Atlas Copco BLM STA6K Data analyser User Manual
Atlas Copco BLM Data analyser
User Manual
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User Guide STa 6000 Atlas Copco Industrial Technique AB 9836 8243 01 2016-06 Edition 3.1 STa 6000 User Guide Revision history Revision history Reference Firmware version Edition Date Author 1.0 17 April 2014 M. Grippa First issue 8.0.x 1.0 2.0 15 July 2014 M. Grippa General manual update 8.0.x 1.0x 2.1 01 October 2014 M. Grippa Free test added (par. 6.1), Identifier updated (par. 11), Display layout updated 8.1.x 1.1x 2.2 04 February 2015 M. Grippa RBU AA added, Statistics and reports updated, Test execution window updated, Pset programming updated (par. 7.1), Settings updated (par. 16), EAP-TLS security type added (par. 21), transducer management updated, MRTT-C firmware update added 8.3.x 2.0x FCC Certification added (par. 1.5), Power Focus Calibration updated (par. 10.1), PowerMACS Calibration updated (par. 10.2), Other Controller Calibration updated (par. 10.3), Text Execution updated (par. 17.2), Execute the Pset (par. 7.2.1), STa 6000 text editing added (par. 3.3), Only angle strategy added (par. 8.2.2) 8.4.x 2.1x Main parameters and control strategy updated (par. 7.1.1), Batch parameters updated (par. 7.1.5), Cm/Cmk (ISO CNOMO) statistics updated (par. 14.1.2), Cm/Cmk (ISO - CNOMO) report updated (par. 14.2.2), Real time statistics on the STa 6000 display updated (par. 14.4.1), CNOMO standard E41.32.110N added (par. 14.4.2), Controller Configuration updated (par. 16.1) 8.5.x 2.2x 2.3 2.4 21 May 2015 21 July 2015 9836 8243 01 Edition 3.1 M. Grippa C. Pacente Description Reference Minimum Software version (ToolsTalk BLM) 3 (324) Revision history STa 6000 User Guide Edition Date Author Description Reference Minimum Software version (ToolsTalk BLM) 2.5 11 November 2015 C. Pacente EC Declaration of Conformity updated (par.1.4), MET Certification added (par. 1.5), Battery Charger updated (par. 2.3.5.1), Mini USB Port updated (par. 3.6), Main parameters and control strategy updated (par. 7.1.1), Torque parameters updated (par. 7.1.2), Angle parameters updated (par. 7.1.3), Time updated (par. 7.1.4), Pulse parameters updated (par. 7.1.5), Options updated (par. 7.1.6), Subgroup parameters added (par. 7.1.7), Results Notes option updated (par. 7.2.2), Results Viewer updated (par. 12), Cm/Cmk (ISO - CNOMO) report updated (par. 14.1.2), Cm/Cmk (Shifting samples) added (par. 14.4.2.2), Offline Programming updated (par. 15), Controller configuration updated (par. 16.1), Test execution window customization updated (par. 16.9) 8.6.x 2.3x 9.0.x 3.0x 3.0 17 March 2016 4 (324) C. Pacente Specifications updated (par. 1.3), FCC Rules added (par. 1.5), STa 6000 Versions updated (par. 2.1), Presentation updated (par. 2.3), IRC-W / IRC-B radio modules updated (par. 2.3.4), Software installation updated (par. 4.1), Software registration updated (par. 4.1.1), ToolsTalk BLM Overview updated (par. 4.2), STa 6000 Map updated (par. 4.2.4), Transducers updated (par. 5), Non-ACTA Transducers Database updated (par. 5.1), ACTA Transducers Information updated (par. 5.2), Pset updated (par. 7), Tools Testing updated (par. 8), Calibration Report updated (par. 10.4), Identifier updated (par. 11), Identifier Concepts updated (par. 11.1), Configuring a work order updated (par. 11.3.2), Configuring result parts updated (par. 11.3.3), Printing identifiers strings updated (par. 11.3.4), Reference Firmware version 9836 8243 01 Edition 3.1 STa 6000 User Guide Edition Date Revision history Author Description Reference Minimum Software version (ToolsTalk BLM) Reference Firmware version 9.1.x 3.1x Scanning barcodes with STa 6000 updated (par. 11.4), View one trace updated (par. 13.1), Traces comparison updated (par. 13.2), Copy, Print and Export traces updated (par. 13.3), STa 6000 settings updated (par. 16), Controller configuration updated (par. 16.1), Information updated (par. 16.2), IRC-C added (par. 16.4), SPC Rules updated (par. 16.6), Memory updated (par. 16.7), Working with IRC-Connect (and relative sub-paragraphs) added (par. 18), Troubleshooting Guide updated (par. 23) 3.1 14 June 2016 C. Pacente Specifications updated (par. 1.3), EC Declaration of Conformity updated (par. 1.4), FCC Rules updated (par. 1.5), Transducers updated (par. 5), Saving Psets (from STa 6000 to PC) added (par. 7.3), PowerMACS calibration updated (par. 10.2), STa 6000 communication method settings Manual / Serial communication (Mode 1 ÷ 50) added (par. 10.2.1), STa 6000 communication method settings Serial communication (Mode 0) added (par. 10.2.2), Identifier Prerequisites and Details updated (par. 11.2) Copyright Atlas Copco Industrial Technique AB NOTE: This manual may be altered without further notice. For further information log on to the Atlas Copco website: www.atlascopco.com NOTE: The programming software (ToolsTalk BLM) may be updated with no changes about the STa 6000 functionalities. The minimum software version indicated here is required for the reference firmware version. NOTE: In the event of conflicts between translations of this User Guide, always refer to the official English version. 9836 8243 01 Edition 3.1 5 (324) Table of Contents STa 6000 User Guide Table of Contents Table of Contents ............................................................................................................ 6 BATTERY INFORMATION according to European regulation 2006/66/EC ...................... 12 INTRODUCTION ............................................................................................................. 13 1.1 About this Document .............................................................................................. 13 1.2 Reference Documents ............................................................................................ 15 1.3 Specifications ......................................................................................................... 15 1.4 EC Declaration of Conformity ................................................................................. 21 1.5 FCC Rules .............................................................................................................. 22 SYSTEM OVERVIEW ...................................................................................................... 23 2.1 STa 6000 Versions ................................................................................................. 24 2.1.1 2.1.2 2.1.3 2.2 STa 6000 Typical Applications Scenario ................................................................. 26 2.2.1 2.2.2 2.3 2.3.6 2.3.7 STa 6000 assembly .................................................................................................31 RBU .........................................................................................................................32 QAT Barcode reader ................................................................................................34 IRC-W / IRC-B radio modules..................................................................................35 Battery......................................................................................................................36 2.3.5.1 Battery Charger..........................................................................................36 External power supply .............................................................................................38 SRTT-L ....................................................................................................................38 USER INTERFACES ....................................................................................................... 42 3.1 Connector ............................................................................................................... 42 3.2 Display.................................................................................................................... 43 3.3 Keyboard ................................................................................................................ 44 3.4 Buzzer .................................................................................................................... 45 3.5 Network Port ........................................................................................................... 45 3.6 Mini USB Port ......................................................................................................... 45 WORKING WITH ToolsTalk BLM ................................................................................... 46 4.1 Software Installation ............................................................................................... 47 4.1.1 4.1.2 4.2 Software registration ................................................................................................51 Software upgrade ....................................................................................................51 ToolsTalk BLM Overview ........................................................................................ 52 4.2.1 4.2.2 6 (324) Stand-alone STa 6000 .............................................................................................26 STa 6000 connected to Torque Supervisor .............................................................27 Presentation ........................................................................................................... 28 2.3.1 2.3.2 2.3.3 2.3.4 2.3.5 Basic ........................................................................................................................25 QC (Quality Control) ................................................................................................25 AA (Advanced Analysis) ..........................................................................................26 Menu list...................................................................................................................53 Toolbar .....................................................................................................................54 9836 8243 01 Edition 3.1 STa 6000 User Guide 4.2.3 4.2.4 4.3 4.4 Adding a transducer to the database ...................................................................... 66 Selecting the transducer for the test ........................................................................ 68 Transducer information ............................................................................................ 70 5.2 ACTA Transducers Information .............................................................................. 71 GETTING STARTED WITH STa 6000 ............................................................................ 73 6.1 Executing a Free Test ............................................................................................ 75 6.2 Executing a Quick Test .......................................................................................... 76 PSET............................................................................................................................... 79 7.1 Programming a Pset .............................................................................................. 79 7.1.1 7.1.2 7.1.3 7.1.4 7.1.5 7.1.6 7.1.7 7.2 Main parameters and control strategy ..................................................................... 83 Torque parameters .................................................................................................. 85 Angle parameters .................................................................................................... 88 Time ......................................................................................................................... 89 Pulse parameters .................................................................................................... 91 Options .................................................................................................................... 92 Subgroup parameters .............................................................................................. 93 Running a Pset....................................................................................................... 97 7.2.1 7.2.2 7.2.3 7.2.4 USB connection ....................................................................................................... 57 Ethernet connection ................................................................................................. 58 4.5 Enabling LOG File .................................................................................................. 61 4.6 Saving Programs (from STa 6000 to PC) ............................................................... 62 TRANSDUCERS ............................................................................................................. 64 5.1 Non-ACTA Transducers Database ......................................................................... 66 5.1.1 5.1.2 5.1.3 Status bar ................................................................................................................ 55 STa 6000 Map ......................................................................................................... 55 Settings in ToolsTalk BLM ...................................................................................... 56 Connecting to the STa 6000 ................................................................................... 56 4.4.1 4.4.2 Table of Contents Execute the Pset ..................................................................................................... 97 Results Notes option ............................................................................................. 100 Customize the Pset execution window .................................................................. 101 View on-screen traces ........................................................................................... 102 TOOLS TESTING ......................................................................................................... 103 8.1 Click-Wrenches Testing ....................................................................................... 109 8.1.1 8.2 Test setup for click-wrench test ............................................................................. 111 8.1.1.1 Measure delay time ................................................................................. 111 8.1.1.2 Reset time................................................................................................ 112 8.1.1.3 End cycle time ......................................................................................... 112 8.1.1.4 Slip Torque .............................................................................................. 113 8.1.1.5 Direction (CW/CCW)................................................................................ 113 8.1.1.6 Filter frequency (Fcut).............................................................................. 113 8.1.1.7 Unit........................................................................................................... 113 Power Tools Testing ............................................................................................ 114 8.2.1 9836 8243 01 Edition 3.1 Test setup for power tool test ................................................................................ 116 8.2.1.1 Measure delay time ................................................................................. 116 7 (324) Table of Contents STa 6000 User Guide 8.2.2 8.2.1.2 Reset time ................................................................................................116 8.2.1.3 End cycle time..........................................................................................117 8.2.1.4 Filter frequency (Fcut) ..............................................................................117 8.2.1.5 Direction (CW/CCW)................................................................................117 8.2.1.6 Unit ...........................................................................................................117 Angle Test ..............................................................................................................118 8.3 Peak Wrench Testing ........................................................................................... 119 8.3.1 8.4 Pulse Tools Testing .............................................................................................. 122 8.4.1 8.4.2 Test setup for Pulse Tool test ................................................................................125 8.4.1.1 End cycle time..........................................................................................125 8.4.1.2 Torque coefficient ....................................................................................126 8.4.1.3 Filter frequency (Fcut) ..............................................................................127 8.4.1.4 Direction (CW/CCW)................................................................................127 8.4.1.5 Minimum pulse and maximum pulse .......................................................128 8.4.1.6 Unit ...........................................................................................................128 8.4.1.7 Threshold .................................................................................................128 Test setup for ACTA Pulse Tool test .....................................................................128 8.4.2.1 Measure delay time..................................................................................128 8.4.2.2 Reset time ................................................................................................129 8.4.2.3 End cycle time..........................................................................................130 8.4.2.4 Filter frequency (Fcut) ..............................................................................130 8.4.2.5 Direction (CW/CCW)................................................................................130 8.4.2.6 Minimum pulse and maximum pulse .......................................................130 8.4.2.7 Unit ...........................................................................................................130 JOINTS TESTING ......................................................................................................... 131 9.1.1 9.1.2 9.1.3 9.1.4 9.1.5 10 Test setup for peak wrench test.............................................................................120 8.3.1.1 End cycle time..........................................................................................120 8.3.1.2 Filter frequency (Fcut) ..............................................................................121 8.3.1.3 Direction (CW/CCW)................................................................................121 8.3.1.4 Unit ...........................................................................................................121 Yield Point (JOINT ANALYSIS) .............................................................................131 Residual Torque/Time ...........................................................................................134 9.1.2.1 Breakaway detection algorithm................................................................135 Residual Torque/Angle ..........................................................................................137 9.1.3.1 Breakaway detection algorithm................................................................140 Residual Torque/Peak ...........................................................................................142 Loose and Re-tight ................................................................................................144 POWER FOCUS, PowerMACS AND GENERIC CONTROLLER CALIBRATION ........ 145 10.1 Power Focus calibration ....................................................................................... 145 10.2 PowerMACS calibration ........................................................................................ 154 10.2.1 10.2.2 STa 6000 communication method settings Manual / Serial communication (Mode 1 ÷ 50) .........................................................................................................155 STa 6000 communication method settings Serial communication (Mode 0) .....160 10.3 Other Controller Calibration .................................................................................. 164 10.4 Calibration Report ................................................................................................. 168 8 (324) 9836 8243 01 Edition 3.1 STa 6000 User Guide 11 IDENTIFIER .................................................................................................................. 170 11.1 Identifier Concepts ............................................................................................... 171 11.2 Identifier Prerequisites and Details ....................................................................... 172 11.3 Configuration of Identifier Functions ..................................................................... 173 11.3.1 11.3.2 11.3.3 11.3.4 12 13 14 Table of Contents Configuring identifiers ............................................................................................ 173 Configuring a work order ....................................................................................... 175 Configuring result parts ......................................................................................... 175 Printing identifier strings ........................................................................................ 176 11.4 Scanning Barcodes with STa 6000....................................................................... 178 RESULTS VIEWER ...................................................................................................... 182 TRACES VIEWER ........................................................................................................ 191 13.1 View One Trace ................................................................................................... 191 13.2 Traces Comparison .............................................................................................. 197 13.3 Copy, Print and Export Traces ............................................................................. 201 STATISTICS ................................................................................................................. 202 14.1 On-Screen Statistics ............................................................................................ 202 14.1.1 14.1.2 X-R Charts ............................................................................................................. 204 Cm/Cmk (ISO - CNOMO) report............................................................................ 206 14.2 ToolsTalk BLM Statistics ...................................................................................... 210 14.2.1 14.2.2 X-R Charts ............................................................................................................. 210 Cm-Cmk (ISO - CNOMO) report ........................................................................... 213 14.3 SPC Rules and Results ........................................................................................ 217 14.4 Statistics Formulas ............................................................................................... 223 14.4.1 14.4.2 15 16 OFFLINE PROGRAMMING .......................................................................................... 227 STa 6000 SETTINGS .................................................................................................... 231 16.1 Controller Configuration ....................................................................................... 232 16.2 Information ........................................................................................................... 236 16.3 MRTT-C ............................................................................................................... 237 16.4 IRC-C ................................................................................................................... 239 16.5 Printer .................................................................................................................. 240 16.6 SPC Rules ........................................................................................................... 241 16.7 Memory ................................................................................................................ 241 16.8 Ethernet ............................................................................................................... 242 16.9 WLAN Settings ..................................................................................................... 243 16.9.1 16.9.2 17 Cm/Cmk calculation ............................................................................................... 223 CAM/Cpk Calculation ............................................................................................ 223 14.4.2.1 CNOMO standard E41.32.110N .............................................................. 223 14.4.2.2 Cm/Cmk (Shifting samples) ..................................................................... 226 WLAN profiles ........................................................................................................ 243 WLAN interfaces .................................................................................................... 246 16.10Test execution window customization .................................................................. 248 WORKING WITH Torque Supervisor .......................................................................... 253 9836 8243 01 Edition 3.1 9 (324) Table of Contents STa 6000 User Guide 17.1 Connecting the STa 6000 to Torque Supervisor ................................................... 255 17.2 Test Execution ...................................................................................................... 258 17.2.1 17.2.2 17.2.3 18 Route of Statistic Control tests ..............................................................................260 Route options .........................................................................................................261 17.2.2.1 Result confirmation and result summary .................................................261 17.2.2.2 ......................................................................261 17.2.2.3 Route execution mode .............................................................................261 17.2.2.4 Route lock ................................................................................................262 Test strategies and parameters .............................................................................262 WORKING WITH IRC-Connect .................................................................................... 265 18.1 How to configure the IRC-W / IRC-B radio module ............................................... 266 18.2 How to pair the STa 6000 with the IRC-Connect................................................... 270 18.3 How to connect the STa 6000 with the IRC-Connect ............................................ 275 18.3.1 18.3.2 ............................................................................275 Offline testing .........................................................................................................277 18.3.2.1 Offline test programming through Pset menu ..........................................277 18.3.2.2 Offline test programming through Tool menu ..........................................279 18.4 How to execute a test by interfacing the STa 6000 with the IRC-Connect............. 283 18.4.1 18.4.2 18.4.3 19 20 21 22 23 24 25 cable replac connection from the Pset menu ..............................................................................................................283 connection from the Tool menu ..............................................................................................................286 Offline test execution .............................................................................................289 18.4.3.1 Working with STa 6000 (P/N 8059 0956 60) ...........................................289 18.4.3.2 Working with STa 6000 PLUS (P/N 8059 0956 61).................................293 18.5 IRC-Connect live result monitor ............................................................................ 298 MAINTENANCE ............................................................................................................ 305 19.1 Yearly Calibration ................................................................................................. 305 19.2 STa 6000 Cleaning ............................................................................................... 305 19.3 Battery Pack Maintenance .................................................................................... 305 CALCULATING CORRECTION COEFFICIENTS FOR MRTT-C EXTENSIONS........... 306 20.1 Torque Correction Coefficient ............................................................................... 306 20.2 Angle Correction Coefficient ................................................................................. 307 20.3 Correction Formulas ............................................................................................. 307 STa 6000 FACTORY SETTINGS .................................................................................. 308 APPENDIX A EAP-TLS SECURITY TYPE ................................................................. 309 TROUBLESHOOTING GUIDE ...................................................................................... 311 23.1 STa 6000 Diagnostic ............................................................................................ 314 23.2 STa 6000 Remote Display .................................................................................... 315 23.3 MRTT-C Firmware Recovery Procedure ............................................................... 316 ABBREVIATIONS ......................................................................................................... 318 INDEX ........................................................................................................................... 319 10 (324) 9836 8243 01 Edition 3.1 STa 6000 User Guide Safety Information SAFETY INFORMATION WARNING: PLEASE CAREFULLY READ THE STa 6000 SAFETY INFORMATION (No. 9836 5229 00) PRIOR TO USE THE PRODUCT AND PAY ATTENTION TO THE SAFETY INSTRUCTIONS PROVIDED. 9836 8243 01 Edition 3.1 11 (324) Battery Information STa 6000 User Guide BATTERY INFORMATION according to European regulation 2006/66/EC BATTERY PACK SPECIFICATION P/N: 8059 0955 61 TYPE: Lithium-ion, 3.75V 6.8Ah WEIGHT: 155g The cells are installed inside the battery shell: NOTE: Once removed, the wasted batteries must be dismissed according to local regulations. NOTE: 12 (324) Battery 9836 8243 01 Edition 3.1 STa 6000 User Guide 1.1 Introduction INTRODUCTION About this Document This document is a User Guide for the STa 6000 and it is divided into the main following parts: Part Name Description Chapter 1 Introduction This chapter introduces this user guide and provides the STa 6000 technical specifications. Chapter 2 System Overview This chapter introduces the STa 6000 with its models and accessories. Chapter 3 User Interfaces This chapter provides an overview of the user interfaces available on the STa 6000 (display, keyboard, ports, etc). Chapter 4 Working with ToolsTalk BLM This chapter introduces the operations of the STa 6000 management software. Chapter 5 Transducers This chapter describes which type of transducer can be connected to the STa 6000. Chapter 6 Getting Started with STa 6000 This chapter explains to the operator how to use the STa 6000 in the Quick Programming mode. Chapter 7 Pset This chapter explains how to create, configure and execute a test program. Chapter 8 Tool Testing This chapter details how to set the parameters to test click-wrenches, slip-wrenches, power and impulse tools. Chapter 9 Joint Testing This chapter details how to set the parameters to test a joint using the various residual torque strategies, and the joint analysis function. Chapter 10 Power Focus / PowerMACS Calibration This chapter explains how to calibrate the torque of the tools/spindles of Power Focus and PowerMACS, using the STa 6000 with a reference transducer. Chapter 11 Identifier This chapter describes the use of barcode readings with the STa 6000. 9836 8243 01 Edition 3.1 13 (324) Introduction STa 6000 User Guide Part Name Description Chapter 12 Results Viewer This chapter explains how to retrieve the test results from the instrument. Chapter 13 Trace Viewer This chapter explains how to retrieve the test traces from the instrument. Chapter 14 Statistics This chapter shows the SPC and Cm-Cmk statistics produced by the STa 6000 and ToolsTalk BLM. Chapter 15 Offline Programming This chapter explains how to define tightening programs and STa 6000 configuration offline, to transfer then the file to one or more STa 6000. Chapter 16 STa 6000 Settings This chapter explains how to setup the STa 6000 and its accessories. Chapter 17 Working with Torque Supervisor This chapter explains the use of the STa 6000 with Torque Supervisor. Chapter 18 Working with IRC-Connect This chapter explains the use of the STa 6000 with IRCConnect. Chapter 19 Maintenance This chapter describes the required maintenance for the STa 6000. Chapter 20 Torque / Angle Coefficient Calculation for MRTT-C Extension This chapter shows the operator how to calculate the correction coefficients when an extension is used with the MRTT-C. Chapter 21 STa 6000 Factory Settings This chapter shows the STa 6000 factory settings. Chapter 22 Appendix A EAP-TLS security type This chapter described how to configure the IRC-W module for EAP-TLS security type. Chapter 23 Troubleshooting Guide This chapter provides a guide to solve the most common problems with the STa 6000. Chapter 24 Abbreviations Table of abbreviations used in this user guide. Chapter 25 Index Index used in this user guide. 14 (324) 9836 8243 01 Edition 3.1 STa 6000 User Guide 1.2 Introduction Reference Documents The following is a list of important documents useful for a complete view of the product in all its applications: STa 6000 Safety Information (No. 9836 5229 01): Multilanguage safety instructions and declaration of conformity ToolsTalk BLM registration procedure: How to register the software on the Atlas Copco website STa 6000 calibration procedure: Procedure to calibrate the STa 6000 (only for use of authorized calibration centers) Installation guides for STa 6000 modules: Detailed installation instructions, delivered with each part IRTT-B, SRTT-B, MRTT-B and MRTT-C User Guides IRC-Connect User Guide (No. 9836 6340 01) Torque Supervisor User Guide (No. 9836 2866 01) 1.3 Specifications TECHNICAL Torque range: The torque range is defined by the transducer connected to the STa 6000. Maximum accuracy error: ± 0.1 %. Maximum linearity error: ± 0.015 %. Angle measurement Results memory capacity: 50000 test results Traces memory capacity: 50000 traces (average duration: 30 s) Pset memory capacity: 1000 Psets (1 for STa 6000 Basic) Tools memory capacity: 1000 Tools (1 for STa 6000 Basic) Number representation for torque values: Nominal Torque (T) T<5 55000 Measured torque shown on display 1000 no digits after decimal point Measured torque < 1000 one digits after decimal point no digits after decimal point NOTE: In the above table, the Unit of Measurement of the torque can be set according to the following available options: N·m, kgf·m, kgf·cm, lbf·ft, lbf·in, ozf·ft, ozf·in, kp·m, dN·m , kN Sampling frequency: - Click-wrench test: 2 kHz - Power tool test: 5 kHz - Peak test: 1 kHz - Pulse tool and ACTA pulse tool test: 10 kHz Maximum number of identifier strings: 1000 Units of Measurement supported: N·m, kgf·m, kgf·cm, lbf·ft, lbf·in, ozf·ft, ozf·in, kp·m, dN·m , kN EXTERNAL POWER SUPPLY Input power: 100 ÷ 240 VAC, 50 ÷ 60 Hz AC Power Consumption: 21 W maximum Output: 6VDC, max 3.0A BATTERY PACK Battery power supply: 3.75 V, 6.8 Ah Battery type: Lithium-ion (Li-ion) Endurance: 8 hours in normal usage, 6 hours in continuous operation (1 test every 30 seconds) Recharging max. 8 hours BATTERY CHARGER Input power: 100 ÷ 230 VAC AC Power Consumption: 70 W maximum Output: 4.2 VDC 13 W maximum Overvoltage category: II 16 (324) 9836 8243 01 Edition 3.1 STa 6000 User Guide Introduction SRTT-L Torque measurement range: 0.1 ÷ 30 Nm Torque static accuracy (from 20% to 100% of the transducer capacity): ± 0.25% of rated max. transducer capacity Overload capacity: 125% of rated max. transducer capacity Temperature stability: 0.1% of capacity/10°C Bridge resistance: 350 ohm Operation humidity: 10-75% non-condensing Operating temperature: 5 to 40°C DIMENSIONS AND WEIGHT Dimensions are in mm. Max Weight (with battery): 500 g 9836 8243 01 Edition 3.1 17 (324) Introduction STa 6000 User Guide INTERFACES MiniUSB 2.0 port Transducer connector: 19 poles military connector for: - IRTT-B and IRTT - SRTT-B and SRTT - MRTT-B and MRTT - MRTT-C - SRTT-L - mV/V torque transducers (0.4 mV/V to 2.5 mV/V, bridge resistance 350 to 1000 Ohm) Barcode reader module (optional): - Visible laser diode 650 nm - Output power: 1 mW maximum - Scan rate: 104 ± 12 scans/second (bi-directional) - Scan angle: 47° ± 3° - Scan patterns: Linear - Minimum Print contrast: Minimum 20% absolute dark/light reflectance measured at 650 nm - Ambient light: o Sunlight: 10000 ft candles (107640 Lux) o Artificial: 450 ft candles (4484 Lux) - EMI/RFI: FCC Part 15 Class B, EN 55024/CISPR 22, AS 3548, VCCI - Laser Safety: IEC 60825 class 2 IRC-W dual band radio module (optional): - Minimum IRC-W module firmware version: 2.14 - Type: 802.11a/b/g/n - Frequencies: CHANNEL CENTER FREQUENCY (MHz) 10 18 (324) 2412 2417 2422 2427 2432 2437 2442 2447 2452 2457 EU USA YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES Max. E.I.R.P. (mW) 0.9 0.79 9836 8243 01 Edition 3.1 STa 6000 User Guide Introduction CHANNEL CENTER FREQUENCY (MHz) 2462 2467 2472 2484 11 12 13 14 EU USA Max. E.I.R.P. (mW) YES YES YES N/A YES N/A N/A N/A 0.58 CHANNEL CENTER FREQUENCY (MHz) FCC U-NII Band(s) EU USA 36 40 44 48 52 56 60 64 100 104 108 112 116 132 136 140 149 153 157 161 165 5180 5200 5220 5240 5260 5280 5300 5320 5500 5520 5540 5560 5580 5660 5680 5700 5745 5765 5785 5805 5825 U-NII-1 U-NII-1 U-NII-1 U-NII-1 U-NII-2A U-NII-2A U-NII-2A U-NII-2A U-NII-2C U-NII-2C U-NII-2C U-NII-2C U-NII-2C U-NII-2C U-NII-2C U-NII-2C U-NII-3 U-NII-3 U-NII-3 U-NII-3 U-NII-3 YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES 9836 8243 01 Edition 3.1 Max. E.I.R.P. (mW) 0.41 0.52 0.64 2.11 1.67 1.3 19 (324) Introduction STa 6000 User Guide IRC-B radio module (optional): - Bluetooth: v4.0 (Bluetooth low energy and Classic Bluetooth) - Frequencies: FREQUENCY RANGE (MHz) EU USA 2402 ÷ 2480 YES YES CENTER FREQUENCY (MHz) Max. E.I.R.P. (mW) 2402 2441 2480 0.37 0.39 0.47 - Throughout: 1.3 Mbps (Classic Bluetooth) - Microprocessor capacity: 72 MHz, ARM 32-bit Cortex M3 processor with 64kB RAM and 384kB flash ENVIRONMENTAL The following conditions must be observed during operation: Internal Use only Environmental Class: II IP Index according to EN IEC 60529: IP40 Room Temperature: 5 to 40°C Atmospheric humidity: 95%, non-condensing Altitude: Up to 2000m SYSTEM REQUIREMENTS The following are the PC minimum requirements for installation of STa 6000 Management Software (ToolsTalk BLM): Processor: 400 MHz (800 MHz or above recommended) Memory: 256 Mb or above Hard disk space: 610 Mb (1 Gb or above recommended) Display: 800 x 600, 256 colors (1024 x 768, High Color (16-bit) recommended) Operating Systems: Windows XP Service Pack 2 (SP2), Windows 7, Windows 8.1, Windows 10 Internet Explorer 5.01 or later (required for installation of the .NET Framework) Windows Installer 3.1 20 (324) 9836 8243 01 Edition 3.1 STa 6000 User Guide Introduction Microsoft Excel 2007 or later (required to view the exported file with the tightening results) NOTE: A system should meet these or the minimum requirements for the operating system, whichever is higher. CALIBRATION CERTIFICATE STa 6000 is provided with an Atlas Copco BLM factory calibration certificate. 1.4 EC Declaration of Conformity The STa 6000 is in conformity with the requirements of the council Directives on 06/22/1998 on the approximation of the laws of the Member States relating: 2004/108/EC 2011/65/EC 1999/05/EC EMC Directive Electromagnetic Compatibility ROHS Directive Risk Of Hazardous Substances R&TTE Directive Radio and Telecommunications Terminal Equipment Safety complies with the following regulations: STa 6000 EN 61010-1:2010 Safety requirements for electrical equipment for measurement, control and laboratory use. General requirements Battery charger IEC 60950-1:2005 + A1:2009 + A2:2013 Safety of electronic equipment within the field of audio/video, information technology and communication technology. General requirements The STa 6000 is marked with the following symbol: 9836 8243 01 Edition 3.1 21 (324) Introduction STa 6000 User Guide The STa 6000 may be operated in the following countries: Country ISO 3166 2 letter code Country ISO 3166 2 letter code Country ISO 3166 2 letter code Country ISO 3166 2 letter code GB IS LI NO CH BG RO TR Austria AT Germany DE Malta MT Belgium Cyprus Czech Republic Denmark Estonia Finland France BE CY CZ Greece Hungary Ireland GR HU IE Netherlands Poland Portugal NL PL PT United Kingdom Iceland Liechtenstein Norway DK EE FI FR Italy Latvia Lithuania Luxembourg IT LV LT LU Slovakia Slovenia Spain Sweden SK SI ES SE Switzerland Bulgaria Romania Turkey 1.5 FCC Rules The STa 6000 complies with part 15 of the FCC Rules. STATEMENT FCC 15.19 Operation is subject to the following two conditions: (1) The STa 6000 may not cause harmful interference. (2) The STa 6000 MUST accept any interference received, including interference that may cause undesired operation. STATEMENT FCC 15.21 Changes or modifications made to this equipment not expressly approved by the party responsible for The FCC ID of the STa 6000 is as follows: FCC ID: 2AEWDSTA6K This device contains: - FCC ID: PVH0941 - FCC ID: PVH0946 22 (324) 9836 8243 01 Edition 3.1 STa 6000 User Guide System Overview SYSTEM OVERVIEW Transducers (cable or wireless) ToolsTalk BLM Barcode reader PC IRC-W STa 6000 The STa 6000 is a modular instrument designed for optimal operations in: Tool testing: The STa 6000 (QC and AA versions) offers a set of tests for evaluating click-wrenches, slip-wrenches, power tools and pulse tools, measuring the torque/angle values and producing results with statistical parameters. This makes possible to keep the quality of the tightening operations on a production line under control. The test results can be retrieved by the STa 6000 management software (ToolsTalk BLM), or exported into Microsoft Excel. Quality tests: The STa 6000 (QC and AA versions) offers a set of strategies to perform residual torque tests and joint analysis. With this instrument it is possible to keep under control the quality of the tightenings on the assembly line and to perform analysis of the joints characteristics. Tightening operations: Not available in this software version. NOTE: The STa 6000 can also work in conjunction with Torque Supervisor, which sends the route of tests and retrieve the results. 9836 8243 01 Edition 3.1 23 (324) System Overview 2.1 STa 6000 User Guide STa 6000 Versions This chapter provides an overview of the STa 6000 versions. The STa 6000 version is defined by the Rapid Backup Unit (RBU) installed: Basic (no RBU) QC AA RBU HARDWARE CAPABILITY Number of Channel Torque Yes Yes Yes Angle (Encoder or Gyroscope) Yes Yes Yes MRTT-C connection for joint checks Yes Yes Yes 110x200x45 110x200x45 110x200x45 Size in mm Weight [grams] Color Display Keyboard 500 Yes 500 Yes 500 Yes Yes Yes Yes Result Storage 50000 50000 50000 Traces Storage 50000 50000 50000 RBU Rapid Backup Unit No Yes Yes Direct power Supply (slow charger 6H) Yes Yes Yes RJ45 (Ethernet) Yes Yes Yes USB Yes Yes Yes Non Atlas Copco analog transducer connection Yes Yes Yes Languages Yes Yes Yes Multi-units Yes Yes Yes SOFTWARE CAPABILITY - ONBOARD Pset 1 (not saved) 1000 1000 Batch Count Yes Yes Yes CW/CCW Yes Yes Yes Database - Tool No 1000 1000 Quick Programming Yes Yes Yes Power Focus and PowerMACS calibration No Yes Yes Traces on display No Yes Yes Advanced analysis graphs on display No No Yes Custom measurement screen No Yes Yes Yes (with IRC-W module) Yes (with IRC-W module) Yes (with IRC-W module) Yes Yes Yes Wrench testing Yes Yes Yes Power tool testing Yes Yes Yes Pulse Tool testing Yes Yes Yes Min, Max, Med, Sigma statistics Yes Yes Yes Cm/Cmk No Yes Yes Wi-Fi print Ethernet print SOFTWARE FUNCTIONALTIES - ONBOARD Tool Check 24 (324) 9836 8243 01 Edition 3.1 STa 6000 User Guide System Overview SPC No Yes Yes Yield Point Yes Yes Yes Residual Torque/Time Yes Yes Yes Residual Torque/Angle Yes Yes Yes Residual Torque/Peak Yes Yes Yes Loose and Tight Yes Yes Yes ToolsTalk BLM to view/export results and traces via Wi-Fi (with IRC-W), USB/RJ45 Yes Yes Yes ToolsTalk BLM to program test strategies via Wi-Fi (with IRC-W), USB/RJ45 No Yes Yes Torque Supervisor via Wi-Fi (with IRC-W), USB/RJ45 No Yes Yes API via Wi-Fi (with IRC-W), USB/RJ45 No Yes (with API RBU) Yes (with API RBU) Joint Check SOFTWARE CAPABILITY - CONNECTIVITY 2.1.1 Basic The STa 6000 without a RBU installed works as STa Basic. It provides the Quick Programming mode with tools testing menu (Click-wrench, Power Tool, Peak Wrench and Pulse Tool). One Pset and one Tool can be defined directly on the STa 6000 menu (not by ToolsTalk BLM), but they are not saved in the STa 6000 Basic memory. The results are stored in the STa 6000 memory and can be retrieved (and possibly printed) by the management software (ToolsTalk BLM), but they cannot be transferred to any remote devices; they can be exported to Excel. 2.1.2 QC (Quality Control) The STa 6000 QC provides tool test and quality test functions. This includes tests of tightening tools (Click-wrench, Power Tool, Peak Wrench and Pulse Tool), and tests of joints to evaluate the residual torque. Free test function is also available. RBU - QC It provides Pset definition, transducers database, real time statistics on the display. This instrument provides also Power Focus / PowerMACS calibration function. The results are stored in the STa 6000 memory and can be retrieved (and possibly printed) by the management software (ToolsTalk BLM), or exported to Excel. This version can also work in conjunction with Torque Supervisor. NOTE 9836 8243 01 Edition 3.1 Working with Torque Supervisor 25 (324) System Overview 2.1.3 STa 6000 User Guide AA (Advanced Analysis) The STa 6000 AA provides the same function of the QC version, plus the Cm-Cmk histogram and SPC X/R Charts available on the STa 6000 display. RBU - AA 2.2 STa 6000 Typical Applications Scenario This chapter provides a quick overview of the main applications of the STa 6000. 2.2.1 Stand-alone STa 6000 The STa 6000 can work as a stand-alone instrument, programmed by its management software (ToolsTalk BLM), which can display the traces, retrieve tightening results, to be exported in a Microsoft Excel file, and possibly printed, if required. NOTE 26 (324) Working with ToolsTalk BLM er details. 9836 8243 01 Edition 3.1 STa 6000 User Guide 2.2.2 System Overview STa 6000 connected to Torque Supervisor The STa 6000 QC and AA versions can work in conjunction with Torque Supervisor. The communication is performed trough USB, network cable or IRC-W. In this application Torque Supervisor generates and sends to the STa 6000 the list of tests to be done (the s, Torque Supervisor downloads the results and stores them in the tool statistics. The ToolsTalk BLM is necessary only for settings of the STa 6000; for basic operation of the STa 6000 with Torque Supervisor, it can be not necessary. In the typical application the Torque Supervisor is installed in one or more dedicated PC, and ToolsTalk BLM on another one. However, they can run on the same PC. NOTE: Refer to the 9836 8243 01 Edition 3.1 Working with Torque Supervisor 27 (324) System Overview 2.3 STa 6000 User Guide Presentation The STa 6000 is modular. The following items are delivered with the STa 6000 package: STa 6000 Controller (STa 6000 PLUS 1) The main module of the STa 6000, which contains all the hardware and firmware. Controller is provided without battery. External Power Supply (P/N 4612 0300 21) (delivered with the STa 6000 package) Power supply. If battery and battery charger are used, the external power supply is not strictly necessary. Battery cover (delivered with the STa 6000 package) This battery cover must be installed in the STa 6000 when the battery is not used (STa 6000 powered by the external power supply). Nylon Strap (delivered with the STa 6000 package) The nylon strap can be attached to the STa 6000 for easy portability. It is allowed to tie the Nylon Strap on the own belt. Attach here the nylon strap Torx wrench (delivered with the STa 6000 package) This wrench is used to remove the STa 6000 back cover to install the RBU or IRC-W module or Barcode module. 28 (324) 9836 8243 01 Edition 3.1 STa 6000 User Guide System Overview The following are additional modules for the STa 6000: STa 6000 RBU (Rapid Backup Unit) (RBU QC (RBU AA P/N 8059 0956 63) Module to be installed in the STa 6000. It defines the STa 6000 type and stores test programs, tools and transducers archives, STa 6000 configuration. If not used, the STa 6000 works as STa 6000 Basic. ToolsTalk BLM (P/N 8059 0981 10) The STa 6000 management software. It features STa 6000 programming, STa 6000 configuration, retrieving results and traces from the STa 6000. STa 6000 Battery (P/N 8059 0955 61) Power supply. NOTE: Battery is optional. The STa 6000 can be powered also by the external power supply. Battery charger adapter (P/N 8059 0955 75) The STa 6000 battery can be recharged when installed in the unit by the external power supply, or on the specific battery charger. The battery charger is the same of the STwrench; it requires the adapter to recharge the STa 6000 battery. QAT Barcode module (P/N 8059 0920 12) Module for scanning barcode labels on assembly components for easy traceability. It cannot be installed on the STa 6000 Basic. 9836 8243 01 Edition 3.1 29 (324) System Overview STa 6000 User Guide QAT IRC-B radio module (P/N 8059 0920 10) Radio module for interfacing the STa 6000 with printer, Torque Supervisor and ToolsTalk BLM. It is possible to install one or two radio modules in the STa 6000. QAT IRC-W dual band radio module (P/N 8059 0920 15) Radio module for interfacing the STa 6000 with printer, Torque Supervisor and ToolsTalk BLM. It is possible to install one or two radio modules in the STa 6000. SRTT-L main plate (P/N 8059 0955 85) Torque transducer to be installed on the STa 6000 to create a single unit with the transducer and the measurement system. Mechanical joint simulators are also available to test power an impulse tools on the SRTT-L. USB / Serial Adapter (P/N 8059 0956 74) This box is used to connect the STa 6000 to the Power Focus and PowerMACS for calibration. STa 6000 Stand (P/N 8059 0956 73) This stand MUST be installed on the back of the STa 6000. It is not allowed to insert the STa 6000 Stand into the own belt. It may get an easy reading once it is leaned on a desk. 30 (324) 9836 8243 01 Edition 3.1 STa 6000 User Guide 2.3.1 System Overview STa 6000 assembly The STa 6000 is delivered in separated packages for each module; in order to start working with the instrument, put all the pieces together: 1. Remove the cover from the controller. 2. If purchased, insert the RBU and IRC-W / IRC-B radio module(s) inside the controller. Tighten the screws (to the torque applied by the fingers. Do not use pliers). 3. If purchased, insert the QAT Barcode Reader module and tighten the two mounting screws. 4. Mount the cover (tighten the two screws). 5. Insert battery, or connect the external power supply. Cover Radio 2 RBU Battery, or battery cover if battery not purchased Barcode reader Radio 1 STa 6000 controller 9836 8243 01 Edition 3.1 31 (324) System Overview STa 6000 User Guide The STa 6000 is ready for the use: Connector for transducers Network Mini USB port Barcode reader Buzzer External power supply connector Display Keyboard NOTE: Once the STa 6000 is assembled with the IRC-W / IRC-B radio module(s), it is not recommended to work by placing it either close to the head or close to the reproductive system. The next paragraphs describe all the STa 6000 modules and user interfaces in detail. NOTE: To start working with the STa 6000 immediately, with STa6000 2.3.2 Getting Started RBU RBU (Rapid Backup Unit) is a memory chip which defines which functions are activated and provides backup for the test programs. It stores also the specific settings of the own STa 6000 ( STa6000 Factory Settings the default configuration); by installing the RBU in another STa 6000 it is possible to get an exact copy of the original one (except for test results, stored in the STa 6000 memory and not in the RBU). 32 (324) 9836 8243 01 Edition 3.1 STa 6000 User Guide System Overview The following types of RBU are available: RBU QC: Enables the strategies to evaluate the residual torque and to execute the joint analysis. RBU AA: Same of RBU QC plus histogram and X/R charts on the STa 6000 display. If the RBU is not installed, the STa 6000 works as STa 6000 Basic. NOTE: RBUs of the STanalyser can be converted into RBU for STa 6000; in that case, once installed on the STa 6000, they cannot be used any longer in the STanalyser. To insert the RBU in the STa 6000, turn off the STa 6000, remove the back cover, insert the RBU module, and tighten the two nuts by hands (do not use pliers). Back cover The first time of RBU usage, the following message is shown: RBU Screws Device The data are loaded from the STa 6000 memory; all the data present in the RBU are overwritten. RBU The data (STa 6000 settings and all the test programs) are loaded from the RBU; all the data stored in the STa 6000 memory are overwritten. 9836 8243 01 Edition 3.1 33 (324) System Overview 2.3.3 STa 6000 User Guide QAT Barcode reader The QAT Barcode reader is a module to be installed into the STa 6000 to permit scanning of barcodes. An identifier, or barcode string, may be used to select the tightening program to be executed, identify motor vehicles (VIN) and other work pieces, variants and operators. The tightening result can then be saved together with this information. To install the barcode reader module, turn off the STa 6000, remove the cover (by removing the two screws) and insert the module (tighten the two screws): QAT Barcode NOTE 34 (324) Identifier 9836 8243 01 Edition 3.1 STa 6000 User Guide 2.3.4 System Overview IRC-W / IRC-B radio modules The IRC-W Dual Band radio module / IRC-B radio module is used to interface the STa 6000 with the Printer, Torque Supervisor and ToolsTalk BLM. It is possible to install one or two modules. To install the IRC-W / IRC-B module, turn off the STa 6000, remove the cover and insert the IRC-W / IRC-B module (tighten the two screws with the fingers). Radio 2 Radio 1 After having installed the module(s) the radio module parameters must be set trough ToolsTalk BLM. NOTE: Talking about Torque Supervisor$ Supervisor 9836 8243 01 Edition 3.1 Working with Torque 35 (324) System Overview 2.3.5 STa 6000 User Guide Battery STa 6000 can operate powered by its battery pack or by the external power supply. 2. Insert this side first Battery 1. Remove the cover Controller When the battery is not used, install the original cover supplied with the STa 6000. To install the battery, turn off the STa 6000, remove the cover and then install the battery. To replace a battery, switch off the STa 6000, remove the battery and install the new one. NOTE: Refer to the a good working order. 2.3.5.1 Maintenance for important notes about how to keep battery in Battery Charger The battery can be charged either when installed in the STa 6000 (by the external power supply) or with the specific battery charger. The battery charger is the same used for the STwrench. The specific adapter to connect the STa 6000 battery is required. Battery charger 36 (324) Adapter 9836 8243 01 Edition 3.1 STa 6000 User Guide System Overview WARNING: The Battery Charger must be installed close to the AC Power (220 V) in order to be easily managed by the user in case of malfunction. Simply connect the input AC power cable to the battery charger and plug in the battery in the adapter. Insert STa 6000 battery in the adapter The three LEDs on the battery charger indicate the battery charge status: LED Status POWER ON CHARGING COMPLETE Power on Charging in progress Charging complete Over temperature Blinking Error In case of Over temperature, disconnect the battery from the battery charger, disconnect charger from AC power, wait few minutes, reconnect the battery charger to AC power and the battery to the charger, and check if the problem gets solved. In case of Error, disconnect and then reconnect the battery to the battery charger and check if the problem gets solved. 9836 8243 01 Edition 3.1 37 (324) System Overview 2.3.6 STa 6000 User Guide External power supply The external power supply provides power to the instrument, and it also charges the battery when the battery is installed in the STa 6000. The battery is charged even if the STa 6000 is switched off. The battery icon on the STa 6000 shows the recharging process only when the STa 6000 is switched on. Connect the external power supply to AC power 100 ÷ 230 VAC 50/60 Hz, and plug the connector into the STa 6000. External power supply Connector for external power supply WARNING: Use only the power supply ordered from Atlas Copco. Warranty does not cover damages to the STa 6000 caused by the use of a different external power supply. 2.3.7 SRTT-L The SRTT-L is a torque transducer to be installed on the STa 6000 to create a single unit with the transducer and the measurement system. Transducer Lever Connector 38 (324) 9836 8243 01 Edition 3.1 STa 6000 User Guide System Overview The following models are available: Code Description Capacity 8059 0955 86 SRTT-L 1 Nm 1 Nm 8059 0955 87 SRTT-L 4 Nm 4 Nm 8059 0955 88 SRTT-L 12 Nm 12 Nm 8059 0955 89 SRTT-L 30 Nm 30 Nm 8059 0955 85 SRTT-L main plate To use the SRTT-L, install first the transducer on the main plate: Then, insert and slide the STa 6000 on the main plate, and finally rotate the SRTT-L lever to connect the SRTT-L to the STa 6000: There is no need of any setup. Simply switch on the STa 6000 and the SRTT-L is ready to use. NOTE: The barcode reader feature is not available when the STa6000 is connected with the SRTT-L. 9836 8243 01 Edition 3.1 39 (324) System Overview STa 6000 User Guide The plate can be attached to a table; refer to the following mechanical drawing for dimensions (dimensions are in millimeters): A series of mechanical joint simulators are available to test power and impulse tools on the SRTT-L: Hard joint simulation 40 (324) Soft joint simulation 9836 8243 01 Edition 3.1 STa 6000 User Guide System Overview The following models are available: Code Description Drive To be used on 4145098480 Test Joint M4 Soft 1Nm M4 SRTT-L 1 Nm 4145098483 Test Joint M4 Hard 1Nm M4 SRTT-L 1 Nm 4145098482 Test Joint M6 Soft 4Nm M6 SRTT-L 4 Nm 4145098485 Test Joint M6 Hard 4Nm M6 SRTT-L 4 Nm 4145098580 Test Joint M6 Soft 12Nm M6 SRTT-L 12 Nm 4145098582 Test Joint M6 Hard 12Nm M6 SRTT-L 12 Nm 4145098581 Test Joint M8 Soft 12Nm M8 SRTT-L 12 Nm 4145098583 Test Joint M8 Hard 12Nm M8 SRTT-L 12 Nm 4145098680 Test Joint M8 Soft 30Nm M8 SRTT-L 30 Nm 4145098682 Test Joint M8 Hard 30Nm M8 SRTT-L 30 Nm 4145098681 Test Joint M10 Soft 30Nm M10 SRTT-L 30 Nm 4145098683 Test Joint M10 Hard 30Nm M10 SRTT-L 30 Nm 9836 8243 01 Edition 3.1 41 (324)
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