MiniMACS Manual, Ver 1

AHB 14/23-10
ASY 9834 0946 01

1997-02
mini MACS
User’s Manual
QCM-T/QCS-T
and QCM/QCS
Ser
Servvo Drives
English
Release 1
A t l as Copco
Assemb
Assembll y Systems
Table of Contents
able II
Introduction .............................................................................................. 1
1. The miniMACS Tightening System........................................................... 1
1.1 Tightening System Overview ................................................................ 2
2. Overview of QCM-T//QCS-T and QCM/QCS ........................................... 3
2.1 General ................................................................................................. 3
2.2 Benefits ................................................................................................. 5
3. Servo Drive Specifications ....................................................................... 6
3.1 Electrical and Mechanical Parameters.................................................. 6
3.2 Main Servo Drive Functions .................................................................. 8
3.2.1 Control Functions .............................................................................. 8
3.2.2 Protective Functions .......................................................................... 9
3.3 Block Diagram ..................................................................................... 10
3.3.1 QCM Master Drive ........................................................................... 10
3.3.2 QCS Slave Drive.............................................................................. 11
3.3.3 QCM-T Master Drive ....................................................................... 12
3.3.4 QCS-T Slave Drive .......................................................................... 13
3.4 Servo Drive Modules .......................................................................... 14
3.4.1 CPU Board ...................................................................................... 14
3.4.2 EPROM and EEPROM .................................................................... 14
3.4.3 Input/Output Board, I/O ................................................................... 14
3.4.4 Motor Power Unit, MPU ................................................................... 15
3.4.5 Power Supply Unit, APU (QCM-T and QCM only) ........................... 15
3.4.6 Torque Transducer Board (QCM-T and QCS-T only) ...................... 16
3.4.7 Mechanical Housing, MECM and MECS ......................................... 16
3.5 Status Indicators ................................................................................. 17
3.6 Input and Output Signals .................................................................... 19
3.6.1 Error Codes Output at NOK ............................................................ 25
3.6.2 Selected Program Set Number ....................................................... 26
3.6.3 Confirmation of Selected Program Set Number .............................. 26
3.7 Power Supply and Control Signal Connectors .................................... 27
3.7.1 Connectors for 15 and 25 Amps Servo Drives, QCM and QCS ...... 27
3.7.2 Connectors for 15 and 25 Amps Servo D., QCM-T and QCS-T ...... 28
Front Panel Mounted Connectors, 15 and 25 Amps .................... 29
3.7.3 Connectors for 50 Amps Servo Drives, QCM .................................. 30
Connectors for 50 Amps Servo Drives, QCS .................................. 31
3.7.4 Connectors for 50 Amps Servo Drives, QCM-T .............................. 32
Connectors for 50 Amps Servo Drives, QCS-T ............................... 33
Front Panel Mounted Connectors ................................................ 34
3.7.5 Connector Specifications ................................................................. 35
3.8 Communication with the Servo Drive .................................................. 36
3.8.1 Communication Cables Specifications ............................................ 37
3.8.2 Signal Designation for Communication Connectors ........................ 39
mini MACS Tightening System User's Manual

Manual Release 1.0 1997-02
Atlas Copco Assembly Systems S-105 23 Stockholm – Sweden
III
4. Nutrunner ............................................................................................... 40
4.1 Nutrunner Motor ................................................................................. 41
Data for Electric Motors ................................................................... 41
4.1.1 Nutrunner Motor Connection ........................................................... 42
4.2 Resolver .............................................................................................. 42
4.2.1 Resolver Connection ....................................................................... 43
4.3 Torque Transducer (for QCM-T/QCS-T only) ...................................... 44
4.3.1 Torque Transducer Connection ........................................................ 44
4.4 Gear .................................................................................................... 44
5. System Design ....................................................................................... 46
5.1 Configuration of a Servo Drive System ............................................... 46
Configuration Examples .................................................................. 47
5.2 Power Supply ...................................................................................... 48
5.2.1 QCM-T and QCM ............................................................................ 48
5.2.2 QCS-T and QCS ............................................................................. 49
5.3 Power Transformer Design .................................................................. 49
5.3.1 Transformer Power Requirement per Nutrunner ............................. 51
5.3.2 Additional Design Rules for the Transformer ................................... 51
5.4 Cable Dimensions ............................................................................... 52
5.5 Emergency Stop Relay, Fuses, Filter, Fans ........................................ 53
5.6 Swervo Drive Cabling Schematics ...................................................... 54
5.6.1 Cabling Schematics QCM/QCS 34015 and 34025 .......................... 54
5.6.2 Cabling Schematics QCM-T/QCS-T 34015/34025 .......................... 56
5.6.3 Cabling Schematics QCM/QCS 34050 ............................................ 58
5.6.4 Cabling Schematics QCM-T/QCS-T 34050 ..................................... 60
6. Parameter Definitions ............................................................................. 62
6.1 Overview ............................................................................................. 62
6.2 Tightening Step Parameters ............................................................... 63
6.2.1 Control Mode ................................................................................... 63
6.2.2 Torque ............................................................................................. 66
6.2.3 Speed .............................................................................................. 67
6.2.4 Angle ............................................................................................... 67
6.2.5 Min. Angle ........................................................................................ 68
6.2.6 Delay Time ...................................................................................... 68
6.2.7 Max. Time ........................................................................................ 69
6.3 Modifying Hardware Parameters ........................................................ 69
6.3.1 Servo Drive Address ....................................................................... 70
6.3.2 Ramp Time ...................................................................................... 70
6.3.3 Nominal Motor Speed...................................................................... 70
6.3.4 Current Scale Factor ....................................................................... 71
6.3.5 Nutrunner Gear Ratio, Gear ............................................................ 72
6.3.6 Cycle OK/Controller OK/Overvoltage Shut-off ................................. 73

IV
6.3.7 Position Hold ................................................................................... 74

6.3.8 Torque Scale Factor ........................................................................ 74
6.3.9 Filter ................................................................................................ 75
6.4 Selecting and Confirming the Set Number ......................................... 75
7. Programming .......................................................................................... 76
7.1 Main Menu .......................................................................................... 77
7.1.1 Results Menu .................................................................................. 77
7.1.2 Tightening Cycles Window .............................................................. 78
7.1.3 Digital Inputs Window ...................................................................... 80
7.1.4 Digital Outputs Window ................................................................... 80
7.2 File ..................................................................................................... 80
7.3 Spindle ................................................................................................ 81
7.3.1 Tightening Steps ............................................................................. 82
7.3.2 Copy Tightening Steps .................................................................... 82
7.3.3 Spindle Parameters ......................................................................... 83
7.3.4 Torque Reading ............................................................................... 84
7.3.5 Special ............................................................................................. 84
7.3.6 Select Current Spindle .................................................................... 85
7.4 Setup .................................................................................................. 86
7.4.1 System ............................................................................................ 86
7.4.2 Change Servo Address ................................................................... 87
7.4.3 Communication ............................................................................... 88
7.5 Load Parameters ................................................................................ 89
7.5.1 Load all Parameters to Spindles ...................................................... 89
7.5.2 Load all Parameters from Spindles ................................................. 89
7.5.3 Compare Parameters in File and Spindles ...................................... 89
7.5.4 Read and Write Parameters ............................................................ 89
7.6 Access Level ....................................................................................... 90
8. Installation and Start-up ......................................................................... 91
8.1 Installation Check List ......................................................................... 91
8.2 Start-up Instruction ............................................................................. 92
9. Trouble Shooting .................................................................................... 95
9.1 Defining the Error................................................................................ 95
9.1.1 Using the Status Indicators ............................................................. 95
9.1.2 Abnormal Nutrunner Function ......................................................... 99
Appendix 1 Servo Drive Front Panels, QCM-T/QCS-T ................................. 101
Appendix 2 Servo Drive Front Panels, QCM/QCS ........................................ 102
Appendix 3 Grounding the Servo Drive QCM-T/QCS-T ............................... 103
Appendix 4 Grounding the Servo Drive QCM/QCS ...................................... 104

V
IMPOR
IMPORTTANT
Please study the entire User’s Manual before you connect
the power supply to the unit. In chapter 8 you will find an
Installation Chec
Checkk List and a Star t-Up Instruction
Start-Up Instruction.
Always disconnect the electrical power before you install
cables or perform service in or near the drive and the motor.
The power stage and DC-bus work at high voltage, 340 VDC.
Therefore do not touch these parts or other components on
the boards without disconnecting the power supply.
Please Note! Capacitors are used in the internal power
conversion section. High voltage may be present up to 60
seconds after the power supply has been disconnected.

1
Introduction
Introduction
1. The miniMACS Tightening System
miniMACS
An electrical powered assembly system with QCM-T/QCS-T or
QCM/QCS servo drive units for tightening and loosening of screws.
It normally comprises the following basic components:
• A number of QMR nutrunners containing a motor, resolver, torque

transducer, mechanical gear, etc.
• One QCM-T/QCS-T or QCM/QCS servo drive unit for each

nutrunner.
• A three-phase transformer to supply power to the servo drive

units and the electric motors in the nutrunners.
Various optional units like displays, printers, external computers,

and controllers can also be connected to the system.

2
1.1 Tightening System Over vie

Overvie w
view
Optional Modules for Optional Portable Optional
Results Reporting Programming Unit LCD Display
External
PLC
QCM-T/QCS-T; QCM/QCS Servo Drives

QMR Nutrunners
Basic Components
Basic components and optional units in the miniMACS tightening system.
The QCM-T/QCS-T and QCM/QCS servo drive units have built-in

programmable computers that control the tightening of a joint. The
electric motor in the QMR nutrunner supplies the tightening force. A
resolver in the nutrunner feeds back speed and angle information to
the servo drive. The torque applied to the joint is either measured by
a transducer in the nutrunner (QCM-T/QCS-T) or calculated from the
motor current supplied by the servo drive (QCM/QCS) to the nut-
runner.
You can program the tightening parameters with an external standard
PC or a terminal. You can make program modifications as well as
safety back-up with the connected PC. Programming takes place with
a software running under Windows 3.X, NT or 95. With the program-
ming unit disconnected, a result reporting unit is avaliable for connec-
tion to the system. Status results such as OK/NOK with error codes
and values for final angle and final torque can be saved on disk, sent
to a printer and displayed on the screen.
Input and output signals are available in each servo drive for connec-
tion to indicator panels or to an external PLC (Programmable Logic
Controller) for cycle control.
Indicators on the servo drive's front panel inform the operator of the
running status and normal/alarm conditions.

3
2. Over vie
Overvie w of QCM-T/QCS-T and QCM/QCS
view
2.1 General
The QCM-T/QCS-T and QCM/QCS are computer powered digital
servo drive units designed to control the motor in a nutrunner to
tighten a screw with constant speed despite the torque variations at
the joint.
The servo drive controls the nutrunner motor according to prepro-
grammed target values for maximum torque or angle. Speed control
can be applied in both modes. In the first mode the servo drive stops
the tightening process when the correct torque is reached. The QCM-
T/QCS-T uses feedback signal from nutrunner torque transducer,
while the QCM/QCS uses the actual motor current for calculating the
applied torque.
In the second mode the servo stops the tightening step at a specified
angle based on measurement of angle pulses produced by the nut-
runner resolver.
Control of torque and speed is achieved by feeding the motor the
correct amount of 3-phase current. The sinusoidal current is created
from a DC voltage, using a PWM signal (Pulse Width Modulation).
Sinusoidal current distribution eliminates torque ripple, providing
smooth tightening force and enhancing tightening accuracy. Internal
heat loss is minimized, providing a substantial increase in efficiency
compared with earlier designs.
The servo drive units are designed for panel mounting. A servo drive
master unit – QCM-T or QCM – supplies DC-power to the slave units
QCS-T or QCS.
All units in a system are easily replaceable. The installation is simple,
service is faster and less costly due to greater accessability. Time
spent on operator training is reduced.
As the servo drive units are interchangeable, fewer spare parts are
required and downtime is reduced. The servo drive unit itself has
several modules: Power conversion, input/output board, CPU board,
indicators, motor current output stage etc.
The servo drive units are housed in protective covers providing users
and service personnel with improved protection against electric shock.
The end cover plates are perforated for improved air cooling. The
integrated packaging simplifies interconneting wiring, reduces wiring
errors and shortens installation time.

4
Front panel LED indicators (Light Emitting Diodes), show running

status and alarm status for the most common errors, making trouble-
shooting easy.
Front mounted connectors provide serial communication with a termi-
nal for programming the tightening steps. The communication link can
be cascaded to all servo drive units. In programming mode each
servo drive can be individually addressed from the terminal.
The master units QCM-T and QCM are provided with a built-in AC/DC
converter and are connected to the 3-phase mains, 3 x 240 VAC. The
AC/DC converter’s output – 340 VDC – is available in a connector for
feeding the slave units QCS-T and QCS. The output is called the DC-
bus
us.
The slave units QCS-T and QCS are supplied with 340 VDC from a
master unit. The high DC-bus voltage allows smaller cable and
connector dimensions. All servo drive units have a built-in DC/DC
converter for the low-voltage electronic circuits.

5
2.2 Benefits
• Integrated pac ka
packa ging
kaging
ging. Integrated packaging eliminates interconnect
wiring, wiring errors and reduces installation time.
• Panel mounting
mounting. The servo drive units are designed to be mounted
on a panel. A backplane with expensive connectors is not needed.
• Compact pac ka
packa ging
ging. The unit’s size is small. Minimizes the required
kaging
mounting area.
• Replaceab
Replaceablele modules
modules. The unit consists of a few modules like power
conversion, input/output board, CPU board, etc. which can be re-
placed in case of a fault.
• Sinusoidal motor current
Sinusoidal current. Sinusoidal three-phase motor current is
used for smooth and efficient motor operation.
• Front panel indicator
Front s . LED indicators on the front panel with alarm
indicators
status for the most common errors simplifies troubleshooting.
• Heat pr otection
protection
otection. The servo drive unit protects from excessive power
output by monitoring the temperature of the servo drive’s internal heat
sink and the motor, assuring long term reliability. The servo drive’s
power output stage can supply high currents for short periods of time
without triggering an overcurrent alarm.
• Shor
Shortt circuit pr
circuit otection
protection
otection. Short circuit current is monitored both in
the positive and the negative line of the DC-bus. This ensures that the
servo drive’s amplifier be fast enough to sense the excessive current
and disable the output power stage, when a short circuit occurs in the
motor — both phase to phase and phase to protective ground.
• Over
Overv volta
oltagg e protection
protection
otection. The internal DC-bus (340 VDC) in the
master drive units QCM-T and QCM is monitored for overvoltage. Two
different protective systems are built-in the master servo drive units.

6
3. Ser
Servvo Drive Specifications
In the table below (two pages) you will find the most important param-
eter values for the servo drive unit. The rightmost columns include in
the heading 15 A, 25 A and 50 A. It refers to the three presently
available sizes of the MPU, Motor Power Unit (current output capaci-
ty). Please also turn to Appendix 1-2 for mechanical drawings of the
servo drive front panels.
All current values are defined as the peak value of the sine curve. The
parameters are explained in the following text.
3.1 Electrical and Mechanical P

Mechanical arameter
Parameters
arameters
Specified Parameter
Parameter 15 A 25 A 50 A
(Current as Peak Value of Sine Curve in Amperes)
Output Current, Peak Value @ 60°C 15 A 25 A 50 A
Output Current, Continuous Value @ 50°C 5A 5A 20 A
Output Current, RMS Continuous Value @ 60°C 3.5 A 7A 14 A
Max. Power Output, Continuous Value @ 340 VDC/40°C 1.3 kW 2.6 kW 5.3 kW
Power Losses at Stand-by @ 50°C 15 W 15 W 15 W

at Continuous Current (5 A) 35 W 35 W 40 W
at Peak Current 110 W 130 W 265 W
(Cont. next page)

7
Specified Parameter
Parameter Value
Efficiency at Continuous Current 95 %
Speed Control Accuracy <1%
Current Open Loop Bandwidth 2 kHz
Speed Loop Bandwidth Depending on Motor/spindle choices
Output Stage Switch Frequency 9 kHz
Operating Temperature and Humidity 0°C to +60°C, 95% RH
Storage Temperature and Humidity -20°C to +80°C, 95% RH
Input Voltage QCM 3-phase 240 VAC, —20% to +10%.

QCS 340 VDC Filtered, —20% to +10%.
Overvoltage Turn-off Level, DC-bus 400 - 425 VDC
Shunt Regulation ON, DC-bus 375 - 400 VDC
Width QCM 15/25 Amps: 76 mm; 50 Amps: 160 mm

QCS 15/25 Amps: 46 mm; 50 Amps: 122 mm
Height (Check with drawing in section 9) 240 mm
Length 227 mm
Weight QCM 15/25 Amps: 3.8 Kg; 50 Amps: 6.8 Kg

QCS 15/25 Amps: 2.7 Kg; 50 Amps: 5.1 Kg
Protective Class IP 20
NEMA 1

8
3.2 Main Ser

Servvo Drive Functions
3.2.1 Control Functions

Control
The servo drive unit is designed to control the nutrunner motor to
tighten a screw to a preprogrammed torque level or to an angle value
with preprogrammed constant speed despite the torque variations at
the joint. The QCM-T/QCS-T version uses signal from nutrunner
torque transducer for feedback control. Please turn to section 4.3 for
more information about the torque transducer. For the QCM/QCS
version the internal programmable control computer calculates actual
torque level from the current used by the nutrunner motor.
When used in angle control mode, the servo drive behaves as a posi-
tioning servo and uses a deceleration ramp (equal to the start ramp)
to ensure high accuracy when the angle value is reached. On the
other hand, when the servo drive performs a torque step, it stops the
nutrunner motor immediately once the torque/current value is
reached.
A built-in servo amplifier distributes electrical power from the mains to
the nutrunner motor. Information on the motor shaft’s position and
speed is returned to the servo amplifier.
The internal programmable computer controls the nutrunner motor
according to preprogrammed limit values for torque, angle, speed,
rotating direction, wait states, and overriding stop (time-out). Cycle
start, emergency stop, program mode selection etc. are controlled by
input signals. Output signals are available for cycle status information,
error reports, etc. You can program the internal computer from a PC
connected to the front panel.
The servo amplifier has separate torque and speed control loops. The
regulators are of PID (Proportional/Integrating/Derivating) type.
The output stage feeds the motor coils with 3-phase voltage, working
like a step-down voltage regulator. A switch signal (9 kHz) is used for
puls width modulation of the motor current. The momentary current is
supplied to the motor coils in the right amount to achieve the speed
and torque required. The currents in the coils are continuous sine
wave with variable frequency and amplitude, while the power supply
current is 9 kHz square-wave with variable pulse width.
The nutrunner uses a resolver as a feedback element to the servo
drive unit. The servo drive supplies the resolver with 5 – 10 Volts AC, 1
kHz. The returning resolver output signals are converted to digital by
the CPU. Please turn to section 4.2 for more information about the
resolver function!

9
3.2.2 Protective Functions

Protective
Following protective functions assure a long operating life for the
servo drive unit and the nutrunner.
• Pr otective Ramp
Protective
The servo drive starts the nutrunner motor softly with a constant
acceleration – called a protective ramp – in order to secure the
mechanical components during the tightening process. You can
program the time to reach the final motor speed – the ramp time –
from the terminal. The programmable range is 0 – 10,000 msec.
Normal ramp time is in the range 0.3 to 1 second for applications
where a high tightening speed is used.
• To rrque
que Reference
Reference
The servo drive limits the torque produced by the motor to the
value programmed as the final torque in torque control mode or to
the value programmed as the max. torque value in angle control
mode. It has priority over the programmed motor speed value. The
servo drive will not exceed the motor current representing the
programmed torque limit.
• Iner tia Brake
Inertia
A motor brake function in the servo drive limits torque overshoot.
At stop command the servo drive reverses the current until the
motor speed is zero.
• Over
Overv volta
oltagge
The internal DC-bus (340 VDC) in the QCM-T and QCM is moni-
tored for overvoltage by two different built-in protective systems.
The first system is designed to reduce the voltage increase caused
by regenerated energy from a nutrunner motor (bleeder function).
When a motor is turned by an external force, it acts as a generator
and feeds voltage back into the servo drive and the DC-bus. If the
voltage exceeds 375 - 400 VDC, a ballast power resistor is con-
nected to the DC-bus to dissipate the regenerated energy.
The second protective system monitors the DC-bus voltage. If the
voltage exceeds 400 - 425 VDC, a shut-down signal activates an
internal relay. Free relay contacts are available at connector K14
K14,
opening at detected overvoltage. It can be used in conjunction with
the emergency stop relay to power down the entire system in appli-
cations with instable power supply.

10
3.3 Block Dia

Block gram
Diagram
QCM Master Drive

11
QCS Slave Drive

12
QCM-T Master Drive

13
QCS-T Slave Drive

14
3.4 Ser
Servvo Drive Modules
The basic servo drive unit is designed with card modules, packaged in
a mechanical housing to be mounted on a panel. We recommend the
servo drive to be repaired at the factory.
3.4.1 CPU Board

Board
The board contains a CPU (microprocessor), memory and support
chips to make a microcomputer. The control program and parameters
are stored in an EPROM chip. The module is connected to the I/O-
board and to the MPU-board with two board-mounted connectors.
3.4.2 EPROM and EEPR

EPROM OM
EEPROM
One EPROM-set containing two EPROM chips covers all servo/nut-
runner sizes. The upper EPROM holds the firmware, i.e., the software
needed to control the servo functions. The lower EPROM stores the
QCM-T/QCS-T and QCM/QCS application software. The tightening
parameter values and the nutrunner motor’s mechanical data are
downloaded and stored in an EEPROM via the serial communication
channel. See section 3.8.
3.4.3 Input/Output Board, I/O

Board,
The I/O board is mounted between the CPU board and the motor
power unit. The input and output signals are mainly used for con-
nection to external lamp panels and control switches. Two 16-pole
connectors – K7A and K7B – are mounted at the board edge. Eleven
digital inputs six digital outputs and two relay outputs are available.
See section 3.6, Input and Output Signals
Signals, for more information.
The board contains ten LED (Light Emitting Diode) indicators visible
on the servo drive’s front panel. Three LED indicators indicate that the
servo drive is working, three indicate tightening status and the remain-
ing four alarm you in case of an error. See section 3.5, Status Indi-
cator
catorss.
On the board you will also find the connector K6 for connecting the
resolver.

15
3.4.4 Motor Po wer Unit, MPU

Po
Twelve power MOSFET transistors with drive circuits are mounted on
the MPU board. An integrated cooler block is used for heat dissipa-
tion. Four connectors – K10
K10, K11
K11, K13
K13, and K14 (K20
K20
K20, K21
K21, K22
K22,
and K23 for 50A model) – are mounted on the board for connecting
the DC-bus and the motor. See section 5.2 for more details. Three
MPU models are available for adaption to the motor size and torque
needed. You can choose max 15, 25, or 50 amperes output current.
They are designed for the nutrunners QMR 42, QMR 55/QMR62, and
QMR 90 respectively.
3.4.5 Po wer Supply Unit, APU (QCM-T and QCM onl

Supply y)
only)
The servo drive units in a tightening system are powered from the 3-
phase mains. A transformer is used to supply the specified 3 x 240
VAC. There is an AC/DC converter in the QCM-T and QCM master
servo drives with the capability of supplying these units themselves
and further seven 15 A, or three 25 A, or one 50 A QCS-T or QCS
slave drive units. The converter’s output is 340 VDC. It is called the
DC-b
DC-bu u ss.
Six power rectifier diodes are mounted on the APU board and its
integrated cooler. A mains noise suppression filter and output filtering
capacitors are other components in the AC/DC converter.
The APU board also holds the components for overvoltage protection
of the DC-bus. It is monitored by two different built-in protective sys-
tems.
The first system is designed to reduce the voltage increase caused by
regenerated energy from a nutrunner motor (bleeder function).
The second protective system will shut down the DC-bus voltage, if it
exceeds the maximum limit value (400 – 425 V). Please turn to page
9 for more information.
A four-pole connector, K1
K1, at the board edge is designed for con-
nection of 3 × 240 VAC and protective ground. The rectified voltage,
340 VDC, is connected to the motor power unit via two stand-off metal
bushings.
From the connector K10 (K20K20 on QCM-T and QCM 50A) on this unit
the same voltage – the DC-bus – is distributed to the QCM-T and
QCS servo drive units. See section 5.2 for more details.

16
3.4.6 To rrque
que Transducer Board (QCM-T and QCS-T onl
Board y)
only)
The board contains a signal amplifier and a D/A converter for a strain
gauge transducer. Connection to the transducer with a 9-pole con-
nector, called K6D
K6D. The 16-pole connector on the board is presently
not used.
3.4.7 Mechanical Housing, MECM and MECS

Mechanical
The mechanical housing kit for the QCM-T and QCM servo drive units
is called MECM and for the QCS-T and QCS units it is called MECS.

17
3.5 Status Indicators

Indicators
There are ten LED (Light Emitting Diode) indicators on the front panel.
Three indicators are green, informing you with steady light that the
servo drive system is working. Three yellow LED indicators light
temporarily during the tightening operation. The remaining four indi-
cators are red and alarm you in case of an error. Please find below a
short description of each indicator.
Symbol Label Color Description
340 V Po wer On Green The logic power is available. Hardware

operated.
CPU CPU OK Green The CPU runs properly. Watch Dog

operated. This indicator does not show
other faults such as high temperature in
the motor or the servo drive unit.
Rdy
Rdy Controller OK
Controller Green Controller On/Reset is set to logic one
Controller
and no fault signals are set. Ready to
accept a start signal.
Controller ON
Controller Yellow The Controller ON input signal is active.
Star
Startt Yellow The Start input signal is active.
Running Yellow Motor current is on (a parameter set has

been started).
>T Motor/Servo Drive Red

Motor/Serv The thermoelectric sensor (two PTC
Temp. High Thermistors) in the motor indicates
exceeded limit for motor temperature
(125 Celsius) or the thermoelectric
sensor (a PTC Thermistor) in the servo
drive unit indicates exceeded limit for the
internal heat sink temperature. The
servo drive unit turns off the motor cur-
rent and will keep it off until a reset
signal is received.
cont.

18
Also indicates disconnected motor cable.

Momentarily set the digital input Con-
t rroller
oller On/Reset to logic zero to reset
the servo drive unit.
If the motor/resolver cab le has been
cable
disconnected, yyou ou m ust reset the
must
ser
serv v o drive with a power -off/po
wer-off/po
power wer
wer--
-off/power
on.
>U DC-bus F
DC-bus ault
Fault Red The voltage of the DC-bus is too high.
The servo drive unit turns off the motor
current and will remain off until reset.
Momentarily set the digital input
Contr oller On/Reset to logic zero to
Controller
reset the servo drive unit.
>I Overcurrent
Overcurrent Red A hardware control that turns off the
motor current if the DC-bus voltage falls
below the minimum limit or if the regula-
tor does not succeed to control the
current, e.g., at short circuit in the motor
or the cables. The motor current will
remain off until the servo drive unit is
reset. Momentarily set the digital input
Contr oller On/Reset to logic zero to
Controller
reset the servo drive unit.
Regulator Fault
Fault Red The difference between the torque
reference value and the actual value in
the current control loop has exceeded
40% of full scale for more than 10 ms. or
the difference between the speed
reference value and the actual value in
the speed control loop has exceeded
25% of full scale for more than 10 ms.
With QCM-T a combination of three or four indicators are used to indicate torque
transducer or torque measurement faults. See Trouble Shooting, section 9.1.1.

19
3.6 Input and Output Signals

The digital input and output signals are connected to the servo drive
unit at two 16-pole connectors, labeled K 7A and K 7B 7B, located at the
bottom of the servo drive unit and one connector K 14 K23 on the
14, (K23
50A model) located at the top.
Please note!
The output circuits for the signals described below consist of PNP
transistors sourcing current out from +24 VDC at logic one. At logical
zero the transistor is switched off and the output terminal is connected
to Digital 0 volt with a 6.8 kΩ internal pull-down resistor. Compare our
QMM/QMS servo drive series which uses NPN transistors in the
output signal circuits and the sink/source situation is reversed.
Following input and output signals are available:
• 11 Digital Input Signals
Max. voltage: 30 VDC
Logic one: > 13 VDC
Logic zero: < 2.0 VDC
Hysteresis: typ. 5 VDC
Resistance to GND: 6.8 kOhm
Filter delay: 0.7 msec.
• 6 Digital Output Signals (three of them with dual functions)
Max. voltage: 30 VDC
Logic one: max. 27 VDC, typ. 24 VDC
Logic zero: < 0.7 VDC.
Max output current: 100 mA.
Max voltage drop: 3 VDC
• 2 Output Relays
Max. voltage: 30 VDC.
Max current: 200 mA.
Input Circuit Output Circuit

+24 VDC
Signal IN 6.8 k 47 k PTC Signal OUT
6.8 k 10 k Load
33V 15V 0.1µ 33V
0 Volt GND

20
The numbers below refer to the pin numbers in the connectors K 7A, K 7B and
K14/K23. You will find a connector drawing in section 3.7.
K14/K23
Nº Signal name Description
K7A:1 Analog input, not used!
K7A:5 Digital 0 vvolt

olt GND. Return wire for digital signals. Internally
Internally
connected to protective gr
protective ound
ground
ound.
K7A:6 Contr oller ON

Controller Set the input to logic one (+24 V) to enable the
Digital Input servo drive to run a parameter set. When Contr ol-
Control-
ler ON is set to logic zero the panel alarm indica-
tors are cleared and the servo drive unit is reset
from any error condition except breakdown in the
resolver connection. In this case you must power
down the servo drive, correct the error and power
up again to reset the error signal.
Please note! The output signal Contr oller OK (see
Controller
below) must indicate the servo drive running prop-
erly (relay contacts closed at connector K7:35 –
K7B:36
K7B:36) at the time Contr oller On is set to logic
Controller
one. The internal computer reads the transition
from one logic level to the other!
K7A:7 Error
Erro Set the input to logic one (+24 V) to select the sec-
Digital Input ond function – Error Indication Bit – for the outputs
Nº K7B:29, K7B:30 and K7B:34. After a cycle
ended with NOK, the combination of the three Error
Indication Bits indicates the type of error. Please
see table at the end of this section!
Set the input to logic zero to select the first function
– Confirm2, Confirm1 and Running – for the out-
puts Nº K7B:29, K7B:30 and K7B:34.
K7A:8 Select4 Third bit (with weight 4) in the address word for se-
Digital Input lecting one program set out of maximum eight.
More information in section 6.4.

21
K7A:9 Star
Startt Set the input to logic one (+24 V) to start a tighten-
Digital Input ing cycle beginning with the step program selected
by the address on Select1/-2/-4 and ending with
the step program containing the control mode End End.
The input signal Contr oller ON has to be set to
Controller
logic one (green LED Rd Rdyy is lit), before the Star
Startt
signal is activated. See section 6.2.
K7A:10 Inhibit Logic one (+24 V) sets the servo drive in status
Digital Input OK. No other operations are involved. Use this
function to enable the spindle to selected work
pieces on a mixed products assembly line.
K7A:11 Mac hine Stop_N

Machine Logic zero will stop the tightening step in
Digital Input progress and put the servo drive in status NOK. No
other operations are involved. Note
Note: Not to be used
with emergency stop.
K7A:12 Cyc le Stop

Cycle Logic one (+24 V) will stop the tightening step in
Digital Input progress and put the servo drive in status OK, if the
control mode for the step is of type End
End. If the con-
trol mode for the step is of type Con (for continue),
the next step program will be started. No other op-
erations are involved. Designed with for instance
positioning tasks in mind. A limit switch can be
used for the Cyc le Stop input.
Cycle
K7A:13 Step Sync. IN Logic one (+24 V) will inhibit a start of a tightening
Digital Input cycle. Set the input to logic zero to enable start.
Use the input in conjunction with the Step Sync.
OUT output signal from the same servo drive or a
combination of several drives. See K7B:31!
K7A:14 Step Mode Set the input to logic zero to have a complete cycle
Digital Input ( with several steps) run for each start signal (nor-
mal mode). If you want the servo drive to run only
one step at a time for each start signal, set this in-
put to logic one (+24 V). Mainly used in test and
start-up situations.
K7A:15 Select2 Second bit (with weight 2) in the address word for
Digital Input selecting one program set out of maximum eight.
More information in section 6.4.

22
K7A:16 Select1 First bit (with weight 1) in the address word for se-
Digital Input lecting one program set out of maximum eight. See
section 6.4.
K7B:21 Analog 0 Volt Return wire for analog signals.
K7B:22 Speed Analog output signal used for test and special cus-
tomer use.
K7B:23 Current Analog output signal used for test and special cus-
tomer use.
K7B:24 0 Volt Power supply common.
K7B:25 + 24 VDC External power supply input for driving the digital
Input PNP output loads. Voltage range 15 ... 30 VDC.
(Max 6 × 100 mA).
Connect the external power supply with plus to
K7B:25 and minus to K7A:5.
K7B:26 + 24 VDC Power supply output; max. 50 mA. Use with care;
not short circuit protected!
K7B:27 + 15 VDC Power supply output; max. 25 mA. Use with care;
K7B:28 – 15 VDC Power supply output; max. 25 mA. Use with care;
K7B:29 Confirm2/ The output has two logic functions. Select desired
Error Bit 2
Error function with the input signal Err
Erroo rr, K7A:7. Set the
Digital Output input to logic zero to select Confirm2
Confirm2, or to logic
one (+24 V) to select the logic function Err or Bit 2
Error 2.
Confirm2 mirrors the state of the input signal Se-
lect2 – see K7A:15 – before a tightening sequence
is started. The current status is locked at cycle
start and hold during the cycle. At the cycle end
(OK or NOK reported) the hold function is released.
With the logic function Err or Bit 2 selected this out-
Error
put together with K7B:30 and K7B:34 produce a 3-
bit error code indicating the type of error that
caused the reporting of Cyc le NOK
Cycle NOK. See table at
the end of this section.

23
K7B:30 Confirm1/ The output has two logic functions. Select desired
or Bit 1
Error
Err function with the input signal Err
Erroo rr, K7A:7. Set the
Digital Output input to logic zero to select Confirm1
Confirm1, or to logic
Error 1.
Confirm1 mirrors the state of the input signal Se-
lect1 – see K7A:16 – before a tightening sequence
is started. The current status is locked at cycle
start and hold during the cycle. At the cycle end
(OK or NOK reported) the hold function is released.
Error
caused the reporting of Cyc le NOK
Cycle NOK. See table at
K7B:31 Step Sync. OUT The output is logic one during a tightening step. At
Digital Output the step end the output switches to logic zero state.
You can parallel outputs from several servo drives
(wired OR function) and connect to all inputs Step
Sync. IN to synchronize the start of next step in a
multiple nutrunner application.
K7B:32 Cyc le OK
Cycle The output is logic zero during a tightening cycle.
Digital Output If the cycle ends with all resulting tightening param-
eters within the programmed limits, the output will
switch to logic one state (+24 V). The same logic
function is available as a relay output with free con-
tacts. See K14:1 – K14:2 below.
K7B:33 Cyc le NOK

Cycle The output is logic zero during a tightening cycle.
Digital Output If the cycle ends with any resulting tightening pa-
rameters outside the programmed limits, the output
will switch to logic one state (+24 V).
K7B:34 Running/ The output has two logic functions. Select desired
Error Bit 3
Error function with the input signal Erro rr, K7A:7. Set the
Erro
Digital Output input to logic zero to select Running
Running, or to logic
Error 3.
With the logic function Running active the output is
set to logic one, when a tightening cycle is started.
The output switches back to logic zero, when the
cycle is finished.

24

Error
caused the reporting of Cyc
Cyclele NOK
NOK. See table at
The Err or Bit 3 is set at cycle end (NOK reported)
Error
and reset to logic zero when Contr oller ON
Controller
switches from logic zero to logic one.
K7B:35 Controller OK
Controller When the servo drive runs properly the relay con-
K7B:36 Relay Output tacts are closed. At an error condition the relay is
deenergized and the contacts will open. Possible
errors are: Internal power supply not OK, CPU er-
ror, motor current or temperature limit exceeded,
DC-bus fault, servo drive or regulator fault.
K14:1 Contr oller OK/

Controller The output relay has three logic functions. You
K14:2 Cyc
Cyclele OK/Over
OK/Over-- make the selection of desired function in the same
volta g e Shut-off
oltag program that holds the tightening parameters.
Relay Output See section 6.3.6 for detailed information.
K23:1 (in QCM-T and With the logic function Contr oller OK selected, you
Controller
K23:2 QCS-T, 50 A and get the same function as with relay K7B:35-36.
in QCM and QCS, Possible use in some PLC communication applica
50A.) tions.
With the logic function Cyc le OK selected, the re-
Cycle
lay contacts are open during a tightening cycle. If
the cycle ends with all resulting tightening param-
eters within the programmed limits, the relay con-
tacts will close. The same logic function is available
as a transistor output. See K7B:32 above.
With the logic function Over
Overv volta
oltagg e Shut-off se-
lected, the relay contacts are closed during normal
conditions. At detected overvoltage the relay con-
tacts will open. See section 3.2.2

25
3.6.1 Error Codes Output at NOK
Error Codes as defined by the outputs K7B:29, K7B:30 and

K7B:34 with input signal Error (K7A:7) in logic one state.
K7B:30 K7B:29 K7B:34

Error Bit 1
Error Error Bit 2
Error Error Bit 3
Error Type of error at NOK
error
Max torque limit reached

1 0 0
in an angle controlled step.
Max angle limit reached

0 1 0
in a torque controlled step.
Min angle limit not reached

1 1 0
in a torque controlled step.
Max time limit reached

0 0 1
in any controlled step.
Tightening cycle stopped

1 0 1
by mac hine stop_N signal.
machine
No error detected,
0 0 0
Cycle OK in logic one state.
Cycle
Min torque limit not reached

0 1 1
in an angle controlled step.
Torque transducer error.

1 1 1
Calibration fault or zero off-
set fault or overflow fault.

26
3.6.2 Selected Program Set Number

Program
K7A:8 K7A:15 K7A:16 Program Set

Select 4 Select 2 Select 1 Number
0 0 0 0
0 0 1 1
0 1 0 2
0 1 1 3
1 0 0 4
1 0 1 5
1 1 0 6
1 1 1 7
3.6.3 Confirmation of Selected Program Set Number
K7B:29 K7B:30 Program Set

Confirm2 Confirm1 Number
0 0 0
0 1 1
1 0 2
1 1 3
Please note! Program Set Numbers 4 - 7 are not confirmed.

27
3.7 Po wer Supply and Contr

Supply ol Signal Connector
Control s
Connectors
3.7.1 Connectors f or 15 and 25 Amps Ser

Connectors Servv o Drives, models
QCM and QCS
Bottom view Top view Bottom view Top view
QCM Master Drive QCS Slave Drive
K1 Power Supply 3 x 240 VAC (QCM only). See section 5.2

K6 Resolver. See section 4.2
K7A Digital Input Signals. See section 3.6
K7B Digital Output Signals. See section 3.6
K10 DC-bus 340 VDC. See section 5.2
K11 Nutrunner Motor. See section 4.1.1
K13 External Bleeder, (not applicable). See section 3.2.2
K14 Overvoltage Shut-off Relay. See section 3.2.2

28
3.7.2 Connectors f or 15 and 25 Amps Ser

Connectors Servv o Drives, models
QCM-T and QCS-T
Bottom view Top view Bottom view Top view
QCM-T Master Drive QCS-T Slave Drive

K6D Torque Transducer See section 4.3
K7D Not Used

29
Front P
Front anel Mounted Connector
Panel Connectorss ffor
or 15 and 25 Amps Ser
Servvo
Drives, models QCM-T
QCM-T,, QCM, QCS-T
QCS-T,, and QCS
ASSEMBLY SYSTEMS ASSEMBLY SYSTEMS
QCM-T 340 15 QCS-T 340 15

4240 0336 80 4240 0339 80
340 V 340 V
CPU CPU
Rdy Rdy
>T >T
>U >U
> I > I
15 15
10 10
5 5
K5 K4 K5 K4
1 1
6 6
11 11
QCM-T and QCM QCS-T and QCS

Master Drive Units Slave Drive Units
K4 Serial Communication, Input See section 3.8

K5 Serial Communication, Output See section 3.8

30
3.7.3 Connectors f or 50 Amps Ser

Connectors Servvo Drives, models
QCM and QCS
Bottom view Top view
QCM 50 Master Drive

See next page for QMS 50 Slave Drive

31
QCS 50 Slave Drive


32
3.7.4 Connectors f or 50 Amps Ser

Connectors Servvo Drives, models
QCM-T and QCS-T
QCM-T 50 Master Drive

K7D Not Used
See next page for QMS 50 Slave Drive

33
QCS-T 50 Slave Drive

K7D Not Used

34
Front P
Front anel Mounted Connector
Panel s, 50 Amps Ser
Connectors, Servvo Drives,
models QCM-T
QCM-T,, QCM, QCS-T
QCS-T,, and QCS
ASSEMBLY SYSTEMS ASSEMBLY SYSTEMS
QCM-T 340 50 QCS-T 340 50

4240 0338 80 4240 0341 80
340 V 340 V
CPU CPU
Rdy Rdy
>T >T
>U >U
> I > I
15 15
10 10
5 5
K5 K4 K5 K4
1 1
6 6
11 11
QCM-T and QCM QCS-T and QCS

Master Drive Units Slave Drive Units
K4 Serial Communication, Input See section 3.8

K5 Serial Communication, Output See section 3.8

35
3.7.5 Connector Specifications
Nº Cable Connector
Cable Ser
Servvo Drive Connector
K1 Phoenix Combicon GMSTB 2,5/4-ST-7,62 Phoenix Combicon GMSTBA 2,5/4-G-7,62
K4 D-SUB High-Density D-SUB High-Density

15-pole pin (male) 15-pole socket (female)
K5 D-SUB High-Density D-SUB High-Density

15-pole pin (male) 15-pole socket (female)
K6 D-SUB Standard 15-pole pin (male) D-SUB Standard 15-pole socket (female)
K6D D-SUB Standard 9-pole pin (male) D-SUB Standard 9-pole socket (female)
K7A Phoenix Mini Combicon MC 1,5/16-ST-3,81 Phoenix Mini Combicon MC 1,5/16-G-3,81
K7B Phoenix Mini Combicon MC 1,5/16-ST-3,81 Phoenix Mini Combicon MC 1,5/16-G-3,81
K7D Phoenix Mini Combicon MC 1,5/16-ST-3,81 Phoenix Mini Combicon MC 1,5/16-G-3,81
K10 Phoenix Power Combicon PC4/3-ST-7,62 Phoenix Power Combicon PC4/3-G-7,62
K13 Phoenix IC 2,5/3-ST-5,08 Phoenix IC 2,5/3-G-5,08
K14 Phoenix MSTBA 2,5/5-ST-5,08 Phoenix MSTBA 2,5/5-G-5,08
K22 Phoenix IC 2,5/3-ST-5,08 Phoenix IC 2,5/3-G-5,08
K23 Phoenix MSTBA 2,5/5-ST-5,08 Phoenix MSTBA 2,5/5-G-5,08
Please see previous pages – sections 3.7.2 and 3.7.4 – for connector
locations. The connectors K10 - K14 are specific for 15 and 25 A
versions of QCM-T/QCS-T and QCM/QCS; K20 - K23 for 50 A version
of QCM-T/QCS-T and QCM/QCS.

36
3.8 Communication with the Ser

Communication Servvo Drive
The servo drive unit includes facilities for communication with an
external computer. You have to download the tightening control pro-
gram and the parameters for the nutrunner and the torque transducer
to each servo drive from an external computer, i.e., a PC compatible.
Connect the computer to the servo drive with a cable for serial com-
munication.
Two electrical interfaces are available. If the total length of the serial
cable is less than 15 meters, you can use an ordinary RS 232 inter-
face. When you have to program from a remote location or high elec-
trical noise immunity is requested, you can choose the RS 422/485
interface. Normally you must in this case also install an interface card
RS 422/485 in the computer.
The two connectors for serial communication – K4 and K5 – are
placed at the lower edge of the front panel. Each connector supports
the signals required for both RS 232 and RS 422/485. The connector
to the right K4 – with the arrow pointing in – is intended for the incom-
ing data from the computer. The connector to the left K5 – with the
arrow pointing out – is an output connector used for cascading the
serial link to the next servo drive unit in the system.
Serial link cascade connection to four servo

drive units from a host computer.
You can cascade up to 30 servo drive units on two separate serial

links (15 per link) and assign them individual addresses in the range
1-15 and 16-30. By using the addresses you can open the communi-
cation with any of the connected servo drives from a remote terminal
or portable PC and download the specific tightening control program.

37
You must use the RS 422/485 interface for cascade link communica-
tion. See section 6 for more information about programming.
The connectors K4 and K5 are 15-pole D-SUB High Density socket
(female) type. The interconnection cables connecting the servo drive
units shall have the corresponding pin (male) type connector in both
ends. Use metal or metallized plastic housing. Check your compu-
ter's communication port for selecting the correct type of connector for
the cable to the first servo drive unit. Normally it is a 9-pole or 25-pole
D-SUB standard pin (male) type requiring a corresponding socket
(female) connector for the cable.
Servo drive mounted female

connectors K4 and K5K5.
Please select the type of inter-
face you want to use – RS 232
or RS 422/485 – and make the
appropriate interconnection
cables as shown below.
3.8.1 Communication Cab

Communication les Specifications
Cables
Cable for RS 232 interface connection to computer (A)

K4 Computer COM-
1 port, 9-pole
2 RX RX 2
3 TX TX 3
7 GND GND 5

38
Cable for RS 232 interface connection to computer (B)

K4 Computer COM-
1 port, 25-pole
2 RX TX 2
3 TX RX 3
7 GND GND 7
Cable for RS 422/485 interface connection to computer

K4 Computer with
1 RS 422 adapter
7 GND GND
9 RX – TX –
10 RX + TX +
11 TX + RX +
12 TX – RX –
Cable for RS 422/485 interface cascade interconnection

K4 K5
1 1
7 GND GND 7
9 RX – TX + 9
10 RX + TX – 10
11 TX + RX + 11
12 TX – RX – 12

39
3.8.2 Signal Designation for Communication Connectors
1. Connector K4
Socket Nº Signal Function Type of Interface

1 Shield (Screen)
2 RX Received Signal RS-232
3 TX Transmitted Signal RS-232
4 Not used
5 Not used
6 Not used
7 Signal Common, 0 Volt
8 + 15 VDC (not used)
9 RX – Received Signal, inverted RS-422/485
10 RX + Received Signal RS-422/485
11 TX + Transmitted Signal RS-422/485
12 TX – Transmitted Signal, inverted RS-422/485
13 Not used
14 Not used
15 – 15 VDC (not used)
2. Connector K5
Socket Nº Signal Function Type of Interface

1 Shield (Screen)
2 RX Received Signal RS-232
3 TX Transmitted Signal RS-232
4 Not used
5 Not used
6 Not used
8 + 15 VDC (not used)
9 TX + Transmitted Signal RS-422/485
10 TX – Transmitted Signal, inverted RS-422/485
11 RX + Received Signal RS-422/485
12 RX – Received Signal, inverted RS-422/485
13 Not used
14 Not used
15 – 15 VDC (not used)

40
4. Nutrunner
The QMR is a powerful, robust nutrunner covering all applications up

to 1,000 Nm in four sizes. It consists of the following main parts:
• A brushless electric motor that offers high power-to-density ratio

and requires little maintenance.
• A resolver that provides speed control even at low speed and
enables torque to be maintained at zero speed.
• Two thermoelectric sensors in the motor armature windings for
continuous monitoring of the temperature to avoid motor burn-
out.
• Transducer section containing a torque transducer and/or angle
encoder (optional).
• Planetary gear for a wide range of torque applications.
• A base plate located inside the bearing housing, simplifying
maintenance of the entire section.
• Connector located at the top of the nutrunner.
The nutrunner has a 20-pole connector at the top end for connecting
the motor, the resolver and the thermoelectric sensors to the servo
drive unit. The same connector is used on all nutrunner models, but
the connection pins for the thermoelectric sensors differ. This arrange-
ment will help connecting the cables safely to nutrunners with different
sizes in a multiple.
Two cables have to be connected to the same connector, the motor
cable with 4 conductors and a screen and the resolver cable with 8
conductors and a screen. The screens should be connected at the
ser
servvo drive unit
unit. The two cable screens must not be in contact with
each other in the motor connector. The motor cable screen should
also be connected at the motor end to the PE pin in the connector.
Caution: Make sure to connect matc hing motor and resolver to
matching
the same ser v
serv o drive!

41
4.1 Nutrunner Motor

The servo drive unit controls a permanent magnet, 3-phase, synchro-
nous motor using a resolver as feedback device. It is an inside-out
version of the permanent magnet DC motor. Due to their location
near the outer surface of the housing, the armature windings are
cooled more effectively, making high power output possible.
A thermoelectric sensor is located in the armature windings to protect

the motor from overheating. The sensor consists of two 100 ohms
PTC thermistors connected in series. Each motor size has a unique
pin output for the sensor in the 20-pole connector. See sections 3.7
and 5.6.
Three motor sizes with different current capability are used for the four
nutrunner sizes. The table below shows the most important data for
the motors at print time:
Data for Electric Motors Used in QMR Nutrunners
Atlas Copco Par

artt Nº
Par 4230 1704 81 4230 1705 80 4230 1706 80
Manufacturer Type Nº BSM 2260C R4.1 BSM 28120 R2 BSM 43165 R2
Diameter [mm] 42 55 80
Weight [Kg] 2 3.5 7
Nominal Max. Speed [rpm] 7,000 6,400 5,000
Nominal Max. Torque [Nm] 2.0 7.0 22.0
Max. Current [A peak] 15 25 50
Resistance [Ω] 9 3.9 2
Corresponding Nutrunner QMR 42 QMR 55/62 QMR 90
Protection IP 54 IP 54 IP 54
Nominal Voltage [V] 340 340 340

42
4.1.1 Nutrunner Motor Connection

The servo drive unit’s output for the 3-phase motor is connected to the
20-pole connector at the top end of the nutrunner. Please note that
the resolver cable is connected to the same connector.
The 15 and 25 Amps servo drive unit’s connector – K11 – is a 5-pole
plug-in screw terminal (see table in section 3.7.3).
The 50 Amps servo drive unit’s connector – K21 – is a 9-pole plug-in
screw terminal (see table in section 3.7.3).
The motor’s cable connector is a 20-pole socket plug with crimp termi-
nals (Burndy Electra UTG62020SN). See sections 5.6 for cabling
details and section 3.7 for servo unit connector locations.
The motor connection to the servo drive unit is shown below:
K11 K21 Description Motor Connector
1 1 Not Used —
2 2–3 Cable Screen (Chassie)
3 4–5 Phase U 3
4 6–7 Phase V 2
5 8–9 Phase W 1
Ground Bar Protective ground (Chassie)
4.2 Resolver
The nutrunner uses a resolver as a feedback element to the servo
drive unit. The resolver is built like a generator with coils in both the
stator and the rotor. It works like a variable transformer with one
primary and two secondary windings.
The primary winding is fed by a 1 kHz constant voltage from the servo
drive unit. The two secondary windings output voltages with an ampli-
tude depending on the resolver shaft angle. The voltage amplitudes
represent the sine and cosine functions of the shaft angle. The out-
puts are returned to the servo drive unit and converted to digital posi-
tion and speed information.

43
The resolver is mounted in the nutrunner and makes possible the

electronic commutation of the motor.
The servo drive unit controls the currents in the motor armature coils
so that the electromagnetic field from the stator always is 90 degrees
ahead of the permanent magnetic field of the rotor. The servo drive’s
amplifier stage needs continuous information of the motor’s rotor
position. The resolver’s output signal supplies that information.
The signal is also used for speed information (emulating a tacho
generator) and as a position feedback element (emulating an angle
encoder). These qualities enables the system to maintain torque at
zero speed.
The resolver must have a predefined angle position relative to the
permanent magnets on the rotor. The synchronization of the resolver
is made at the motor factory.
4.2.1 Resolver Connection

The resolver and the thermoelectric sensor are connected to the
servo drive unit with a 15-pole D-Sub pin (male) connector K6 at the
bottom of the servo drive. The cable’s other end is connected to the
same 20-pole connector at the top of the nutrunner as the motor cable
(section 4.1.1).
Following signals are used:
K6 Signal name Description

1. Shield Cable screen. Connected to signal
ground inside the servo drive unit.
Do not connect at the motor end end!
2. Sine – 10 volts maximum peak value, 1 kHz.
3. Sine + 10 volts maximum peak value, 1 kHz.
4. Cosine + 10 volts maximum peak value, 1 kHz.
5. Cosine – 10 volts maximum peak value, 1 kHz.
7. Signal Common Return wire for signals Nº 2 - 9.
9. Excitation 5 – 10 volts peak value, 1 kHz.
14. +15 V Supplies the thermoelectric sensor in
the nutrunner motor.
15. Thermistor input Signal wire for the thermoelectric
sensor.
See section 3.7 for connector details and section 5.6 for cabling de-
tails (screening, pair twinning, grounding etc.).

44
4.3 To rrque
que Transducer (for QCM-T/QCS-T onl
(for y)
only)
The nutrunner torque transducer for feedback signal to the servo drive
is of strain gauge type. It measures the reaction torque in the nut-
runner during the tightening cycle. The reaction torque is equal to the
applied torque on the bolthead/nut. The transducer is mounted inside
a replaceable section of the nutrunner. Excitation level is 10 VDC. The
output signal is 8 mV at nominal load in footpounds and 5.9 mV at
nominal load in Nm.
4.3.1 To rrque
que Transducer Connection
The torque transducer is connected to the servo drive unit with a 9-
pole D-Sub pin (male) connector – K6D – at the bottom of the servo
drive. The cable is connected at the motor end with an 8-pole socket
plug with crimp terminals (Burndy Electra UTG 6128 SN. Please see
connector specification in our nutrunner ASL 14/36-30).
Following signals are used:
N° Signal name Description

1. Shield Cable screen. Connected to signal
ground inside the servo drive unit.
4. Signal +
Output signal 5.9 mV @ nom. load [Nm]
5. Signal –
7. Excitation + + 5 VDC.
9. Excitation – - 5 VDC.
See section 3.7 for connector details and section 5.6 for cabling de-
tails (screening, pair twinning, grounding etc).
4.4 Gear
The QMR nutrunner includes a planetary gear to transform the output
from the electric motor to lower speed and higher torque. Each of the
four nutrunner sizes comes with different gear ratios. You can convert
a nutrunner to an other model by changing the gear unit.
The same gear units are used for straight and offset nutrunner mod-
els.
You must know what gear unit the nutrunner uses, when you make a
control program for the QCM-T/QCS-T or the QCM/QCS servo drive.

45
It is important that you also change the program for a nutrunner if you
change to a gear unit with a different gear ratio. See section 6.3.5,
Nutrunner Gear Ratio, GearGear, for information regarding the program-
ming terms. The section also contains a table with all available stand-
ard gear units listed.

46
5. System Design
An electrically powered QCM-T/QCS-T or QCM/QCS assembly sys-

tem for tightening screws comprises the following main components:
• A number of nutrunners containing the motor, resolver, torque
transducer (for QCM-T/QCS-T only), mechanical gear, etc.
• One QCM-T/QCS-T or QCM/QCS servo drive for each nutrunner
controlling the tightening parameters (torque, angle, speed, etc.).
• A 3-phase mains transformer to supply power to the servo drive
units and the electric motors in the nutrunners.
• A master PLC (Programmable Logic Controller), if required.
• A standard PC or LCD terminal for modifying the parameters.
• Various system components.
5.1 Configuration of a Servo Drive System

Serv
You can configure the servo drive system to fit the tightening system’s
requirements. Each nutrunner will use one servo drive unit. The servo
drive’s size depends on the nutrunner motor capacity. Presently three
servo drive sizes are available, 15, 25, and 50-amperes respectively.
The master servo drive of each size – QCM-T or QCM – contains an
AC/DC converter to convert 240 VAC to 340 VDC for the DC-bus.
One QCM-T or QCM master servo drive can supply seven 15 A, or
three 25 A, or one 50 A QCS-T or QCS slave drive units.
The table below shows what servo drive unit to use for a selected
nutrunner. You will find configuration examples on the next page.
Nutrunner Master Ser

Servvo Drive Slave Ser
Slave Servvo Drive
QCM-T 340 15 4240 0336 80 QCS-T 340 15 4240 0339 80

QMR 42
QCM 340 15 4240 0326 80 QCS 340 15 4240 0329 80
QCM-T 340 25 4240 0337 80 QCS-T 340 25 4240 0340 80

QMR 55
QCM 340 25 4240 0327 80 QCS 340 25 4240 0330 80
QCM-T 340 25 4240 0337 80 QCS-T 340 25 4240 0340 80

QMR 62
QCM 340 25 4240 0327 80 QCS 340 25 4240 0330 80
QCM-T 340 50 4240 0338 80 QCS-T 340 50 4240 0341 80

QMR 90
QCM 340 50 4240 0328 80 QCS 340 50 4240 0331 80

47
Configuration Examples
A system shown with one sin-

340 15 (15 A)
340 15 (15 A)
340 15 (15 A)
340 15 (15 A)
340 15 (15 A)
QCM-T / QCM
QCM-T / QCM
QCS-T / QCS
QCS-T / QCS
QCS-T / QCS
gle servo drive unit and one
with four units of the 15-am-
peres size. One QCM unit sup-
plies 3 QCS units.
The system contains eight 15-

340 15 (15 A)
340 15 (15 A)
340 15 (15 A)
340 15 (15 A)
340 15 (15 A)
340 15 (15 A)
340 15 (15 A)
340 15 (15 A)
QCM-T / QCM
QCS-T / QCS
QCS-T / QCS
QCS-T / QCS
QCS-T / QCS
QCS-T / QCS
QCS-T / QCS
QCS-T / QCS
amperes servo drive units. One
single QCM supplies 7 QCS
units, which is the maximum
capacity.
One system is shown with one

340 25 (25 A)
340 25 (25 A)
340 25 (25 A)
340 25 (25 A)
340 50 (25 A)
QCM-T / QCM
QCM-T / QCM
QCS-T / QCS
QCS-T / QCS
QCS-T / QCS
single servo drive unit and a

second with four units of the 25-
amperes size. One QCM unit
supplies 3 QCS units, which for
this size is maximum.
340 25 (25 A)
340 25 (25 A)
340 25 (25 A)
340 25 (25 A)
340 25 (25 A)
340 25 (25 A)
340 25 (25 A)
340 25 (25 A)
QCM-T / QCM
QCM-T / QCM
This system contains eight 25-

QCS-T / QCS
QCS-T / QCS
QCS-T / QCS
QCS-T / QCS
QCS-T / QCS
QCS-T / QCS
amperes servo drive units. Two

QCM drives are needed to sup-
ply 6 QCS units. Each group
has an isolated DC-bus.
One single servo drive unit and

340 50 (50 A)
340 50 (50 A)
340 50 (50 A)
340 50 (50 A)
340 50 (50 A)
QCM-T / QCM
QCM-T / QCM
QCM-T / QCM
QCS-T / QCS
QCS-T / QCS
a system with four units of the

50-amperes size are shown.
Each QCM unit supplies only
one QCS unit.
340 50 (50 A)
340 50 (50 A)
340 50 (50 A)
340 50 (50 A)
340 50 (50 A)
340 50 (50 A)
340 50 (50 A)
340 50 (50 A)
This system contains eight 50-

QCM-T / QCM
QCM-T / QCM
QCM-T / QCM
QCM-T / QCM
QCS-T / QCS
QCS-T / QCS
QCS-T / QCS
QCS-T / QCS
amperes servo drive units.

Four servo drives need to be
QCM drives to supply the re-
maining four QCS units. Nor-
mally two mounting rows are
required in the cabinet.

48
5.2 Power Supply

Supply
The power supplies needed for the servo drive system is 3-phase AC
mains 3 x 240 VAC, 50 - 60 Hz and 24 VDC for the output signals.
The QCM-T/QCM servo drive’s built-in AC/DC converter powers the
servo drive system with 340 VDC (the DC-bus). Each servo drive
contains an internal DC/DC converter to step down the supply voltage
to +5 V, ±15 V, and +24 V for the logic circuits and the internal signals.
5.2.1 QCM-T and QCM

The QCM-T and QCM versions of the servo drive unit – with built-in
AC/DC converter – have the input power connection at the top end of
the drive. The four-pole connector K1 has the following connections:
Nº Description
1. Protective ground.
2. Phase R in 240 VAC, 50 - 60 Hz, 3-phase power supply
3. Phase S in 240 VAC, 50 - 60 Hz, 3-phase power supply.
4. Phase T in 240 VAC, 50 - 60 Hz, 3-phase power supply.
The DC-b
DC-bu u s output connector K10 / K20 (15, 25 A / 50 A) on the
QCM-T and QCM servo drives are placed close to the motor connec-
tor, K11 / K21
K21. (Connector positions in sections 3.7.1 and 3.7.2).
The 3-pole connector K10 (15, 25 A) has the following connections:
Nº Description
2. 340 VDC voltage output, DC-bus positive polarity.
3. 340 VDC voltage output, DC-bus negative polarity.
The 6-pole connector K20 (50 A) has the following connections:

Nº Description
See section 3.7 ffor

or connector specifications.

49
5.2.2 QCS-T and QCS

The QCS-T and QCS versions of the servo drive – the slave unit –
have the DC-bus input power connector K10 / K20 (15, 25 A / 50 A) at
the top end of the servo drive close to the motor connector K11 / K21
K21.
(Connector positions in sections 3.7.1 and 3.7.2).
The 3-pole connector K10 (15, 25 A) has the following connections:
Nº Description
2. 340 VDC voltage input, DC-bus positive polarity.
3. 340 VDC voltage input, DC-bus negative polarity.
The 6-pole connector K20 (50 A) has the following connections:

Nº Description
See section 3.7 ffor

or connector specifications.
5.3 Po wer Transformer Design

ransformer
Proper design of the power supply transformer will save money and
avoid application problems. The transformer output (3 x 240 VAC) is
full-wave rectified within the QCM-T and QCM servo drives to the 340
V DC-bus voltage. The servo drive’s output stage feeds the motor
coils with variable amplitude and variable frequency 3-phase voltage.
The output stage works like a step-down voltage regulator. By using a
9 kHz puls-width modulated signal, current from the DC-bus power
supply is fed to the motor coils in the right amount to achieve the nut-
runner speed and torque required. The current in the coils is continu-
ous sine wave with variable frequence and amplitude, while the supply
current from the DC-bus is 9 kHz square-wave with variable pulse
width.

50
The final steps in a tightening sequence requires the highest torque

while the nutrunner speed is low. It means that the maximum motor
current is supplied at a low motor speed, i.e., at a low motor back EMF.
The DC-bus power supply voltage still remains at 340 VDC. Due to the
conversion technique used, the DC-bus supply current is in the main
proportional to the motor speed in the first tightening steps with a low
specified output torque, and to the required nutrunner output torque in
the final steps at low nutrunner speed.
The specification for the servo/nutrunner combination includes an out-
put power limiting factor. When you run the motor at full speed, you
have to limit the output torque to 20 % of the maximum torque.
If you want to operate at full output torque, you have to limit the motor
speed to 20 % of maximum speed. The maximum DC-bus output cur-
rent will be about 25 % of the motor’s peak current .
Current/ The motor will quickly

Torque get hot when run with
low speed at high load.
100%
20%
Operating area
20% 100% Speed
Limiting the Nutrunner Output Power
In tightening applications the nutrunner duty cycle is less than 100 %.

When a tightening cycle has finished, the nutrunner motor current is
zero until the next tightening starts. During this time the transformer
supplies current only to the servo drive's internal circuits.
The servo drive system normally contains more than one nutrunner.
To select the proper transformer size you will have to add the power
requirement for each connected nutrunner.

51
The power requirements for the currently available nutrunner models

are shown in the table below. Add up the Transformer Power Design
Values for all nutrunners used in your system and select a corre-
sponding transformer size.
You can reduce the transformer size in applications where all spindles
are not run at the same time. The reduction factor must be calculated
carefully for each specific application.
You can select two or more smaller transformers in place of one big.
In this case you should distribute the servo drives/nutrunners among
the multiple transformers equally according to the power require-
ments.
5.3.1 Transformer P
ransformer o wer Requirement per Nutrunner
Po
Nutrunner Transformer Power Max. Output

Model Design Value [kVA] Current [A]
QMR 42 0.9 3 × 2.2
QMR 55 1.7 3 × 3.7
QMR 62 1.7 3 × 3.7
QMR 90 3.4 3 × 7.4
5.3.2 Additional Design Rules ffor

Additional or the Transformer
ransformer
Primary voltage 3 × RST mains ± 10 %
Secondary voltage 3 × 230 VAC at rated output power
and nominal primary voltage
Max. 3 × 240 VAC at no-load
condition and nominal primary
voltage
Duty Cycle 5%
(Normally the size is approx. 40 %
of a continuous duty transformer)
Extra primary windings taps Plus and minus 10 %

52
5.4 Cable Dimensions

Cable
The following cable dimensions should be used in the system:
5.4.1 Transformer — QCM-T and QCM drives

ransformer
4 × 2.5 mm2 (AWG 12, 18×25). Max length 25 m.
5.4.2 Master ser

servvo drives — Slave ser
Slave servvo drives (DC-bus)
(DC-bus)
Area 2.5 mm2 (AWG 12, 18×25). Max length 0.5 m.
5.4.3 Motor — Ser

Servvo Drive
QCM-T/QCS-T, 15 A and 25 A and QCM/QCS, 15 A and 25 A:
4 × 1.5 mm2 (AWG 14, 18×27) shielded. Max length 25 m.
QCM-T/QCS-T, 50 A and QCM/QCS, 50 A:
4 × 2.5 mm2 (AWG 12, 18×25) shielded. Max length 25 m.
5.4.4 Resolver — Ser

Servvo Drive
Area min. 0.33 mm2 (AWG 22, 7×30). Pair twisted (4 x 2 leads) and
shielded, max length 25 m.
5.4.5 To rrque
que Transducer — Ser
Servvo Drive (only QCM-T/QCS-T)
(only
Area min. 0.33 mm2 (AWG 22, 7×30). Pair twisted (2 x 2 leads) and
shielded, max length 25 m.
5.4.6 I/O Cables

Cables
Area min. 0.33 mm2 (AWG 22, 7×30). Max length 1.5 m. Install mini-
mum 0.2 m from power cables.
5.4.7 Serial Communication Cab

Communication le
Cable
Area min. 0.33 mm2 (AWG 22, 7×30), shielded 3-part (RS 232) or
5-part (RS 422) cable.
5.4.8 Protective Gr
Protective ounding
Grounding
Please check with our drawing Nº 9834 5177 00 – see section 10 – for
full information about the complex and important grounding system.

53
5.5 Emerg enc

Emerg y Stop Rela
ency y, Fuses, Filter
Relay Filter,, Fans
Fans
The remaining system components should be incorporated as normal.
The emergency stop relay shall disengage the three phases from the
transformer’s secondary side and the external 24 VDC power supply
connected to K7B:25 (for the output signals).
Install an over-voltage protection unit in case of unreliable mains

power supply.
We recommend you to install a mains filter for EMC suppression to

comply with European standards and FCC regulations.
Forced cooling with fans is not needed for the servo drives.

54
5.6 Ser
Servvo Drive Cabling Sc
Cabling hematics
Schematics
5.6.1 Cabling Sc
Cabling hematics QCM/QCS 34015 and 34025
Schematics
QMR 42 Connector
Continued

55
Cabling Sc
Cabling hematics QCM/QCS 34015 and 34025 (cont.)
Schematics
K10 K10
1 1 DC-bus. Internal Power Supply between
340 VDC, Positive
2
340 VDC, Negative
2 Master and Slave Servo Drives.
3 3 See Section 5.2
Ground Bar
K4
1 Screen
2 RX, Received Signal for RS 232
3 TX, Transmitted Signal for RS 232
4 Not used
5 Not used
6 Not used
K4: Communication signals for connection
8 Not used
9 RX -, Received Signal, inv., for RS 422/485
to an external computer for incoming
10 RX+, Received Signal, for RS 422/485 data or for connection to an another
11 TX+, Transmitted Signal, for RS 422/485 servo drive in a cascade connection.
12 TX -, Transmitted Signal, inv., for RS 422/485 See section 3.8 for more information.
13 Not used
14 Not used
15 Not used
K5
1 Screen
4 Not used
5 Not used
6 Not used
8 Not used
9 TX+, Transmitted Signal, for RS 422/485
10 TX -, Transmitted Signal, inv., for RS 422/485 to a servo drive in a cascade connection
11 RX+, Received Signal, for RS 422/485 to send data down-stream.
12 RX -, Received Signal, inv., for RS 422/485 See section 3.8 for more information.
13 Not used
14 Not used
15 Not used

56
5.6.2 Cabling Sc
Cabling hematics QCM-T/QCS-T 34015 and 34025
Schematics
QMR 42 Connector
Continued

57
Cabling Sc
Cabling hematics QCM-T/QCS-T 34015 and 34025 (cont.)
Schematics
K10 K10
1 1 DC-bus. Internal Power Supply between
340 VDC, Positive
2
340 VDC, Negative
2 Master and Slave Servo Drives.
3 3 See Section 5.2
Ground Bar
K4
1 Screen
4 Not used
5 Not used
6 Not used
8 Not used
10 RX+, Received Signal, for RS 422/485 data or for connection to an another
13 Not used
14 Not used
15 Not used
K5
1 Screen
4 Not used
5 Not used
6 Not used
8 Not used
10 TX -, Transmitted Signal, inv., for RS 422/485 to a servo drive in a cascade connection
13 Not used
14 Not used
15 Not used

58
5.6.3 Cabling Sc
Cabling hematics QCM/QCS 34050
Schematics
QMR 90 Connector
Continued

59
Cabling Sc
Cabling hematics QCM/QCS 34050 (cont.)
Schematics
K20 K20
1/2
340 VDC, Positive
1/2 DC-bus. Internal Power Supply between
3/4
340 VDC, Negative
3/4 Master and Slave Servo Drives.
5/6 5/6 See Section 5.2
Ground Bar
K4
1 Screen
4 Not used
5 Not used
6 Not used
7 Signal Common, 0 Volt K4: Communication signals for connection
8 Not used
10 RX+, Received Signal, for RS 422/485
data or for connection to an another
13 Not used
14 Not used
15 Not used
K5
1 Screen
4 Not used
5 Not used
6 Not used
8 Not used
10 TX -, Transmitted Signal, inv., for RS 422/485
to a servo drive in a cascade connection
13 Not used
14 Not used
15 Not used

60
5.6.4 Cabling Sc
Cabling hematics QCM-T/QCS-T 34050
Schematics
QMR 90 Connector
Continued

61
Cabling Sc
Cabling hematics QCM-T/QCS-T 34050 (cont.)
Schematics
K20 K20
1/2
340 VDC, Positive
1/2 DC-bus. Internal Power Supply between
3/4
340 VDC, Negative
3/4 Master and Slave Servo Drives.
5/6 5/6 See Section 5.2
Ground Bar
K4
1 Screen
4 Not used
5 Not used
6 Not used
7 Signal Common, 0 Volt K4: Communication signals for connection
8 Not used
10 RX+, Received Signal, for RS 422/485
data or for connection to an another
13 Not used
14 Not used
15 Not used
K5
1 Screen
4 Not used
5 Not used
6 Not used
8 Not used
10 TX -, Transmitted Signal, inv., for RS 422/485
to a servo drive in a cascade connection
13 Not used
14 Not used
15 Not used

62
6. Parameter Definitions
6.1 Overvie
Overvie w
view
The programming capacity for a QCM-T/QCS-T or a QCM/QCS servo
drive allows for storing of parameters for eight steps. Each step corre-
sponds to one operation in the tightening process, e.g., tightening to
preset angle, run-down, etc.
One or more steps constitute a set. You can use all the eight available
steps in one set or use eight sets with only one step in each. Any
combination between these two is allowed.
For each step you define whether the operation should be linked to a
new step in the same set or be the last step in the set, thus defining
the end of the current set.
A tightening step is defined by up to six parameters, for example
torque, angle, speed, time, etc. The parameter values are transmitted
from the programming PC (preferably a Laptop PC running our pro-
gramming software for Windows) to the servo drive units and stored in
the unit's internal memory. There are 48 registers reserved for this
purpose, denoted R150 to R197.
There are no places reserved for set numbers in the program. The
first step definition in registers R150 to R155 starts the set numbering
with Set 00. The second set, Set 1 1, is defined by the first step following
a step of type _End in Set 0
0, etc.
You select the appropriate set for a tightening operation with the input
signals Select4
Select4, Select2
Select2, and Select1 before activating the start
signal. See section 3.6 and 3.6.2 for more information.
You can use the output signals Confirm2 and Confirm1 to indicate
the current set number during a tightening cycle. However, since only
two signals are available, only the first four set numbers can be identi-
fied, Set 0 . . . Set 3
3. If you use more than four sets, the confirm sig-
nals are invalid.
The confirm signals mirror the select signals Select2 and Select1
before the start. During the tightening cycle the confirm signals are
locked to the state at the start time. See section 3.6 and 3.6.3 for
more information.

63
6.2 Tightening Step Parameter

Parameters
arameters
This is a description of the step parameters that are programmed in
the Tightening Steps menu in the programming software for Windows.
See Programming, section 7.
You define each of the available eight steps by entering six parameter
values. Each parameter consists of a numerical value, ranging from 0
to a five digit number.
Please obser
observe ve that yyou
ou m ust not enter vvalues
must alues outside the rang
rangee
defined abo
aboveve
ve.. There are no monitoring functions in the pr ogram
program
to create warning messa
messag g es!
6.2.1 Control Mode

Control
Eight control modes are available. They are programmed in the Tight-
ening Steps menu, see Programming, section 7.1.2.
Control modes of type Dela
Delayy End, To rrque
que End, Angle End, and Jog
End defines the step as the last step in a set, while corresponding
mode types without End make the set continue with a new step.
The control mode entered defines the action of the parameters follow-
ing the control mode value in the step definition. You will find the
specification of each control mode value below.
Control Mode: Delay End

Delay
Action: If the previous step was a Dyna-T ork step, keep the
Dyna-Tork
nutrunner motor current constant during the delay time
entered in the Dela
Delayy Time box and then stop the cycle.
If the previous step was NOT a Dyna Tork step, only
delay the cycle stop without any other action.
Control Mode: To rrque

que End
Action: Run with the speed value entered in the Speed box until
the torque value entered in the To rrque
que box is reached,
then stop the cycle and set OK if the minimum angle
entered in the Min Angle box was exceeded, else set
NOK
NOK.
Interrupt the cycle and set NOK
NOK, if the maximum angle
or maximum time entered in the Max Angle respectively
Max Time boxes was reached before targeted torque
value.

64
Control Mode: Angle End

the angle value entered in the Angle box is reached,
then stop the cycle and set OK
OK.
Interrupt the cycle and set NOK if the maximum torque
or maximum time entered in the Max To rrque
que respec-
tively Max Time boxes was reached before targeted
angle value.
Control Mode: Jog End

Action: Run with the speed value entered in the Speed box as
long as the Star
Startt input signal is logical one (K7A:9, see
section 3.6). Stop the cycle and set OK if the minimum
angle entered in the Min Angle box was reached before
the Star
Startt input signal was released.
Interrupt the operation and set NOK if any of maximum
torque, maximum angle or maximum time values en-
tered in the Max To rrque
que
que, Max Angle respectively Max
Time boxes was reached before the Star Startt input signal
was released
Control Mode: Delay

Delay
Action: If the previous step was a Dyna-T ork step, keep the
Dyna-Tork
nutrunner motor current constant during the Dela y Time
Delay
entered in the Dela y Time box and then continue with
Delay
the next step.
If the previous step was NOT a Dyna-T ork step, con-
Dyna-Tork
tinue with the next step after the delay time entered in
the Dela
Delayy Time box.

65
Control Mode: To rrque

que
que box is reached,
then continue with the next step if the minimum angle
entered in the Min Angle box was exceeded, else set
NOK
NOK.
Max Time boxes was reached before the targeted torque
value.
Control Mode: Angle

the angle value entered in the Angle box is reached,
then continue with the next step.
Interrupt the cycle and set NOK if the maximum torque
or maximum time entered in the Max To rrque
que respec-
tively Max Time boxes was reached before targeted
angle value.
Control Mode: Dyna-Tork

Dyna-Tork
que box is reached.
Keep the nutrunner motor current constant at the actual
value until the Step Sync.IN signal (see section 3.6)
indicates that all servo drives in the group have finished
the corresponding step.
Then continue with the next step, that has to be a Dela
Delayy
End or Dela
Delay y step. The nutrunner motor current will stay
constant at the actual value during the Dela y End or
Delay
Dela
Delayy step.
Max Time boxes was exceeded or the minimum angle
entered in the Min Angle box was not reached before
targeted torque value.

66
6.2.2 Torque
orque
The To rrque
que value is used as the target torque value for control modes
To rrque
que
que, To rrque
que End
End, and Dyna-T ork
Dyna-Tork
ork.
The Max To rrqueque value is used for checking that the actual torque level
is below the specified during a tightening step in control modes An-
gle
gle, Angle EndEnd, and Jog End (fail safe limit monitoring).
The Min To rrque
que value is used for checking that the actual torque level
has reached the specified level during an Angle or Angle End step.
A few hardware parameters also influence the torque level achieved or
checked in each step.
1. Parameter Current Scale F actor
Factor
actor.
The torque value measured at the electric motor´s shaft at maxi-
mum motor current. Used for current control of torque in the Dyna-
Tork control mode or when QCM/QCS servo drives are used.
When selecting spindle type in the Spindle P arameter menu (see
Parameter
Programming, section 7.3.3) default values can be set. They are
modifiable. Values for each nutrunner are listed in section 6.3.4.
The parameter is common for all steps programmed in the servo
drive. See section 6.3 for detailed information.
2. Nutrunner gear ratio parameter, Gear
Gear.
Parameter
Programming, section 7.3.3) default values can be set. They are
modifiable. Values for each nutrunner are listed in section 6.3.5.
The parameter is common for all steps programmed in the servo
drive. See section 6.3 for detailed information.
3. Torque transducer parameter To rrque
que Scale F actor
Factor
actor.
When a torque transducer signal is used as actual torque level, you
must specify the To rrque
que Scale Factor for the correct torque trans-
Factor
ducer type. (See Torque Reading menu, Programming, section
7.3.4).
Values for each nutrunner type are listed in section 6.3.8. The
parameter is common for all steps programmed in the servo drive.

67
6.2.3 Speed
The Speed value is used to set the nutrunner's speed [rpm] during the
tightening step in the control modes To rrque
que
que,, To rrque
que End, Angle
Angle,,
Angle End, Jog End, and Dyna-T ork
Dyna-Tork
ork.
The speed is measured on the motor shaft with the resolver. The
resolver signal is divided by a constant, specific for the resolver (but
common to all nutrunner sizes), and by the gear ratio parameter Gear Gear.
Parameter
Programming, section 7.3.3), default values can be set and they are
modifiable. Values for each nutrunner are listed in section 6.3.5. The
See section 6.3 for detailed information.
Although the Speed value range is large, all currently delivered nut-
runners have a max speed below 2,000 rpm.
6.2.4 Angle
The Angle value is used as the target angle value in control modes
Angle and Angle End End. Max Angle is used for checking that the
actual angle value is below the specified during a tightenig step in
control modes To rrque
que
que, To rrque
que End
End, Jog End
End, and Dyna-T ork (fail
Dyna-Tork
safe limit monitoring). Use the value 0 to inhibit fail safe monitoring.
The angle is measured on the motor shaft with the resolver. The
resolver signal is divided by a constant, specific for the resolver but
common for all nutrunner sizes, and by the gear ratio parameter Gear Gear.
Parameter
Programming, section 7.3.3), default values can be set and they are

68
6.2.5 Min. Angle

The Min Angle value is used to check that the minimum angle posi-
tion is reached before the final torque value is reached in a tightening
step. It is valid in the control modes To rrque
que
que, To rrque
que End
End, Dyna-T ork
Dyna-Tork
ork,
and Jog End (fail safe limit monitoring).
In control mode Jog End the step is accepted only if the minimum
angle is reached before the action is stopped.
The angle is measured on the motor shaft with the resolver. The
resolver signal is divided by a constant, specific for the resolver but
common for all nutrunner sizes, and by the gear ratio parameter GearGear.
When selecting spindle type in the Spindle P arameter menu, (see
Parameter
Programming, section 7.3.3) default values can be set and they are
6.2.6 Delay Time

Delay
The parameter defines a delay time in the control modes Dela Delayy and
Dela
Delay y End
End. The function is mostly used in sequence tightening and
for relaxation of joints.
If the previous step was a Dyna-T ork step, the nutrunner motor cur-
Dyna-Tork
rent will stay constant during the delay time entered.
If the previous step was NOT a Dyna-T
Dyna-Torkork step, the next step will
start after the delay time entered. This function can be used as the
first step in a set to delay the start of the tightening cycle after the
start signal. (The start signal always activates the first step of the
selected set.)

69
6.2.7 Max. Time

Use the Max Time parameter to set the time contr controlled overriding
olled o verriding
stop for the step. It is active in the control modes To rrque
que
que, To rrque
que
End
End, Angle
Angle, Angle EndEnd, Jog End
End, and Dyna-T ork
Dyna-Tork
ork.
If the action specified in the step has not finished before the time
entered for Max Time has elapsed, the tightening cycle will be inter-
rupted and the Cycle NOK output signal set to logic one. See section
3.6, K7B:33.
6.3 Modifying Hardware P

Hard arameter
Parameters
arameters
The program in the servo drives QCM-T/QCS-T and QCM/QCS con-
tains some parameters that are part of the tightening sequence con-
trol, but are modified only in exceptional cases. They are called the
har
hardd ware parameter
parameters s and are stored in the servo drive's memory like
the step parameters.
The table below lists all current parameters with comments. For the
parameters that can be changed use the proper menu in the program-
ming software, see Programming, section 7.
Hard ware P
Hard arameter
Parameter Default Comment
Value
Servo Drive Address – Can be changed

Ramp Time 300 Can be changed
PGAIN – Can be changed *
IGAIN – Can be changed *
DGAIN – Can be changed *
Nominal Motor Speed – Can be changed *
Current Scale Factor – Can be changed *
Gear – Can be changed *
Cycle OK/Overvoltage Shut-off – Can be changed
Torque Scale Factor – Can be changed *
Filter 1 Can be changed
Input Gain 8 Can be changed
* Motor size dependent

70
The Ser
Servvo Drive Ad
Address
dress parameter should be changed only for
servo drives used in a communication linked system. You may find it
valuable to change the Ramp Time parameter in some special appli-
cations.
The PGAIN, IGAIN, DGAIN, Nominal Motor Speed, Current Scale
Factor, Torque Scale Factor, and Gear parameters should be changed
to new nominal values, if the servo drive in a break-down situation is
connected to a different nutrunner model.
6.3.1 Ser
Servvo Drive Address
Address
You can identify each servo drive unit in a communication cascaded
linked system (see section 3.8) of max 30 units by assigning it an indi-
vidual address in the range 1 – 15 (group 1) and 16 – 30 (group 2).
The servo drive address is changed in the Setup menu, see Program-
ming, section 7.4.2.
6.3.2 Ramp Time

The Ramp Time parameter sets the acceleration time from start to
specified speed for the nutrunner motor. Normal values are in the
range 300 . . . 1000 ms. The default value is 300 ms. Max. Ramp
Time is 10000 ms. Program the Ramp Time in the Spindle menu, see
Programming, section 7.3.3.
6.3.3 Nominal Motor Speed

The Nominal Motor Speed parameter refers to the electric motor
shaft, internal in the nutrunner. Following values are valid:
Nutrunner Model Nominal Motor Speed [rpm]
QMR 42 7000
QMR 55 6400
QMR 62 6400
QMR 90 5000
Program the Nominal (Motor) Speed in the Spindle – Spindle Param-

eters menu. See Programming, section 7.3.3.

71
6.3.4 Current Scale Factor

Factor
The Current Scale F Factor
actor refers to the torque value measured at the
electric motor's shaft at maximum current (15 A – 25 A – 50 A re-
spectively). You will find the scale factors for each nutrunner type in
the table below. They differ from the nominal max. torque values
found in the motor data table in section 4.1 which are real output with
built-in safety factors etc. The scale factors listed below are calculated
in [torque/current]
Decimals are not allowed in a hardware parameter value. You can,
however, scale the actual Current Scale F actor value to take advan-
Factor
tage of the servo drive's calculating accuracy. By default you should
multiply it by 100 and put this new value in the servo drive's memory.
The calculating program produces correct results as long as the
To rrque/Max
que/Max To rrque
que values in the step programs for the application
are below 400 Nm. In this case you multiply the To rrque/Max
que/Max To rrque
que
values by 10 and use the new values in the step programs.
If the torque levels are above 400 Nm you cannot multiply the To rrque/
que/
Max To rrque
que values by 10, because the max. allowed value in the
program is 4095. You must in this case use the torque value in [Nm]
as is and at the same time substitute the Current Scale F actor × 100
Factor
for Current Scale Factor
Factor × 10.
• When the To rrque/Max
que/Max To rrque
que value is entered in [dNm], the Cur
Cur--
rent Scale Factor value should be entered multiplied by 100.
Factor
• When the To rrque/Max
que/Max To rrque
que value is entered in [Nm], the Cur
Cur--
rent Scale Factor value should be entered multiplied by 10.
Factor
• The Current Scale F actor is common to all steps programmed for
Factor
the servo drive. Should a To rrque/Max
que/Max To rrque
que value for any step be
entered in [Nm], all To rrque que values be entered in [Nm]
que /Max To rrque
and the Current Scale Factor be multiplied by 10 instead of 100.
Nominal Current Scale Factor v alues

Factor
Nutrunner Current Current Scale Current Scale
Model Scale Factor × 100 Factor × 10
Factor 0<Max To rrque<400
que<400 400<Max To rrque<4000
que<4000
QMR 42 2.5 250 25

QMR 55 8.0 800 80
QMR 62 8.0 800 80
QMR 90 23.0 2300 230

72
The table values are subject to modification at start-up. You should

calibrate the system by using an in-line torque transducer with an
appropriate amplifier as reference and modify the Current Scale
Factor
actor.
Please obser
observeve that each n
each utrunner has an individual Current
nutrunner
Scale Factor
actor..
Factor
Program the Current Scale factor in the Spindle – Spindle Parameters
menu. See Programming, section 7.3.3.
6.3.5 Nutrunner Gear Ratio, Gear

The nutrunner parameter Gear is the gear ratio for the nutrunner –
electric motor to output spindle – multiplied by 100. You will find the
values for each standard nutrunner type in the tables below.
Program the Gear value in the Spindle – Spindle Parameters menu.
See Programming, section 7.3.3.
Note that for current QMR nutrunner models (straight nutrunners and
3-wheel gear offset nutrunners), the rotational direction of motor and
outgoing shaft are the same. The 3-wheel gear offset nutrunners
have a part number ending with 1, e.g., 8432 5020 21. For these
nutrunners the Gear value shall be negative (default). See the first
table below!
The Gear value must be changed to positive for older QMR offset
nutrunners (with 2-wheel gears, the part number ending with 0, e.g.,
8432 5020 20) as well as for specially designed nutrunners with oppo-
site rotational direction of motor and outgoing shaft. See the second
table below for older QMR nutrunner models! Please revert to our
representative for help regarding specially designed nutrunners or try
it out yourself by testing!
The parameter is common to all steps programmed for the servo
drive.

73
Nutrunner Parameter Gear (1)

Parameter
Current Straight and Offset models
Nutrunner Model Gear Ratio Gear
QMR 42-16 16.00 –1600
QMR 42-25 25.77 –2577
QMR 55-15 15.74 –1574
QMR 55-24 24.25 –2425
QMR 62-32 32.08 –3208
QMR 62-46 46.54 –4654
QMR 90-30 30.33 –3033
QMR 90-47 47.79 –4779
Nutrunner Parameter Gear (2)

Parameter
Older Offset models (par
(partt n umber ending with 0)
number
Nutrunner Model Gear Ratio Gear
QMR 42-16 16.00 1600
QMR 42-25 25.77 2577
QMR 55-15 15.74 1574
QMR 55-24 24.25 2425
QMR 62-32 32.08 3208
QMR 62-46 46.54 4654
QMR 90-30 30.33 3033
QMR 90-47 47.79 4779
6.3.6 Cycle OK / Contr

Cycle oller OK / Over
Controller Overvvoltag e Shut-off
oltag
The servo drive contains a relay with free contacts connected to out-
put connector K14:1 and K14:2, (K23:1 and K23:2 in 50 A QCM-T/
QCS-T and QCM/QCS). You can select one of the following three
logic functions for the relay output: Controller OK
Controller OK, Cyc le OK
Cycle OK, or
Over
Overv voltag e Shut-off
oltag Shut-off. See section 3.6 for additional specifications
and Programming, section 7.3.5.

74
6.3.7 Position Hold

In a normal tightening the nutrunner motor current is switched off as
soon as a tightening step in a set has finished. Any reaction torque
from the tightening joint will turn the spindle in reverse direction.
In some applications you may want the nutrunner to hold its position
between the steps in the tightening cycle. You can activate a built-in
function called Position Hold to perform the task. The motor current
stays on between the steps and the servo drive acts as a position
servo, trying to maintain the socket's angle position. After the last
step in each set the current is switched off as normal.
The nutrunner motor current is limited to 25 percent of max. current in
order to protect the windings from overheating. As a result the posi-
tion cannot be held, if the reaction torque is too big.
Once you have activated the Position Hold function, it works for all
steps except the last in all sets until you reset the function.
The position hold function is activated/deactivated in the Spindle –
Special menu, see Programming, section 7.3.5.
Warning:
A reaction tor que acting on the spindle between the steps in
torque
combination with the P osition Hold function heats up the motor
Position motor..
If the motor current reac hes the 25 per
reaches cent limit and the time
percent
between the steps is long enough, the o verheating pr
overheating otection
protection
cir cuits will sswitc
circuits witch off the motor current.
witch
6.3.8 To rrque
que Scale Factor
Factor
The To rrque
que scale factor is the torque transducer signal at 100 %
load. There are four different transducer sizes, one for each nutrunner
size. See table below!
The To rrque
que scale factor is common to all steps programmed for the
servo drive. Enter the value in the Spindle – Torque Reading menu.
See Programming, section 7.3.4.
Nutrunner type QMR 42 QMR 55 QMR 62 QMR 90
Transducer type 50 100 200 1000

75
6.3.9 Filter
The signal from nutrunner torque transducer are filtered to surpress
noise. Filter constants 0,1,2 or 3 can be selected. 0 means no filter at
all and with rising number the filter gets harder, i.e., the cut-off fre-
quency is decreasing. The Filter constant is common to all steps
programmed for the servo drive. Enter the value in the
Spindle – Torque Reading menu. See Programming, section 7.3.4.
6.4 Selecting and Confirming the Set Number

One or more steps constitute a set. You can use all the eight available
steps in one set or use eight sets with only one step in each. Any
combination between these two is allowed.
The first step definition starts the set numbering with Set 0 0. The
second set, Set 1 1, is defined by the first step following a step of type
Dela
Delay que End, Angle End, or Jog End in Set 0
y End, To rrque 0, etc.
You can select any of the defined sets for a tightening operation with
the input signals Select4
Select4, Select2
Select2, and Select1 before activating the
start signal. See section 3.6 and 3.6.2 for more information.
Use the output signals Confirm2 and Confirm1 to indicate the current
set number during a tightening cycle. Only the first four set numbers
can be identified, Set 0 . . . Set 3
3. If you use more than four sets, the
confirm signals are invalid.
The confirm signals mirror the select signals Select2 and Select1
before start. During the tightening cycle the confirm signals are
locked to the state at the start time. See section 3.6 and 3.6.3 for
more information.
The input and output signals work at 24 VDC. This is perfect for
switches controlling the select signals and incandescent lamps indi-
cating confirm status. If you want to control and indicate with compu-
ter components it is normally necessary to incorporate level translator
circuits.

76
7. Programming
Programming
Win QCM is a Windows program for programming the QCM-T/QCS-T

and QCM/QCS servo drives.
Win QCM can run on a PC with:
• CPU 386 or higher
• Windows 3.X with the Win32s extension installed, Windows 95,
or Windows NT.
• Minimum 8 MB RAM
• Minimum 2 MB harddisc space available to Win QCM.
• One free serial port.
The program can be in on-line or off-line mode. In on-line mode pa-

rameters are sent to the servo drives when they are changed. In off-
line mode a program can be modified without any servo drives con-
nected.
The servo drives can be connected one at a time, or all at the same
time.
The program can handle systems with maximum 30 spindles (maxi-
mum 15 per serial port in the PC host).

77
7.1 Main Menu

Menu
The main menu has four windows: The result window, the tightening
cycles window, the digital input window, and the digital output window.
7.1.1 Results Menu

Menu
With the program in on-line mode, the tightening results are continu-
ously collected from all connected spindles in the system and dis-
played on the screen. By checking the disconnected box, results are
no longer collected and reported for the corresponding spindle.
The results (status, final torque and final angle values) are shown in
one box for each spindle. If the status is OK the box is green and if it’s
NOK it will be red combined with a fault type message. While the
spindle is running the box is white and the status message is Run-
ning
ning. The presented torque and angle values are the values from the
last step with the spindle running forward.
By clicking on a box you activate the spindle/servo drive you want to
program.
File View
View Spindle Setup Load parameter
parameterss Access level
level Help
Spindle 1 OFF LINE
Spindle 1 Spindle 2
disconnected disconnected
OK Running
T: 17,3 Nm.
A: 123 deg.
Spindle 3 Spindle 4
disconnected disconnected
To rrque
que high
T: 18,7 Nm.
A: 121 deg.

78
7.1.2 Tightening Cycles Windo

Cycles w
Window
This picture below shows an example of the setup window for eight
tightening steps.
Tightening cycles
(Nm) (Sec.) (deg.) (rpm)

Torque Angle
Step Mode Min Max Time Min Max Speed Rev.
Step 1 Torque 10.0 5 30000 0 100

Step 2 Torque 40.0 5 340 300 50
Step 3 Angle 100.0 85.0 5 70 30 No
Step 4 Angle End 100.0 0.0 2 3 50 Yes
Step 5 Angle 100.0 0.0 5 30 Yes
Step 6 Angle End 100.0 0.0 5 120 Yes
Step 7 Delay End 0.0
Step 8 Delay End 0.0
Here you can edit the tightening steps. Select a step by

clicking on it in the window. Double-click the step to
enter the dialogue box for that step (shown below).
Tightening steps
Step: Step 3 Mode: To rrque

que Delete step
Insert step
To rrque:
que: Nm Min To rrque:
que: Nm
Max Time: Sec. Speed: rpm Rever

Re verse
ver se
Max Angle: deg. Min Angle: deg.
OK Cancel

79
You can select control mode from one of the following step types:
To rrque
que
que, Angle
Angle, Dela y , Dyna-T
Delay ork
ork, Dela
Dyna-Tork Delay End, Angle End
y End End, Jog End
End,
or To rrque
que End
End.
When the control mode in a step is of type DelaDelayy End
End, Angle End
End,
Jog End
End, or To rrque
que End
End, there will be a horizontal line under the step
data to indicate that this is the end of a tightening set.
Depending on the selected mode the editable parameters change

according to the following table:
To rrque
que Angle
Mode Max Min Time Max Min Speed Rever
Rever se
verse
To rrque
que Yes No Yes Yes Yes Yes No
Angle Yes Yes Yes Yes No Yes Yes
Delay
Delay No No Yes Yes No No No
Dyna-Tork
Dyna-Tork Yes No Yes Yes Yes Yes No
Delay End
Delay No No Yes Yes No No No
Angle End Yes Yes Yes Yes No Yes Yes
Jog End Yes No Yes Yes Yes Yes Yes
To rrque
que End Yes No Yes Yes Yes Yes No
All torque values are programmed in dNm/dfl.lb if Maxim

Maximum torque
um tor que
is less than 400 and Nm/fl.lb if Maximum tor
Maximum que is bigger than 400.
torque
The Maxim um tor
Maximum que is programmed in the Spindle P
torque arameter
Parameter
arameterss
menu, see section 7.3.3.
Time is programmed in seconds except for DelaDelayy and Dela
Delayy End
steps, where the time is programmed in 1/10 of seconds, i.e., multiply
the time in seconds by 10 when entering the value.
All angle values are programmed in degrees (360 degrees/revolution).
Speed is programmed in rpm (revolutions per minute). Re ver
Rever se can
verse
be selected to run the spindle in reverse direction in Angle
Angle, Angle
End
End, and Jog End steps.
When deleting a step it is removed from the window and the following
steps will be moved up one line. Step number 8 will be an empty step.
When you insert a step the current step will be an empty step and all
following steps will be moved down one line.

80
7.1.3 Digital Inputs Window

Window
In the Digital Input window you can see the status of all digital inputs
for all spindles.
7.1.4 Digital Outputs Window

Window
In the Digital Output window you can see the status of all digital out-
puts for all spindles.
7.2 File
Under the File menu you will find the standard functions for file han-
dling: New , Open
New Open, Save
ve, Sa
Save ve as
Save as, Print
Print, and Open an y of last three
any
files
files.
File View
level Help
New
New Ctrl +N
Open ... Ctrl +O
Save
Save Ctrl +S
ve As ...
Save
Sa
Print ... Ctrl +P
Print Previe
Previe w
view
Print Setup ...
filename1
filename2
filename3
filename4
Exit

81
Press New to initiate the system. Following dialog box will appear.
New
As an example the fields are filled in and 'Radio buttons' are selected.
System
Number of spindles: 10 Default spindle type: QMR 42-16
Ser
Servvos connected all: one by one:
by
QCM/S: QCM/S - T: OK
Nm: Foot-pound:
Open an existing system file: When programming in On-line mode

there will be a choice whether or not to load all parameters to the
servo drives.
Use Print to make a printout from the program, listing all parameters
stored in the registers for each spindle, one spindle per page.
Exit – to end the program. If the current file is changed there will be
an option to save the file.
7.3 Spindle
Under the Spindle menu you will find the following functions:
File View
level Help
Tightening steps
Copy tightening sets
Copy
Spindle parameters
parameters
To rrque
que reading
Special
Select current spindle

82
7.3.1 Tightening Steps

This is another way to reach the same dialogue for editing tightening
steps as when clicking on a tightening step in the main menu, see
section 7.1.2.
7.3.2 Copy Tightening Steps

Copy
Copy tightening steps from one spindle to other spindles. Select the
spindle to copy tightening steps from – Sour ce – and the spindle to
Source
copy to – Destination
Destination. Select the tightening steps to copy and the
dedicated step number in destination spindles.
In the example below the steps 3, 4, and 5 for spindle 1 are copied to
spindles 2 to 10.
Copy tightening steps
Sour ce:
Source:
OK
Spindle 1
From step
From 3 to 5 Cancel
Destination:
From spindle
From 2 to 10
Star
Startt with step 3

83
7.3.3 Spindle parameters

parameters
Standard parameters for the current product line of nutrunners are
stored within the program. You can call the parameters and have them
entered in the spindle parameters menu.
Spindle parameters
Spindle type: QMR42-16

OK
Set default parameters ffor

parameters or spindle Cancel
Parameters:
arameters
IGAIN DGAIN PGAIN
Nominal speed: Ramp time:
Gear: Current scale factor:
Maximum tor
Maximum que:
torque:
Select a spindle type and press the Set default vvalues or spindle
alues ffor
button. Default parameters will be automatically inserted.. See sec-
tion 6.3 for description of the parameters. In cases where it’s neces-
sary to modify one or more of the parameters, please consult the
Atlas Copco representatives.
The range for the spindle is set with the Maxim
Maximumum tor que parameter.
torque
If the Maximum torque is above 400 Nm/Ftlb, torque values cannot be
programmed with a decimal.
For standard QMR nutrunners with the same rotational direction of
motor and outgoing shaft (straight nutrunners, 3-wheel offset
nutrunners, etc.) the Gear value shall be negative (default). For non-
standard nutrunners with opposite rotational directions of motor and
outgoing shaft (2-wheel offset nutrunners, etc.) the Gear value must
be positive.

84
7.3.4 To rrque
que Reading
Torque reading is valid only if a QCM-T/QCS -T servo drive is se-
lected.
Example:
Torque reading
To rrque
que transducer: 20 Nm / ffoot-pound
oot-pound
OK
Set default vvalues

alues ffor
or the Cancel
transducer
To rrque
que scale factor:
Filter constant:
Input gain :
Select a torque transducer and press the Set default vvalues

alues ffor
or the
transducer button. Default parameters will then be automatically
inserted.. See section 6.3 for description of the parameters. In cases
where it’s necessary to modify one or more of the parameters, please
consult the Atlas Copco representatives.
7.3.5 Special
Hold spindle in position between steps can be switched off and on.
When set to on, the nutrunner motor current will be maintained be-
tween the steps in order to hold the rotational position of the socket.
Normally the current is switched off between the steps and the reac-
tion torque from the joint will turn the socket in reverse direction.
The servo drive contains a relay with free contacts connected to the
output connector K14:1 and K14:2. You can select one of the following
three logic functions for the relay action: OK (cycle OK), Contr oller
Controller
OK or Over
Overvvoltag e Shut-off
oltag Shut-off.
See next page for an example!

85
Special
Hold spindle in position between steps:

OK
Cancel
Relay function:
Relay OK
Controller OK
Controller
Over
Overvv oltag e shutoff
oltag
7.3.6 Select Current Spindle

The last option on the Spindle menu is Select current spindle
spindle.
In the Setup menu (see section 7.4.1) you enter the number of spin-
dles in the system (max. 30), using the System option. You can select
one of the available spindles to be the current spindle, i.e., the spindle
to send new programming data to, or receive current data from.
Alternative methods to select current spindle are:
– Click on Spindle 2 in the toolbar.
– Click on a spindle in the result menu.
Example:
Select current spindle
Select current spindle to communicate with:

communicate Stand alone OK
Spindle 1
Cancel
Spindle 2
Spindle 3
.......
Spindle 13
Spindle 14
Spindle 15

86
7.4 Setup
Under the Setup menu you will find options for defining the servo
drives, change their addresses, select communication ports, and set
the servo drives on-line/off-line.
File View
level Help
System
Chang
Changee ser
servvo address
address
Communication
Communication
On-line / off-line
7.4.1 System
In the system option you define the configuration of the system, i.e.,
the number of spindles and the type of servo drive for each spindle.
Example:
System
Number of spindles: 10
Ser
Servvos connected all: one by one:
by
QCM/S: QCM/S - T: OK
Nm: Foot-pound: Cancel
Select Ser
Serv vos connected all when all servo drives in the system are
interconnected through a cascaded link, and only the first servo drive
in the link is connected to the PC. Communication with any servo
drive in the link is then possible from the PC. In such a link the servo
drives have addresses from 1 and upwards.

87
Servo drives connected one b by

y one means that all servo drives in the
system have the address 0 (stand alone servo drive) and that only
one servo drive is connected to the PC at a time.
Select also the type of servo drive, QCM-T or QCS-T with torque
transducer feedback or QCM or QCS without.
7.4.2 Change Ser

Change Servvo Address
Address
In systems where all servo drives are connected through a cascaded
link, you must assign a unique address to each unit.
Use Chang
Change e ser
servvo address to in order to set individual addresses.
address
Please note: Connect only one servo drive at a time to the PC during
this operation! The servo drive connected will store the address you
select in the menu.
Example:
Change servo drive address
Chang
Changee ser
servvo address to:
address Stand alone ser
servvo Chang
Changee address
address
Ser
Servvo 1
Ser
Servvo 2 Read current ad dress
address
Ser
Servvo 3
....... Close
Ser
Servvo 14
Current ad dress:
address: Ser
Servvo 15
To be able to change the servo drive address the program must know
the current address. Use the Read current ad dress button for infor-
address
mation on the current address.

88
7.4.3 Communication
Communication
One serial port on the PC can communicate with max. 15 servo drives
connected through one cascaded link. When the system contains
more than 15 servo drives, you must configure two cascaded links. It
is also possible to use two links in a system with fewer than 15 servo
drives.
Connect the links to two serial ports on the PC, normally COM1 and
COM2. You can also use COM3 and COM4, if the PC is setup with
the appropriate communication card.
Communication
Po rrtt 1 (ser
(servvo 1 - 15): COM1 OK
Po rrtt 1 (ser
(servvo 16 - 30): COM2 Cancel
Specify the serial communication port for communication with the

servo drives. Parity is always None, databits 8, stopbit 1 and
baudrate 9600.

89
7.5 Load Parameter

Parameters
arameters
File View
level Help
Load all parameters to spindles

parameters
Load all parameters fr
parameters om spindles
from
Compare parameters in file and spindles
parameters
Read and write parameters
parameters
7.5.1 Load all Parameter

Parameters to Spindles
arameters
Load all programmable parameters to the servo drives. If the program
is in off-line mode it will automatically be set in on-line mode.
7.5.2 Load all Parameter

Parameters fr
arameters om Spindles
from
Read all programmable parameters from the servo drives. If the
program is in off-line mode it will automatically be set in on-line mode.
7.5.3 Compare Parameter

Parameters in File and Spindles
arameters
Use for checking that the parameters in a servo drive and the current
parameter for that spindle in the program are equal.
7.5.4 Read and Write Parameter

Parameters
arameters
Use for reading and writing values directly from/to the servo drive's
registers. Use only for special functions.

90
7.6 Access Level

Level
File View
level Help
Login
Logout
User list
The program has 3 different access levels. The access level 3 is the
highest with the right to modify everything. In the user list you can
add new users and select the user's access level.
Also a default access level is selected in the User list menu. This is
the access level used by the program when it is started. If access
level 3 is selected as default access level, the user doesn’t need to
login, since the user automatically has the right to do everything.
(The default user – Administrator, with the access level 3 – has the
preliminary password ATLASQCM.)

91
8. Installation and Star t-Up

Start-Up
W A R N I N G!
Always disconnect the AC power supply before
you install cables or perform service in or near
the servo drive and the motor.
The power stage and DC-bus work at high volt-
age – 340 VDC. First disconnect the power sup-
ply before you touch these parts or other com-
ponents in the servo drive.
Please Note! Due to the internal capacitors the
high voltage may be present up to 60 seconds
after the power supply has been disconnected!
8.1 Installation Check List

Check
Please check the following list before connecting the power and you
will avoid the most annoying incidents.
1. The transformer connection to the mains. Cables dimensions,
main switch and fuses according to local specifications.
2. The transformer secondary 3-phases correctly connected to all
QCM-T and QCM master drive units, connector K1K1.
3. All QCS-T and QCS slave drive units should have the DC-bus
correctly connected to the corresponding QCM-T or QCM master
drive. Check the polarity (plus/minus) for all DC-bus connections,
connector K10 (QCM-T/QCS-T 340 15 and 340 25 or QCM/QCS
340 15 and 340 25) or K20 (QCM-T/QCS-T 340 50 or QCM/QCS
340 50).
4. Check that the protective ground cables are correctly connected
with sufficient cable area and that the cables are as short as
possible. Ref. Atlas Copco Controls drawing Nº 9834 5177 00.
5. The motor phases U, V and W connected in correct order.
6. The resolver cable connected to the correct servo drive.
7. Ensure that all cable shields are correctly connected.

92
8.2 Star t-Up Instruction

Start-Up
Please follow the steps below at start-up of the servo drive unit.
1. Disconnect the power connector K1 (3 x 240 VAC) from the mas-

ter servo drives.
2. Power-on the system.
3. Check with a voltmeter that the AC power supply voltage is within

limits. See table section 3.1, Input Voltage.
4. Power-off the system and reconnect the AC power supply con-

nector K1 to the master servo drives.
5. Check that the three green LEDs, 340 V, CPU CPU, and RDRDYY, on each
servo drive are lit in sequence. If not, see section 9.1.1 (Trouble
Shooting) for help. Normally the LED 340 V is lit first and the LED
CPU shortly after. The LED RD RDYY is lit when the input signal Con-
t rroller
oller ON is set as described below.
6. Disconnect the motor cable connector K11 from the nutrunner

motor. Check that the LED > T is lit on the corresponding servo
drive. If OK, power off the servo drive and reconnect the cable.
Power-on the servo drive.
7. Check that the Contr oller On input signal (shown with the yellow
Controller
LED ) is set in the correct sequence.
In order to avoid unwanted heating of the motor, normally set the
Contr oller On signal just before the start of a tightening se-
Controller
quence and reset it after the cycle is finished. If the Contr oller On
Controller
signal is on continuously, it is important that it is not set until the
internal Contr oller OK relay is closed.
Controller
If more than one servo is connected in a cascaded link constella-
tion (each servo has its own address), the Contr oller On signal
Controller
shall be set after the Contr oller OK relay in the servo with the
Controller
highest address number is activated. The correct sequence is
achieved if the Contr oller On signal is connected in series with
Controller
the Contr oller OK relay contacts from all servos.
Controller
The LED Rd Rdy y shall be lit when Contr oller On is set.
Controller
8. Connect a PC and download a valid PDF (Parameter Data File)

for test.

93
9. Check the digital inputs without starting a cycle (disconnect the

resolver cable). The digital inputs must have the following status/
wiring to enable the first parameter set in the PDF to be run:
Controller On
Controller high
Machine Stop_N
Machine high
Select1, Select2, and Select4 low
Inhibit low
Step mode low
Step synch in connected with Step sync out
synch
Star
Startt (the input signal) is indicated with the yellow LED .
10. Make the test with one spindle at a time by either disconnecting
the resolver cables for the others (in this case you must probably
activate the Contr oller On separately to the servo you want to
Controller
run), or by activating Inhibit to the other servos.
11. The following functions shall be tested for each spindle which
implicates that you need some different PDFs for the testing:
• Direction of rotation. If wrong, check that the gear ratio sign

and the speed value sign in the PDF are correct.
(-) gear ratio = same rotaional direction of motor and

outgoing shaft
(+) gear ratio = opposite rotaional direction of motor
and outgoing shaft
(+) speed value = tightening
(-) speed value = loosening
• Speed. Check with a tachometer. Run with 100% speed. If

wrong actual speed, check the gear ratio as well as allowed
maximum speed for the spindle.
• Angle step. Can be checked visually. Run a single step angle

program, 360 degrees with 10% speed. If the actual angle is
too high, check the gear ratio value. If the actual angle is too
low, check the gear ratio value as well as that the spindle did
not stop because of a fault like too high torque or over-time.

94
• Torque step. Check with an inline torque transducer. Start by

programming a single step torque program with a low torque
(10%) in order to check, that torque tightening is working. Then
change the torque value to the final torque level specified by the
customer.
Calibrate the spindle by changing the torque scale factor Mtor
Mtorqq.
Note that each nutrunner shall have its individual torque scale
factor, which implements an individual PDF for each nutrunner.
12. Repeat the start-up sequence for all nutrunners.

95
9. Tr ouble Shooting
ouble
9.1 Defining the Error

Erro
9.1.1 Using the Status Indicators
Indicators
There are ten LED (Light Emitting Diode) indicators available on the
front panel. Three indicators are green, informing you with steady
light that the servo drive system is working. Another three yellow
LEDs light temporarily during a tightening operation. The remaining
four indicators are red and alarm you in case of an error. You will find
below a short description of possible reasons for error alarms.
The green status indicator 340 V (Po wer On) is not lit.
(Po
1. The main power (QCM-T or QCM) or the DC-bus (QCS-T or QCS)
is missing.
– Check the transformer, fuses and cables.
– Check the voltages at the cable connectors.
2. Defective servo drive.
– Replace the servo drive.
The green status indicator CPU (CPU OK) is not lit.

1. EPROM missing, defective or incorrectly mounted.
– Check the EPROMs.
The green status indicator Rdy (Contr

Rdy oller Read
(Controller y) is not lit.
Ready)
1. The input signal Controller ON is missing.
2. An alarm is indicated with one of the four red LEDs.
The yyello
ellow status indicator
ellow (Controller ON) is not lit.
(Controller
1. The input signal Controller ON is missing.
The yyello
ellow (Star t) is not lit.
(Start)
1. This LED mirrors the digital input signal Star
Startt and is only lit when
the Star
Startt signal is active (high).

96
The yyello
ellow (Running) is not lit after star t.
start.
1. Digital input signal(s) missing.
– Check the signal communication with the external control system.
2. The digital input signal Inhibit is activated (high).
3. The parameter set is incorrect – the servo drive is set in NOK state
immediately after start.
– Correct the parameter set.
The red status indicator > T (Motor/Ser

(Motor/Servvo Drive Temp. High) is lit.
1. The nutrunner motor is overheated.
– Wait until the motor has cooled down and try again. Check the
tightening parameters, speed, and torque. Modify if necessary.
– Faulty motor. Replace the motor.
2. If the motor is cool, the motor thermistor may be defective .
– Check the resistance between pin G and J, K, or L respectively.
(Only one of the pins J, K, or L exists, depending on the motor
size). Correct value shall be between 100 and 300 Ohms at 20 °C.
If the thermistor is defective , you will have to replace the motor.
3. The resolver cable is not connected in both ends, incorrectly made
or defective.
– Check and repair the cable.
4. The servo drive is overheated. (This fault is very unlikely to occur).
– Check the cabinet inside temperature. Additional heat sources
inside the cabinet may cause the high temperature.
– Check the ambient temperature.
– If there is a cooling unit or a heat exchanger built into the system,
check the function.
The red status indicator > U (DC-bus F

(DC-bus ault) is lit.
Fault)
1. The DC-bus voltage has exceeded the limit. See Section 3.1 Elec-
trical and Mechanical P
Mechanical arameter
Parameter
arameterss.
– Check the DC-bus voltage with an oscilloscope and if necessary,
use the 10% tap on the transformer in order to decrease the sec-
ondary AC supply voltage.

97
– If the high DC-bus voltage only occurs temporarily and the level
above 400 – 425 VDC has some duration, the servo might be per-
manently damaged. In this case the Over
Overvvoltag e Shut-off relay
oltag
output shall be used to power off the system.
The red status indicator > I (Overcurrent) is lit.

(Overcurrent)
1. Short circuit in the motor or the motor cable.
– Check the motor and the cable.
2. The bus-voltage is too low.
– Check the DC-bus voltage with an oscilloscope. Observe the DC
level and the ripple at no load and at full load condition. If it is
outside the limits +10% to -20%, the transformer may be under-
sized, the mains is too weak or a phase is missing.
– If necessary, use the 10% tap on the transformer in order to in-
crease the secondary AC supply voltage.
3. The DC-bus voltage becomes too low when loaded.
– The transformer may be too small for the application. If possible,
increase the AC voltage using the 10% tap on the transformer.
– Decrease the maximum speed set in the program.
4. Illegal To rrque/Max
que/Max To rrque
que is programmed in the parameter set.
The red status indicator (Regulator F ault) is lit. (It is normall

Fault) y
normally
lit tog ether with one of the other alarm indicator
together s).
indicators).
1. The combination of control parameters is exceeding the limits.
– The condition maximum 20% speed at more than 20% current
(torque) or maximum 20% current (torque) at more than 20%
speed is not fulfilled in the control program. Adjust the control
parameters.
2. The DC-bus voltage becomes too low when loaded.
3. Defective cables.
– Check and repair the cables.

98
4. Defective resolver.
– Replace the nutrunner motor.
6. The external power supply for driving the output loads (+24 VDC
connected to K7B:25) is high before the main power (3 x 240 VAC)
or the DC-bus (340 DC) is on.
– You must arrange that the external power supply (+24 VDC) is
switched off together with the main power, for instance at Emer-
gency Stop.
When the Ser

Servvo Drive is Programmed as QCM-T or QCS-T
Programmed QCS-T::
The red status indicators > T, > U
indicators U,, and > I are lit tog ether
ether..
together
The servo drive has detected a zero offset fault in the torque trans-
ducer. The fault appears efter the start of the tightening program and
the limit for a zero offset fault is < 50 % of the torque scale.
– Check the torque cable and connectors, see Appendix 3.
– Replace the torque transducer.
The red status indicators >U

indicators U,, > I and (Regulator Fault) are lit
Fault)
tog ether
ether..
together
The servo has detected a calibration error after start of a tightening
program. The allowed calibration error is <5 % of torque scale.
– Check the torque cable and connectors, see Appendix 3.
– Replace the torque transducer.
The red status indicators >T

indicators >T,, >U
>U,, >I and (Regulator Fault) are lit
Fault)
tog ether
ether..
together
This combination indicates overflow in the torque amplifier.
– Check the programmed GAIN factor and if necessary decrease it.
Note that with GAIN=16 it is only possible to use <50 % of torque
scale.
– The programmed Max Torque in an angle controlled step is to high.
Reduce Max Torque or decrease the GAIN factor.

99
9.1.2 Abnormal Nutrunner Function

The motor is not rrotating
otating when expected b
expected ut the status indicator
but s
indicators
340 V, CPU
CPU,, Rdy, and
Rdy (Running) are lit.
1. Faulty parameter set programmed.
– Check and correct the program.
2. The input Controller On/Reset was set to logic one before the
Controller
output Controller OK was read logic one.
Controller
– Change the signal sequence between the servo and the control
system.
3. The motor cable is broken or not properly connected.
– Check and repair the motor cable.
The nutrunner motor is not running smoothl

nutrunner y.
smoothly
1. The resolver signal is disturbed by electrical noise.
– Check that the resolver and the motor cables are well separated.
– Check that the resolver cable screen is properly connected and not
in electrical contact with the motor cable screen.
See Appendix 4.
2. Faulty Motor parameters are loaded with the control parameters.
3. The resolver alignment with the motor windings is incorrect.
– Replace the nutrunner motor.
4. The motor cable or the resolver cable is incorrectly manufactured.
– Repair the cable. (It may have shifted wires).
The nutrunner is running with incorrect speed.

nutrunner
1. The faulty Gear ratio or Nominal Motor Speed parameters in the
parameter program.
2. The DC-bus voltage is too low – the maximum speed cannot be
reached. The red status indicator (Regulator F ault) is lit.
Fault)
3. A nutrunner with incorrect gear ratio has been installed.
– Replace the nutrunner or the gear module.

100
The n utrunner is rrotating

nutrunner otating with normal speed but in the wr
but ong direc-
wrong
tion.
1. The nutrunner Gear ratio or the Speed parameter is programmed
with wrong sign.
The n utrunner al
nutrunner wa
always runs with an angle vvalue
ways alue too big or too small
with an angle step programmed
programmed in the control system.
control
1. The resolver signal is disturbed by electrical noise.
– Check that the resolver and the motor power cables are well sepa-
rated.
– Check that the resolver cable shield is properly connected and not
in electrical contact with the motor cable shield.
2. A nutrunner with incorrect gear ratio has been installed.
– Replace the nutrunner or the gear module.
3. Faulty nutrunner Gear ratio parameter in the program.
4. If a tightening cycle has ended with NOK
NOK, the spindle has stopped
too early because the To rrque/Max
que/Max To rrque
que or the Max Time value
is exceeded.
The nutrunner does not reac

nutrunner reachh the expected tor
expected que le
torque vel.
level.
1. Incorrect torque scaling.
– Check the Current Scale F actor in the parameter program.
Factor
2. The servo drive stops the nutrunner too early because the Angle
Angle/
Max Angle or Max Time value is exceeded.
– Check that the data limits for the specific nutrunner are not ex-
ceeded in the actual application.
If yyou
ou during the fault localization find out that the ser servvo
drive is def ective
defective , y
ective, youou should in the fir st
first place consider re-
placing the entire ser vo drive
serv drive.. Send the def ective unit to a
defective
ser vice center ffor
service or repair or e x cchang
ex hang
hange e.

101
Appendix 1. Ser
Servvo Drive Front P
Front anels, QCM-T/QCS-T
Panels,
75 75 160
ASSEMBLY SYSTEMS ASSEMBLY SYSTEMS ASSEMBLY SYSTEMS
QCM-T 340 15 QCM-T 340 25 QCM-T 340 50

4240 0336 80 4240 0337 80 4240 0338 80
340 V 340 V 340 V

CPU CPU CPU
Rdy Rdy Rdy
>T >T >T

>U >U >U
>I >I >I
Master Module Master Module Master Module

15 Amps 25 Amps 50 Amps
45 45 122
QCS-T 340 25 QCS-T 340 25 QCS-T 340 50

4240 0339 80 4240 0340 80 4240 0341 80
232
340 V 340 V 340 V
CPU CPU CPU
Rdy Rdy Rdy
>T >T >T

>U >U >U
>I >I >I
Slave Module Slave Module Slave Module


102
Appendix 2. Ser
Servvo Drive Front P
Front anels, QCM/QCS
Panels,
75 75 160
QCM 340 15 QCM 340 25 QCM 340 50

4240 0326 80 4240 0327 80 4240 0328 80
340 V 340 V 340 V

CPU CPU CPU
Rdy Rdy Rdy
>T >T >T

>U >U >U
>I >I >I
Master Module Master Module Master Module

45 45 122
QCS 340 15 QCS 340 25 QCS 340 50

4240 0329 80 4240 0330 80 4240 0331 80
232
340 V 340 V 340 V
CPU CPU CPU
Rdy Rdy Rdy
>T >T >T

>U >U >U
>I >I >I
Slave Module Slave Module Slave Module


103
Appendix 3. Grounding the Ser

Grounding vo Drive QCM-T/QCS-T
Serv
Motor cable
Mains ground
Ground bar
Protective Mounting plate

grounding of
other compo-
nents in the
cabinet.
K6D
K6
Input/Output Torque Transducer cable

signal cables Resolver cable
Ground bar, connected to mains ground

Grounding of mounting plate
Mounting plate for servo drives
Ensure good electric contact in these places

Insulation removed from motor cable screen
Green/yellow ground wire in cable
Grounding of servo drive power supplies
Motor cable screen connection
Connector K6 (15-pole pin)

Ensure good electric contact between cable
screen and metallic connector housing
Resolver cable
Connector K6D (9-pole pin)

Torque Transducer cable

104
Appendix 4. Grounding the Ser

Grounding Servvo Drive QCM/QCS
Motor cable
Mains ground
Ground bar
Protective Mounting plate

grounding of
other compo-
nents in the
cabinet.
QCS 340 15 QCS 340 15 QCM 340 15
340V 340V 340V

CPU CPU CPU
Rdy Rdy Rdy
>T >T >T

>U >U >U
>I >I >I
Input/Output Resolver cable

signal cables
Ground bar, connected to mains ground
Grounding of mounting plate
Mounting plate for servo drives
Ensure good electric contact in these places

Insulation removed from motor cable screen
Green/yellow ground wire in cable
Grounding of servo drive power supplies
Motor cable screen connection
Connector K6

Resolver cable
9834 5177 00


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AHB 14/23-10

ASY 9834 0946 01

mini MACS Tightening System User's Manual

mini MACS Tightening System User's Manual

6.3.7 Position Hold ................................................................................... 74

mini MACS Tightening System User's Manual

mini MACS Tightening System User's Manual

• A number of QMR nutrunners containing a motor, resolver, torque

• One QCM-T/QCS-T or QCM/QCS servo drive unit for each

• A three-phase transformer to supply power to the servo drive

Various optional units like displays, printers, external computers,

mini MACS Tightening System User's Manual

1.1 Tightening System Over vie

QCM-T/QCS-T; QCM/QCS Servo Drives

Basic components and optional units in the miniMACS tightening system.

The QCM-T/QCS-T and QCM/QCS servo drive units have built-in

mini MACS Tightening System User's Manual

mini MACS Tightening System User's Manual

Front panel LED indicators (Light Emitting Diodes), show running

mini MACS Tightening System User's Manual

mini MACS Tightening System User's Manual

3.1 Electrical and Mechanical P

Output Current, Peak Value @ 60°C 15 A 25 A 50 A

Output Current, Continuous Value @ 50°C 5A 5A 20 A

Output Current, RMS Continuous Value @ 60°C 3.5 A 7A 14 A

Power Losses at Stand-by @ 50°C 15 W 15 W 15 W

(Cont. next page)

mini MACS Tightening System User's Manual

Efficiency at Continuous Current 95 %

Speed Control Accuracy <1%

Current Open Loop Bandwidth 2 kHz

Speed Loop Bandwidth Depending on Motor/spindle choices

Output Stage Switch Frequency 9 kHz

Operating Temperature and Humidity 0°C to +60°C, 95% RH

Storage Temperature and Humidity -20°C to +80°C, 95% RH

Input Voltage QCM 3-phase 240 VAC, —20% to +10%.

Overvoltage Turn-off Level, DC-bus 400 - 425 VDC

Shunt Regulation ON, DC-bus 375 - 400 VDC

Width QCM 15/25 Amps: 76 mm; 50 Amps: 160 mm

Height (Check with drawing in section 9) 240 mm

Weight QCM 15/25 Amps: 3.8 Kg; 50 Amps: 6.8 Kg

mini MACS Tightening System User's Manual

3.2 Main Ser

3.2.1 Control Functions

mini MACS Tightening System User's Manual

3.2.2 Protective Functions

mini MACS Tightening System User's Manual

3.3 Block Dia

QCM Master Drive

mini MACS Tightening System User's Manual

QCS Slave Drive

mini MACS Tightening System User's Manual

QCM-T Master Drive

mini MACS Tightening System User's Manual

QCS-T Slave Drive

mini MACS Tightening System User's Manual

3.4.1 CPU Board

3.4.2 EPROM and EEPR

3.4.3 Input/Output Board, I/O

mini MACS Tightening System User's Manual

3.4.4 Motor Po wer Unit, MPU

3.4.5 Po wer Supply Unit, APU (QCM-T and QCM onl

mini MACS Tightening System User's Manual

3.4.7 Mechanical Housing, MECM and MECS