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Alpha Controller User Manual - Stanley Engineered Fastening

1. Results Port The port on the XML protocol network server where the Alpha controller transmits messages Command Port The port where the Alpha controller receives commands from the XML protocol network server Use the right arrow to move to the next tab or press EXIT to save the changes and return to the Run screen See section 2 9 1 7 Setup Exit HIE SIS HE C H 2 9 2 7 SCANNER tab This tab appears on the Alpha controllers with the DeviceNet Master option Baudrate Sets the communication rate of the DeviceNet network The choices are 125 Kbits s 250 Kbits s and 500 Kbits s 28 Alpha Controller Communication Screens Options Screen Mac Id Sets the node number of the Alpha controller on the DeviceNet network RER Press the SCANLIST interactive menu button to setup slave devices on the DeviceNet network DH SCAM LIST Poll 16C6 DP The devices added to the Scanlist are listed here The first column identifies the device node number The second column shows the type of communications used with the selected device The third column indicates the number of bytes the device consumes The fourth column reveals the number of bytes the device produces Use the up down arrow buttons to select the device Press the Toggle button to get a detail window for the device D Socket Tray Poll 16 16 324 267 11 Mac Id The node number of the devic
2. 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 54 Alpha Controller 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 overheating Temperature is sensed inside the tool either in the motor windings of E series or on the resolver board on EA tools and the value is reported to the controller The thermal protection does not allow the tool to operate if the tool temperature raises abnormally the thermal protector resets automatically when the tool cools down The maximum tool temperature before damage occurs is 150 C EN60745 1 Hand Held Motor Operated Electric Tools Safety is the most appl
3. seeeesssssseeneeeee 83 5 3 Converting the NS a il Sad te ait a ea sd tad het 88 5 3 1 de bere 89 5 3 2 Predefining String or Integer Files ceeeeeeeeeeees 90 5 3 3 Applying a Name and Version 90 GloSGal Vise aie ata a ate ee ae eee 91 Appendix A Embedded Toolbox Installaton ceeeeeseeeeeeeeneeees 93 Appendix B Torsion Compensation ecceeeeeeeeeeeeeeeeeeeeeeeeeeteee 94 NEEN eebe ee Ter 96 Alpha 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 Operated Electric Tools Safety 89 336 EEC Electromagnetic Compatibility Directive Standard Title Description EN59011 Conducted and Radiated Emissions EN61000 3 2
4. SEC 5 SR High Torque The Wizard uses the maximum torque for the connected tool Co EE High Torque z 1 Low Torque Low Torque The Wizard uses zero as the low torque limit of the strategy Speed The Wizard uses the maximum speed of the connected tool 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 Wizard programming if desired Press the PREV interactive menu button to move back to previously programmed screens within the Wizard Next select the controls specific to your application Option screens appear for each specific control chosen The Wizard makes assumptions and calculates specific values modify these values if necessary JIE 5 6 HE e Use the Toggle button to select or deselect the controls specific to your application Press the NEXT interactive menu button to view the 2s xg Condition Fastener option screens for each specific control chosen ClPre Torque i The Wizard makes assumptions calculates and Sur S resents specific values Modify these values if H P p y Backout Fastener necessary Fastener Release 0 L Not Selected Selected Wobble Creates a step with an Angle Control Tor
5. bot ot barcode lo I second 32 characters I minute po i hour p year day month overall status A OK R NOK angle status A OK H HIGH L LOW angle result last step ran or audit step whichever is smaller fixed decimals torque status A OK H HIGH L LOW torque result last step ran or audit step whichever is smaller decimals are tool units dependant job number spindle number 1 MASTER 2 SLAVE The barcode input monitors inter character timing When there is a 500ms gap between characters a complete barcode is assumed When received the controller logs it with all fastening cycles until another barcode is received or until the controller power is cycled If the incoming barcode is longer than 32 characters then the last 32 characters received are used 4 1 4 Alpha Controller Ethernet Connector Alpha controllers have a single RJ 45 Ethernet connection located on the bottom of the module for connecting to an Ethernet network This network can consist of the controller and a PC or a plant wide fastening network An optional second Ethernet connector is available to provide connections to two separate networks The networks are not and cannot be connected internally 58 Alpha Controller Listen Transmit Internet Protocol Description 13 ICMP Listen TCP IP ICMP timestamp request 14 ICMP Transmit TCP IP ICMP tim
6. Contact Type The Contact Type can be Normally Open N O or Normally Closed N C Sourcing Outputs PNP type Alpha Controller Connections 71 User Manual If an output s contact type is normally open and the output is asserted the output pin transitions from OVDC to 24VDC If an output s contact type is normally closed and the output is asserted the output pin transitions 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 transitions from 24VDC to OVDC If an output s contact type is normally closed and the output is asserted the output pin transitions from O0VDC 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 is finished the output resets if a reset condition has occurred otherwise it remains 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 is asserted Period Sets the flashing On and Off times which are equal Units are in seconds Outputs Description NOT USED The output is not use
7. Job Task number When the Keypad Mode is set to PART ID see E i PART IH section 2 9 3 1 General Tab at the run screen This is the FARTID press the Toggle button or a number on the keypad A PARTID window opens Use the up down arrows to write a value to use as the PART ID Press the OK interactive menu button to save it Shutoff Codes on the display indicate why a tightening cycle terminates prior to completion Shutoff Code Description TIME Tightening time exceeds programmed cycle abort time value STOP Spindle stopped by either the operator or other device gt 125 Spindle stopped due to torque achieving greater than 125 torque limit for the spindle FAULT Precedes a fault described in section 2 7 Faults STALL Spindle in stall status CAN Can occur during a tightening cycle when a spindle firmware update is in progress Alpha Controller Icons Icon Status Description Locked Unlocked Changes possible automatically re locks in time Busy working Wait Password required to make changes Kei RI Fault system not Check the run screen for Fault message operable Force on or off Identifies an input output forced on or off Active User ke H Appears beside the user on the User list that entered a password and unlocked the controller Programming 11 Stop Tool Operation press trigger for cause 2 7 Faults Overcurrent Fault 12 User Manual Along with the onscreen indication the blue light on the
8. Outputs Description FAULT CODE This output is the number value of the fault code present in the controller It asserts when a fault is active and resets when the fault clears The values are as follows 1 Overcurrent Fault 2 Logic Voltage Fault 3 Position Feedback Fault 4 Transducer Span Fault 5 Temperature Fault 6 Unrecognized Tool 7 Tool Communications 8 Transducer Current Fault 9 Transducer Zero Fault 10 Unused 11 Unused 12 Unused 13 Unsupported Tool Size Can be any size from 0 to 32 bytes depending on Data Type Data Type Float Int8 Int16 Int32 Fixed Point String PARAMETER This output is the value of the selected Parameter It changes when the parameter changes Size Can be any size from 0 to 32 bytes depending on Data Type Data Type Float Int8 Int16 Int32 Fixed Point String Parameter Target Torque High Torque Low Torque Target Angle High Angle Low Angle Snug Torque Speed Step Name Torque Cal Tool Serial Number Torque Bailout Angle Bailout Downshift Torque Downshift Speed Tool Model Number Step Audit Audit 1 Audit 2 START Asserts when the tool s trigger is pressed Resets when the tool trigger is released TRIGGER Size 1 bit Configuration Contact Type Normally Open N O Normally Closed N C Output Type Normal Timed Flash Minimum ON Time Time Period MFB Asserts when the tool s Multi function Button is pressed R
9. PM Threshold Trip Counter Counts the number of OK tightening cycles between resets Use the RESET button to reset back to zero either the PM Counter or the Trip Counter BE SET I PH Counter Use the left right arrow to move to the next tab or press EXIT to save the changes and return to the Run screen See section 2 9 1 7 Setup Exit 2 9 5 1 3 CAL Tab Nominal Cal This is a calculated value based on the torque output of the motor the gear ratios and efficiencies This is a reference value only and cannot be modified Torque Cal This is the specific torque calibration value for the tool Enter a new value after performing a lab certification The Torque Cal should not deviate from the Nominal Cal value by more than 20 Modified A value that is changed by the Programming 41 Tool Tab Screens User Manual Options Screen controller to indicate the date and time the tool was last calibrated Press EXIT when finished modifying the value 2 9 5 2 Controller Controller Tab Screens Options Screen TER say 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 Press EXIT when finished 42 Update Tab This tab is used to update the firmware in the Alpha controller Get the binary file from your Stanley representative Put th
10. Timer Timing Bit TT rung conditions are true and the accumulated Rung conditions go false or when Bit 14 value is less than the preset value the done bit is set Timer Enable Bit EN rung conditions are true rung conditions go false or if the Bit 15 timer is reset with the RES instruction SOR Start of Rung Marks the beginning of a new rung SUB Subtract Use the SUB instruction to subtract one value source B from another source A and place the result in the destination Embedded PLC 87 User Manual Instructions Description TOF Timer Off Delay Use the TOF instruction to turn an output on or off after its rung has been off for a preset time interval The TOF instruction begins to count millisecond intervals when the rung makes a true to false transition As long as rung conditions remain false the timer increments its accumulated value ACC each millisecond until it reaches the preset value PRE The accumulated value is reset when rung conditions go true regardless of whether the timer has timed out The Time Base must be 10 msec The timer will not work in any other Time Base This Bit Is Set When And Remains Set Until One of the Following Timer Done Bit DN Bit 13 rung conditions are true rung conditions go false and the accumulated value is greater than or equal to the preset value Timer Timing Bit TT Bit 14 rung conditions are false and rung conditions go true or when the done the accumulated v
11. Trip Counter 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 Units 92 The following torque units and associated labels are used with Stanley controllers and tools The labels are derived from SP811 SI Unit rules and style conventions from the National Institute of Standards and Technology Abbreviation Common Term 1 Ibfft 1Nm Nm Newton meter 1 355 818 1 Nem Newton centimeter 135 581 8 100 kgm Kilogram meter 0 138 255 2 0 101 9716 kgfm kilogram force meter kecm Kilogram centimeter 13 825 52 10 197 16 kgfem kilogram force centimeter ft Ib Foot pound 1 0 737 562 1 Ibfft pound force foot in lb Inch pound 12 8 850 745 Ibfin pound force inch in oz inch ounce 192 141 6119 ozfin ounce force inch Alpha Controller Appendix A Embedded Toolbox Installation Requirements for Alpha Controllers Ethernet Connection e Javascript enabled browser Internet Explorer IE v6 v7 e Adobe Flash Player v9 or above e http www adobe com e QA1001 Alpha Controller Version 3 0 or above e Q1001 Alpha Controller Version 4 0 or above Connect to the controller using the IP address in the browser Alpha controllers can also connect through the Controller Gateway using the serial port as described for the QO001 Kappa controller Requirements for Alpha Controllers Using the Controller Gateway Serial Connection e Microsoft Windows XP
12. 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 discontinue task reassign user to a different job if relief is not found contact experts skilled in treating such disorders Wrist supports torque reaction devices and balancers should be used if it can be determined that such devices can reduce the risk of repetitive motion disorders 3 2 2 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 is exposed to and the individ
13. as they add powerful multiple dimensions to each element not previously seen in Stanley tool controllers These new dimensions allow integration of these controllers in unique ways providing an amazing amount of flexibility 64 Alpha Controller Inputs Please see the full description of each element in the section following this table Description Configuration Options IGNORE Input is not used Input is not assigned START Start the tool N O N C Latch Timer SELECT JOB Select a job N O N C Job Disable when open SELECT TASK Selecta task N O N C Task Disable when open STOP Stop the tool N O N C RESET JOB Reset a job N O N C TASK SELECT BIT One bit in a series to select the task N O N C Bit JOB SELECT BIT One bit in a series to select the job N O N C Bit REVERSE Put the tool in reverse N O N C DISABLE TASK Disable the task N O N C Task DISABLE JOB Disable the job N O N C Job TASK VERIFY Verify the selected task to the inputs N O N C Task JOB VERIFY Verify the selected job to the inputs N O N C Job TASK VERIFY BIT Verify the selected task to one of the input N O N C Bit bits in a series JOB VERIFY BIT Verify the selected job to one of the input N O N C Bit bits in a series RESET RESULT STATUS Clear the result status N O N C REVERSE START Put the tool in reverse and start the tool N O N C DISABLE TOOL Dis
14. 2 7 Faults EE EE The Event Log lists the fastening cycles or TOP 13 ONN 136 09 faults that have occurred in the QA Alpha TOF 2 DUNN controller While viewing the Run Display press the down arrow to access the Event Log Use the up down arrow keys to scroll through the events listed chronologically newest at the top oldest at the bottom Each line identifies an event The first column indicates the fault the fastening cycle status or the fastening cycle shutoff code The second column indicates the achieved torque during the fastening cycle The third column indicates the achieved angle during the fastening cycle The fourth column indicates the working bolt count 10 Alpha Controller Press the Toggle button after selecting an event to display event detail TS Es vent Details Fastening cycle 1 31 2089 H Lists details about the event and when it occurred Most are self explanatory SOC is Shutoff Code see list below Event Details Fault Unrecognized Tool l 12 04 2008 Lists details about the event and when it occurred 22 44 29 Most are self explanatory Controller i i Fault Asserted D State Indicates when the fault asserted or cleared When Keypad Mode is set to Job or Task Select see section 2 9 3 1 General Tab at the run screen press the Toggle button or a number on the keypad A Job Task window opens Use the toggle or interactive menu button to accept and switch controller operation to the selected
15. 7 Setup Exit 2 9 1 4 Setup Task Button Task Tab Screens Options Screens Task settings apply to all Steps inside the Task D ee a Select Tasks by pressing the TASK interactive menu button or a e 2 5 8 E 6 9 H ee a Name Name the Task to define the operation performed 15 character maximum RS Use the up down arrows for letters or use the Can numeric keypad cw Batch Count This is the number of fasteners the Job is required to count Zero is not allowed The maximum is 99 Limit Rejects Limits the number of NOK CS fastening cycles in a Task If the limit is LAST achieved the tool is disabled Use Reset Job LAST Task Select or Task Select Bit inputs to recover Yes turns this function on and increases the Task menu to insert the Reject Reject Count nits Reject Count The maximum number of NOK fastening cycles allowed during this Task Units Operating torque units See section 2 7 1 1 for a list of available units Each Task does not have to use the same operating torque units as the other Tasks Thread Direction For tightening a right hand fastener use clockwise CW Use counter clockwise CCW for left hand fasteners Threshold Torque The torque level during the tightening cycle when the In Cycle Output transitions high Data is not printed or available to eTB unless Threshold Torque is exceeded during the tightening cycle A
16. Administrator NO H The Administrator must login to change user s access The unlocked icon appears in the upper left corner of screen after Administrator login EEN RER See LOS LH See Administrator Setup Tool HOHE Diagnostics HOHE Statistics OCALY Communications HOHE li Each access is exclusive and must be assigned individually Options include NONE denies access LOCAL allows access from the keypad REMOTE allows access from a computer BOTH allows access from the keypad and a computer Setup Users at this level can modify all 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 save To delete a user press the MANAGE button and select option 2 Delete Confirm deletion by pressing OK This action requires the Administrator password once entered user is deleted Import Users can be entered from a backup file Connect a USB memory stick to the USB port scroll to desired file and press IMPORT The new users display on the Us
17. C Job Type the job number to select when this input is asserted TASK When asserted on any input type the controller verifies the selected and active task is equal VERIFY to this input s task Use the TASK parameter under Configuration to select the task number to verify If the wrong task is selected the tool is disabled When removed verification will not happen Size 1 bit Configuration Contact Type Normally Open N O Normally Closed N C Task Type the task number to verify when this input is asserted JOB VERIFY When asserted on any input type the controller verifies the selected and active job is equal to this input s job Use the JOB parameter under Configuration to select the job number to verify If the wrong job is selected the tool is disabled When removed verification will not happen Size 1 bit Configuration Contact Type Normally Open N O Normally Closed N C Job Type the job number to verify when this input is asserted TASK When asserted on any input type the controller verifies the selected and active task is equal VERIFY BIT to this input s task Use the BIT parameter under Configuration to select the task number to verify If there is a mismatch between the active task and the selected task the tool is disabled This is one bit of a binary number created by many of these bits See TASK SELECT BIT to understand how to use bits to create binary numbers When removed verifi
18. 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 in 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 death or severe Warning personal injury may result if proper precautions are not taken Indicates that eye protection should be worn This icon appears as a part of a Danger Warning or Caution notice Read and understand all the safety recommendations and all operating instructions before operating tools and controllers Indicates that property damage Caution may result if proper precautions are not taken GE Getting Started User Manual Indicates an electrical hazard Indicates an item of special This icon appears a
19. Limit controller access to trained and qualified personnel Lock controller cabinets Turn controllers off when removing or attaching tools Stanley electric tools must be connected to a controller to operate To ensure superior performance and safe operation use a Stanley controller specifically designed for each tool These instructions are specific to Stanley electric tools when used with Stanley electric tool controllers and accessories Some features may not be applicable performance may be degraded and some safety systems may not be available when tools are connected to non Stanley controllers and accessories 3 3 1 Sockets and Adapters Use only industrial grade sockets and adapters power bit and power or impact socket type Replace worn or damaged sockets that are unsuitable for safe operation immediately QPM DC Electric Tools 51 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 sup
20. PLC 2 9 Alpha 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 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 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 press the Setup menu button Programming 13 User Manual Se SE LUES 1 Jobs use to perform tool strategy programming such as torque and speed parameters 2 Communications use to program Ethernet serial port fieldbus and data protocol options 3 Other use to set parameters for all other features including system level users passwords I O and tool functions 4 Restore Factory Defaults use to backup restore delete programming and return controller to factory defaults To access press the corresponding menu number on the keypad or use the up down arrow keys to highlight then press the Toggle button 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 Up Down Arrow Keys Scroll through menu selection and char
21. Pp Shows a performance index of a stable process Ppk Shows a performance index of a stable process typically defined by a minimum of two calculations PR Identifies the performance ratio for a stable process 30 Identifies the sample estimated Standard Deviation times three X bar Displays the value s average mean Use the right arrow to move to the next tab or press BACK to return to the Analysis screen ieee Latte EEEEEERS Coefficient D aptitude Moyen Tab orque CH i This screen shows the CAM statistics for the 4 90 selected Job and Task CAM Coefficient d Aptitude Moyen Mean Aptitude Coefficient shows a capability index for a stable process used in Europe R bar Identifies the average range of a constant size subgroup series 30 Identifies the sample estimated Standard Deviation times three X bar Displays the value s average mean Use the left arrow to move to the next tab or press BACK to return to the Analysis screen Press the EXPORT interactive menu button to export Rundown Data or Fault Event Data to the USB memory stick Connect a USB memory stick to the USB port on the bottom of the Alpha controller Use the up down arrows and or the numeric keypad to select option DEE PEE Use the up down arrows and or the numeric keypad to type a file name Pressing the OK interactive menu button saves the data to the USB memory s
22. See section 2 9 1 7 Setup Exit 1 2 3 is Salat 2 9 2 9 PROFIBUS tab This tab appears on Alpha controllers with the Profibus slave port option This tab sets the communications parameters for the Alpha controller slave on a Profibus network The baudrate is determined automatically and set to the Network baudrate as determined by the master device Mac Id Sets the node number of the slave Alpha controller on the Profibus network Endian Provides the correct byte order of DATA words only not I O or strings when communicating to other devices Choose Little for other PLCs and Intel devices Choose Big for Motorola devices 32 Alpha Controller Communication Screens Options Screen FEIE Press the GSD interactive menu button to create a GSD file equivalent to the Profibus T O map created using Embedded Toolbox Connect a USB memory stick to the USB port on the bottom of the Alpha controller Use the up down arrows and or the numeric keypad to type a file name Pressing the OK interactive menu button saves the file to the USB memory stick Use this controller generated GSD file in the PLC connected to the Alpha controller If the Profibus I O map is changed a new GDS file must be generated Use the left arrow to move to the next tab or press EXIT to save the changes and return to the Run screen See section 2 9 1 7 Setup Exit 2 9 3 Setup Menu 3 Other Other Screens Options Scre
23. Starting Torque gt 20 of TSP Batch Count The number of tightening cycles required to be within specified limits to complete a batch The Run display shows the batch count and number of complete tightening cycles Downshift Mode Disable no downshift Manual Occurs at specified torque ATC automatically adapts to the joint Downshift Speed Once the tool reaches the Downshift Torque point the controller changes the operating speed of the tool from the initial Tool Speed to the Downshift Speed Downshift Torque The controller changes the operating speed of the tool from the initial Tool Speed to the Downshift Speed at the Downshift Torque level High Angle Anytime the peak angle recorded exceeds the High Angle the tightening cycle is recorded as a reject for high angle the high angle light red illuminates and the tightening cycle is given an overall status of NOK High Torque Anytime the peak torque recorded exceeds the High Torque the tightening cycle is recorded as a reject for high torque the high torque light red illuminates and the tightening cycle is given an overall status of NOK Low Angle Anytime the peak angle recorded during the Angle Audit Step fails to reach the Low Angle the tightening cycle is recorded as a reject for low angle the low angle light yellow illuminates and the tightening cycle is given an overall status of NOK Low Torque When the peak torque recorded fai
24. angle after the snug point results in a corresponding increase in the tension or clamp load within the joint Soft Stop Soft stop minimizes the torque impulse to the operator during tool shutoff at the end of the tightening cycle Speed The speed at which the tool operates during the initial portion of the tightening cycle prior to ATC or downshift Spindle A spindle represents a connection to a hand held or fixtured tool connected to a controller Strategy Identifies what variables will be used to control the tool during a tightening cycle Thread Direction Sets assembly direction to clockwise CW or counter clockwise CCW Threshold Torque Sets the point at which the tool is In Cycle When the tool is In Cycle the tool and controller tightening cycle status lights turn off the controller displays dashes for data and the In Cycle output is turned on Tool Tones Distinctive sounds assigned to tool functions Torque Calibration Determines how torque values are assigned to the electrical signals from the torque transducer on the tool This value is unique to each tool and changes over time Torque Target When the tool is being controlled for torque the torque target instructs the controller when to shutoff the tool The torque target should be greater than Low Torque and less than High Torque and is required for torque control Trace A display plot of torque vs time or angle of a tightening cycle
25. be modified by subtracting 0 1 times the torque value For example at 15 NM the controller will subtract 1 5 degrees from the angle reading for that sample At 30 NM the controller will subtract three degrees for that sample The easiest way to determine the correct value for the Torsion Factor is to look at a torque vs angle trace with Torsion Factor set to zero The amount of degrees that the socket appears to loosen after the maximum torque divided by that maximum torque is the Torsion Factor For example consider a torque vs angle trace that indicates a maximum torque of 40 NM and the maximum angle at this torque of 50 degrees But the angle appears to loosen by four degrees as the torque drops to zero The Torsion Factor can be determined by dividing four degrees by 40 NM to arrive at a Torsion Factor of 0 1 degrees per NM When this value is entered into the Torsion Factor parameter each angle reading will be corrected by this factor When this factor is set correctly any torque vs angle trace will now indicate no apparent loosening of the fastener as the torque drops to zero after shut off which is exactly as it should be 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 It has
26. 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 94 Alpha Controller compared to a torque reading from the external torque monitor it can easily have several percent differences higher or lower This means that the tool s controller will start counting angle at a different point than the external torque angle monitor starts counting This could be five 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 pre torque the joint slightly higher than the snug torque Run the tool on this already tightened joint with the snug torque set to the same value in both the controller and the monitor even if the tool s transducer and the external transducer do not exactly agree near the snug torque they will both start counting angle just before the fastener starts to rotate so their zero angle will be synchronized exactly For example if a brake line fitting requires six NM plus 40 degrees pre torque the joint to seven NM first Then change to an Angle Control strategy with six NM snug torque plus 40 degrees angle target and reset the external torque angle monitor Then as the tool is run in this angle contr
27. cycle is complete before the IN CYCLE bit resets The value resets to zero 0 when the tool is commanded to run again Size Can be any size from 0 to 32 bytes depending on Data Type Data Type Float Int8 Int16 Int32 Fixed Point String OK User Defined Value Low User Defined Value High User Defined Value Step Audit Audit 1 Audit 2 80 Alpha Controller Outputs Description RUNDOWN This output will be one of three selections The selections are the User Defined Value for ANGLE the associated angle status of the last fastening cycle For example if the last fastening STATUS cycle s angle status was Low and the User Defined Value for Low is then this output value is The OK User Defined Value is selected when the achieved angle for the defined Step are within specified limits The Low User Defined Value is selected when the achieved angle for the defined Step is below the Low Angle limit The High User Defined Value is selected when the achieved angle for the defined Step is above the High Angle limit It asserts when the fastening cycle is complete before the IN CYCLE bit resets The value resets to zero 0 when the tool is commanded to run again Size Can be any size from 0 to 32 bytes depending on Data Type Data Type Float Int8 Int16 Int32 Fixed Point String OK User Defined Value Low User Defined Value High User Defined Value Step Audit Audit 1 Audit 2 Outputs not a
28. fastening cycle torque rate This rate is then used in the Torque Rate or Yield Control strategies Torque Average Number of Torque samples averaged for the Rate calculation Calculates a running average from torque samples taken every millisecond A higher number gives a smoother Rate Angle Interval Angle interval used to calculate the Torque vs Angle Rate Larger intervals may give a smoother Rate Modified A value that is changed by the controller to indicate the date and time parameter values were last changed in this Task Press the EXIT interactive menu button to save changes and return to the Run screen See section 2 9 1 7 Setup Exit Press the MANAGE interactive menu button to Add Delete Copy or Paste Tasks See section 2 9 1 3 Setup Manage Button Job and replace the word Job with Task when managing Tasks in this section Press the STEP interactive menu button to setup the parameters of the Step s inside the selected Task See section 2 9 1 5 Setup Step Button for further information 2 9 1 5 Setup Step Button Step Tab Screens Options Screens Step settings only affect the selected Job and Task There can be only one Audit step per Task Each step is represented by its own tab Use the left right arrow keys to select the tabs steps for modifying 22 Alpha Controller Step Tab Screens Options Screens IE 5j 8 HE Name Provides an identifier for the step 15 character maxi
29. good starting point is 20 of Target Torque Statistical Torque The torque level required to be exceeded before the fastening cycle data is included into Statistics or sent via a network protocol Disassembly Speed The speed of the tool during Reverse operation in RPM revolutions per minute Disassembly Acceleration The rate at which the tool gets to Disassembly Speed in RPM s revolutions per minute per second Cycle Lock Out This is a timer in seconds that activates after the tool has reached its target While active it disables the tool Torque Audit Step Identifies which step the fastening cycle torque data is received The status of the Audit step determines which of the Red Green and Yellow fastening cycle status Programming 21 User Manual Task Tab Screens Options Screens lights is energized at the end of a fastening cycle The value of LAST always chooses the last step programmed in this Task as the Audit step Angle Audit Step Identifies which step the fastening cycle angle data is received The status of the Audit step determines which of the Red Green and Yellow fastening cycle status lights is energized at the end of a fastening cycle The value of LAST always chooses the last step programmed in this Task as the Audit step Synchronization Yes turns on the synchronization function No turns off the synchronization function Torque Rate This section sets values used in determining
30. input 3 The controller reads the PART ID data into its memory and sets the PART ID CHANGED output to high 1 indicating the data has been read 5 The PLC reads the high level on the PART ID CHANGED output then sets the PART ID TRIGGER input to high 1 6 The controller sets the PART ID CHANGED output to low 0 7 The external PLC sets the PART ID TRIGGER input to low 0 Auto The controller reads the PART ID automatically when it changes no handshake required SYNC IN When asserted on any input type the controller sets an internal bit and waits for the active step to end When the controller is synchronized and both conditions are met it energizes the SYNC OUT output indicating to the next controller in line that all controllers upstream are finished with the current step When removed nothing happens Size 1 bit Configuration Contact Type Normally Open N O Normally Closed N C SYNC When asserted on any input type the controller turns off the SYNC OUT output and starts RESUME the next step in the multi step strategy When removed nothing happens Size 1 bit Configuration Contact Type Normally Open N O Normally Closed N C Outputs not available on 24 VDC 4 2 2 Output Descriptions Each of the output elements has Configuration settings Contact types Output types and others It is recommended to configure them immediately once the output elements are assigned to a pin
31. instruction is a retentive input instruction that triggers an event to occur one time Use the OSR instruction when an event must start based on the change of state of the rung from false to true When the rung conditions preceding the OSR instruction go from false to true the OSR instruction will be true for one scan After one scan is complete the OSR instruction becomes false even if the rung conditions preceding it remain true The OSR instruction will only become true again if the rung conditions preceding it transition from false to true The address assigned to the OSR instruction is not the one shot address referenced by the program nor does it indicate the state of the OSR instruction This address allows the OSR instruction to remember its previous rung state OTE Output Energize Use the OTE instruction in the ladder program to turn on a bit when rung conditions are evaluated as true OTL Output Latch OTL is a retentive output instruction OTL can only turn on a bit while OTU can only turn off a bit This instruction is usually used in pair with the OTU instruction The program can examine a bit controlled by OTL instructions as often as necessary When rung conditions become false after being true the bit remains set and the corresponding output remains energized When enabled the latch instruction tells the controller to turn on the addressed bit Thereafter the bit remains on regardless of the rung condition until
32. is a 15 character limit to this parameter This is active in Alpha controller version QA1 3 4 1 or higher P writetoscreen xml Notepad j ioj x File Edit Format View Help lt controller gt lt plc gt lt param id 700 gt S5T14 0 This is the message that appears non the screen Change this text nto match your requirements SOR XIC 1 0 0 5 OSR B3 0 0 AwT 1 5T14 0 R6 1 37 EOR SOR sto 1 0 0 5 OSR B3 0 1 MSG O 210H o 0 EOR lt param gt lt fple gt lt fcontroller gt To provide a display version put another XML parameter tag after lt param gt tag and before the lt plc gt lt controller gt ending tags The new tag will be lt param id 702 gt VERSION lt param gt There is a 15 character limit to this parameter 90 Alpha Controller Glossary Abort Timer The tightening cycle aborts if the tool does not shutoff before this pre selected time Acceleration How fast the controller changes the speed of the tool from 0 stopped to the rated speed Accept Tone Controls the tone made from the handle of handheld QPM tools for accepted tightening cycles Allows distinct tones for tools in adjacent workstations ATC Allows Adaptive Tightening Control modes to be selected so that consistent torque can be maintained over a wide range of joints Manual downshift should be used when e High Prevailing Torques Prevailing Torque gt 20 of the Torque Set Point TSP e High Starting Torque
33. its RJ45 jack Obtain IP From Network Yes allows the Alpha controller to receive an address from the network DHCP server BOOTP and RARP are not supported IP Address The IP Address of the Alpha controller Subnet Mask The Subnet address of the Alpha controller Gateway The Gateway address to a connecting network DNS The address of the network s DNS server Physical This is the MAC id of the RJ45 jack on the Alpha controller This value comes from the Ethernet board inside and cannot be changed Master Used when a Two Spindle system is desired IP Address The IP Address of the Master Alpha controller This causes the working Alpha controller identified under Network to become a slave to the Alpha controller located at this IP Address Both Alpha controllers must be connected using the same Ethernet switch to create their own Ethernet network The fastening cycle data from the slave Alpha controller is sent to the master Alpha controller The Master then presents both sets of data to other networks using the embedded protocols PLC logic added to the master Alpha controller can help integrate both controllers into the end user s processes Use the right arrow to move to the next tab or press EXIT to save the changes and return to the Run screen See section 2 9 1 7 Setup Exit PAIE DIOIG IO Co EES 2 9 2 2 Serial tab E BARCODE PRINTER COM Port 1 Choose the function fo
34. 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 file exports can be created These files can be imported to a connected controller in the future Appendix A Embedded Toolbox Installation 93 User Manual Appendix B Torsion Compensation Torsion Factor For all Stanley electric assembly tools the angle information is based on the rotation of the resolver which is directly attached to the rotor This information is used for motor commutation and it also serves as an angle encoder The rotation of the tool output can be determined by dividing the rotor angle by the total gear ratio for the tool All things can deflect when loaded Just as a long steel bar attached to a socket to produce high torque will deflect likewise the gears within an assembly tool will deflect when subjected to the torque loads In effect the gears act as a torsion spring between the rotor and the socket and it is the deflection of this spring that can give false angle data In addition to the angular deflection within the gears of the tool there can also be deflection of the parts of the joint Whenever this deflection is present in the tool or the joint or the tool mounting device the angle information derived from the resol
35. on any input type the controller makes this input s Job the active Job When removed either nothing happens or if Disable when open is selected as yes then the tool becomes disabled Size 1 bit Configuration Contact Type Normally Open N O Normally Closed N C Job Type the job number to select when this input is asserted Disable when open Yes Disables the tool when this input is removed No Does not disable the tool upon input removal SELECT When asserted on any input type the controller makes this input s Task the active Task TASK When removed either nothing happens or if Disable when open is selected as yes then the tool becomes disabled Size 1 bit Configuration Contact Type Normally Open N O Normally Closed N C Task Type the Task number to select when this input is asserted Disable when open Yes Disables the tool when this input is removed No Does not disable the tool upon input removal Alpha Controller Connections 67 User Manual Inputs Description STOP When asserted on any input type the controller stops the tool It also prevents the tool from running while it is applied When removed nothing happens other than the tool runs Size 1 bit Configuration Contact Type Normally Open N O Normally Closed N C RESET JOB When asserted on any input the controller resets the accumulated bolt count to zero for the active job and
36. only be used to back out fasteners after a NOK fastening cycle No allows the use of Disassembly mode after any fastening cycle unless the logic of the other two events is met On Job Complete Yes does not allow the use of Disassembly mode after the active Job is complete accumulated count equals target count No allows the use of Disassembly mode after a Job is complete unless the logic of the other two events is met On All Fasteners Removed Yes does not allow the use of Disassembly mode after all fasteners have been removed i e accumulated count is back to zero No allows the use of Disassembly mode after all fasteners have been removed unless the logic of the other two events is met Disable Assembly This identifies whether the tool disables after each Task has completed This requires a Reset Job Task Select or Task Select Bit input to select an incomplete Task which enables the tool for an incomplete Task only If Auto Sequence Task is used the tool re enables when the active Task switches to an incomplete Task On Task Complete Yes disables the tool when the active Task is complete If an input switches the controller to a completed Task the tool disables No will not disable the tool when the active Task is complete Press the EXIT interactive menu button to save changes and return to the Run screen See section 2 9 1 7 Setup Exit Press the MANAGE interactive menu button to Add Delete Copy or Paste Jobs Se
37. r l Via Parco 47 20046 Biassono MI Italy Tel 39 039 238 9950 Fax 39 039 238 9970 SATinfo stanleyworks com STANLEY ASSEMBLY TECHNOLOGIES Rm 202 Building 12 No 899 Zuchongzhi Road Zhangjiang High Tech Park Shanghai China Tel 86 21 6162 1858 ext 2151 Fax 86 21 5080 5101 Mobile 86 137 0174 6593 mting stanleyworks com STANLEY ASSEMBLY TECHNOLOGIES Stanley Works India Pvt Ltd A B House 4 24A Asaf Ali road New Delhi 110002 India Tel 91 11 4356 9000 ext 102 Fax 91 11 4356 9069 sagarwal stanleyworks com www stanleyAssembly com 98
38. screen 2 9 1 2 Setup Job Tab Jobs Tasks and Steps are required to setup a tool strategy Inputs and Triggers are used to select specific Jobs or Tasks with different tool strategies including Error Proofing bolt counting Program Job parameters according to the plant integration strategy desired and then program Task s and Step s to create the tool strategy 18 Alpha Controller Job Tab Screens Options Screens Job settings apply to all Tasks and Steps within the Job Px HIE 5j 6 HE WURR reg Select Jobs by pressing the SETUP interactive menu button on the Run screen Communications Other Restore Factory Defaults Press 1 or highlight selection and press Toggle button SIS or LOJ HE kHE 2 kg H RER Name Name the Job to define the operation performed 15 character maximum Use the up down arrows to spell with letters or use the numeric keypad Barcode Id This is a mask that when equal to an incoming PART ID selects this Job as the active Job The PART ID can come from the serial port a network protocol a fieldbus input the internal PLC or the keypad itself Use periods to mask the negligible portions of the PART ID use the exact characters in their exact PART ID positions to select the Job Example If a PART ID is 723ABC and if the 3A determines when this Job is to run the third and fourth positions then enter 3 A as th
39. tool MFP extinguishes and the STOPPED output asserts CH EE i TOOL DISAELEDS Not Armed Stop Tool Explanations Undefined Task The selected Task is not programmed to run a tool select another Task or program currently selected Task Invalid Job Task Appears when a Job or Task number less than zero or greater than 99 is selected Network Protocol The plant control system issued a Stop via a network protocol Wait for the protocol to remove the Stop command Error Proofing Bolt count has been met reset with a Job Reset input Stop Issued An Input is disabling the tool remove the Stop input 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 Not Armed There are two things that can cause this event a Tubenuts By default tubenut tools require arming by tapping the MFB before the trigger is pressed to run the tool b Reset Reject The fastening cycle is NOK and the MFB mode is set to Reset Reject preventing the tool from running until the MFB is pressed to reset the NOK Reject Count Exceeded Indicates the Reject Count has been exceeded 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 backgrou
40. weighted values For example on the 24 VDC input pin L is bit 0 pin M is bit 1 pin N is bit 2 pin P is bit 3 and pin R is bit 4 Therefore to select task 21 assert pins L N and R Size 1 bit except on fieldbus where it can be any size to fit the need Configuration Contact Type Normally Open N O Normally Closed N C Bit Type the number of this bit in the binary number scheme to select tasks Mode All TASK SELECT BITs must be the same mode no mixing of modes allowed Binary Creates a decimal number equivalent to the weighted value of this binary bit s Binary 1 Creates a number equivalent to the weighted value of this binary bitte and adds the value of one 1 to that number JOB SELECT When asserted or removed on any input type the controller selects a job This is one bit in a BIT series of bits to create a binary number See TASK SELECT BIT function description for explanation of this bit note that this references Jobs not Tasks Size 1 bit except on fieldbus where it can be any size to fit the need Configuration Contact Type Normally Open N O Normally Closed N C Bit Type the number of this bit in the binary number scheme to select jobs Mode All JOB SELECT BITs must be the same mode modes cannot be mixed Binary Creates a decimal number equivalent to the weighted value of this binary bit s Binary 1 Creates a number equivalent to the weighted value of this b
41. 44 and ISO 11203 single axis EO E1 E2 EA2 E3 EA3 lt 70dBA lt 2 5 m s F4 and E5 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 Lycpeax not applicable to these products Uncertainty Kpa Kwa Kpcpeak not relevant declared levels are maximum values WARNING To Avoid Injury This information is provided to assist in making rough estimates of sound and vibration exposure levels in the workplace The declared emission values were obtained by laboratory type testing in accordance with the stated standards Levels measured in individual workplaces may be higher The actual exposure levels and risk of harm experienced by an individual user depends upon the work piece workstation design duration of exposure and the physical condition and work habits of the user To help prevent physical impairment a program of health surveillance is highly recommended to detect early symptoms which may relate to sound and or vibration exposure such that appropriate preventive measures may be taken QPM DC Electric Tools 49 o gt User Manual 3 2 Operator Protection WARNING ROTATING EQUIPMENT To Avoid Injury e Always wear eye and foot protection when operating installing
42. 6 Int32 Fixed Point String CONSTANT This value is defined by the end user in the Constant parameter It asserts when the fastening cycle is complete after the IN CYCLE bit resets The value resets to zero 0 when the tool is commanded to run again Size Can be any size from 0 to 32 bytes depending on Data Type Data Type Float Int8 Int16 Int32 Fixed Point String Constant Type the value of the constant required RUNDOWN BOLT This is the accumulated bolt count value of the last fastening cycle It asserts when the fastening cycle is complete after the IN CYCLE bit resets The value resets to zero 0 when the tool is commanded to run again Size Can be any size from 0 to 32 bytes depending on Data Type Data Type Float Int8 Int16 Int32 Fixed Point String Alpha Controller Connections 79 User Manual Outputs Description RUNDOWN This is the numeric equivalent value of the torque units of the last fastening cycle It UNITS asserts when the fastening cycle is complete after the IN CYCLE bit resets The value resets to zero 0 when the tool is commanded to run again The numeric equivalent values are 0 Newton Meters 1 Ftlbs 2 inlbs 3 inoz 4 KgM 5 Kom 6 Newton Decimeters Size Can be any size from 0 to 32 bytes depending on Data Type Data Type Float Int8 Int16 Int32 Fixed Point String RUNDOWN This output will be one of two selections The selections
43. 9 3 8 TOOL Tab Tool Output Angle Identifies the number of circular degrees of rotation on the tool output Resets at each start Tool Output Speed Identifies the real time speed of the tool output Press the STATS interactive menu button to enter the Statistics area of the controller Alpha controllers maintain both sample and population statistics Sample statistics are calculated using the last completed subgroup of rundowns for a given Task The subgroup size is set using Subgroup Size Population statistics are calculated using all of the rundowns for a given Task up to the Population Size To be included in sample or population statistics a rundown must exceed the Task s Threshold Torque and Statistical Torque The statistics are calculated for Torque and Angle Data is filtered by Task Press the interactive menu button and choose the Job and Values are recalculated each time a tab is selected 44 Alpha Controller Analyze Screens Options Screen Results Tab Torque R 24 F This screen shows a summary of the fastening cycle data results stored in the controller n Shows the number of rundowns included in the population size n OK Identifies the number of OK rundowns n NOK Identifies the number of NOK rundowns n Displays the number of fastening cycles that exceeded the high limit n Displays the number of fastening cycles that did not achieve the low l
44. B 9 connector is used when Profibus is ordered The ModbusTCP card in slot 2 and the EthernetIP card in slot 3 come installed as standard equipment on all Alpha controllers Each uses the RJ45 Ethernet jack on the bottom of the Alpha The optional DeviceNet Master Scanner card in slot 4 can be configured to auto map the devices connected to it This card uses the M 5 DeviceNet connector on the bottom of the Alpha if this option is ordered 5 1 1 Addressing Scheme Use the following syntax when programming to reference any input or output Type Slot Word Bit Type can be Input J or Output O For example if a switch was wired to Pin L a light was wired to Pin C and logic was required to turn on the light when the switch was turned on the logic and addressing would look like this 1 0 0 0 0 0 RK Et 0 0 As ASCII it would be SOR XIC I 0 0 0 OTE 0 0 0 EOR See section 4 1 8 Alpha Controller Model QA1001 __V Input and Output Connector for 24V DC Connector PLC addressing 82 Alpha Controller 5 2 Supported Instructions and File Types See Table 1 and Table 2 for a listing of supported instructions and file types NOTE The Alpha controller supports only one ladder in the program file Jump commands are not supported so all logic must be performed in one ladder Table 1 Supported Instructions Instruction Descriptions Instr
45. Controller Outputs Sourcing example CPU m In Cycle e P Read D IL cc Disassembly E Detected mA if JS1 r C JS 2 G y 4 JS 3 H Zi Cycle OK yx Cycle NOK 24V Return d 24V Return TE Output Common B A External Power Supply 24V DC Internal Power Supply 24V DC SKA EC m For PNP Outputs use EITHER the Internal 24V Return OR the External 24V Return to provide the Output Common supply voltage Alpha Controller Connections 63 User Manual Outputs Sinking example CPU c In Cycle e F Read Disassembly E Detected mA JS1 i oom JS 2 e d 4 JS3 H 0 Cycle OK Cycle NOK i nao 24V Return 24V Return Output Common B External Power Supply 24V DC Internal Power Supply U 24V DC 1 Sh RR EG ae a EE D WM For NPN Outputs use EITHER the Internal 24V Return OR the External 24V Return to provide the Output Common supply voltage 4 2 Assignable Input and Output Elements The following Input Output I O elements 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 There is a maximum of 512 bytes of input and 512 bytes of output on each type of Fieldbus used with the controller except DeviceNet with a limit of 256 bytes for
46. EAA Assembly Technologies Alpha Controller User Manual Software Version QA1 3 4 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 2009 THE STANLEY WORKS ALL RIGHTS RESERVED www StanleyAssembly com User Manual Contents SEET 1 1 1 ele 1 Eine Eat Le 1 13 Specifications Layout and Display 2 1 4 Installation Instructions ccc cette eee eeeeeteeeeeeeeeeetteees 4 1 4 1 Alpha Controller E Stop Precaution cccceeeee 7 Programming eet aaea aa A AA EAEn aa EASE ENANA 8 2 1 Theory of Operation 8 2 1 1 Data Storages mo ee 8 2 1 2 Input and Output Elements 8 2 2 SOOUMWAl C53 hierar eene ees 8 2 3 Embedded PLO ee 8 Ee e EE 8 2 5 QA Alpha Controller Navigation and Programming 9 267 tee ee EE 9 2 6 1 Eet 9 Pio 2 Ree EE 9 2 6 3 Menu LE ees 10 260 4 ET EE 10 2 6 5 Character el TE 10 26 6 anre EE 10 SE Faults ee 12 2 8 Messages E 13 2 9 Alpha Controller Programmmg 13 2 9 1 Set p Men I leese Eet 14 2 9 1 1 Wizard Screens EE 15 2 9 1 2 Setup Job Tab E 18 2 9 1 3 Setup Manage Button obt 20 2 9 1 4 Setup Task Button cee cc eeeeeeeeeeeeeeeeeeeeneeeeeeeeees 21 2 9 1 5 Setup Step ER oa A aera aes 21 2 9 1 6 Setup Manage Button ien 25 2917 Setups E
47. I O or the tool trigger When removed the tool is allowed to run after the next START input Size 1 bit Configuration Contact Type Normally Open N O Normally Closed N C 70 Alpha Controller Inputs Description PART ID When asserted on any fieldbus input type the PART ID CHANGED output goes high This TRIGGER input function is NOT available on the 24 VDC type of I O This lets the PLC program know the controller has read the new PART ID See PART ID input function for an explanation of the handshake between controller and external PLC When removed the PART ID CHANGED output goes low Size 1 bit Configuration Contact Type Normally Open N O Normally Closed N C PART ID When asserted on any fieldbus input type the controller reads the new PART ID input and places the data into the Part ID buffer This is added to the fastening cycle data and stored in the controller or sent out via the serial or Ethernet port This input function is NOT available on the 24 VDC type of I O Size Can be any size from 0 to 32 bytes When removed nothing happens Configuration Length Type the length of the expected data string in bits Trigger Manual A handshake must be performed in order for the controller to read the new PART ID The definition of a handshake is as follows 1 The external PLC verifies the PART ID CHANGED output is low 0 2 The external PLC writes the data into the PART ID fieldbus
48. IT Asserts at the end of the fastening cycle to indicate the last step ran This is one bit in a series of bits to create a binary number Size 1 bit except on fieldbus where it can be any size to fit the need Configuration Contact Type Normally Open N O Normally Closed N C Bit Type the number this bit will be in the binary number scheme for steps Mode All STEP BITs must be the same mode no mixing of modes allowed Binary Creates a decimal number equivalent to the weighted value of this binary bit s Binary 1 Creates a number equivalent to the weighted value of this binary bit s and add the value of one 1 to that number SYNC OUT Asserted when the controller has finished a synchronized step and the SYNC IN input is asserted Resets when the SYNC RESUME input is asserted Size 1 bit Configuration Contact Type Normally Open N O Normally Closed N C Output Type Normal Timed Flash Minimum ON Time Time Period BOLT COUNT This output is the value of the active accumulated bolt count As the bolt count changes so does this output Size Can be any size from 0 to 32 bytes depending on Data Type Data Type Float Int8 Int16 Int32 Fixed Point String String Length Number of Decimal Positions Pad Character Delimiter RUNDOWN This is the year value of the last fastening cycle date It asserts when the fastening cycle YEAR is complete before the IN CYCLE bit resets The valu
49. ON T4 0 0 01 50 0 EOR SOR XIC 1 0 0 1 TON T4 1 0 01 50 0 EOR SOR XIC T4 0 TT XIC T4 1 TT OSR B3 0 3 OTE B3 0 1 EOR SOR BST XIO 1 0 0 0 NXB XIO 1 0 0 1 BND OSR B3 0 4 OTE B3 0 2 EOR SOR END EOR This must now be converted to an XML file Type the following BEFORE the first SOR in the pasted logic in Notepad lt controller gt lt plc gt lt param id 700 gt Then type the following AFTER the last EOR in the pasted logic in Notepad lt param gt lt plc gt lt controller gt P untitled Notepad File Edit Format View Help SOR XIC I 0 0 0 TON T4 0 0 01 50 EOR SOR XIC I 0 0 1 TON 1 0 0 0 NXB XIO 1 0 0 1 BND OSR B3 0 4 OTE B3 0 2 EOR SOR END EOR Save the file using the xml extension and choose All Files under Save as type in the Save window meas ais Save in E Manual gt fi My Recent Documents Desktop 9 My Documents PE My Computer RE e Weta File name TwoHandStart xml D Places Save as type Jan Files zl Cancel Encoding Jansi zl 4 Once the file is saved it can be put into the Alpha controller See section 2 9 3 10 PLC Tab 5 3 1 Invalid Characters When the logic refers to a specific word in a string file it uses DATA X where X is the referenced word The Alpha controller does not support the DATA X syntax This must be converted to a number For example if the word referred to is ST14 3 DATA 5 then this must be Embedded PLC 89 User Manual conver
50. Outputs Description TORQUE LOW Asserts at the end of a fastening cycle when the achieved torque value is below the Low Torque limits Audit step Resets when the tool is commanded to start again Can also be reset with the RESET RESULTS STATUS input Size 1 bit Configuration Contact Type Normally Open N O Normally Closed N C Step Audit Audit 1 Audut 2 Output Type Normal Timed Flash Minimum ON Time Time Period ANGLE OK Asserts at the end of a fastening cycle when the achieved angle value is within limits for the Audit step Resets when the tool is commanded to start again Can also be reset with the RESET RESULTS STATUS input Size 1 bit Configuration Contact Type Normally Open N O Normally Closed N C Step Audit Audit 1 Audut 2 Output Type Normal Timed Flash Minimum ON Time Time Period ANGLE HIGH Asserts at the end of a fastening cycle when the achieved angle value is above the High Angle limit for the Audit step Resets when the tool is commanded to start again Can also be reset with the RESET RESULTS STATUS input Size 1 bit Configuration Contact Type Normally Open N O Normally Closed N C Step Audit Audit 1 Audut 2 Output Type Normal Timed Flash Minimum ON Time Time Period ANGLE LOW Asserts at the end of a fastening cycle when the achieved angle value is below the Low Angle limits for the Audit step Resets when the tool is commanded to start again Can also
51. a Controller Connections Alpha Controllers Mini DeviceNet Connector 59 User Manual 4 1 6 Alpha Controller Model QA1001 _P_ Profibus Port Alpha Controllers can have a single Profibus port for connecting the Alpha Controller to a master Profibus controller from another manufacturer 9 LL 6 5 eeeoeee 1 Figure 4 1 DB 9 Connecter Pins Profibus Port Pin Function Pin Function Pin Function 1 Empty 4 Repeater 7 Blank 2 Empty 5 Data Ref 8 Data Line Inverse 3 Data Line 6 Power Supply 9 Empty 4 4 7 Alpha Controller Model QA1001 M__ Master DeviceNet Connector Alpha controllers can have a single Micro DeviceNet port for connecting peripheral devices to the Alpha Controller as a master controller The assignable I O and the embedded PLC can be programmed to run the peripheral devices Pin Master e ENSCH L 1 Drain S ve Sex 2 V CANL He 4 V 8 3 V gt KI drain 4 CAN H CAN H 5 CANL Alpha Controllers Micro DeviceNet Connector 4 14 8 Alpha Controller Model QA1001 __V Input and Output Connector All eight inputs and eight outputs are optically isolated 24VDC The Alpha has an internal 24VDC power supply that can be used to provide the I O signals an external 24VDC power supply may be used instead The following are amperage ratings e Internal 24 VDC supply Maximum ampere total e External 24 VDC supply Maximum ampere per output The Alpha controller
52. able tool will complete running if it is VON in cycle PART ID Sets the part identification Length Trigger Trigger for PART ID Resets PART ID PART ID TRIGGER CHANGED output N O N C SYNC IN Other Alpha is finished with current step N O N C SYNC RESUME Start the next step in the strategy N O N C Input not available on 24V Outputs Description Configuration Options NOT USED Output is not in use None IN CYCLE The tool is in cycle N O N C Type Time JOB SELECTED Indicates a specific job is selected N O N C Type Time Job DISASSEMBLY A tightened fastener removed has been DETECTED loosened NOJN G Lype lime TOOL RUNNING The tool is running N O N C Type Time CYCLE OK Fastening cycle was OK N O N C Type Time CYCLE NOK Fastening cycle was NOK N O N C Type Time TASK SELECTED Indicates a specific task is selected N O N C Type Time Task JOB COMPLETE Job complete all bolts in job are OK N O N C Type Time Job TASK COMPLETE Task complete all bolts in task are OK N O N C Type Time Task TASK SELECTED BIT G i e indicate the selected task in a series N O N C Bit Mode JOB SELECTED BIT S e i indicate the selected job in a series N O N C Bit Mode Alpha Controller Connections 65 User Manual Inputs Description Confi
53. acter selection Ch i Toggle Button Selects option for data input accepts changes YD Numeric Keypad Data input and when applicable menu selection Can HE be used for job selection when enabled to do so HIOI H The left column shows the currently defined Alpha 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 Px a Emm Batch Count Ca Units ci M Thread Direction oan cH 4 _ Batch Count i Units Thread Direction NOTE Programming changes are stored after exiting current menu and returning to run screen 2 9 1 Setup Menu 1 Jobs Jobs controls tool operation for tightening a fastener one to ninety nine Tasks and one to twelve Steps Most controllers operate with a single Job and Task with one or two Steps Users must have ADMINISTRATOR or SETUP access in order to modify Job settings This includes Wizard Manage and Step parameters The Wizard automatically appears after selecting Jobs if a tool is attached and a Job or Task is added The Wizard sets a Job or Task for simple or complex tightening cycles using the optional strategy controls Co Ca 14 Alpha Controller If no tool is attached or if at least one Job exists the Job tab appears allowing for advanced user programming jAuto Reset Job et Enable Error Proofin
54. acts as a Part Entry to re enable the tool if disabled The tool could be disabled due to Error Proofing and the accumulated bolt count equal to target bolt count When removed nothing happens Size 1 bit Configuration Contact Type Normally Open N O Normally Closed N C TASK When asserted or removed on any input type the controller selects a Task This is one bit SELECT BIT ina series of bits to create a binary number The number created by this and other TASK SELECT BITs determines which the active task for the tool becomes More than one input assigned as a TASK SELECT BIT creates a number greater than one The maximum number of tasks required determines the maximum number of these inputs In binary numbers the digit furthest to the right is the ones digit The next digit to the left is the twos digit next is the fours digit then the eights digit and so on The integer equivalent to a binary number can be found by summing all the weighted values of the selected digits For example the binary number 10101 is equivalent to the integer 21 The math is 1 4 16 21 the high digits one are added together and the low digits zero are ignored Bit Number 4 3 2 1 0 Weighted Value 16 8 4 2 1 Binary Number 1 0 1 0 1 24 VDC Pins example R P N M L To select task 21 on the controller at least five inputs are assigned as TASK SELECT BIT Each would then be given a bit number to have a series of bits with different
55. alue is less bit is reset than the preset value Timer Enable Bit EN Bit 15 rung conditions are true rung conditions go false TON Timer On Delay Use the TON instruction to turn an output on or off after the timer has been on for a preset time interval The TON instruction begins to count millisecond intervals when rung conditions become true As long as rung conditions remain true the timer adjusts its accumulated value ACC each evaluation until it reaches the preset value PRE The accumulated value is reset when rung conditions go false regardless of whether the timer has timed out The Time Base must be 10 msec The timer will not work in any other Time Base This Bit Is Set When And Remains Set Until One of the Following Timer Done Bit DN bit 13 accumulated value is equal to or rung conditions go false greater than the preset value Timer Timing Bit TT bit 14 rung conditions are true and the rung conditions go false or when the accumulated value is less than done bit is set the preset value Timer Enable Bit EN bit 15 rung conditions are true rung conditions go false XIC Examine If Closed Use the XIC instruction in the ladder program to determine if a bit is on When the instruction is executed if the bit addressed is on 1 then the instruction is evaluated as true When the instruction is executed if the bit addressed is off 0 then the instruction is evaluated as false XIO Examine If O
56. am 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 Alpha controller can be setup to change tightening Jobs or Tasks from the tool s MFB QPM DC Electric Tools 55 User Manual 3 6 Special Application Tools 3 6 1 Exposed Gear Socket Tools WARNING PINCH POINT AT THE EXPOSED GEARS OR TEETH To Avoid Injury Keep body parts and clothing away from the exposed gear sockets Dress properly Do not wear loose fitted clothing or jewelry Exposed gear socket tools are designed to fit into tight spaces where other tools do not fit These tools have exposed gears or ratchet teeth It is recommended to use the ARMING feature for these types of tools 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 stops after reaching torque Release the lever and lift the tool from the fastener all tool status
57. 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 Be prepared for the change in direction and or a higher reaction force when a tool is in reverse The 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 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 trigger Release start lever after the cycle is complete 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
58. are the User Defined Value for STATUS the associated status of the last fastening cycle For example if the last fastening cycle status was OK and the User Defined Value for OK is Good then this output value is Good The OK User Defined Value asserts at the end of a fastening cycle when the achieved torque and angle for the Audit step are within specified limits The NOK User Defined Value asserts at the end of a fastening cycle when the achieved torque and angle for the Audit step are NOT within specified limits The value resets to zero 0 when the tool is commanded to run again Size Can be any size from 0 to 32 bytes depending on Data Type Data Type Float Int8 Int16 Int32 Fixed Point String OK User Defined Value NOK User Define Value RUNDOWN This output will be one of three selections The selections are the User Defined Value for TORQUE the associated torque status of the last fastening cycle For example if the last fastening STATUS cycle s torque status was High and the User Defined Value for High is then this output value is The OK User Defined Value is selected when the achieved torque for the defined step are within specified limits The Low User Defined Value is selected cycle when the achieved torque for the defined Step is below the Low Torque limit The High User Defined Value is selected when the achieved torque for the defined step is above the High Torque limit It asserts when the fastening
59. be reset with the RESET RESULTS STATUS input Size 1 bit Configuration Contact Type Normally Open N O Normally Closed N C Step Audit Audit 1 Audut 2 Output Type Normal Timed Flash Minimum ON Time Time Period CYCLE Asserts when the controller shuts the tool off due to a fault or if the Stop Abort within ABORTED Limits parameter is used and the fastening cycle has a shutoff code of ABORT Resets when the tool is commanded to run again Can also be reset with the RESET RESULTS STATUS input Size 1 bit Configuration Contact Type Normally Open N O Normally Closed N C Output Type Normal Timed Flash Minimum ON Time Time Period Alpha Controller Connections 75 User Manual Outputs Description STOPPED Asserts when the STOP input is received or anytime the tool is stopped See section 2 5 6 Stop Tool Operation Resets when the STOP input or the Stop Tool Operation is reset The icon is on when this output is on Size 1 bit Configuration Contact Type Normally Open N O Normally Closed N C Output Type Normal Timed Flash Minimum ON Time Time Period FAULTED Asserts when there is a fault on the controller Resets when the fault clears Size 1 bit Configuration Contact Type Normally Open N O Normally Closed N C Output Type Normal Timed Flash Minimum ON Time Time Period READY Asserts when there is no fault on the controller and the tool is rea
60. both inputs and outputs Ninety nine is the maximum number of I O elements that can be assigned to each Fieldbus input or output Each I O element can have a length of to 32 bits You must keep track of the lengths for each I O element you assign to stay within the maximum length of the Fieldbus you are using More than one Fieldbus connection can be used at the same time For instance the Alpha controller can use the 24 VDC I O connector AND Modbus TCP on Ethernet AND DeviceNet all at the same time If more than one type of Input uses a particular element the controller responds to an input when an element is asserted on any one of those inputs It is important to understand how the Alpha controller and the internal PLC responds to the rising and falling edges of input elements 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 One type of Input does not have priority over the other The controller responds to the first change in status of an input element no matter which Fieldbus connection makes the change If more than one Fieldbus shares a particular output function that function is asserted on all shared Fieldbuses The table below lists the available input and output elements gives a brief description and indicates the configuration options for each The configuration options are an important aspect of the I O elements
61. cation will not happen Size 1 bit except on fieldbus where it can be size any size to fit the need Configuration Contact Type Normally Open N O Normally Closed N C Bit Type the number this bit will be in the binary number scheme to verify a task Mode All TASK VERIFY BITs must be the same mode no mixing of modes allowed Binary Creates a decimal number equivalent to the weighted value of this binary bit s Binary 1 Creates a number equivalent to the weighted value of this binary bit s and add the value of one 1 to that number Alpha Controller Connections 69 User Manual Inputs Description JOB VERIFY When asserted on any input type the controller verifies the selected and active job is equal BIT to this input s job Use the BIT parameter under Configuration to select the job number to verify If there is a mismatch between the active job and the selected job the tool is disabled This is one bit of a binary number created by many of these bits See TASK SELECT BIT to understand how to use bits to create binary numbers When removed verification will not happen Size 1 bit except on fieldbus where it can be any size to fit the need Configuration Contact Type Normally Open N O Normally Closed N C Bit Type the number this bit to be in the binary number scheme to verify a job Mode All JOB VERIFY BITs must be the same mode no mixing of modes allowed Binary Creates a decima
62. d This is essentially a placeholder For fieldbus the length of this input function may be set to any size that meets the need IN CYCLE Asserts during the fastening cycle when the achieved torque value exceeds the Threshold Torque value Resets when the fastening cycle has ended Size 1 bit Configuration Contact Type Normally Open N O Normally Closed N C Output Type Normal Timed Flash Minimum ON Time Time Period JOB Asserts when a job is selected by any means Resets when the active job is complete SELECTED Size 1 bit Configuration Contact Type Normally Open N O Normally Closed N C Job Type the job number that when selected asserts this output Output Type Normal Timed Flash Minimum ON Time Time Period DISASSEMBLY Asserts when the tool is running in Reverse and the achieved torque value exceeds the DETECTED Threshold Torque value through some rotation Resets when the tool is stopped Size 1 bit Configuration Contact Type Normally Open N O Normally Closed N C Output Type Normal Timed Flash Minimum ON Time Time Period 72 Alpha Controller Outputs Description TOOL Asserts anytime the tool is energized Resets when the tool is commanded to stop RUNNING Size 1 bit Configuration Contact Type Normally Open N O Normally Closed N C Output Type Normal Timed Flash Minimum ON Time Time Period CYCLE OK Asserts at the end of a fas
63. d in the destination Embedded PLC 83 User Manual Instructions Description ADD Use the ADD instruction to add one value source A to another value source B and place the result in the destination AEX String Extract Use the AEX instruction to create a new string by taking a portion of an existing string and moving it to the new string Enter the following parameters when programming this instruction Source is the existing string The source value is not affected by this instruction Index is the starting position from 1 to 82 of the string to extract an index of 1 indicates the left most character of the string G Number is the number of characters from 1 to 82 to extract startis at the indexed position If the index plus the number is greater than the total characters in the source string the destination string will be the characters from the index to the end of the source string Destination is the string element ST14 X where the extracted string is stored AIC Integer to String Converts an integer value between 32 768 and 32 767 to an ASCII string AND Performs a bit by bit logical AND The operation is performed using the value at source A and the value at source B The result is stored in the destination ARD ASCII read characters Performs a read from a source channel and moves the value into a destination string Provides a Result integer for the status of the read Chann
64. diting press the INSERT interactive menu button to add the device to the Scanlist 2 Insert from EDS Connect a USB memory stick to the USB port to import an EDS file D ORT _EDS S55 Use the up down arrow keys to select the correct file then press the IMPORT interactive menu button Gs INFORT DEVICE Enter new device MAC Id Si IMPORT E ANCE Enter a device node number then press the IMPORT interactive menu button to add the device to the Scanlist D EN ICE IMPORT Device 2 1s imported A message appears indicating the device has been added to the Scanlist Press the OK interactive menu button to return to the Scanlist 3 Delete Deletes the selected device from the Scanlist HN asia got DELETE DEVICE Are you sure top ss delete device 2 Press the YES interactive menu button to delete the device from the Scanlist Press the NO interactive menu button to keep the device on the Scanlist Press the CANCEL interactive menu button to go back to the Scanlist 4 Edit Opens an edit window for the selected device See 2 9 2 7 SCANNER tab and Device Details for an explanation of terms in the Edit window When finished editing press the APPLY interactive menu button to save the edits and return to the Scanlist Press the BACK interactive menu button to return to the SCANNER tab Reeg 23 5 6 LE G H Press the ONLINE interactive menu button to perform a network scan or monitor
65. dy to run This output resets when the tool is disabled and the J icon is on the screen See section 2 4 6 Size 1 bit Configuration Contact Type Normally Open N O Normally Closed N C Output Type Normal Timed Flash Minimum ON Time Time Period PM Asserts when the Preventive Maintenance Count in the tool s memory has exceeded the Preventive Maintenance Threshold Resets when the Preventive Maintenance Count is reset to zero Size 1 bit Configuration Contact Type Normally Open N O Normally Closed N C Output Type Normal Timed Flash Minimum ON Time Time Period TORQUE This output is the peak achieved torque value during the fastening cycle from the Audit step It asserts when the fastening cycle is complete before the IN CYCLE bit resets The value resets to zero 0 when the tool is commanded to run again Size Can be any size from 0 to 32 bytes depending on Data Type Data Type Float Int8 Int16 Int32 Fixed Point String Step Audit Audit 1 Audit 2 ANGLE This output is the peak achieved angle value during the fastening cycle from the Audit step It asserts when the fastening cycle is complete before the IN CYCLE bit resets The value resets to zero 0 when the tool is commanded to run again Size Can be any size from 0 to 32 bytes depending on Data Type Data Type Float Int8 Int16 Int32 Fixed Point String Step Audit Audit 1 Audit 2 76 Alpha Controller
66. e file onto a USB memory stick Install the USB memory stick to the USB port on the bottom of the Alpha controller Scroll to the binary file provided and then press the UPDATE interactive menu button Alpha Controller Controller Tab Screens Options Screen EE Loa TE JUpdate Controller Firmware RABE EE t Up One Level D stanley_alpha 3 4 14 bin EAT E N 4 Update firmware will take effect after nextreboot Z r g Failed to update controller E STEFE Y DS E NGRE Z Invalid firmware file A new screen appears to confirm the action Press YES to continue with the update Press NO to cancel the update A progress bar on the bottom of the screen indicates the file transfer status from the USB memory stick to the Alpha controller memory When the file transfer is complete a new window appears indicating it is time to reboot the controller to complete the upgrade Turn off the controller wait 20 seconds then turn on the controller After the controller starts it checks that the file is complete and written to permanent memory The controller auto reboots When the run screen appears the controller is updated and ready During the file transfer process a file error can cause the transfer to abort and this message appears Contact your Stanley representative if this happens This screen appears if the update file is for a different controller Contact your Stanley representativ
67. e if this happens 2 9 6 Analyze Analyze Screens Options Screen Analyze displays tool and controller diagnostic information traces and I O status ANALYZE Press the ANALYZE button to perform diagnostics on the controller tool or I O look at fastening cycle traces perform Statistical Process Control analysis or to download fastening cycle or fault data Tool Tab This tab shows live status It updates every millisecond Use this tab to perform controller or tool diagnostics during troubleshooting operations Transducer Health The thickness of the vertical line within the horizontal bar indicates transducer health a thicker line means less healthy Once the line reaches the tick mark on Programming 43 User Manual Analyze Screens Options Screen either side of center 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 7 Faults for limits ES Controller DC Bus voltage The bus should always be approximately 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 This interacts with the Temperature Limit parameter See section 2
68. e on the DeviceNet network Name Identifies the device Connection Type The type of DeviceNet communications used with the device Produce Size This identifies the size in bytes of the device s output Consumed Size This identifies the size in bytes of the device s input Vendor Id This shows the unique DeviceNet OEM identifying number Product type The number indicating the type of device from the specified vendor Product code The number indicating the code of the product type of the specified vendor Major rev This identifies the major revision level for the device s product code Minor rev This identifies the minor revision level of the device s product code Press the BACK interactive menu button to return to the Scanlist TIN HIE DE HE ER H Press the MANAGE interactive menu button to manage the devices in the Scanlist Use the up down arrows to select the option desired then press the OK interactive menu button or press the corresponding number on the keypad Programming 29 User Manual Communication Screens Options Screen 1 Insert Opens a device edit window to define the device before adding it to the Scanlist ET DEN ee E Connection type Produced size Consumed size A value of 0 in any field is valid and can prevent conflicts with slave devices See 2 9 2 7 SCANNER tab and Device Details for an explanation of terms When finished e
69. e 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 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 96 Alpha Controller 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 th
70. e 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 and 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 Cus
71. e parameter value Notice that the periods match the length of the expected PART ID Auto Sequence Tasks When set to Yes the controller automatically sequences from Task 1 to the final Task in the Job after the fastener count in each Task is complete No requires an input to select the Task to run within a Job Auto Reset Job Yes resets the Job automatically after the Batch Count has been met The tool will not disable with Error Proofing enabled No requires an Input or Trigger to Reset the Job The tool disables with Error Proofing enabled If Error Proofing is disabled the tool is always enabled but will not count higher than the Batch Count 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 Yes also enables more parameters that will dynamically appear on the screen see below No keeps the tool enabled even after the Job s target count is met The count will not increase beyond the target value No will not cause new parameters to appear nable Error Proofing Disable Disassembly Reverse function on one of the following events On Cycle OK Yes does not allow the use of Disassembly mode after each OK Programming 19 User Manual Job Tab Screens Options Screens fastening cycle The tool can
72. e resets to zero 0 when the tool is commanded to run again Size Can be any size from 0 to 32 bytes depending on Data Type Data Type Float Int8 Int16 Int32 Fixed Point String 78 Alpha Controller Outputs Description RUNDOWN MONTH This is the month value of the last fastening cycle date It asserts when the fastening cycle is complete before the IN CYCLE bit resets The value resets to zero 0 when the tool is commanded to run again Size Can be any size from 0 to 32 bytes depending on Data Type Data Type Float Int8 Int16 Int32 Fixed Point String RUNDOWN DAY This is the day value of the last fastening cycle date It asserts when the fastening cycle is complete before the IN CYCLE bit resets The value resets to zero 0 when the tool is commanded to run again Size Can be any size from 0 to 32 bytes depending on Data Type Data Type Float Int8 Int16 Int32 Fixed Point String RUNDOWN HOUR This is the hour value of the last fastening cycle time It asserts when the fastening cycle is complete before the IN CYCLE bit resets The value resets to zero 0 when the tool is commanded to run again Size Can be any size from 0 to 32 bytes depending on Data Type Data Type Float Int8 Int16 Int32 Fixed Point String RUNDOWN MINUTE This is the minute value of the last fastening cycle time It asserts when the fastening cycle is complete before the IN CYCLE bit resets Th
73. e section 2 9 1 3 Setup Manage Button Job for further information Press the TASK interactive menu button to setup the parameters of the Tasks and Step s inside the selected Job See section 2 9 1 4 Setup Task Button for further information 2 9 1 3 Setup Manage Button Job Manage Button Job Screens Options Screen Manage enables Jobs and their settings to be added deleted and or copied to the clipboard and pasted Add Adds a Job to the controller If a tool is attached the Wizard begins for easy setup of Job parameters If a tool is not attached the Jobs tab appears for manual parameter setup elected Tab Before Selected Tab Jobs do not have to be added sequentially A Job can be added before or after the one that is selected Jobs renumber automatically after being added Make a selection and press OK to add a Job or CANCEL to not add a Job Delete Deletes the selected Job from the controller Jobs cannot be recovered once deleted Copy Copies the selected Job and its associated Tasks and Steps to the Clipboard Paste Overwrites the selected Job with the values residing in the Clipboard To move a Job first create a new one where it is needed next copy the Job to be moved then paste it into the new one created and finally delete the original Press the EXIT interactive menu button to save changes and return to the Run screen See 20 Alpha Controller section 2 9 1
74. e system runs with forces applied until they are removed or until the controller s next power cycle 48 Alpha Controller QPM DC Electric Tools This chapter promotes proper and safe use and gives guidance to owners employers supervisors and others responsible for training and safe use by operators DC electric tools from STANLEY ASSEMBLY TECHNOLOGIES are intended for use in industrial threaded fastening or precision position and or adjustment applications only Some instructions may not apply to all tools Please contact your Stanley Sales Engineer for information or assistance on Stanley training for assembly tool operation 3 1 Tool Specifications Operating Conditions Temperature 32 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 L 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 37
75. e to the next tab or press EXIT to save the changes and return to the Run screen See section 2 9 1 7 Setup Exit Programming 31 User Manual Communication Screens Options Screen 2 9 2 8 DNET tab This tab appears for Alpha controllers with the DeviceNet slave port option This tab sets communications parameters for the Alpha controller slave on a DeviceNet network Baudrate Sets the slave Alpha controller s communication rate on the DeviceNet network Choices include 125 Kbits s 250 Kbits s and 500 Kbits s Mac Id Sets the slave Alpha controller s node number on the DeviceNet network Endian Provides the correct byte order of DATA words only not I O or strings when communicating to other devices Choose Little for other PLCs and Intel devices Choose Big for Motorola devices Press the EDS interactive menu button to create an EDS file equivalent to DeviceNet T O map created using Embedded Toolbox Connect a USB memory stick to the USB port on the bottom of the Alpha controller Use the up down arrows and or the numeric keypad to type a file name Pressing the OK interactive menu button saves the file to the USB memory stick Use this controller generated EDS file in the PLC connected to the Alpha controller If the DeviceNet I O map is changed a new EDS file must be generated Use the right arrow to move to the next tab or press EXIT to save the changes and return to the Run screen
76. e value resets to zero 0 when the tool is commanded to run again Size Can be any size from 0 to 32 bytes depending on Data Type Data Type Float Int8 Int16 Int32 Fixed Point String RUNDOWN SECOND This is the second value of the last fastening cycle time It asserts when the fastening cycle is complete before the IN CYCLE bit resets The value resets to zero 0 when the tool is commanded to run again Size Can be any size from 0 to 32 bytes depending on Data Type Data Type Float Int8 Int16 Int32 Fixed Point String RUNDOWN JOB This value indicates the job in which the last fastening cycle was performed It asserts when the fastening cycle is complete before the IN CYCLE bit resets The value resets to zero 0 when the tool is commanded to run again Size Can be any size from 0 to 32 bytes depending on Data Type Data Type Float Int8 Int16 Int32 Fixed Point String RUNDOWN TASK This value indicates the task in which the last fastening cycle was performed It asserts when the fastening cycle is complete after the IN CYCLE bit resets The value resets to zero 0 when the tool is commanded to run again Size Can be any size from 0 to 32 bytes depending on Data Type Data Type Float Int8 Int16 Int32 Fixed Point String PART ID This value is equal to and changes as the PART ID input changes Size Can be any size from 0 to 32 bytes depending on Data Type Data Type Float Int8 Int1
77. eer 25 2 9 2 Setup Menu 2 CGommuntceatons 25 ZO le Ke E TAD EE 26 SE Eeer 26 EN E EE 27 29 24 OPEN tab EN 27 2 9 2 5 TOOLSNET tab EE 27 2 92 06 KML er 27 2 9 2 7 SCANNER tab ict dcoitocsiatnsadcaveweuscat ten cdavasanadvonaces 27 2 9 2 8 DNET teste 32 Selen 32 2 9 3 Setup Menu 3 Ober 33 29 8 17 General VAD E 33 293 2 Us rs E ane E eoad aa anaa Een Seaain aiaei 34 Alpha Controller 293 3 OUTPUTS Tab inthis tet eebe enee etc ets 36 29 34 INPUTS LEE 36 2 9 3 5 TRIGGERS Tab EE 37 2 93 0 LIGHTS e EEN 37 Zoe ENEE ee 37 See TOOL Tabi yeni s 37 293 9 C STATS e ea E a EA EAA 39 Zoe VO E E GE 39 2 9 3 11 REGIONAL Tab NEE 39 2 9 4 Setup Menu 4 Restore Factory Deiaults 40 BIOS 2OCIVICC ee 40 Bese gt WOON Eeer 40 29 5 1T GADOUR E 41 2 9 5 1 2 Counters Tab EE 41 E CAE Ta EE 41 Se EE eege 42 eG Be Analyze besa oes goes EE EE 43 QPM DC lee deeg 49 3 1 Tool Specifications EE 49 3 2 Operator EEN 50 3 2 1 Repetitive Motion ites ecetecptvenrysctesctnnstvuatweiiveatenctewciwenteuts 50 3 2 2 Hearing Protection s e ccescierce coes es ie ee hoe ie eee 50 3 230 MIDTANOM sieer n ie 51 3 2 4 Breathing Protection cccccceceeeeeeeeeeeeteeeeeeeeeeeeeeees 51 3 3 Tool INSTANT Le EE 51 3 3 1 Sockets and ACAplels sis 2c cicarscewcstiiarecctscarecaiwiarneevents 51 3 3 2 Suspension Devices AAA 52 3 3 3 Cable Installation cceeceeeceeeeeeeeeeeeeeeneeeeeeeeeeeeeeees 52 34 QPM Eelere ee 52 3 4 1 Displa
78. el 0 Serial port Channel 1 Screen Channel 2 Ethernet port 8786 ASC String Search Use the ASC instruction to search an existing string for an occurrence of the source string Enter the following parameters when programming this instruction Source is the string you want to find when examining the search string Index is the starting position from 1 to 82 of the source string An index of 1 indicates the left most character of the string Search is the string you want to examine Result is an integer where the processor stores the position of the search string where the source string begins If no match is found result is set equal to zero ASR ASCII String Compare Use the ASR instruction to compare two ASCII strings The system looks for a match in length and upper lower case characters If two strings are identical the rung is true if there are any differences the rung is false AWT ASCII Write Writes a source string to the designated channel Provides a Result integer for the status of the write Channel 0 Serial port Channel 1 Screen limited to 3 lines and 99 characters 33 characters per line Use n to create a new line Channel 2 Ethernet port 8786 BND Branch End Marks the end of branches on a rung BST Branch Start Marks the beginning of a new branch on a rung CLR Clear Sets the value of a destination word to zero 84 Alpha Controller Instructions D
79. electrical noise such as arc welding equipment Alpha Controller 6 152 mm 4 102 mm 0 375 10 mm 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 holes in different plinths is 6 152 4 mm Getting Started 5 User Manual 1 Install the Alpha Controller either directly to the wall or to a plinth 2 Fasteners through four mounting holes secure plinths to a wall or other surface Plinths can be connected using 10 32 threaded holes on the bottom and left side and through holes on the top and right side 3 Make sure the bolts of the barrel latches 5 on the plinth are retracted Place the lower flange of the Alpha 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 Alpha Controlle
80. en This area sets the parameters for all other Alpha features including system level users passwords I O and tool functions Each category is represented by its own tab Use the left right arrows to select the tabs category for modification Users must have ADMINISTRATOR or SETUP access level to modify values in this area Use the up down arrows to select the option desired or press the corresponding number on the keypad 2 9 3 1 General Tab RT kd PART ID Name A name distinguishes this controller COUHT UP from other Alpha controllers on the same plant floor Keypad Mode During normal operation the keypad on the face of the controller can be used to select Jobs Job Select or Tasks Task Select It can also write a PART ID for storing with fastening cycle data or these functions can be disabled DISABLED TASK SELECT JOB SELECT FART ID Count Mode Choose Count Up to indicate the fasteners that have been completed OK Choose Count Down to indicate the number of fasteners yet to be completed Stop Abort within Limits Choose OK to mark the fastening cycle as OK even if the fastening cycle is stopped or aborted while the achieved torque and angle are within limits Choose NOK to mark the fastening cycle as NOK when the fastening cycle is stopped or aborted and the Programming 33 User Manual Other Screens Options Screen achieved torque and angle values are within limits When
81. er list Export To backup Users connect a USB memory stick to the USB port name the file then press SAVE Press OK to save Use the right arrow to move to the next tab or press EXIT to save the changes and return to the Run screen See section 2 9 1 7 Setup Exit Programming 35 Other Screens User Manual Options Screen 2 9 3 3 OUTPUTS Tab The 24 VDC Connector has pins C through K designated as Outputs from the controller The pin assignments are selectable on this tab Use the up down arrows to select the pin to assign then press the Toggle button A list of available output elements displays See section 4 2 2 Output Descriptions for the complete list and descriptions Highlight element to assign to the selected pin and press the Toggle button An Output element can be assigned to more than one pin The selected Output element must then be configured See section 4 2 Assignable Input and Output Elements for configuration options and descriptions Press CONFIG interactive menu button to configure the selected output element After modifying press BACK Contact Type Bit Mode Use the right arrow to move to the next tab or press EXIT to save the changes and return to the Run screen See section 2 9 1 7 Setup Exit ZC 2 9 3 4 INPUTS Tab The 24 VDC Connector has pins L through U designated as Inputs to the controller The pin assignments are selectable
82. erior 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 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 whether the tool is armed on or not armed off and tool rotation direction disassembly 1 or assembly 2 A single multiple function button 5 can change tool direction and or parameter sets When the button is used to select the Job one of two orange indicators 4 or 6 illuminates to show the active Job EA tools have four sets of lights 3 and 7 and an LED 8 indicates when the tightening cycle count exceeds the PM limit e Si Si e f Display 7 Display and MFB for E02P to E34P pistol Models 6 5 Display and MFB for E23L to E55L lever Models 8 Display for EA23L to EA34L lever Models 52 Alpha Controller 3 4 2 MFB Mode The MFB Mode configures the multiple function button for ha
83. escription COP Copy Copies blocks of data from one location to another Source is the address of the file to copy Destination is the starting address where the instruction stores the copy Length is the number of elements in the file to copy CTD Count Down Counts false to true rung transitions When rung conditions for a CTD instruction have made a false to true transition the accumulated value is decremented by one count provided that the rung containing the CTD instruction is evaluated between these transitions The accumulated counts are retained when the rung conditions again becomes false The accumulated count is retained until cleared by a reset RES instruction that has the same address as the counter reset This Bit Is Set When And Remains Set Until One of the Following Count Down Accumulated value wraps around A RES instruction having the same address as Underflow Bit OV to 32 768 from 32 767 the CTD instruction is executed OR the count Bit 11 is incremented greater than or equal to 32 767 with a CTU instruction Done Bit DN Bit 13 Accumulated value is equal to or The accumulated value becomes less than the greater than the preset value preset value Count Down Enable rung conditions are true Rung conditions go false or a RES instruction Bit CU Bit 14 having the same address as the CTD instruction is enabled CTU Count Up Counts false to true rung transitions When rung condi
84. esets when the Multi function Button is pressed again Size 1 bit Configuration Contact Type Normally Open N O Normally Closed N C Output Type Normal Timed Flash Minimum ON Time Time Period SNUG Asserts at the end of a fastening cycle if the achieved torque value exceeds the Snug ACHIEVED Torque value during the fastening cycle Resets when the tool is commanded to run again Can also be reset with the RESET RESULTS STATUS input Size 1 bit Configuration Contact Type Normally Open N O Normally Closed N C Step Audit Audit 1 Audut 2 Output Type Normal Timed Flash Minimum ON Time Time Period Alpha Controller Connections 77 User Manual Outputs Description CYCLE STOP Asserts when the tool shuts off due to a loss of Start signal or the operator released the trigger before the target was achieved Resets when the tool is commanded to run again Can also be reset with the RESET RESULTS STATUS input Size 1 bit Configuration Contact Type Normally Open N O Normally Closed N C Output Type Normal Timed Flash Minimum ON Time Time Period PART ID This output works in conjunction with PART ID and PART ID TRIGGER inputs Read CHANGED the PART ID input section for an understanding of this output element Size 1 bit Configuration Contact Type Normally Open N O Normally Closed N C Output Type Normal Timed Flash Minimum ON Time Time Period STEP B
85. estamp reply 21 FTP Listen TCP IP User Password required 23 TELNET Listen transmit TCP IP Fastening cycle data printed after each fastening cycle no login response 80 HTTP Listen transmit TCP IP Browser access to the embedded web server for configuration and analysis browser can use port proxy 502 ModbusTCP Listen transmit TCP IP ModbusTCP I O traffic 2000 ETB Listen TCP IP Parameter server for Embedded Toolbox 2222 EthernetIP I O Listen TCP IP EthernetIP I O traffic 3414 Stanley Listen transmit TCP IP Link between Stanley devices 4545 OPEN Listen transmit TCP IP OPEN protocol traffic port is assignable by end user 4700 XML Listen TCP IP XML commands to controller Command 4710 XML Result Transmit TCP IP XML response from controller 6547 Toolsnet Listen Transmit TCP IP Toolsnet protocol traffic port is assignable by end user 8786 PLC Listen Transmit TCP IP ARD AWT PLC read and write 44818 EthernetIP Listen TCP IP EthernetIP messaging traffic Messaging The Alpha controller listens on the ports specified but transmits on any available port to the port specified of the target computer Alpha Controller Model QA1001 _D_ Slave DeviceNet Connector Alpha controllers can have a single Mini DeviceNet port for connecting the Alpha Controller to a master controller such as a PLC 4 1 5 Pin Slave 1 Drain 2 V 3 V 4 CAN H 5 CAN L Alph
86. event occurs this option illuminates the red and yellow LEDs on the tool and controller Use the right arrow to move to the next tab or press EXIT to save the changes and return to the Run screen See section 2 9 1 7 Setup Exit 2 9 3 2 Users Tab To add a user press the MANAGE interactive menu button A maximum of eight users with unique passwords can be added Passwords can contain any character symbol or number combination maximum length of 16 If users are assigned one must be an Administrator If the lock icon appears the controller is password protected The controller automatically re locks the system 15 minutes after the last keypad input Adding users is a three step process first add user by choosing option 1 Add E EE DEE d Delete Chanae Password Change Access Imrort 2 3 4 D 6 Export Name user and press OK If this is the first time adding a password leave the Old password blank Otherwise key the old password arrow down and create a New password Verify the password by typing it a second time Press OK Third change the access level of the new user press MANAGE and select option 4 Change Access One user must be an Administrator Administrator rights give a user full access to the controller This enables all privileges including restoring factory defaults and adding users 34 Alpha Controller Other Screens Options Screen _ SS ACCES S
87. fied under this tab are saved to the tool not the controller Users must have TOOL or ADMINISTRATOR access level to modify these values 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 Identifies the threshold in degrees Celsius for tool shut off This is caused by excessive duty cycle on the tool Torsion Factor See Appendix B Torsion Compensation for an explanation of this parameter and how to determine a correct value Otherwise use the default zero Requires Arming Forces the Tap Action on the MFB to Arm See section 3 4 2 MFB Mode Tubenut tools require arming as a factory setting Dog Torque Sets the torque level at which the tubenut stops when it returns home 38 Alpha Controller Other Screens Options Screen Home Speed Sets the speed of the tubenut tool when it returns home Use the right arrow to move to the next tab or press EXIT to save the changes and return to the Run screen See section 2 9 1 7 Setup Exit 2 9 3 9 STATS tab Sets values required to calculate the statistics on the stored fastening cycle data Population Sets the number of fastening cycles included in statistical analysis Subgroup Size Sets the size of the subgroups for the population Use the right arrow to m
88. for serial connection to a controller e Q0001 Kappa Controller v2 0 or above e Javascript enabled browser and Adobe Flash Player described above The Controller Gateway is a Windows based software program that provides a web based interface to an Alpha controller connected 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 the Controller Gateway icon displays its menu From the menu select the Auto Connect option Note that Auto Connect is 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 looks port by port for a compatible Stanley controller connection When one is found the browser redirects to the controller s main menu From the
89. forward direction after the controller detects a fastener has been removed 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 Serial Number Torque Cal calibration factor Angle Cal calibration factor 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 Trip Counter Records the number of tightening cycles completed since the last reset e PM Counter Records the number of tightening cycles completed since the last 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 power up QPM DC Electric Tools 53 o gt User Manual 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 Be alert
90. from the plant floor equipment The Alpha controller supports the XML PFCS TOOLSNET OPEN and FORD version of OPEN protocols For those that haven t switch to the more robust means of collecting data the Alpha controller supports the PFCS OPEN and Toyota PI protocols over a serial connection Alpha Controller 2 5 QA Alpha Controller Navigation and Programming The Alpha controller s three navigation and input areas facilitate menu navigation selection and data input Menu buttons e Atrows and Toggle button e 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 Task selection when enabled The five LEDs 5 specify Red indicates high torque angle Green indicates an OK fastening cycle Yellow indicates low torque angle Orange indicates preventive maintenance is due on the tool and Blue indicates when during the fastening cycle ATC is active 2 6 Display 2 6 1 Scroll Bar A scroll bar appears when more items are available than space within the display allows T
91. g 2 9 1 1 Wizard Screens Wizard Screens Options Screens The Wizard presents programming parameters and gives a list of strategy controls JIE 5j 8 HE Strategy Choose the strategy required for the maa ei t hea Audit step of the job and task being Units programmed Thread Direction TORQUE TC AM Torque Control with Angle Monitor The controller shuts off the tool when the tool reaches the target torque value The controller also Li monitors angle which can indicate changes in joint rate Audit torque and angle results must fall within their specified limits for the fastening cycle to be acceptable ANGLE AC TM Angle Control with Torque Monitor The controller shuts off the tool when the tool reaches the target angle value after a selected snug torque value occurs The controller also monitors torque The final torque and angle readings must fall within their specified limits for the fastening cycle to be acceptable TORQUE amp ANGLE Angle Control and Torque Control This strategy enables precision control for both torque and angle on critical joints The controller shuts off the tool when the tool reaches both a target torque value and a target angle value after a selected snug torque value occurs The final torque and angle results must fall within their specified limits for the fastening cycle to be acceptable The controller also shuts off the tool or bails out of the fastening cycle when
92. greater than 0 Power The maximum power available to the tool to perform the tightening cycle required for this step Units are percent of maximum rated torque of the tool 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 the tightening cycle during this step Delay Between Steps The time the tool delays before proceeding with the next step in the Task Entered in seconds Accumulate Angle Allows angle to be accumulated between steps in multiple step strategies Yes adds the active step s angle to the value achieved from the previous step No turns this function off When finished modifying the tool strategy step s press EXIT save the changes and return to the Run screen See section 2 9 1 7 Setup Exit 24 Alpha Controller 2 9 1 6 Setup Manage Button Step Manage Button Step Screens Options Screen Manage enables step settings to be added deleted and or copied to the clipboard and pasted 2 5 H RER Add Allows the addition of more steps Selected ected Steps do not have to be added sequentially A Step can be added before or after the one that is selected Steps renumber automatica
93. guration Options TORQUE OK Fastening cycle Torque was within limits N O N C Type Time Step TORQUE HIGH Fastening cycle Torque exceeded High limit N O N C Type Time Step TORQUE LOW Fastening cycle Torque under Low limit N O N C Type Time Step ANGLE OK Fastening cycle Angle was within limits N O N C Type Time Step ANGLE HIGH Fastening cycle Angle exceeded High limit N O N C Type Time Step ANGLE LOW Fastening cycle Angle under Low limit N O N C Type Time Step CYCLE ABORTED The fastening cycle was aborted stopped N O N C Type Time STOPPED A STOP input is asserted N O N C Type Time FAULTED A fault condition is active N O N C Type Time READY The tool is ready to run N O N C Type Time PM The tool requires service N O N C Type Time TORQUE Torque result value Format Step ANGLE Angle result value Format Step FAULT CODE Fault code value Format PARAMETER Parameter number Format Step START TRIGGER Shows the state of the tool trigger N O N C Type Time MFB Shows the state of the multifunction button N O N C Type Time SNUG ACHIEVED Is set when Snug torque exceeded N O N C Type Time CYCLE STOPPPED Shut off code is STOP N O N C Time PART ID CHANGED Controller has received a new PART ID N O N C Type Time STEP BIT E EES N O N C Bit Mode SYNC OUT Alpha is finished with current step N O N C Type Time BOLT COUNT Active Accumulated Bolt Count Format RUNDOWN YEAR Year of last fasteni
94. ha Controller Connections 57 User Manual 4 1 3 Alpha Controller Serial Connector Alpha controllers have two male DB 9 connectors The setup is 9600 baud rate 8 data bits No Parity and 1 Stop bit and is not programmable The connection between the computer and the controller is a simple null modem cable The one that is labeled COM PORT 1 has the intended purpose of connecting a laptop computer for access to Embedded Toolbox software Other communication functions can be selected for the serial port besides Embedded Toolbox Those choices are Barcode Printer Barcode or Printer o o DB 9 Connector Pins Pin Function Pin Function Pin Function Carrier Detect 4 Data Terminal Ready 7 Request to Send 2 Receive Data 5 Signal Ground 8 Clear to Send Transmit Data 6 Data Set Ready 9 Ring Indicator A second DB 9 connector COM PORT 2 is available if needed It also has options for different communication functions The list includes e Barcode Printer This reads a barcode scanner and prints the fastening cycles after they occur see string below e Barcode This only reads a barcode scanner e Printer This only prints after a fastening cycle occurs see string below e PFCS Use this to connect to a Chrysler PFS system e Toyota Use this to connect to a Toyota PI box e Open Use this to connect to an Open protocol serial network S01 JB01 4 1 A 126 2 A A 06 09 2008 10 20 19 7 Io bot to
95. he IP Address of the PFCS server on the network Port Type the port number for this Alpha controller to communicate the PFCS protocol Time Out If this is the Master Alpha in a Two Spindle setup this sets the time the master Alpha controller waits after its fastening cycle finishes to receive the fastening cycle results from the slave Alpha controller before sending both sets data to the network server If it does not receive the slave s fastening results within this time it sends a blank record for the slave Use the right arrow to move to the next tab or press EXIT to save the changes and return to the Run screen See section 2 9 1 7 Setup Exit HIE SIS HE H 2 9 2 4 OPEN tab The plant s IT department must provide these values to allow the Alpha controller to communicate on the OPEN protocol network Port Type the port number for this Alpha controller to communicate the OPEN protocol Cell Type the cell number where this Alpha controller resides Buffer While Off Line Yes creates a buffer of 100 rundowns when the server connection is lost Upon reconnection the buffered rundowns transmit to the server No does not buffer any rundowns when the server connection is lost Send Fastener Removed Yes sends the FASTENER REMOVED message when the Alpha controller detects a tightened fastener is removed No stops the message from transmitting Number of Tries This is the number of time
96. he up arrow 1 and down arrow 3 direct scrolling The black white scroll bar 2 indicates which list items are currently displayed No scroll bar means all items are currently displayed To navigate between menu items use the up down arrows or if available use the keypad to identify the corresponding menu item number 2 6 2 Dropdown TCAMM ei A dropdown 1 arrow appears to the right of menu items with multiple choices To view choices highlight the menu item using the up down arrows then use the Toggle button to expand the dropdown Use up down arrows to scroll and the toggle or interactive menu button to select accept Programming 9 User Manual 2 6 3 Menu Tree mm GR A menu tree 1 appears beside related menu items Tabs 1 appear at the top when multiple menu selections exist E ELE BECHER To navigate between tabs use the left right arrows The active tab is white inactive tabs are grey Sa er ae 2 6 5 Character Scrollbar 1 gt DN This scrollbar enables adding a z A Z 0 9 space _ amp anda 2 gt period language and or field determines character availability The up arrow 1 3 gt B and down arrow 3 direct scrolling with the active character 2 displayed between Use the Alpha Controller s up down arrows to scroll through character choices The left arrow backspaces The right arrow moves one position to the right to input next character Push Toggle button or OK
97. hen a controller is in an unknown programmed state Requires ADMINISTRATOR privileges RESTORE Are you sure Press EXIT to save the changes and return to the Run screen See section 2 9 1 7 Setup Exit 2 9 5 Service 2 9 5 1 Tool Tool Tab Screens Options Screen The Service area presents information about the tool and controller Users must have TOOL or ADMINISTRATOR access level to modify parameters 1 Tool All tool parameters are stored in the tool memory board in the tool s handle This area reads writes values to the tool memory board not to the controller 40 Alpha Controller Tool Tab Screens Options Screen 2 9 5 1 1 About Tab This tab displays information about the tool currently attached to the controller Only the Serial value field is editable If there is no serial number enter one can only be entered one time Use the left right arrow to move to the next tab or press EXIT to save the changes and return to the Run screen See section 2 9 1 7 Setup Exit 2 9 5 1 2 Counters Tab Each of the three counters increments at the same time after an OK tightening cycle Odometer Cannot be reset Indicates the total number of OK tightening cycles the attached tool has performed over its lifetime PM Counter Causes the preventive maintenance LED to illuminate on front panel and tool when this value exceeds the
98. icable standard to the E and EA series tools It defines 60 C as the limit for thermal rise over ambient of a contactable surface e g if the ambient is 25 C the surface limit is 85 C Since the default limit is 85 C inside the tool regardless of ambient no external surface can exceed this value no matter what the ambient temperature Stanley Assembly allows the temperature limit adjustment to provide flexibility to the professional user Once a customer changes the setting from the factory default it is their responsibility to ensure the safety of the user Controller parameter settings can have a significant effect on tool operating temperatures 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 3 5 5 Setting Torque Angle and Other Operating Parameters WARNING EXCESSIVE TORQUE CONDITION To Avoid Injury e Only trained and qualified personnel should progr
99. ide basic switching control for the tool Pin descriptions are shown in the following table Pin Description PLC Address Pin Description PLC Address C Output 0 0 0 0 L Input 1 0 0 0 D Output 0 0 0 1 M Input 1 0 0 1 E Output 0 0 0 2 N Input 1 0 0 2 F Output 0 0 0 3 P Input 1 0 0 3 G Output 0 0 0 4 R Input 1 0 0 4 H Output 0 0 0 5 S Input 1 0 0 5 J Output 0 0 0 6 T Input 1 0 0 6 K Output 0 0 0 7 U Input 1 0 0 7 A 24 VDC N A Vv 24 VDC Return N A B Output Supply N A Schematics of the Inputs Outputs and other pins with cabling are shown below Alpha Controller Connections User Manual Inputs example 7T k e L L k L e e DI l o O On Q O O O O O ey E d lie detente y S CO A O08 a O O O on xa 4 N e Se D no n gt z gt gt gt v a g 2 S 2 E D N O aA E oO NY E NY NY NY VV Lu Ka EZ GE Ge eer on Ase ces EH EE EE EE EENEG E fsee l iisi mi aa er ae Ee UH 1 H H i 1 1 H H i 1 i i E D eae O BE i E EEE ease a Se i a tee eee ee 1 E E NEE NEE E HSN CR ee 4 Ee ES WEEN dE ME NEE BET EE AE E Roses see ass Ry ees EE eee 1 ere oes beets Alt ate EE eee eal eee ee tos ee i i NY d lt a ac n E SC D B E E E E E EE O 1 a gt x CH 62 Alpha
100. imit n Abr Displays the number of fastening cycles that were aborted n Stp Shows the number of fastening cycles that were stopped R Shows the subgroup range highest minus lowest value Identifies the highest value of all the fastening cycles in the population Identifies the lowest value of all the fastening cycles in the population Use the right arrow to move to the next tab or press BACK to return to the Analysis screen Capability Tab Torque d i wi ege AF This screen shows the capability statistics for ER the selected Job and Task 42 Cp Displays the capability index for a stable process op 3836 67 Cpk Displays the capability index for a ER 4948 44 stable process typically defined as the 28 90d A0 minimum of CPU or CPL CR Displays the capability ratio for a stable process and is simply the reciprocal of Cp CPL Shows the lower capability index CPU Shows the upper capability index R bar Identifies the average range of a constant size subgroup series 30 Displays the sample estimated Standard Deviation times three X bar Displays the value s average mean Use the right arrow to move to the next tab or press BACK to return to the Analysis screen Programming 45 User Manual Analyze Screens Options Screen Performance Tab 0 78 i This screen shows the performance statistics GEN for the selected Job and Task 1 29 1930
101. inary bitte and adds the value of one 1 to that number 68 Alpha Controller Inputs Description REVERSE When asserted on any input type the tool is placed in Reverse disassembly mode This does NOT run the tool in Reverse mode it changes the tool mode from Forward to Reverse If one input is required to do both functions see REVERSE START When removed from any input type the controller places the tool into Forward assembly mode Size 1 bit Configuration Contact Type Normally Open N O Normally Closed N C DISABLE When asserted on any input type the tool is disabled while this specific task is selected TASK This acts like a STOP to stop the tool during use Use the Task parameter under Configuration to select the disabled task When removed the tool will be allowed to run while this specific task is selected Size 1 bit Configuration Contact Type Normally Open N O Normally Closed N C Task Type the task number to disable when this input is asserted DISABLE When asserted on any input type the controller disables the tool while this specific job is JOB selected This acts like a STOP to stop the tool during use Use the JOB parameter under Configuration to select the job to be disabled while this input is asserted When removed the tool will be allowed to run while this specific job is selected Size 1 bit Configuration Contact Type Normally Open N O Normally Closed N
102. ing 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 o gt 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 applicable regulatory electrical codes and safety codes Limit module access to trained and qualified personnel Lock module cabinets WARNING ELECTRICAL HAZARD To Avoid Injury e 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
103. instruction moves the source value to the destination location As long as the rung remains true the instruction moves the data each scan MUL Multiply Use the MUL instruction to multiply one value source A by another source B and place the result in the destination MVM Masked Move The MVM instruction is a word instruction that moves data from a source location to a destination and allows portions of the destination data to be masked by a separate word As long as the rung remains true the instruction moves the data each scan NEG Negate Use the NEG instruction to change the sign of the source and then place it in the destination The destination contains the two s complement of the source NEQ Not Equal Use the NEQ instruction to test whether two values are not equal If source A and source B are not equal the instruction is logically true If the two values are equal the instruction is logically false NOT This instruction performs a bit by bit logical NOT The operation is performed using the value at source A The result one s complement of A is stored in the destination NXB Next Branch Marks the beginning of another branch 86 Alpha Controller Instructions Description OR This instruction performs a bit by bit logical OR The operation is performed using the value at source A and the value at source B The result is stored in the destination OSR One Shot Rising The OSR
104. is no priority each one is equal The Alpha controller switches its active Job or Task with each input change The last one to change becomes the active Job or Task Inputs Description IGNORE The input is not used This is a placeholder For fieldbus the length of this input function may be set to any size that meets the need START When asserted on any input type the tool starts and runs the currently selected job task This input is overridden by the STOP input If STOP is used and a tool restart is required remove the STOP remove the START then re assert the START If the tool is required to operate in Disassembly mode remove the START assert the REVERSE input and then re assert the START When removed from any type of Input the tool stops Even if a second START input is active the tool stops when any START is removed Size 1 bit Configuration Contact Type Normally Open N O Normally Closed N C Latch This is applicable to external inputs only This is not applicable to the trigger on the tool handle Yes Causes the START input to latch internally after a time period has elapsed The physical START input can be removed without stopping the tool The tool runs until all steps in the active task are complete or time out A TIME parameter is available to set how long the START input must be applied in seconds before the Latch becomes active No The Latch function is off SELECT JOB When asserted
105. it determines that E torque and angle cannot be reached ANGLE OR TORQUE Angle Control or Torque Control The controller shuts off the tool when the tool reaches either a target torque value or a target angle value after a selected snug torque value occurs The final torque and angle readings must fall within their specification limits for the fastening cycle to be judged acceptable Batch Count The number of bolts in a group Used with an error proofing remote input and output unit Can be set for each parameter set Acceptable values are between and 99 The default value is 1 Units Tool operating units NM Newton Meters FTLB Foot Pounds INLB Inch Pounds INOZ Inch Ounces KGM Kilogram Meters KGCM Kilogram Centimeters NCM Newton Centimeters NDM Newton Decimeters Programming 15 User Manual Wizard Screens Options Screens Thread Direction Use CW clockwise for tightening right hand fasteners Use CCW counter clockwise for tightening 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 Press the PREV interactive menu button to move back to previously programmed screens within the Wizard Press the CANCEL interactive menu button at any time to stop Wizard operation HE SIS HE
106. itions Temperature 32 to 122 F 0 to 50 C Humidity 0 to 95 non condensing 100 126 VAC 50 60 Hz 15 20A service or Power Source 207 253 VAC 50 60 Hz 10 16A service Power Consumption Stand by 0 2 A amperes Continuous 1 2 5kVA Tool Motor Power Service Rating E02 E_23 E_33 E_34 E44 E45 E55 Consumption 115 VAC 15A 15A 20A 230 VAC 10A 10A 10A 16A Continuous kVA 0 3 0 7 1 1 7 Alpha Controller OK o be 5 CE geit reit Fechanlgies T e anaes vaniam o wG SIN mb zeen WE 230VAC 50 60HZ D AMP 1 N PE REI Getting Started hy O A MAC ID XX XX XX LEE de ETHER HET La gt A WARNING T Item Functional Description 1 Red Green Yellow LEDs for Limits Evaluation 2 Display 3 Function Keys with Active Label Above 4 Cursor Keys with Center Button to Expand Lists 5 Maintenance Due and ATC Active LEDs 6 Numeric Keypad to Enter Numbers or Select Options 7 Controller Label and Serial Number 8 Power Switch 9 Power Input 10 USB Port for Data Transfer 11 Optional 24 VDC Input Output Connector 12 Tool Connector 13 Serial Connectors 14 Optional Device Net Connector Master slave 15 Optional P
107. l number equivalent to the weighted value of this binary bit s Binary 1 Creates a number equivalent to the weighted value of this binary bit s and add the value of one 1 to that number RESET When asserted on any input type the controller resets to 0 zero any fastening cycle results RESULT status output bit on the same type of I O Meaning if asserted on DeviceNet only the STATUS DeviceNet output status bits are reset Output status bits on other types of I O will remain in their original state The list of status bits that will reset are CYCLE OK CYCLE NOK TORQUE OK TORQUE HIGH TORQUE LOW ANGLE OK ANGLE HIGH ANGLE LOW CYCLE ABORTED CYCLE STOP When removed nothing happens Size 1 bit Configuration Contact Type Normally Open N O Normally Closed N C REVERSE When asserted on any input type the tool mode is switched to Reverse Disassembly AND START the tool is started This is different from the REVERSE input function in that the REVERSE input function puts the tool into Reverse mode only When removed the tool stops and switch back to Forward mode Size 1 bit Configuration Contact Type Normally Open N O Normally Closed N C DISABLE When asserted on any input type the controller prevents the tool from running It does NOT TOOL stop the tool if the tool is running but prevents it from running when the next START signal is applied The START input can come from any type of
108. 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 56 Alpha Controller Alpha Controller Connections Each controller or Alpha 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 not 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 Alpha Controller Connections 4 1 1 Alpha Controller Power Cord Alpha 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 14 2 Alpha Controller Tool Connector Alpha controllers use a single 30 pin connector to connect two types of QPM DC electric tool cables QPM E DC electric tool cables use a MIL C 38999 Series HI connector The connector is a 17 30S with the insert clocked in the normal position 30 pin Tool Connector QPM EA DC electric tools use a similar connecter except for B clocking 30 pin Tool Connector Alp
109. ller is communicating to the tool but does not recognize the model number written in the tool memory board Tool Communications The controller is not communicating to a tool Transducer Current Transducer current has fallen outside nominal values For E series Fault tools that is 15 74 mA 75 4 5 26mA For EA series tools that is 4 16 mA 75 1 to 7mA Transducer Zero Fault The transducer zero point has shifted too far for the controller to compensate These points are visible on the controller diagnostics screen under Analyze Unsupported Tool The wrong tool type has been connected to the controller The Alpha controller cannot run the tool that is connected 2 8 Messages 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 Used for Toyota PI protocol only Controller has lost communications to the PI box Count Fault Used for Toyota PI protocol only Controller and PI box have a bolt count mismatch Program Fault Used for Toyota PI protocol only More tightening cycles were performed than the PI box expected Reboot Required This message appears anytime the serial port or Ethernet parameters are changed Tool Update Failed Controller failed to update the tool configuration Failed to Access Fieldbus Hardware failure of the optional fieldbus card PLC Message A user defined message controlled by the internal
110. lly after being added Make a selection and press OK to add a Step or CANCEL to not add a Step Delete Removes the selected Step from the tool strategy Steps cannot be recovered once deleted Copy Copies the selected Step to the Clipboard Paste Overwrites the selected Step with Clipboard values The clipboard information must match the step for it to be successfully pasted To move a Step first create a new one where it is needed next copy the Step to be moved then paste it into the new one created and finally delete the original 2 9 1 7 Setup Exit Exit Screens Options Screen Programming changes are stored after exiting current menu EXIT EXIT Save changes 2 9 2 Setup Menu 2 Communications Communication Screens Options Screen This area changes the setting of the Ethernet Serial and fieldbus Communications port s located on the bottom of the Alpha Users must have COMMUNICATIONS SETUP or ADMINISTRATOR access level to modify values in this area Select Communications by pressing the SETUP interactive menu button on the Run screen Press 2 or highlight selection and press Toggle button Programming 25 Communication Screens User Manual Options Screen HIE 5 6 HE H Obtain IP From Network D Address ubnet Mask 2 9 2 1 TCP IP tab Network This information is required when connecting the Alpha controller to an Ethernet network using
111. ls to reach the Low Torque the tightening cycle is recorded as a reject for low torque the low torque light yellow illuminates and the tightening cycle is given an overall status of NOK MFP Mode Controls the operation of the multiple function panel MFP on QPM tools The choices for handheld tools are Disable Reverse Disassembly Parameter Select Arming and Reset Reject The default value is Disable PM Counter Records the number of tightening cycles completed since the last time it was reset for Planned Maintenance PM Limit When the PM Counter exceeds the PM Limit the controller provides a maintenance alert Parameter Set A Parameter Set is a collection of instructions that define how the tool should perform the tightening process It may be selected from the keypad or 24V device such as a socket tray Reject Tone Controls the tone made from the handle of handheld QPM tools for rejected tightening cycles Allows distinct tones for tools in adjacent workstations Slow Seek Slow Seek helps engage the socket or fastener at a pre selected speed torque level and angular rotation Once engaged the tightening cycle completes at a higher speed Slow Seek prevents crossthreaded fasteners and previously secured fasteners from being counted in a batch Glossary 91 User Manual Snug Torque The controller begins to monitor the tool for angle at a preselected threshold torque Any increase in
112. menu button to accept entry The following screens contain the character scrollbar option Job Name Step Name System Name General System Users 2 6 6 Run Display Icons identify events 1 see list below Displays last torque and angle readings with units when a tool is connected 2 Up down arrows next to the torque or angle value indicate the last fastening cycle NOK status whether it exceeded A or did not achieve V torque or angle limits Identifies the active Job 6 and active Task 7 Identifies Target bolt count 3 and Accumulated bolt count 4 for the active Job The side scroll bar indicates events are available in the Event Log Press the down arrow to view the events The number of fastening cycle attempts indicator is below the bolt count box The run screen displays unless other programming functions 5 are in use A Shutoff code is also displayed when applicable 8 B PRE TORQUE The run display changes to indicate the step in which the tool stopped providing it did not stop during the audit step The display background color in normal operation is white After an OK fastening cycle the display background color changes to green for two seconds then reverts back to white for the next cycle After a NOK fastening cycle the display background color changes to red for two seconds then reverts back to white for the next cycle The display background color turns red in the event of a fault see section
113. mum Use the up down arrows for letters or use the numeric keypad es rg Strategy Identifies values used to control the tool during a step and to control the step s direction Strategies include TC AM Torque Control Angle Monitor AC TM Angle Control Torque Monitor AC TC Angle Control Torque Control AC TA Angle Control Torque Average RC AM Rate Control Angle Monitor YC AM Yield Control Angle Monitor BACK OFF Reverse Angle Control Torque Control Torque Target The torque at which the controller shuts off the tool Should be greater than Low Torque and lower than High Torque High Torque The maximum peak torque for an acceptable tightening cycle required for all steps If the actual torque exceeds this limit the tightening cycle will be flagged as NOK and the RED LED on the front panel and tool illuminates Must be greater than Torque Target and less than or equal to the rated torque marked on the tool elay Between Steps An T Appears for YC AM strategy only Appears for RC AM strategy only Appears for AC TA strategy only Appears for any Angle Control strategy Low Torque The minimum peak torque for an acceptable tightening cycle If the actual torque does not reach this limit the tightening cycle is flagged as NOK and the YELLOW LED on the front panel and tool illuminates Must be less than the Torque Target Torque Bailout Determines when to stop the tool based on torque value during any A
114. n the safe and proper use of power tools Operators should report any unsafe condition Store idle tools and accessories in a safe location accessible only by trained persons Disconnect power source air electricity etc from tool prior to making adjustments changing accessories or storing Prior to operation always check and test tools and accessories for damage misalignment binding or any other condition that may affect operation Maintenance and repair should be performed by qualified personnel Do not operate tools in or near explosive environments or in the presence of flammable liquids gases dust rain or other wet conditions Keep the work area clean well lit and uncluttered Keep unauthorized personnel out of the work area DC Electric Tools 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
115. nation If the remainder is 0 5 or greater round up occurs in the destination The unrounded quotient is stored in the most significant word of the math register The remainder is placed in the least significant word of the math register END Program End Marks the end of the program EOR End of Rung Marks the end of a rung Embedded PLC 85 User Manual Instructions Description EQU Equal Use the EQU instruction to test whether two values are equal If source A and source B are equal the instruction is logically true If these values are not equal the instruction is logically false GEQ Greater than or Equal Use the GEQ instruction to test whether one value source A is greater than or equal to another source B If the value at source A is greater than or equal to the value at source B the instruction is logically true If the value at source A is less than the value at source B the instruction is logically false GRT Greater Than Use the GRT instruction to test whether one value source A is greater than another source B If the value at source A is greater than the value at source B the instruction is logically true If the value at source A is less than or equal to the value at source B the instruction is logically false LEG Less Than or Equal Use the LEQ instruction to test whether one value source A is less than or equal to another source B If the value at source A is less than or equal to
116. nd color reverts to white only when the fault is cleared 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 three phases of the motor and asserts this fault when the total current applied to the tool does not equal the total current returned from the tool All phases are turned off immediately to protect the controller from shorts at the tool end b Total Current the controller software limits the current applied to any tool based on what the tool can handle This fault is asserted if there is a short at the tool end and the total current applied is greater than allowed Alpha Controller Logic Voltage Fault The controller monitors the 5 VDC 5 VDC and 12VDC of its onboard Power Supply This fault is asserted when those voltages fall outside of nominal range Position Feedback Fault The controller is constantly monitoring the resolver zero and span points and asserts this fault if they go outside specification Transducer Span Fault This fault is asserted when the transducer zero point has shifted far enough to prevent a full scale reading from the transducer Temperature Fault This fault is asserted when the tool temperature detector has reached the temperature limit set by the Temperature Limit parameter It resets after detected temperature has dropped by 5 C Unrecognized Tool The contro
117. ndheld QPM tools The button can be configured to operate in any of the following modes Disable default The button does nothing Reverse Disassembly Pressing the button toggles between assembly and disassembly and illuminates the appropriate blue light 1 or 2 All tool status lights 3 and 7 flash when the tool is in disassembly mode Job Task Select Pressing the button toggles between Job Task 1 and Job Task 2 and illuminates the appropriate orange light 6 or 4 Arm Pressing the button arms activates the trigger but does not start the tool The blue assembly light 2 comes on to show that the tool is armed for three seconds Reset Reject This function when selected will cause the tool to disable after a NOK tightening cycle The Reject Tone when enabled will sound Pressing the button re enables the tool indicating the operator acknowledges the rejected tightening cycle and wishes to repair it Job Reset Pressing the button causes the selected Job to be reset This means that the fastener count is set to zero and the tool if disabled due to Error Proofing requirements re enables Reset and Reverse This function when selected causes the tool to disable after a NOK tightening cycle The Reject Tone when enabled will sound Pressing the button re enables the tool in the Reverse direction and indicates that the operator acknowledges the rejected tightening cycle and wishes to repair it The tool switches to the
118. ng cycle Format RUNDOWN MONTH Month of last fastening cycle Format RUNDOWN DAY Day of last fastening cycle Format RUNDOWN HOUR Hour of last fastening cycle Format E WN Minute of last fastening cycle Format fe ia Second of last fastening cycle Format RUNDOWN JOB Job of last fastening cycle Format RUNDOWN TASK Task of last fastening cycle Format PART ID Active PART ID Format CONSTANT User defined value Format RUNDOWN BOLT ae Bolt Count of last fastening Format RUNDOWN UNITS Torque Units of last fastening cycle Format RUNDOWN STATUS Overall status of last fastening cycle Format Stee ATUS Torque status of last fastening cycle Format SE ER EER Angle status of last fastening cycle Format Outputs not available on 24 VDC 66 Alpha Controller 4 2 1 Input Descriptions Each of the single bit input elements has a Configuration setting of Contact Type The Contact Type can be Normally Open N O or Normally Closed N C If an input s contact type is normally open the input is asserted when 24 VDC is applied to the 24 VDC connector input pin or when the fieldbus bit transitions from low to high If an input s contact type is normally closed the input is asserted when 24 VDC is removed from the 24 VDC connector input pin or when the fieldbus bit transitions from high to low The Input elements assert on the transition only Job or Task selection can come from multiple inputs at once including the MFB There
119. ngle Control strategy Should be equal to or above High Torque 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 Angle Target The angle at which the controller shuts off the tool Should be greater than Low Angle and lower than High Angle High Angle The maximum peak angle for an acceptable tightening cycle required for all steps If the actual angle exceeds this limit the tightening cycle will be flagged as NOK and the RED LED on the front panel and tool illuminates Must be greater than Low Angle Units are degrees of rotation Low Angle The minimum peak angle for an acceptable tightening cycle If the actual angle does not reach this limit the tightening cycle will be flagged as a NOK and the YELLOW LED on the front panel and tool illuminates Must be less than High Angle Units are degrees of rotation Angle Bailout Determines when to stop the tool on angle during any Torque Control strategy 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 cycle Programming 23 User Manual Step Tab Screens Options Screens DISABLED MANUAL ATC Disabled Does not reduce the speed of the motor Manual Reduces the tool speed to a specific
120. nsures more consistent results If selected this is the first step AFTER Start Delay and Pre Torque Options include Up Angle Target IT rzek Down Target Torque The Target Torque for this step prior to the Backoff Delay Time The time delay before the controller starts the next sequential step Triggered when the tool meets the Down Torque Target and entered in seconds Max Time The maximum time permissible to have the tool energized during this step Entered in seconds Up Angle Target The target angle for the Backoff step Pre Torque The pre torque runs the fastener to a preliminary torque level and suspends the fastening cycle for a period of time After a time delay the Audit step begins If selected this is the first step AFTER Start Delay Options include HISARO PRETORGUE Torque Target Delay Between Steps Programming 17 User Manual Wizard Screens Options Screens Torque Target The Target Torque for this step Delay Between Steps The time period to suspend the tool strategy before continuing ATC Adaptive Tightening Control This is not a strategy or a step it is an algorithm that modifies the tool s speed as the torque rises Select ATC instead of downshift as an option to increase tool capability If ATC is not selected Downshift Mode for the Audit step is disabled Backout Fastener Accomodates assembly procedures requiring partial removal of the fastener before addi
121. oducts to the original purchaser to be free from deficiencies in material or workmanship for a period of one year after the date of shipment Under this limited warranty Stanley will at its discretion repair or replace any product which upon inspection is acknowledged by Stanley to be defective This warranty shall apply to products which have been used under normal operating conditions for their intended use and shall not apply to products which have been subjected to abnormal wear and tear neglect component degradation improper handling overload abuse misuse improper maintenance use with improper accessories or where alterations have been made 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 hardwar
122. ol mode the tool will start counting angle as soon as it has six NM which might have been five or seven NM according to the external transducer which is before the joint actually starts to rotate And the external monitor will start counting angle as soon as it has six NM which is also before the joint starts to rotate This way both meters are reading angle from the same point even though the torque readings may differ slightly because of the allowable tolerances in the torque calibration Appendix B Torsion Compensation 95 User Manual 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 pr
123. ol trigger and the tool push to start switch must be activated to start the tool Lever Only the trigger on the tool starts the tool PTS Only the push to start switch on the tool starts the tool None Neither the tool trigger nor the tool push to start switch starts the tool Use the right arrow to move to the next tab or press EXIT to save the changes and return to the Run screen See section 2 9 1 7 Setup Exit 2 9 3 6 LIGHTS tab Lights 1 2 Defines whether the lights indicate a Job or Task Headlight Timer Sets the time the pistol tool headlights remain on in seconds after the trigger is pressed Enable Tool Light Timer Yes enables the Programming 37 Other Screens User Manual Options Screen timer and the light No disables the light Use the right arrow to move to the next tab or press EXIT to save the changes and return to the Run screen See section 2 9 1 7 Setup Exit 2 9 3 7 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 selected tone STOP stops playing the tone Use the right arrow to move to the next tab or press EXIT to save the changes and return to the Run screen See section 2 9 1 7 Setup Exit 2 9 3 8 TOOL Tab Values modi
124. on this tab Use the up down arrows to select the pin to assign then press the Toggle button A list of available Input elements displays See section 4 2 1 Input Descriptions for the complete list and descriptions Highlight the element to assign to the selected pin and press the Toggle button An Input element can be assigned to more than one pin The selected Input element must then be configured See section 4 2 Assignable Input and Output Elements for configuration options and descriptions Press the CONFIG interactive menu button to configure the selected Input element After modifying press BACK 36 Alpha Controller Other Screens Options Screen E CEET Contact Type Bit d Use the right arrow to move to the next tab or press EXIT to save the changes and return to the Run screen See section 2 9 1 7 Setup Exit EE ulti Fun Tap Action Hold Action EEE 2 9 3 5 TRIGGERS Tab See section 3 4 2 MFB Mode for an explanation of the options Options include Tap Action Defines the operation when the MFB on the tool is tapped pressed quickly Hold Action Defines the operation when the MFB on the tool is held for one second Start Input Defines which input starts the tool In all cases the 24 VDC Start input is always available to start the tool Any Either the tool trigger or tool push to start switch starts the tool All Requires that both the to
125. 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 3 2 1 Repetitive Motion The use of power tools may involve highly repetitive motions of the fingers hands wrists and shoulders These repetitive motions can lead to cumulative trauma disorders CTD Many personal and workplace factors can contribute to these disorders Currently available data have identified the following risk factors These risk factors are not necessarily causation factors of CTDs The mere presence of a risk factor does not necessarily mean there is excessive risk of injury Generally the greater the exposure to a single risk factor or combination of factors the greater the risk for CTDs Forceful exertions and motions Extreme postures and motions Repetitive exertions and motions Intended duration of exertion postures motions vibration and cold Insufficient rest or pauses
126. ove to the next tab or press EXIT to save the changes and return to the Run screen See section 2 9 1 7 Setup Exit 2 9 3 10 PLC Tab If a PLC logic file is running the Name and Version is identified If a PLC file is not running the Name and Version are blank Press the MANAGE interactive menu button to Import Export or Delete a PLC file Connect a USB memory stick in the USB port for Importing and Exporting Use the right arrow to move to the next tab or press EXIT to save the changes and return to the Run screen See section 2 9 1 7 Setup Exit EENEN 2 9 3 11 REGIONAL Tab Select language Enslish i Deutsch Espa ol Portusau s Use the right arrow to move to the next tab or press EXIT to save the changes and return to the Run screen See section 2 9 1 7 Setup Exit Programming 39 User Manual 2 9 4 Setup Menu 4 Restore Factory Defaults Restore Factory Defaults Screens Options Screen Use the up down arrows to select the option desired or press the corresponding number on the keypad The BACKUP interactive menu button writes the values for the entire Alpha controller to the USB memory stick The RESTORE interactive menu button reads an Alpha controller backup file on the USB memory stick and overwrites all values in the Alpha controller The DEFAULTS interactive menu button restores all values for all parameters to factory default settings This helps w
127. pen Use the XIO instruction in the ladder program to determine if a bit is off When the instruction is executed if the bit addressed is off 0 then the instruction is evaluated as true When the instruction is executed if the bit addressed is on 1 then the instruction is evaluated as false XOR Exclusive Or Performs a bit by bit logical Exclusive Or The operation is performed using the value at source A and the value at source B The result is stored in the destination 5 3 Converting the File After designing the ladder logic program using RSLogix 500 as an editor the information must then be converted to a format recognized by the Alpha First highlight all the rungs from top to bottom then select Copy from the Edit menu 88 Alpha Controller RSLogix 500 TEMPLATE RSS LAD 2 OF x SS File Edit View Search Comms Tools Window Help lej sl H 1746 1 16 1747 SDN Ni G LW 20001 APP READ 7 Paste the information into a text file by launching Notepad then selecting Paste from the Edit menu RSLogix adds characters to certain addresses which are carried over to the paste operation The Alpha controller does not support these added characters They must be removed or converted to the appropriate address before saving the file for use in the Alpha See section 5 3 1 Invalid Characters For Help press F1 Een notene STi File Edit Format View Help SOR XIC 1 0 0 0 T
128. pha controller s functions Its eight inputs and eight outputs on the optional 24 VDC connector support these functions to provide advanced plant integration by external devices such as a PLC The inputs and outputs are assignable and configurable The Alpha controller supports other bus types such as the standard EthernetIP and ModbusTCP plus optional Profibus and DeviceNet DeviceNet can be ordered as either Master or slave mode 2 2 Software Any computer with a modern web browser connected on an Ethernet network is used to view the Alpha controller s web based application server and its Embedded Toolbox screens Software is not loaded onto a computer to access the data or configure the controller The Controller Gateway connects to the Alpha via a serial connection and performs all the functions of the Embedded Toolbox This software is required to reside on the end user s computer 2 3 Embedded PLC The Alpha controller comes with a software PLC that emulates many commands and features of the Allen Bradley SLC 500 series controller Anyone with logic writing skills and the RSLogix500 program from Rockwell can program a logic file to add more versatility to the already abundant features of the Alpha controller 2 4 Networking Ethernet and the Internet Protocol using Transport Control Protocol are a powerful and robust means of moving data from one computer to another Many end users rely on it to collect as much information
129. que Monitoring strategy that rotates the fastener in the opposite direction as the Audit step is programmed The fastener threads align with the locking device threads before standard forward rotation and high speed are applied prevents cross threads If selected this will be the first step in the tool strategy Options include HIZARO HOEBBLE Angle Target The number of degrees of rotation the socket turns during this step Speed The socket speed during this step Max Torque The maximum allowed torque during this step A low value is calculated by 16 Alpha Controller Wizard Screens Options Screens the Wizard to detect cross threads Slow Seek Creates a step with an Angle Control Torque Monitoring strategy that rotates the fastener in the same direction as the Audit step is programmed The flats of the socket align with the flats on the fastener before standard forward rotation and high speed are applied Using Slow Seek as a first step also allows for cross thread detection If selected this is the first step AFTER Wobble Options include HIZARO SLOH SEER Angle Target The number of degrees of rotation the socket turns during this step Speed The socket speed during this step Max Torque The maximum allowed torque during this step A low value is calculated by the Wizard to detect cross threads Start Delay In some fastening situations the initial fastening cycle torque is as high as o
130. r higher than the high torque specification limit for the joint In some cases particularly very large tools this high initial torque is actually within the tool and not the joint In other cases such as thread rolling overcoming friction in getting the fastener started causes the high initial torque In order to compensate for this high initial torque the Start Delay control allows the controller to initially ignore torque and angle for a specified amount of time at the start of a fastening cycle Creates a step with a Torque Control Angle Monitoring strategy in the same direction as the Audit step is programmed If selected this is the first step AFTER Slow Seek Options include belay Time Max Torque Delay Time The time the step is allowed to run during which the controller ignores torque and angle Triggered from the start of the fastening cycle and entered in seconds Max Torque The maximum allowed torque during this step The Wizard uses the maximum tool torque to prevent any interference Condition Fastener Creates two steps before the Audit step The first step is a Torque Control Angle Monitoring strategy that rotates the fastener in the same direction as the Audit step is programmed This runs a fastener down to an initial torque level The second is a Backoff strategy which partially removes the fastener The purpose of this procedure is to polish the threads and reduce friction variation during the Audit step This e
131. r this DB 9 connector on the bottom of the Alpha controller COM Port 2 Choose the function for this DB 9 connector on the bottom of the Alpha controller ETB Allows the controller to communicate to the Controller Gateway software on a PC See Appendix A Embedded Toolbox Installation Printer A pre defined data string is sent to the port after each tightening cycle that exceeds the Threshold Torque See section 4 1 3 Alpha Controller Serial Connector for string definitions Barcode The port reads input from a barcode scanner and places it into the PART ID buffer Data in the PART ID buffer is added to the fastening cycle data when stored and 26 Alpha Controller Communication Screens Options Screen transmitted via a network protocol or printed Barcode Printer The port performs both functions Toyota Connects this port to the Toyota PI box PFCS Connects this port to the Chrysler network OPEN Connects this port to a network using the OPEN protocol with serial messaging PLC The internal PLC takes over communications on this port Use the right arrow to move to the next tab or press EXIT to save the changes and return to the Run screen See section 2 9 1 7 Setup Exit HIE SIS HE kHE 2 kg H 2 9 2 3 PFCS tab The plant s IT department must provide these values to allow the Alpha controller to communicate on the PFCS network Serve IP Type t
132. r to a power source 7 Connect the tool cable to the Alpha controller and press the power switch on the controller 8 The controller displays a language list at the first factory boot up Press the up down arrows to select a language then press either OK from the interactive menu button or use the Toggle button to save the selection The controller next displays the run screen and is ready for programming and operation LANGUAGE Alpha Controller 1 4 1 Alpha Controller E Stop Precaution WARNING INTEGRATED E STOP CIRCUIT NOT PRESENT To Avoid Injury When a Alpha controller connects to a tool where a fault can result in personal injury or substantial damage to property an E stop circuit is required An E stop circuit must be created in the external power supply line Getting Started 7 User Manual Programming 2 1 Theory of Operation The Alpha controller is designed as a high end full feature transducerized DC tool controller It will control any QPM E or EA model series tool It will not control EC model series tools 2 1 1 Data Storage Data associated with 10 000 fastening cycle results 10 OK traces and 10 NOK traces is stored in the Alpha controller This data can be retrieved with the Controller Gateway software or the Embedded Toolbox SPC analysis is performed by the Alpha controller on the stored data 2 1 2 Input and Output Elements Bolt Count or Error Proofing functions are an integral part of the Al
133. rofibus Connector 16 Ethernet Connector second one is optional 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 check and test tools and accessories for damage misalignment binding or any other condition that may affect operation Maintenance and repair should be performed by qualified personnel Do not operate tools in or near explosive environments or in the presence of flammable liquids gases dust rain or other wet conditions Keep the work area clean well lit and uncluttered Keep unauthorized personnel out of the work area DC Electric Tools 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 programm
134. s Input circuits conform to the IEC 61131 2 standard for PLCs LIMITS per IEC 61131 2 Raa Type Type 2 limits ate z Voltage a State 0 Transition State 1 Limit V low v llow ma Vtrans v Itrans ma V high v I high ma Max 5 30 11 30 30 30 24 volt Min 3 ND 5 2 11 6 The Alpha controller has a MIL C 26482 Series I plug connector with cable clamp and solder cup pins NOTE One I O mating connector P N 21C104800 is included with each Alpha controller Optional crimp style mating connectors crimp tools round connector to terminal strip and pig tail I O cables are also available 60 Alpha Controller Part No 19 pin 24V I O Port Included 21C104800 Mating Connector Solder pins Standard 21C104802 Mating Connector Crimp pins Optional 21C104804 Mating Connector Crimp pins crimp tool Optional 21E102202 Breakout Box for plinth mounting Optional 21C202005 I O Cable 5M Optional 21C202010 I O Cable 10M Optional 21C202020 I O Cable 20M Optional A BLACK 7 BROWN e E ORANGE YELLOW GREEN 6 BLUE f VIOLET J GRAY WHITE WHITE BLACK M WHITE BROWN WHITE RED p WHITE ORANGE 2 WHITE YELLOW WHITE GREEN z T WHITE BLUE WHITE VIOLET y WHITE GRAY 21C2020XX schematic When the Alpha controller is used with fixtured tools it must use a Remote Start Stop Reverse pendent to the controller to prov
135. s 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 and Display Dimensions Width 6 0 in 152 mm Height 14 2 in 361 mm Depth 10 3 in 262 mm Weight 17 Ib 7 7kg Operating Cond
136. s the Alpha controller sends a message to the Programming 27 User Manual Communication Screens Options Screen server when a no ACK message is received Max Connections The number of connections the Alpha controller allows the server Send Spindle Number Yes transmits the spindle number in the header of each message No does not transmit the spindle number Send supplier code Yes sends the Rev 2 ACK message No does not transmit the Rev 1 ACK message Use the right arrow to move to the next tab or press EXIT to save the changes and return to the Run screen See section 2 9 1 7 Setup Exit HIE SIS HE bet od a G H 2 9 2 5 TOOLSNET tab The plant s IT department must provide these values to allow the Alpha controller to communicate on the Toolsnet protocol network Serve IP Type the IP Address of the Toolsnet server on the network Port Type the port number for this Alpha controller to communicate the Toolsnet protocol Cell Type the cell number where this Alpha controller resides Station Type the Station number where this Alpha controller resides Use the right arrow to move to the next tab or press EXIT to save the changes and return to the Run screen See section 2 9 1 7 Setup Exit HIE SIS HE ije ee H 2 9 2 6 XML tab The plant s IT department must provide these values to allow the Alpha controller to communicate on the XML protocol network
137. series of bits to create a binary number As jobs change so will the binary number created from these bits Size 1 bit Configuration Contact Type Normally Open N O Normally Closed N C Bit Type the number this bit to be in the binary number scheme for selected jobs Mode All JOB SELECTED BITs must be the same mode modes cannot be mixed Binary Creates a decimal number equivalent to the weighted value of this binary bit s Binary 1 Creates a number equivalent to the weighted value of this binary bit s and adda the value of one 1 to that number TORQUE OK Asserts at the end of a fastening cycle when the achieved torque value is within limits for the Audit step Resets when the tool is commanded to start again Can also be reset with the RESET RESULTS STATUS input Size 1 bit Configuration Contact Type Normally Open N O Normally Closed N C Step Audit Audit 1 Audut 2 Output Type Normal Timed Flash Minimum ON Time Time Period TORQUE HIGH Asserts at the end of a fastening cycle when the achieved torque value is above the High Torque limit for the Audit step Resets when the tool is commanded to start again Can also be reset with the RESET RESULTS STATUS input Size 1 bit Configuration Contact Type Normally Open N O Normally Closed N C Step Audit Audit 1 Audut 2 Output Type Normal Timed Flash Minimum ON Time Time Period 74 Alpha Controller
138. t as ON There is a horizontal bar cursor under the active pin Use the Left Right and Up Down arrow keys to move the bar cursor The text at the screen s bottom left corner indicates the active pin s assigned element Manually control the I O by forcing pins either ON or OFF Applying force means the pin will always be in that forced state and does not toggle to the opposite state even if the system requires it to toggle This is useful for troubleshooting signals that integrate with other equipment OFF REMOVE Move the horizontal bar cursor under a pin and press the ON interactive menu button to force it on press the OFF interactive menu button again to force it off When the force is no longer required press the REMOVE button to remove the force and return the pin to system control When forcing I O changes during operation the system provides a warning first SRN ING TS Forcing may interrupt operation Continue A clear pin icon with a small F indicates the pin is forced OFF A dark pin icon with a small F indicates the pin is forced ON oo RAE To Programming 47 User Manual Analyze Screens Options Screen If a force is active when the EXIT button is pressed a prompt appears REMOVE Remove Forces Choose the YES interactive menu button to remove the force s and return to the run screen Choosing the NO interactive menu button does NOT remove the force s it returns to the run screen Th
139. ted to ST14 3 6 in the Notepad file DATA 5 refers to word six in the string The Alpha controller must be given the word number not the DATA X number The X value in DATA X is always one less than the word number referenced in the string RSLogix can also substitute one address for a value When this happens it puts a pound sign in front of the address The Alpha controller does not support this pound sign Find another way to program without using substitutions 5 3 2 Predefining String or Integer Files To use predefined strings or integers type the string or integer file address and its value before the logic in the Notepad file There must be a space between the address and the value For Strings the value must be encapsulated within double quotes There must be a space after the string or integer value and before the first SOR command P writetoscreen xml Notepad loj x File Edit Format View Help lt controller gt lt plc gt lt param id 700 OR XIC 1 0 0 5 OSR B3 0 0 AWT 1 5T14 0 R6 1 37 EOR SOR XIO 1 0 0 5 OSR B3 0 1 MSG O 210H a 0 EoR lt param gt lt ple gt lt controller gt 5 3 3 Applying a Name and Version The name as it appears on the screen of the Alpha can be different from the file name given To provide a display name put another XML parameter tag after lt param gt tag and before the lt plc gt lt controller gt ending tags The new tag will be lt param id 701 gt NAME lt param gt There
140. tening cycle when the achieved torque and angle for the Audit step are within specified limits Will not assert if the Stop Abort within Limits parameter is set to Yes and the tool is stopped or aborted within limits Resets when the tool is commanded to run again Can also be reset with the RESET RESULTS STATUS input Size 1 bit Configuration Contact Type Normally Open N O Normally Closed N C Output Type Normal Timed Flash Minimum ON Time Time Period CYCLE NOK Asserts at the end of a fastening cycle when the achieved torque and or angle for the Audit step are NOT within specified limits Also asserts when the Stop Abort within Limits parameter is set to Yes and the tool is stopped or aborted within limits Resets when the tool is commanded to run again Can also be reset with the RESET RESULTS STATUS input Size 1 bit Configuration Contact Type Normally Open N O Normally Closed N C Output Type Normal Timed Flash Minimum ON Time Time Period TASK Asserts when a task is selected by any means Resets when the active task is complete SELECTED Size 1 bit Configuration Contact Type Normally Open N O Normally Closed N C Task Type the task number that when selected asserts this output Output Type Normal Timed Flash Minimum ON Time Time Period JOB Asserts when a job is completed accumulated bolt count equals target bolt count Resets COMPLETE when a different job is selected or
141. the I O on the DeviceNet network 30 Alpha Controller Communication Screens Options Screen SSS on _ ONL Te d D ic H Scan atic Hetwork 1 8utomatic e 2 10 Monitor Use the up down arrows or the corresponding number on numeric keypad to select option 1 Automatic Network Scan The scanner scans the network and automatically adds devices it recognizes aye L go Press the YES interactive menu button to continue with the scan Press the NO interactive menu button to return to the SCANNER tab Any devices found will be added to the Scanner List Use the SCANLIST interactive menu button to view devices 2 IO Monitor Monitors the status of the I O bits on the DeviceNet network Bits with a white background are OFF bits with a black background are ON Use the left right arrows to scroll through I Os longer than one word Press the BACK interactive menu button to return to the SCANNER tab Press the DIAG interactive menu button to diagnose the DeviceNet network EH DT AGHOST E This information is for Stanley engineers OFFLINE reference only ACLR bit FATL bit NRDY bit PDP bit Press the HELP interactive menu button to get a description of any errors Press the OK interactive menu button to EERROR DEES Error code Of gt return to the DNM Diagnostics screen Press No error E the OK interactive menu button again to cs return to the SCANNER tab Use the right arrow to mov
142. the bit is turned off typically by an OTU instruction in another rung OTU Output Unlatch OTU is a retentive output instruction OTU can only turn off a bit while OTL can only turn on a bit This instruction is usually used in pairs with the OTL instruction The program can examine a bit controlled by the OTU instruction as often as necessary The unlatch instruction tells the controller to turn off the addressed bit Thereafter the bit remains off regardless of the rung condition until it is turned on typically by an OTL instruction in another rung RES Reset Use a RES instruction to reset a timer or counter When the RES instruction is enabled it resets the Timer On Delay TON Retentive Timer RTO Count Up CTU or Count Down CTD instruction having the same address as the RES instruction RTO Retentive Timer Use the RTO instruction to turn an output on or off after its timer has been on for a preset time interval The RTO instruction is a retentive instruction that begins to count millisecond intervals when rung conditions become true The RTO instruction retains its accumulated value when the rung conditions become false The Time Base must be 10 msec The timer will not work in any other Time Base This Bit Is Set When And Remains Set Until One of the Following Timer Done Bit DN accumulated value is equal to or greater than the appropriate RES instruction is Bit 13 the preset value enabled
143. the value at source B the instruction is logically true If the value at source A is greater than the value at source B the instruction is logically false LES Less Than Use the LES instruction to test whether one value source A is less than another source B If source A is less than the value at source B the instruction is logically true If the value at source A is greater than or equal to the value at source B the instruction is logically false LIM Limit Test Use the LIM instruction to test for values within or outside a specified range depending on how limits are set If the Low Limit has a value equal to or less than the High Limit the instruction is true when the Test value is between the limits or is equal to either limit If the Test value is outside the limits the instruction is false MEQ Masked Comparison for Equal Use the MEQ instruction to compare data at a source address with data at a compare address Use of this instruction allows portions of the data to be masked by a separate word The source is the address of the value to compare The mask is the address of the mask through which the instruction moves data The mask can also be a hexadecimal value constant The compare is an integer value or the address of the reference If the 16 bits of data at the source address are equal to the 16 bits of data at the compare address less masked bits the instruction is true MOV Move This output
144. tick L eck Ce File Saved 46 Alpha Controller Analyze Screens Options Screen After the file is saved press the OK button Press BACK to return to the Analysis screen Use the left right arrow to move to the next tab or press EXIT to save the changes and return to the Run screen See section 2 9 1 7 Setup Exit TRACE Tab This tab plots a torque verses 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 left right arrow to move to the next tab or press EXIT to save the changes and return to the Run screen See section 2 9 1 7 Setup Exit T O Tab This tab indicates the real time status of the 24VDC Inputs and Outputs Forcing the I O on or off is also performed here Users must have DIAGNOSTICS or ADMINISTRATOR access level to force I O Each 24VDC connector pin 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 8 Alpha Controller Model QA1001 __V Input and Output Connector for a schematic Pins L through U are for Inputs Pins C through K are for Outputs See Sections 2 9 3 3 OUTPUTS Tab and 2 9 3 4 INPUTS Tab to assign elements to the pins A clear Input or Output pin icon identifies it as OFF a dark Input or Output pin icon identifies i
145. tional components can be added to the joint Creates a Backoff strategy step after the Audit step The tool stops after achieving either the angle or torque target If selected this is the first step AFTER the Audit step Options include HIZARO ERCROUT Angle Target The number of degrees of rotation the socket turns during this step Torque Target The Target Torque for this step Speed The socket speed during this step Fastener Release In some fastening situations sockets become stuck on the fasteners This step reverses the tool and releases the socket without losing audit step data Creates the last step in a tool strategy as an Angle Control or Torque Control AC TC strategy that rotates the fastener in the opposite direction of the Audit step Options include HI ZAROD RELERSE Speed Angle Target Max Torque Speed The socket speed during this step Angle Target The number of degrees of rotation the socket turns during this step Max Torque The maximum allowed torque during this step The Wizard uses the maximum torque of tool to prevent any interference Press the FINISH interactive menu button to close 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 Beit changes This saves the parameters and opens Wave changes the Run
146. tions for a CTU instruction have made a false to true transition the accumulated value is incremented by one count provided that the rung containing the CTU instruction is evaluated between these transitions The accumulated value is retained when the rung conditions again become false The accumulated count is retained until cleared by a reset RES instruction that has the same address as the counter reset The count value must remain in the range of 32768 to 32767 If the count value goes above 32767 the overflow OV bit is set If the count value goes below 32768 the counter status underflow UN bit is set A counter can be reset to zero using the reset RES instruction This Bit Is Set When And Remains Set Until One of the Following Count Up Overflow Bit Accumulated value wraps around A RES instruction having the same address OV Bit 12 to 32 768 from 32 767 as the CTU instruction is executed OR the count is decremented less than or equal to 32 767 with a CTD instruction Done Bit DN Bit 13 Accumulated value is equal to or The accumulated value becomes less than greater than the preset value the preset value Count Up Enable Bit Rung conditions are true Rung conditions go false or a RES CU Bit 15 instruction having the same address as the CTU instruction is enabled DIV Divide Use the DIV instruction to divide one value source A by another source B The rounded quotient is then placed in the desti
147. tomer 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 contact name and telephone number If possible have facsimile and pager numbers if any available e The Stanley model number serial number and description for the item e A short description of the problem Warranty 97 User Manual 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 48083 USA Tel 1 248 824 1100 Fax 1 248 824 1110 Toll Free Service 877 787 7830 Toll Free Sales 877 709 8006 SATinfo stanleyworks com STANLEY ASSEMBLY TECHNOLOGIES Outils Portatifs et Systemes d Assemblage Zone Immoparc Route De Chartres B timent Loire 4 78190 Trappes Cedex France Tel 33 130 50 91 00 Fax 33 130 51 07 08 SATinfo stanleyworks com STANLEY DEUTSCHLAND GmbH Division Assembly Technologies Frankfurter Stra e 74 D 64521 Gro Gerau Germany Tel 49 6152 8052 0 Fax 49 6152 8052 22 SATGER stanleyworks com STANLEY ASSEMBLY TECHNOLOGIES Divisione SWK UTENSILERIE s
148. ual s exposure time over the work day are important factors in determining hearing protection requirements Worker sound level exposure can only be determined at the job site and is the responsibility of tool owners and employers 50 o gt Alpha 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 3 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 experiencing 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 4 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 i
149. uction Descriptions Instruction Descriptions ABS Absolute CTU Count Up NXB Next Branch ACI String to Integer DIV Divide OR OR ACL ASCII Clear Buffer END Program End OSR One Shot Rising ACN String Concatenate EOR End of Rung OTE Output Energize ADD Add EQU Equal OTL Output Latch AEX String Extract GEQ Greater Than or Equal OUT Output Unlatch AIC Integer to String GRT Greater Than RES Reset AND And LEQ Less Than or Equal RTO Retentive Timer ARD ASCII Read LES Less Than SOR Start of Rung Characters ASC String search LIM Limit Test SUB Subtract ASR ASCII String Compare MEQ Masked Comparison TOF Timer Off Delay for Equal AWT ASCII Write MOV Move TON Timer On Delay BND Branch End MUL Multiply XIC Examine if Closed BST Branch Start MVM Masked Move XIO Examine if Open CLR Clear NEG Negate XOR Exclusive OR COP Copy NEQ Not Equal CTD Count Down NOT Not Table 2 Supported Files OU OUTPUT Il INPUT B3 BINARY T4 TIMER CH COUNTER R6 CONTROL N7 INTEGER ST14 STRING Instructions Description ABS Absolute Calculates the absolute value of the source and places the result in the destination ACI String to Integer Use the ACI instruction to convert a numeric ASCII string to an integer value between 32 768 and 32 767 ACL ASCII Clear Buffer Clears the send and or the receive buffers ACN String Concatenate Combines two strings using ASCII strings as operands The second string is appended to the first and the result store
150. vailable on 24 VDC Alpha Controller Connections 81 User Manual Embedded PLC Each Alpha Controller has an internal software PLC This PLC serves to enhance the integration of the Alpha controller into an end user s plant The PLC emulates the Allen Bradley SLC 505 controller and uses many of the same layouts addressing structures and commands RSLogix500 can be used to program ladder logic for the embedded PLC 5 1 Rack Layout The Alpha controller s PLC has a 5 slot virtual rack layout There are some differences between a SLC 505 rack and the Alpha rack The CPU card does not have its own slot rather it is taken into account since it is embedded and cannot be changed The discreet 24 VDC I O uses the same slot rather than separate input or output cards The virtual rack is filled as follows 24VDC Slave Fieldbus ModbusTCP EthernetIP Master Fieldbus P DeviceNet or Profibus Ethernet Slave Ethernet Slave DeviceNet D W E D D D D U l U l l l a R Cc N T N T N T N N e S amp P P T U u u P U amp p U SP o Ir e ZS P T u T J T a T ei 7 D P S T 3 T A T S T T ha L s S S s S S Y Optional Optional Standard Standard Optional SLOT 0 SLOT 1 SLOT 2 SLOT 3 SLOT 4 The 24VDC I O Module in slot 0 reflects the physical I O on the Alpha The Slave Fieldbus card in slot 1 uses the M 12 DeviceNet connector on the bottom of the Alpha when the DeviceNet slave option is ordered The D
151. value Downshift Speed when a specific torque value Downshift Torque is reached during the tightening cycle Speed units are RPM torque is in torque units Downshitt Mode i ownshift Torque Downshitt Speed L ali ATC Enables the Adaptive Tightening Control algorithm to slow the tool speed as the torque rises Downshitt Mode D R LAT Starting Torque 3 PATE Ending Torque F AT Ending Speed SZ Log The default values can be modified for when the algorithm starts ATC Starting Torque when it ends ATC Ending Torque and the tool speed after the algorithm ends ATC Ending Speed The torque units are a percent of Target Torque The speed values are a percent of Speed 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 simply de energizes and coasts to a stop Soft Stop FESHI Current Off Time Le oos a EE Current Hold Time La azs Current Ramp Time aars If Yes is selected the tool s current will be removed for the time specified in Current Off Time then reapplied for the time specified in the Current Hold Time then 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 required for this step Units are RPM Must be
152. ver will indicate a larger angle than the tool output actually rotates This error is directly proportional to the torque level That is the deflection at 40 NM will be twice that at 20 NM In a torque vs angle curve of a fastening cycle at the end when the torque reaches its maximum value the angle will also be at its maximum value After shut off as the torque falls to zero the angle should remain at its maximum value But in the typical torque vs angle curve as the torque falls to zero the angle also appears to fall some amount This is not because the fastener is being loosened It is actually the resolver indicating that the angular deflection of the gears is relaxing to the neutral position In this case the maximum angle indicated at the maximum torque was incorrect The resolver indicated more angle than the tool output actually rotated To correct for this slight error in angle data the Alpha controller has a Stanley exclusive solution The Torsion Factor allows the user to input a value that compensates for the torsional spring rate of any part of the fastening system the gears of the tool the joint components or the tool mounting device and this factor is used to correct the angle reading throughout the fastening cycle This factor is entered as Degrees per NM and its default value is zero If the default value is used there will be no angular correction If a value of 0 1 is used each angle data point every millisecond will
153. when the input RESET JOB is asserted Size 1 bit Configuration Contact Type Normally Open N O Normally Closed N C Output Type Normal Timed Flash Minimum ON Time Time Period TASK Asserts when a task is complete all bolts assigned to task are OK Resets when a task is COMPLETE selected Size 1 bit Configuration Contact Type Normally Open N O Normally Closed N C Task Type the task number that when completed asserts this output Output Type Normal Timed Flash Minimum ON Time Time Period Alpha Controller Connections 73 User Manual Outputs Description TASK SELECTED BIT Asserts when required to indicate the active task This is one bit in a series of bits to create a binary number As tasks change so will the binary number created from these bits Size 1 bit except on fieldbus where it can be any size to fit the need Configuration Contact Type Normally Open N O Normally Closed N C Bit Type the number this bit will be in the binary number scheme for selected tasks Mode All TASK SELECTED BITs must be the same mode no mixing of modes allowed Binary Creates a decimal number equivalent to the weighted value of this binary bit s Binary 1 Creates a number equivalent to the weighted value of this binary bit s and add the value of one 1 to that number JOB SELECTED BIT Asserts when required to indicate the active job This is one bit in a
154. y and Multiple Function Button for PIANO e Ee Mie EE 52 3 4 2 MER lee 53 3 4 3 Tool MeMO EE 53 3 4 4 Tightening Cycle Counters eeeeeeeeeeeeeeeeeeeeeeeeeee 53 3 5 Tool LEE tege Ee 54 3 5 1 Directional Control See 54 3 5 2 Torque Reaction Devices AAA 54 3 5 3 Tool Temperature EEN 55 3 5 4 OO Status Lights EE 55 3 5 5 Setting Torque Angle and Other Operating PGI AITIGI OTS eege deeg edd 55 3 6 Special Application Tools 56 3 6 1 Exposed Gear Socket Tools 56 3 6 2 Tubenut Nutrunners EE 56 Alpha Controller Conme ctrons 4 ssisiesstecesciateinteintesstaiadeinidintensteceteiedeinieintel 57 4 1 Alpha Controller Connections ssssseeeeeeeeeeeneneeeeeereeenne 57 4 1 1 Alpha Controller Power Com 57 4 1 2 Alpha Controller Tool Connector sssssseseseeeeeesseeeen 57 Contents iii User Manual 4 1 3 Alpha Controller Serial Connector ceeeeeeeeeees 58 4 1 4 Alpha Controller Ethernet Connechor 58 4 1 5 Alpha Controller Model QA1001 _D_ DeviceNet 59 4 1 6 Alpha Controller Model QA1001 _P_ Profibus Port 60 4 1 7 Alpha Controller Model QA1001 M__ Master DeviceNet Connector E 60 4 1 8 Alpha Controller Model QA1001 Vi Input and Output COMMECION AAE EA A 60 4 2 Assignable Input and Output Elements 64 4 2 1 INPUE RT el E 67 4 2 2 Output Descriptions E 71 0A101216 6 RE 82 Bell Rack Layout yeaa rE aE 82 5 1 1 Addressing Gcheme ENEE 82 5 2 Supported Instructions and File Types

Alpha Controller User Manual - Stanley Engineered Fastening

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