AHB System Design and Installation Guide PMACS 4000

ASL Number 14 - PowerMACS 4000 System Design and Installation Page
Guide Page 1 of 33
AHB Number 9834 1134 01 Date of Issue
Oct 2009
System Design & Installation Guide

PowerMACS 4000
Guide Page 2 of 33
Oct 2009
Contents
GENERAL...........................................................................................................................................4
1 BEFORE YOU START.....................................................................................................................4

1.1 GENERAL ELECTRICAL SAFETY DEMANDS.............................................................................................4
1.2 SPECIFIC INSTALLATIONS DEMANDS....................................................................................................6
2 MAIN SWITCH BOX AND DISTRIBUTOR BOX.......................................................................7
2.1 OVERVIEW...................................................................................................................................7
2.2 MAIN SWITCH BOX.......................................................................................................................8
2.3 POWER DISTRIBUTOR BOX..............................................................................................................9
2.4 DB II........................................................................................................................................9
2.5 MECHANICAL DESIGN..................................................................................................................11
2.6 MAIN SWITCH BOX CONNECTOR SPECIFICATION.................................................................................12
2.7 DESCRIPTION OF SIGNAL CONNECTIONS...........................................................................................12
2.8 DESCRIPTION OF POWER CONNECTORS AND FUSES.............................................................................12
2.9 MAIN SWITCH BOX FRONT WITH ACTUATORS AND INDICATORS...............................................................14
2.10 MAIN SWITCH BOX DIMENSIONAL DRAWINGS.................................................................................15
2.11 MSB AND DB TECHNICAL DATA.................................................................................................15
2.12 DB II TECHNICAL DATA..............................................................................................................15
3 INSTALLATION.............................................................................................................................16
3.1 INSTALLATION LAYOUTS................................................................................................................16
3.2 POWER CABLES...........................................................................................................................16
3.3 E-STOP CABLES...........................................................................................................................17
3.4 ETHERNET CABLES.......................................................................................................................18
3.5 ACCESSORIES..............................................................................................................................18
3.6 MOUNTING................................................................................................................................19
4 POWER SUPPLY............................................................................................................................21
4.1 FUSES AND POWER CONSUMPTION ..................................................................................................23
4.2 HEAT GENERATION......................................................................................................................23
4.3 24V OUTPUT FOR E-STOP AND ACCESSORIES.....................................................................................24
4.4 CONTROL LOGIC EXTERNAL POWER SUPPLY........................................................................................24
5 I/O.....................................................................................................................................................25
5.1 INTERNAL I/O............................................................................................................................25
5.2 EXTERNAL I/O...........................................................................................................................25
5.3 EXTERNAL FIELDBUS INTERFACE....................................................................................................25
6 CABLES ..........................................................................................................................................25
6.1 I/O CABLES...............................................................................................................................25
6.2 QST CABLE.............................................................................................................................25
7 E-STOP.............................................................................................................................................25
7.1 CONNECTION EXAMPLES...............................................................................................................26
7.2 E-STOP CARD ...........................................................................................................................28
8 TO CHECK BEFORE POWER ON AND DURING STARTUP................................................32
9 DIMENSIONS..................................................................................................................................33
Guide Page 3 of 33
Oct 2009
Document history
Date of Issue Version Modifications
2007-05-07 1
2007-05-09 2 Naming of Secondary TC changed
2007-05-24 3 Added info on accessories cables
2007-07-30 4 Changed to 63A MSB
2007-09-19 5 Added text about calculation of 24V current consumption
2008-03-28 6 Added info about E-stop Card. Chapter 4, added max input 10A
2008-05-22 7 4.1 Changed info about current for different spindles, max no of TC
per MSB
2008-10-03 8 Simpler explanation in chapter 7. E-STOP regarding the
emergency stop with redundant breaking according to EN954-1
category 3 built in the TC.
2008-11-07 9 Corrected some formatting errors
2009-06-03 10 Changed info on E-stop for secondary stand-alone,7.1.
Added info on TC power loss and TC heat generation. 4.1-4.2
2009-08-27 11 Corrected Phoenix Connector on MSB/DB
2009-10-19 12 1.2.1 Max ambient temperature corrected, 50ºC. 4.2 24V info. 2.4
Added the DB II.
Guide Page 4 of 33
Oct 2009
General
This document describes how to design and install a PowerMACS 4000 system from
standard components using the Express product range and how to use 3rd party devices
(cables, switches etc). It contains information about the electrical and mechanical
procedures.
For Technical TC data, see document “AHB Functional and Technical Description
PowerMACS 4000”.
1 Before you start
1.1 General electrical safety demands

This part describes necessary conditions and basic demands of connecting and operating
the PowerMACS 4000 systems for personal safety.
Where our customers are integrating PowerMACS 4000 modules in their own systems, the
responsibilities to meet these demands are equally transferred.
It is demanded for personal safety, system security and a safe system operation, that these
basic rules are followed in operating, installing or handling the systems and its parts.
Atlas Copco, its subsidiaries or its legally involved partners, may not be held responsible for
any damage caused by not fulfilling these rules.
A. Grounding the system and each connected unit

This is the first basic rule of safe operation.
This is mandatory:
- Follow the rules and recommendations in this guide
- Make sure that the system and each unit is grounded correctly
- Measure resistance of system and units grounding, if necessary
- (A good value of resistance to ground is below 0,1 Ohm)
- If you are not convinced that these rules are fulfilled, contact factory expertise or Atlas
Copco Tools and Assembly Systems service personnel
- Systems must not be connected to mains or put into operation before these rules are
fulfilled
- Units that are damaged, must not be put into operation
- Systems can or must not be used with mains or nets that do not contain a ground lead
If requested, Atlas Copco Assembly Systems service personnel will supply you with
further advice.
These rules are necessary for personal safety.
It is involved with danger to life and health, to use systems or units,

Warning which are not in good condition or not connected according to
electrical regulations and system requirements, whether
manufactured by Atlas Copco Assembly Systems or third party.
Systems found, with damages to ground connections or missing or inadequate

grounding to any system unit, must be disconnected and repaired immediately.
Guide Page 5 of 33
Oct 2009
B. Checking of system power connections and cabling

This is the second basic rule of safe operation.
- Make sure that cables are in good condition before connecting them to the system, by
- Checking by visual inspection that
- Cables are not damaged,
- Connectors are not damaged
- Checking by electrical measurement that
- Grounding is correctly connected (see A, Grounding the system.. )
- Systems must not be connected to mains or switched on, if these conditions are not
fulfilled
It is involved with danger to life and health, to use systems, cables or
Warning
units that are not in good condition or not connected according to
electrical regulations and system requirements, whether
manufactured by Atlas Copco Assembly Systems or third party.
Systems where damages to connections or cables are found must be disconnected

and repaired immediately.
C. Follow the Installation Guide and meet the operation demands

This is the third basic rule of safe operation.
- Make sure that this Installation Guide is read and followed
- Make sure that the User Manual is read and followed
It is involved with danger to life and health, to use systems that are not installed or not
operated within the requirements of the manuals.
Systems found not to comply with these requirements, must be disconnected and
repaired immediately.
D. General requirements and recommendations on installation and handling of power

connections to mains supply of PowerMACS 4000 systems
- Make sure that this Installation Guide is read and followed

- Make sure that the User manual is read and followed
- All applicable regulations to handling, installing and operating equipment connected to
mains supply and operating under conditions at site of operation must be fulfilled.
It is involved with danger to life and health, to use systems, which are not installed or
not operated within the requirements of the manuals or applicable regulations at site
of operation.
Systems found not to comply with these requirements, must be disconnected,
reworked or repaired immediately.
Guide Page 6 of 33
Oct 2009
E. General considerations
- The manuals must be read thoroughly by skilled personal that are taking part in the
installation or start up work.
- If you consider there to be unclarities, contact Atlas Copco Assembly Systems before
advancing in the work.
- False connections may damage the equipment.
- In case of faulty operation of the equipment – disconnect the system and clarify faulty
events, replace faulty equipment, before connecting the system to supply again.
- Always make sure that the operation of the system can be safe and not a hazard to
people at the site of operation.
- Any connection or service to the system must only be carried out by trained service
personnel, and may only be done when supply is disconnected.
- Security instructions at site, in this manual or elsewhere and applicable to the
installation, must always be regarded in use, service and operation of the system.
- Only operate the system by skilled operators. False commands can jeopardize safe
operation of installed equipment in this system or other systems connected or in
systems dependent of this system. This could cause hazard to life and health.
It is involved with danger to life and health, to change any connections of the systems,
if you are not a skilled technician and understand the requirements and act according
to applied rules.
Systems found not to comply with these requirements, must be disconnected,
reworked or repaired immediately.
1.2 Specific installations demands

During build up of the PowerMACS 4000 system beware of the following:
• Installation must be done in accordance with all safety and legal regulations in force
where the machinery will operate. The main regulations in the EC are the
- IEC/EN 61010-1 (2001)
- En 61800-3 (2004)
- En 61000-6-2 (2005)
The necessary information to make an EMC compatible installation is found in this
document.
• Separation of power and control cables when practically possible.
• Min. 200mm space above the TC in order to not restrict the free circulation of cooling
airflow.
• Only Atlas Copco Nutrunner can be used together with the TCs.
1.2.1 Specific installation requirements for the TC according UL
• Use 60/75°C copper wire only.
• Tightening torque for field wiring terminals according connector manufacturer’s
recommendations.
• For use in a pollution degree 2 environments.
• Use Class 1 wire only or equivalent.
• Suitable for use on a circuit capable of delivering not more than 5kA rms symmetrical
amperes and for a Max voltage of 480 V.
• Max ambient temperature 50ºC.
Guide Page 7 of 33
Oct 2009
2 Main Switch Box and distributor box
2.1 Overview
The Main Switch Box (MSB) and Distributor box (DB) are the Power Distribution units for the
PowerMACS 4000 system. This chapter describes the features of the Main Switch Box unit
as well as the Distribution Box, and the DB II, a distributor box specially designed for the
American market.
The Main Switch connects up to 6 PowerMacs 4000 units providing a common main switch
and also a common over-current protection.
Guide Page 8 of 33
Oct 2009
2.2 Main Switch Box

The Main Switch Box has the following principal schematics:
The MSB contains 6 three-phase outlets divided into two groups. Each group of outlets are
fused with 10A with a common miniature circuit breaker. The rotary main switch rated for
63A, is of lockable type and breaks all the phases.
1. One or more additional Power Distribution Boxes (DB) can connect to the MSB
screw terminal outputs.
Guide Page 9 of 33
Oct 2009
2.3 Power Distributor Box
The Power Distributor Box is similar to a Main Switch Box, but it is not provided with a Main
Switch. The principal schematics of the Power Distributor Box are as below:
2.4 DB II
The Distribution box II must be connected to one of following mains switch.
Manufacturer: Square D (Schneider Electric)
H361AWK, rated 30A
H362AWK, rated 60A
H363AWK, rated 100A
H264AWK, rated 200A
Approved Fuses. Type Class CC. One of following fuses:

Ferraz Schawmut type ATQR10
Littelfuse type CCMR 010.
Guide Page 10 of 33
Oct 2009
Guide Page 11 of 33
Oct 2009
2.5 Mechanical Design
Any work inside the Service area of the Main Switch Box and
Warning Distributor Box must only be done by people authorized to work
with high voltage electrical installations
The Main Switch Box is designed to fit PowerMacs4000 with respect to height and depth,
but the unit is slightly wider than PM4000.
The unit is designed as a box that can be easily opened in the front. When opening the
front, all the connectors for the cabling to the PM4000 units is accessible, in addition the
connector for status indication is accessible. The cabling is led out on the bottom of the unit.
The inside of the box can be opened to be able to connect the incoming cables. This must
only be done by authorized personnel and is done by loosing a number of screws at the
front of the box.
The incoming cable as well as cables connecting a Main Switch Box with other units is
connected to screw terminals located at the back of the unit. The cables are fed through
Strain Relief Cord Connectors. Thus, this is regarded as a fixed installation that must be
done by authorized personnel only.
The unit has some spare space on standard 35mm DIN rails for customer specific additions,
e.g. safety relay or power supply.
Service area.
Must only be
opened by people
authorized to work
with high voltage
electrical
installations
User area.
Installation here
can be done by
skilled personell
Guide Page 12 of 33
Oct 2009
2.6 Main Switch Box connector specification

The picture below shows the output connectors of the Main Switch Box.
Circuit Breaker
Group 1
J1-J3 Outlets
Group 1 J2-J6 Outlets
Group 2
X1: Connector
for indication
Circuit Breaker
Group 2
2.7 Description of Signal Connections

2.7.1 X1: Connector for status indication
The connector is of type Phoenix MC 1,5/ 6-ST-3,81and has the following pin out:
1-2: Rotary Main switch position. The potential free contact is open when the Main switch is
set in off position. (Not Connected on DB)
3-4: Miniature circuit breaker position. The potential free contact is open when circuit
breakers F1 is open (tripped).
5-6: Miniature circuit breaker position. The potential free contact is open when circuit
breakers F2 is open (tripped).
The DB II do not have connector X1
2.8 Description of Power Connectors and Fuses

2.8.1 J1 to J6: Outlets
This connector is for incoming power for TCs. The pin out for the connector is:
1. Phase L1
2. Phase L2
3. Phase L3
4. Neutral (Not connected on DB II)
5. NC
6. Ground
Guide Page 13 of 33
Oct 2009
2.8.2 Input Connection

The incoming power from the factory net is connected to the Main Switch Box by fixed
installation to screw terminals inside the box. Maximum cable area for the connection is 10
mm2.
DB II:
The DB II is connected to a Main Disconnect:
Cable rating
Flammability rating: VW-1, FT-1 or
UL 94 V-1
Min Voltage: 600V
Area: Depending on input fuse
Installation Table for Wire Size
from the Main Disconnect Switch
to
DB II
Qty. of Min.
DB II’s Wire Max. Main
on Size Fuse Size
Circuit (AWG) (Amps)
1 12 20
2 8 40
3 4 70
4 3 85
5 1 100
2.8.3 Connection between Main Switch Box and Distribution Box

The connection between the Main Switch Box and the Distribution Box or between two
Distribution Boxes is done with a fixed installation using screw terminals inside the box.
Maximum cable area for the connection is 10 mm2 but the gauge must be at least the same
as the incoming connector, since there are no fuses for this cable inside the box.
For DB II max cable is AWG 1.
Guide Page 14 of 33
Oct 2009
2.9 Main switch Box front with actuators and indicators
Rotary
Main
Switch
The only actuator of the Main Switch Box is the Rotary Main Switch, which is a switch that is
of lockable type.
Guide Page 15 of 33
Oct 2009
2.10 Main Switch Box Dimensional Drawings
2.11 MSB and DB Technical data

Design Voltage: 400/480V
Maximum Input fuse: 63A
Minimum Input fuse: 16A
Maximum Input cable area: 10 mm2
2.12 DB II technical data

Design Voltage: 480V
Maximum Input fuse: 100A
Minimum Input fuse: 16A
Maximum Input cable area: AWG 1.
Guide Page 16 of 33
Oct 2009
3 Installation
3.1 Installation layouts

Standard cables come in lengths suitable for installations with rows of one MSB or DB plus
1 to 6 TCs for up to 3 rows.
3.2 Power cables

Power from factory drop to MSB and from MSB to DB must be installed by a qualified
electrician. For more info on the Main Switch Box see chapter 2.
Any work inside the Service area of the Main Switch Box and
Warning Distributor Box must only be done by people authorized to work
with high voltage electrical installations
The Power Cables between Main Switch Box and TC, and between
Warning Distributor Box and TC must not be connected or disconnected
with power switched on
Standard cables are 1350mm for TC1 and TC2, 1650mm for TC3 and TC4 and 1950mm for
TC5 and TC6.
Guide Page 17 of 33
Oct 2009
3.3 E-stop cables

The E-stop cables run in a chain from the first TC in a system or station to the last. The last
TC will have an E-stop terminator. If the system has more than one station using separate
E-stop chain, each station will need an E-stop terminator.
How to calculate the power consumption of the e-stop chain please see chapter 4.1.
Standard cable lengths are 1200mm and 3000mm.
To E-stop
connection on
Indicator box or
Operator panel
or other E-stop
breaker
Guide Page 18 of 33
Oct 2009
3.4 Ethernet cables

The Primary TCs all have an Ethernet switch mounted in the bracket. It has six ports and the
15V power is supplied from the TC. If more ports are needed, the Secondary TCs can be
ordered with a bracket containing an extra switch, or extra switches can be ordered
separately.
To Factory
network
connected
to IF2
(Optional)
PC
Connection
point for
programmin
g / service
connected to
switch
Ethernet switch mounted in bracket
3.5 Accessories
The PM4000 system can be connected with Atlas Copco accessories using standard
cabling. For more information see the documentation for the accessories.
Ethernet Cable
24V Ext Cable
Mini Display
IO Bus Cable IO Bus Cable IO Bus Cable
Stack light IO Box

Operator Panel
Indicator Box Cable
Indicator Box
Guide Page 19 of 33
Oct 2009
Article Order Number

24V Cable 4243 0166 05
24V Extension Cable 4243 0167 xx
IO Bus Cable 4222 0917 xx
Indicator Box Cable 4243 0158 81
xx = length
The 24V Ext Cable must be wired to the 0V and 24V pins of the DIG IN, Em Stop IN or Em
Stop Out connectors of the PTC:
24V Ext Cable Dig IN Em Stop In Em Stop Out
Connector Connector Connector
1 Brown 24V 1 4 4
2 White 0V 2 6 6
3 Black NC
4 Blue NC
3.6 Mounting
The TC and Main Switch Box can be mounted in any normal industrial environment
without any extra enclosure, if local regulations not prescribe otherwise.
Mount the TC, Main Switch Box and Distributor Box in a convenient place where it is easily
accessible. It shall be possible to open the MSB in order to get access to the fuses. The
ambient temperature must not exceed 40ºC.
• The TC can be mounted on any hard surface.
• Make sure there is enough space for the cables below the TC.
• If all TCs and the Main Switch Box are mounted on the same electric conductive
surface, it isn’t necessary to use the potential equalization terminal. If not, connect
an individual wire (area min. 2.5 mm2) from the connection point on the TC bracket to
the potential equalization terminal on the MSB. The purpose with the wire is to
equalize potential differences between different units in the system. NOTE: the
color of the potential equalization wire shall not be Green/Yellow
Note: For some applications, en extra gap between TC's is needed due to high heat
dissipation. See section 4.2.
The following drawing illustrates how to install the modules. See drawing for mounting hole
patterns.
Guide Page 20 of 33
Oct 2009
ℵ
ℑ
Guide Page 21 of 33
Oct 2009
4 Power Supply
The TCs are designed to be used together with the Main Switch Box and Distributor box
units. If they are not connected using a MSB or DB, then incoming power must have
maximum fuse 10A.
Main supply voltage:
3-phase min 400V, Max 480 VAC +5%, 50/60 Hz min.10A
Generally, the Atlas Copco TC should only be connected to three-phase,

grounded industrial mains. A PHASE/GROUND voltage of 300VAC must not
be exceeded. In general, these requirements are met in TN (Terra/neutral) or
TT (Terra/terra) mains.
An isolation transformer with grounded star point on the secondary winding

should be connected to ungrounded mains (IT (Isolated/terra) mains) or
asymmetrically grounded mains with a PHASE/GROUND voltage exceeding
300VAC.
Connection example:
TN or TT mains are to be preferred

Guide Page 22 of 33
Oct 2009
Below are shown some additional power supply system types using up to 480VAC (phase to
phase) where an isolation transformer is required.
Example 1
Example 2
Example 3
Example 4
Guide Page 23 of 33
Oct 2009
Example 5
Important If the supply voltage is less than 380VAC, the maximum speed rating of the
QST Nutrunner spindle may not be achieved.
4.1 Fuses and power consumption

The Main Switch Box and the Distributor Box each contain two 10A fuses with slow
characteristics, one for each side of three connectors. Up to three TCs are connected to
each fuse.
Standard cables are used to connect the TCs to the Main Switch box.
Use the table below to calculate the power and current consumption. As the average
currents depends on the tightening cycles in a specific installation, the values below must
be seen only as typical examples.
Motor Average Peak Number of Number of TC power loss
size Power(W) current (A)1 Spindles on spindles on (W)
each fuse one MSB2
QST 42 110 1,3 3 50 50
QST 50 120 2,0 3 36 55
QST 62 150 2,7 3 24 60
QST 200 3,4 3 18 70
80/90
1
Average of the max 2s during a tightening
2
These numbers are based on a MSB connected to a 63A input fuse with slow
characteristics.
4.2 Heat generation

Some applications will generate a high power loss in the TC and special considerations
must be taken.
An extra 20mm gap between TC’s to allow more air flow is recommended:
• For TC’s running QST80/90,
• For TC’s running special QST62 with a torque > 450Nm.
An extra gap or forced cooling, e.g. AC or fan, can be recommended in special applications.
Please contact Atlas Copco for consultation if needed. High heat generation can be caused
by:
• Special spindles with high torque.
• High Duty Cycle (time running/time idle) especially on large spindles
• Very long rundown or joint conditioning.
• Low tightening speed.
Guide Page 24 of 33
Oct 2009
4.3 24V output for E-stop and accessories

Each TC has a 24V output for supply to accessories etc. For the Primary PTC in the system,
this 24V output also feeds the E-stop circuit. The 24V of up to three TCs can be connected
in parallel to deliver:
1 TC max 1.0A
2 TC's max 2.0A
3 TC’s max 3.0A
The output has overcurrent protection. The protection is automatically reset then current
goes back below limit.
To connect the 24V in parallel, suggested is to use the E-stop In and E-stop Out
connectors:
PTC TC 2
E-Stop Out Connector E-stop In Connector
Pin Function Pin Function
3 24V 3 24V
5 0V 5 0V
TC 2 TC 3
E-Stop Out Connector E-stop In Connector
Pin Function Pin Function
3 24V 3 24V
5 0V 5 0V
To total current supplied by the PTC is the sum of the current for E-stop circuit and all
connected devices.
The 24V of the PTC delivers power for the E-stop circuit. The current draw is 50mA for each
connected TC and E-stop card.
The current consumption of the Atlas Copco Accessories is found in the manuals. It is
typically 0,3 to 0,5 A.
Examples:
1 TC Operator Panel
0,050A + 0,3A (Typically) = 0,350A
20 TCs
20*0,050A = 1A
20 TCs Operator Panel

20*0,050A + 0,3A (Typically) = 1,3A Two TCs must be connected in parallel
36 TCs
36*0,050A = 1,8A Two TCs must be connected in parallel
50 TCs
50*0,050A = 2,5A Three TCs must be connected in parallel
4.4 Control logic external power supply

The TC is has an internal supply for the 24v for internal logic etc. There is an option to
supply the 24v from an external source, to avoid a shutdown of the control logic if the
primary power supply is disconnected.
The external power supply only supply parts of the controller. The Ethernet (including the
Ethernet switch), fieldbus and serial communication will run on the external power supply.
Guide Page 25 of 33
Oct 2009
24 VDC +/-20% preferably stabilized
Approximate current consumption for one TC is 0,8A, 24 VDC
5 I/O
There are different ways to connect Digital Input and Output signals to a PowerMACS
system. Local IO, IO connected over CAN-bus (MACS IO) and Fieldbus.
5.1 Internal I/O

Each Primary TC has four local inputs and four local outputs using 24V logic. More
information is found in the document “AHB Functional and Technical Description PM4000”
5.2 External I/O

Atlas Copco standard accessories or external I/O devices can be connected to the Primary
TC MACS I/O ports. The devices must be of Atlas Copco approved type and brand, see
Atlas Copco AHBs for available units. A maximum of 192 DI and 192 DO (divided in up to 6
nodes) can be connected to each station in the system. The accessories or external I/O
devices must connect to the Primary TC in a station. The device must be supplied with 24V
from the TC, or if the 24V is separately supplied the 0V must be connected to the TC 0V.
5.3 External FieldBus interface.

If fieldbus is used it must be connected to the primary TC in a station which shall be of a
fieldbus version. The fieldbus TC acts as a slave in the communication with an external
fieldbus master.
6 Cables
Cables shall be chosen so that national electrical and other regulations are fulfilled in the
country where the system is to be used.
Cables shall be divided into groups (e.g. power-, control- and signal- cables) and not be
located close to each other.
All cables needed for an installation are available as Atlas Copco standards cables
6.1 I/O cables

• Serial communication cables: Shielded, twisted pair min. 0.3 mm².
• FieldBus signal cables: According to respective FieldBus standard.
• Discrete I/O signals: Multiple lead cable, min. 0.5 mm².
6.2 QST Cable

Two or more QST cables can be combined. The max total length is 60meters for
QST42/50/62 and 50 meters for QST80/90.
7 E-stop
The TC has a built in emergency stop with redundant breaking according to EN954-1
category 3.
The emergency stop acts by breaking the supply voltage to the gate drive units. Since the
emergency stop is distributed to all TCs in the system, proper cabling needs to be made
between the units.
Guide Page 26 of 33
Oct 2009
The Emergency Stop needs to be reset before the unit will start or after the emergency stop
has been activated. The reset can be done either by using the pushbutton on the Primary
TC front panel or by connecting an external reset pushbutton to connector EM STOP IN on
the Primary TC, or automatic reset by setting a jumper on EM STOP OUT. Note that
automatic reset is not always allowed, depending on the application.
The interconnection between the TCs is supported by the Atlas Copco standard cable 4222
0755 XX. The jumper in the EM STOP OUT is also available as a standard product, 4222
0755 00.
7.1 Connection Examples
Primary TC, standalone

E-stop contact 1 is connected between EM STOP IN:3 and EM STOP IN:7
Jumper between EM STOP OUT:10 and EM STOP OUT:12
External reset is connected between EM STOP IN:8 and EM STOP IN:12 (optional if
external reset is used, if jumpered auto reset is achieved)
Secondary TC, standalone

A standalone TC cannot have any emergency stop function enabled. To be able to run a
standalone Secondary TC for test purposes, the emergency stop relays have to be
activated. This made by the following connections:
Jumper between EM STOP IN:3 and EM STOP IN:11

Jumper between EM STOP IN:5 and EM STOP IN:9
Connection of 3 TC units.
Primary TC
External reset is connected between EM STOP IN:8 and EM STOP IN:12 (optional if
external reset is used, if jumpered auto reset is achieved)
Secondary TC 1
No jumpers needed.
Secondary TC 2
Jumper between EM STOP OUT:10 and EM STOP OUT:12. Use 4222 0755 00.
Connections
Four wires are needed for connection between the TCs as follows:
PTC STC1
EM STOP OUT:9 EM STOP IN:9
STC1 STC2
Guide Page 27 of 33
Oct 2009
See Drawing 1.
This connection is supported by the Atlas Copco Standard cable 4222 0755 XX.
Emergency Stop Circuit
PTC
EM STOP IN :3 +24V_EXT
EM STOP IN :4
EM STOP OUT :3
EM STOP OUT :4
EM STOP IN :5 0V_EXT
EM STOP IN :6
EM STOP OUT :5
EM STOP OUT :6
EM STOP IN :9 EM_STOP-
EM STOP OUT :9
EM STOP IN :7 EM_STOP+
EM STOP OUT :7
External Reset Circuit
EM STOP IN :8
EM STOP OUT :8
EM STOP IN :11 EM_STOP
EM STOP OUT :11
EM STOP IN :10
EM STOP OUT :10 EM_RESET
EM STOP IN :12 EM_NC1
EM STOP OUT :12 EM_NC2
TC 2
EM STOP IN :4
EM STOP OUT :3
EM STOP OUT :4
0V_EXT
EM STOP IN :5
EM STOP IN :6
EM STOP OUT :5
EM STOP OUT :6
EM STOP OUT :9
EM STOP OUT :11
EM STOP IN :10
EM STOP OUT :10
TC 3
EM STOP IN :4
EM STOP OUT :3
EM STOP OUT :4
EM STOP IN :5 0V_EXT
EM STOP IN :6
EM STOP OUT :5
EM STOP OUT :6
EM STOP OUT :9
EM STOP OUT :11
EM STOP IN :10
EM STOP OUT :10

Drawing 1
Guide Page 28 of 33
Oct 2009
7.2 E-stop Card

The E-stop Card is for extension of the PM4000 emergency stop to include external
equipment. It allows for example lifting cylinders that are controlled by the PM4000, and
connected to an external 24V supply, to be E-stopped together with the PM4000.
The E-stop card is designed to be a part of a PM4000 TC, located in the backplate, or
mounted in a separate enclosure. Then located in the backplate of a TC it uses the same
space as for the Ethernet Switch, so an E-stop card and an Ethernet Switch cannot be
equipped on one TC.
The Atlas Copco Standard E-stop Cable 4222 0755 XX is used for connecting between the TC
and the E-Stop Card.
7.2.1 Connectors
E-stop In
Type: Phoenix Mini-Combicon MC1.5/12-ST.3,5 12 poles
Use: Input of E-stop from the PM4000 E-stop chain.
Pin Function
1 N/C
2 N/C
3 N/C
4 N/C
5 N/C
6 N/C
7 N/C
8 N/C
9 EM-STOP-
10 EM_RESET
11 EM_STOP
12 EM_NC2
Ext:
Type: Phoenix Mini-Combicon MC1.5/6-ST.3,5 6 poles
Use: Connection of external 24V
Pin Function
1 E-stop Circuit 1 In
2 E-stop Circuit 1 Out
7 NC In Only for non-safety functionality
8 NC Out Only for non-safety functionality
9 NO In Only for non-safety functionality
10 NO Out Only for non-safety functionality
E-stop Circuit 1 to 3 can be used for safety applications. NC and NO connectors are only for
indication etc.
Example 1. A lifting block controlled by the PM4000 system. No external 24V and no E-stop
Date of Issue
Page 29 of 33
card. This setup is possible if the total current needed for E-stop circuit, lifting block and
E-Stop
Oct 2009
button
Page
PTC TC 4
CAN_L 1 1 CAN_L
CAN_H 2 2 CAN_H
24V 3 3 24V Em Stop
24V 4 4 24V
0V 5 5 0V In
Em St op 0V 6 6 0V
In EM_STOP+ 7 7 EM_STOP+
PowerMACS 4000 System Design and Installation
EM_STOP+ 8 8 EM_STOP+
EM_STOP- 9 9 EM_STOP-
- less than 2.6A and 24V of TC1, TC2 and TC3 is connected in parallel.
EM_RE SET 10 10EM_RESET

EM_STOP 11 11EM_STOP
EM_NC 12 12EM_NC
CAN_L 1 1 CAN_L
Em St op CAN_H 2 2
24V 3 CAN_H
Out 24V 4 3 24V
- less than 1.8A and 24V of TC1 and TC2 is connected in parallel.
0V 5 4 24V
5 0V Em S top
0V 6 6 0V Out
EM_RE SET 10
EM_STOP 11 10EM_RESET
EM_NC 12 11EM_STOP
12EM_NC
RLY1_NC 1
RLY1_COM 2
RLY1_NO 3
Relay RLY2_NC 4
RLY2_COM 5
Out RLY2_NO 6
RLY3_NC 7
RLY3_COM 8
RLY3_NO 9
RLY4_NC 10
RLY4_COM 11
RLY4_NO 12
TC 2 TC 3
CAN_L 1 1 CAN_L
16,8V
57mA
Em St op CAN_H 2 2 CAN_H
other accessories connected to the 24V is
In 24V 3 3 24V
24V 4 4 24V
24V
24V
Guide
0V 5 5 0V
Em Stop
8A
0V 6 6 0V
EM_STOP+ 7 7 EM_STOP+ In
- less than 1.0A for a one TC system

EM_RESET 10 10 EM_RESET
EM_STOP 11 11 EM_STOP
EM_NC 12 12 EM_NC
7.2.2 Technical specification
CAN_L 1 1 CAN_L
CAN_H 2
7.2.3 Connection examples

Em Stop 2 CAN_H
24V 3
Out 24V 4 3 24V
4 24V
9834 1134 01
0V 5 5 0V
0V 6 6 0V Em Stop
EM_STOP+ 7 7 EM_STOP+ Out
EM_STOP+ 8
EM_STOP- 9 8 EM_STOP+
EM_RESET 10 9 EM_STOP-
10 EM_RESET
EM_STOP 11
Switching Characteristics: EM_NC 12
11 EM_STOP
12 EM_NC
14 -
Min pickup voltage

AHB Number
ASL Number
Nominal Current
Control Voltage
Max Voltage
Max Current
Lift ing Block
Up
Down
0V
Coils:
Example 2. A lifting block controlled by the PM4000 system using the relay outputs. 24V for
the lifting block is supplied by an external 24V supply and connected to the PM4000 E-stop
Date of Issue
Page 30 of 33
Oct 2009
Page
E-Stop
but ton
PTC TC 2
circuit using an E-stop card. Max current for the lifting block is 8A
CAN_L 1 1 CAN_L
CAN_H 2 2 CAN_H
24V 3 3 24V Em St op
24V 4 4 24V
0V 5 5 0V In
Em Stop 0V 6 6 0V
EM_NC 12 12 EM_NC
CAN_L 1 1 CAN_L
Em Stop CAN_H 2 2 CAN_H
24V 3 3 24V
Out 24V 4
0V 5 4 24V
5 0V Em Stop
0V 6
EM_STOP+ 7 6 0V Out
7 EM_STOP+
EM_NC 12 12 EM_NC
RLY1_NC 1
RLY1_COM 2
Guide
RLY1_NO 3
Relay RLY2_NC 4
RLY2_COM 5
Out RLY2_NO 6
RLY3_NC 7
RLY3_COM 8
RLY3_NO 9
RLY4_NC 10
RLY4_COM 11
RLY4_NO 12
9834 1134 01
External 24V Supply

E-Stop Card
24V
0V
14 -
Em Stop NC 1
NC 2
In NC 3
NC 4
NC 5
NC 6
AHB Number
NC 7
ASL Number
NC 8
EM_STOP- 9
EM_RESET 10
EM_STOP 11
EM_NC 12 Lifting Block
EXT
E-Stop Circuit 1 IN 1
E-St op Circuit 1 OUT 2 Up
E-Stop Circuit 2 IN 3 Down
E-St op Circuit 2 OUT 4 0V
E-Stop Circuit 3 IN 5
E-St op Circuit 3 OUT 6
NC_IN 7
NC_OUT 8
NO _IN 9
NO_OUT 10
24V for the lifting block is supplied by an external 24V supply and connected to the PM4000
Example 3. A lifting block controlled by the PM4000 system using an IO-Expander Sealed.
E-stop circuit using an E-stop card. Max current for the lifting block is 8A. The IO-Expander
Date of Issue
Page 31 of 33
Oct 2009
has to be setup to use external 24V, please refer to the IO-Expander Sealed Manual.
Page
E-Stop
button
PTC TC 2
CAN_L 1 1 CAN_L
CAN_H 2 2 CAN_H
24V 3 3 24V Em Stop
24V 4 4 24V
0V 5 5 0V In
Em Stop 0V 6 6 0V
EM_STO P+ 1 8 EM_STOP+
EM_NC 12 12 EM_NC
CAN_L 1 1 CAN_L
Em Stop CAN_H 2 2 CAN_H
24V 3 3 24V
Out 24V 4
0V 5 4 24V
5 0V Em Stop
0V 6 6 0V Out
EM_STO P+ 7
EM_STO P+ 8 7 EM_STOP+
EM_STOP- 9 8 EM_STOP+
EM_RESET 10 9 EM_STOP-
EM_STOP 11 10 EM_RESET
EM_NC 12 11 EM_STOP
12 EM_NC
Guide
9834 1134 01
External 24V Supply

E-Stop Card
24V
0V
Em Stop NC 1
NC 2 IO Expander Sealed
14 -
In NC 3
NC 4 1 24V B: External
NC 5 2 0V Power
NC 6 3 0V
NC 7 4 24V Ext. Stopped
NC 8
AHB Number
1 0V
ASL Number
EM_STOP- 9 2 24V
EM_RESET 10 3 0V
EM_STOP 11 4 Output 8 H: Relay
EM_NC 12 5 Output 7 Output
EXT 6 Output 6
E-Stop Circuit 1 IN 1 7 Output 5
E-St op Circuit 1 OUT 2 8 0V
E-Stop Circuit 2 IN 3 (IO Expander has to be set up
E-St op Circuit 2 OUT 4
E-Stop Circuit 3 IN 5 correctly to use E-stopped 24
E-St op Circuit 3 OUT 6 for Outputs)
NC_IN 7
NC_OUT 8 Lifting Block
NO_IN 9
NO_OUT 10 Up+
Up-
Down+
Down -
Guide Page 32 of 33
Oct 2009
7.2.4 Mounting
See below drawing for hole pattern and dimensions.
8 To check before Power On and during startup

The following general rules shall be followed when connecting the TCs together to a
system.
• All TCs in a system shall have its individual IP address for the internal Ethernet
interface. in consecutive order starting with the primary TC of the system, the default
and most commonly used is 192.168.0.xxx. The first three digits in the IP address e.g.
192.168.0 are setup using the setup menu on the TCs and must be the same for all TCs
in the system. The last part of the IP The address is called the TC number and is also
setup using the setup menu. After startup the TC number will be visible on the screen of
each TC.
• Primary TC. The system Primary TC should be setup as primary, the setup is done
using the setup menu on the TC. PTC will be default setup as primary, and Secondary
TC as non-primary. The system primary must have the lowest TC number in the system.
• Emergency stop must be connected to the Primary TC. It can be an external E-stop
circuit or the E-stop circuit from an Atlas Copco accessory.
• All cables, connectors, etc. shall be tested before the installation for short circuit, lead
and isolation.
• Supply voltages shall be checked to be within the specified tolerances before

connecting to the TC modules. The voltage may not exceed 480 V +5% (see chapter
5.1).
• Check protective grounding and that the other demands described in paragraph 1.1 and
1.2 are fulfilled.
Guide Page 33 of 33
Oct 2009
9 Dimensions
2-D and 3-D CAD files are available per request.

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ASL Number 14 - PowerMACS 4000 System Design and Installation Page

System Design & Installation Guide

1 BEFORE YOU START.....................................................................................................................4

1 Before you start

1.1 General electrical safety demands

A. Grounding the system and each connected unit

It is involved with danger to life and health, to use systems or units,

Systems found, with damages to ground connections or missing or inadequate

B. Checking of system power connections and cabling

Systems where damages to connections or cables are found must be disconnected

C. Follow the Installation Guide and meet the operation demands

D. General requirements and recommendations on installation and handling of power

- Make sure that this Installation Guide is read and followed

1.2 Specific installations demands

2 Main Switch Box and distributor box

2.2 Main Switch Box

2.3 Power Distributor Box

Approved Fuses. Type Class CC. One of following fuses:

2.5 Mechanical Design

2.6 Main Switch Box connector specification

2.7 Description of Signal Connections

The DB II do not have connector X1

2.8 Description of Power Connectors and Fuses

2.8.2 Input Connection

2.8.3 Connection between Main Switch Box and Distribution Box

2.9 Main switch Box front with actuators and indicators

2.10 Main Switch Box Dimensional Drawings

2.11 MSB and DB Technical data

2.12 DB II technical data

3.1 Installation layouts

3.2 Power cables

3.3 E-stop cables

3.4 Ethernet cables

Ethernet switch mounted in bracket

24V Ext Cable

IO Bus Cable IO Bus Cable IO Bus Cable

Stack light IO Box

Indicator Box Cable

Article Order Number

3-phase min 400V, Max 480 VAC +5%, 50/60 Hz min.10A

Generally, the Atlas Copco TC should only be connected to three-phase,

An isolation transformer with grounded star point on the secondary winding

TN or TT mains are to be preferred

4.1 Fuses and power consumption

4.2 Heat generation

4.3 24V output for E-stop and accessories

20 TCs Operator Panel

4.4 Control logic external power supply

24 VDC +/-20% preferably stabilized

Approximate current consumption for one TC is 0,8A, 24 VDC

5.1 Internal I/O

5.2 External I/O

5.3 External FieldBus interface.

6.1 I/O cables

6.2 QST Cable

Primary TC, standalone

Secondary TC, standalone

Jumper between EM STOP IN:3 and EM STOP IN:11

EM STOP IN :11 EM_STOP

EM STOP OUT :11

EM STOP OUT :10 EM_RESET

EM STOP IN :12 EM_NC1

EM STOP OUT :12 EM_NC2