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Theta Controller User Manual

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1. SULEMA Assembly Technologies Theta Controller User Manual Software Version QC1 10 1 Important Safeguards For your protection please read these instructions completely and keep this manual for future reference Carefully observe and comply with all warnings cautions and instructions placed on the equipment or described in this manual 2008 THE STANLEY WORKS ALL RIGHTS RESERVED www StanleyAssembly com ThetaUser091008 User Manual Contents KEEN 1 SN Ge Bil E 1 1 2 Warnings and Cautions eese 1 1 3 Specifications Layout and Display 2 14 installation InstucllolBS uc rece ise ie edes eet ved vetu eig esi ede eius 4 1 4 1 Theta Controller E Stop Precaution 6 ProgramMMINO met 2 1 QA Theta Controller Navigation and Programming 7 2 2 JDISDIOV EE 7 2 2 1 SCO EE EE 7 22 2 NOD COW EE 8 229 Menu HEGER eg ege 8 22A AS EE 8 225 en Le eer le EEN 8 22 0 JAUM DISDIAY ee ee E 8 2 9 ER TICE 9 24 MESSAGES EE 10 2 5 Theta Controller Hrogrammmg seus 11 2 5 1 oetubp Menu 1 3JODS E 12 2514 Wizard SOL ee 13 2 5 1 2 SUP JOD TAD anta emnt ies ee 16 2 5 1 3 Setup Manage Button Job 17 2 9 1 4 SUD Step BUM OM se cemere haee stets 18 2 5 1 5 Setup Manage Button Step 20 2 OEO o Mui E 21 2 5 2 Setup Menu 2
2. Communications 21 2 5 3 Setup Menu 3 Other 22 2 5 4 Setup Menu 4 Restore Factory Defaults 27 LASSEN UM 28 APO tm 28 ZOOL COMMON Cle siste dirt te box temor bsec ria 29 E ENEE 30 OPM DC Fleche Ke Le EE 33 Sl TOON SPSCIICAN ONS mm 33 9 2 Operator RICE CHON eege genee ro eU de tim ee ite utes emcees 34 miseriae HM 34 3 2 1 Heanng Protection DORT REMO 34 Q2 NWO EU OND EE 35 32 37 Breathing ProlecllOll use cedi oe bed decli ded decla onda 35 So OO WITS UTM NU OA EE 35 3 3 1 SOCKETS Be Ee EEN 35 33 2 SUSPENSION RTE e 36 9 Gable e EE de E 36 34 el Ree 37 Theta Controller 3 4 1 Display and Multiple Function Button for Hand Held Tools 37 3 4 2 MFB Mode EE 37 343 TOOLMEMOV EE 37 3 4 4 Tightening Cycle Counters ssessse 38 9 9 Ee ei ODSLAllOD EE 38 3 5 1 Directional COMI BEER 39 3 5 2 Torque Reaction Devices A 39 30 0 TOO TGMpPECatUre aun 39 904 iOOWSatuS LIONS sede e b ee eg 39 3 5 5 Setting Torque Angle and Other Operating Parameters 40 36 Special Applicaton TOO Su isti o ote ces 40 3 6 1 Exposed Gear Socket Tools 40 362 Tu benut NUTFUFPlfierS ca oot Ses Seene 40 Theta Controller Re eat ele EE 41 4 1 Theta Controller Connections s00nnoannnnennnennennnnnennnnni 41 4 1 1 Theta Controller Power Cord 41 4 1 2 Th
3. 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 54 Theta Controller Warranty Mechanical Products Limited Warranty STANLEY ASSEMBLY TECHNOLOGIES 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 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 use
4. operating tools and controllers Getting Started 1 User Manual Indicates an electrical hazard o Indicates an item of special This icon appears as a part of a interest Danger Warning or Caution notice WARNING To Avoid Injury Read and understand all the safety recommendations and all operating instructions before operating tools and controllers Save these instructions for future reference 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 tools 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 Qualified Personnel WARNING To Avoid Injury Only allow suitably qualified personnel to install program or maintain this equipment and or system 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 1 3 Specifications Layout a
5. EXIT key save the changes and return to the run screen See Section 2 5 1 6 TONES tab The alarm in the tool handle can emit different tones based on the status of the tightening cycle Choose an Accept Tone for an OK tightening cycle and a Reject Tone for a NOK tightening cycle Play previews the tone selected Stop stops playing the tone selected Use the right or left arrow to move to the next tab or press the EXIT key save the changes and return to the run screen See Section 2 5 1 6 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 values here PM Limit When the PM Counter in the tool exceeds this threshold the preventive maintenance LED on the front panel illuminates indicating it is time to perform maintenance on the attached tool Temperature Limit Torsion Factor Requires Arming Temperature Limit The threshold in degrees Celsius when the tool will shut off This is caused by excessive duty cycle on the tool Torsion Factor See Appendix B for an explanation of this parameter and how to determine a correct value Otherwise leave at the default of zero Requires Arming Forces the Tap Action on the MFB to Arm See section 3 4 2 Tubenut tools require arming as a factory setting 26 Theta Controller Other Screens Options Screen Use the right or left arrow to move to the
6. Fault Position Feedback Fault Transducer Span Fault Temperature Fault Unrecognized Tool Tool Communications Transducer Current Fault Transducer Zero Fault Unsupported Tool 2 4 Messages User Manual There are two things that can cause this hardware fault a GFI the Ground Fault Interrupter has exceeded its current trip point A current detector monitors the current through the 3 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 of immediately to protect the controller from shorts at the tool end b Total Current the controller software limits the current applied to any tool based on what the tool can handle This fault 1s asserted 1f there 1s a short at the tool end and the total current applied is greater than allowed The controller monitors the S VDC 5VDC and 12VDC of its onboard Power Supply This fault is asserted when those voltages fall outside of nominal range The controller is constantly monitoring the resolver zero and span points and asserts this fault if they go outside specification This fault is asserted when the transducer zero point has shifted far enough to prevent a full scale reading from the transducer This fault is asserted when the tool temperature detector has reached the temperature limit set by the Temperature Limit parameter It resets after detect
7. 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 Warranty 95 User Manual 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 Specification Changes Stanley retains the right to discontinue and or change specifications of any Assembly Technologies products without responsibility for incorporating changes in products already sold Warranty Claims To apply for warranty consideration the original purchaser should take the following action Contact the Stanley Assembly Technologies customer service department to obtain a Return Authorization Number and Warranty Claim Report Form Package the product including proof of purchase and the completed warranty claim form Note the Return Authorization Number on the exterior of the package an
8. User Manual 2 5 3 Setup Menu 3 Other Other Screens Options Screen This area has the parameters for all other features on the Theta They include setting up system level parameters users and passwords assigning I O and tool functions Each category is represented by its own tab Use the left or right arrow keys to select the tabs category to modify them Users must have ADMINISTRATOR or SETUP access level to modify values in this area General Tab Name This gives a name to the controller so it can be distinguished from other Theta couNT UP controllers on the same plant floor Stop Abort within Limits ok Wf Keypad Mode The keypad on the face of the controller can be used to select Jobs Job Select to run while in the run screen Or this function can be Disabled Use the right arrow to move to the next tab or press the EXIT key save the changes and return to the run screen See Section 2 5 1 6 S Reeg Users Tab To add a user press the Manage button The Theta controller can have 8 users assigned each with unique passwords The passwords can be any length up to 16 characters and can be made up of any characters that can be created using the up and down arrows and numbers on the keypad Adding users is a 3 step process First add the user and give them a User Name Press OK If users are assigned one of them must be an Administrator If the lock icon appears the controller is pa
9. a wall or 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 3 Make sure the bolts of the barrel latches 5 on the plinth are retracted Place the lower flange of the Theta controller 1 into the lip 2 on the plinth 4 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 5 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 6 Connect the Theta Controller to a power source 7 Connect the tool cable to the Theta controller and press the power switch on the controller 8 Thecontroller will display a list of languages after the first boot up from the factory Press the up or down arrows to select the appropriate language for the region then press the Enter key to save the selection The controller will display its run screen indicating it 1s ready for programming and operation Lae Getting Started 5 User Manual 1 4 1 Theta Controller E Stop Precaution WARNING INTEGRATED E STOP CIRCUIT NOT PRESENT To Avoid Injury When a Theta 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
10. limit the tightening cycle is flagged as NOK and the RED LED on the front panel and the tool will illuminate Required for this step Must be greater than Low Angle Units are degrees of rotation Low Angle The minimum peak angle for an acceptable tightening cycle If the actual angle does not reach this limit the tightening cycle is flagged as a NOK and the YELLOW LED on the front panel and the tool will illuminate Must be less than High Angle Units are degrees of rotation Angle Bailout Determines when to stop the tool on angle Should be set equal to or above High Angle Units are degrees of rotation Downshift Mode Selects the type of spindle inertia control toward the end of a tightening 18 Theta Controller Step Button Screens Options Screens cycle DISABLED HOH UO HTC Disabled Does not reduce the speed of the motor Manual Reduces the tool speed to a specific value Downshift Speed when a specific torque value Downshift Torque is achieved during the tightening cycle Speed units are RPM Torque is in torque units Downshift Mode LMAHUAL DS Downshift Torque ole Downshift Speed al ATC Enables the Adaptive Tightening Control algorithm to slow the tool speed as the torque rises DownshiTft Mode Sab ATC Starting Torque 2a i HATE Ending Torque X rsl ATC Ending Speed X a The default values can be modified for when the algorithm starts ATC Starting Torque
11. to make changes Unlocked Changes possible automatically re locks in time ei Busy working Wait Fault system not operable Check the run screen for Fault message T Force on or off Identifies an input output forced on or off i User Entered Password This icon appears next to the user in the User list that has entered their password and unlocked the box Stop Tool Operation Undefined Job The selected Job is not press the trigger for an indication programmed to run a tool select another Job or of what is causing the tool Stop program the currently selected Job Network Protocol The plant control system is issuing 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 Reset Reject is enabled and active reset the reject by pressing the MFB Invalid Job The selected Job is wrong based on the validation inputs System Initializing the controller is booting up please wait Cycle Lock out The Cycle Lockout timer is active wait for it to reset 2 3 Faults The display background color in normal operation is white In the event of a fault the display background becomes red and the fault description appears on screen The background color reverts to white only when the fault is cleared Programming 9 Overcurrent Fault Logic Voltage
12. torque recorded exceeds the High Torque the tightening cycle is recorded as a reject for high torque the red light illuminates and the tightening cycle is given an overall status of NOK Anytime the peak angle recorded during the Angle Audit Step fails to reach the Low Angle the tightening cycle is recorded as a reject for low angle the yellow light illuminates and the tightening cycle is given an overall status of NOK When the peak torque recorded fails to reach the Low Torque the tightening cycle is recorded as a reject for low torque the yellow light illuminates and the tightening cycle is given an overall status of NOK Controls the operation of the multiple function button MFB on QPM tools The choices for handheld tools are Disable Reverse Disassembly Parameter Select Arming and Reset Reject The default value is Reverse Records the number of tightening cycles completed since the last time it was reset for Planned Maintenance When the PM Counter exceeds the PM Limit the controller provides a maintenance alert 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 Controls the tone made from the handle of handheld QPM tools for rejected tightening cycles Allows distinct tones for tools in adjacent workstations Slow Seek helps engage the socket or fastener at a pre selected speed torque
13. when it ends ATC Ending Torque and what the tool speed 1s after the algorithm ends ATC Ending Speed The torque units are percent of Target Torque The speed values are percent of Speed Soft Stop 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 If No is selected the tool will simply de energize and coast to a stop Doft Stop ESE i Current Off Time _6 BasS i Current Hold Time BEER Current Ramp Time D SC If Yes is selected the tools current will be removed for the time specified in Current Off Time then reapplied for the time specified in the Current Hold Time then it will ramp to zero over the time specified in Current Ramp Time Units are in seconds Speed The velocity of the output of the tool during this step before any Downshift Mode activates Units are RPM Required for this step Must be greater than 0 Power The maximum power available to the tool to perform the tightening cycle Units are percent of maximum rated torque of the tool Required for this step should not be less than 100 Acceleration The rate the tool gets up to Speed in RPM s revolutions per minute per second Required for this step Should be greater than 1000 RPM s Abort Timer Stops the tool when the time has elapsed from the start of the step Required for this step The value should be long enough to complete
14. 2 to 122 F 0 to 50 C Humidity 0 to 95 non condensing Noise Level A weighted emission sound pressure level at the work station lt 70dBA ref 20uPa as determined according to ISO 15744 2002 Vibration Level Weighted root mean square acceleration value at the handle lt 2 5 m s 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 Product A weighted emission sound pressure level Weighted emission root mean at the work station Lp ref 20uPa square acceleration level at the Value determined according to handle Value determined ISO 15744 2002 using as basic standards according to ISO 8662 ISO 3744 and ISO 11203 single axis ECO ECI EC2 EC3 lt 70dBA 2 5 m s EC4 and EC5 electric tools 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 Lycpeak 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 t
15. 89 336 EEC Electromagnetic Compatibility Directive Standard Title Description EN55011 Conducted and Radiated Emissions EN61000 3 2 Current Harmonics EN61000 3 3 Voltage Fluctuation and Flicker EN61000 4 3 Radiated Immunity EN61000 4 4 Fast Burst Transients EN61000 4 5 Surge EN61000 4 6 Conducted Immunity EN61000 4 8 Magnetic Immunity EN61000 4 11 Voltage dips interruptions EN61000 4 2 Electrostatic Discharge Immunity Level 4 Contact Discharge 8 KV Air Discharge 15 KV 1 2 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 m this document and marked on the equipment itself have the following significance Indicates that death or severe Danger personal injury will result if proper precautions are not taken 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 Indicates that death or severe personal injury may result if Warning proper precautions are not taken appears as a part of a Danger Warning or Caution notice Indicates that property damage Read and understand all the Caution may result if proper precautions safety recommendations and all O gt are not taken operating instructions before
16. C Electric Tools amp Controllers e Install tools in dry indoor non flammable and non explosive environments only Humidity 0 to 95 non condensing and Temperature 32 to 122 F 0 to 50 C 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 controllers off when 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 3 3 1 Sockets and Adapters Use only industrial grade sockets and adapters power bit and power or impact socket type Replace worn o
17. E stop circuit must be created in the external power supply line Theta Controller Programming 2 1 QA Theta Controller Navigation and Programming The Theta controller s three navigation and input areas facilitate menu navigation selection and data input Menu buttons Arrows and Toggle button Keypad 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 display 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 menu button The numeric keypad 4 facilitates data input and menu selection where applicable and job step selection when enabled 2 2 Display 2 2 1 Scroll Bar 1 T A scroll bar appears when more items are available than space within the 2 2 display allows The up arrow 1 and down arrow 3 direct scrolling The black white scroll bar 2 indicates which list items are currently displayed No d scroll bar means all items are currently displayed 3 n To navigate between menu items use the up down arrows or if available use the keypad to identify the corresponding menu item number Programming 7 User Manual 2 2 2 Dropdown EE 4 1 A dropdown 1 arrow appears to the right of menu items w
18. Parameter Set Reject Tone Slow Seek Snug Torque 50 User Manual The tightening cycle aborts if the tool does not shutoff on target before this pre selected time The rate at which the controller increases tool speed from 0 stopped to the Speed value Controls the tone made from the handle of handheld QPM tools for accepted tightening cycles Allows distinct tones for tools in adjacent workstations Adaptive Tightening Control allows a consistent achieved torque to be maintained over a wide range of joints Manual downshift should be used when High Prevailing Torques Prevailing Torque gt 20 of the Torque Set Point TSP High Starting Torque Starting Torque gt 20 of TSP The number of OK tightening cycles to complete a job The Run display shows the accumulated and target counts for the selected job Disable no downshift Manual Occurs at specified torque ATC automatically adapts to the joint 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 The controller changes the operating speed of the tool from the initial Tool Speed to the Downshift Speed at the Downshift Torque level Anytime the peak angle recorded exceeds the High Angle the tightening cycle is recorded as a reject for high angle the red light illuminates and the tightening cycle is given an overall status of NOK Anytime the peak
19. applicable regulatory electrical codes and safety codes Limit module access to trained and qualified personnel Lock module cabinets WARNING ELECTRICAL HAZARD To Avoid Injury Install modules 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 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 Theta Controller 6 152 mm e Ar 102 mm gt E Be ae a T as a EN a 63 5 mm 18 457 mm um E E Va en 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 center to 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 holds in different plinths is 6 152 4 mm 1 Install the Theta Controller either directly to the wall or to an optional mounting plinth 2 Fasteners through four mounting holes secure plinths to
20. arrow to move to the next tab or press the EXIT key save the changes and return to the run screen See Section 2 5 1 6 EH SE oo an ded Programming I O tab This tab indicates the live status of the 24VDC Inputs and Outputs Forcing the I O on or off is also performed here Users must have the DIAGNOSTICS or ADMINISTRATOR access level to force I O Each pin of the 24VDC connector is represented Pin A is for supplying 24VDC to the I O elements Pin V is the 24VDC Return to complete the current loop Pin B is the bus for the Outputs See section 4 1 4 for a schematic Pins L through U are for Inputs Pins C through K are for Outputs See section 2 5 3 to assign elements to the pins If an Input or Output pin icon is Clear that means it is OFF If the pin icon 1s Dark this means the pin is ON There is a horizontal cursor under the pins Use the cursor keys to move the cursor The bottom left hand corner of the screen will indicate which pin the cursor is at and what element has been assigned to that particular pin You can take manual control of the I O by using forcing Pins can be force ON or OFF Applying a force means the pin will always be in that forced state and will not toggle to the opposite state even though the system requires it to toggle This is useful for troubleshooting signals that integrate with other equipment Use the horizontal cursor under the pins to select the pin to be forced Pr
21. asserted the controller will reset the accumulated fastener count back to zero for the active job and act as a Part Entry to re enable the tool if disabled If Error Proofing is enabled the tool will disable when the accumulated count equals target count When removed nothing will happen The size of this input function is 1 bit Configuration Contact Type JOB SELECT When asserted or removed the controller will select a Job This is one bit of a binary number BIT created by several of these bits The size of this input function is 1 bit Configuration Contact Type Bit The number you wish this bit to be in your binary number scheme to select jobs Mode All JOB SELECT BITs must be the same mode no mixing of modes allowed Binary Will create a decimal number equivalent to the weighted value of this binary bit s Binary 1 Will create a number equivalent to the weighted value of this binary bit s and add the value of one 1 to that number REVERSE When asserted the controller will place the tool in Reverse disassembly mode This will NOT run the tool in Reverse it simply changes the tool mode from Forward to Reverse When removed the controller will place the tool into Forward assembly mode The size of this input function is 1 bit Configuration Contact Type 4 2 2 Output Descriptions Each of the output elements has Configuration settings of Contact types Output types and others It is recommend
22. aximum 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 Theta 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 3 degrees for that sample The easiest way to determine the correct value for the Torsion Factor 1s to look at a torque vs ang
23. bet Use the number keypad Torque Target fara bers i High Torque Low Torque Snug Torque j High Angle Low Angle Torque Target The torque at which the controller shuts off the tool required for this step Should be greater than Low Torque and lower than High Torque Wi kb n cn Ajj Oh e un VD 4 VD VD Ww VD 4 VD VD Eu angle Bailout j Downshift Mode Soft Stop j 5peed J Power Acceleration j Abort Timer High Torque The maximum peak torque for an acceptable tightening cycle If the actual torque exceeds this limit the tightening cycle will be flagged as NOK and the RED LED on the front panel and the tool will illuminate Required for this step Must be greater than Torque Target and less than or equal to the rated torque marked on the tool D b 4 C4 P m e rcp a o m uw 4 Low Torque The minimum peak torque for an acceptable tightening cycle Ifthe actual torque does not reach this limit the tightening cycle is flagged as NOK and the YELLOW LED on the front panel and the tool will illuminate Required for this step Must be less than the Torque Target Snug Torque The point in this 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 High Angle The maximum peak angle for an acceptable tightening cycle If the actual angle exceeds this
24. ccepts changes Data input and when applicable menu selection Can be used for job selection when enabled to do so H 6 9 5 Numeric Keypad U Programming 11 User Manual The left column shows the currently defined Theta Controller settings and menu choices The Options Screen column shows options for each selection Screen navigation options appear above each screen Default Screens Options Screen Programming changes are stored after exiting current menu and returning to run screen Job Reset resets bolt count back to zero 2 5 1 Setup Menu 1 J obs The Setup menu programs the controller to operate a spindle or tool Jobs control tool operation for tightening a fastener and consist of one TC AM Torque Control Angle Monitor Step with up to three optional Smart Steps Most controllers will operate with a single Job and Step Users must have ADMINISTRATOR or SETUP access in order to modify Job settings This includes Wizard Manage and Step parameters If a tool 1s attached and no jobs are programmed the Wizard automatically appears after selecting Jobs The Wizard can setup a Job for simple or complex tightening cycles using the optional Smart Steps auto Reset Job Enable SES SEA The Wizard will be discussed first and then the Job setup afterwards 12 Theta Controller 2 5 1 1 Wizard Screens Wizard Screens Options Screen The Wizard assists with programming the controller to assign a J
25. d return freight to Stanley Assembly Technologies 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 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 Return Material Authorization RMA Procedures A Return Material Authorization or RMA is required before returning any material for warranty or repair service e Contact STANLEY ASSEMBLY TECHNOLOGIES or their agents e 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 e Have the following information available for the person answering the telephone to obtain an RMA e Company name and address e A co
26. d 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 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 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
27. d via a serial link Installing the Controller Gateway Using the provided installation media run the setup program and follow the on screen instructions During installation TCP IP ports for the web interface and the live event interface can be set Leave the default values unless you understand their meaning and require a port change for your specific environment Running the Controller Gateway The installer sets the Controller Gateway to automatically launch each time the computer is started When Controller Gateway is running a small icon appears on the system tray or Windows Task bar typically at the bottom right corner of the screen Right clicking on the Controller Gateway icon displays its menu From the menu select the Auto Connect option Note that Auto Connect 1s the default option this means that double clicking the Controller Gateway icon also starts the auto connection process The auto connection process launches the default web browser and examines the computers available serial ports The Controller Gateway seeks each port for a compatible Stanley controller connection When one is found the browser displays the main menu From the main menu setup maintenance and analysis functions can be performed If a compatible controller is not found the auto connect mechanism offers to try again If you choose to not try again the browser is redirected to an Offline Mode menu In offline mode setups and configuration fi
28. e ATC Adaptive Tightening Control controls tool inertia toward the end of the tightening cycle This allows for more consistent fastening Angle Target The number of Geen of rotation the socket will turn during this step Speed The speed of the tool during this step Max Torque The maximum allowed torque during this step A low value is calculated by the Wizard to detect cross threads Slow Seek is an Angle Control Torque Monitoring strategy in the same direction for which the final tool strategy is programmed This allows the flats of the socket to align with the flats on the fastener before a standard forward rotation and high speed are applied Using Slow Seek as a first step also allows for cross thread detection If selected this is the first step AFTER Wobble If Wobble is not selected this is the first step in the tool Strategy 14 Theta Controller Wizard Screens HIZARDO LOW SEER Auto Reset Job Enable Slates SEA Programming Options Screen Angle Target The number of degrees of rotation the socket will turn during this step Speed The speed of the tool during this step Max Torque The maximum allowed torque during this step A low value is calculated by the Wizard to detect cross threads Self Tap is an Angle Control Torque Monitoring strategy in the same direction for which the final tool strategy is programmed This Smart Step allows the tool to compen
29. e low torque limit of the strategy Speed The Wizard uses the maximum speed of the connected tool 13 User Manual Wizard Screens Options Screen Press the Prev button to move back to previously programmed screens within the Wizard The final TC AM step is now defined The Wizard uses the median value between the High and Low Torque parameters as the Target Torque It also calculates and programs other parameters automatically including Snug Torque Threshold Torque Statistical Torque and High Angle Bailout Change these values after saving your Wizard programming if desired Next select the modifiers specific to your application Option screens appear for each specific modifier chosen The Wizard makes assumptions and calculates specific values modify these values if necessary H EE Buobble 51au Seek Mid Tap CAMCEL E Wobble i is an agate Control Torque Wobble Slow Seek and Self Tap are Smart Monitoring strategy in the opposite direction Steps that can be added to the beginning of the Eas ane ores I tool strategy These modifiers only exist programmed This allows the fastener threads ii to align with the locking device threads before when an audit step exists they cannot be a standard forward rotation and high speed are programmed as steps unto themselves applied thereby preventing cross threads If selected this will be the first step in the tool strategy Wobble Options includ
30. e maximum is 99 Units the Theta supports the following operating torque units NM Newton Meters FTLB Foot Pounds INLB Inch Pounds INOZ Inch Ounces KGM Kilogram Meters KGCM Kilogram Centimeters NCM Newton Centimeters Each Job does not have to use the same operating torque units as the other Jobs 16 Theta Controller Job Tab Screens Options Screens Thread Direction for tightening a right hand fastener use CW clockwise Use CCW counter clockwise for left hand fasteners Threshold Torque The torque level during the tightening cycle when the In Cycle Output transitions high Data is not printed stored or available to eTB unless Threshold Torque is exceeded during the tightening cycle A good starting point is 20 of Target Torque Disassembly Speed The speed of the tool during Reverse operation in RPM revolutions per minute Disassembly Acceleration The rate the tool gets up to Disassembly Speed in RPM s revolutions per minute per second Cycle Lock Out This is a timer 1n seconds that activates after the tool has reached its target While active it disables the tool Press Exit to save changes and return to the Run screen Press Manage to Add Delete Copy or Paste Jobs See section 2 5 1 3 for further information Press Step to setup the parameters of the step s inside the selected Job See section 2 5 1 4 for further information 2 5 1 3 Setup Manage Button J ob Manage Butt
31. e operation 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 3 2 1 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 are exposed to The actual sound level an individual 1s 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 1s the responsibility of tool owners and employers 34 Theta Controller 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 3 2 2 Vibration Power tools can vibrate during use To minimize the possible effects of vibration e Keep hands and body dry e Avoid anything that inhibits blood circulation such as tobacco cold temperatures and certain drugs e Operators should notify their employer when exper
32. eck 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 amp Controllers Install tools in dry indoor non flammable and non explosive environments only Humidity 0 to 95 non condensing and Temperature 32 to 122 F 0 to 50 C 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 WARNING To Avoid Injury Install modules in dry indoor non flammable and non explosive environments only Qualified personnel should perform installation and programming Follow all manufacturer installation instructions
33. ed temperature has dropped by 5 C The controller is communicating to the tool but does not recognize the model number written in the tool memory board The controller is not communicating to a tool Transducer current has fallen outside nominal values For EC series tools that is 4 16 mA 75 1 to 7mA The transducer zero point has shifted too far for the controller to compensate These points are visible on the controller diagnostics screen under Analyze The wrong tool type has been connected to the controller The Theta controller cannot run the tool that is connected Messages appear on the screen when certain non critical conditions exist that asserts the warning They may appear on any screen at any time Communication Fault Count Fault Program Fault Tool Update Failed Nothing to Configure 10 Used for Toyota Protocol only Controller has lost communications to the PI box Used for Toyota Protocol only Controller and PI box have a bolt count mismatch Used for Toyota Protocol only More tightening cycles were performed than the PI box expected Controller failed to update the tool configuration The parameter selected has nothing to configure Theta Controller 2 5 Theta Controller Programming WARNING EXCESSIVE TORQUE CONDITION To Avoid Injury e Only trained and qualified personnel should program controllers e Never set control limits above the maximum rating of the tool e Setting cont
34. ed to configure them immediately once the output elements are assigned to a pin Contact Type The Contact Type can be Normally Open N O or Normally Closed N C Sourcing Outputs PNP type If an output s contact type is normally open and the output is asserted the output pin will transition from OVDC to 24VDC If an output s contact type is normally closed and the output is asserted the output pin will transition from 24VDC to OVDC sinking Outputs NPN type If an output s contact type is normally open and the output is asserted the output pin will transition from 24VDC to OVDC If an output s contact type is normally closed and the output is asserted the output pin will transition from OVDC to 24VDC Output Type The Output Type defines the behavior of the output signal Normal The output asserts and stays asserted until a reset condition occurs Minimum On Time Keeps the output asserted for this minimum time in seconds even though a reset condition occurs After the timer 1s finished the output will reset 1f a reset condition has occurred otherwise it will remain asserted until a reset condition occurs Timed The output asserts for this period of time then resets on its own without waiting for the reset condition to occur Time Units are in seconds Flash The output flashes for as long as it 1s asserted Period Sets the flashing On and Off times which are equal Units are in seconds Theta Contro
35. egy Job Tab Screens Options Screens Tool settings apply to all Steps Select Jobs by pressing the SETUP button on the run screen Press 1 or with the Jobs menu item highlighted press the Enter key Communicati ons Other Name Name Job to define the operation performed 15 character limit Use the Auto Reset Job up down arrows to spell with letters or use the Enable Error Proofing numeric keypad Batch Count Auto Reset Job Yes resets the Job nits HE automatically after the fastener count has end Direction been met The tool will not disable with Error threshold Torque Proofing enabled No requires an Input or Disassembly Speed M 4E Trigger to Reset the Job The tool disables Disassembly Acceleration ME th Error Proof bled If Error Proof icycle Lock Out with Error Proofing enabled If Error Proofing S is disabled the tool is always enabled but will not count higher than the target value Enable Error Proofing 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 No keeps the tool enabled even after the Job s target count is met The count will not increase beyond the Batch Count value Batch Count This is the number of fasteners the Job is required to count Zero is not allowed Th
36. erted This is essentially a spare input START When asserted the tool will start and run the currently selected job This input is overridden by the STOP input If STOP is used and a tool restart 1s required remove the STOP remove the START then re assert the START If the tool 1s required to operate in Disassembly mode remove the START assert the REVERSE input and then re assert the START When removed the tool will stop Even if a second START input is active the tool will stop when any START is removed The size of this input function is 1 bit Configuration Contact Type Latch This is applicable to external inputs only This is not applicable to the trigger on the tool handle Yes when selected causes the START input to latch internally after a time period has elapsed This means the physical START input can be removed without stopping the tool The tool will run until the currently active Job is complete or times out A TIME parameter becomes available to set how long the START input must be applied in seconds before the Latch becomes active No when selected turns the Latch function off When asserted the controller will stop the tool It will also keep the tool from running while it is applied When removed nothing will happen other than the tool will be allowed to run The size of this input function is 1 bit Configuration Contact Type 46 Theta Controller Inputs Description RESET JOB When
37. ess the ON button to force it On press the OFF button 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 an operation the system provides a warning first 31 32 Analyze Screens User Manual E Screen If the pin icon 1s Clear with a small F icon that means it is forced OFF If the pin icon is Dark with a small F icon this means the pin is forced ON Outputs Ee Pos SE If a force is active when the EXIT button is pressed you hin be dS to remove the force Yes will remove the forces and return to he run screen No will NOT remove the forces and return to the run screen The system will run with the forces applied until they are removed or until the next power cycle on the controller Theta Controller QPM DC Electric Tools This chapter 1s intended to promote proper and safe use and give 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 3 1 Tool Specifications Operating Conditions Temperature 3
38. eta Controller Tool Connector 41 4 1 3 Theta Controller Serial Connector 42 4 1 4 Theta Controller Input and Output Connector 42 4 2 Assignable Input Output Functions 45 4 2 1 Input Red EE 46 CHE ele Re e le RE 47 erige C 50 Appendix A Controller Gateway cccccceecccssseeeseeeeseeeeesseeeseeeeesaaeees 52 Appendix B Torsion Compensation sannnennnennnnnnennoennnnrnsnnnnnnnenennnn gt 53 WV de 55 Contents lii Theta Controller 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 EC Directives The QPM tightening systems are designed and built in whole or in part using the following standards and or directives 2006 42 EC Machinery Directive Standard Title Description EN292 1 2 Safety of Machinery Basic Concepts EN14121 1 Safety of Machinery Principles of Risk Assessment EN50178 Electronic Equipment for Use in Power Installations EN60204 1 Safety of Machinery Part 1 Electrical Equipment of Machines EN60745 1 Hand Held Motor O perated Electric Tools Safety
39. gers 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 e Use minimum hand grip force consistent with proper control and safe operation e Keep wrists as straight as possible e Avoid repetitive movements of the hands and wrists e If wrist pain hand tingling numbness or other disorders of the shoulders arm wrist or finger occur notify supervisor discontinu
40. iencing prolonged symptoms of pain tingling numbness or blanching of the fingers e Wear vibration damping gloves if it can be determined that they reduce the risk of vibration disorders without introducing other hazards 3 2 3 Breathing Protection Respirators shall be used where contaminants in the work area present a hazard 3 3 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 D
41. ing cycle The Reject Tone when enabled will sound continuously Pressing the button re enables the tool and stops the reject tone indicating the operator acknowledges the rejected tightening cycle and wishes to repair it Job Reset Pressing the button will cause the selected Job to be reset meaning the fastener count will be set to zero and the tool will be re enabled if disabled due to Error Proofing requirements 3 4 3 Tool Memory QPM tools have an onboard tool memory that stores tool identification calibration factors and tightening cycle counters Memory parameters include e Model Number e Serial Number e Torque Cal calibration factor QPM DC Electric Tools 37 User Manual e Angle Cal calibration factor e Tightening cycle counters 3 4 4 Tightening Cycle Counters QPM tools have onboard counters that record the number of tightening cycles completed by the tool e Odometer Counter Records the total number of tightening cycle completed e rip Counter Records the number of tightening cycles completed since the last time it was reset e PM Counter Records the number of tightening cycles completed since the last time it was reset e 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 LED on the front panel and the tool The controller reads the tightening cycle counters from the tool on each p
42. ion following this table See Appendix A for assigning of inputs and outputs using Embedded Tool Box Inputs Description Configuration Options IGNORE Input is ignored Input is not assigned STOP Stop the tool Contact Type JOB SELECT BIT One bit in a series to select the Job Contact Type Bit Mode Theta Controller Connections 45 User Manual Outputs Description Configuration Options Output is turned off Output is not assigned IN CYCLE The tool is in cycle Contact Type Output Type DISASSEMBLY A tightened fastener removed has DEE DETECTED been loosened SRS Un TID CYCLE OK Tightening cycle was OK Contact Type Output Type CYCLE NOK Tightening cycle was NOK Contact Type Output Type JOB SELECTED A bit in a series of bits to indicate thesclectediob Contact Type Bit Mode READY The tool is ready to run Contact Type Output Type 4 2 1 Input Descriptions Each of the input elements has Configuration settings of Contact types and others It is recommended to configure them immediately once the input elements are assigned to a pin Contact Type The Contact Type can be Normally Open N O or Normally Closed N C Normally Open the input is asserted when 24 VDC is applied to the 24 VDC connector input pin Normally Closed the input is asserted when the 24 VDC is removed from the 24 VDC connector input pin Inputs Description IGNORE The pin that is assigned as IGNORE means the input will do nothing when ass
43. ith multiple choices To view these choices first select the menu item using the up down arrows or use the keypad to identify the corresponding menu item number Then use the toggle button to expand the dropdown The up down arrows scroll through the choices and the toggle button selects accepts the highlighted choice 2 2 3 Menu Tree RHE HH A menu tree 1 appears beside related menu items 2 2 4 Tabs Tabs 1 appear at the top when multiple menu selections exist 1 pod HOBBLE EECOSSEEHE To navigate between tabs use the left right arrows The active tab is white inactive tabs are grey 2 2 5 Character Scrollbar 1 p F9 This scrollbar enables adding a z A Z 0 9 space amp 2 anda 2 period language and or field determines character availability The up arrow 1 3 Bd and down arrow 3 direct scrolling with the active character 2 displayed between Use the Theta 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 next character Push toggle button or OK menu button to accept entry The following screens contain the character scrollbar option Job Name Step Name System Name General and System Users 2 2 6 Run Display M el Displays last torque reading and units 2 when a tool is connected Icons 1 identify controller events see list below Specifies target bo
44. l temperature rises abnormally the thermal protector resets automatically when the tool cools down Controller parameter settings can have a significant effect on tool operating temperatures 3 5 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 or control panel Green Tightened to The tightening cycle meets all of the specified parameters specified limits Yellow Low torque or angle The tightening cycle was rejected for not achieving either low torque or low angle Red High torque or angle The tightening 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 User Manual 3 5 5 Setting Torque Angle and Other Operating Parameters WARNING EXCESSIVE TORQUE CONDITION To Avoid Injury e Only trained and qualified personnel should program controllers e Never set control limits above the maximum rating of the tool e Setting control limits above the maximum rating of the tool can cause high reaction torque e Always test for proper tool operation after programming the controller The Theta controller can be setup to change tightening Jobs from the tool 3 6 Special Application Tools 3 6 1 Exposed Gear Socket Tools WARNING PINCH POINT AT THE EXPOSED GEARS OR TEETH To A
45. le exports can be created These files can be imported to a connected controller in the future 52 Theta Controller Appendix B Torsion Compensation Torsion Factor For all Stanley electric assembly tools the angle information is based on the rotation of the resolver which 1s 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 m
46. le 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 4 degrees as the torque drops to zero The Torsion Factor can be determined by dividing 4 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 Angle Validation Now that the angle can be indicated with great precision the other challenge is to validate these results against a master 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 Appendix B Torsion Compensation 53 User Manual 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 co
47. lected step with the values in the clipboard The type of information in the clipboard must match the step into which it will be pasted Smart Step values cannot be pasted into audit steps and vice versa Theta Controller 2 5 1 6 Setup Exit Exit Screens Options Screen Programming changes are stored after exiting the current menu EXIT omen 1 A nr ditt ES E mee tine PT KE CHE i Ben M m EE save changes i oe oa Sate at E H re GE A E EL EXIT 2 5 2 Setup Menu 2 Communications Communication Screens Options Screen This area changes the setting of the serial Communications ports on the bottom of the Theta Users must have COMMUNICATIONS SETUP or ADMINISTRATOR access level to modify values in this area E The Theta controller has two serial LU Port i ETE communication ports COM Port 1 must be jLUM Port 2 TOYOTA DPEH used for ETB COM Port 2 can be used for error proofing or data collection protocols Toyota an error proofing protocol used in handheld tool applications in Toyota ETB This selection allows the controller to d facilities communicate to the Controller Gateway l software on a PC See Appendix A OPEN an error proofing data collection protocol used in tool applications in Ford and Honda facilities This protocol can be used by others as it does not take special equipment like the Toyota protocol EXIT Save Saa Programming 21
48. ler Tool Tab Screens Options Screen Use the right or left arrow to move to the next tab or press the EXIT key save the changes and return to the run screen See Section 2 5 1 6 CAL tab SE Sc Nominal Cal This is a calculated value E based on the torque output of the motor the S gear ratios and efficiencies This is a a SS reference value only it can not be modified Mominal Cal Torque Cal Torque Cal This is the specific torque calibration value for the tool Enter the new calibration value for the tool after performing a lab certification This value should not deviate from the Nominal Cal value by more than 20 Press EXIT when finished modifying the value eM rig ar EXIT i ENT E Update tool d 2 5 5 2 Controller Controller Tab Screens Options Screen hr CONTROLLER SERVICE 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 Programming 29 User Manual 2 5 6 Analyze Analyze Screens Options Screen ANALYZE displays tool and controller diagnostic information traces and I O status AMAL ZE TOOL tab This tab shows live status of the following events It is updated every millisecond Use this tab to perform diagnostics during troubleshooting operations Feo Ac eH EN Transducer Health The thickness of the vertical line withi
49. ler Users must have TOOL or ADMINISTRATOR access level to modify any parameters here CN X 4 9 TOOL All of the tool s parameters are stored in the tool memory board in the handle of the tool This area reads or writes those values on the tool memory board not in the controller SERVICE Ze Lopttrol ler ABOUT tab This tab displays information about the tool currently attached to the controller None of 1 eae the fields are editable except the Serial value Bee IF there i ial number in the tool software Version CR ere is no serial number in the tool you SC Har Torque JE are allowed to enter one into the tool one Use the right or left arrow to move to the next tab or press the EXIT key save the changes and return to the run screen See Section 2 5 1 6 COUNTERS tab All three counters count up at the same time after each OK tightening cycle 3PM Counter d Odometer Cannot be reset Indicates the total arrip Counter number of OK tightening cycles the attached tool has performed over its lifetime PM Counter Causes the preventive maintenance LED on the front panel and the tool to illuminate when this value exceeds the PM Threshold value Trip Counter This counter can be used to count the number of OK tightening cycles between resets REZET EN Cour Use the RESET button to reset back to zero either Ze the PM Counter or the Trip Counter 28 Theta Control
50. level and angular rotation Once engaged the tightening cycle completes at a higher speed Slow Seek prevents cross threaded fasteners and previously secured fasteners from being counted in a batch The controller begins to monitor the tool output for angle at this torque Any Theta Controller Soft Stop Speed Spindle Strategy Thread Direction Threshold Torque Tool Tones Torque Calibration Torque Target Trace Trip Counter Units Glossary increase in angle after the snug point results in a corresponding increase in the tension or clamp load within the joint Soft stop minimizes the torque impulse to the operator during tool shutoff at the end of the tightening cycle The speed at which the tool operates during the initial portion of the tightening cycle prior to ATC or downshift A spindle represents the tool its cable and connected controller Identifies what variables will be used to control the tool during a tightening cycle Sets assembly direction to clockwise CW or counter clockwise CCW Sets the point at which the tool is considered to be performing work the tool and controller tightening cycle status lights turn off the controller displays dashes for data and the In Cycle output is turned on Distinctive sounds assigned to tool functions Determines how torque values are assigned to the electrical signals from the torque transducer on the tool This value is unique to each tool a
51. ll parameters in the Job and Communications areas They may modify parameters under the Input Output and Trigger tabs in the Other area 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 Communications Users at this level can modify the serial port settings Press OK To Delete a user press the Manage key and then Delete You will be asked Are You Sure If you are press OK It will ask for the Administrator password Once entered the user will be deleted Press Ok 23 User Manual Other Screens Options Screen Use the right or left arrow to move to the next tab or press the EXIT key save the changes and return to the run screen See Section 2 5 1 6 OUTPUTS tab The 24 VDC connector has pins 7 through 14 designated as Outputs from the controller DISHSSENELY DETECTED E The pin assignments are selectable on this tab 308 SELECTED BIT E Use the up or down arrows to select the pin J06 SELECTED BIT fae you wish to assign then press the Enter key ST Op SELECTED BIT ABE A list of available output elements will al CYCLE ok iBE display See Section 4 2 for the complete list Pe CYCLE NOK T LTTE and their descriptio
52. ller Outputs Sinking je Nic lt 7 OUTPUT 0 ene 8 Nic 9 OUTPUT 1 eno X lt 10 lenic 11 OUTPUT 2 eu lt 12 enc lt 13 OUTPUT 3 eNO lt 14 24V Return 24V Return Output Common Internal Power Supply 24V DC l For PNP Outputs use EITHER the Internal 24V Return OR the External 24V Return to provide the Output Common supply voltage 4 2 Assignable Input Output Functions The following Input Output I O functions apply to the 24 VDC I O connector There is a maximum of eight inputs and eight outputs for the 24 VDC I O connector It is important to understand the controller responds to the rising and falling edges of input functions as they are asserted or removed not while the levels are high or low The STOP bit is an exception it is a true OR function rather than working off the transition The table below lists the available input and output functions gives a brief description and indicates the configuration options for each The configuration options are an important aspect of the I O functions as they add powerful multiple dimensions to each function not previously seen in Stanley tool controllers These new dimensions allow integration of these controllers in unique ways providing an amazing amount of flexibility Please see the full description of each function in the sect
53. ller Connections 47 Outputs IN CYCLE DISASSEMBLY DETECTED CYCLE OK CYCLE NOK JOB SELECTED BIT READY 48 User Manual Description The pin that is assigned as OFF means the output will do nothing when asserted This is essentially a spare output The size of this output function is 1 bit This output asserts when the tool torque level during the tightening cycle exceeds the Threshold Torque value It resets when the tool is shutoff either by reaching target a fault a Stop input a Start input removed or by the operator The size of this output function is 1 bit Configuration Contact Type Output Type This output asserts when Error Proofing is enabled and the accumulated count is greater than one and the tool mode is Disassembly and Threshold Torque is achieved It resets when the tool lever or Start input is removed The size of this output function is 1 bit Configuration Contact Type Output Type Asserts when a tightening cycle that exceeds the Threshold Torque is completed and the achieved torque and angle are audited within the limits of the audit step Resets when the tool exceeds Threshold Torque on the next tightening cycle The size of this output function is 1 bit Configuration Contact Type Output Type Asserts when a tightening cycle that exceeds the Threshold Torque is completed and the achieved torque and angle are audited outside the limits of the audit step Resets when the t
54. lt count in active job 3 The run ps SC SE T screen displays unless other programming functions 4 are in use The active job 5 The display background color in normal operation is white After an OK fastening cycle the display background color will change to green for 2 seconds then revert back to white for the next cycle Aftera NOK fastening cycle the display background color will change to red for 2 seconds then revert back to white for the next cycle The display background color will turn red in the event of a fault see section 2 3 If the keypad mode is set to Job Select press a number key corresponding to a programmed Job A Job window will pop up and allow you to enter a number Press the OK button to switch the controller operation to the selected Job number See section 2 5 3 to select keypad mode Theta Controller Shutoff Codes on the display indicate why a tightening cycle shutoffs other than upon completion of tool strategy Run Display Description Code TIME Tightening time exceeds programmed Cycle Abort time value STOP Spindle stopped by either the operator or other device 125 Spindle stopped due to torque achieving greater than 125 torque limit for the spindle FAULT Precedes a fault described in section 2 3 STALL Spindle in stall status CAN Can occur during a tightening cycle when a spindle firmware update is in progress Theta Controller Icons Icon Status Description Locked Password required
55. mpared to a torque reading from the external torque monitor you can easily have several percent difference 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 5 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 6 NM plus 40 degrees pre torque the joint to 7 NM first Then change to an Angle Control strategy with 6 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 6 NM which might have been 5 or 7 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 6 NM which is also before the joint starts to rotate This way
56. n the horizontal bar indicates transducer health The thicker the line the less healthy Once the line reaches the tick mark on either side of center the transducer zero shift can no longer be compensated for and the transducer needs to be replaced Transducer Torque Provides a live transducer torque value during the tightening cycle Transducer Current The transducer is powered with a constant current value This current should be present and not varying See section 2 3 for limits Controller DC Bus voltage The bus should always be around 320 VDC Controller AC Supply Voltage Frequency See section 1 3 for controller AC volts specification Tool Temperature Temperature is not measured during tool operation Interacts with the Temperature Limit parameter See section 2 5 3 TOOL tab Tool Output Angle number of circular degrees of rotation on the output of the tool Resets at each start Tool Output Speed Real time speed of the output of the tool 30 Theta Controller Analyze Screens Options Screen Use the right arrow to move to the next tab or press the EXIT key save the changes and return to the run screen See Section 2 5 1 6 TRACE tab This tab will plot a torque vs time curve after every tightening cycle The Y axis is scaled from 0 to rated torque of the attached tool The X axis has a variable scale to include the entire tightening cycle Use the right or left
57. nd Display D mam uas Diam 0 pes Fain x mm Ewa ss w ME 100 126 VAC 50 60 Hz 15 20A service or 207 253 V AC 50 60 Hz 10 16A service BERENS eomunpion ansvac ma fa m amv m wk wm wA ewmasv fos for ju Theta Controller Getting Started Functional Description Red Green Yellow LED s for Limits Evaluation Cursor Keys with Center Button to Expand Lists 6 Numeric Keypad to Enter Numbers orSelect Options WE Power Switch CS Power Input 24 VDC Input Output Connector 10 Serial Connector for Laptop Tool Connector Serial Connector for Network Protocols 11 o gt User Manual 1 4 Installation Instructions 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 ch
58. nd changes over time When the tool is being controlled for torque the torque target instructs the controller when to shut the tool off The torque target should be greater than Low Torque and less than High Torque and is required for torque control A display plot of torque vs time or angle of a tightening cycle Records the number of tightening 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 S7 Unit rules and style conventions from the National Institute of Standards and Technology Abbreviation Common Term 1 Ibfft 1Nm Nm Newton meter 1 355817 I Ncm Newton centimeter 135 5817 100 Ndm Newton Decimeter 13 55817 10 kgm Kilogram meter 0 138255 2 0 101 971 6 kgcm Kilogram centimeter 13 825 52 10 197 16 ft Ib Foot pound 1 0 737 562 1 in Ib Inch pound I2 8 850 745 in OZ inch ounce 192 141 611 9 91 User Manual Appendix A Controller Gateway Requirements for Theta Controllers Using the Controller Gateway Serial Connection e Computer with Microsoft Windows XP and one serial port can be a USB to serial adapter e QA1001 Theta Controller v1 0 or above e Javascript enabled browser and Adobe Flash Player The Controller Gateway is a Windows based software program that provides a web based interface to a Theta controller connecte
59. next tab or press the EXIT key save the changes and return to the run screen See Section 2 5 1 6 REGIONAL tab Select the language for your region of the world Enalish if Deutsch Esranal Frangais Italiana Portugues th Use the right or left arrow to move to the next tab or press the EXIT key save the changes and return to the run screen See Section 2 5 1 6 EREGIOHWAE CLOCK PEI 12 sale azir 2888 F Clock tab The Theta has a real time clock which must be set manually Time format is hh mm ss where h is hour m is minute and s is seconds The format for hour is military or 24 hour clock rather than 12 hour clock with a m and p m Date format is mm dd yyyy where m is for month d is for day and y 1s for year Use the left arrow to move to the next tab or press the EXIT key save the changes and return to the run screen See Section 2 5 1 6 2 5 4 Setup Menu 4 Restore Factory Defaults Restore Factory Defaults Screens Programming Options Screen Restores all values for all parameters to their factory default settings This is good for starting fresh with a controller that is in an unknown programmed state Users must have the ADMINISTRATOR access level to restore factory defaults i x RESTORE Are vou sure 27 User Manual 2 5 5 Service 2 5 5 1 Tool Tool Tab Screens Options Screen The Service area presents information about the tool and control
60. ns Scroll the list and A a choose the element you wish to assign to the selected pin Press the Enter key 1 READY z An Output element can be assigned to more than one pin The selected Output element must then be configured See section 4 2 for configuration options and their descriptions Press the CONFIG button to configure the selected output element After modifying press the BACK button EE DEE Contact Type EE Bit ae Mode BINARY 1 F Use the right or left arrow to move to the next tab or press the EXIT key save the changes and return to the run screen See Section 2 5 1 6 INPUTS tab The 24 VDC Connector has pins 3 through 6 designated as Inputs to the controller The pin assignments are selectable on this tab Use the up or down arrows to select the required pin then press the Enter key A list of available Input elements displays See Section 4 2 for the complete list and their descriptions Scroll the list and select the element to assign to the selected pin Press the Enter key An Input element can be assigned to more than one pin SE STOP sl were REUERSE JJO B SELECT BIT The selected Input element must then be configured See section 4 2 for configuration options and their descriptions Press the CONFIG button to configure the selected Input element After modifying press the BACK button 24 Theta Controller Other Screens Options Screen Use the right or left arr
61. ntact 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 e A short description of the problem 56 Theta Controller Contacts STANLEY ASSEMBLY TECHNOLOGIES 5335 Avion Park Drive Cleveland Ohio 44143 2328 USA Tel 1 440 461 5500 Fax 1 440 461 5592 SATinfo stanleyworks com STANLEY ASSEMBLY TECHNOLOGIES 1875 Research Drive Suite 200 Troy Michigan 48092 USA Tel 1 248 824 1100 Fax 248 824 1110 Toll Free Service 877 787 7830 Toll Free Sales 877 709 8006 STANLEY ASSEMBLY TECHNOLOGIES Outils Portatifs et Systemes d Assemblage Zone Imoparc bat Loire 4 78190 Trappes France Tel 33 1 3050 9100 Fax 33 1 3051 0708 STANLEY GERMANY Inc Frankfurter Strasse 74 D 64521 Gross Gerau Germany Tel 49 0 6152 8052 0 Fax 49 0 6152 8052 22 SATGER stanleyworks com STANLEY TOOLS S r l ITALY Divisione Assembly Technologies 47 Via Parco 20046 Biassono MI Tel 39 039 2389 1 Fax 39 039 2389970 STANLEY ASSEMBLY TECHNOLOGIES Gowerton Road Brackmills Northhampton NN4 7BW England Tel 44 1604 827247 Fax 44 1604 827277 STANLEY ASSEMBLY TECHNOLOGIES SHANGHAI REPRESENTATIVE OFFICE Room 1908 Shanghaimart Tower 2299 Yan An Road West Shanghai 200336 China Tel 011 86 21 3208 4550 Fax 011 86 21 6236 0191 STANLEY ASSEMBLY TECHNOLOGIES Stanley Works India Pvt Ltd A B House 4 24A A
62. o provide the I O signals An external 24VDC power supply may be used instead The following are the amperage ratings depending on the power supply used e Internal 24VDC supply Maximum ampere total e External 24VDC supply Maximum 1 ampere per output The Theta controller s Input circuits conform to the IEC 61131 2 standard for PLCs LIMITS per IEC 61131 2 Type 2 limits Rated TPS V ma V n i EEN LU me am The Theta controller has a terminal block connector for error proofing Error proofing in the Theta controller is based on simple bolt counting with Poki Oki NOTE One I O mating connector P N 21C104800 is included with each Theta controller 42 Theta Controller When the Theta controller is used with fixtured tools it must use a Remote Start Stop Reverse pendent to the controller to provide basic switching control for the tool Inputs Graphic to be added Theta Controller Connections 43 User Manual Outputs Sourcing N C lt 7 OUTPUT 0 ene lt 8 Nic 9 OUTPUT 1 eno lt 10 NIC 11 OUTPUT 2 eu lt 12 ene lt 13 OUTPUT 3 eN O M 24V Return 24V Return Output Common Internal Power Supply 24V DC For PNP Outputs use EITHER the Internal 24V Return OR the External 24V Return to provide the Output Common supply voltage 44 Theta Contro
63. ob which consists of one Audit Step with optional Smart Steps To function the Wizard requires a tool to be connected The Wizard automatically appears when there are no configured Jobs or when Jobs are added The Wizard presents programming parameters about the FINAL strategy desired and then it will give a list of modifiers for that strategy These modifiers are explained further down in this section Strategy TORQUE TC AM is the only strategy the Theta controller supports There are no other options for this parameter Units the Theta supports the following operating units NM Newton Meters FTLB Foot Pounds INLB Inch Pounds INOZ Inch Ounces KGM Kilogram Meters KGCM Kilogram Centimeters NCM Newton Centimeters Thread Direction for tightening a right hand fastener use CW clockwise Use CCW counter clockwise for left hand fasteners To modify select using the up down arrow keys 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 Pressing the CANCEL interactive menu button at any time to stop Wizard operation High Torque Low Torque Use the keypad to enter the desired values for High Torque Low Torque and Speed Programming High Torque By default the Wizard uses the maximum torque for the connected tool Low Torque The Wizard uses zero as th
64. on J ob Screens Options Screen Manage enables active job settings to be added deleted and or copied to the clipboard and pasted Add Adds a Job to the controller Ifa tool is attached the Wizard will begin for easy setup of the Job parameters Ifa tool is not attached the Jobs tab will appear for manual parameter setup Jobs do not have to be added sequentially A Job can be added before or after the one that is selected Jobs will be renumbered automatically after being added Make a selection and press OK to add a Job or Cancel to not add a Job Delete Deletes the selected Job from the controller This cannot be recovered once deleted Copy This will copy the selected Job and its associated Steps to the Clipboard Programming 17 User Manual Paste Overwrites the selected Job with the values of the Job residing in the Clipboard 2 5 1 4 Setup Step Button Step Button Screens Options Screens Step settings only affect the selected Job There can be only one audit step per Job In the Theta that audit step is a Torque Control Angle Monitor TC AM strategy The audit step can have Smart Steps associated with it Without the audit step the Smart Steps are deleted Each step is represented by its own tab Use the left or right arrow keys to select the tabs steps to modify them Name Provides an identifier for the step Use the up and down arrows to write a name using the alpha
65. ool exceeds Threshold Torque on the next tightening cycle The size of this output function is 1 bit Configuration Contact Type Output Type Asserts or resets according to the binary value of the selected Job This is one bit of a binary number created by several of these bits The size of this output function is 1 bit Configuration Contact Type Bit Bit defines the number you wish this bit to be in your binary number scheme of the selected job Mode All JOB SELECTED BITs must be the same mode no mixing of modes allowed Binary Will create a decimal number equivalent to the weighted value of this binary bit s Binary 1 Will create a number equivalent to the weighted value of this binary bit s and add the value of one 1 to that number Asserts when the controller is energized and there are no faults and there is nothing disabling the tool such as Error Proofing or a Stop input See section 2 2 6 for the conditions that can Stop Tool Operation Resets when the controller is turned off or there is anything stopping the tool from operating The size of this output function is 1 bit Configuration Contact Type Output Type Theta Controller This page is blank Theta Controller Connections 49 Glossary Abort Timer Acceleration Accept Tone ATC Batch Count Downshift Mode Downshift Speed Downshift Torque High Angle High Torque Low Angle Low Torque MFB Mode PM Counter PM Limit
66. ool 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 that indicates when the tightening cycle count exceeds the PM limit Display Display and MFB Display for EC Lever Models for EC02P to EC34P pistol Models 3 4 2 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 These functions can be assigned to a tapping or holding for 1 second operation Disable The button does nothing Pressing the button causes the tool default alarm to beep once Only the assembly blue light 2 illuminates 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 Select Pressing the button toggles between Job 1 and Job 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 Reset Reject This function when selected will cause the tool to disable after a NOK tighten
67. ow to move to the next tab or press the EXIT key save the changes and return to the run screen See Section 2 5 1 6 TRIGGERS tab See Section 3 4 2 for an explanation of the uiti FURCETOR Button selectable items Tap Action REVERSE ltl Hold Action DISABLED Jog Lever Push To Start Switch Start input 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 1 second Start Input Defines which inputs are required to start the tool In all cases the 24 VDC Start input 1s always available to start the tool Any Either the tool trigger or tool push to start switch will start 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 will start the tool PTS Only the push to start switch on the tool will start the tool None Neither the tool trigger nor the tool push to start switch will start the tool Use the right or left arrow to move to the next tab or press the EXIT key save the changes and return to the run screen See Section 2 5 1 6 LIGHTS tab Sets the time the pistol tool headlights remain on in seconds after the trigger is pressed Programming 25 User Manual Other Screens Options Screen Use the right or left arrow to move to the next tab or press the
68. ower up 3 5 Tool Operation WARNING ROTATING SPINDLE To Avoid Injury e Always wear eye and foot protection when operating and when in areas where power tools are being used e Keep all body parts and clothing away from the rotating end of the tool Dress properly Do not wear loose fitted clothing or jewelry TORQUE REACTION FORCE To Avoid Injury e Bealert and maintain good balance footing and posture at all times in anticipation of the tool s torque reaction Do not over extend or over reach e Be prepared for the change in direction and or a higher reaction force when a tool is in reverse e he start lever should be positioned to avoid trapping the operator s hand between the tool and the work piece TOOL MAY NOT SHUT OFF To Avoid Injury e If the tool does not shut off at the end of the tightening cycle contact the person responsible for tool installation or repair Note When the tool does not shut off a stall condition occurs A stall condition can cause a higher than expected torque reaction impulse Ensure tool is properly installed adjusted and in good working order Do not use the power tool if the switch does not turn it on and off Apply the tool to the joint following all recommendations in this manual Check to ensure the drive socket is fully seated and locked into position before connecting power to the tool Prepare to resist the tool s torque reaction Start the tool by depressing the start lever or
69. r damaged sockets that are unsuitable for safe operation immediately QPM DC Electric Tools 35 User Manual Always ensure drive socket is fully seated and locked into position before connecting power to tool 3 3 2 Suspension Devices Tool suspension devices or bails help support the weight of the tool during tightening operations Attach these devices securely and periodically inspect them for damage or loosening 3 3 3 Cable Installation WARNING ELECTRICAL HAZARD To Avoid Injury e Never use a tool with a damaged cable e 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 36 Theta Controller 3 4 QPM Tools 3 4 1 Display and Multiple Function Button for Hand Held Tools Handheld QPM tools have a display and a multiple function button MFB Two sets of lights 3 and 7 indicate tightening cycle status Two blue lights indicate t
70. rol limits above the maximum rating of the tool can cause high reaction torque e Always test for proper tool operation after programming the controller The controller uses three main menus to display information and enable programming e Setup menu e Service menu e Analyze menu To begin programming a tool strategy on the Theta press the SETUP menu button The list of setup functions will appear Communications e Other Restore Factory Defaults 1 Jobs this is where the tool strategy programming is performed such as torque and speed parameters 2 Communications this area is where the Serial port options are programmed 3 Other this area has the parameters for all other features on the Theta They include setting up system level parameters users and passwords assigning I O and tool functions 4 Restore Factory Defaults this area deletes all prior programming stored fastening cycle data and statistics and sets the controller back to factory defaults To enter an area simply press the corresponding numbers on the keypad or us the up and down buttons to highlight the area and press the Enter key Icon Legend Icon Description Navigation Menu Buttons Press to activate menu option noted above button Left Right Arrow Keys Navigate tabs as well as backspace and space NEN i Up Down Arrow Keys Scroll through menu selection and character selection Lei Toggle Button Selects option for data input a
71. saf Ali road New Delhi 110002 Mail Id sagarwal stanleyworks com Office 91 11 43569000 ext 102 Fax 91 11 43569069 www StanleyAssembly com Warranty 57
72. sate for a high prevailing torque application If selected this step follows the Slow Seek step and just prior to the audit step HIZHED ZELF TAF Angle Target L EAP anug Torque B 3875 Speed Max Torque Angle Target The number of degrees of rotation the socket turns during this step Snug Torque Angle measurement for the target angle starts at this torque Speed The speed of the tool during this step Max Torque The maximum allowed torque during this step ATC Adaptive Tightening Control is not a strategy or a step It is an algorithm that modifies the tool s speed as the torque rises Select this instead of a downshift as an option to increase tool capability There are no options with this selection The values are calculated automatically Press the Finish button to complete the Wizard The Job Tab screen appears This allows parameter changes to be made 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 15 User Manual 2 5 1 2 Setup J ob Tab Jobs are required to setup a tool strategy Inputs and Triggers are used to select specific Jobs with different tool strategies including Error Proofing bolt counting Program the Job parameters according to the integration strategy desired then program the Step s to create the desired tool Strat
73. ssword protected The controller automatically re locks the system after 15 minutes Then select the user you just added in the list 22 Theta Controller Other Screens AEE E Gel Administrator TE Setup AH Dune Diagnostics Statistics Communications Ze Programming Options Screen press the Manage key then Change Password If this is the first time adding a password leave the Old password blank otherwise key in the old password scroll down and create a New password and Verify you have the correct password by typing a second time Press OK Now change the access level of the user you just created by pressing the Manage button again then Change Access One user has to be an Administrator If other users added are not then select NO The Administrator has to log in to change access for a user Once the Administrator has logged into the controller it is unlocked The unlocked icon will appear in the upper left hand corner of the screen Select the Access level you wish to give to the selected user NONE does not allow them access to the level LOCAL will allow them access on the keypad to that level Each access 1s exclusive of the other You must assign to users each access level that applies to them Administrator gives the user full access to the controller They can do anything the other access levels can do plus restore factory defaults and add users Setup Users at this level can modify a
74. t using a connector keep the connector securely covered with the provided cap This reduces the opportunity for transfer of static electricity and prevents dirt and water from entering the controller 4 1 Theta Controller Connections 4 1 1 Theta Controller Power Cord Theta Controllers use an IEC 60320 style connector The power source connector for the power cord is based on customer requirements The power cord should be rated at either 15A 125V for 115 V or 10A 250V for 230 V use of the controller 4 1 2 Theta Controller Tool Connector Theta controllers use a single 30 pin connector to connect the EC series QPM DC electric tool cables QPM EC DC electric tool cables use a MIL C 38999 Series III connector The connector is a 17 308 with the insert having a B clocking position 30 pin Tool Connector 30 pin Tool Connector Theta Controller Connections 41 User Manual 4 1 3 Theta Controller Serial Connector Theta Controllers have two male DB 9 connector The function of COM port 2 serial connector 1s assignable see section 3 COM port 1 allows a connection to a laptop computer for access to Embedded Toolbox software The connection between the computer and the controller is a simple null modem cable Only pins 2 3 and 5 are active on this connector 4 1 4 Theta Controller Input and Output Connector All four inputs and four outputs are optically isolated 24VDC The Theta has an internal 24VDC power supply that can be used t
75. the tightening cycle during this step Once the audit step has been created Smart Steps can be added Smart Steps allow you to modify the tool strategy BEFORE the audit step See section 2 5 1 5 for adding Smart Steps When finished modifying the tool strategy step s press the EXIT key save the changes and return to the run screen See Section 2 5 1 6 Programming 19 Step Button Screens Es EA Save changes foai pos nee TELE ABBR HARB aASR Eno n y o ve maa uua 2 5 1 5 Setup Manage Button Step User Manual Options Screens Manage Button Step Screens Options Screen Manage enables step settings to be added deleted and or copied to the clipboard and pasted 20 a rie Cory d Pazte Add Allows the addition of Smart Steps The Smart Step choices are Wobble Slow Seek and Self Tap When added they are inserted into the correct position before the audit step Smart Step sequencing cannot be altered Wobble always occurs first followed by Slow Seek and Self Tap then the audit step Smart Steps are not required to run a tool strategy however they may help Add and modify the appropriate Smart Step s for the application See section 2 5 1 1 fora description of the Smart Steps r Ug LL ee Pee Delete Allows the deletion of the selected step from the tool strategy Copy Copies the selected step to the clipboard Paste Overwrites the se
76. trigger Release start lever after the cycle is complete 38 Theta Controller 3 5 1 Directional Control WARNING UNEXPECTED REACTION FORCES To Avoid Injury e 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 e The tool can have a higher initial reaction force when loosening a fastener e Always stop the tool before changing direction of spindle rotation 3 5 2 Torque Reaction Devices WARNING PINCH POINT BETWEEN TORQUE REACTION BAR AND WORK PIECE To Avoid Injury e Never place any body part between a reaction bar and the work piece e Before starting the tool position the reaction bar firmly against a stationary rigid member that is opposite to the spindle rotation Torque reaction devices absorb tool torque reaction forces Always use reaction devices when high reaction force could injure an operator Some reaction devices may require modification to fit the application Follow all appropriate installation instructions 3 5 3 Tool Temperature WARNING POTENTIAL BURN HAZARD Fixtured tools have higher operating temperatures and do not have additional thermal protection To Avoid Injury Wear thermal protective gloves when handling fixtured tools Stanley electric tools are thermally protected to prevent damage due to overheating The thermal protection does not allow the tool to operate if the too
77. void 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 3 6 2 Tubenut Nutrunners WARNING PINCH POINT AT THE EXPOSED GEARS OR TEETH To Avoid Injury e Never place body parts or clothing near the socket opening Dress properly Do not wear loose fitted clothing or jewelry e Follow the Tubenut Nutrunner Sequence of Operation Tubenut nutrunners are used for installing tube fittings Tubenut Sequence of Operation QPM Tools e Place nutrunner socket on fastener Press the MFB to arm the start function Depress start lever the tool will run the selected Job The tool stops after reaching torque Release the lever and lift the tool from the fastener all tool status lights flash to indicate the tool will now run in reverse to open the socket Depress the start lever until the socket returns to the open position e Release the lever e Remove the tool 40 Theta Controller Theta Controller Connections Each controller or Theta Controller has a different combination of connectors These connectors serve several purposes such as e Power e Tool Connections e Discrete inputs and outputs CAUTION POTENTIAL ELECTROSTATIC DISCHARGE HAZARD AND WATER AND DIRT INGESTION To Avoid Damage If no
78. ype 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 QPM DC Electric Tools 33 User Manual 3 2 Operator Protection WARNING ROTATING EQUIPMENT To Avoid Injury e 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 1 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 Repetitive Motion The use of power tools may involve highly repetitive motions of the fin

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