Stanley Alpha QB [PDF]

Zitiervorschau

Instruction Manual

QB Expert Alpha Controller Software Version 5.2.6

English - Original Document - Revision 1 © 2015 STANLEY Black and Decker, Inc. All rights reserved.

Table of Contents Introduction ��������������������������������������������������������������������������������1 1.1 What’s Included

������������������������������������������������������������������������������ 2

1.2 Controller Functions and Connections 1.3 CE Declaration of Conformity

���������������������������������������������� 4

��������������������������������������������������������� 4

1.4 Regulatory Notices for Transmitter ��������������������������������������������������������� 4 1.4.1 1.4.2 1.4.3 1.4.4 1.4.5

FCC Notice (USA) ������������������������������������������������������������������������������� 4 Canadian Compliance Notice ������������������������������������������������������������������� 5 Industry Canada Notice (Canada) ������������������������������������������������������ 5 CE Notice (Europe) ������������������������������������������������������������������������������� 5 WEEE and RoHS Exemption Statement (Europe) ������������������������������������������ 5

1.5 Safety ���������������������������������������������������������������������������������������������������� 6 1.5.1 Warnings and Cautions ������������������������������������������������������������������������������� 6 1.5.2 Safety Instructions for QB Expert Alpha Controllers ������������������������������ 7

1.6 Specifications ������������������������������������������������������������������������������������������ 8 1.6.1 1.6.2 1.6.3 1.6.4 1.6.5

Physical and Environmental Ratings ������������������������������������������������������ 8 Electric Service Ratings ������������������������������������������������������������������������������� 8 E-Stop Precaution ������������������������������������������������������������������������������� 8 Tool Speed and Torque Scatter Versus Electric Supply ������������������������������ 8 Tool Temperature Versus Electric Supply ������������������������������������������������������ 8

1.7 Installation Instructions

Controller Operation

�������������������������������������������������������������������� 9

������������������������������������������������������������� 13

2.1 Data Storage ���������������������������������������������������������������������������������������� 14 2.2 Input and Output Functions 2.3 Software

������������������������������������������������������� 14

���������������������������������������������������������������������������������������� 14

2.4 Embedded PLC

���������������������������������������������������������������������������� 14

2.5 Networking ���������������������������������������������������������������������������������������� 14 2.6 Navigation ���������������������������������������������������������������������������������������� 15 2.7 Display II

���������������������������������������������������������������������������������������� 15

QB Expert Alpha Controller

Table of Contents 2.7.1 Scroll Bar �������������������������������������������������������������������������������������������15 2.7.2 Dropdown �������������������������������������������������������������������������������������������15 2.7.3 Menu Tree �������������������������������������������������������������������������������������������16 2.7.4 Tabs ��������������������������������������������������������������������������������������������������������16 2.7.5 Character Scrollbar ������������������������������������������������������������������������������16 2.7.6 Run Display �������������������������������������������������������������������������������������������16 2.7.7 Fastening Cycle Log ������������������������������������������������������������������������������17 2.7.8 Keypad Mode ������������������������������������������������������������������������������������������ 20 2.7.9 Controller Display Icons ����������������������������������������������������������������������������� 20

2.8 Faults �������������������������������������������������������������������������������������������������� 21 2.9 Messages ���������������������������������������������������������������������������������������� 22

Programming ������������������������������������������������������������������������������25 3.1 SETUP Area ���������������������������������������������������������������������������������������� 26 3.1.1 3.1.2 3.1.3 3.1.4 3.1.5

JOBS: Wizard ������������������������������������������������������������������������������������������ 26 JOBS: Manual Programming ����������������������������������������������������������������� 33 COMMUNICATIONS Menu ����������������������������������������������������������������� 48 OTHER Menu ������������������������������������������������������������������������������������������ 59 RESTORE FACTORY DEFAULTS Menu ���������������������������������������������������� 68

3.2 SERVICE Area

����������������������������������������������������������������������������68

3.2.1 Tool ������������������������������������������������������������������������������������������������������� 69 3.2.2 Controller ������������������������������������������������������������������������������������������ 71

3.3 ANALYZE Area 3.3.1 3.3.2 3.3.3 3.3.4 3.3.5

���������������������������������������������������������������������������� 73

TOOL Tab ������������������������������������������������������������������������������������������ 73 TRACE Tab �������������������������������������������������������������������������������������������74 STATS Tab ������������������������������������������������������������������������������������������ 75 LOG Tab ������������������������������������������������������������������������������������������ 77 I/O Tab ������������������������������������������������������������������������������������������������������� 78

Alpha Toolbox ������������������������������������������������������������������������������81 4.1 Connection ���������������������������������������������������������������������������������������� 82 4.2 Controls

���������������������������������������������������������������������������������������� 82

4.2.1 Menus ������������������������������������������������������������������������������������������������������� 83 4.2.2 Navigation Buttons ����������������������������������������������������������������������������� 84 4.2.3 Import/ Export Buttons ����������������������������������������������������������������������������� 84 4.2.4 Manage Buttons ����������������������������������������������������������������������������� 84

Instruction Manual

III

Table of Contents 4.3 Editing Parameters ����������������������������������������������������������������������������84 4.3.1 Parameter and Data Retrieval ����������������������������������������������������������������� 85

4.4 Trace Data ����������������������������������������������������������������������������������������86 4.4.1 Analyzing Traces ����������������������������������������������������������������������������� 87 4.4.2 Events ������������������������������������������������������������������������������������������������������� 92

4.5 Icons and Security ���������������������������������������������������������������������������� 93

Tool Operation

���������������������������������������������������������������������97

5.1 Tool Specifications ����������������������������������������������������������������������������98 5.1.1 Operator Protection ����������������������������������������������������������������������������� 99 5.1.2 Repetitive Motion ����������������������������������������������������������������������������� 99 5.1.3 Hearing Protection ����������������������������������������������������������������������������� 99 5.1.4 Vibration �����������������������������������������������������������������������������������������100 5.1.5 Breathing Protection ����������������������������������������������������������������������������100 5.1.6 Tool Installation �����������������������������������������������������������������������������������������101 5.1.7 Sockets and Adapters ����������������������������������������������������������������������������101 5.1.8 Cable Installation ����������������������������������������������������������������������������102

5.2 QPM Tool Controls and Operation ����������������������������������������������������� 102 5.2.1 Start Trigger Switch ����������������������������������������������������������������������������102 5.2.2 Tool Memory �����������������������������������������������������������������������������������������102 5.2.3 Display and Multiple Function Button ���������������������������������������������������103 5.2.4 Tool Status Lights ����������������������������������������������������������������������������104 5.2.5 MFB Mode �����������������������������������������������������������������������������������������104 5.2.6 Worklights �����������������������������������������������������������������������������������������105 5.2.7 Program Selection ����������������������������������������������������������������������������105 5.2.8 Directional Control ����������������������������������������������������������������������������105 5.2.9 Tool Temperature ����������������������������������������������������������������������������105 5.2.10 Setting Torque, Angle, and Other Operating Parameter ���������������������������106 5.2.11 Assembly (Forward) Operation ����������������������������������������������������������������106 5.2.12 Disassembly (Reverse) Operation ���������������������������������������������������106

5.3 Special Application Tools ���������������������������������������������������������������� 106 5.3.1 Exposed Gear Socket Tools ����������������������������������������������������������������106 5.3.2 Tubenut Nutrunners ����������������������������������������������������������������������������107

Controller Connections ����������������������������������������������������������� 111 6.1 Power Cord ���������������������������������������������������������������������������������������112 IV

QB Expert Alpha Controller

Table of Contents 6.2 Tool Connector

���������������������������������������������������������������������������112

6.2.1 EA, EB and EC Tools ���������������������������������������������������������������������������� 112 6.2.2 E Tools ������������������������������������������������������������������������������������������������������ 112

6.3 USB Connector

���������������������������������������������������������������������������112

6.4 Serial Connector

���������������������������������������������������������������������������113

6.5 Alpha Toolbox Ethernet Connector

�������������������������������������������114

6.6 Facility/ Spindle Network Ethernet Connectors ���������������������������������114 6.7 Ethernet/IP or Profinet Connectors

�������������������������������������������115

6.8 Trailing DeviceNet™ Connector ������������������������������������������������������115 6.9 Profibus Connector ���������������������������������������������������������������������������115 6.10 Leading DeviceNet Connector

������������������������������������������������������116

6.11 Input and Output Connector

������������������������������������������������������116

6.12 Assignable Input and Output Functions ������������������������������������������ 120 6.12.1 Input Descriptions 6.12.2 Output Descriptions

6.13 MODBUS TCP

����������������������������������������������������������������������������123 ����������������������������������������������������������������������������129

�������������������������������������������������������������������������� 140

6.13.1 Example Map �����������������������������������������������������������������������������������������142

Embedded PLC

������������������������������������������������������������������� 145

7.1 “Rack” Layout 7.1.1

�������������������������������������������������������������������������� 146

Addressing Scheme

����������������������������������������������������������������������������146

7.2 Supported Instructions and File Types 7.3 PLC Editor 7.3.1 7.3.2 7.3.3 7.3.4

�������������������������������������������������������������������������������������� 155

Edit Page Controls ����������������������������������������������������������������������������155 Instruction Box �����������������������������������������������������������������������������������������157 MON and MSG Instructions ����������������������������������������������������������������158 Applying a Name and Version ����������������������������������������������������������������158

7.4 Converting a RSS File

Instruction Manual

������������������������������������������ 147

���������������������������������������������������������������� 158

V

Table of Contents 7.4.1 Invalid Characters ����������������������������������������������������������������������������159 7.4.2 Predefining String or Integer Files ���������������������������������������������������159 7.4.3 Applying a Name and Version ����������������������������������������������������������������160

Multiple Spindle

������������������������������������������������������������������� 163

8.1 Connection �������������������������������������������������������������������������������������� 164 8.2 Disconnect �������������������������������������������������������������������������������������� 166 8.3 Synchronization

�������������������������������������������������������������������������� 166

8.3.1 Operation �����������������������������������������������������������������������������������������167 8.3.2 Recovery �����������������������������������������������������������������������������������������167 8.3.3 Networking �����������������������������������������������������������������������������������������167

Maintenance ���������������������������������������������������������������������������� 171 9.1 Scheduled Maintenance

���������������������������������������������������������������� 172

9.2 Diagnostics and Troubleshooting ����������������������������������������������������� 172 9.2.1 Fault Guide

9.3 Message Guide 9.4 Parts List

�����������������������������������������������������������������������������������������175

�������������������������������������������������������������������������� 183

�������������������������������������������������������������������������������������� 186

Appendix A ���������������������������������������������������������������������������� 189 10.1 Torsion Factor

�������������������������������������������������������������������������� 190

10.2 Angle Validation

�������������������������������������������������������������������������� 190

Glossary ������������������������������������������������������������������������������������� 193 Limited Warranty ������������������������������������������������������������������� 197 12.1 Mechanical Products Limited Warranty ������������������������������������������ 198 12.2 Electronic Products Limited Warranty VI

������������������������������������������ 198

QB Expert Alpha Controller

Table of Contents 12.3 Software Products Limited Warranty

������������������������������������������ 198

12.4 OEM Products Limited Warranty ����������������������������������������������������� 198 12.5 General Terms

�������������������������������������������������������������������������� 198

12.6 Specification Changes

���������������������������������������������������������������� 198

12.7 Warranty Claims

�������������������������������������������������������������������������� 199

12.8 Product Services

�������������������������������������������������������������������������� 199

12.9 Return Material Authorization (RMA) Procedures

Instruction Manual

��������������������� 199

VII

QB Expert Alpha Controller

1

Introduction

What’s Included Controller Functions and Connections CE Declaration of Conformity Regional Notices for Transmitter Safety Specifications Installation Instructions

What’s Included 1

Getting Started This manual is intended to promote proper and safe use and give guidance to owners, employers, supervisors, and others responsible for training and safe use by operators and maintainers. Please contact your Stanley Sales Engineer for further information or assistance on Stanley training or assembly tool operations.

1.1

What’s Included Included with the QB Expert Alpha controller is a power cord, plinth (for mounting), documentation (in the envelope) and a mating connector for the I/O port. The mating connector is included so the end user may connect wires the controller’s I/O port to their requirements.

5

1 2

STANLEY ASSEMBLY TECHNOLOGIES Telephone: +1 (440) 461-5500

5335 Avion Park Drive , Cleveland, OH 44143 USA

Email: [email protected]

URL: http://StanleyAssembly.com

4 3 Item Number

2

Description

1

QB Expert Alpha Controller

2

Plinth for mounting controller

3

Power cord

4

24 V DC I/O mating connector

5

Envelope with Getting Started Documentation

QB Expert Alpha Controller

Introduction

9 POWER

USB

8

2

10 ETHERNET

1

19

SPINDLE

TOOL

12

11 17

I/O

COM PORT

3

13

14

16 4

!

WARNING

ELECTRIC SHOCK HAZARD

To prevent injury disconnect power cord before removing cover

5 7

15

115/230VAC 50/60HZ 10 AMP 1/N/PE~

! AVERTISSMENT RISQUE DE DECHARGE ELECTRIQUE

Pour empecher des dommages debranches le cordon de secteur avant d enlever la couverture

PROTECTED BY ONE OR MORE OF THE FOLLOWING US PATENTS: 5,315,501 5,637,968 6,516,896

6 FIELDBUS OPTIONS

18

See Description on next page

Instruction Manual

3

Controller Functions and Connections 1.2

Controller Functions and Connections This table refers to the picture on the previous page. Item Number

Functional Description

1

Red, Green, Yellow LEDs for Limits Evaluation

2

Programmable and Tool Ready LEDs

3

Display

4

Function Keys with Active Label Above

5

Maintenance Due Indicator

6

Cursor Keys with Center Button to Expand Lists

7

Numeric Keypad to Enter Numbers or Select Options

8

Power Switch

9

Alpha Toolbox Connector

10

USB Port for Data Transfer

11

Tool Connector

12

Plant/ Spindle Network Ethernet Connectors

13

Optional Master DeviceNet Connector

14

Serial Connector

15

Optional Profibus or DeviceNet Connector

16

Power Input

17

19-Pin, 24V DC Input/Output Connector

18

Optional Fieldbus Ethernet Connectors

19

Indicates WiFi Enabled (when present)

Information about these items is discussed elsewhere in this manual. Use the Table of Contents to find the page for the item of interest. If this is an electronic document you are reading click on the item in the Table of Contents and it will link you directly to the page. Or press CNTRL+F on the keyboard to search the document for the item of interest.

1.3

CE Declaration of Conformity STANLEY Engineered Fastening Assembly Technologies declares that the QPM QB Expert Alpha controller conforms to all the applicable regulations of the Machinery Directive. See the CE Declaration of Conformity that is delivered with each QB Expert Alpha controller. The safety instructions on the supplied product information are to be followed.

1.4

Regulatory Notices for Transmitter It is mandatory that national, state and local codes and standards be followed.

1.4.1 FCC Notice (USA) This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) this device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation. This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to Part

4

QB Expert Alpha Controller

Introduction 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures: • reorient or relocate the receiving antenna, • increase the separation between the equipment and receiver, • connect the equipment into an outlet on a circuit different from that to which the receiver is connected, or • consult the dealer or an experienced radio/TV technician for help. This device contains transmitter module FCC ID: TE7WR702N.

CAUTION • To satisfy FCC RF exposure requirements for mobile transmitting devices, a separation distance of 20 cm (7.87 in) or more should be maintained between the antenna of this device and persons during operation. To ensure compliance, operations at closer distances than this are not recommended.

1.4.2 Canadian Compliance Notice This device complies with Industry Canada license-exempt RSS standard(s). Operation is subject to the following two conditions: • This device may not cause interference, and • This device must accept any interference, including interference that may cause undesired operation of the device. Cet appareil est conforme aux norms CNR exemptes de licence d’Industri Canada. Le fonctionnement est soumis aux deux conditions suivantes: • cet appareil ne doit pas provoquer d’interférences et • cet appareil doit accepter toute interérence, y compris celles susceptibles de provoquer un fonctionnement non souhaité de l”appareil.

1.4.3 Industry Canada Notice (Canada) Complies with the Canadian ICES-003 Cleass B specifications. Cet appareil numérique de la classe B est conforme à la norme NMB-003 du Canada. This device complies with RSS 210 of Industry Canada. This device meets all the requirements of the Canadian interference-causing equipment regulations. Cet appareil numérique de la classe B respecte toutes les exigences du Règlement sur le matériel brouilleur de Canada.

1.4.4 CE Notice (Europe) This device has been tested and certified for use in the European Union as a class B product. The ‘CE’ mark has been placed on the device per the labeling requirements of the Directive.

The use of this product in the following countries might be subject to restriction: France, Italy and Norway.

1.4.5 WEEE and RoHS Exemption Statement (Europe) The above listed product is onsidered exempt from the requirements of the RoHS and WEEE directives per the exemption granted to large-scale stationary industrial tools.

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5

Safety 1.5

Safety

1.5.1 Warnings and Cautions The safety notices and warnings for protection against loss of life (the users or service personnel) or for the protection against damage to property are highlighted in this document by the terms and pictograms defined here. The terms used in this document and marked on the equipment itself have the following significance: DANGER Indicates that death or severe personal injury will result if proper precautions are not taken. WARNING Indicates that death or severe personal injury may result if proper precautions are not taken. CAUTION Indicates that property damage may result if proper precautions are not taken.

Indicates an electrical hazard. This icon appears as a part of a DANGER, WARNING, or CAUTION notice. Indicates a fire hazard. This icon appears as a part of a DANGER, WARNING, or CAUTION notice. Indicates a general hazard. This icon appears as a part of a DANGER, WARNING, or CAUTION notice. Indicates that eye protection should be worn. This icon appears as a part of a DANGER, WARNING, or CAUTION notice. Read and understand all the safety r­ ecommendations and all operating instructions before operating tools and controllers.

!

Indicates an item of special interest. Indicates a pinch point hazard. This icon appears as a part of a DANGER, WARNING, or CAUTION notice. Indicates an open wrench pinch point hazard. This icon appears as a part of a DANGER, WARNING, or CAUTION notice. Indicates an environmental hazard. Do not throw equipment into the normal housekeeping refuse bin.

6

QB Expert Alpha Controller

Introduction 1.5.2 Safety Instructions for QB Expert Alpha Controllers

WARNING To Avoid Injury: • Save these instructions for future reference. • Read and understand all the safety recommendations and all operating instructions before operating tools and controllers. Failure to follow all instructions listed below may result in electric shock, fire and/or serious personal injury. • Train all operators in the safe and proper use of power tools. Operators should report any unsafe condition to their supervisor. • Follow all safety recommendations in the manual that apply to the controllers, tools, battery packs and chargers being used and the nature of the work being performed. • Verify that all warning labels illustrated in this manual are readable. Replacement labels are available at no additional cost from ­STANLEY Assembly Technologies. • Only allow suitably qualified personnel to install, program, or maintain this equipment and or system. Follow all manufacturer installation instructions and applicable regulatory electrical codes and safety codes. • These persons must be knowledgeable of any potential sources of danger and maintenance measures as set out in the I­nstallation, Operations, and Maintenance manual. • This product must be transported, stored, and installed as intended, and maintained and operated with care to ensure that the product functions correctly and safely. • Persons responsible for system planning and design must be familiar with the safety concepts of automation equipment. • Install tools in dry, indoor, non-flammable, and non-explosive environments only–Humidity: 0 to 95% noncondensing and T­ emperature: 32 to 122 ºF (0 to +50 ºC). • Do not install worn, damaged, or modified equipment that may be unsuitable for safe use. • Controller plugs must match the outlet and must be earth grounded. Never modify a plug in any way or use any adaptor plugs. • Avoid body contact with electrically energized surfaces when holding a grounded tool. • Prior to connecting a power source, always ensure the tool or controller is turned off. • Limit controller access to trained and qualified personnel. Lock controller cabinets. • Only use equipment and accessories specifically designed to operate with STANLEY assembly tools and use them only in the m ­ anner for which they are intended. • Store idle tools and accessories in a safe location accessible only by trained persons. • Disconnect power source (battery, electricity, etc.) from tool or controller prior to making adjustments, changing accessories, or storing. • Prior to operation, always check and test tools and accessories for damage, misalignment, binding or any other condition that may affect operation. Maintenance and repair should be performed by qualified personnel. • Do not operate tools in or near explosive environments or in the presence of flammable liquids, gases, dust, rain or other wet conditions. • Keep the work area clean, well lit and uncluttered. • Keep unauthorized personnel out of the work area.

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7

Specifications 1.6

Specifications

1.6.1 Physical and Environmental Ratings Width: Dimensions: Height: Depth: Weight: Temperature: Operating Conditions: Humidity: Ingress Protection Rating: IP54

6.0 inches

152 mm

16.0 inches 406 mm 10.4 inches 264 mm 18 pounds 8.2 kgrams 32 to 122 ºF (0 to +50 ºC) 0 to 95 % non-condensing NEMA 3

1.6.2 Electric Service Ratings These are the minimum electric service ratings for the QB Expert Alpha controller and the tools it can control. Tool Model:

100 − 126.5V AC 200 − 253V AC Standby Power Consumption: Continuous

Current for Supply Voltage:

E02-E23 EA23 EB02−EB22 EC02−EC22 15 A 10 A 0.2 A 0.3 kVA

E33-E34 EA33−EA34 EB33-EB34 EC33-EC34 15 A 10 A 0.2 A 0.7 kVA

E44-E45 EB44-EB45 EC44

E55 EB55

20 A * 10 A 0.2 A 1.0kVA

30 A * 10 A 0.2 A 2.2 kVA

* 200−240V AC highly recommended

1.6.3 E-Stop Precaution

WARNING INTEGRATED E-STOP CIRCUIT NOT PRESENT To Avoid Injury: • When a QB Expert Alpha controller connects to a tool where a fault can result in personal injury or substantial damage to property, an E-stop circuit is required. An E-stop circuit must be created in the external electrical service supply line.

1.6.4 Tool Speed and Torque Scatter Versus Electric Supply The minimum electric supply voltage required to attain catalog speeds is 104V AC or 208V AC depending which supply voltage system is used. Supply voltages above these minimums should have NO effect on reducing speed. Supply voltages BELOW these minimums will reduce maximum free speed proportionally; actual speed should be the LOWER of the speed command or the maximum attainable speed. Slow Seek and downshift speeds should not be affected unless they are set close to maximum attainable speed. Similarly torque scatter should NOT be affected by reduced supply voltages.

1.6.5 Tool Temperature Versus Electric Supply Supply voltages that remain within recommended limits during the fastening cycle will provide shortest cycle times and lowest tool temperatures. Tool temperatures on applications with moderate to high prevailing torque levels and/or low (i.e. soft) torque rates stand the most chance of being negatively impacted by low or “sagging”

8

QB Expert Alpha Controller

Introduction supply voltages. Voltage “sag” is a reduction in voltage which occurs when high current draw causes a voltage drop in the supply wiring which reduces voltage at the power plug and consequently reduces maximum attainable tool speed under load. Fuses and breakers are also more likely to blow or trip under these conditions. To minimize these effects, always connect the system to electric service that meets the recommended supply service ratings.

1.7

Installation Instructions

WARNING ELECTRICAL HAZARD To Avoid Injury: • This product should be located away from heat sources such as radiators or other devices that produce heat. • This product should not be subjected to vibration or shock or in close contact with water or other liquids. • To minimize electrical interference, place the module as far away from possible sources of electrical noise, such as arc welding equipment. • Install tools and controllers in dry, indoor, non-flammable, and non-explosive environments only. • Do not use this product near water, for example near a washbowl, wet basement, or the like. • Avoid body contact with electrically energized surfaces when holding a grounded tool. Please refer to the picutres of a plinth and mounting of the QB Expert Alpha controller on the next two pages. Plinths connect to each other with four 10-32 machine screws through openings on the top and right side to threaded openings on the bottom and left side. When mounting plinths are placed next to each other, the centerto-center distance between the mounting holes in different plinths is 2” (50.8 mm). When mounting plinths are place one above another, the center-to-center distance between the mounting holes in different plinths is 6” (152.4 mm). Install the QB Expert Alpha Controller either directly to the wall or to a plinth (part number 21E204300). Fasteners through four mounting holes secure plinths to a wall or other surface. Plinths can be connected using 10-32 threaded holes on the bottom and left side and through holes on the top and right side. Make sure the bolts of the barrel-latches [5] on the plinth are retracted. Place the lower flange of the QB Expert Alpha controller [1] into the lip [2] on the plinth. Align the slot [3] in the flange with the lower mounting-pin [4] on the plinth while placing. Rotate the top of the controller back towards the plinth. Place the openings on the upper flange of the controller [6] over the upper mounting pins [7] on the plinth. Release the bolts on the barrel-latches [5] making sure the bolts enter the two barrels [8] on the controller. Connect the QB Expert Alpha Controller to a power source. Connect one end of the tool cable to the tool and the other end to the QB Expert Alpha controller and press the power switch on the controller. The controller displays a language list at the first boot up. Press the up/down arrows to select a language, then press either NEXT from the interactive menu button or use the Toggle button to save the selection. The controller next prompts for regional settings like Time Zone, Time and Date. Follow the prompts until the run screen appears indicating the controller is ready for programming and operation.

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9

Specifications 6.06 [154] 4.00 [101,6]

2.50 [63,5]

n .195 [4,95]

n .375 [9,53]

12.00 [304,8]

(6-PLACES)

(6-PLACES)

18.00 [457,2]

13.00 [330,2]

Plinth 21E204300

10

QB Expert Alpha Controller

Introduction

4 2

1

1 6

3 7

5

8

8

7

5

Mounting QB Alpha Expert Controller onto Plinth

Instruction Manual

11

QB Expert Alpha Controller

2

Controller Operation Data Storage Input and Output Functions Spoftware Embedded PLC Networking Navigation Display Faults Messages

Data Storage 2

QPM QB Expert Alpha Controller The QB Expert Alpha controller is a modular, high-end, full-featured controller for QPM DC servo power tools with torque transducers. It will control any QPM E, EA, EB or EC series servo motor-powered tool. It utilizes closed loop control of torque, speed and angle so that it can perform various routines for the tool to secure each fastener with the highest quality results. The high precision torque and angle sensors in the tool provide feedback to the QB Expert Alpha controller’s digital control circuit. This circuit compares the feedback values to the programmed values and adjusts the tool’s power and speed values to maintain the programmed speed on the output of the tool until the fastener has achieved the programmed target torque and/or angle value. Once the programmed target value is sensed the control circuit turns off the tool leaving the fastener with the desired amount of preload or clamping force. The QB Expert Alpha controller is certified to IP54 level to withstand the dust, dirt and liquids found in industrial facilities. Installing into other panels is not necessary. Future versions of QB Expert Alpha controllers will have an IEEE 802.11b/g/n radio so that the new QPM cordless line of tools may be added to it as well. Software version 5.2.5 is the first software version to support the QPM cordless tools. The QB Expert Alpha controller is designed to be a lead controller in a multiple tool system. Multiple systems of up to 24 spindles can be configured and managed by the QB Expert Alpha controller. Trailing controllers used in multiple spindle systems can be QB Advanced Alpha or QB Node Alpha or the new QPM cordless tools. The QB Expert Alpha controller can be used as a standalone system as it runs its own tool.

2.1

Data Storage Data associated with 30,000 fastening cycle results and 10,000 traces is stored in the QB Expert Alpha controller. This data is retrieved with a USB memory stick or Alpha Toolbox. SPC analysis is performed by the QB Expert Alpha controller on the stored data.

2.2

Input and Output Functions Bolt Count or Error Proofing functions are an integral part of the QB Expert Alpha controller’s functions. Its eight inputs and eight outputs on the 24V DC I/O connector support these functions to provide expert plant integration to external devices such as a PLC. The inputs and outputs are assignable, and configurable. The QB Expert Alpha controller supports other bus types such as ModbusTCP, which is standard, plus optional Ethernet/IP, Profibus, ProfiNet and DeviceNet. DeviceNet can be ordered as either a scanner or device.

2.3

Software Any computer with a modern web browser connected wirelessly or with an Ethernet cable on the Ethernet network port, or the ATB port, is used to view the QB Expert Alpha controller’s web-based application called Alpha Toolbox. Software is not loaded onto a computer to access the data or configure the controller. Alpha Toolbox updates come with the controller updates.

2.4

Embedded PLC The QB Expert Alpha controller comes with a software PLC that emulates many commands and features of the Allen Bradley SLC-500 series controller. Anyone with logic writing skills and the Alpha Toolbox PLC Editor can program a logic file to add more versatility to the already abundant features of the QB Expert Alpha controller.

2.5

Networking Ethernet and the Internet Protocol using Transport Control Protocol are a powerful and robust means of moving data from one computer to another. Many end users rely on it to collect information from the plant floor equipment. The QB Expert Alpha controllers support the XML (2.0, 2.1), PFCS, NPL, TOOLSNET, OPEN and FORD protocols.

14

QB Expert Alpha Controller

Controller Operation For those that haven’t switched to this more robust means of collecting data, the QB Expert Alpha controller supports the PFCS, OPEN and Toyota PI protocols over a serial connection.

2.6

Navigation The QB Expert Alpha controller’s four navigation and input areas facilitate menu navigation, selection and data input: –– Interactive Menu buttons –– Arrows and Toggle button –– Keypad –– Touch screen Labels for the four interactive menu buttons [1] change with menu selection. If the label is blank, the button has no function for the current screen. 5 The up/down arrows [2] navigate menu and character selections; the left/ right arrows enable backspace and space, as well as navigate between tabs. The Toggle button [3] switches between modes and selects/accepts choices (synonymous with OK interactive menu button). The numeric keypad [4] facilitates data input and menu selection (where applicable) and Job/Task selection when enabled. The five LEDs [5] specify status of the fastening cycle for spindle 1: –– Red indicates high torque/angle; 1 –– Green indicates an OK fastening cycle; 6 –– Yellow indicates low torque/angle; –– White is programmed by the embedded PLC, and 3 4 –– Blue indicates when the tool is enabled to run. 2 The Orange Wrench icon [6] indicates preventive maintenance is due on the tool of spindle 1.

2.7

Display

2.7.1 Scroll Bar A scroll bar appears on the right of the screen when more items are available than the display allows to view at one time. The black scroll bar indicates which list items are currently displayed. No scroll bar means all items are currently displayed. To navigate between menu items, use the up/down arrows or, if available, use the keypad to identify the corresponding menu item number.

2.7.2 Dropdown A dropdown arrow appears to the right of menu items with multiple choices. To view choices, highlight the menu item using the up/down arrows then use the Toggle button to expand the dropdown. Use up/down arrows to scroll and the toggle or interactive menu button to select/accept.

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Display 2.7.3 Menu Tree A menu tree appears beside related menu items.

2.7.4 Tabs Tabs appear at the top when multiple menu selections exist. To navigate between tabs, use the left/right arrows. The active tab is white; inactive tabs are grey.

2.7.5 Character Scrollbar This scrollbar enables adding: a-z, A-Z, 0-9, space, _, -, &, *, $, #, @, !, and a period (language and/or field determines character availability). The up arrow [1] and down arrow [3] direct scrolling with the active character [2] displayed between. Use the QB Expert Alpha controller’s up/down arrows to scroll through character choices. The left arrow backspaces. The right arrow moves one position to the right to input the next character. Push Toggle button or OK interactive menu button to accept entry. The following screens contain the character scrollbar option: ALL, Job (Name), Task (Name) Step (Name), System (Name General), System (Users), WIFI (SSID, Password).

2.7.6 Run Display The Run screen displays normal operating information one spindle at a time. To display a different spindle on a multiple spindle unit press the right or left arrow key to switch to the next spindle tab. 10

6

7

1 2

4

8

3

9 5

Icons identify events [1], see list below. Displays last torque and angle readings with units, when a tool is connected [2]. Up/down arrows next to the torque or angle value indicate the last fastening cycle NOK status whether it

16

QB Expert Alpha Controller

Controller Operation exceeded (up) or did not achieve (down) torque or angle limits. Identifies the active Job [6] and active Task [7]. Identifies Target bolt count [3] and Accumulated bolt count [4] for the active Job. The side scroll bar indicates events are available in the Event Log. Press the down arrow to view the events. The number of fastening cycle attempts indicator is below the bolt count box. The run screen displays unless other programming functions [5] are in use. A Shutoff code is also displayed when applicable [8]. The display also has the current time [10] for the specified region and fastening cycle history in the Fastening cycle Log [9]. The time display [10] will change in the following manner: When a Part ID is received the time will change to the Part ID for 5 seconds and then return to the clock. If the Job or Task has been selected the Job Name:Task Name appear on the screen until the batch count (Job) has been completed and then returns to the clock. The display background color turns red in the event of a fault; see section “2.8 Faults” on page 21. The run display changes to indicate the step in which the tool stopped (providing it did not stop during the audit step).

The Fastening Cycle Log [9] lists the fastening cycles that have occurred in the QB Expert Alpha controller. While viewing the Run Display press the down arrow to access the Fastening Cycle Log.

Use the up/down arrow keys to scroll through the data listed chronologically (newest at the top, oldest at the bottom). Each line identifies a fastening cycle. The first column indicates the fastening cycle status or shutoff code. The second column indicates the achieved torque during the fastening cycle. The third column indicates the achieved angle during the fastening cycle. The fourth column indicates the working bolt count.

2.7.7 Fastening Cycle Log Press the interactive MANAGE button after selecting a data line to display the MANAGE dialog box.

Use the up/down arrow keys and the interactive OK button, or the Toggle button, or the number keys, to select the action required.

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17

Display Export Rundowns will transfer all fastening cycle data to the USB memory stick after choosing a file name. Export Trace will transfer the highlighted fastening cycle trace data to the USB memory stick after choosing a file name. Delete Rundowns will delete all fastening cycle and trace data from the QB Alpha Expert controller. This action cannot be undone.

Press the interactive YES button to delete the data. Press the interactive NO button to cancel the delete action. Use the following sequence to save a Rundown or Trace file. Insert a USB memory stick into the USB port on the bottom of the QB Expert Alpha controller. Use the down arrow to select the Name field. Use the Toggle button to enter edit mode. Use the left arrow to delete the name. Use the up/down arrows or the numeric keypad to write a new file name if required. Press the interactive OK button or the Toggle button to accept the file name.

Press again to save the file to the USB memory stick.

Press the interactive EXIT button to return to the Run screen.

2.7.7.1

Fastening Cycle Details Press the interactive DETAILS button or the Toggle button after selecting a data line to display the details. Details about the event and when it occurred are listed. Rundown ID: The sequential number of the fastening cycle data

Not all items are shown

Tool Model:

The model number of the tool used during this fastening cycle.

Tool Serial:

The serial number of the tool used during this fastening cycle.

Date:

The date the fastening cycle was ran.

Time:

The time the fastening cycle completed.

Job:

The active Job number in which the fastening cycle ran.

Task:

The active Task number in which the fastening cycle ran.

Status:

The overal status of the fastening cycle.

SOC:

Shutoff Code, see section “2.7.7.2 Shutoff Codes” on page 19

Job Count:

The active fastener number for the Job.

Task Count:

The active fastener number for the Task.

Tool The temperature of the tool at shutoff. Temperature: Part ID:

18

The value in the Part ID buffer when the fastening cycle ran.

QB Expert Alpha Controller

Controller Operation Steps:

List the steps used during the fastening cycle. The Audit step values are in Bold.

TC/AM

The Strategy or Smart Step used in the current step.

Torque:

The Torque value achieved in the current step.

Angle

The Angle value achieved in the current step.

Current

The Current value achieved in the current step.

Rate

The Rate value achieved in the current step (if enabled)

Deviation

The Rate Deviation achieved in the current step (if enabled)

Use the up/down arrows to scroll through the Details. Press the interactive BACK button to return to the Fastening Cycle Log.

2.7.7.2

Shutoff Codes Shutoff Codes on the display indicate why a fastening cycle terminates prior to completion. Shutoff Code TIME

Fastening cycle time exceeds programmed Cycle Abort time value.

STOP

Spindle stopped by either the operator or other device.

>115%

Spindle stopped due to torque achieving greater than 115% torque limit for the tool.

FAULT

The tool shutoff due to a Fault. See section “2.8 Faults” on page 21.

STALL

Spindle stopped due to a stall.

SYNC

Spindle failed fastening cycle due to a synchronization error.

T1≠T2

Primary and secondary redundant transducer values are outside comparative limits.

A1≠A2

Primary and secondary redundant angle values are outside comparative limits.

TD YIELD [T] RATE I

2.7.7.3

Description

Spindle stopped due to torque dropping below Torque Drop Threshold Spindle stopped due to bailout on detecting yield during an Angle Control strategy. A torque/angle window violation for the Torque Monitoring portion of the fastening cycle. Torque Rate has exceeded the High Limit or not achieved the Low Limit during a Rate Monitoring portion of the fastening cycle. Current has exceeded the High Current Limit or not achieved the Low Current Limit.

Fastening Cycle Trace Press the interactive TRACE button after scrolling through the log and highlighting a particular line. A Torque vs. Time trace screen is drawn for the highlighted line.

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19

Display

Press the third interactive menu button to change the trace axes.

Use the up/down arrow keys and the interactive OK button or the Toggle button, or the number keys, to select the type required. 1. Torque – Torque vs. time 2. Angle – Angle vs. time 3. Torque/Angle – Torque vs. Angle 4. Speed – Tool Speed vs. time. Press the interactive BACK or EXIT buttons to leave the trace screen.

2.7.8 Keypad Mode When Keypad Mode is set to Job or Task Select (see “3.1.4.1 General Tab” on page 60) at the run screen press the Toggle button or a number on the keypad. A Job/Task window opens. Use the toggle or interactive OK button to accept and switch controller operation to the selected Job/Task number. When the Keypad Mode is set to PART ID (see “3.1.4.1 General Tab” on page 60) at the run screen press the Toggle button or a number on the keypad. A PART ID window opens. Use the up/down arrows to write a character, then the right arrow to move to the next character value to use as the PART ID. The numeric keypad may also be used to write numbers as PART ID. Press the OK interactive menu button to save it. The limit is 32 characters.

2.7.9 Controller Display Icons The QB Expert Alpha Controller has Icons in the upper left corner of the screen to indicate the following: Icon

20

Status

Description

Locked

A password is required to make edits.

Unlocked

Edits are possible, automatically re-locks in time.

Busy/working

Wait for icon to clear before continuing.

Fault; system not operable

Check the run screen for Fault message.

QB Expert Alpha Controller

Controller Operation Icon

2.8

Status

Description

Remote User

A user is editing the parameters in the controller remotely, i.e. through Alpha Toolbox.

Audi Command Port Connected

The controller is connected to an AUDI XML protocol server on the Command port.

Audi Results Port Connected

The controller is connected to an AUDI XML protocol server on the Results port.

PFCS Solicited Port Connected

The controller is connected to a PFCS protocol server on the Solicited port.

PFCS Un-Solicited Port Connected

The controller is connected to a PFCS protocol server on the Un-Solicited port.

OPEN Connected

The controller is connected to an OPEN protocol server.

Toolsnet Connected

The controller is connected to a Toolsnet protocol server.

ToytotaPI Connected

The controller is connected to a ToyotaPI protocol server.

Faults The display background color in normal operation is white. In the event of a fault, the spindle display and the time display backgrounds turn red and the fault description appears on screen. The background color reverts to original only when the fault is cleared.

Here is a list of the Faults in the QB Expert Alpha controller: Overcurrent Fault!

Total Current – the controller software limits the current applied to any tool based on what the tool can handle. This fault is asserted if the total current applied is greater than allowed.

GFI Fault!

The Ground Fault Interrupter has exceeded its current trip point. A current detector monitors the current through the three phases of the motor and asserts this fault when the total current applied to the tool does not equal the total current returned from the tool. All phases are turned off immediately to protect the controller from shorts at the tool end.

Logic Voltage Fault!

The controller monitors the +5VDC, -5VDC and +12VDC of its onboard Power Supply. This fault is asserted when those voltages fall outside of nominal range.

Position Feedback Fault!

The controller is constantly monitoring the resolver zero and span points and asserts this fault if they go outside specification.

Transducer Span Fault!

This fault is asserted when the transducer zero point has shifted far enough to prevent a full scale reading from the transducer.

Transducer Zero Fault!

This fault is asserted when the transducer zero point has shifted far enough to prevent drift compensation at the zero point.

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Messages Temperature Fault!

This fault is asserted when the tool temperature detector has reached the temperature limit set by the Temperature Limit parameter. It resets after detected temperature has dropped by 5°C.

Unrecognized Tool!

The controller is communicating to the tool but does not recognize the model number written in the tool memory board.

Tool Communications!

The controller is not communicating to a tool.

Transducer Current Fault!

Transducer current has fallen outside nominal values. For EA, EB and EC series tools that is 4.16 mA +/- 75% (1 to 7mA).

Unsupported Tool!

The wrong tool type has been connected to the controller. The Alpha controller cannot run the tool that is connected.

Servo Connection Fault!

The CPU has lost communication to the DSP on the Logic board. This may happen on a reboot after and upgrade as the CPU resets before the DSP.

Spindle Communications The lead controller loses communications with a trailing spindle controller.

2.9

Messages Messages appear on the screen when certain non-critical conditions exist. They may appear on any screen at any time.

22

Communication Fault

Used for Toyota PI protocol only. Controller has lost communications to the PI box.

Count Fault

Used for Toyota PI protocol only. Controller and PI box have a bolt count mismatch.

Program Fault

Used for Toyota PI protocol only. More Fastening cycles were performed than the PI box expected.

Tool Update Failed

Controller failed to update the tool configuration.

PLC Message

A user defined message controlled by the internal PLC.

Invalid PLC File

Appears when an invalid PLC file is imported into the controller.

Identifying Spindle

Appears when the Expert is identifying a trailing spindle when the trailing spindle connects or when the interactive IDENTIFY button is pressed.

QB Expert Alpha Controller

Controller Operation

Tool Disabled

Instruction Manual

Along with the onscreen indication, the blue light on the controller and tool MFP extinguishes and the STOPPED output asserts. Tool Disabled Explanations: Undefined Task – The selected Task is not programmed to run an audit step; select another Task or program currently selected Task. Invalid Job/Task – Appears when a Job or Task number less than one or greater than 255 is selected. Network Protocol – The plant control system issued a Stop via a network protocol. Wait for the protocol to remove the Stop command. Error Proofing – Bolt count has been met, reset with a Job Reset input. Stop Issued – An Input is disabling the tool; remove the Stop input. May also be caused by Job/ Task Verify inputs not matching selected Job/ Task. System Initializing – The controller is booting up, please wait. Cycle Lock-out – The Cycle Lockout timer is active, wait for it to reset. Reject Count Exceeded – Indicates the Reject Count has been exceeded. Internal PLC – The internal PLC is commanding the tool to STOP. Not Armed – There are two things that can cause this event: 1. Tubenuts – By default tubenut tools require arming by tapping the MFB before the trigger is pressed to run the tool. 2. Reset Reject – The fastening cycle is NOK and the MFB mode is set to Reset Reject preventing the tool from running until the MFB is pressed to reset the NOK.

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QB Expert Alpha Controller

3

Programming

SETUP Area SERVICE Area ANALYZE Area

SETUP Area 3

Programming WARNING EXCESSIVE TORQUE CONDITION To Avoid Injury: • Only trained and qualified personnel should program controllers. • Never set control limits above the maximum rating of the tool. • Setting control limits above the maximum rating of the tool can cause high reaction torque. • Always test for proper tool operation after programming the controller. The controller uses three main menus to display information and enable programming: –– SETUP menu –– SERVICE menu –– ANALYZE menu Fields with bold font are editable. Fields with gray font are not editable.

To begin programming a tool strategy, press the SETUP interactive menu button.

1. Jobs – use to perform tool strategy programming such as torque and speed parameters. 2. Communications – use to program Ethernet, serial port, fieldbus and network protocol options. 3. Other – use to set parameters for all other features, including system level, users, passwords, I/O and tool functions. 4. Restore Factory Defaults – use to backup/restore/delete programming and return controller to factory defaults. To access, press the corresponding menu number on the keypad, or use the up/down arrow keys to highlight then press the Toggle button.

3.1

SETUP Area This area changes the settings of the Job,s Tasks, Steps, tool strategies, error-proofing, and bolt counting. Users must have SETUP or ADMINISTRATOR access level to modify values in this area.

3.1.1 JOBS: Wizard Jobs controls tool operation for tightening a fastener: one to ninety-nine Tasks and one to twelve Steps. Most controllers operate with a single Job and Task with one or two Steps. Users must have ADMINISTRATOR or SETUP access in order to modify Job settings. This includes Wizard, Manage and Step parameters. The Wizard automatically appears after selecting Jobs if a tool is attached and when a Job or Task is added. The Wizard sets up a Job or Task for simple or complex fastening cycles using the optional strategy controls called Smart Steps.

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QB Expert Alpha Controller

Programming

If no tool is attached or if at least one Job exists, the Job tab appears allowing for expert user programming.

3.1.1.1

Wizard Screens The Wizard presents programming parameters and gives a list of strategy controls (Smart Steps). The first 2 Wizard screens define the Audit step of the Task. The Smart Steps are helper steps inserted either before or after the Audit step. Smart Steps cannot be audit steps. Only STRATEGY steps can be audit steps. A Task must have at least one STRATEGY (non-Smart step) step. When complete the Wizard will have created the Job, Task and appropriate steps based on programming input.

Strategy

Instruction Manual

Identifies the values used for controlling the tool during the a step. Choose the strategy required for the Audit step of the Job and Task being programmed. See section “3.1.2.4 Step Button” on page 39 for an explanation of the strategies. • TORQUE - Torque Control/ Angle Monitor (TC/AM) • ANGLE - Angle Control/ Torque Monitor (AC/TM) • TORQUE & ANGLE - Torque Control/ Angle Control (TC/AC)

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SETUP Area Batch Count

The number of fasteners required to be secured in a Task. Typically used with an error proofing scheme and remote input and output device. Acceptable values are between 1 and 99. The default value is 1. Tool operating units: • NM, Newton Meters • FT LB, Foot Pounds • IN LB, Inch Pounds

Units

• IN OZ, Inch Ounces • KG M, Kilogram Meters • KG CM, Kilogram Centimeters • N CM, Newton Centimeters • N DM, Newton Decimeters

Thread Direction

= 1 FT LB

= 1 NM

1.355818 1 12 192 0.1382552 13.82552 135.5818 13.55818

1 0.7375621 8.850745 141.6119 0.1019716 10.19716 100 10

Use CW (clockwise) for tightening right hand fasteners. Use CCW (counter-clockwise) for tightening left hand fasteners.

To modify a parameter, select the parameter using the up/down arrow keys then press the Toggle button. Enter the appropriate value then press the TOGGLE button. After all parameters/ selections/options are finished, press the NEXT interactive menu button to advance through the Wizard. Repeat for subsequent windows. Press the PREV interactive menu button to move back to previously programmed screens within the Wizard. Press the CANCEL interactive menu button at any time to stop Wizard operation.

TC/AM Selected High Torque

The maximum allowed torque during this step. The Wizard uses the rated torque for the connected tool.

Low Torque

The minimum allowed torque during this step. The Wizard uses zero as the low torque limit of the strategy.

Speed

The speed of the tool’s output in Revolutions Per Minute (RPM). The Wizard uses the maximum speed of the connected tool.

AC/TM Selected Snug Torque

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The point in this step when the controller begins to monitor the tool’s output angle.

QB Expert Alpha Controller

Programming High Angle

The maximum allowed angle in degrees during this step. The Wizard chooses the maximum value as default.

Low Angle

The minimum allowed angle during this step. The Wizard chooses the value of zero degrees as default.

AC/TC Selected See parameter definitions from the other selected strategies. The Audit step is now defined. The Wizard uses the median value, between the High and Low parameters, as the Target. It also calculates and programs other parameters automatically, including: Snug Torque, Threshold Torque, Statistical Torque and High Angle Bailout. Change these values after saving Wizard programming if desired. Next, select the controls (Smart Steps) specific to your application. Multiple step strategies are ways of using more than one step to meet the requirements of a difficult joint. The following features are available through multiple strategies programmed via the Wizard. Use the Toggle button to select or deselect the controls specific to your application. Press the NEXT interactive menu button to view the option screens for each specific control chosen. The Wizard makes assumptions, calculates and presents specific values. Modify these values if necessary.

Not Selected Selected

Instruction Manual

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SETUP Area Creates a Smart Step with an Angle Control/Torque Monitoring strategy that rotates the fastener in the opposite direction as the Audit step is programmed. The fastener threads align with the locking device threads before standard forward rotation and high speed are applied (prevents cross-threads). If selected, this is the first step in the tool strategy. Options include: Wobble

Angle Target

The number of degrees of rotation the socket turns during this step. The Wizard uses 360˚ by default.

Speed

The speed of the tool’s output in Revolutions Per Minute (RPM). The Wizard uses 60 RPM as default.

Max Torque

The maximum allowed torque during this step. A low value is calculated by the Wizard to detect cross-threads and double hits (Rehits).

Creates a Smart Step with an Angle Control/Torque Monitoring strategy that rotates the fastener in the same direction as the Audit step is programmed. The flats of the socket align with the flats on the fastener before standard forward rotation and high speed are applied. Using Slow Seek as a first step also allows for cross-thread and re-hit detection. If selected, this is the first step AFTER Wobble. Options include: Slow Seek

Angle Target

The number of degrees of rotation the socket turns during this step. The Wizard uses 180˚ by default.

Speed

The speed of the tool’s output in Revolutions Per Minute (RPM). The Wizard uses 60 RPM as default.

Max Torque

The maximum allowed torque during this step. A low value is calculated by the Wizard to detect cross-threads and double hits (Re-hits).

In some fastening situations, the initial fastening cycle torque is as high as or higher than the target torque specification limit for the joint. In other cases, such as thread rolling or forming, overcoming friction in getting the fastener started causes the high initial torque. In order to compensate for this high initial torque, the Self Tap control allows the controller to drive the tool for a specified amount of angle at the start of a fastening cycle. Creates a Smart Step with an Angle Control/Torque Monitoring strategy in the same direction as the Audit step is programmed. If selected, this is the first step AFTER Slow Seek. Options include: Snug Torque, Angle Target, Speed, Max Torque. Self Tap

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Snug Torque

The point in this step when the controller begins to monitor the tool’s output angle.

Angle Target

The number of degrees of rotation the socket turns during this step. The Wizard uses 800˚ by default.

Speed

The speed of the tool’s output in Revolutions Per Minute (RPM). The Wizard uses the rated speed of the tool in RPM as default.

Max Torque

The maximum allowed torque during this step. The Wizard uses the tool’s rated torque to prevent any interference.

QB Expert Alpha Controller

Programming Creates two Smart Steps before the Audit step. The first step is a Torque Control/Angle Monitoring strategy that rotates the fastener in the same direction as the Audit step is programmed. This runs a fastener down to an initial torque level. The second is a Back off strategy which partially removes the fastener. The purpose of this procedure is to polish the threads and reduce friction variation during the Audit step. This ensures more consistent results. If selected, this is the first step AFTER Self Tap and Pre-Torque. Options include: Condition Fastener

Down Target Torque

The Target Torque for this step prior to the Back off.

Delay Time

The time delay before the controller starts the next sequential step. Triggered when the tool meets the Down Torque Target and entered in seconds. The Wizard uses 0.05 seconds by default.

Max Time

The maximum time permissible to have the tool energized during this step. Entered in seconds.

Angle Target

The target angle for the Back off step. The Wizard uses 360˚ by default.

The pre-torque runs the fastener to a preliminary torque level and suspends the fastening cycle for a period of time. After a time delay, the Audit step begins. Creates a Smart Step with a Torque Control/Angle Monitoring strategy in the same direction as the Audit step is programmed. If selected, this is the first step AFTER Self Tap. Options include: Pre-Torque

Instruction Manual

Torque Target

The Target Torque for this step. The Wizard uses the Audit step’s Low Torque value by default.

Delay Between Steps

The time period to suspend the tool strategy before continuing entered in seconds. The Wizard uses 0.05 seconds as default.

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AC TM SETUP Area

AC TC

Creates a Torque Control/ Angle Monitor Strategy step AFTER the Audit step and will make the Torque Recovery step the Audit step. The torque parameters of the Torque Recovery step are the same as the Audit step. Sets Merge Torque to Yes. Sets Accumulate Angle to Yes. Sets Torque Display to Final for both steps. TC AM

Torque Recovery

This is the value for the Delay Between Steps of the Audit step prior Relaxation Time to running the Torque Recovery step. The Wizard uses 0.05 seconds as default. Speed

The Speed of the tool’s output in Revolutions Per Minute (RPM) during the Torque Recovery step. The Wizard uses 10 RPM as default.

Rotation Threshold

If the achieved angle in the Torque Recovery step exceeds the Rotation Threshold the torque and angle values displayed and saved are the final torque and final angle of the Torque Recovery step. If the achieved angle in the Torque Recovery step does not exceed the Rotation Threshold in the Torque Recovery step, the torque and angle values displayed and saved are the final torque and final angle of the Audit step. The Wizard uses 0 degrees as default.

Accommodates assembly procedures requiring partial removal of the fastener before additional components can be added to the joint. Creates a Back off strategy Smart Step after the Audit step. The tool stops after achieving either the angle or torque target. If selected, this is the first step AFTER the Audit step. Options include: Backout Fastener

Angle Target

The number of degrees of rotation the socket turns during this step. The Wizard uses 1800˚ by default.

Torque Target

The Target Torque for this step. The Wizard uses the tool’s rated torque as default.

Speed

The speed of the tool’s output in Revolutions Per Minute (RPM). The Wizard uses the rated speed of the tool in RPM as default.

In some fastening situations sockets become stuck on the fasteners. This step reverses the tool and releases the socket without loosening the fastener. Creates an Angle Control or Torque Control (AC/TC) strategy Smart Step that rotates the fastener in the opposite direction of the Audit step. Options include: Fastener Release

Angle Target

The number of degrees of rotation the socket turns during this step. The Wizard uses 50˚ by default.

Speed

The speed of the tool’s output in Revolutions Per Minute (RPM). The Wizard uses the rated speed of the tool in RPM as default.

Max Torque

The maximum allowed torque during this step. The Wizard uses 50% of the rated torque of the tool by default.

Press the FINISH interactive menu button to close the Wizard.

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QB Expert Alpha Controller

Programming The Job tab screen appears. This allows manual editing of parameters prior to saving Wizard programming. To save, press the EXIT interactive menu button.

Press the YES interactive menu button to save changes. This saves the parameters and opens the Run screen.

3.1.2 JOBS: Manual Programming Jobs, Tasks and Steps are required to setup a tool strategy. Inputs and Triggers are used to select specific Jobs or Tasks with different tool strategies, including Error Proofing (bolt counting). Program Job parameters according to the plant integration scheme desired and then program Task(s) and Step(s) to create the tool strategy. Job settings apply to all Tasks and Steps within the Job. There can be up to 255 Jobs per Alpha controller. Select Jobs by pressing the SETUP interactive menu button on the Run screen.

Press 1 or highlight Jobs selection and press the Toggle button.

There can be more than one Job. Name

Instruction Manual

Use the left/right arrow keys to select the tab/Job for modifying.

Name the Job to define the operation performed (15 character maximum). Use the up/ down arrows to spell with letters or use the numeric keypad. When using the PFCS protocol a Machine ID value must be entered here. This name will appear on the Run screen when the Job is selected.

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SETUP Area

Barcode Id

This is a mask that when equal to an incoming PART ID (barcode scan) this Job is selected as the active Job. The PART ID can come from the USB port, serial port, a network protocol, a fieldbus input, the internal PLC or the keypad itself. Use periods (.) to mask the negligible portions of the PART ID; use the exact characters in their exact PART ID positions to select the Job. Example: If a PART ID is 123ABC and if the 3A determines when this Job is to run (the third and fourth positions), then enter “..3A..” as the parameter value. Notice that the periods (.) match the length of the expected PART ID.

Setting this parameter to Yes will allow the selected Job’s bolt count to increment on both Increment Count OK and NOK fastening cycles. If set to No the Job’s bolt count will increment only on OK on NOK fastening cycles.

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Auto Sequence Tasks

When set to Yes, the QB Expert Alpha controller automatically sequences from Task 1 through each Task to the final Task in the Job after the fastener count in each Task is complete. The value of No requires an input to select the Task to run within a Job.

Auto Reset Job

The value of Yes resets the Job automatically after the Batch Count has been met. The tool will not disable with Error Proofing enabled. The value of No requires an Input to Reset the Job.

QB Expert Alpha Controller

Programming The value of Yes causes the tool to disable after the accumulated fastener count equals the target fastener count for the job, unless Auto Reset Job is set to Yes. A Trigger or Input is required to Reset the Job and set the accumulated count to zero. Yes also enables more parameters that will dynamically appear on the screen, see below. The value of No keeps the tool enabled even after the Job’s target count is met. The count will not increase beyond the target value. The value of No will not cause new parameters to appear. This section identifies whether the tool removes the Disassembly (Reverse) function on one of the following events: Yes does not allow the use of Disassembly mode after each OK fastening cycle. The tool can be used to back out fasteners after a NOK fastening cycle. On Cycle OK No allows the use of Disassembly mode after any fastening cycle unless the logic of the following two events is met. Disable Disassembly

On Job Complete

Yes does not allow the use of Disassembly mode after the active Job is complete (accumulated count equals target count). No allows the use of Disassembly mode after a Job is complete unless the logic of the other two events is met.

On All Fasteners Removed

Yes does not allow the use of Disassembly mode after all fasteners have been removed i.e. accumulated count is back to zero. No allows the use of Disassembly mode after all fasteners have been removed unless the logic of the above two events is met.

Enable Error Proofing

This identifies whether the tool disables after each Task has completed. This requires a Reset Job, Task Select or Task Select Bit input to select an incomplete Task which enables the tool for an incomplete Task only. If Auto Sequence Task is used, the tool reenables when the active Task switches to an incomplete Task. Disable Assembly On Task Complete

3.1.2.1

Yes disables the tool when the active Task is complete. If an input switches the controller to a completed Task, the tool is disabled. If an input switches the controller to an incomplete Task, the tool is enabled to complete the Task. No will not disable the tool when the active Task is complete.

Manage Button (Jobs) Press the MANAGE interactive menu button to Add, Delete, Copy or Paste Jobs. The Manage interactive button enables Jobs to be added, deleted, copied to the clipboard and pasted into another Job, imported or Exported using a USB memory stick.

Instruction Manual

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SETUP Area

Adds a Job to the controller. If a tool is attached, the Wizard begins for easy setup of parameters. If a tool is not attached, the Jobs tab appears for manual parameter setup. Add Jobs do not have to be added sequentially. A Job can be added before or after the one that is selected. Jobs renumber automatically after being added. Make a selection and press the OK interactive menu button to add a Job, or CANCEL to not add a Job.

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Delete

Deletes the selected Job from the controller. Jobs cannot be recovered once deleted.

Copy

Copies the selected Job and its associated Tasks and Steps to the Clipboard.

Paste

Overwrites the selected Job with the values residing in the Clipboard. To copy/ move a Job: first create a new Job where it is needed, then copy the Job to be moved, then paste it into the new Job created and delete the original if required.

Import

Imports the selected Job file from the USB memory stick and overwrites all Jobs in the controller. Insert a USB memory stick into the USB port on the bottom of the controller. Use the up and down arrow keys to select Import. Scroll through the files on the USB memory stick until the desired file is selected. Press the OK interactive menu button to import the file. Press EXIT then YES to save the file.

QB Expert Alpha Controller

Programming Writes all Jobs and their parameters to a Job file on the USB memory stick. Use the following sequence to save a Jobs file.

Export

Use the down arrow to select the Name field. Use the Toggle button to enter edit mode. Use the left arrow to delete the name. Use the up/down arrows or the numeric keypad to write a new file name. Press the interactive OK button or the Toggle button to accept the file name. Press again to save the file to the USB memory stick.

Press the interactive OK button to acknowledge the save. Press the EXIT interactive menu button to save changes and return to the Run screen. See section “3.1.2.6 Exit” on page 48

3.1.2.2

Task Button Press the TASK interactive menu button to setup the parameters of the Tasks and Step(s) inside the selected Job. Task settings apply to all Steps inside the Task. The maximum number of Tasks in the Expert Alpha controller is 255. Share these Tasks between the programmed Jobs. There can be up to 99 Tasks per Job. Select Tasks by pressing the TASK interactive menu button. Use the left/right arrow keys to select the tab/Task for modifying.

Name

Name the Task to define the operation performed (15 character maximum). Use the up/ down arrows for letters or use the numeric keypad.

Batch Count

This is the number of OK fastening cycles the Task is required to count before it is completed OK. Zero is not allowed. The default value is 1. The maximum is 99.

Instruction Manual

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SETUP Area Limits the number of NOK (Not OK) fastening cycles in a Task. If the limit is achieved the tool is disabled. Use Reset Job, Task Select or Task Select Bit inputs to recover. Yes turns this function on and increases the Task menu to insert the Reject Count parameter. No turns this function off. The default value is No. Limit Rejects

Reject Count

The maximum number of NOK fastening cycles allowed during this Task. The default value is 3.

Units

Operating torque units. See section “3.1.1.1 Wizard Screens” on page 27 for a list of available units. Each Task does not have to use the same operating torque units as the other Tasks. The default value is Nm.

Thread Direction

For tightening a right-hand fastener use clockwise (CW). Use counter-clockwise (CCW) for left-hand fasteners. The default value is clockwise (CW).

Threshold Torque

The torque level during the fastening cycle when the In Cycle output transitions high. Data is not stored, or available to Alpha Toolbox, unless Threshold Torque is exceeded during the fastening cycle. A good starting point is 20% of Target Torque. The default value is 0.

Statistical Torque

The torque level required to be exceeded before the fastening cycle data is included into Statistics or sent via a network protocol. The default value is 0.

Disassembly Speed

The speed of the tool during (Reverse) operation in RPM (revolutions per minute). The default value is 9999. To limit the speed of the tool reduce this parameter to a value less than the maximum speed of the tool.

Disassembly Acceleration

The rate at which the tool gets to Disassembly Speed in RPM/s (revolutions per minute per second). The default value is 3,000.

Cycle Lock-Out

This is a timer, in seconds, that activates after the tool has reached its target. While active, the tool is disabled. This section sets values used in determining fastening cycle torque rate used in the Rate Control or Yield Control strategies.

Torque Rate

Torque Average Number of Torque samples averaged for the Rate calculation. Calculates a running average from torque samples taken every millisecond. A higher number gives a smoother Rate. The default value is 10 m sec. Angle Interval

Modified

3.1.2.3

Used to calculate the Torque vs. Angle Rate. Larger intervals may give a smoother Rate. The default value is 20°.

A value that is changed by the controller to indicate the date and time parameter values were last changed in this Task or associated Steps.

Manage Button (Task) Manage enables Tasks and their settings to be added, deleted, copied to the clipboard and pasted into another

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QB Expert Alpha Controller

Programming Task.

Adds a Task to the controller. If a tool is attached, the Wizard begins for easy setup of parameters. If a tool is not attached the Tasks tab appears for manual parameter setup. Add Tasks do not have to be added sequentially. A Task can be added before or after the one that is selected. Tasks renumber automatically after being added. Make a selection and press OK to add a Task, or CANCEL to not add a Task Delete

Deletes the selected Task from the controller. Tasks cannot be recovered once deleted.

Copy

Copies the selected Task and its associated Steps to the Clipboard.

Paste

Overwrites the selected Task with the values residing in the Clipboard. To copy/ move a Task: first create a new Task where it is needed, than copy the Task to be moved, then paste into the new Task created and delete the original if required.

Press the EXIT interactive menu button to save changes and return to the Run screen. See section “3.1.2.6 Exit” on page 48. Press the BACK interactive menu button to return to the Job level.

3.1.2.4

Step Button Press the STEP interactive menu button to setup the parameters of the Step(s) inside the selected Task.

Step settings only affect the selected Job and Task. There can be only one Audit step per Task. Each Step is

Instruction Manual

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SETUP Area represented by its own tab. Use the left/right arrow keys to select the tab/Step for modifying. There are a maximum of 12 Steps in each Task. The parameters for all strategy types are listed. Not all parameters are shown on the display at one time. Use the TC more parameters. AC TMbar on the display toAC scroll view Name

Provides an identifier for the step (15 characters maximum). Use the up/down arrows for letters or use the numeric keypad. Identifies values used to control the tool during a Step and to control the Step’s direction. Strategies include: TC / TC AM AM

Torque Control with Angle Monitor. The controller shuts off the tool when the target torque value is achieved. The controller also monitors angle which can indicate changes in joint rate. Audit Step torque and angle results must fall within their specified limits for the fastening cycle to be acceptable (OK).

TM AC AC / TM

AC TC Angle Control with Torque Monitor. The controller shuts off the tool when the target angle value is achieved after a selected snug torque value. The controller also monitors torque. Audit Step torque and angle readings must fall within their specified limits for the fastening cycle to be acceptable.

Strategy (Standard)

AC/TA

AC / TC

AC TM

AC TC

AC/TA Strategy (Advanced) TC AM

AC AC/TA / TA

AC TC AC TM Angle Control and Torque Control. This strategy enables precision TC AM control for both torque and angle on critical joints. The controller shuts off the tool when both a target torque value and a target angle value are achieved after a selected snug torque value occurs. Audit Step final torque and angle results must fall within their specified limits for the fastening cycle to be acceptable. The controller also shuts off the tool when it determines that target torque and angle TC AM cannot be reached (i.e. Bailout limits have been achieved). Angle Control or Torque Control. The controller shuts off the tool when either a target torque value or a target angle value is achieved after a selected snug torque value occurs. Bailouts are set to the targets. Audit Step final torque and angle results must fall within their specification limits for the fastening cycle to be judged acceptable.

Angle Control with Torque Average. The controller performs a standard Angle Control strategy with the exception that the torque results are the average torque achieved during the step.

/TA

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QB Expert Alpha Controller

Programming TC AM

RC / AM

AC/TA AC/TA

YC / AM

Yield Control with Angle Monitor. The controller shuts off the tool when the falling target rate value is achieved after a selected snug torque value. The controller also monitors angle. Audit Step torque and angle readings must fall within their specified limits for the fastening cycle to be acceptable.

BACK OFF

Reverse Angle Control or Torque Control. The controller runs the tool in the opposite direction and shuts off the tool when either a lowering target torque value or a target angle value. Torque has priority over TC will shut off if torque target is reached TM Angle.ACWhich means theACtool before the angle target. Audit Step torque and angle readings must fall within their specification limits for the fastening cycle to be judged acceptable.

PC / TM

Position Control with Torque TC AM Monitor. The controller shuts off the tool when the tool zero position is achieved after a selected snug torque value. The controller also monitors the torque. Audit Step torque and angle readings must fall within their specified limits for the fastening cycle to be acceptable.

AC/TA Strategy (Advanced)

Rate Control with Angle Monitor. The controller shuts off the tool TCtarget AM rate value is achieved after a selected snug when the rising torque value. The controller also monitors angle. Audit Step torque and angle readings must fall within their specified limits for the fastening cycle to be acceptable.

TC AM

AC TM

AC TC

AC/TA

Torque Target

The torque at which the controller shuts off the tool. Should be greater than Low Torque and lower than High Torque. Units are the selected torque units.

High Torque

The maximum peak torque for an acceptable fastening cycle (required for all steps). If the actual torque exceeds this limit the fastening cycle will be flagged as NOK and the RED LED on the front panel and tool illuminates. Must be greater than Torque Target and less than or equal to the rated torque marked on the tool. Units are the selected torque units.

Low Torque

The minimum peak torque for an acceptable fastening cycle. If the actual torque does not reach this limit, the fastening cycle is flagged as NOK and the YELLOW LED on the front panel and tool illuminates. Must be less than the Torque Target. Units are the selected torque units.

Torque Display

Selects which achieved torque value to store, display and use to compare against limits for fastening cycle status. PEAK will choose the peak torque during the step, FINAL will choose the torque at peak angle during the step.

Accumulate Angle

Yes carries the angle over from the previous step. The angle value is from the previous step’s Snug Torque to this active step’s peak angle. No turns this function off. The default is NO requiring a Snug Torque value for this step.

Snug Torque

The point in the step when the controller begins to monitor the tool’s output angle. Should be greater than 0 and less than Low Torque. A value of 50% of Torque Target is a good starting point. Units are the selected torque units.

Instruction Manual

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SETUP Area Angle Target

The angle at which the controller shuts off the tool after a selected Snug Torque value. Should be greater than Low Angle and lower than High Angle. Units are degrees of rotation.

High Angle

The maximum peak angle for an acceptable fastening cycle (required for all steps). If the actual angle exceeds this limit the fastening cycle will be flagged as NOK and the RED LED on the front panel and tool illuminates. Must be greater than Low Angle. Units are degrees of rotation.

Low Angle

The minimum peak angle for an acceptable fastening cycle. If the achieved angle does not reach this limit the fastening cycle will be flagged as a NOK and the YELLOW LED on the front panel and tool illuminates. Must be less than High Angle. Units are degrees of rotation.

Angle Reset

Resets the achieved angle value to zero if torque drops below Snug Torque during the step. Yes will shutoff the tool when the High Torque parameter is exceeded during any Angle Control strategy. No will shutoff the tool when the Torque Bailout parameter is exceeded during any Angle Control strategy. Requires the Torque Bailout value to be set. Should be set equal to or above High Torque. Units are the selected torque units.

Bailout on High Torque Torque Bailout

The torque value at which the tool will shutoff during an Angle Control strategy if the tool has not reached target angle.

Yes will shutoff the tool when the High Angle parameter is exceeded during any Torque Control strategy. No will cause the tool to stop when the Angle Bailout parameter is exceeded during any Torque Control strategy. Requires the Angle Bailout value to be set. Should be set equal to or above High Angle. Units are degrees of rotation. Bailout on High Angle Angle Bailout

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The angle value at which the tool will shutoff during an Torque Control strategy if the tool has not reached target torque.

QB Expert Alpha Controller

Programming Provides a torque window during the rundown phase of the fastening cycle into which achieved torque must pass through. This window looks back from the Snug Torque of the step over the angle interval defined. If achieved torque is outside the window the fastening cycle is ended with the Shutoff Code of [T]. YES enables this monitor, NO disables this monitor.

Monitor Torque Window Upper Torque

Defines the high torque limit for the window.

Lower Torque

Defines the low torque limit for the window.

Upper Angle

Defines the low angle limit for the window referenced from when the Snug Torque value.

Lower Angle

Defines the high angle limit for the window referenced from when the Snug Torque value.

Provides Torque Rate Monitoring during the step between a Rate Threshold to final torque of the step. AVERAGE will provide the average torque rate during the step. INSTANT will provide the instantaneous rate at the step target. Only available during Torque Control strategies. NO disables this monitoring. The shutoff code is RATE.

Monitor Torque Rate

Instruction Manual

Rate Threshold

Defines the torque at which this monitoring begins

High Rate

The maximum peak rate for an acceptable fastening cycle. If the actual rate exceeds this limit the fastening cycle will be flagged as NOK and the RED LED on the front panel and tool illuminates.

Low Rate

The minimum peak rate for an acceptable fastening cycle. If the actual rate does not achieve this limit the fastening cycle will be flagged as NOK and the YELLOW LED on the front panel and tool illuminates.

Deviation Limit

Correlation coefficient for least square fit (straight line) of the torque rate curve. A higher number correlates to a straighter line. If any point exceeds the Deviation Limit the fastening cycle will be flagged as NOK and the RED and YELLOW LEDs on the front panel and tool illuminates.

43

SETUP Area The controller shuts off the tool if the achieved torque drops below the peak torque by a defined percentage. YES turns this monitoring on. NO turns this monitoring off.

Bailout on Torque Drop

Torque Drop Torque Threshold Filter

44

The value, as a percentage of running peak torque, the torque must drop before the controller shuts off the tool. The torque at which this monitoring begins. The amount of angle the tool’s output must rotate where the torque drop must be maintained before the fastening cycle is ended with a shutoff code of TD.

Speed

The velocity of the output of the tool before any Downshift Mode activates (required for any step). Units are RPM. Must be greater than 0. Default is 9999.

Acceleration

The rate the tool ramps up to Speed in RPM/s (revolutions per minute per second). Should be greater than 1,000 RPM/s. The default is 3,000 RPM/s.

QB Expert Alpha Controller

Programming Selects the type of spindle inertia control toward the end of a fastening cycle. Disabled

Manual

Downshift Mode

ATC

ATC+

Does not reduce the speed of the motor. Reduces the tool speed to a specific value (Downshift Speed) when a specific torque value (Downshift Torque) is reached during the fastening cycle. Speed units are RPM, torque is in torque units.

Enables the Adaptive Tightening Control algorithm to slow the tool’s speed as the torque rises. The default values can be modified for when the algorithm starts (ATC Starting Torque), when it ends (ATC Ending Torque) and the tool speed after the algorithm ends (ATC Ending Speed). The torque units are a percent of Target Torque. The speed values are a percent of Speed.

Enables the Adaptive Tightening Control Plus algorithm to slow the tool’s speed based on a sampled torque rate. The default values can be modified for when the algorithm starts monitoring rate (Threshold Low), when it stops monitoring rate (Threshold High) and the tool speed after the algorithm ends (Minimum Speed). The torque units are a percent of Target Torque. The speed values are a percent of maximum speed of the tool.

Abort Timer

Stops the tool when the time has elapsed from the start of the step. The value should be long enough to complete the fastening cycle during this step.

Delay Between Steps

The time the tool delays before proceeding with the next step in the Task. Entered in seconds.

Power

The maximum power available to the tool to perform the fastening cycle. Required for all steps. Units are percent of maximum rated torque of the tool. Should not be less than 100%.

High Current

The maximum current for an acceptable fastening cycle. If the achieved tool current exceeds this limit the fastening cycle is flagged as NOK and the RED LED on the front panel and tool illuminates. Must be greater than Low Current. Units are percent.

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SETUP Area Low Current

The minimum current for an acceptable fastening cycle. If the actual tool current does not reach this limit the fastening cycle is flagged as a NOK and the YELLOW LED on the front panel and tool illuminates. Must be less than High Current. Units are percent. This controls how the tool is turned off AFTER reaching target torque. This is designed as an ergonomic benefit to ease operator discomfort with direct-drive tools.

Soft Stop If AUTO is selected the tool is dynamically controlled to a stop. If Yes is selected the tool’s current will be removed for the time specified in Current Off Time, then reapplied for the time specified in the Current Hold Time, then current will ramp to zero over the time specified in Current Ramp Time. Units are in seconds.

3.1.2.5

Max Torque Bailout

Determines when to stop the tool based on exceeding a maximum torque value during the Angle Control/ Torque Averaging strategy. Units are the selected torque units.

Min Torque Bailout

Determines when to stop the tool based on dropping below a minimum torque value during the Angle Control/ Torque Averaging strategy. Units are the selected torque units.

Torque Compensation

Yes will use the average torque achieved during an Angle Control/ Torque Averaging strategy as the zero torque for the next immediate step only.

Merge Torque

Carries the torque over from one step to another as if the two steps were actually one step.

Rate Target

The rising slope rate at which the controller shuts off the tool. Units are the selected torque units/degrees of rotation.

Yield Target

The falling slope rate at which the controller shuts off the tool. Units are the selected torque units/degrees of rotation.

Max Torque

A combination of the High Torque and Bailout on High Torque parameters. Used in Angle Control Smart Steps only.

Position Target

The number of degrees from Tool Zero Position where the controller will shut off the tool during a Position Control / Torque Monitor strategy after achieving Snug Torque.

Manage Button (Step) Manage enables step settings to be added, deleted, and/or copied to the clipboard and pasted.

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QB Expert Alpha Controller

Programming

Adds a Step to the selected Task.

Steps do not have to be added sequentially. A Step can be added before or after the one that is selected. Steps renumber automatically after being added. Make a selection and press OK to add a Step, or CANCEL to not add a Step.

Add

Use the Up and Down arrow to select the option required then press the interactive OK button. STRATEGY creates a step using a strategy from the list above. Only Strategy steps can be assigned as audit steps. WOBBLE, SLOW SEEK, SELF TAP, PRE-TORQUE, BACKOUT and RELEASE selections create Smart Steps in their required order. Smart Steps cannot be audit steps. See section “3.1.1.1 Wizard Screens” on page 27 for a description of these Smart Steps. Delete

Deletes the selected Step from the Task. Steps cannot be recovered once deleted.

Copy

Copies the selected Step to the Clipboard.

Paste

Overwrites the selected Step with the values residing in the Clipboard. To copy/ move a Step: first create a new Step where it is needed, than copy the Step to be moved, then paste into the new Step created and delete the original if required.

Press the EXIT interactive menu button to save changes and return to the Run screen. See section “3.1.2.6 Exit” on page 48. Press the BACK interactive menu button to return to the Task level.

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SETUP Area 3.1.2.6

Exit Programming changes are stored after exiting current menu.

Press the YES interactive menu button to save the changes and exit the programming mode. Press NO to discard the current changes and exit the programming mode. Press CANCEL to not exit the programming mode and continue modifying parameters.

3.1.3 COMMUNICATIONS Menu This area changes the setting of the Ethernet, Serial and fieldbus Communications port(s) located on the bottom of the Alpha. Users must have COMMUNICATIONS, SETUP or ADMINISTRATOR access level to modify values in this area. Select Communications by pressing the SETUP interactive menu button on the Run screen. Press 2 or highlight selection and press Toggle button.

3.1.3.1

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TCP/IP Tab

QB Expert Alpha Controller

Programming This information is required when connecting the Alpha controller to an Ethernet network using the Ethernet port. Yes allows the Alpha controller to receive an address from the network DHCP server. No requires the address parameters to be filled in manually. Obtain IP From Network

Network

Physical

3.1.3.1.1

IP Address

The IP Address of the Alpha controller.

Subnet Mask

The Subnet address of the Alpha controller.

Gateway

The Gateway address to a connecting network.

DNS

The address of the network’s DNS server.

This is the MAC id of the Ethernet port on the Alpha controller. This value comes from the Ethernet board inside and cannot be changed.

RENEW Button Press this button have the controller initiate a GET IP ADDRESS request to the network. Use the right arrow to move to the next tab or press EXIT to save the changes and return to the Run screen. See section “3.1.2.6 Exit” on page 48.

3.1.3.2

WIFI Tab Use these parameters to setup the access point to connect QPM Cordless tools to the Expert Alpha controller. The access point may also be used to connect computers or other devices with browsers to Alpha Toolbox.

To enable wireless communications for the Expert Alpha controller, type in an SSID value, type in a PASSWORD and choose the applicable REGION. Enable

Instruction Manual

Yes - Enables the radio in the Expert Alpha controller. No - Disables the radio in the Expert Alpha controller. The following parameters do not appear unless Enable is set to YES.

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SETUP Area

3.1.3.2.1

Name

This parameter sets the Service Set Identifier (SSID) for the access point in the QPM Expert Alpha controller. The maximum number of case sensitive, alphanumeric (ASCII) characters is 32. It is recommended to use a value that best defines the station under test from other stations. Use the up and down arrows on the keypad to insert characters. Use the right arrow to move the cursor for the next character. If left blank the default SSID for the QPM Expert Alpha controller is QB-serialnumber, where serialnumber is the serial number of the controller; i.e. QB-032014007.

Password

This parameter sets the encryption key needed to connect a wireless device to the access point in the QPM Expert Alpha controller. Must be a minimum of 8 characters and no longer than 63 printable characters or 64 hexadecimal digits. Use the up and down arrows on the keypad to insert characters. Use the right arrow to move the cursor for the next character. This parameter can be left blank.

Region

Select from the drop-down list the region of the world where the tool is operating. This selects the correct frequency channels allowed by that region.

SHOW Button Normally the password displays as dots when typed. To see the password press the SHOW interactive menu button.

3.1.3.2.2

PAIR Button Press the PAIR interactive menu button to initiate the pairing mode to a QPM Cordless Tool. This will switch the access point to a pairing SSID while the Expert Alpha controller is in pairing mode. To pair a QPM Cordless Tool after pressing the PAIR button ensure the QPM Cordless Tool is off by removing the battery pack and re-installing the battery pack. Wake the QPM Cordless Tool into pairing mode by pressing and holding the MFB and then tap the start trigger switch. Wait for the tone before releasing the MFB. The QPM Cordless Tool will find the Expert Alpha controller and request to be added as a trailing spindle by turning on, then off, the status lights in sequence. Accept the QPM Cordless Tool as a trailing spindle on the Expert. See Section “8.1 Connection” on page 164 to see how to accept the spindle as a trailing device. Press the BACK interactive menu button when the pairing operation is complete to return the access point to normal mode and the user defined SSID. Use the right arrow to move to the next tab or press EXIT to save the changes and return to the Run screen. See section “3.1.2.6 Exit” on page 48.

3.1.3.3

Serial Tab Selects the function for the db-9 COM PORT connector on the bottom of the Alpha controller.

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QB Expert Alpha Controller

Programming

BARCODE / PRINTER

The port performs both functions at the same time. Barcode: The port reads input from a barcode scanner and places it into the PART ID buffer. Data in the PART ID buffer is added to the fastening cycle data when stored and transmitted via a network protocol or printed. Print: A pre-defined data string is sent out the port after each fastening cycle that exceeds the Threshold Torque. See section “6.4 Serial Connector” on page 113 for string definitions. Baudrate

The data transmission rate in bits/second for communication.

Parity

Used to determine if data was lost or compromised during transfer.

TOYOTA PI

Connects this port to the Toyota PI box.

PFCS

Connects this port to the Chrysler network.

OPEN

Connects this port to a network using the OPEN protocol with serial messaging.

PLC

The internal PLC takes over communications on this port. Baud rate and Parity of the Serial port may be changed for PLC communications. Set these values according to the requirements of the end user. Baudrate

The data transmission rate in bits/second for communication.

Parity

Used to determine if data was lost or compromised during transfer.

Use the right arrow to move to the next tab or press EXIT to save the changes and return to the Run screen. See section “3.1.2.6 Exit” on page 48.

3.1.3.4

PFCS Tab The plant’s System group must provide these values to allow the Alpha controller to communicate on the PFCS or NPL network. If using the NPL network there is a setup per spindle, even in a multiple. Be sure to select each spindle that needs to report to the NPL and setup these parameters.

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SETUP Area Choose which type of PFCS communications to be used.

Type

Server IP

BASIC

This is the standard protocol used at Chrysler facilities.

BASIC NPL

This is the enhanced protocol used at Fiat facilities. The controller is enabled by the network, performs many operations until disabled by the network.

SMART NPL

This is the enhanced protocol used at Fiat facilities. The controller is enabled for a specific Job by the network, after successfully completing the job the controller disables itself.

Type the IP Address of the PFCS server on the network. This port is used to send fastening cycle status and data to the PFS system. Enable or Disable this port as required. When enabled type the port number.

Solicited Port

Port Number

The required virtual port on which the Alpha will communicate to the plant network. Starts with 10,000.

Wait to Connect

Time period in seconds between a disconnect and an attempt to reconnect.

Wait for Data

The time period in seconds where the controller waits for a reply to a request sent to the server.

Wait for ACK

The time period to wait between when the controller sends data to the server and it should receive an acknowledgment. If no ACK in this time period the data sent again 3 times.

Keep Alive

The time in seconds for an inactivity timeout between messages when the controller sends a KEEP ALIVE message to ensure cable integrity.

This port is used by the PFS system to select the Job number on the Alpha controller. Enable or Disable this port as required. When enabled type the port number.

Unsolicited Port

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Port Number

The required virtual port on which the Alpha will communicate to the plant network. Must be a different port number than the Solicited Port.

Machine ID

Required for Smart or Basic NPL. May be used for Basic PFCS. The Machine ID for the port.

Wait to Connect

Time period in seconds between a disconnect and an attempt to reconnect.

Wait for Data

The time period in seconds where the controller waits for a reply to a request sent to the server.

Wait for ACK

The time period to wait between when the controller sends data to the server and it should receive an acknowledgment. If no ACK in this time period the data sent again 3 times.

Keep Alive

The time in seconds for an inactivity timeout between messages when the controller sends a KEEP ALIVE message to ensure cable integrity.

QB Expert Alpha Controller

Programming Use these setting when implementing the NPL protocol communications at Fiat facilities. Operation Mode

AUTO: Sends keep alive messages as necessary. MANUAL: Keep Alive messages are not sent.

Manual Messaging Buffer Size

The size in characters to set aside to receive network messages. Maximum size is 4096 characters (bytes).

Transfer Mode

For Smart NPL only. Mode 1: NOKs are sent when they happen (TR) and in final message when the Job is complete (ER). Mode 2: N  OKs are sent when they happen (TR) and sent in the final message only when the Job failed. OKs are send as ER when Job is complete and passes. Mode 3: All results are sent as they happen (TR). Final fastening cycle in Job is sent as ER.

NPL Settings

There are OPTIONS which can be adjusted based on plant Systems requirements. Options

Rundown Data

Specify the PART ID as VIN or AVI.

Buffer While Offline

Select YES to allow the controller to buffer the fastening cycle data while the controller is off line (disconnected from the network). NO means the controller will not buffer data for network retrieval.

Change these parameter values as required by Systems department. Units are in seconds. Wait to Connect Wait for Data

The time period where the controller waits for a reply to a request sent to the server.

Wait for ACK

The time period to wait between when the controller sends data to the server and it should receive an acknowledgment. If no ACK in this time period the data sent again 3 times.

Keep Alive

The time for an inactivity timeout between messages when the controller sends a KEEP ALIVE message to ensure cable integrity.

Timers

PFCS Version

Time period between a disconnect and an attempt to reconnect.

This is the installed version of the PFCS protocol. Check with the Chrysler’s Systems group to determine if this has been approved for use in the facility.

Use the right arrow to move to the next tab or press EXIT to save the changes and return to the Run screen. See section “3.1.2.6 Exit” on page 48.

3.1.3.5

OPEN Tab The plant’s IT department must provide these values to allow the Alpha controller to communicate on the OPEN protocol network.

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SETUP Area

Port

The required virtual port on which the Alpha will communicate to the plant network. Normally 4545.

Cell

Type the cell number where this Alpha controller resides.

Yes causes the Alpha controller to buffer data for 100 fastening cycles when the server Buffer While Off connection is lost. Upon reconnection, the buffered data transmits to the server. No does Line not buffer any data when the server connection is lost. Send Fastener Removed

Yes sends the FASTENER REMOVED message when the Alpha controller detects a tightened fastener is removed. No stops the message from transmitting.

Number of Tries

This is the number of times the Alpha controller sends a message to the server when no ACK message is received.

Max Connections

The maximum number of connections the Alpha controller allows the server. The Alpha cannot have more than 10 connections.

Wait for Ack

The time in seconds to wait for an ACK before retransmitting information.

Use the right arrow to move to the next tab or press EXIT to save the changes and return to the Run screen. See section “3.1.2.6 Exit” on page 48.

3.1.3.6

TOOLSNET Tab The plant’s IT department must provide these values to allow the Alpha controller to communicate on the Toolsnet protocol network. The Expert Alpha controller will communicate only with a Toolsnet server that employs a PIM server (i.e. World Version 7).

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QB Expert Alpha Controller

Programming

Server IP

Type the IP Address of the Toolsnet server on the network.

Port

The required virtual port on which to communicate this protocol. For the Expert Alpha controller it is normally 6575.

System

Type the cell number where this Alpha controller resides.

System Name

Type the system number where this Alpha controller resides.

Station

Type the Station number where this Alpha controller resides.

Station Name

Type the Station name where this Alpha controller resides. Selects the types of traces that are sent to the server.

Trace

None

No traces are sent to the server.

All

All traces are sent to the server.

OK

Only OK fastening cycle traces are sent to the server.

NOK

Only NOK fastening cycle traces are sent to the server.

Use the right arrow to move to the next tab or press EXIT to save the changes and return to the Run screen. See section “3.1.2.6 Exit” on page 48.

3.1.3.7

XML Tab The plant’s IT department must provide these values to allow the Alpha controller to communicate on the XML protocol network.

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SETUP Area

Enable or Disable XML communications as required. Once enabled select the correct software and results server and ports. Version XML Results Server Communications

Now supports version 2.0 and 2.1. Choose the correct one for the facility. Type the IP Address of the Results Server on the network.

Results Port

The virtual port on the XML protocol network server where the Alpha controller transmits messages.

Command Port

The virtual port where the Alpha controller receives commands from the XML protocol network server.

Use the right arrow to move to the next tab or press EXIT to save the changes and return to the Run screen. See section “3.1.2.6 Exit” on page 48.

3.1.3.8

SCANNER Tab This tab appears on Alpha controllers only when the leading DeviceNet port option is installed and sets the communications parameters for the Alpha controller’s DeviceNet network. This allows the Expert Alpha controller to control devices on its own DeviceNet network.

To set the DeviceNet network’s communication rate use the up/down arrows to select Baudrate. Press the Toggle button. Choices include: 125 K bits/s, 250 K bits/s and 500 K bits/s. Use the up/down arrows to choose the baud rate and press the OK interactive menu button. If no trailing devices are listed then they have to be added. They can be added in two different ways. They can be added manually using ADD function or automatically by using the SCAN function. Both functions are accessed with the MANAGE interactive menu button.

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QB Expert Alpha Controller

Programming 3.1.3.8.1

MANAGE Button Press the MANAGE interactive menu button.

EDIT

This edits the selected device that has already been added to the controller. This adds a device for the Expert to control. Set the options for the devices added in the Scanner dialog box.

ADD

Mac Id

The Machine Id or Node number of the new device.

Connection

The type of connection to the device. The Expert DeviceNet Scanner card supports Change of State, Polled, Cyclic and Bit Strobe.

Consumed Length Output Produced Length Input

The number of bytes consumed by the device. The output address of the device for embedded PLC logic. Controller generated The number of bytes produced by the device. The input address of the device for embedded PLC logic. Controller generated.

Delete

This deletes the selected device from the controller’s DeviceNet network.

Import

This imports devices from a file on the USB memory stick.

Scan

Scans the DeviceNet network and adds any devices it finds to the controller. After adding the user must use EDIT to modify the options for the device.

Use the right arrow to move to the next tab or press EXIT to save the changes and return to the Run screen. See

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SETUP Area section “3.1.2.6 Exit” on page 48.

3.1.3.9

FIELDBUS Tab The Fieldbus tab is a generic term for any of the optional fieldbus types that can be added to the controller and this tab appears only when one of those options are installed. These fieldbus allow the Expert Alpha controller to be added to end users’ compatible systems as trailing devices. The types of optional fieldbus are DeviceNet, EthernetIP, Profibus and Profinet. The type of fieldbus installed will be identified at the top of the screen.

3.1.3.9.1

DeviceNet This tab appears on Alpha controllers only when the DeviceNet port option is installed and sets the communications parameters for the Alpha controller on a DeviceNet network.

Baudrate

Sets the Alpha controller’s communication rate on the DeviceNet network. Choices include: 125 K bits/s, 250 K bits/s and 500 K bits/s.

Mac Id

Sets the Alpha controller’s node number on the DeviceNet network.

The Expert Alpha controller automatically detects the type of communications controlled by the device in the connected network. The Alpha controller has no default I/O mapped on the DeviceNet bus. The I/O must be assigned before an EDS file can be obtained. See Section “3.1.4.3 I/O Tab” on page 62 to assign and configure the DeviceNet I/O.

3.1.3.9.2

EDS Button Press the EDS interactive menu button to create an EDS file equivalent to the DeviceNet I/O map created. Connect a USB memory stick to the USB port on the bottom of the Alpha controller. Use the up/down arrows and/ or the numeric keypad to type a file name or use the default. Pressing the OK interactive menu button saves the file to the USB memory stick. Use this controller generated EDS file in the PLC to which the Alpha controller is connected. If the DeviceNet I/O map is changed, a new EDS file must be generated. Use the right/ left arrow to move to the next tab or press EXIT to save the changes and return to the Run screen. See section “3.1.2.6 Exit” on page 48.

3.1.3.9.3

Ethernet/IP This tab appears on the Alpha controllers only when the Ethernet/IP option is installed and sets the communications parameters for the Alpha controller on a EthernetIP network.

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QB Expert Alpha Controller

Programming

This information is required when connecting the Alpha controller to an EthernetIP network using the Ethernet/IP port. Yes allows the Ethernet/IP board to receive an address from the network DHCP server. No requires the address parameters to be filled in manually.

Ethernet/IP

Obtain IP From Network

Physical

IP Address

The IP Address of the Ethernet/IP port.

Subnet Mask

The Subnet address of the Alpha controller.

Gateway

The Gateway address to a connecting network. This value is required. If there is no actual gateway then type in the controller’s IP Address.

DNS

The address of the network’s DNS server.

This is the MAC id of the EthernetIP port on the Alpha controller. This value comes from the EthernetIP board inside and cannot be changed.

The Alpha controller has no default I/O mapped on the Ethernet/IP bus. The I/O must be assigned before an EDS file can be obtained. See Section “3.1.4.3 I/O Tab” on page 62 to assign and configure the Ethernet/IP I/O.

3.1.3.9.4

EDS Button Press the EDS interactive menu button to create an EDS file equivalent to the Ethernet/IP I/O map created. Connect a USB memory stick to the USB port on the bottom of the Alpha controller. Use the up/down arrows and/ or the numeric keypad to type a file name or use the default. Pressing the OK interactive menu button saves the file to the USB memory stick. Use this controller generated EDS file in the PLC to which the Alpha controller is connected. If the Ethernet/IP I/O map is changed, a new EDS file must be generated. Use the right/ left arrow to move to the next tab or press EXIT to save the changes and return to the Run screen. See section “3.1.2.6 Exit” on page 48.

3.1.4 OTHER Menu This area sets the parameters for all other Alpha features, including: system level, users, passwords, I/O and tool functions. Each category is represented by its own tab. Use the left/right arrows to select the tabs/category for modification.

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SETUP Area Users must have ADMINISTRATOR or SETUP access level to modify values in this area.

3.1.4.1

General Tab

Lock Keypad

In Alpha Toolbox only. When YES is selected the Alpha controllers keypad cannot be used to edit any parameters. It will allow the user to navigate through the system and view any parameters. If the keypad is locked and it is desired for it to be unlocked one must connect to Alpha Toolbox on the controller and set this parameter to No. If set to NO the keypad on the Alpha controller can be used to edit parameters.

Name

A name distinguishes this controller from other Alpha controllers on the same plant floor. Use the up/down arrows to type letters. Use the numeric keypad to type numbers. This is also the main Machine ID for PFCS protocol. This value will also be used to label any files exported via the USB port or Alpha Toolbox. There is a 15 character limit for this parameter.

Keypad Mode

During normal operation the keypad on the face of the controller can be used to select Jobs (Job Select) or Tasks (Task Select). It can also write a PART ID for storing with fastening cycle data or these functions can be disabled. If Job Select, Task Select or PART ID mode is enabled, simply type a number or letter on the keypad when on the run screen to select the Job, Task or Part ID, then press the Enter key.

Count Mode

Choose Count Up to indicate the fasteners that have been completed OK. Choose Count Down to indicate the number of fasteners yet to be completed. This affects the count in the box on the run screen.

Stop within Limits

Choose OK to mark the fastening cycle as OK, even if the fastening cycle is stopped when the achieved torque and angle are within limits. Choose NOK to mark the fastening cycle as NOK when the fastening cycle is stopped and the achieved torque and angle values are within limits. When event occurs, this option illuminates the red and yellow LEDs on the tool and controller. Yes enables the power saving mode for the Expert Alpha controller or the Cordless Tool. No will turn off the power saving mode.

Enable Sleep Timer

Sleep Timer

Time in minutes from last operation when the power saving mode will turn off the controller’s screen or turn off the Cordless Tool. Minimum value is 1, maximum value is 60, default value is 10.

Running a tool, pressing a button or the touch screen, connecting with Alpha Toolbox, changing the state of I/O are all operations that will wake up the controller. Press the Start Trigger Switch on the Cordless Tool to recover from power saving mode. Use the right arrow to move to the next tab or press EXIT to save the changes and return to the Run screen. See section “3.1.2.6 Exit” on page 48.

3.1.4.2

Users Tab A maximum of eight users with unique passwords can be added. Passwords can contain any character, symbol or number combination written by the keypad (maximum length of 16). If users are assigned, one must be an Administrator. The first user assigned will be an Administrator by default. When a user is trying to modify a parameter and the controller is locked, or the user has insufficient privileges, the log in screen appears.

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QB Expert Alpha Controller

Programming

Select the appropriate user from the drop-down and then type in the correct password for the selected user. The parameter value will be modified if the logged in user has sufficient privileges. Otherwise the controller will display the Insufficient Privileges screen and the parameter value will not be modified.

Press OK to acknowledge and try again or CANCEL the modifying operation. When a user is logged in the controller is unlocked at that user’s access level. The unlocked icon appears and the LOGOUT interactive menu button appears on the run screen.

The controller automatically re-locks the system 15 minutes after the last keypad input. Press the LOGOUT button to re-lock the controller when finished modifying parameters. When the controller is locked the lock icon appears, the LOGOUT button disappears and the controller is password protected. To add a user, press the MANAGE interactive menu button. Adding users is a two step process. First add user by choosing option 1. Add:

Name user, enter password, enter password again to verify and press OK.

Second, manage the users access by selecting the new user.

Press the MANAGE interactive menu button and select option 4. Change Access. One user must be an Administrator. Administrator rights give a user full access to the controller. This enables all privileges including restoring factory defaults, deleting logs and adding users.

To assign the selected user as an Administrator choose Yes, for non-administrators choose NO, then press OK. Select the Access level for non-administrators.

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SETUP Area

Options include: NONE

denies access.

LOCAL

allows access from the keypad.

REMOTE

allows access from a computer via Alpha Toolbox.

BOTH

allows access from the keypad and a computer.

There is no overlap between areas. Select more than one area for access if required. Setup

Users at this level can modify all parameters in the Job area. They may also modify parameters in the Other area except in the Users, Tool and Stats tabs.

Tool

Users at this level can modify parameters under the Tool tab in the Other area, as well as set Preventive Maintenance Threshold and reset the PM and Cycle counters in the SERVICE menu.

Diagnostics

Users at this level can force Inputs or Outputs ON or OFF and REMOVE forces in the I/O tab of ANALYZE.

Statistics

Users at this level can modify parameters under the Stats tab in the Other area.

Communications Users at this level can modify all parameters in the Communications area. Press OK to save. To delete a user press the MANAGE button and select option 2. Delete. Confirm deletion by pressing OK. This action requires the Administrator password; once entered, user is deleted. Import – Users can be entered from a backup file. Connect a USB memory stick to the USB port, scroll to desired file and press IMPORT. The new users display on the User list. Export – To backup Users, connect a USB memory stick to the USB port, name the file, then press SAVE. Press OK to save. Use the right arrow to move to the next tab or press EXIT to save the changes and return to the Run screen. See section “3.1.2.6 Exit” on page 48.

3.1.4.3

I/O Tab Press the BUS interactive menu button then the up/down arrows to select the I/O bus for editing/ viewing. Then press OK. The buses available are dependent on the options installed.

3.1.4.3.1

Outputs The 24V DC Connector has pins C through K designated as Outputs from the controller. The pin assignments are

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Programming selectable on this tab. Use the up/down arrows to select the pin to assign, then press the Toggle button. A list of available output functions displays. See section “6.12 Assignable Input and Output Functions” on page 120 for the complete list and descriptions.

Highlight function to assign to the selected pin and press the NEXT button. An Output functions can be assigned to more than one pin. The selected Output function must then be configured. See section “6.12.2 Output Descriptions” on page 129 for configuration options and descriptions. After modifying press FINISH.

3.1.4.3.2

Inputs The 24V DC Connector has pins L through U designated as Inputs to the controller. The pin assignments are selectable on this tab. Use the up/down arrows to select the pin to assign, then press the Toggle button. A list of available Input functions displays. See section “6.12 Assignable Input and Output Functions” on page 120 for the complete list and descriptions. Highlight the function to assign to the selected pin and press the Toggle button. An Input function can be assigned to more than one pin.

The selected Input function must then be configured. See section “6.12.1 Input Descriptions” on page 123 for configuration options and descriptions. After modifying press FINISH.

3.1.4.3.3

Fieldbus Unlike the 24V DC inputs and outputs the fieldbus buses do not have any pre-assigned I/O functions. After selecting a fieldbus, such as ModbusTCP Output, the required amount of bytes to be used must be added so that functions can be assigned to the individual bits, bytes or words. Press the Toggle button to add a function assignment. Highlight the function to assign to the selected pin and press the Toggle button. A function can be assigned to more than one pin. The fieldbus functions are an expanded list of the 24V DC bus functions.

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SETUP Area

The selected Input function must then be configured. See section “6.12.1 Input Descriptions” on page 123 or “6.12.2 Output Descriptions” on page 129 for configuration options and descriptions. Each fieldbus function has its own unique configuration parameters. After modifying press FINISH.

If this is the first one bit wide function added to the bus then an entire byte will be added with the remaining bits assigned as IGNORED or NOT USED. These functions will have a bit length of 7 to fill out the byte.

To continue adding functions choose the next bit that is IGNORED or NOT USED and press the Toggle button. Each time a function is added the IGNORED or NOT USED functions will decrease their bit length until all bits in a byte are used then a new byte will be added with the next function addition. If any byte, word or double word length function is assigned it must be assigned at bit 0 or bit 8. To insert a new byte to assign these types of functions press the MANAGE button and choose Add.

If the highlight is on an IGNORED or NOT USED or last bit of a byte the Add After Selection window appears. If the highlight is on bit 0 the Add Before Selection window appears. If the highlight is on a bit in the middle of a byte the Can’t Add! window appears. Press the OK button after one of these windows appears. The new byte will be added either before or after the highlighted byte. Be sure to highlight the correct part of the byte before adding a new byte where required.

Select the desired function and press the NEXT button. Modify the configuration settings then press the FINISH button. A new byte, word or double word will be added to match the length of the new function.

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3.1.4.3.4

Manage Button Edit

Modifies the highlighted function. To edit a function or its configuration, highlight the function then press the MANAGE button. Then choose Edit. Choose the same function or a different one then press the NEXT button. Modify the configuration for the function then press the FINISH button.

Add

Adds a new byte, word or double word and function to the selected bus.

Delete

Deletes the highlighted byte, word, double word and function from the bus.

Import

Imports an I/O file from a memory stick on the USB port. This will overwrite all I/O information on all buses.

Export

Exports all I/O on all buses to a file on a memory stick on the USB port.

Use the right arrow to move to the next tab or press EXIT to save the changes and return to the Run screen. See section “3.1.2.6 Exit” on page 48.

3.1.4.4

Triggers Tab See section “5.2.5 MFB Mode” on page 104 for an explanation of the options. Options include:

Tap Action

Defines the operation when the MFB on the tool is tapped (pressed quickly).

Hold Action

Defines the operation when the MFB on the tool is held for one second.

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SETUP Area Defines which input starts the tool. In all cases, the 24V DC Start input is always available to start the tool.

Start Mode

Any

Either the tool trigger or tool push-to-start switch starts the tool.

All

Requires that both the tool trigger and the tool push-to-start switch must be activated to start the tool.

Lever

Only the trigger on the tool starts the tool.

PTS

Only the push-to-start switch on the tool starts the tool.

None

Neither the tool trigger nor the tool push-to-start switch starts the tool.

Use the right arrow to move to the next tab or press EXIT to save the changes and return to the Run screen. See section “3.1.2.6 Exit” on page 48.

3.1.4.5

Lights Tab Lights (1, 2)

Defines whether the lights indicate a Job or Task.

Headlight Timer

Sets the time the tool’s headlights remain on, in seconds, after the trigger is pressed.

Yes enables the timer and the tool’s Red, Green and Yellow status lights will illuminate for the period of time specified after a fastening cycle and then extinguish. If No is selected the time is disabled and the tool’s Red, Green and Yellow status lights Enable Tool Light will remain illuminated after a fastening cycle until the tool is started again. They will Timer only extinguish while the tool is running. Tool Light Timer

The time in seconds the Red, Green and Yellow status lights will remain on after a fastening cycle.

Use the right arrow to move to the next tab or press EXIT to save the changes and return to the Run screen. See section “3.1.2.6 Exit” on page 48.

3.1.4.6

Tones Tab The alarm in the tool handle can emit different tones based on the status of the fastening cycle. Choose an Accept Tone for an OK Fastening cycle and a Reject Tone for a NOK Fastening cycle.

The PLAY Button when pressed will preview the selected tone. A tool needs to be connected to the controller to perform this action. The STOP button will end the preview.

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Programming Use the right arrow to move to the next tab or press EXIT to save the changes and return to the Run screen. See section “3.1.2.6 Exit” on page 48.

3.1.4.7

Tool Tab Values modified under this tab are saved to the tool not the controller. Users must have TOOL or ADMINISTRATOR access level to modify these values. The “Update tool” exit window appears anytime changes are made in this tab.

PM Limit

When the PM Counter in the tool exceeds this threshold, the preventive maintenance indicator on the front panel illuminates indicating it is time to perform maintenance on the attached tool.

Temperature Limit

Identifies the threshold, in degrees Celsius, for tool shut off. This is caused by excessive duty cycle on the tool.

Torsion Factor

See Appendix A – Torsion Compensation for an explanation of this parameter and how to determine a correct value. Otherwise, use the default (zero).

Requires Arming

Forces the Tap Action on the MFB to Arm. See section “5.2.5 MFB Mode” on page 104. Tubenut tools require arming as a factory setting.

Dog Torque

Sets the torque level at which the tubenut stops when it returns home. The value is a percentage of the rated torque of the tool; where 0.1 = 10%.

Home Speed

Sets the speed of the tubenut tool when it returns home.

Use the right arrow to move to the next tab or press EXIT to save the changes and return to the Run screen. See section “3.1.2.6 Exit” on page 48.

3.1.4.8

Statistics Tab Sets values required to calculate the statistics on the stored fastening cycle data. Display

–

Sets the default screen under statistical analysis in the ANALYZE area. Display Population

Sets the number of fastening cycles included in statistical analysis.

Subgroup Size

Sets the size of the subgroups for the population.

Use the right arrow to move to the next tab or press EXIT to save the changes and return to the Run screen. See section “3.1.2.6 Exit” on page 48.

3.1.4.9

REGIONAL Tab Sets the values for the region of the world in which the controller is used. Language

Selects the language for the controller screens and files.

Date Format

Selects the Date format for the controller.

24-Hour Time

Selects the 12 hour or 24 hour clock.

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SERVICE Area Time Zone

Selects the time zone for the controller referenced to GMT (Greenwich Mean Time).

Use the right arrow to move to the next tab or press EXIT to save the changes and return to the Run screen. See section “3.1.2.6 Exit” on page 48.

3.1.4.10

Clock Tab Local Date and Time can be set here. These will be stored with the events and files. Daylight Saving Time

Modifies the controller time by the appropriate amount.

Time

Sets the controller time.

Date

Sets the controller date.

Press the SYNC interactive button in Alpha Toolbox to set the controller to the connected computer’s date and time. Use the right arrow to move to the next tab or press EXIT to save the changes and return to the Run screen. See section “3.1.2.6 Exit” on page 48.

3.1.4.11

PLC Tab If a PLC logic file is running, the Name, Version and Length parameters are identified. If a PLC file is not running, the Name, Version and Length are blank. Press the MANAGE interactive menu button to Import, Export or Delete a PLC file. Connect a USB memory stick in the USB port for Importing and Exporting.

Ladder logic for the embedded PLC can be created or edited using Alpha Toolbox. See section “7.3 PLC Editor” on page 155. Use the left arrow to move to the next tab or press EXIT to save the changes and return to the Run screen. See section “3.1.2.6 Exit” on page 48.

3.1.5 RESTORE FACTORY DEFAULTS Menu Use the up/down arrows to select the option desired or press the corresponding number on the keypad. The BACKUP selection writes the parameter values for the entire Alpha controller to the USB memory stick. The RESTORE selection reads an Alpha controller backup file on the USB memory stick and overwrites all values in the Alpha controller. The DEFAULTS selection restores all values for all parameters to factory default settings. It also deletes all fastening cycle, trace and error log data. This helps when a controller is in an unknown programmed state. Requires ADMINISTRATOR privileges. Press EXIT to save the changes and return to the Run screen. See section “3.1.2.6 Exit” on page 48.

3.2

SERVICE Area In this area the user can view information about the tool and controller, reset tool counters, adjust tool calibration values and upgrade the firmware in the controller and tool. Users must have TOOL or ADMINISTRATOR access level to modify parameters.

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Programming 3.2.1 Tool All tool parameters are stored in the tool memory board in the tool’s handle. This area reads/writes values to the tool memory board, not to the controller. Updating the tool’s configuration and firmware is managed here.

3.2.1.1

About Tab This tab displays information about the tool currently attached to the controller. Only the Serial Number value is editable. If there is no serial number, enter one (can only be entered one time).

3.2.1.1.1

UPDATE Interactive Menu Button Use this button to change the tool configuration or to update the firmware in the tool. Change the tool configuration. Download a configuration INI file from the Internet and transfer it to a USB memory stick. Insert the USB memory stick into the USB port. Press the UPDATE interactive menu button to open the file browse window. Use the up and down arrows to find and highlight the desired INI file. Press the OK interactive menu button. The “Update Tool INI file?” window appears. Press Yes to import and load the new configuration file. Press No to return to the About screen. Change the tool firmware. Download a software BIN file from the Internet and transfer it to a USB memory stick. Insert the USB memory stick into the USB port. Press the UPDATE interactive menu button to open the file browse window. Use the up and down arrows to find and highlight the desired BIN file. Press the OK interactive menu button. The “Update Tool Firmware?” window appears. Press Yes to import and load the new configuration file. Press No to return to the About screen. Use the right arrow to move to the next tab or press EXIT to save the changes and return to the Run screen. See section “3.1.2.6 Exit” on page 48.

3.2.1.2

Counters Tab Each of the three counters increments at the same time after an OK Fastening cycle.

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SERVICE Area

Odometer – Cannot be reset. Indicates the total number of OK Fastening cycles the attached tool has performed over its lifetime. PM Counter – Causes the preventive maintenance indicator to illuminate (on front panel and tool) when this value exceeds the PM Threshold. Trip Counter – Counts the number of OK fastening cycles between resets. Use the RESET interactive menu button to reset (back to zero) either the PM Counter or the Trip Counter.

Use the right arrow to move to the next tab or press EXIT to save the changes and return to the Run screen. See section “3.1.2.6 Exit” on page 48.

3.2.1.3

CAL Tab This area is used to set the calibration value(s) for the attached tool.

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Programming Nominal Cal

This is a calculated value based on the torque output of the motor, the gear ratios and efficiencies. This is a reference value only and cannot be modified.

Primary Transducer

Choose which transducer will be used as the primary transducer for control and data collection. This parameter is only available when a tool with a redundant transducer is attached.

Torque Cal

This is the specific torque calibration value for the tool. Enter a new value after performing a lab certification. The Torque Cal should not deviate from the Nominal Cal value by more than 20%.

Redundant Transducer

ENABLE or DISABLE the redundant transducer to check the primary transducer’s operation. This parameter is only available when a tool with a redundant transducer is attached. When enabled the controller compares the redundant transducer’s signal to the primary transducer’s signal continuously, even at rest. If the difference in the values exceeds the Tolerance the controller stops the tool with a shutoff code of T1 ≠T2. To calibrate a tool with a redundant transducer, first disable the redundant transducer and select T1 as the Primary Transducer. Calibrate the tool normally. Then select T2 as the Primary Transducer and calibrate the tool normally. Enable the redundant transducer if required. Choose the correct Primary Transducer.

Tolerance

Redundant Angle

ENABLE or DISABLE the redundant angle sensor to check the primary angle sensor’s operation. This parameter is only available when a tool with a redundant transducer is attached. When enabled the controller compares the redundant angle sensor’s signal to the primary angle snesor’s signal continuously, even at rest. If the difference in the values exceeds the Tolerance the controller stops the tool with a shutoff code of A1 ≠A2. Tolerance

Modified

This is the specific tolerance value for the redundant transducer to check against the primary transducer. Units are percentage of Max Torque of the tool. This parameter is only available when a tool with a redundant transducer is attached.

This is the specific tolerance value for the redundant angle sensor to check against the primary angle sensor. Units are defrees of rotation of the tool.

A value that is changed by the controller to indicate the date and time the tool was last calibrated.

Press EXIT to save the changes and return to the Run screen. See section “3.1.2.6 Exit” on page 48.

3.2.2 Controller This tab displays the controller information. Updating the controller’s firmware is managed here.

3.2.2.1

About Tab This tab displays information about the controller. These values are read only unless blank. The Model and Serial fields can be written to once.

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SERVICE Area

Press the EXIT interactive menu button when finished. The About Tab changes to add information about the optional fieldbus card installed such as DeviceNet, Profibus, ProfiNet or Ethernet/IP.

3.2.2.1.1

UPDATE Button This button is used to update the firmware in the Alpha controller. Download a software BIN file from the Internet and transfer it to a USB memory stick. Insert the USB memory stick into the USB port on the bottom of the Alpha controller. Scroll to the binary file provided and then press the OK interactive menu button. The “Update Controller Firmware” screen appears to confirm the action. Press YES to continue with the update. Press NO to cancel the update. A progress bar on the bottom of the screen indicates the file transfer status from the USB memory stick to the Alpha controller memory. When the file transfer is complete, the “Cycle power to complete the update” window appears indicating it is time to reboot the controller to complete the upgrade. Turn off the controller, remove the USB memory stick, wait 20 seconds, then turn on the controller. After the controller starts, it checks that the file is complete and written to permanent memory. The controller auto-reboots. When the run screen appears, the controller is updated and ready.

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Programming During the file transfer process, a file error can cause the transfer to abort and the error message appears. Contact your STANLEY representative if this happens. The “Invalid File” screen appears if the update file is for a different controller. Contact your STANLEY representative if this happens. Trailing controllers and QPM Cordless Tools that are connected to the Expert may also be updated this way by simply choosing the spindle before selecting SERVICE > CONTROLLER. It is advised to update trailing controllers and QPM Cordless Tools before updating the lead controller (Expert). Press EXIT when finished.

3.3

ANALYZE Area Analyze displays tool and controller diagnostic information, traces and I/O status. Press the ANALYZE button to perform diagnostics on the controller, tool or I/O, look at fastening cycle traces, perform Statistical Process Control analysis, or to download error log data.

3.3.1 TOOL Tab This tab shows live status. It updates every millisecond. Use this tab to perform controller or tool diagnostics during troubleshooting operations.

Transducer Health – The thickness of the vertical line within the horizontal bar indicates transducer health (a thicker line means less healthy). Once the line reaches the tick mark, on either side of center, the transducer needs to be replaced.

Transducer Torque – Provides a live transducer torque value during the Fastening cycle. Transducer Current – The transducer is powered with a constant current value. This current should be present and not varying. See section “2.8 Faults” on page 21 for limits.

Controller DC Bus voltage – The bus should always be approximately 320V DC. Controller AC Supply Voltage/Frequency – See section “1.6.2 Electric Service Ratings” on page 8 for controller

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ANALYZE Area AC volts specification.

Tool Temperature – Indicates instantaneous temperature of the tool’s stator windings. Temperature is not measured during tool operation. This interacts with the Temperature Limit parameter. See section “3.1.4.7 Tool Tab” on page 67.

Tool Output Angle – Identifies the number of circular degrees of rotation on the tool output. Resets at each start.

Tool Output Speed – Identifies the real time speed of the tool output. The IDENTIFY interactive menu button will flash the red, yellow and green status lights on the selected tool and controller to distinguish it from another.

The Identify Spindle dialog box will appear when identifying is active. Press the OK interactive menu button to clear and stop the flashing lights. Use the right arrow to move to the next tab or press EXIT to save the changes and return to the Run screen. See section “3.1.2.6 Exit” on page 48.

3.3.2 TRACE Tab Press the right arrow to enter the Trace area of the controller.

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This tab plots a torque verses time curve after every fastening cycle. The Y-axis is auto-scaled from 0 to maximum torque of the data. The X-axis has a variable scale to include the entire fastening cycle. Use the TORQUE interactive menu button to choose how to view the trace.

Torque – Displays Torque vs. Time. Angle – Displays Angle vs. Time. Torque/Angle – Displays Torque vs. Angle. Speed – Displays Speed vs. Time. Torque Rate – Displays the Torque Rate vs. Time. Use the right arrow to move to the next tab or press EXIT to save the changes and return to the Run screen. See section “3.1.2.6 Exit” on page 48.

3.3.3 STATS Tab Press the right arrow to enter the Statistics area of the controller.

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ANALYZE Area

Alpha controllers maintain both sample and population statistics. Sample statistics are calculated using the last completed subgroup of fastening cycles for a given Task. The subgroup size is set using Subgroup Size. Population statistics are calculated using all of the fastening cycles for a given Task up to the population. To be included in sample or population statistics, a rundown must exceed the Task’s Threshold Torque and Statistical Torque and the fastening cycle must not be marked as a STOP or ABORT shutoff code. interactive The statistics are calculated for Torque and Angle. Data is filtered by Task. Press the menu button and choose the Job and Task under analysis.

Values are recalculated each time a tab is selected. Results This section shows a summary of the fastening cycle data results stored in the controller. n – Shows the number of rundowns included in the population size. n OK – Identifies the number of OK rundowns. n NOK – Identifies the number of NOK rundowns. n – Displays the number of fastening cycles that exceeded the high limit. n – Displays the number of fastening cycles that did not achieve the low limit. n Abr – Displays the number of fastening cycles that were aborted. n Stp – Shows the number of fastening cycles that were stopped. R – Shows the subgroup range (highest minus lowest value). – Identifies the highest value of all the fastening cycles in the population – Identifies the lowest value of all the fastening cycles in the population The Display parameter under Setup/Other/STATS tab determines which of the following sections are displayed after the Results. Capability This section shows the capability statistics for the selected Job and Task.

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Programming Cp – Displays the capability index for a stable process. Cpk – Displays the capability index for a stable process, typically defined as the minimum of CPU or CPL. CR – Displays the capability ratio for a stable process and is simply the reciprocal of Cp. CPL – Shows the lower capability index. CPU – Shows the upper capability index. R bar – Identifies the average range of a constant size subgroup series. 3 sigma – Displays the sample estimated Standard Deviation times three. X bar – Displays the value’s average (mean). Performance This section shows the performance statistics for the selected Job and Task. Pp – Shows a performance index of a stable process. Ppk – Shows a performance index of a stable process typically defined by a minimum of two calculations. PR – Identifies the performance ratio for a stable process. 3 sigma – Identifies the sample estimated Standard Deviation times three. X bar – Displays the value’s average (mean). Coefficient D’aptitude Moyen This section shows the CAM statistics for the selected Job and Task. CAM – Coefficient d’Aptitude Moyen (Mean Aptitude Coefficient) shows a capability index for a stable process used in Europe. R bar – Identifies the average range of a constant size subgroup series. 3 sigma– Identifies the sample estimated Standard Deviation times three. X bar – Displays the value’s average (mean). Use the right arrow to move to the next tab or press EXIT to save the changes and return to the Run screen. See section “3.1.2.6 Exit” on page 48.

3.3.4 LOG Tab The Expert Alpha controller stores up to 1000 Events in the log. Use the up/down arrows to select an event the press the Toggle key to get more details.

The details provide the Date and Time the event occurred. Source – Shows where the user changed the values. Controller means the keypad was used, aTB means the Alpha Toolbox was used. Details – Shows which part of the controller the changes were made. Press the BACK interactive menu button to return the LOG screen. Press the MANAGE interactive menu button to export Log Data to the USB memory stick or to clear the event log. Connect a USB memory stick to the USB port on the bottom of the Alpha controller. Use the up/down arrows and/ or the numeric keypad to select option.

Use the up/down arrows and/or the numeric keypad to type a file name. Pressing the OK interactive menu button

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ANALYZE Area saves the data to the USB memory stick. After the file is saved, press the OK button to return to the LOG screen. Press the MANAGE interactive menu button to clear the data. Press OK to clear the data or press CANCEL to return to the LOG screen. Press YES to clear the data, NO to return to the LOG screen. Use the right arrow to move to the next tab or press EXIT to save the changes and return to the Run screen. See section “3.1.2.6 Exit” on page 48.

3.3.5 I/O Tab This tab indicates the real time status of the 24V DC Inputs and Outputs. Forcing the I/O on or off is also performed here. Users must have DIAGNOSTICS or ADMINISTRATOR access level to force I/O.

Each 24V DC connector pin is represented. Pin A is for supplying 24V DC to the I/O functions. Pin V is the 24VDC Return to complete the current loop. Pin B is the bus for the Outputs. See section “6.11 Input and Output Connector” on page 116 for a schematic. Pins L through U are for Inputs. Pins C through K are for Outputs. See section “3.1.4.3 I/O Tab” on page 62 to assign functions to the pins. A clear Input or Output pin icon identifies it as OFF; a green Input or Output pin icon identifies it as ON. There is a square cursor around the active pin; Use the Left/Right and Up/Down arrow keys to move the cursor. The text at the screen’s bottom left corner indicates the active pin’s assigned function. Manually control the I/O by forcing pins either ON or OFF. Applying force means the pin will always be in that forced state and does not toggle to the opposite state (even if the system requires it to toggle). This is useful for troubleshooting signals that integrate with other equipment. Move the horizontal bar/cursor under a pin and press the ON interactive menu button to force it on, press the OFF interactive menu button again to force it off. When the force is no longer required, press the REMOVE button to remove the force and return the pin to system control. When forcing I/O changes during operation, the system provides a warning first.

A clear pin icon with a small F indicates the pin is forced OFF. A green pin icon with a small F indicates the pin is forced ON.

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If a force is active when the EXIT button is pressed a prompt appears. Choose the YES interactive menu button to remove the force(s) and return to the run screen. Choosing the NO interactive menu button does NOT remove the force(s), it returns to the run screen. The system runs with forces applied until they are removed or until the controller’s next power cycle. Press EXIT to save the changes and return to the Run screen. See section “3.1.2.6 Exit” on page 48.

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4

Alpha Toolbox

Connection Controls Editing Parameters Trace Data Icons and Security

Connection 4

Alpha Toolbox Each Alpha Controller has an Alpha Toolbox port for the purposes of local configuration, backup of parameters and data, restoring parameters and performing updates. The Alpha Toolbox port on the leading spindle provides access to all spindles if in a multiple spindle configuration. The Alpha Toolbox port is not used on a network. If configuration and data collection over an Ethernet network is required the normal Network port, and its IP Address, is used.

WARNING NETWORK INTERRUPTION To Avoid Issues: • Never connect an Alpha Toolbox port to a plant network. The Alpha Toolbox port provides an easy connection with a computer. It has a DHCP server and a DNS server built in. The controller has its own private IP Address and will provide a private IP Address to the computer to create its own network. Knowledge of the IP Address is not required.

4.1

Connection Connect a computer to the Alpha Toolbox port using a standard CAT 5, 5E or 6 Ethernet cable. It does not matter if the cable is straight-through or crossover. The computer’s Ethernet port must be set to DHCP rather than a static IP Address. Observe the computer’s notifications to determine when the controller has provided the IP Address. Open a web browser, any current browser will do, and type http://ATB.QPM into the uniform resource locator bar. The controller’s web server will provide the Alpha Toolbox screens and controls.

4.2

Controls The menus on the left coincide with the interactive menu buttons on the controller’s run screen. See section “3 Programming” on page 26 for descriptions on these menu items. The controller display windows on the right mimic the controller run screen. See section “2.7 Display” on page 15 for a description of the items on these windows. Normally only one window is displayed. When connected to a leading controller on a multiple spindle system all the spindles’ windows will appear on the Alpha Toolbox run screen with a scroll bar, if necessary, to view them all.

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Alpha Toolbox The controller display windows are dynamic, rather than static, and indicate the status of the fastening cycle. They will turn green for an OK fastening cycle and red for a NOK fastening cycle for one second then return to normal. A red box will cover the display if there is a fault until the fault is cleared.

A yellow box will cover the display if there is a message until the condition is cleared.

The active spindle number is displayed in the upper right hand corner and the controller display window for the active spindle will be a darker color than the others.

To switch between spindles click on the controller display window for the desired spindle. Once a spindle is selected it becomes the active spindle and all menu items on the left belong to the active spindle.

4.2.1 Menus Click on a menu item to view or edit that area of the controller. The menu item’s window appears with its own controls.

The black bar at the top of the Alpha Toolbox screen provides a navigation button as well as area appropriate buttons. Underneath the black bar on the left are the controls for the area. The Add, Delete, Copy, Paste buttons are the same as the MANAGE interactive menu button on the controller for each particular area. The windows below that are the tabs that correspond to each area. The area on the right displays the parameters for each area. See section “3 Programming” on page 26 for descriptions on these menu items and parameters and how to

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Editing Parameters use them.

4.2.2 Navigation Buttons Use the navigation buttons and menus provided instead of the browser’s Back and Forward buttons to navigate through the Alpha Toolbox’s screens. The Home button brings up the Alpha Toolbox run screen. Any others such as and

,

will send the user back one screen.

4.2.3 Import/ Export Buttons The Print button will use a printer attached to the computer to print a parameters report for the selected area. If in the Trace area it will print a picture of the trace. The Import button w ill display the computer’s browse window. Browse to the file required and press open to import a previously saved (Exported) JSON file. When the file has finished importing the “Imported complete” window displays and the parameters are immediately overwritten. Click the OK button to close.

It is important to understand that the JSON files are specific to a controller area. If the Import button is clicked while in the Jobs area the imported file must be a Jobs.json file. If a different file, such as an IO.json file, is imported the file will delete all jobs currently in the controller since there is no Jobs information in the IO file. There is no recovery other than importing the correct file for the active area. The Export button will download the JSON file for the active area to the computer. Be sure to understand the browser setting to know where the file is saved. These files are different from the Backup file. They contain the parameters from the active area only. They cannot be used in the Restore function.

4.2.4 Manage Buttons The Manage buttons perform the same function as the interactive menu MANAGE buttons on the controller. See section “3 Programming” on page 26 for descriptions on these buttons and how to use them.

4.3

Editing Parameters Drill down through the menus to get to the parameter of interest. While viewing parameters the font is black in color and the background for the value box is light grey. When the parameter is clicked once the screen is selected for editing and the background for the value box turns white. Type the required value into the box. When finished entering the value press the computer’s Enter or Tab keys to set the value. The “Save Changes” dialog box opens. Click Apply to save the changes to the controller. Click Cancel to discard the changes.

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Alpha Toolbox 4.3.1 Parameter and Data Retrieval It is a good idea to capture the stored parameters and data on a regular basis to analyze and understand the application.

4.3.1.1.1

Parameters Parameters for areas of the controller or the whole controller can be retrieved in separate files. The Export button is explained above for retrieving parameters from the areas of the controller. This section explains a complete backup of the controller’s parameters. Click on the Setup>Full Backup / Restore menu from the Home screen in Alpha Toolbox.

Click on the Backup menu. The params.json file is immediately transferred to the computer. Be sure to understand the browser setting to know where the file is saved.

4.3.1.1.2

Fastening Cycle Data The Expert Alpha controller stores resultant audit data for 30,000 fastening cycles on a first in/ first out basis. Click on the Full Backup / Restore menu from the Home screen in Alpha.

Click on the Rundowns menu. The rundowns.csv file is immediately transferred to the computer. Be sure to understand the browser setting to know where the file is saved.

The CSV file has headings for all of the columns that are obvious with the exception of column A “ID” and column G “SOC”. The ID column header will have numbers in front of the words ID. The syntax is n:Next_Rundown_Number[space] ID. The column contains unique numbers for each fastening cycle. When the controller is defaulted this value starts at 0 and runs to 4 billion before starting at 0 again.

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Trace Data SOC is short for Shutoff Code. This column will contain numbers representing the reason the tool shutoff. Here are the values for the numbers, see section “2.7.7.2 Shutoff Codes” on page 19 for a description: 1 = ”TORQUE”

2 = ”ANGLE”

3 = ”TORQUE/ ANGLE”

4 = ”CURRENT”

5 = ”TORQUE BAILOUT”

6 = ANGLE BAILOUT”

7 = ”MINIMUM TORQUE BAILOUT” 16 = ”RATE MONITOR” 32 = ”YIELD MONITOR”

128 = "TIME"

129 = "STOP"

130 = ">115%"

131 = "FAULT"

132 = "STALL"

133 = "CAN"

134 = "SYNC"

135 = "T1≠T2"

136 = "TD"

137 = "YIELD"

138 = "[T]"

139 = “Rate”

140 = “I”

141 = “A1≠A2 This same file can be saved to a USB memory stick from the controller’s USB port.

4.4

Trace Data The Expert Alpha controller stores resultant audit data for 10,000 fastening cycles on a first in/ first out basis. Click on the Analyze>Trace menu from the Home screen in Alpha Toolbox.

Select the Rundowns button to display the rundowns. A list of rundowns appears on the left. Click on the rundown that corresponds to the trace to be retrieved. The selected rundown turns blue.

Click on the Export button and the trace#.csv file will download to the computer. Be sure to understand the browser setting to know where the file is saved. The file will be numbered (#) with the unique rundown ID

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Alpha Toolbox number to distinguish it from the rest and so it can be correlated with the record in the rundowns.csv file.

4.4.1 Analyzing Traces The Trace menu screen in Alpha Toolbox makes it easy to view, print, analyze, export for sharing, and import saved trace files.

4.4.1.1

Screen Controls The left side of the screen has three types of content. The Rundown button lists the fastening cycles stored in the controller. The Information button shows detailed step by step information about the selected fastening cycle. The Point Details button displays details about a point on the trace graph where the mouse is hovering.

4.4.1.1.1

Rundowns There is a trace file for each fastening cycle. Each fastening cycles is represented by a controller run screen with a miniature trace box. The trace box contains an actual representation of the trace for the fastening cycle. The trace in the box will change depending on the values chosen for the X, Y1 and Y2 axes. See section “2.7 Display” on page 15 for a description on the other elements of the run screen. The run screen background can be green, red or blue. Green indicates the fastening cycle status is OK. Red indicates the fastening Cycle status of NOK. Blue indicates the fastening cycle selected for display on the right of the Trace screen, Information, Point Details, print or export. The most recent fastening cycle will always be at the top of the list. A scroll bar is provided to view older fastening cycles. Click on the torque value in the run screen to select the fastening cycle. The trace will draw on the right of the Trace screen. If the top most fastening cycle is selected any new fastening cycle will pop into the top of the list and be selected automatically. If a different fastening cycle is selected any new fastening cycle will pop into the top of the list but will not be selected automatically. Click on the miniature trace box to lock the trace for viewing. More than one trace may be locked. Each locked trace will draw on the right and overlay on top of each other. They will be represented by dotted lines rather than a solid line. Selected and locked fastening cycles will move down the list as new ones come into the list. Use the scroll bar to view or unlock older traces.

4.4.1.1.2

Information Click on the Information button to display information about the selected fastening cycle. The left side of the Trace screen will change to display this information.

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Trace Data Rundown – Indicates the unique number for the fastening cycle. Date – The date the fastening cycle occurred. Time – The time the fastening cycle occurred. Job – The Job in which the fastening cycle occurred. Task – The Task in which the fastening cycle occurred. Status – Overall status of the fastening cycle. Job Count – The working bolt of the Job during this fastening cycle. Task Count - The working bolt of the Task during this fastening cycle. Tool Model – The model number of the tool performing the fastening cycle. Tool Serial – The serial number of the tool performing the fastening cycle. Tool Temperature – The temperature of the tool at the tool shutoff. Steps – The steps performed during the fastening cycle. The step’s strategy type, peak Torque, Current, Angle, Torque Rate and Deviation achieved during the step is displayed. The audit step is indicated by blue font. Smart Steps are indicated by name rather than by strategy type. Click on the step name and the graph on the right will highlight that individual step.

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Alpha Toolbox 4.4.1.1.3

Point Details Click on the Points Detail button to display information about the selected fastening cycle. Use the mouse to hover over the drawn trace graph on the right in the Trace screen. The values in the Points Detail window change with the mouse hover.

Time – The time in milliseconds the point occurred in the fastening cycle from start. Torque – The torque achieved at the mouse hover point. Angle – The angle achieved at the mouse hover point. Speed Command – The commanded speed at the mouse hover point. Speed – The actual tool speed achieved at the mouse hover point. Bus Voltage – The actual DC Bus voltage achieved at the mouse hover point. Current Command – The commanded current at the mouse hover point. Current – The actual tool current achieved at the mouse hover point. Torque Rate – The actual torque rate achieved at the mouse hover point. This values is derived by using the Torque Rate algorithm associated with the parameters Torque Average (ms) and Angle Interval.

4.4.1.1.4

Print Clicking the Print button will open the printer dialog. This window allows the user to modify printer parameters and displays what is to be printed. The currently selected Y axis values are printed separately in their own box on the same page. The X axis is either Time or Angle depending on the current selection. If no physical printer is attached, choose an installed PDF printer to save as a PDF file.

4.4.1.1.5

Export Click the Export button to save the selected fastening cycle trace file to the computer. Each trace must be selected and saved individually. There is not a “Save All” button. The exported trace file is a comma separated values file and contains four sections. They are the identifier section, the step values sections, the trace values section and the events section. The identifier section repeats some of the same information from the fastening cycle record so it can be correlated with the trace file. This information is displayed when the Information button is clicked. The step values section provides the torque, angle and current values for each step in the fastening cycle. The fastening cycle file has only the audit step for each record. If the values for each individual step are required this is the place from which to parse the information. The trace values section provides the captured X and Y axes information to draw the graph. The events section marks the time at which the events occur so they can be entered on the graph.

4.4.1.1.6

Import

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Trace Data Click the Import button to import a saved trace file for analysis. The file is placed at the top of the fastening cycle list and be treated as if it were just received from the controller. It will travel down there list as new fastening cycles are received. When the user navigates away from the Trace screen the imported files are removed from the list.

4.4.1.2

Graph The selected fastening cycle graph (plot) is drawn in the window on the right in the Trace screen. There are two Y axes and one X axis. The values for the axes can be selected. By default the Y1 axis is Torque while the Y2 Axis 1/20/15, 3:08 PM

1.2

1

0.8

0.6

0.4

0.2

0 -1,000 -0.2

-500

NM vs deg 0

500

1,000

is None and the X axis is Angle. The graph for each Y axes value has its own color. The value selected on one Y axis is not available to the other. The Angle value is not available if the X axis has Angle selected.

http://10.114.17.44/pages/print-trace.html

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Alpha Toolbox Y1 Axis Selector

Y2 Axis Selector

Preset Selector

Event Torque Window

Graph

Event

Angle Window

X Axis Selector

Master Detail Icon

The Y axes field selectors are at the top of each axis. The X axis field selector is at the bottom center of the screen. An axes presets selector is at the top center of the screen. Data for the trace is collected every millisecond from start to finish of the fastening cycle. Once the number of data points exceeds ~2000 the graph is automatically scaled between event points for graph and file manageability while ensuring a high resolution around the event points. Event points are things such as Threshold Exceeded, ATC Active and Control Point (target achieved). The X axis zero point for Time is when the achieved torque reaches or exceeds Task’s Threshold Torque value. The X axis zero point for Angle is when the achieved torque reaches or exceeds the audit step’s Snug Torque value. Time and Angle values between start and the zero point are negative. The Master Detail icon arrow in the bottom right corner of the screen allows the user to zoon in on a graph.

Click the icon to open the Master Detail window.

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Trace Data

Slide the left arrow bubble to the right or the right arrow bubble to the left to change the screen zoom. The graph window will follow and display only the area indicated in white.

Hover the mouse over the zoomed, white to change the mouse cursor to four arrows. Click and drag the white area to move the zoom to different areas of the graph.

Double click the zoomed, white area to return the graph to normal. Click the arrow in the bottom right corner of the Master Detail to reduce the window to its icon.

4.4.1.2.1

Points on Graph Crosshairs and a point information box appear at the point where the mouse hovers over the graph. The X and Y axes information is presented in the point information box. Move the mouse alonteh the X and Y axes and the values change in the point information box.

4.4.2 Events The dots on the graphs indicate events that occurred during the fastening cycle. Events are things such as

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Alpha Toolbox Threshold Exceeded, ATC Active and Control Point (target achieved). The point information box changes color and the event is indicated when the mouse hovers over the event point on the graph.

4.4.2.2.1

Overlay Multiple fastening cycle graphs can be layered on top of one another. Click the Rundown button at the top of the left window in the Trace screen. Click on the miniature trace box to lock the trace for viewing. More than one trace may be locked. Each locked trace will draw on the right and overlay on top of each other. They will be represented by dotted lines rather than a solid line.

The zero point of the X axis of Time for each graph in overlay view is the programmed Threshold Torque. Change the X axis from Time to Angle and the zero point changes to the programmed Snug Torque. Selected and locked fastening cycles will move down the list as new ones come into the list. Use the scroll bar to view or unlock older traces.

4.5

Icons and Security The Alpha controller will allow only one user to edit parameters at any one time. However, it will allow multiple

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Icons and Security users to view the contents of the controller at any one time. There are icons on the bottom of the Alpha Toolbox screen to indicate user status.

Locked

Unlocked

Other User Editing

Wireless is Active While viewing parameters in Alpha Toolbox the Locked icon will appear in the botom of the Screen. When the user begins to edit any parameter the Locked icon changes to an Unlocked icon. Alpha Toolbox supports user security. If users are programmed into the controller the user must have Remote rights to make edits using Alpha Toolbox. If user1 is editing parameters, the Locked icon and the Other User Editing icon will appear for user2. The controller supports 5 simultaneous Alpha Toolbox connections. These same icons and their behaviors are mimicked on the controller display so the local user can see when a remote user is editing and vice versa.

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5

Tool Operation

Display Multiple Function Button Start Trigger Switch Tool Memory Worklights Tool Operation Special Application Tools

Tool Specifications 5

QPM DC Electric Tools This chapter promotes proper and safe use and gives guidance to owners, employers, supervisors and others responsible for training and safe use by operators. DC electric tools from STANLEY Assembly Technologies are intended for use in industrial threaded fastening or precision position and or adjustment applications only. Some instructions may not apply to all tools. Please contact your STANLEY Sales Engineer for information or assistance on STANLEY training for assembly tool operation.

5.1

Tool Specifications Operating Conditions

Temperature

32 to 122 ºF (0 to +50 ºC)

Humidity

0 to 95 % non-condensing

Noise Level: A-weighted emission sound pressure level at the work station < 70dBA (ref 20μPa) as determined according to ISO 15744-2002. Vibration Level: Weighted root mean square acceleration value at the handle < 2.5 m/s2 as determined according to ISO 8662. STANLEY ASSEMBLY TECHNOLOGIES hereby declares the following sound and vibration emission levels as required by the Machinery Directive 98/37/EC. A-weighted emission sound pressure level at the work station LpA (ref 20µPa) of < 70dBA. Value determined according to ISO 15744‑2002 * using as basic standards ISO 3744 and ISO 11203. Weighted emission root mean square acceleration level at the handle. Value determined according to ISO 8662 * (single axis) of < 2.5 m/s². * Operating conditions for all measurements: full rated speed, no load, rated supply voltage or pressure. A-weighted emission sound power level LWA: not required, declared sound pressure emission levels are below 85dBA. C-weighted peak emission sound pressure level LpCpeak: not applicable to these products. Uncertainty KpA, KWA, KpCpeak: not relevant, declared levels are maximum values.

WARNING To Avoid Injury: This information is provided to assist in making rough estimates of sound and vibration exposure levels in the workplace. The declared emission values were obtained by laboratory type testing in accordance with the stated standards. Levels measured in individual workplaces may be higher. The actual exposure levels and risk of harm experienced by an individual user depends upon the work piece, workstation design, duration of exposure, and the physical condition and work habits of the user. To help prevent physical impairment, a program of health surveillance is highly recommended to detect early symptoms which may relate to sound and/or vibration exposure, such that appropriate preventive measures may be taken.

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Tool Operation 5.1.1 Operator Protection

WARNING ROTATING EQUIPMENT To Avoid Injury: • Always wear eye and foot protection when operating, installing, or maintaining power tools, and when in areas where power tools are being used, maintained, or installed. Some applications may require the use of safety glasses and face shields. Use eye protection that conforms to ANSI Z87.1.[3] and ANSI Z41-PT99M I/75 C/75. • Always stay alert when operating tools and/or their accessories. Do no operate tools and/or their accessories while tired, under the influence of drugs, alcohol or any other mind-altering substance. • Repetitive work motions or vibration may be harmful to your hands, arms, shoulders or back.

• Use suitable protective equipment and work methods whenever an application presents a hazard.

5.1.2 Repetitive Motion The use of power tools may involve highly repetitive motions of the fingers, hands, wrists, and shoulders. These repetitive motions can lead to cumulative trauma disorders (CTD). Many personal and workplace factors can contribute to these disorders. Currently available data have identified the following risk factors. These risk factors are not necessarily causation factors of CTDs. The mere presence of a risk factor does not necessarily mean there is excessive risk of injury. Generally, the greater the exposure to a single risk factor or combination of factors the greater the risk for CTDs. • Forceful exertions and motions • Extreme postures and motions • Repetitive exertions and motions • Intended duration of exertion, postures, motions, vibration, and cold • Insufficient rest or pauses • Work organization risk factors • Environmental risk factors These risk factors span job design and content, operator training, work method, work pace, work environment, proper tool selection and other work place factors beyond the control of the tool manufacturer. Tool owners and employers should analyze jobs for all of the risk factors identified above and take appropriate action. Some measures which may reduce the risk of CTDs: • Use minimum hand grip force consistent with proper control and safe operation. • Keep wrists as straight as possible. • Avoid repetitive movements of the hands and wrists. • If wrist pain, hand tingling, numbness, or other disorders of the shoulders, arm, wrist or finger occur; notify supervisor, discontinue task, reassign user to a different job; if relief is not found contact experts skilled in treating such disorders. Wrist supports, torque reaction devices, and balancers should be used if it can be determined that such devices can reduce the risk of repetitive motion disorders.

5.1.3 Hearing Protection Power tool operators and adjacent personnel may be exposed to excessive sound levels. The tool in use is generally only one of many sources of noise that an operator experiences. Other tools and machines in the area, joint assembly noise, work processes, and other ambient noise sources all contribute to the sound level operators

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Tool Specifications are exposed to. The actual sound level an individual is exposed to and the individual’s exposure time over the work day are important factors in determining hearing protection requirements. Worker sound level exposure can only be determined at the job site and is the responsibility of tool owners and employers. Measure worker sound level exposure and identify high-risk noise areas where hearing protection is required. Follow federal (OSHA), state or local sound level statues, ordinances and or regulations.

5.1.4 Vibration Power tools can vibrate during use. To minimize the possible effects of vibration: • Keep hands and body dry. • Avoid anything that inhibits blood circulation such as tobacco, cold temperatures and certain drugs. • Operators should notify their employer when experiencing prolonged symptoms of pain, tingling, numbness or blanching of the fingers. • Wear vibration damping gloves if it can be determined that they reduce the risk of vibration disorders without introducing other hazards.

5.1.5 Breathing Protection Respirators shall be used where contaminants in the work area present a hazard.

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Tool Operation 5.1.6 Tool Installation

WARNING To Avoid Injury: • Always wear eye and foot protection when installing equipment. • Only use equipment and accessories specifically designed to operate with STANLEY assembly tools and use them only in the manner for which they are intended. • Do not install worn, damaged, or modified equipment that may be unsuitable for safe use. • Train all operators in the safe and proper use of power tools. Operators should report any unsafe condition. • Store idle tools and accessories in a safe location accessible only by trained persons. • Disconnect power source (air, electricity, etc.) from tool prior to making adjustments, changing accessories, or storing. • Prior to operation, always check and test tools and accessories for damage, misalignment, binding or any other condition that may affect operation. Maintenance and repair should be performed by qualified personnel. • Do not operate tools in or near explosive environments or in the presence of flammable liquids, gases, dust, rain or other wet conditions. • Keep the work area clean, well lit and uncluttered. • Keep unauthorized personnel out of the work area.

DC Electric Tools & Controllers: • Install tools in dry, indoor, non-flammable, and non-explosive environments only – Humidity: 0 to 95% non-condensing and Temperature: 32 to 122 ºF (0 to +50 ºC). • Installation, maintenance and programming should be performed by qualified personnel. Follow all manufacturer installation instructions and applicable regulatory electrical codes and safety codes. • Tool and controller plugs must match the outlet. This equipment must be earth grounded. Never modify a plug in any way or use any adaptor plugs. • Avoid body contact with electrically energized surfaces when holding a grounded tool. • Prior to connecting a power source, always ensure the tool or controller is turned off. • Limit controller access to trained and qualified personnel. Lock controller cabinets. Turn the controllers off when removing or attaching tools. STANLEY electric tools must be connected to a controller to operate. To ensure superior performance and safe operation, use a STANLEY controller specifically designed for each tool. These instructions are specific to STANLEY electric tools when used with STANLEY electric tool controllers and accessories. Some features may not be applicable, performance may be degraded and some safety systems may not be available when tools are connected to non-STANLEY controllers and accessories.

5.1.7 Sockets and Adapters Use only industrial grade sockets and adapters (power bit and power or impact socket type). Replace worn or damaged sockets that are unsuitable for safe operation immediately. Always ensure drive socket is fully seated and locked into position before connecting power to tool.

5.1.7.1

Quick Change Chuck NOTE: The chuck accepts 1/4” (6.35 mm) hex accessories and bit tips only. Remove power or air before changing accessories and bits.

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QPM Tool Controls and Operation To install an accessory or bit , fully insert the accessory. The accessory is locked into place. To remove an accessory, pull the chuck collar away from the front of the tool. Remove the accessory.

5.1.7.2

Square Drive

WARNING To Avoid Injury: • Use only industrial or grade impact accessories. Other grade accessories may break and cause a hazardous condition. Inspect accessories prior to use to ensure that it con­tains no cracks.

CAUTION • Inspect square drives and detent pins prior to use. Missing or damaged items should be replaced before use. Remove power or air before changing accessories. To install an accessory on the square drive, align the hole in the side of the accessory with the detent pin on the anvil square drive. Press the accessory on until the detent pin engages in the hole. Depression of detent pin may be necessary to aid installation of the accessory. To remove an accessory, depress the detent pin through the hole and pull the accessory off.

5.1.7.3

Suspension Devices Tool suspension devices or bails help support the weight of the tool during tightening operations. If needed, attach these devices securely and periodically inspect them for damage or loosening.

5.1.8 Cable Installation

WARNING ELECTRICAL HAZARD To Avoid Injury: • Never use a tool with a damaged cable. • Never abuse a cable, carry a tool by its cable, hang a tool by its cable, or pull on a cable to disconnect it from the tool or the controller. To ensure superior performance and safe operation, use the STANLEY cables specifically designed to operate these tools. Never use a tool with a damaged cable. Never abuse a cable, carry a tool by its cable or pull a cable to disconnect it. Also, keep the cord away from heat, sharp edges, or moving parts. Use cables of appropriate length (60M maximum) for each application; position and or suspend them in such a way as to prevent tripping and cable damage, and to provide good work area maneuverability.

5.2

QPM Tool Controls and Operation

5.2.1 Start Trigger Switch The trigger switch is used to start the tool in either direction. The speed of the tool is programmable in the controller, not the trigger switch. It is not a variable speed trigger. The trigger switch function is on or off. Press the start trigger switch to start the tool. Release the start trigger switch to allow the tool to stop.

5.2.2 Tool Memory QPM tools have an on board tool memory that stores tool identification, calibration factors and fastening cycle counters. Memory parameters include:

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Tool Operation • • • • • • • •

5.2.2.1

Model Number Serial Number Torque Cal (calibration) factor Gear Ratio Fastening cycle counters Jobs parameters Fastening cycle data Trace data

Fastening Cycle Counters QPM tools have on board counters that record the number of fastening cycles completed by the tool. Odometer Counter

Records the total number of fastening cycle the tool has completed during its lifetime.

Trip Counter

Records the number of fastening cycles the tool completed since the last reset to zero.

PM Counter

Records the number of fastening cycles the tool completed since the last reset to zero. Interacts with PM Threshold.

PM Threshold

A static value set by the end user. When the PM Counter exceeds the PM Threshold (Limit), the controller provides a maintenance alert. The alert is an orange indicator on the front of the controller and on the tool.

The controller reads the fastening cycle counters from the tool on each power up.

5.2.3 Display and Multiple Function Button Handheld QPM tools have a display and a multiple function button (MFB). Two sets of lights [3 and 7] indicate Fastening cycle status. Two blue lights indicate whether the tool is armed (on) or not armed (off) and tool rotation direction, disassembly [1] or assembly [2]. A single multiple function button [5] can change tool direction and or parameter sets. When the button is used to select the Job, one of two orange indicators [4 or 6] illuminates to show the active Job. EA tools have four sets of lights [3 and 7] and an LED [8] indicates when the fastening cycle count exceeds the PM limit.

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QPM Tool Controls and Operation

1

4

2

3

6

5

7 5.2.4 Tool Status Lights Handheld tools from STANLEY ASSEMBLY TECHNOLOGIES have three (green, yellow, and red) status lights. The status light mirror or copy the status lights on the controller. Green

Tightened to specified limits

The Fastening cycle meets all of the specified parameters.

Yellow

Low torque or angle

The Fastening cycle was rejected for not achieving either low torque or low angle.

Red

High torque or angle

The Fastening cycle was rejected for exceeding either high torque or high angle.

All lights

Reverse

The next time the start trigger is engaged the tool will remove the fastener.

5.2.5 MFB Mode The MFB Mode configures the multiple function button for handheld QPM tools. The button can be configured to operate in any of the following modes.

104

Disable

The button does nothing.

Reverse (Disassembly)

Pressing the button toggles between assembly and disassembly and illuminates the appropriate blue light [1] or [2]. All tool status lights [3] and [7] flash when the tool is in disassembly mode.

Job/Task Select

Pressing the button toggles between Job/Task 1 and Job/Task 2 and illuminates the appropriate orange light [6] or [4].

Arm

Pressing the button arms (activates) the trigger but does not start the tool. The blue assembly light [2] comes on to show that the tool is armed for three seconds.

Reset Reject

This function, when selected, will cause the tool to disable after a NOK Fastening cycle. The Reject Tone, when enabled, will sound. Pressing the button re-enables the tool indicating the operator acknowledges the rejected Fastening cycle and wishes to repair it.

QB Expert Alpha Controller

Tool Operation Job Reset

Pressing the button causes the selected Job to be reset. This means that the fastener count is reset and the tool, if disabled due to Error Proofing requirements, re-enables.

Reset and Reverse

This function, when selected, causes the tool to disable after a NOK Fastening cycle. The Reject Tone, when enabled, will sound. Pressing the button re-enables the tool in the Reverse direction and indicates that the operator acknowledges the rejected Fastening cycle and wishes to repair it. The tool switches to the forward direction after the controller detects a fastener has been removed.

5.2.6 Worklights

!

There are two worklights located above the MFB, below the motor on pistol type tools, but is opposite the start trigger switch on standard tools. The worklights are activated when the trigger switch is depressed, and will automatically turn off after the programmed amount of seconds after the trigger switch is released. If the trigger switch remains depressed, the worklights will remain on. NOTE: The worklights are for lighting the immediate work surface and are not intended to be used as a flashlight.

5.2.7 Program Selection The QPM Expert Alpha controller has various means of changing the selected Job/Task such as inputs or barcode scans of product. See Section “6.12 Assignable Input and Output Functions” on page 120 to understand how to select a Job/Task.

5.2.8 Directional Control

WARNING UNEXPECTED REACTION FORCES To Avoid Injury: • Be prepared – when a tool operates in reverse, the tool’s torque reaction is opposite to the reaction produced when the tool operates in forward direction. • The tool can have a higher initial reaction force when loosening a fastener. • Always stop the tool before changing direction of spindle rotation. Clockwise is the normal direction for securing a fastener, however a fastener can have left hand threads which requires the tool’s output to turn counter-clockwise to secure the fastener. The direction of rotation to secure a fastener is programmed in the controller. If a reverse, or disassembly, operation is required the operator must press the MFB to change the tool’s mode to reverse. Then the start trigger switch is pressed to run the tool in reverse. While the tool is in reverse mode, the blue disassembly ready light [1] will illuminate if the tool is ready to run, all the tool’s display status lights [3] and [6] will flash and the tool’s noise maker will emit a tone that alternates between on and off. To return the direction of rotation to forward, or assembly, the operator must press the MFB again. The blue assembly ready light [2] will illuminate if the tool is ready to run, the tool’s status lights will no longer flash and the alternating tone will stop.

5.2.9 Tool Temperature STANLEY tools are thermally protected to prevent overheating. Temperature is sensed inside the tool and the value is reported to the controller. The thermal protection does not allow the tool to operate if the tool temperature rises abnormally – the thermal protector resets automatically when the tool cools down. The maximum tool temperature before damage occurs is 150°C. EN60745-1 Hand-Held Motor-Operated Electric Tools - Safety is the most applicable standard to the tools. It

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Special Application Tools defines +60°C as the limit for thermal rise over ambient of a contactable surface (e.g. if the ambient is 25°C, the surface limit is 85°C.) Since the default limit is 85°C inside the tool regardless of ambient, no external surface can exceed this value no matter what the ambient temperature. STANLEY allows the temperature limit adjustment to provide flexibility to the professional user. Once a customer changes the setting from the factory default, it is their responsibility to ensure the safety of the user. Controller parameter settings can have a significant effect on tool operating temperatures.

5.2.10 Setting Torque, Angle, and Other Operating Parameter

WARNING EXCESSIVE TORQUE CONDITION To Avoid Injury: • Only trained and qualified personnel should program controllers. • Never set control limits above the maximum rating of the tool. • Setting control limits above the maximum rating of the tool can cause high reaction torque. • Always test for proper tool operation after programming via the controller.

CAUTION • Ensure fastener and/or system will withstand the level of torque generated by the tool. Excessive torque may cause breakage and possible personal injury. The Alpha controller can be setup to change tightening Jobs or Tasks from the tool’s MFB.

5.2.11 Assembly (Forward) Operation Prepare to resist the tool’s torque reaction. Keep the tool pointed straight at (perpendicular to) the fastener. Start the tool by depressing the start trigger switch. The tool stops after reaching torque. Release start trigger switch after the cycle is complete.

5.2.12 Disassembly (Reverse) Operation Prepare to resist the tool’s torque reaction which will be the opposite of the assembly reaction. Start the tool by depressing the start lever or trigger. The tool is not running inside of a strategy so it will not stop on its own. Release start lever after sufficient time or rotation to stop the tool.

5.3

Special Application Tools

5.3.1 Exposed Gear Socket Tools

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Tool Operation WARNING PINCH POINT AT THE EXPOSED GEARS OR TEETH To Avoid Injury: • Keep body parts and clothing away from the exposed gear sockets. Dress properly. Do not wear loose-fitted clothing or jewelry. Exposed gear socket tools are designed to fit into tight spaces where other tools do not fit. These tools have exposed gears or ratchet teeth. It is recommended to use the MFB ARMING feature for these types of tools.

5.3.2 Tubenut Nutrunners

WARNING PINCH POINT AT THE EXPOSED GEARS OR TEETH To Avoid Injury: • Never place body parts or clothing, near the socket opening. Dress properly. Do not wear loose-fitted clothing or jewelry. • Follow the Tubenut Nutrunner Sequence of Operation Tubenut nutrunners are used for installing tube fittings.

5.3.2.1

General Sequence of Operation Place nutrunner socket around the tube and onto the nut. Press the MFB to ARM the start function if this is programmed. Depress start trigger to start the tool’s tightening strategy. The tool stops after reaching torque. Release the start trigger and lift the tool from the nut. All tool status lights flash to indicate the tool will now run in reverse to open the socket. Depress the start trigger until the socket returns to the open position. Release the start trigger. Remove the tool from the tube.

5.3.2.2

ARM Mode All tubenut tools are programmed with ARM required for personal safety. End users are free to reprogram the tool so that ARM is not required. The tubenut operation will behave differently between ARM required and not required. This table explains the operations of the tubenut tool with and without ARM required.

Instruction Manual

107

Special Application Tools Arming

Normal Operation Assembly Mode:

Not Required

Required

Tool is Disabled

Assembly Mode:

Tool will run in Normal Assembly mode when operator presses the start trigger switch. When operator releases start trigger switch the tool will switch to Homing mode.

Assembly Mode:

After the operator starts the tool and when the trigger switch is released the tool switches to Homing mode. Tool does not have to reach target.

Homing Mode:

Homing Mode:

Homing Mode:

Assembly Mode:

Assembly Mode:

Assembly Mode:

Operator must ARM the tool by pressing the MFB once quickly. Operator must start the tool before ARM times out. When the start trigger switch is released the tool switches to Homing mode. Tool does not have to reach target.

The tool will not run. The controller display will indicate “Arming Required”.

The tool will not run when operator presses the start trigger switch. The controller display will indicate “Error Proofing”. When operator releases start trigger switch the tool will switch to Homing mode.

Homing Mode:

Homing Mode:

Homing Mode:

Tool will run in Homing mode when operator presses the start trigger switch. Tool will remain in Homing mode until one of the following conditions is met: 1. Dog Torque is achieved. 2. T otal Homing angle is TOOL screen

Download correct tool INI file to tool

Defective tool

Visual/mechanical Re-engage and lock inspection of pins pins in connector in in tool handle handle connector

Fault condition resets when cable length is reduced.

Re-engage and lock pins in connector in handle

177

Diagnostics and Troubleshooting Fault

Transducer Zero Fault!

178

Possible Cause

Major Consideration To Clear/Reset from That Led to Solution Fault Condition

Probable Solution

Torque Cal. set to a non-standard value (i.e. greater than 20% variance from Nominal Cal.)

Read the Nominal Set Torque Cal. to Torque Cal. value the specific torque from the tool and calibration value for compare it to the the tool specific Torque Cal.

May require tool recertification

Tool gear case binding

Remove the object wrapped around gear case. Open gear case and inspect for wrong components or components are in backward

Remove the object wrapped around gear case. Reassemble gear case with proper components.

Defective tool

Visual/mechanical Re-engage and lock inspection of pins pins in connector in in tool handle handle connector

ANALYZE screen shows a zero offset on the transducer health meter

Re-engage and lock pins in connector in handle

QB Expert Alpha Controller

Maintenance Fault

Possible Cause

Wrong value in Temperature parameter

Temperature Fault!

Modify Temperature parameter value

Major Consideration To Clear/Reset from That Led to Solution Fault Condition Viewed Temperature value under SETUP-> OTHER-> TOOL tab and compared with Temperature value on ANALYZE screen

Tool is hot to touch and shuts down: QPM tools shutdown when Use a larger tool for tool internal Excessive duty cycle the job temperature reaches and stays above programmed set point for 8 minutes

Inefficient Rundown Strategy

Instruction Manual

Probable Solution

Contact STANLEY Assembly Technologies for help on modifying strategy

Tool is hot to touch and shuts down: QPM tools shutdown when tool internal temperature reaches and stays above programmed set point for 8 minutes

Modify Temperature parameter value. The maximum for handheld tools is 85˚C. The maximum for fixtured tools is 125˚C. This error automatically resets when temperature drops and stays below trip point for 8 minutes on QPM tools. It can also be reset by cycling power, however, if the tool has not cooled down this error will reappear in 8 minutes. For fixtured tools turn off Soft Stop. To prevent an over temperature, modify the strategy by raising downshift speed or eliminating the downshift; Also try a multi-step strategy with a Delay Between Steps of at least 0.5 seconds. For fixtured tools turn off Soft Stop.

179

Diagnostics and Troubleshooting Fault

Possible Cause

180

Major Consideration To Clear/Reset from That Led to Solution Fault Condition

Output / gearing failure

Open and inspect tool head and gearing; replace any worn or broken parts

Tool has operated without overheating for a significant period of time but suddenly overheats; operator notices change of tool operation (i.e., noise, vibration, and speed are different than normal)

Perform maintenance on tool; open and inspect tool head and gearing; replace any worn or broken parts

Reduced incoming voltage

The type of joint (hard or soft) can cause (see Excessive Duty Cycle cause above); switch from 115 V AC to 230 V AC or correct reduced incoming voltage problem

When tested with a voltmeter, or as observed on the ANALYZE screen, incoming voltage is TOOL screen

Download correct tool INI file to tool

Temperature Fault! Continued

Unrecognized Tool!

Probable Solution

QB Expert Alpha Controller

Maintenance Fault

Possible Cause

Defective tool, cable, or controller

Probable Solution

Replace defective tool, cable, or controller

Major Consideration To Clear/Reset from That Led to Solution Fault Condition

Exchanging known good tools controllers and cables can determine which caused a failure

Replace defective tool, cable, or controller. If the controller is found to be defective, return to STANLEY Assembly Technologies for repair. If the tool is found to be defective, see the next row for troubleshooting and repair.

Tool found to be defective

Replace and reprogram the Tool Memory Board in the handle of the tool

Tool Communications!

Instruction Manual

Tool Memory Board failure

Replace the Tool Memory Board

Defective tool

Visual/mechanical Re-engage and lock inspection of pins pins in connector in in tool handle handle connector

Re-engage and lock pins in connector in handle

Tool not electrically connected to controller

Check tool whip/ extension cable connections and ensure they are tight

Connect tool to controller

No values indicated under SERVICE>TOOL screen

181

Diagnostics and Troubleshooting Fault

Possible Cause

Defective tool, cable, or controller

Probable Solution

Replace defective tool, cable, or controller

Major Consideration To Clear/Reset from That Led to Solution Fault Condition

Exchanging known good tools controllers and cables can determine which caused a failure

Replace defective tool, cable, or controller. If the controller is found to be defective, return to STANLEY Assembly Technologies for repair. If the tool is found to be defective, see the next row for troubleshooting and repair.

View transducer health, current and torque output meters on ANALYZE screen and determine if values are in normal range. Tool found to be defective

Open tool handle and check transducer cable connections to ensure tightness and the wiring is not damaged. Remove motor housing sleeve and check blue transducer wire for damage. Remove the gear pack from the motor on the tool and replace the torque transducer; testing with a known good transducer connected to the tool before replacement helps determine which parts are faulty.

Unsupported Tool! fault on display

Change tool to a type the controller can run. Look under SERVICE-> Controller for list of supported tools.

Transducer Current Fault!

Transducer / transducer cable within tool failure

Unsupported Tool!

182

The wrong tool type has been connected to the controller.

Replace transducer / transducer cable in tool

Change tool to a type the controller can run.

QB Expert Alpha Controller

Maintenance Fault Servo Connection Fault!

Spindle Communications

Possible Cause

Major Consideration To Clear/Reset from That Led to Solution Fault Condition

Reboot controller; Controller Firmware keep controller has just been off for at least 20 updated seconds

Servo Connection Fault! on display

Lead or trailing controller is off

Turn lead or trailing controller on

Spindle Turn lead or trailing Communications on controller on display

Controller is setup as a lead or trailing controller

Default the controller

Controller is a single spindle

Default the controller

Visual/Mechanical inspection to ensure cable connections are tight

Reconnect Ethernet cable between Lead and trailing controllers. If using external switches ensure they are energized.

Ethernet cable disconnected

9.3

Probable Solution

Reconnect Ethernet cable between Lead and trailing controllers

Reboot controller; keep controller off for at least 20 seconds

Message Guide Message

Possible Cause

Probable Solution

Major Consideration To Clear/Reset from That Led to Solution Message Condition

Communication Fault

Cable has disconnected from controller or PI box

Reconnect cable

Visual inspection

Reconnect cable

Count Fault

Operator backed out a fastener

Re-fasten loosened fastener

Actual bolt count on display is less than required

Re-fasten loosened fastener

Program Fault

Operator performed a double hit or fastened more fasteners than was expected

Reset Job or loosen a secured fastener to return to the proper bolt count

Actual bolt count on display is more than required

Reset Job or loosen a fastened fastener

Tool INI file is corrupt

Download a new file and try to load it again

Tool Update Failed error message appears.

Download a new file and try to load it again

Loss of communication between tool and controller

See Tool Communications! in Tool section “9.2.1 Fault Communications! Guide” on page fault on display 175

The PLC is providing the message

None

Tool Update Failed

PLC Message

Instruction Manual

PLC Message is displayed on controller

See Tool Communications! in section “9.2.1 Fault Guide” on page 175 Press OK

183

Message Guide Message

Invalid PLC File

Identifying Spindle

Possible Cause

Probable Solution Read the entire file and fix the syntax issue

Invalid PLC File appears on display

Press OK. Delete the PLC file. Read the entire file and fix the syntax issue.

Trailing spindle is wanting to connect to lead controller

Choose a number and add the spindle

Red, Greed, Yellow Status lights are blinking in sequence on trailing controller and tool with ‘Add Spindle’ dialog box on display of lead controller

Press OK. Choose a number and add the spindle

Operator pressed the Identify button under ANALYZE

Press OK

Display on lead controller is on ANALYZE screen

Press OK

Select a different Task

Tool Disabled: Undefined Task message on display when the operator pressed the tool’s start trigger

Program the selected Task or select another Task that is already programmed

Select a different Job/Task

Tool Disabled: Invalid Job/Task message on display when the operator pressed the tool’s start trigger

Select a different Job/Task from 1 to 99

Have a valid part enter the station

Tool Disabled: Network Protocol message on display when the operator pressed the tool’s start trigger

Have a valid part enter the station. Disconnect the Ethernet cable from the controller.

Select a new Job/ Task. Reset the Job.

Tool Disabled: Error Proofing message on display when the operator pressed the tool’s start trigger

Select a new Job/ Task. Reset the Job.

Bad command or syntax used in the PLC.json file

An unprogrammed Task has been selected

A non-valid Job/ Task has been selected Tool Disabled Network needs to know that a valid unprocessed part has entered the station

Accumulated bolt count is equal to Job/Task bolt count

184

Major Consideration To Clear/Reset from That Led to Solution Message Condition

QB Expert Alpha Controller

Maintenance Message

Possible Cause

Major Consideration To Clear/Reset from That Led to Solution Message Condition Tool Disabled: Stop Issued message on display when the operator pressed the tool’s start trigger

Remove the active input. Reassign input.

Select a different Job/Task. Job/ Task Verify inputs not matching Select a different selected Job/ Task. socket for verification.

Tool Disabled: Stop Issued message on display when the operator pressed the tool’s start trigger

Select a different Job/Task. Select a different socket for verification.

The controller is in the process of booting

Wait until the controller has finished the boot up process

Tool Disabled: System Initializing message on display when the operator pressed the tool’s start trigger

Wait until the controller has finished the boot up process

The Cycle Lock-out timer is active

Wait for the timer to reset. Change the Cycle Lock-out timer value.

Tool Disabled: Cycle Lock-out message on display when the operator pressed the tool’s start trigger

Wait for the timer to reset. Change the Cycle Lock-out timer value.

Reset the Job

Tool Disabled: Reject Count Exceeded message on display when Reset the Job the operator pressed the tool’s start trigger

Retrain operator on proper process to insure the internal PLC logic is met

Tool Disabled: Internal PLC message on display when the operator pressed the tool’s start trigger

A input is applied that is assigned as STOP

Tool Disabled Continued

Reject Count Exceeded

Logic criteria not met for tool operation

Instruction Manual

Probable Solution

Remove the active input. Reassign input.

Retrain operator on proper process to insure the internal PLC logic is met. Delete the PLC program.

185

Parts List Message

Possible Cause

Tool is not armed

Probable Solution

Press the MFB to arm the tool

Tool Disabled: Not Armed message appears on display whenever the operator presses the tool’s start trigger

Press the MFB to arm the tool. Change the tool’s parameter to not require arming.

Press the MFB to acknowledge and reset the NOK fastening cycle

Tool Disabled: Not Armed message appears on display whenever the operator presses the tool’s start trigger. Reset Reject is programmed.

Press the MFB to acknowledge and reset the NOK fastening cycle. Change the MFB parameter to not require Reset Reject.

Tool Disabled Continued A Reset Reject is active

9.4

Major Consideration To Clear/Reset from That Led to Solution Message Condition

Parts List WARNING To Avoid Injury: • Only use approved replacement parts when repairing controllers. Using unapproved parts could cause injury to personnel and or damage to equipment. Users may order installation and repair parts directly from STANLEY, or their agents. Device Tool

186

Description

Item Number

Label, Warning, Pinch Point

X5557

Label, Warning, Reaction Point

X5571

Label, Warning, Tubenut

X5556

QB Expert Alpha Controller

Maintenance

Instruction Manual

187

QB Expert Alpha Controller

10 Appendix A

Torsion Compensation Angle Validation

Torsion Factor 10

Torsion Compensation

10.1 Torsion Factor For all STANLEY electric assembly tools, the angle information is based on the rotation of the resolver, which is directly attached to the rotor. This information is used for motor commutation, and it also serves as an angle encoder. The rotation of the tool output can be determined by dividing the rotor angle by the total gear ratio for the tool. All things can deflect when loaded. Just as a long steel bar attached to a socket to produce high torque will deflect, likewise the gears within an assembly tool will deflect when subjected to the torque loads. In effect, the gears act as a torsion spring between the rotor and the socket, and it is the deflection of this spring that can give false angle data. In addition to the angular deflection within the gears of the tool, there can also be deflection of the parts of the joint. Whenever this deflection is present in the tool or the joint or the tool mounting device, the angle information derived from the resolver will indicate a larger angle than the tool output actually rotates. This error is directly proportional to the torque level. That is, the deflection at 40 NM will be twice that at 20 NM. In a torque vs. angle curve of a fastening cycle, at the end when the torque reaches its maximum value, the angle will also be at its maximum value. After shut off, as the torque falls to zero, the angle should remain at its maximum value. But in the typical torque vs. angle curve, as the torque falls to zero, the angle also appears to fall some amount. This is not because the fastener is being loosened. It is actually the resolver indicating that the angular deflection of the gears is relaxing to the neutral position. In this case, the maximum angle indicated at the maximum torque was incorrect. The resolver indicated more angle than the tool output actually rotated. To correct for this slight error in angle data, the Alpha controller has a STANLEY-exclusive solution. The Torsion Factor allows the user to input a value that compensates for the torsional spring rate of any part of the fastening system (the gears of the tool, the joint components, or the tool mounting device), and this factor is used to correct the angle reading throughout the fastening cycle. This factor is entered as Degrees per NM, and its default value is zero. If the default value is used, there will be no angular correction. If a value of 0.1 is used, each angle data point (every millisecond) will be modified by subtracting 0.1 times the torque value. For example, at 15 NM, the controller will subtract 1.5 degrees from the angle reading for that sample. At 30 NM, the controller will subtract three degrees for that sample. The easiest way to determine the correct value for the Torsion Factor is to look at a torque vs. angle trace with Torsion Factor set to zero. The amount of degrees that the socket appears to loosen after the maximum torque, divided by that maximum torque is the Torsion Factor. For example, consider a torque vs. angle trace that indicates a maximum torque of 40 NM, and the maximum angle at this torque of 50 degrees. But the angle appears to loosen by four degrees as the torque drops to zero. The Torsion Factor can be determined by dividing four degrees by 40 NM to arrive at a Torsion Factor of 0.1 degrees per NM. When this value is entered into the Torsion Factor parameter, each angle reading will be corrected by this factor. When this factor is set correctly, any torque vs. angle trace will now indicate no apparent loosening of the fastener as the torque drops to zero after shut off; which is exactly as it should be.

10.2 Angle Validation Now that the angle can be indicated with great precision, the other challenge is to validate these results against an external torque/angle transducer with monitor. This is not as simple as setting both the controller and the monitor to the same snug torque and comparing the resulting angle. It has been found that a tool’s torque trace will never track exactly the same as the external. The calibration is only the average of a number of readings, generally at a high torque near the maximum capacity of the tool. When any individual torque reading from the tool’s controller is compared to a torque reading from the external torque monitor, it can easily have a difference of several percent higher or lower. This means that the tool’s controller will start counting angle at a different point than the external torque/angle monitor starts counting. This could be five

190

QB Expert Alpha Controller

Appendix A to 10 degrees different depending of the hardness of the joint. The only way to get consistent results when validating an angle reading against an external monitor is to pretorque the joint slightly higher than the snug torque. Run the tool on this already-tightened joint, with the snug torque set to the same value in both the controller and the monitor, even if the tool’s transducer and the external transducer do not exactly agree near the snug torque, they will both start counting angle just before the fastener starts to rotate, so their zero angle will be synchronized exactly. For example, if a brake line fitting requires six NM plus 40 degrees, pre-torque the joint to seven NM first. Then change to an Angle Control strategy, with six NM snug torque, plus 40 degrees angle target, and reset the external torque/angle monitor. Then as the tool is run in this angle control mode, the tool will start counting angle as soon as it has six NM (which might have been five or seven NM according to the external transducer), which is before the joint actually starts to rotate. And the external monitor will start counting angle as soon as it has six NM which is also before the joint starts to rotate. This way, both meters are reading angle from the same point, even though the torque readings may differ slightly because of the allowable tolerances in the torque calibration.

Instruction Manual

191

QB Expert Alpha Controller

11 Glossary

 11

Glossary Abort Timer

The Fastening cycle aborts if the tool does not shutoff before this pre-selected time.

Acceleration

How fast the controller changes the speed of the tool from 0 (stopped) to the rated speed.

Accept Tone

Controls the tone made from the handle of handheld QPM tools for accepted Fastening cycles. Allows distinct tones for tools in adjacent workstations.

ATC

Allows Adaptive Tightening Control modes to be selected, so that consistent torque can be maintained over a wide range of joints. Manual downshift should be used when: • High Prevailing Torques – Prevailing Torque > 20% of the Torque Set Point (TSP). • High Starting Torque –Starting Torque > 20% of TSP.

Batch Count

The number of Fastening cycles required to be within specified limits to complete a batch. The Run display shows the batch count and number of complete Fastening cycles.

Downshift Mode

Disable: no downshift; Manual: Occurs at specified torque; ATC automatically adapts to the joint.

Downshift Speed

Once the tool reaches the Downshift Torque point, the controller changes the operating speed of the tool from the initial Tool Speed to the Downshift Speed.

Downshift Torque

The controller changes the operating speed of the tool from the initial Tool Speed to the Downshift Speed at the Downshift Torque level.

High Angle

Anytime the peak angle recorded exceeds the High Angle, the Fastening cycle is recorded as a reject for high angle, the high angle light (red) illuminates and the Fastening cycle is given an overall status of NOK.

High Torque

Anytime the peak torque recorded exceeds the High Torque, the Fastening cycle is recorded as a reject for high torque, the high torque light (red) illuminates and the Fastening cycle is given an overall status of NOK.

Low Angle

Anytime the peak angle recorded during the Angle Audit Step fails to reach the Low Angle, the Fastening cycle is recorded as a reject for low angle, the low angle light (yellow) illuminates and the Fastening cycle is given an overall status of NOK.

Low Torque

When the peak torque recorded fails to reach the Low Torque, the Fastening cycle is recorded as a reject for low torque, the low torque light (yellow) illuminates and the Fastening cycle is given an overall status of NOK. Controls the operation of the multiple-function panel (MFP) on QPM tools.

MFP Mode

194

The choices for handheld tools are Disable, Reverse (Disassembly), Parameter Select, Arming and Reset Reject. The default value is Disable.

PM Counter

Records the number of Fastening cycles completed since the last time it was reset for Planned Maintenance.

PM Limit

When the PM Counter exceeds the PM Limit, the controller provides a maintenance alert.

Parameter Set

A Parameter Set is a collection of instructions that define how the tool should perform the tightening process. It may be selected from the keypad or 24V device such as a socket tray.

Reject Tone

Controls the tone made from the handle of handheld QPM tools for rejected Fastening cycles. Allows distinct tones for tools in adjacent workstations.

Slow Seek

Slow Seek helps engage the socket or fastener at a pre-selected speed, torque level and angular rotation. Once engaged, the Fastening cycle completes at a higher speed. Slow Seek prevents crossthreaded fasteners and previously secured fasteners from being counted in a batch.

Snug Torque

The controller begins to monitor the tool for angle at a preselected threshold torque. Any increase in angle after the snug point results in a corresponding increase in the tension or clamp load within the joint.

Soft Stop

Soft stop minimizes the torque impulse to the operator during tool shutoff at the end of the Fastening cycle.

QB Expert Alpha Controller

Glossary Speed

The speed at which the tool operates during the initial portion of the Fastening cycle prior to ATC or downshift.

Spindle

A spindle represents a connection to a hand held or fixtured tool connected to a controller.

Strategy

Identifies what variables will be used to control the tool during a Fastening cycle.

Thread Direction

Sets assembly direction to clockwise (CW) or counter clockwise (CCW).

Threshold Torque

Sets the point at which the tool is "In Cycle". When the tool is "In Cycle" the tool and controller Fastening cycle status lights turn off, the controller displays dashes (-) for data, and the "In Cycle" output is turned on.

Tool Tones

Distinctive sounds assigned to tool functions.

Torque Calibration

Determines how torque values are assigned to the electrical signals from the torque transducer on the tool. This value is unique to each tool and changes over time.

Torque Target

When the tool is being controlled for torque, the torque target instructs the controller when to shutoff the tool. The torque target should be greater than Low Torque and less than High Torque, and is required for torque control.

Trace

A display plot of torque vs time (or angle) of a Fastening cycle.

Trip Counter

Records the number of Fastening cycles completed since the last time it was reset. It is usually used as a supplementary count of the PM Counter. The following torque units and associated labels are used with STANLEY controllers and tools. The labels are derived from SP811, SI Unit rules and style conventions from the National Institute of Standards and Technology

Units

Instruction Manual

Abbreviation

Common Term

= 1 lbfft

= 1 Nm

Nm

Newton meter

1.355 818

1

Ncm

Newton centimeter

135.581 8

100

kgm

Kilogram meter

0.138 255 2

0.101 971 6

kgcm

Kilogram centimeter

13.825 52

10.197 16

ft lb

Foot pound

1

0.737 562 1

in lb

Inch pound

12

8.850 745

in oz

inch ounce

192

141.611 9

195

QB Expert Alpha Controller

12 Limited Warranty

Mechanical Products Limited Warranty Electronic Products Limited Warranty Software Products Limited Warranty OEM Products Limited Warranty General Terms Specification Changes Warranty Claims Product Services Return Material Authorization (RMA) Procedures

Mechanical Products Limited Warranty 12

Limited Warranty

12.1 Mechanical Products Limited Warranty Stanley Black&Decker, Inc. (“STANLEY”) warrants its Assembly Technologies mechanical products to the original purchaser to be free from deficiencies in material or workmanship for the useful life of the product. Under this lifetime limited warranty STANLEY will, at its discretion, repair or replace any product which, upon inspection, is acknowledged by STANLEY to be defective. This limited lifetime warranty shall apply to products which have been used under normal operating conditions for their intended use and shall not apply to products which have been subjected to: abnormal wear and tear, abuse, misuse, improper maintenance, negligence, continued use after partial failure, accident, alterations or repairs with non-genuine STANLEY replacement parts.

12.2 Electronic Products Limited Warranty STANLEY warrants its Assembly Technologies electronic products to the original purchaser to be free from deficiencies in material or workmanship for a period of one year after the date of shipment. Under this limited warranty STANLEY will, at its discretion, repair or replace any product which, upon inspection, is acknowledged by STANLEY to be defective. This warranty shall apply to products which have been used under normal operating conditions for their intended use and shall not apply to products which have been subjected to: abnormal wear and tear, neglect, component degradation, improper handling, overload, abuse, misuse, improper maintenance, use with improper accessories, or where alterations have been made.

12.3 Software Products Limited Warranty STANLEY warrants its Assembly Technologies software products to the original purchaser to be free from deficiencies in material or workmanship for a period of one year after the date of shipment. Under this limited warranty STANLEY will, at its discretion, make available replacement software or an upgrade for any product which, upon inspection, is acknowledged by STANLEY to be defective. Installation of the software shall be the responsibility of the requestor. This warranty shall apply to products which have been used with specified, compatible hardware under normal operating conditions for their intended use and shall not apply to products which have been: modified, misused, improperly handled, improperly maintained, or used with non-compatible hardware or accessories.

12.4 OEM Products Limited Warranty Some STANLEY Assembly Technologies custom engineered systems include components manufactured by others. The limited warranties of each individual manufacturer shall apply to these components and STANLEY makes no representation or warranty of any kind, expressed or implied, with respect to such components.

12.5 General Terms This limited warranty gives you specific legal rights and is in lieu of all other warranties, expressed or implied, including the implied warranties of merchantability and fitness for a particular purpose. Some states and countries do not allow limitations on implied warranties, so the above may not apply to you. You may also have other rights which vary by state or country. STANLEY shall not be responsible for incidental or consequential damages or the inability to use its products for any purpose whatsoever. STANLEY’s maximum liability shall not in any case exceed the contract price for the products claimed to be defective. Some states and countries do not allow the exclusion or limitation of incidental or consequential damages, so this specific limitation or exclusion may not apply to you.

12.6 Specification Changes 198

QB Expert Alpha Controller

Limited Warranty STANLEY retains the right to discontinue and/or change specifications of any Assembly Technologies products without responsibility for incorporating changes in products already sold.

12.7 Warranty Claims To apply for warranty consideration, the original purchaser should take the following action: a. Contact the STANLEY Assembly Technologies customer service department to obtain a “Return Authorization Number” and “Warranty Claim Report Form.” b. Package the product including proof of purchase and the completed warranty claim form. c. Note the Return Authorization Number on the exterior of the package and return freight to: STANLEY Assembly Technologies Central Repair Facility 5335 Avion Park Drive Cleveland, Ohio 44143-2328 In the event that a product is repaired or replaced under the terms of the warranty, the warranty period of the repaired or replacement product shall be limited to the remaining portion of the original warranty period.

12.8 Product Services STANLEY provides full services for design, modification, service, repair, and training on STANLEY products. Contact STANLEY Assembly Technologies or their agents for information on training courses to aid users in becoming familiar with operations, maintenance, or programming of the STANLEY DC electric tools and controllers. No modification of STANLEY tools and controllers can be made without the express permission of STANLEY Assembly Technologies. Refer all service to STANLEY Assembly Technologies, or their representatives.

12.9 Return Material Authorization (RMA) Procedures A Return Material Authorization or RMA is required before returning any material for warranty or repair service. • Contact STANLEY Assembly Technologies or their agents. • Request Customer Service or Repair Services.

!

NOTE: An RMA can be given without a purchase order. However, non-warranty repairs cannot be performed until a written purchase order or credit card authorization is received. Have the following information available for the person answering the telephone to obtain an RMA: • Company name and address. • A contact name and telephone number. If possible, have facsimile and pager numbers (if any) available. • The STANLEY model number, serial number, and description for the item • A short description of the problem.

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199

GLOBAL LOCATIONS World Headquarters

Germany

STANLEY Assembly Technologies 5335 Avion Park Drive Cleveland, Ohio 44143-2328, USA Tel: +1.440.461.5500 Fax: +1.440.461.5592 Email: [email protected]

STANLEY Engineered Fastening Germany Max-Eyth-Str. 1, 35394 Giessen, Germany Tel: +49 (0) 641 405 - 728 Fax: +49 (0) 641 405 - 383 Email: [email protected]

Sales and Support Americas/Asia-Pacific

STANLEY Engineered Fastening INDIA 6th Floor, Apex Towers, No 54, 2nd Main Road, R A Puram CHENNAI – 600 028, India Tel: +91 44 4343 7100 Fax: +91 44 4306 0768 Email: [email protected]

India

STANLEY Assembly Technologies 2380 Meijer Drive Troy, MI 48084, USA Tel: +1.248.677.9709 Sales: 877.709.8006 Service: 877.787.7830 Email: [email protected]

China STANLEY Engineered Fastening CHINA BUILDING NO. 9, 615 FENGDENG ROAD MALU TOWN, JIADING DISTRICT Shanghai 201801, China Tel: +86 21.3915.5588-5511 Fax: +86 21.3915.5555 Email: [email protected]

France STANLEY Engineered Fastening France Outils Portatifs et Systemes d’Assemblage Zone Imoparc bat Loire 4, 78190 Trappes, France Tel: +33 (1) 3050 9100 Fax: +33 (1) 3051 0708 Email: [email protected]

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