Atlas Copco Power MACS 4000 Fixed Nut Runner (Servo Tightening Shaft) Control System

Atlas Copco Power MACS 4000 Fixed Nut Runner (Servo Tightening Shaft) Control System

Core advantages of the product

QST tightening shaft speed improvement: Compared to the old QMX series, the tightening speed has increased by up to 67%, while maintaining ± 2.5% accuracy and durability; The high torque model QST80/90 controller automatically increases the bus voltage without the need to replace the controller/servo.

DynaTork ™ Patent torque recovery strategy, improving clamping force output, addressing bolt relaxation type joints, achieving optimal fastening effect.

Intelligent Chip is built into the QST tightening shaft, storing shaft body information and calibration parameters; Digital communication, cable length does not affect calibration, reduces overall system calibration work, and avoids configuration errors.

Hot Swap connector: You can replace cables or tighten shafts without cutting off the power; The connector is adjustable in both directions for easy wiring.

Inertial braking, high-speed tightening will not cause torque overshoot.

Modular design without control cabinet, saving installation space; Standardize components, extend lifespan, reduce spare parts and maintenance costs.

High reliability: The preventive maintenance cycle can reach 1 million tightening cycles, reducing downtime.

ToolsTalk Power MACS software: graphical drag and drop menu for simple programming of complex tightening strategies.

Support Reject Management and enrich the built-in tightening strategy library; Support SPC statistical process control and interface with ToolsNet traceability software.

QST Tightening Shaft Model System and Naming Rules

Naming example: QST50-150CT-T50-L137-H13

Q: Fixed installation tightening shaft; ST: Synchronous motor, digital communication

Number (50): Motor specifications; 150: Maximum torque (Nm)

CT/COT/CTT/COTT/CATT/CTV: suffix definition structure

Meaning of suffixes

CT standard, single torque sensor

COT bias output head, single torque sensor

CTT/COTT dual torque sensor, redundant verification torque reading

CATT dual torque+dual angle sensor, dual verification of torque angle

CTV angle elbow output tightening shaft

Txx: Spring floating stroke: T50=50   mm; T76=76   mm; T100=100   mm

L: Sleeve bracket length; H: Socket interface specifications

Torque coverage range: 2 Nm to 1750 Nm.

Main sub series

CT/COT: Single sensor, standard type, offset type, 50mm standard floating stroke, optional 76/100mm extended spring stroke.

CTT/COTT: Dual torque sensor redundancy, verifying torque readings.

CATT: Dual torque+dual angle sensor, highest safety level, dual verification of angle and torque.

CTV elbow series: with angled elbow, available with or without floating spring version.

The document provides complete information for each model, including torque range, speed, center distance Min C-C, weight, reduction ratio, sleeve size, and order number.

Power MACS 4000 Controller

Divided into primary controller TC-P and secondary controller TC-S.

1. Main controller TC-4000-P

Equipped with a display screen, status indicator lights (ALL OK/OK NOK/ALARM/E stop), operation buttons, and emergency stop reset button.

Hardware interface: 6-port built-in Ethernet switch; Class3 redundant emergency stop relay; Optical isolation digital input/output; 24V external power supply; Anybus fieldbus slot; Dual Ethernet ports; TC dedicated communication LAN (isolated from the factory WAN network to prevent multicast storms).

Multiple fieldbus versions are available: Profibus‑DP、DeviceNet、EtherNet/IP、Modbus‑TCP、Profinet、CC‑Link， Is there a fieldbus basic version available.

2. From controller TC-4000-S

No fieldbus; Divided into version without switch and version with 6-port Ethernet switch; As a system extension slave station.

Supporting Backplane Accessories: Backplane with/without Ethernet switch, spare parts for independent 6-port switch.

Power supply units MSB, DB

MSB (Main Switch Box): three-phase 400-480VAC total input with total emergency stop; A single unit can supply power to up to 6 controllers; Emergency stop can be upgraded to Class4 security level.

DB (Distribution Box), extended power supply, up to 6 channels, with 1800mm power cable included.

Complete system topology: Three phase power supply to MSB → power cable, emergency stop daisy chain connected to multiple TC controllers; Ethernet networking connection QST tightening axis.

Complete set of cable materials

Tool cable: Single cable integrated power+digital bus, 12mm new thin cable, durable and flexible; Supports hot plugging, connectors with positioning marks, and long-distance wiring; Provide a full range of 2-40m order numbers.

Power cable between MSB and TC: 1.35m~20m.

Ethernet cable: 0.5-15m.

Emergency stop E-stop cable and terminal resistor.

I/O bus expansion cable, terminal plug.

The document includes a complete set of cable packages selected by the number of axes: 1-18 axis workstations, directly select the package order number, including all power, Ethernet, emergency stop cables, and switch backboards.

Software and human-machine interface accessories

ToolsTalk Power MACS V10: Supports basic/advanced modes; Quick parameter setting; Drag and drop programming; Multi language license (1 user/5 users/10 users/factory level authorization).

Peripheral accessories: MiniDisplay touch screen, Stacklight signal light, Indicator box, Com Node2, I/O expansion module, operator panel, etc; The accessory cables are fully ordered; Some attachments are compatible with the Power Focus series.

Customer Case (ZF ZF)

The ZF transmission chassis production line uses Power MACS4000; The system eliminates the need for post torque wrench re inspection, shortens the cycle time by up to 50%, saves thousands of euros per year for a single assembly station, improves assembly safety, and reduces human operational errors.

Service Projects

RCM focuses on reliability centered maintenance: analyzing production line conditions and optimizing maintenance plans.

Full Coverage Agreement: Fixed annual fee, including planned and unplanned fault repairs, to eliminate human misuse.

Preventive Maintenance Agreement (PMA): Regular on-site/factory maintenance.

Calibration service: Tightening shaft torque calibration; The service center has ISO9000 qualification.

Training services, on-site/training center lectures.

ToolStart startup service: engineer on-site installation, programming, debugging, operator training.