Atlas Copco Power Macs 4000 Us

Power MACS 4000The winning advantage in tightening control

38419_PowerMacs_US:Layout 1 2010-01-08 12.35 Sida 1

The race for lean produc

State-of-the-art control and class-leading

functionality; a good way to begin any

fastening cycle, but it’s only the start.

The new Atlas Copco Power MACS 4000

represents the pinnacle of automated

fastening control and a new generation

of upgradeable controller.

Intuitive monitoring and communication

capabilities combined with advanced

management programs allow processes

to be fine-tuned and productivity hurdles to

be overcome.

The Power MACS 4000 has been developed

with one overriding goal in mind: To get your

production line in the fast lane, and keep it there.

Every cycle can be a winning

performance

2

uction is over

Total

control

Absolute

flexibility

Easy

programming

Uncompromised

reliability

3

Power MACS 4000 – the to

Outstanding nutrunner speeds

New QST-nutrunner:Up to 67% faster thanQMX nutrunners whiledelivering the samesuperior accuracy anddurability.

Easy programming

The all-new ToolsTalkPower MACS. Allows easy programming ofadvanced, flexibletightening strategies via simple and intuitivemenus.

DynaTorkTM – Correct

residual clamp force

Unique torquerecovery strategy,patented by Atlas Copco.Delivers optimizedfastening throughimproved clamploading.

4

total productivity solution

Designed for

error-free setup"Intelligent Chip" in QSTspindle provides bothspindle and calibrationparameters to assure error-free setup. Digitalcommunications allow forextended cable length.

Modular plug-and-play

System requires no cabinetand therefore less space.Standardized componentsincrease lifetime andreduce maintenance andspare parts costs.

Maximize uptime

Heavy duty controller designand nutrunners that arecertified for accuracy to +/- 2.5 %.More than one million cyclesbetween preventivemaintenance; reducesmaintenance and down timecosts.

5

6

Introducing the QST – a smThe new QST nutrunner is based on the proven success of it's predecessors. The improvements result in a speed increase of up to 67%. The tightening controllerautomatically increases the bus voltage for the larger size nutrunner QST80 and 90, withoutthe need for a different controller or servo, giving unique speed capabilities for high-torqueapplications. A new, quick-coupling Hot Swap cable connector and electronic chip round upthe package of improvements.

Delivers an accuracy of+/- 2.5% after one million cyclescreating longer serviceintervals.

Simple, easy-to-installsandwich/pilot mountallows flexiblemaintenancepossibilities.

Available with extendedspring travel (76 and 100 mm)and/or extended socket holderlength.

Electronic chip stores dataincluding calibration value,serial numbers andmaintenance intervals –reducing costs and errors.

7

smarter spindle

Inertia braking – allowsnutrunner to run fasterwithout overshooting.

New QST motor basedon the proven QMXnutrunner – up to 67%improved speedcharacteristics.

Digital communi-cation betweennutrunner and TC – allows spindlecalibration to beindependent ofcable length,reducing the needfor a systemcalibration.

New connectordesign – cable isfastened in just acouple of turns.

Hot Swap – replacecable or spindlewithout turningpower off. Cable connector is adjust-

able in two directions foroptimal cable management.

Torque range

CT and COT models*

QST34-8CT-T50-L150-H6QST34-20CT-T50-L150-H10QST42-20CT -T50 -L134 -H10QST42-20COT -T50 -L134,5 -H10QST42-50CT -T50 -L134 -H13QST42-50COT -T50 -L134,5 -H13QST50-90CT -T50 -L137 -H13QST50-90COT -T50 -L137 -H13QST50-150CT -T50 -L137 -H13QST50-150CT-T50-L237, H16***QST50-150COT -T50 -L137 -H13QST62-150CT -T50 -L152 -H13QST62-150COT -T50 -L152,5 -H13QST62-230CT -T50 -L152 -H19QST62-230COT -T50 -L152,5 -H19QST62-350CT -T50 -L152 -H19QST62-350COT -T50 -L152 -H19QST80-450CT -T50 -L146 -H19QST80-450COT -T50 -L146 -H19QST80-600CT -T50 -L146 -H19QST80-600COT -T50 -L146 -H19QST90-750CT -T50 -L152 -H25QST90-750COT -T50 -L153 -H25QST90-1000CT -T50 -L152 -H25QST90-1000COT -T50 -L153 -H25QST95-1750CT-T50-L149-H38QST95-1750COT-T50-L155-H38

SocketholderTravelmm

505050505050505050505050505050505050505050505050505050

Weight

kg lb

2.0 4.42.0 4.43.1 6.94.2 9.33.8 8.44.5 9.95.8 12.77.8 17.25.8 12.85.8 12.87.8 17.2

10.2 22.512.8 28.210.2 22.512.8 28.210.2 22.512.8 28.216.7 3721 4617 3721 4625 5529 6426 5730 6642 9343 95

Gearratio

––

7.507.50

21.3321.3318.2118.2131.2431.2431.2413.9413.9419.0419.0428.3328.3322.6722.6729.5629.5638.8938.8946.8446.8498.2198.21

8

Nutrunner TechnologyQ = Fixtured nutrunnerST = Syncronized MotorDigital Communication

Motor size34 = Min CC 34 mm42 = Min CC 43 mm50 = Min CC 51 mm62 = Min CC 63 mm80 = Min CC 81 mm90 = Min CC 91 mmOffset nutrunner minCC is stated in specification

MAX TORQUE(Nm) C = Communication

U = U-nutrunnerO = OffsetA = Angle encodeT = TransducerTT = Double transducerV = Angle headHAD = Hold and DriverFS = Flush socketCF = Crowfoot

General Note: from here, specify the spindle from back to frontQST COATT-15050

Socket HolderSize (mm)

H = Hole ThroughP = PinB = Ball Q = Quick

L137 = 137 mmLength between pilot mount and end of socket holder (Straight model only)

T50 = 50 mm Travel lengthTelescope (Straight and Angle model)

13-H-L137-T50

Tool key - QST nutrunners

For example: QST50-150CATT-T50-L134-H13

QST42-20CT-T76-L189-H10QST42-50CT-T76-L189-H13QST50-90CT-T76-L200-H13QST50-150CT-T76-L200-H13QST62-230CT-T76-L200-H19QST62-350CT-T76-L200-H19QST80-600CT-T76-L214-H19QST90-1000CT-T76-L176-H25QST42-50CT-T100-L191-H13QST50-150CT-T100-L186-H13

SocketholderTravelmm7676767676767676

100100

Nm

6 - 2010 - 5020 - 9030 - 15040 - 23050 - 350

120 - 600200 -100010 - 5030 - 150

ft lb

4 - 147 - 35

15 - 6522 -11029 -17037 -25888 -442

147 -7377 - 35

22 -110

Maxspeed

2000700650380330220200130700380

MinC-C

43435151636381914351

Weight

kg lb

3.1 6.93.8 8.45.78 12.75.8 12.8

10.2 22.510.2 22.517 37.026 57.03.8 8.45.8 12.8

Gearratio

7.521.318.231.219.028.329.646.821.331.2

Socketholder

sizeinch

3/81/21/21/23/43/43/41

1/21/2

Lmm

190190200201200200214176191186

Bmm

23232323252530322323

Cmm

372399441441517517595600399441

Dmm

15151515151520201515

Emm

----------

Socket holder **)

Ordering No.

4230 2114 004230 2120 004230 2127 004230 2127 004230 2137 004231 2137 004231 2664 994231 1106 004231 2055 004231 3189 00

Ordering No.

8435 6020 118435 6030 118435 6040 118435 6050 118435 6065 118435 6070 118435 6080 118435 6090 118435 6030 128435 6050 12

Torque range

76 and 100 mm spring travel models*Nutrunners with extended spring travel for longer bolt lengths.

*) Dimensional drawings are available at http://webbox.atlascopco.com/dimdrw/index.html. See also page 16. **) Socket holder is included when the complete spindle is ordered.*** ) Nutrunner with reinforced front part for wheel applications.

*) Dimensional drawings are available at http://webbox.atlascopco.com/dimdrw/index.html. See also page 16. **) Socket holder is included when the complete spindle is ordered.

Nm

2 - 84 - 206 - 206 - 20

10 - 5010 - 5020 - 9020 - 9030 - 15030 - 15030 - 15030 - 15030 - 15040 - 23040 - 22050 - 35050 - 33090 - 45090 - 450

120 - 600120 - 600150 - 750150 - 750200 -1000200 -1000350 - 1750350 - 1750

ft lb

1.5 - 63 - 144 - 144 - 147 - 357 - 35

15 - 6515 - 65

22 - 11022 - 11022 - 11022 - 11022 - 11029 - 17029 - 16237 - 25837 - 24366 - 33266 - 33288 - 44288 - 442

111 - 553111 - 553147 - 737147 - 737

260 - 1290260 - 1290

Maxspeed

30001000200020007007006506503803803804504503303302202202602602002001501501301306060

MinC-C

3434433143315137515037634563456345815581559163916396

73/81

Socketholder

sizeinch

1/4”3/8”3/83/81/21/21/21/21/21/21/21/21/23/43/43/43/43/43/43/43/41111

1 1/21 1/2

Lmm

150150134134.5134134.5137137137237137152152.5152152.5152152146146146146152153152153149155

Bmm

171723-

23-

23-

2323-

25-

25-

25-

30

30

32

32-

32-

Cmm

358358372

-399

-441

-441440

-517

-517

-517

-595

595

600

600-

683-

Dmm

101015-

15-

15-

1515-

15-

15-

15-

20

20

20

20-

20-

Emm

---

446-

472-

521--

521-

586-

586-

592-

685-

685-

705-

710-

795

Socketholder **)

Ordering No.

4230 2753 014230 2753 004230 1818 004230 1818 004230 1819 004230 1819 004230 1820 004230 1820 004230 1820 004230 2433 004230 1820 004230 1829 004230 1829 004230 1822 004230 1822 004230 1822 004230 1822 004230 1971 004230 1971 004230 1971 004230 1971 004230 1824 004230 1824 004230 1824 004230 1824 004230 2767 004230 2767 00

Ordering No.

8435 6000 108435 6010 108435 6020 108435 6020 208435 6030 108435 6030 208435 6040 108435 6040 208435 6050 108435 4078 508435 6050 208435 6060 108435 6060 208435 6065 108435 6065 208435 6070 108435 6070 208435 6075 108435 6075 208435 6080 108435 6080 208435 6085 108435 6085 208435 6090 108435 6090 208435 6095 108435 6095 20

9

QST42-20CTTA -T50 -L134 -H10

QST42-50CTTA -T50 -L134 -H13

QST50-90CTTA -T50 -L137 -H13

QST50-150CTTA -T50 -L137 -H13

QST62-150CTTA -T50 -L152 -H13

QST62-230CTTA -T50 -L152 -H19

QST62-350CTTA -T50 -L152 -H19

QST80-450CTTA -T50 -L146 -H19

QST80-600CTTA -T50 -L146 -H19

QST90-750CTTA -T50 -L152 -H25

QST90-1000CTTA -T50 -L152 -H25


50

50

50

50

50

50

50

50

50

50

50

Nm

6 - 20

10 - 50

20 - 90

30 - 150

30 - 150

40 - 230

50 - 350

90 - 450

120 - 600

150 - 750

200 -1000

ft lb

4 - 14

7 - 35

15 - 65

22 -110

22 -110

29 -170

37 -258

66 -332

88 -442

111 -553

147 -737

Maxspeed

2000

700

650

380

450

330

220

260

200

150

130

MinC-C

43

43

51

51

63

63

63

81

81

91

91

Weight

kg lb

3.1 6.9

3.8 8.4

5.8 12.7

5.8 12.8

10.2 22.5

10.2 22.5

10.2 22.5

16.7 36.9

17 37

25 55

26 57

Gearratio

7.50

21.33

18.21

31.24

13.94

19.04

28.33

22.67

29.56

38.89

46.84

Socketholder

sizeinch

3/8

1/2

1/2

1/2

1/2

3/4

3/4

3/4

3/4

1

1

Lmm

134

134

137

137

152

152

152

146

146

152

152

Bmm

23

23

23

23

25

25

25

30

30

32

32

Cmm

372

399

441

441

517

517

517

595

595

600

600

Dmm

15

15

15

15

15

15

15

20

20

20

20

Emm

-

-

-

-

-

-

-

-

-

-

-

Socketholder **)

Ordering No.

4230 1818 00

4230 1819 00

4230 1820 00

4230 1820 00

4230 1829 00

4230 1822 00

4230 1822 00

4230 1971 00

4230 1971 00

4230 1824 00

4230 1824 00

Ordering No.

8435 6020 70

8435 6030 70

8435 6040 70

8435 6050 70

8435 6060 70

8435 6065 70

8435 6070 70

8435 6075 70

8435 6080 70

8435 6085 70

8435 6090 70

CATT models*Nutrunners with dual angle and torque transducer feedback. This allows for angle and torque verificationto double-check system accuracy.

*) Dimensional drawings are available at http://webbox.atlascopco.com/dimdrw/index.html. See also page 1 **) Socket holder is included when the complete spindle is ordered.

QST42-20CTT -T50 -L134 -H10

QST42-20COTT -T50 -L134,5 -H10

QST42-50CTT -T50 -L134 -H13

QST42-50COTT -T50 -L134,5 -H13

QST50-90CTT -T50 -L137 -H13

QST50-90COTT -T50 -L137 -H13

QST50-150CTT -T50 -L137 -H13

QST50-150COTT -T50 -L137 -H13

QST62-150CTT -T50 -L152 -H13

QST62-150COTT -T50 -L152,5 -H13

QST62-230CTT -T50 -L152 -H19

QST62-230COTT -T50 -L152,5 -H19

QST62-350CTT -T50 -L152 -H19

QST62-350COTT -T50 -L152 -H19

QST80-450CTT -T50 -L146 -H19

QST80-450COTT -T50 -L146 -H19

QST80-600CTT -T50 -L146 -H19

QST80-600COTT -T50 -L146 -H19

QST90-750CTT -T50 -L152 -H25

QST90-750COTT -T50 -L153 -H25

QST90-1000CTT -T50 -L152 -H25

QST90-1000COTT -T50 -L153 -H25


50

50

50

50

50

50

50

50

50

50

50

50

50

50

50

50

50

50

50

50

50

50

Nm

6 - 20

6 - 20

10 - 50

10 - 50

20 - 90

20 - 90

30 - 150

30 - 150

30 - 150

30 - 150

40 - 230

40 - 220

50 - 350

50 - 330

90 - 450

90 - 450

120 - 600

120 - 600

150 - 750

150 - 750

200 -1000

200 -1000

ft lb

4 - 14

4 - 14

7 - 35

7 - 35

15 - 65

15 - 65

22 - 110

22 - 110

22 - 110

22 - 110

29 - 170

29 - 162

37 - 258

37 - 243

66 - 332

66 - 332

88 - 442

88 - 442

111 - 553

111 - 553

147 - 737

147 - 737

Maxspeed

2000

2000

700

700

650

650

380

380

450

450

330

330

220

220

260

260

200

200

150

150

130

130

MinC-C

43

31

43

31

51

37

51

37

63

45

63

45

63

45

81

55

81

55

91

63

91

63

Weight

kg lb

3.1 6.9

4.2 9.3

3.8 8.4

4.5 9.9

5.8 12.7

7.8 17.2

5.8 12.8

7.8 17.2

10.2 22.5

12.8 28.2

10.2 22.5

12.8 28.2

10.2 22.5

12.8 28.2

16.7 37

21 46

17 37

21 46

25 55

29 64

26 57

30 66

Gearratio

6.9

9.3

8.4

9.9

12.7

17.2

12.8

17.2

22.5

28.2

22.5

28.2

22.5

28.2

37

46

37

46

55

64

57

66

Socketholder

sizeinch

3/8

3/8

1/2

1/2

1/2

1/2

1/2

1/2

1/2

1/2

3/4

3/4

3/4

3/4

3/4

3/4

3/4

3/4

1

1

1

1

Lmm

134

134.5

134

134.5

137

137

137

137

152

152.5

152

152.5

152

152

146

146

146

146

152

153

152

153

Bmm

23

-

23

-

23

-

23

-

25

-

25

-

25

-

30

-

30

-

32

-

32

-

Cmm

372

-

399

-

441

-

441

-

517

-

517

-

517

-

595

-

595

-

600

-

600

-

Dmm

15

-

15

-

15

-

15

-

15

-

15

-

15

-

20

-

20

-

20

-

20

-

Emm

-

446

-

472

-

521

-

521

-

586

-

586

-

592

-

685

-

685

-

705

-

710

Socket holder **)

Ordering No.

4230 1818 00

4230 1818 00

4230 1819 00

4230 1819 00

4230 1820 00

4230 1820 00

4230 1820 00

4230 1820 00

4230 1829 00

4230 1829 00

4230 1822 00

4230 1822 00

4230 1822 00

4230 1822 00

4230 1971 00

4230 1971 00

4230 1971 00

4230 1971 00

4230 1824 00

4230 1824 00

4230 1824 00

4230 1824 00

Ordering No.

8435 6020 50

8435 6020 60

8435 6030 50

8435 6030 60

8435 6040 50

8435 6040 60

8435 6050 50

8435 6050 60

8435 6060 50

8435 6060 60

8435 6065 50

8435 6065 60

8435 6070 50

8435 6070 60

8435 6075 50

8435 6075 60

8435 6080 50

8435 6080 60

8435 6085 50

8435 6085 60

8435 6090 50

8435 6090 60

CTT and COTT models*Nutrunners with dual torque transducer feedback. This allows for transducer redundancy, enablingverification that readings are within certain tolerances.

Torque range

Torque range

QST42-20CTV -P10

QST42-20CTV-T25-H10

QST42-30CTV-P10

QST42-30CTV-T25-H10

QST42-70CTV-P13

QST42-70CTV-T25-H13

QST50-170CTV-P13

QST50-170CTV-T50-P13

QST50-200CTV-H19

QST50-200CTV-T25-H19


QST62-310CTV-H19


QST62-350CTV-H19


QST62-600CTV-H25


-

25

-

25

-

25

-

50

-

25

50

-

25

-

25

-

Nm

6 - 20

6 - 20

6 - 30

6 - 30

14 - 70

14 - 70

34 - 170

34 - 170

40 - 200

40 - 200

40 - 200

60 - 310

60 - 310

70 - 350

70 - 350

120 - 600

ft lb

4 - 14

4 - 14

4.5 - 22

4.5 - 22

10 - 52

10 - 52

25 -125

25 -125

29 -145

29 -145

29 -145

44 -229

44 -229

52 -258

52 -258

88 -440

Maxspeed

1200

1200

440

440

440

440

210

210

210

210

210

175

175

120

120

100

MinC-C

28

28

36

36

40

40

51

48

51

51

51

66

66

66

66

109

Socketholder

sizeinch

3/8

3/8

3/8

3/8

1/2

1/2

1/2

1/2

3/4

3/4

3/4

3/4

3/4

3/4

3/4

1

L B C D Emm mm mm mm mm

65 - - - 409

- - - - -

83 - - - 436

- - - - -

84 - - - 431

- - - - -

136 - - - 481

- - - - -

136 - - - 481

- - - - -

- - - - -

153 - - - 564

- - - - -

153 - - - 564

- - - - -

174 - - - 563

Ordering No.

9831 4077 27

9831 4077 57

9831 4077 26

9831 4077 58

9831 4077 28

9831 4077 59

9831 4078 38

9831 4078 44

9831 4078 43

9831 4078 46

9831 4078 47

9831 4079 78

9831 4079 76

9831 4079 73

9831 4087 10

9831 4087 02

CTV models*Nutrunners equipped with angle heads with or without spring travel.

Torque range

*) Dimensional drawings are available at http://webbox.atlascopco.com/dimdrw/index.html. See also page 1

*) Dimensional drawings are available at http://webbox.atlascopco.com/dimdrw/index.html. See also page 1 **) Socket holder is included when the complete spindle is ordered.

Geared for lean productivity

Advanced networking,powerful communication

Power MACS 4000 supports a zero- faultproduction philosophy with its capacity tocollect tightening data for analysis,continuous improvement and traceability.Power MACS processing power andmemory are designed to handle and sendlarge amount of data without influencing thetightening process.

Reject Management

With the Power MACS 4000 you can easilydefine your tightening strategy based onresults to make sure valuable time andresources are not wasted. RejectManagement on-board can easily be set tofullfil your requirements to handle faultytightening in the most efficient way,regardless of whether a basic or advancedstrategy is used.

Powerful, flexibletightening strategies

Power MACS 4000 library has a wealth oftested tightening strategies so now everyjoint can be tightened in the best possibleway in terms of cycle time and quality.DynaTorkTM is Atlas Copco’s uniquetightening strategy that provides optimizedfastening of joints that present relaxationchallenges.

Indictor lamps• ALL OK• OK, NOK• ALARM• E-stop

Ethernet switch • 6 ports

Internal Redundant E-stoprelays • Class 3

Digital in/output, optoisolated (TC-4000-P only)• 4 inputs, 4 outputs

24V for external use(TC-4000-P only)

Anybus slot (TC-4000-P only)• Fileldbus card interface

Double ethernet ports(TC-4000-P only)• Only 1 factory IP-address• Internal Ethernet connected

to switch

TC communication LAN• Separated from factory WAN.

Eliminates multicasting.

Text display• TC node address• IP-address• Error messages• Software version• Cycle data

Push buttons• Toogle between

displayed information• Set IP-address

Reset E-stop button (TC-4000-P only)

One model providesthe entire torquerange

1 0

Lean production requires decisions based on facts and the basis for all improvementsis the ability to monitor the result of changes. Power MACS 4000 has effective tools to work with statistical process control to ensure that quality issues are identified long before they cause production problems. Connect your complete line to the Atlas Copco ToolsNet software portfolio to maximize the uptime of your production line.

Secondary controller

Model

TC-4000-STC-4000-S-ES

Fieldbus version

No fieldbus, No Ethernet switch No fieldbus, Ethernet switch

Primary and secondary controller

Primary controller

Model

TC-4000-P-ESTC-4000-P-PB-ESTC-4000-P-DN-ESTC-4000-P-EIP-ESTC-4000-P-MTCP-ESTC-4000-P-PN-ESTC-4000-P-CC-ES

Fieldbus version

No FieldbusProfibusDeviceNetEthernet IPModBus TCPProfinetCC-Link

Back plates

Model

Back plate with 6 port Ethernet SwitchBack plate, no Ethernet Switch6 port Ethernet switch

Main switch box (MSB) anddistribution box (DB)The MSB and DB are used for power distribution and makespower management easy. They are designed for 400-480 VAC 3ph and leave room for customer adaptations. The E-stopfunctionality can be upgraded from class 3 to class 4. Each MSBor DB supplies up to 6 controllers with power.

Main switch box

Model

Main switch box (Max 6 channels)

Distribution box

Model (for more than 6 channels in one system)

Distribution box (Max 6 channels) + Power cable 1800 mm

Ordering No.

8435 6500 008435 6501 00

Ordering No.

8435 6511 008435 6511 108435 6511 308435 6511 608435 6511 708435 6511 508435 6511 80

Ordering No.

4222 0982 904222 0982 914222 0984 90

Ordering No.

8435 5660 00

Ordering No.

8435 6560 50

Secondary

Controller (TC-S)

Primary

Controller (TC-P)

Main Switch Box (MSB) Distrubution Box (DB)

1 1

TC = Tightening controller

Version

Generation

S = SecondaryP = Primary ES = Ethernet switch

DN = DeviceNetPB = Profi busEIP = Ethernet IP

TC 4 000 P DN ES

MTCP = Modbus TCPPN = Profinet

The tool key to theright explains thesignificance of theletters/numbersforming the name ofthe tool model.

Back plates*

General box

Model Ordering No.

General box (distribution box housing) 4222 1249 85

Tool key – controller

*) For spare parts and upgrades

Tool cables and extension cable

Tool cables and extension cableTool cables and extension cableTool cables and extension cableTool cables and extension cableTool cables and extension cableTool cables and extension cableTool cables and extension cableTool cables and extension cableTool cables and extension cableTool cables and extension cableTool cables and extension cable

Ordering No.

4220 3799 024220 3799 034220 3799 054220 3799 074220 3799 104220 3799 154220 3799 204220 3799 254220 3799 304220 3799 354220 3799 40

Length

2 m3 m5 m7 m10 m15 m20 m25 m30 m35 m40 m

Tool and extension cable

Ethernet Cables

Ethernet cablesEthernet cablesEthernet cablesEthernet cablesEthernet cablesEthernet cablesEthernet cables

Length

0.5 m1 m2 m3 m5 m

10 m15 m

Ordering No.

4222 1246 004222 1246 014222 1246 024222 1246 034222 1246 054222 1246 104222 1246 15

E-stop components

E-stop terminationE-stop cable E-stop cable

Ordering No.

4222 0755 004222 1247 124222 1247 30

Length

1200 mm3000 mm

E-stop componentEvery TC-P comes with an e-stoptermination.

Cables between MSB and TC

Power cable (TC1-TC2, TC7-TC8, TC13-TC14)Power cable (TC3-TC4, TC9-TC10, TC15-TC16)Power cable (TC5-TC6, TC11-TC12, TC17-TC18)Power cablePower cablePower cablePower cable

Ordering No.

4222 1248 134222 1248 164222 1248 194222 1248 504222 1370 104222 1370 154222 1370 20

Length

1350 mm1650 mm1950 mm

5 m10 m15 m20 m

Cable between MSB or DB and TC

Single cablesolution – Power andcommunicationbus cables arecombined.

Compatible cables – Use same cable forextensions and doubletorque/angle transducer QST.

Digital communicationchannel allows longercable lengths.

New, slimmer 12 mm cable offersincreaseddurability andflexibility.

Ethernet cable

1 2

Position marking on cable and connectorAlignment markers on the cable connector and spindle connector guide youto a quick and easy cable installation in those hard to reach locations.

Alignment markers

Power cables 4222 1248 xx

Ethernet cable 4222 1246 xx

E-Stop cable 4222 1247 xx

Motor cable 4220 3799 xx

No. of

spindles

123456789

System

cable kitb)

111111111

TC-P

111111111

TC-S

012345678

MSB

111111111

DB

000000111

tool cables

123456789

No. of

spindles

101112131415161718

System

cable kitb)

111111111

TC-P

111111111

TC-S

91011121314151617

MSB

111111111

DB

111222222

tool cables

101112131415161718

System ordering tablea)

1 3

No. of

spindles

123456789101112131415161718

Ordering No.c)

8435 6560 018435 6560 028435 6560 038435 6560 048435 6560 058435 6560 068435 6560 078435 6560 088435 6560 098435 6560 108435 6560 118435 6560 128435 6560 138435 6560 148435 6560 158435 6560 168435 6560 178435 6560 18

1350 mm

4222 1248 13122222444444566666

Power cable

1650 mm

4222 1248 16--1222343444445666

Ethernet cable

1950 mm

4222 1248 19----12--2234444456

1 m

4222 1246 01-11114564567789101011

3 m

4222 1246 03--------3333444444

1200 mm

4222 1247 12-112345678910101112131415

E-stop cable

3000 mm

4222 1247 30--1111111111222222

Ethernetswitch incl.Backplate

4222 0982 90----11112222333344

System cable kits

Easy-to-build systemIncoming E-stop Factory network (1 IP)

Power input

a) For a system with one station.

c) Based on Atlas Copco suggested set-up.

b) See system cable kits below.

b) See system cable kits below.

Number of Number of

2 m

4222 1246 02--1231111111111122

Simple setup, quick configurationWith the Power MACS 4000 controller, multiple-spindle systems are easy to configure. Simply refer to the system ordering table to see which compo nents you need.

1 4

Designation

1 user5 user 10 userPlant license1 user5 user 10 userPlant license1 user5 user 10 userPlant license

Ordering No.

8092 1307 018092 1307 058092 1307 108092 1307 978092 1307 118092 1307 158092 1307 208092 1307 988092 1307 218092 1307 258092 1307 308092 1307 99

Language

EnglishEnglishEnglishEnglishGermanGermanGermanGermanFrenchFrenchFrenchFrench

Software ToolsTalk Power MACS World Release 7

Quick-set variable – trim your processin seconds.

Drag and dropinterface – savetime with intuitiveuser interface.

Choose Basic orAdvanced mode– view only thefunctions youneed.

M12 Extension cable for 24V supply

Standardized modular solutions

MiniDisplay8435 3070 00 (software included)

Touch-screen interface forprogram selection. Configureinput and view cycle data andtraces.

Stacklight8433 0570 13

Stacklight – givescontinuous station feedbackon the tightening process.

Indicator box8435 3010 03

Indicator box – directoperator feedback onthe tightening process.

Can act as station PC to runToolTalk Power MACS.

I/O expander 8433 0564 45

Provides an additionaleight digital inputs andoutputs.

Operator panel8433 0565 00 (advanced)8433 0565 10 (basic)

With command buttonsand integrated lamp foroperator feedback.Allows the manualselection of programsvia selector switch.

Cable guide

Ethernet switch port

Ethernet cable

I/O bus cable

All above accessories and I/O bus cables arethe same as for Power Focus.

I/O bus cable and extension cable

1 5

Com Node 28433 2711 10 (touch screen)8433 2711 00

Accessory cables Ordering No.

I/O bus cable 0.5 m 4222 0470 00I/O bus cable 1 m 4222 0470 01I/O bus cable 3 m 4222 0470 03I/O bus cable 5 m 4222 0470 05I/O bus cable 10 m 4222 0470 10I/O bus cable 15 m 4222 0470 15I/O Termination plug 4222 0443 00

Indicator box cable

for Power MACS 4000 Ordering No.

Extension cable 3 m 4243 0282 03Extension cable 5 m 4243 0282 05Extension cable 10 m 4243 0282 10Extension cable 15 m 4243 0282 15Extension cable 30 m 4243 0282 30

Proven, production-line performance

ZF AG is a world leader in driveline and chassis technology. Theircustomers include the world’s leading automotivemanufacturers. They have always used the most modern,productive equipment in their production processes; a fact thatmakes the results of their experience with the new Power MACS4000, all the more impressive.

The Power MACS controller eliminates the need of a torquewrench check, reducing cycle times by up to 50%

The result? An annual saving of several thousand Euro – from just one component assembly process.

Guiseppe de Giacomo, operator, ZF: “Super! Much easier to operatethan before, I cannot make any errors with this system!”

Thomas Weissenrieder,Process Engineer, ZF Friedrichshafen: “The assembly of thiscomponent is now fasterand safer than before. ThePower MACS 4000 is thefirst system to fulfill thequality demands.”

ZF AG, Germany

1 6

1 7

ServiceToolScan RCMRCM (Reliability Centered Maintenance) is awidely used process to optimize your overallservice. Together we analyse your existingservice program and how it can be optimizebased on each application together withyour operating cost for a failed spindle inyour production. A wrong working spindlein the production can have costly impacts allthe way to he end-user.

Full Coverage AgreementOur Full Coverage Service is exactly hat itstates, acomplete tailored aintenance solu -tion with a fixedannual cost. It onsists ofdifferent standard servicemodules thatsecure the needs and availability of yourequipment. The service is available incombi nation with newly purchasedequipment as well as for your existingspindles after a review check. It provides

much more cove rage than the standardwarranty i.e. covers as well all unplannedrepairs providing the equipment has notbeen misused. No nasty surprises of costlyrepairs throughout the contracted period.

Preventive Maintenance AgreementThe Preventive Maintenance Service is ourstandard recommended maintenanceprogram Maintenance work is carried outeither on your premises or in our centralworkshop with a fixed interval. We alsotake care of all planning and data storageduring the agreement.

Calibration ServicesOn the assembly line, you need to be cer -tain about the performance of your spind -les and equipment. The spindles have to becalibrated at regular intervals. These servi -ces keep your spindles and torque measu -rement equipment calibrated for optimumperformance. Atlas Copco offers a comple -te range of calibration services for all yourspindles and equipment. Most Atlas CopcoService Centers are today ISO 9000 Certi -fied or accredited.

Training We offer an established program of trai -ning courses and workshops to guaranteeoptimized use of your equipment. Thesetraining can be held either on your ownpremises or in our Training Centre.

ToolStartWe offer tool installation and start-up byqualified Atlas Copco engineers at a fixedprice. The service also includes: program -ming, test running and operator training.

For more information about aboveservices, please contact your Atlas Copcorepresentative.

D

BA CA E

QST – CT, CTT & CATT nutrunner QST – COT & COTT nutrunner

L

Dimensional drawings

Power MACS 4000 Primary TC

Power MACS 4000 Secondary TC

L

1 8

QST - CTV nutrunner


Main Switch Box

Distribution Box

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