Atlas Copco G 4 Instruction sheet
MicroTorque Controller G4
Printed Matter No.9836 6202 00 Control and drive unit
2012-03-01 Product Instructions
MicroTorque Controller G4 (4k7) 8432 0831 63
WARNING
Read all safety warnings and instructions
Failure to follow the safety warnings and in-
structions may result in electric shock, fire and/
or serious injury.
Save all warnings and instructions for future
reference
2© Atlas Copco Industrial Technique AB - 9836 620200 00
Table of Contents
EN Product Instructions.......................................................................... 3
FR Notice d'utilisation du produit........................................................ 18
DE Produktanweisungen...................................................................... 34
ES Instrucciones del producto ............................................................ 50
PT Instruções para Produto ................................................................ 65
IT Istruzioni sul prodotto..................................................................... 80
SV Produktinstruktioner ....................................................................... 95
PL Instrukcja użytkowania produktu ................................................ 110
CS Pokyny kpoužívání výrobku ....................................................... 126
HU Termékre vonatkozó utasítások ................................................. 141
RO Instrucţiuni pentru produs............................................................ 156
ZH 产品说明......................................................................................... 171
JA 製品に関する指示......................................................................... 184
KO 제품 지침........................................................................................ 198
MicroTorque Controller G4 EN Product Instructions
© Atlas Copco Industrial Technique AB - 9836 620200 00 3
Product Instructions
Overview
WARNING
• Read all safety warnings and all instructions.
Failure to follow the warnings and instructions may result in electric
shock, fire and/or serious injury.
• Save all warnings and instructions for future reference.
Limited Liability / Warranty
Contact the Atlas Copco sales representative within your area to claim a prod-
uct. Warranty will only be approved if the product has been installed, operated
and maintained according to the product instructions. Warranty will not be ap-
proved if it should be detected that the Tool has been opened.
Any repair work carried out under the guarantee conditions is free of charge.
Our responsibility is limited to the repair or, if we consider it necessary, to its
free replacement. The following are not covered by our guarantee: damage due
to incorrect handling, failure to observe the instruction manual, or attempts by
any non-qualified party to repair the instrument; any consequences what ever
which may be connected either directly or indirectly with the instrument sup-
plied or its use. Do not open the driver housing, the controller housing and the
housing of the power supply. Breaking the seals invalidates warranty.
MicroTorque G4 controller
The MicroTorque screw fastening systems are transducerized or “digitork” pre-
cision tools, based on cutting edge technology. Each driver contains a servo
motor, planetary gear, incremental encoder, torque transducer (MicroTorque
ETF MT types only), signal conditioning electronics and data memory. The
highly integrated controller is designed for servo control, torque measurement,
angle measurement, I/O-management via serial and PLC interface, and user dia-
log control for parameter settings via USB.
The most significant advantages of these assembly tools are:
• Multi step screw fastening procedure with torque and angle control
• Flexible programmable screw fastening step sequence
• Precise tightening torque, torque and angle control and multistep process
data documentation
• Multipoint communication via USB for parameter settings, graphical read-
out and process data communication
These features make the spindle system particularly suitable for highly demand-
ing assembly work and guarantee an exactly controlled tightening procedure
even under difficult conditions.
Product Instructions EN MicroTorque Controller G4
4© Atlas Copco Industrial Technique AB - 9836 620200 00
Installation
Basic set-up
NOTE
Each controller is programmed to operate together with a certain tool, i.e. it is
not possible to use one tool with multiple controllers. If the tool is to be ex-
changed, it must be set-up and calibrated together with the controller.
Controller connectors
NOTICE Always disconnect the USB connector before connecting or discon-
necting the power supply plug.
1. Connection for ESD protective wrist strap.
2. DIGITAL I/O: Connection for various accessories.
3. POWER: Power supply connection. Use only with specified Atlas Copco
power supply.
4. VP: Vacuum pump connection.
5. I/O: Single digital input for special purpose.
6. Spindle, connected with the tool cable.
7. EXT SEN: Connection for external sensor.
8. USB: PC, connected with a USB cable.
9. RS232-C: Serial interface, for various accessories.
Connecting accessories
The internal 24 V supply can be loaded with max 700 mA. If the sum of all
loads tend to exceed this value - use an external +24 V source.
Serial interface (RS232-C)
15-pole D-sub socket connector for the serial interface.
Use a 15-pole D-sub pin plug.
MicroTorque Controller G4 EN Product Instructions
© Atlas Copco Industrial Technique AB - 9836 620200 00 5
COM0: Used for process data documentation, if USB communication is not
available.
COM port settings: 9600 Baud, 8 Data bits, 1 Stop bit, No parity, No hand-
shake.
Pin Signal Description
8 TxD Transmitted data
5 GND Data ground
7 RxD Received data
COM1: Can be used for communication with ToolsTalk MT for parameter set-
tings and for firmware upgrades.
Pin Signal Description
2 TxD Transmitted data
5 GND Data ground
3 RxD Received data
COM2: (Used for special purposes only.)
Pin Signal Description
6 TxD Transmitted data
5 GND Data ground
4 RxD Received data
Vacuum pump output (VP)
5-pole socket connector for the connection of Atlas Copco Vacuum pump
VPX6 (24 V, 600 mA).
Digital input (I/O)
5-pole pin connector, configurable, e.g. as input for depth control or device
holder switch. The digital input can be used when programming an Input or
Align step. The digital input is referred as IO DI12 in the Digital IO Status map
in ToolsTalk.
For information on configuration of the input, see ToolsTalk MT - Reference -
I/O status.
Use a 5-pole socket plug from the Binder 719 Series.
This input is not opto-isolated.
Input resistance 10 kΩ
Product Instructions EN MicroTorque Controller G4
6© Atlas Copco Industrial Technique AB - 9836 620200 00
If used to reset the tool, the signal duration must be more than 20 ms.
Pin Output Description
1 +24 V Internal +24 V
2 GND (0 V) 0 V output
3
4
5 Digital in Digital input
A 2 wire switch (e.g. a reed switch) is connected to pin 1 and 5.
A sensor with PNP output is connected to pin 1, 2 and 5.
External sensor (EXT SEN)
6-pole socket connector for an optional external torque/angle transducer or
force sensor / length gauge. Use Atlas Copco equipment only.
Configurable digital inputs and outputs (DIGITAL I/O)
26-pole D-sub socket connector for configurable signals.
Use a 26-pole D-sub pin plug.
Voltage range 11-30 VDC
Input resistance >5 kΩ
Output resistance 23-35 Ω
Output current protection 120 mA max. peak/continuous current, over current
protected.
If the max. current is exceeded, the output voltage will switch off. This can
be resolved by switching the output off and on again.
Pin I/O Description
Screw cylce sequence en-
abled
1 B2 +24 Internal 24 V supply Internal 24 V supply
2 OUT A External common line for
DO00-DO03
External common line for
DO00-DO03
3 OUT B External common line for
DO04-DO07
External common line for
DO04-DO07
4 DO00 Busy Sequence Busy
5 DO01 OK Sequence OK
6 DO02 NOT OK Sequence NOT OK
7 DO03 Joint not completed Not used
8 DO04 Vacuum Vacuum
9 DO05 Start key Busy
10 DO06 Unscrew key OK
11 DO07 Push-to-start NOT OK
MicroTorque Controller G4 EN Product Instructions
© Atlas Copco Industrial Technique AB - 9836 620200 00 7
Pin I/O Description
Screw cylce sequence en-
abled
12 DI00 Start Sequence Start
13 DI01 Reset Error confirmation
14 DI02 Unscrew Unscrew
15 DI03 Program select bit 0 Product type select bit 0
16 DI04 Program select bit 1 Product type select bit 1
17 DI05 Program select bit 2 Product type select bit 2
18 DI06 Program select bit 3 Not used
19 DI07 Program select bit 4 Sequence reset
20 DI08 Disable Not used
21 DI09 Program select bit 5 Joint start
22 DI10 Not used Not used
23 DI11 Not used Not used
24 IN A External common line for
DI00-DI07
External common line for
DI00-DI07
25 IN B External common line for
DI08-DI11
External common line for
DI08-DI11
26 B2 DGND Internal ground Internal ground
For information on configuration on the outputs and inputs, see ToolsTalk MT
- Reference - I/O status.
If used to reset the tool, the signal duration must be more than 20 ms.
All inputs are opto isolated.
Interface connection can be connected in PNP mode (source type, positive
logic), or in NPN mode (sink type, negative logic).
PNP and NPN mode can, if required, be mixed bank wise (e.g. OUT-A
PNP and OUT-B NPN).
If the DISABLE input is high, any start of the spindle will be inhibited. As
long as there is no error message shown on the controller display, the DIS-
ABLE status will be displayed as long as active.
Product Instructions EN MicroTorque Controller G4
8© Atlas Copco Industrial Technique AB - 9836 620200 00
PNP mode
I/O Description
INT -24V +24 V output
EXT-OUT-COM0 Connect to B2 +24
or external +24 V
(not at the same time)
EXT-OUT0...EXT- OUT3 The outputs will be connected to the external +24 V
when activated.
EXT-IN0...EXT- IN3 The inputs will be activated by a +24 V signal applied
to the input pin.
EXT-IN-COM0 Connect to B2 DGND
or external 0 V.
DGND 0 V output
MicroTorque Controller G4 EN Product Instructions
© Atlas Copco Industrial Technique AB - 9836 620200 00 9
NPN mode
I/O Description
INT -24V +24 V output
EXT-OUT-COM0 Connect to B2 DGND
or external 0 V.
EXT-OUT0...EXT- OUT3 The outputs will be connected to the external 0 V
when activated.
EXT-IN0...EXT- IN3 The inputs will be activated by a 0 V signal applied to
the input pin.
EXT-IN-COM0 Connect to B2 +24
or external +24 V
(not at the same time)
DGND 0 V output
PLC communication
(Explained for positive logic / PNP.)
If the spindle is ready, the BUSY signal is LOW. With a positive signal on
START a screw fastening cycle is initialized, then the BUSY signal becomes
HIGH. Now the START signal has to become LOW to finish the starting hand-
shake. After the screw fastening process is finished the BUSY-signal becomes
LOW again. After start, the OK-signal becomes always LOW. It changes to
HIGH before BUSY comes down if the screw was tightened correctly, other-
wise it remains LOW. The error message can be confirmed by applying the RE-
SET signal or pressing the jog dial at the driver controller. A running fastening
process can be stopped with RESET.
The signals OK and NOT OK are complementary. The Vacuum Output is
HIGH if configured as active in the related screw tightening step.
Product Instructions EN MicroTorque Controller G4
10 © Atlas Copco Industrial Technique AB - 9836 620200 00
Operating instructions
Safety and operating instructions
NOTE
The safety and operating instructions as described in the Product instructions
that is delivered together with the system must be read and complied.
Ensure that you read and understand all instructions. Failure to follow all the in-
structions may result in electric shock, fire and/or serious personal injury.
All locally legislated safety regulations with regard to installation, operation
and maintenance must be adhered to at all times.
Refer installation and servicing to qualified personnel only.
Contact your Atlas Copco representative if questions regarding the safety and
operating instructions arise.
User interface
The controller front has a display (1) a jog dial (2) and a stetus indicator (3).
This manual suits for next models
1
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