenever a new task is assigned to a Virtual station or when the task starts again. The start state can differ depending on the type of task, as described in the Disable Loosening settings section.

Allowing a disabled tool to unlock after loosening

• In the general virtual station configuration assigned to the virtual station to which the tool is connected, set the Unlock tool on loosening to On OK or Always.

To enable the setting above, the following conditions need to be met:

• The Disable loosening parameter cannot be set to Off or Always.

• The Disable loosening parameter cannot be set to the same value as Disable tightening.

• The tightening program used must have loosening enabled.

When the tool is locked for either tightening or loosening due to a disable state, it can be unlocked by any of the following input signals:

• Master Unlock - 10005

• Unlock Tool on Disable - 10059

It is not possible to unlock a disabled tool with the input signals ifLock tool on loosening is set to Always.

Assigning a configuration to a virtual station

Each virtual station can have its own configuration and multiple virtual stations can share the same configuration. A configuration must be assigned to a virtual station to become active.

PF6 FlexSystem menu

IAM

The Intelligent Application module (IAM) is a non volatile storage that is located in the controller. The storage module contains all the controller programs, configurations and results. Certain modules may also include additional loaded feature items.

Software

Software is used to load new system software.

To update the software perform the following steps:

The controller can store two installed software versions, current and stored. By using Software activation, it is possible to choose which software version to use.

The configuration of the active software will not be cloned when you switch to the other software version. That is, any configuration changes in one software will not affect the other installed software.

To activate an installed software:

1. On the PF6 FlexSystem menu, go to Software.

2. Swipe Software activation and follow the instructions.

3. Restart the system.

Hardware

Channels

Channels is used for fault finding. It lists all the channels in the system and show the current status of each one.

Export/Import

The Export/Import Tab supports the user to make one of the following operations: Export, Import, and Automated backup.

The Export window supports the user to export controller configurations, settings, results, and events. In addition, it is possible to export tool logs, which can be shared with Atlas Copco Service personnel to troubleshoot problems with the tool(s).

The Import window supports the user to import controller configurations and settings.

It is only possible to have one active Export or Import at the time. Any attempt to start a new Export/Import while there is an ongoing Export/Import is rejected.

The Automated backup window supports the user to generate automatically a backup file.

Export/Import Between Controllers

Controllers may have different IAM types that could have different capabilities.
A controller can export all the configurations that are applicable for the current type of IAM module.

A controller cannot import a file exported from a different type of IAM module. This is applicable also when using ToolsTalk 2.

Automated Backup

The Automated Backup window enables or disables sFTP export.

By default, Enable sFTP export switch is set to OFF.
When turning ON Enable sFTP export switch, an export file is created 10 minutes after the last configuration change.
If Enable sFTP export switch is set to ON on system startup, an export file is automatically created within 2-3 minutes. The export file is created within 2-3 minutes to reflect changes that might have been done before the system was shutdown.

The old Backup file is deleted before the new Backup file is available.

The data in the exported file include all configurations and settings of the controller.

The sFTP users can retrieve the exported file stored in the following directory of the system: /Export/<export file name>.

A system supporting sFTP is needed.

To retrieve the file sFTP users do not need to use any password.

The username for sFTP users is as follows:

Reports menu

In the Reports menu information regarding Events is displayed. This menu is useful for fault finding.

For detailed information of events:

Settings menu

The Settings menu is used to configure the IP address of the FlexController and set how the FlexController connects to ToolsTalk 2. It is also used to change the date and time of the system.

Network

The Ethernet ports pane includes an illustration that points out the service ethernet port and the factory ethernet port.

Server connections

Configuring the Log Levels

Preferences

This is where you set the date and time for the FlexSystem.

PIN

Set if PIN should be active and after how long it should turned on. Refer to Set PIN protection on the FlexSystem.

Alarms

Alarms are set to control when to perform maintenance or calibration on the tools connected to the system.

The tool service interval and other information are found in the tool view in the Tool menu.

Enabling an alarm

Events

It is possible to configure the events available in the controller as either or several of:

• Acknowledged

• Logged

• Displayed

Fieldbus

Extended logging

The FlexController automatically creates logs and stores them. These logs can be configured to include extended logging using log groups.

Reset

Setting up the Firewall

The controller can be set up to use a firewall. The firewall is based on the trusted host principle, and only allows incoming connections via ports that are enabled, or addresses that are whitelisted.

By default, the firewall is disabled.

The firewall applies only to incoming connections on the Factory Ethernet Port.

Activating and configuring the firewall

When activating the general firewall feature, Port Filtering (layer 4 firewall) and all its predefined services are enabled by default.

A connection is allowed, when any of the firewall layers accepts it. When no firewall layer is enabled, all incoming connections are allowed through.

Further firewall configuring is done by enabling/disabling connections through the predefined services specified, by adding TCP or UDP ports manually and/or by whitelisting IP/MAC addresses.

Port Filtering (layer 4 firewall)

When Port Filtering (layer 4 firewall) is enabled, the following predefined services are shown with their respective On / Off switches:

• Open ports for web (TCP 80, TCP 8080)

• Open ports for SSH and SFTP (TCP 22)

• Open ports for wireless tools (UDP 6677, TCP 6678)

• Open ports for accessories (TCP 25000)

Predefined service	Description
Open ports for web (TCP 80, TCP 8080)	Ports required for web services so the controller is accessible over the factory network. Setting Open ports for web (TCP 80, TCP 8080) to Off, triggers a warning that the connection with the Web HMI can be lost.
Open ports for SSH and SFTP (TCP 22)	Port required for SSH and SFTP functionality on the Factory Ethernet Port.
Open ports for accessories (TCP 25000)	Ports required for accessories to communicate with the controller over the factory network.

Adding additional TCP and UDP ports

Any additional TCP and UDP ports can be added in their respective entry boxes, that is Open additional TCP ports and Open additional UDP ports. Accepted are both comma-separated ports and port ranges using a dash (-). Example: when entering 1,2,3,4-10, all ports between 1 and 10 are opened.

Invalid port entries trigger an immediate pop-up warning.

Ports are automatically sorted after pressing the Apply button.

Open Protocol and NTP

When using Open Protocol, the ports to be opened must be added manually in the Open additional TCP ports entry box. For example: 4545,4546,4547 (depending on the ports configured in Virtual Station > Virtual Station 1 > Protocols > Open Protocol > Server Port). When using an NTP server, port 123 must be added manually in the Open additional UDP ports entry box.

Multiple ports can be added by using comma separation. Port ranges can be added by using a dash.

IP Filtering (layer 3 firewall)

IP Filtering (layer 3 firewall) allows specifying trusted hosts or networks by entering their IP addresses in the IP White List entry box. To access the entry box, set the switch to On. Accepted entries are lists of IP addresses or network addresses in the form of IP tables, that is, host IP addresses or network IP addresses. The network mask can be entered as mask length (for example, /24) or as network IP address (for example, /255.255.255.0). Packets coming from a whitelisted IP address are immediately allowed. Other packets are screened by the other firewall layers (Port Filtering and MAC Filtering).

Due to security issues, entering host names or network names is not accepted.

Note that processes like NATing (Network Address Translation) may change source IP addresses. Consult your local network administrator when whitelisting a host based on source IP address is required.

MAC Filtering (layer 2 firewall)

MAC Filtering (layer 2 firewall) allows specifying trusted hosts or networks by entering their MAC addresses in the MAC White List entry box. To access the entry box, set the switch to On. Accepted entries are comma-separated lists of MAC addresses. Packets coming from a whitelisted MAC address are immediately allowed. Other packets are screened by the other firewall layers (Port Filtering and IP Filtering).

Invalid entries trigger an immediate pop-up warning.

Note that routing may change source MAC addresses. Consult your local network administrator when whitelisting a host based on source MAC address is required.

Packet counters

To view the packet counter values for each firewall layer, select Packet Counters. To refresh or reset the packet counter values, select the corresponding switch and release.

Firewall status

The status of the general firewall feature and its firewall layers is shown in the Firewall main view directly under Settings > Network.

Status	Description
OK	The firewall is enabled and the firewall configuration is applied.
Disabled	The firewall is disabled and the firewall configuration is not applied.
Configuration Error	The firewall is enabled, but the firewall configuration is not applied due to an internal error. For safety reasons, the fail-open policy is applied, meaning all connections are allowed through.

When the general firewall status is OK, the status (Enabled / Disabled) for the respective firewall layers is also shown.

License assignment

Many features and functions in the controller require a license in order to be assigned and used by a virtual station. In the License assignment menu it is possible to synchronize licenses and see current licenses status. The following types are available:

Virtual station types

Fixed collection of features bundled together in a single package. The Virtual Station Type determines, among other things, what tools can be run, how many programs and sequences can be used, which tightening strategies are available, and the type of reporting that can be done. The features contained in each Virtual Station Type are features that often are used in conjunction with each other, or which have internal dependencies that require the presence of other features in the package. Virtual Station Types are assigned in their entirety to a virtual station. The virtual station can then make use of all features contained in the Virtual Station Type. In order to be able to perform tightenings, a Virtual Station has to be assigned a Virtual Station Type license. Depending on the license type, various tightening options will be enabled or blocked.

Sync functionalities

Works in the same way as described in Virtual Station Type but used for fixtured systems.

Virtual station features

Individual features which can complement Virtual Station Types. A lot of features can be purchased as a single license.

Controller features

Features that are controller-wide. These are features which are assigned to a controller and once assigned can be used by all virtual stations on that controller.

Source Overview

The Source Overview tab, License assignment > Source Overview, provides the user with an overview of the licenses installed on the controller, as well as where they were installed from. A maximum number of 10 different sources can be displayed here, and each will be designated with FMS P (for FMS Portable, or dongle), or License Server (TT2).

Live results

The live result icon locates at the bottom of the home page. The live result window shows results from the different virtual stations on the controller in the upper four as well as the lower four panes. The reason for this is that you can choose two different result views for the same virtual station to be shown at the same time.

Click a result pane to open a window where you can step through the different result views by clicking the arrows at the side of the result window.

Result View - Numbers

The first window will display the result in numbers.

1	Virtual station name
2	Batch sequence name
3	Batches in sequence An OK batch is colored green. An ongoing batch is colored yellow. An NOK batch is colored red.
4	Tightenings in batch An OK tightening is colored green. An ongoing tightening is colored yellow. An NOK tightening is colored red.
5	Result status An NOK tightening will give a detailed status of the unsuccessful tightening.
6	Target torque/angle
7	Tightening program name
8	Number of completed batches in sequence
9	Number of completed tightenings in a batch
10	Tightening result

Result View - Identifier Strings

This result view shows the identifier strings included in a multiple barcode scan.

Operation

• General operation
• LED indicators
• Change FlexIAM

General operation

WARNING

Read all safety warnings, instructions, illustrations and specifications provided with this power tool.

Failure to follow all instructions listed below may result in electric shock, fire, and/or serious injury.

Save all warnings and instructions for future reference.

Do not place anything on top of the FlexSystem.

Make sure you know where the emergency stop (e-stop) is located and how to initiate a system start.

Wait at least 30 seconds between power off and power on when you restart the FlexSystem.

LED indicators

The FlexSystem light indicators are used to indicate if the system is running in normal mode, if a failure occurred or when it is time for service.

Status	Description	FlexCarrier	FlexController	FlexDrive	FlexDrive
Booting	The red and green lights are on until the software is up and running.
Normal operation	A constant green light on the FlexCarrier during normal operation indicates that the power is on.
Channel error	A red flashing light on the FlexDrive indicates a channel error. The green light on the FlexCarrier indicates that the power is on.

Change FlexIAM

Make sure that the power, 3-phase and 24 VDC, is off when you change the FlexIAM.

Reference

• Input Signals
• Output Signals
• Input/Output Signals
• Event Codes

Input Signals

Abort Sequence - 10012

When a Batch sequence abort request is received, the Batch sequence functionality aborts the batch sequence only after getting the ongoing tightening result.

Name in SoftPLC: ABORT_BATCH_SEQUENCE

Devices

• Fieldbus: TRUE

• Indicator Box: FALSE

• Internal I/O: TRUE

• Operator Panel: TRUE

• Tool Functions: TRUE

• ST Selector: FALSE

• Stacklight: TRUE

• TLS Tag: FALSE

• I/O Expander: TRUE

Abort Sequence and Clear Results - 10127

When signal "Abort sequence and clear results" is set, the ongoing sequence is aborted and signals related to "Clear results" are cleared.

Name in SoftPLC:ABORT_SEQ_AND_CLEAR_RES

Devices

• Fieldbus: TRUE

• Indicator Box: FALSE

• Internal I/O: TRUE

• Operator Panel: TRUE

• Tool Functions: TRUE

• ST Selector: FALSE

• Stacklight: TRUE

• TLS Tag: FALSE

• I/O Expander: TRUE

Acknowledge Events - 10004

Acknowledge of an event.

Name in SoftPLC: ACKNOWLEDGE_EVENT

Devices

• Fieldbus: TRUE

• Indicator Box: FALSE

• Internal I/O: TRUE

• Operator Panel: TRUE

• Tool Functions: TRUE

• ST Selector: FALSE

• Stacklight: TRUE

• TLS Tag: FALSE

• I/O Expander: TRUE

Activate Tool Scanner - 10075

Activates the tool scanner through an external source.

Name in SoftPLC: ACTIVATE_TOOL_SCANNER