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Assembly Technologies Alpha Controller User Manual v3.0

1. 72 32 2 ETT Ttt T TT 72 li Getting Started Alpha Controller 3 2 9 Breathing ek oai vr aii mi vada 72 922 uuu 72 3 3 1 Sockets and Adapters 73 3 3 2 SUSPENSION DEVICES 7 3 9 9 Gable ecc rr Uo tereti 73 OPM TOOLS uu un dtt eae eee 74 3 4 1 Display and Multiple Function Button for Hand Held Tools 74 94 2 MFP MOJE dt audes uude 74 om tomo sae RE 75 3 4 4 Tightening Cycle Counters 75 865 75 9 5 Direcional 76 3 5 2 Torque Reaction Devices 76 3 9 9 qayakusaq 76 9 54 Tool Status 76 3 5 5 Setting Torque Angle and Other Operating Parameters 77 36 Special Application Tools 77 3 6 1 Exposed Gear Socket Tools 77 3 6 2 Tubenut Nutrunners 77 Controller Connections and Inputs Outputs 79 4 1 Alpha Controller Connections 79 4 1 1 Alp
2. subgroup Psat Torque Torque Low Limit Torque High Limit 54111 1980 01 01 1 5 2153 benak modnm 1980 01 01 O15 m 1980 01 01 1UHU DI DI 01 49 12 1980 01 01 01 48 30 Appendix A Embedded Toolbox QA Alpha Controller 1 4 2 1 2 2 Initial Magnification Click the back arrow lower left of trace to return to the initial magnification Assembly Technologies Appendix A Embedded Toolbox 1 01 1950 01 01 deme 1950 01 01 1950 01 01 1 01 1990 0 1 01 DI 52 53 arbre DE Sire DI 39 48 1 45 12 01 43 30 embedded Toolbox Rundown Analysis Torque Time LEE Tire ira spindle Fst Analyze e Rundown Analysis o Trace 149 1 4 2 1 3 Statistics User Manual The Statistics view displays statistical overview summary Analyze Click on the information icon to choose either torque or angle data e Rundown Analysis After making data selections click the green check to accept or the red x to abort Click the information icon again to close Task Population Size Subgroup Size Number of Bars zucl Assembly Technologies Torque Angle 1 1 25 E 20 17 Statistics embedded Toolbox show AH J Piet Hiph Torque Low Torque High angle Low angle 1980 01901 1980 01 01 191 01 01
3. zi Strategy 5 Audit Step 6 Controls T Wobble 8 Slow Seek 9 Start Delay 10 Condition Fastener What is the down torque target 0 NM What is the delay between steps 0 05 Seconds What is the cycle abort time 5 Seconds 11 Pre Torque 12 Backout Fastener 13 Release Fastener 14 Finished Save the Job Appendix A Embedded Toolbox 111 1 4 1 1 11 Pre Torque Set target torque NM and delay between steps seconds embedded Toolbox y2 0RC1 Assembly Technologies Show All Quick Start 1 Job 2 Task Definition 3 Task Name 4 Strategy re Audit Step 6 Controls T Wobble 8 Slow Seek User Manual Setup e Quick Start Pre Torque 9 Start Delay 10 Condition Fastener 11 Pre Torque What is the target torque NM What is the delay between steps Seconds 12 Backout Fastener 4 3 Release Fastener 14 Finished Save the Job Appendix A Embedded Toolbox QA Alpha Controller 1 4 1 1 12 Backout Fastener Set output rotation degrees high torque NM and tool speed RPM Setup e Quick Start Backout Fastener embedded Toolbox Assembly Technologies Quick Start Ler onnriaguratuanm wizard TOF Easy contri 1 Job Name 2 Task Definition 3 Task Name 4 Strategy 5 Audit Step 6 Controls T Wobble 8 Slow Seek 9 Start Delay 1 0 Condition Fastener 11 Pre Torque 12
4. Target Controls 8 Soft Stop 9 Step Timers Appendix A Embedded Toolbox QA Alpha Controller 1 4 1 2 3 6 Adaptive Tightening Control ATC Adaptive Tightening Control option identifies downshift mode starting Setup and ending torque and ending speed e Jobs Management o Steps Adaptive Tightening Control ATC embedded Toolbox Assembly Technologies v2 0RC1 Show All Jobs Management 2 Job ec nfia uration and management Jobs 1 Tasks 1 lt 01 JOB 1 New Step Duplicate Duplicate Duplicate 1 General 2 Strategy 3 Torque Specification Limits 4 Angle Specification Limits 5 Tool Motor Control 6 Adaptive Tightening Control ATC What downshift mode should be selected Disabled What is the starting torque for the ATC algorithm 20 NM What is the ending torque for the ATC algorithm 75 7 Target Controls 8 Soft Stop 9 Step Timers Appendix A Embedded Toolbox 127 User Manual 1 4 1 2 3 7 Target Controls Target Controls choices include yield and TRC targets Setup e Jobs Management o Steps Target Controls embedded Toolbox Assembly Technologies 22 01 Show All Jobs Management Job cantiguratian and management sna Jobs 1 Tasks 1 01 JOB 1 Duplicate Duplicate Duplicate 1 General 2 Strategy 3 Torque Specification Limits 3 Angle Specification Limits 5 Tool Motor Control 6 Ad
5. 15 Assembly Technologies Alpha Controller User Manual v3 0 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 THE STANLEY WORKS ALL RIGHTS RESERVED www StanleyAssembly com QA Alpha V 3 0 0308 User Manual Contents Geng 1 11 Warnings and 1 1 2 User Manual Conventions 2 1 3 Specifications Layout and Display 2 1 4 Installation Instructions 4 1 4 1 Alpha Controller E Stop Precaution 6 e me EES 7 2 1 Alpha Controller Navigation and Programming 7 22 7 2 2 MEE E 7 222 DIOBGOWIDZssoyusapasspsasasasayasayasawppqusyaqanaqayaqapasapaqaypuny punapunpshuapuqa 8 2 2 S MENU uu 8 lt sx 8 2 2 9 Gharacter 8 220 8 ME FAO ee 9 9 2 5 Alpha Controller Programming 10 2 5 1 Setup Men T JODS ione epe 10 Z
6. i 4 ira 21a L L el Rundown Analysis TTE WE Bla 55 25 259 Subgreupi 5 alz 229 shit 0 0 CRY Pr 027 Ranga 07 Accepts 100 SPL Lawit 55 High Tarque D CPU 25 Highest 92 Low Torque Ot R lE High angie 0 D e HUS Low Torque 0 Xx 5 gs4 5 agma 2259 Control Limite T UCL T Pande 3 145 Range Mean 12 Range L amp L D 1950 01 01 21140179 H 64 M LIUHU I I DI pg NA IBSBU Dl D1 01 38 30 7 20 MIA Appendix Embedded Toolbox QA Alpha Controller 1 4 2 1 4 Histogram The Histogram view shows the histogram for torque or angle Analyze Click on the information icon to choose either torque or angle data e Rundown Analysis After making data selections click the green check to accept or the red x to abort Click the information icon again to close Settings Statistical Data Set Torque Angle Job 1 Task 1 o Histogram Population Size 25 Subgroup Size 5 Numberof Bars 20 17 Elcl Rucl embedded Toolbox Rundown Analysis Populaien Histogram 1980 01 01 DIFAI 19A0 01 01 71 52 53 1980 01 021 011520109 1980 0 1 01 nri l8n 11 il 11 45 13 1UHg DI l 30 Appendix A Embedded Toolbox 151 User Manual 1 4 2 1 5 X Bar Range T
7. 3 6 2 Tubenut Nutrunners WARNING PINCH POINT AT THE EXPOSED GEARS OR TEETH To Avoid Injury Never place body parts or clothing near the socket opening Dress properly Do not wear loose fitted clothing or jewelry 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 e Press the button on the multiple function panel to arm the start function not required in modes and 2 e Depress start lever e The tool stops after reaching torque e Release the lever and lift the tool from the fastener all tool status lights flash to indicate the tool will now run in reverse to open the socket e Depress the start lever until the socket returns to the open position e Release the lever e Remove the tool QPM DC Electric Tools 77 Alpha Controller Controller Connections and Inputs Outputs Each Alpha Controller can have 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 Contro
8. Current Ramp Time Soft Stop Speed ae Programming Alpha Controller Strategy AC TA Screens Options Screen Abort Timer Delay Between Steps Accumulate ae Abort Timer j Delay Between Steps d Accumulate Abort Tiner Delay Between Steps j Accumulate dai 2 5 1 5 Setup Manage Manage Screens Options Screen Manage enables active tab settings to be added deleted and or copied to the clipboard and pasted into another tab The Nothing to Paste error indicates an attempt to paste information to the wrong tab type 2 5 1 6 Setup Exit Exit Screens Options Screen Programming changes are stored after exiting current menu Programming 47 User Manual 2 5 2 Setup Menu 2 Communications Communication Screens Options Screen Programming changes are stored after exiting current menu Obtain IP From Network oi IIF Address E EIP Address Subnet Mask ME B subnet Mask Obtain IP From Networ 1 Address HH subnet Mask IP es j Subnet Mask com Port 4 0 Port 2 48 Programming Alpha Controller Communication Screens Options Screen ow Port 1 0 Port 2 5 EET BEES OREHI serial Part 5 RUNS PART Toyota PI Test Mode Disabled Im jRundawn Angle Step ame PI Test Mode TECTA Rundown Angle Step J Final Angl Programming Communication Screens User Manual Options
9. Ex 20 Downshi ft Mode Jd Downshift Torque Dawnshi ft aus stop Current Off Time COU eu Hold Time Programming DISABLED YES Options Screen soft Stop LuUrrent A Soft Stop Time Mode Downshift Torque Dawnshi ft RE Dounshi ft Mode j HDownshift Torque Downshi ft speed Dawnshitft Torque rDounshi ft Mode Downshi ft 80 Soft stop Current Off Time Current Hold Time Time Lurrent Hold Time Current Ramp Soft stop d Current Off Time Current Hold li 41 Strategy YIELD Screens mn j Abort Timer Acceleration j Abort Timer Between Abort Tiner Delay Between Steps Sa 42 User Manual Options Screen Current orf Time Lurrent Hold Time Current Ramp Time Soft Stop Speed ae Programming Alpha Controller Strategy YIELD Screens Options Screen Abort Timer Delay Between Steps Accumulate j Abort Timer j Delay Between Steps d Accumulate Abort Tiner Delay Between Steps j Accumulate ai 2 5 1 4 7 Strategy AC TA Strategy AC TA Screens Options Screen Step settings affect only the active Task Torque rate strategy Torque Average and Angle Interval configuration 15 set in the Task tab Gr S
10. Programming 2 1 QA Alpha Controller Navigation and Programming The Alpha controller s three navigation and input areas facilitate menu navigation selection and data input Menu buttons Arrows and Toggle button Keypad Labels for the four interactive menu buttons 1 change with menu selection If the label is blank the button has no function for the current display The up down arrows 2 navigate menu and character selections the left right arrows enable backspace and space as well as navigate between tabs The toggle 2 button 3 switches between modes and selects accepts choices Synonymous with 3 OK menu button The numeric keypad 4 facilitates data input menu selection where applicable and job task selection when enabled 4 2 2 Display 2 2 1 Scroll Bar 1 gt A scroll bar appears when more items are available than space within the 2 2 display to allow them to be visible The 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 3 p To navigate between menu items use the up down arrows if available use the keypad to identify the corresponding menu item number Programming User Manual 2 2 2 Dropdown T CAM 1 A dropdown 1 arrow appears to the right of menu items with multiple choices To view these choices first select
11. Task Definition 3 Task Name 4 Strategy 5 Audit Step 6 Controls T Wobble 8 Slow Seek How many degrees should the output rotate 180 What tool speed should be used 0 RPM What is the maximum torque that should be measured n 9 Start Delay 10 Condition Fastener 11 Pre Torque 12 Backout Fastener 13 Release Fastener 14 Finished Save the Job Appendix A Embedded Toolbox 109 1 4 1 1 9 Start Delay Set delay time seconds and high torque Assembly Technologies Show All Quick Start Parameter onntiauration wizard for easy controll 1 Job Name 2 Task Definition 3 Task Hame 4 Strategy 5 Audit Step 6 Controls T Wobble embedded Toolbox User Manual Setup e Quick Start Start Delay 8 Slow Seek 9 Start Delay What is the delay time 0 25 Seconds What is the high torque 10 Condition Fastener 11 Pre Torque 1 2 Backout Fastener 13 Release Fastener 14 Finished Save the Job Appendix A Embedded Toolbox QA Alpha Controller 1 4 1 1 10 Condition Fastener Set down torque target NM delay between steps seconds cycle abort Setup time seconds and angle target degrees e Quick Start Condition Fastener embedded Toolbox Assembly Technologies 2 DRC1 Quick Start Parameter configu tor easy uration wl controller setup 1 Job 2 Task Definition 3 Task
12. Yes No Strategy YIELD Yield Target High Torque Low Torque Torque Bailout Snug Torque User Manual Software Map Alpha Controller High Angle Low Angle Angle Bailout Downshift Mode Disabled Manual ATC e Manual Downshift Mode e Manual Downshift Speed e ATC Starting Torque e Ending Torque e ATC Ending Speed Soft Stop Yes No e Yes Current Off Time e Yes Current Hold Time e Yes Current Ramp Time Speed Power Acceleration Abort Timer Delay Between Steps Accumulate Angle Yes No e Strategy AC TA Snug Torque Angle Target High Angle Low Angle Torque Target High Torque Low Torque Max Torque Bailout Mind Torque Bailout Downshift Mode Disabled Manual ATC e Manual Downshift Mode e Manual Downshift Speed e ATC Starting Torque e Ending Torque e ATC Ending Speed Soft Stop Yes No e Yes Current Off Time e Yes Current Hold Time e Yes Current Ramp Time Speed Power Acceleration Abort Timer Delay Between Steps Software Map 93 User Manual e Accumulate Angle Yes No 6 1 3 Communications e Obtain IP From Network No Yes e IP Address e Subnet Mask e Gateway e DNS e Physical e Serial e Serial Port 1 Barcode Printer Barcode Printer ETB e Serial Port 2 Barcode Printer Barcode Printer Toyota PFCS Open e 5 e Server IP e Port e Time Out e Open e Port e Cell e Buffer while off line e Toolsn
13. Backout Fastener How many degrees should the output rotate 1800 3 What is the high torque 0 What tool speed should be used 13 Release Fastener 14 Finished Save the Job Appendix A Embedded Toolbox 113 User Manual 1 4 1 1 13 Release Fastener Set tool speed RPM output rotation degrees and maximum torque Setup NM e Quick Start Release Fastener embedded Toolbox SURE Assembly Technologies Show All Quick Start y i 1 Job Name 2 Task Definition 3 Task Hame 4 Strategy 5 Audit Step 6 Controls T Wobble 8 Slow Seek 9 Start Delay 10 Condition Fastener 11 Pre Torque 12 Backout Fastener 1 3 Release Fastener What tool speed should be used 0 How many degrees should the output rotate 30 What is the maximum torque that should be measured 0 NM 14 Finished Save the Job Appendix A Embedded Toolbox QA Alpha Controller 1 4 1 1 14 Finished Setu Save to record the recently defined tick Start Use the save button tasks Parameter Change Notice Parameters in the controller have changed Do you wish to update the workflow to reflect the new parameter values Yes No Use the export button Export to make the defined tasks available outside of this controller definition File Download X Do you want to open or save this file Mame jobs xml Type XML Do
14. CHMCEL E Programming 13 14 User Manual Wizard Screens Options Screen Backout Fastener BlFastener Release Angle Target Max Torque Angle Target Max Torque ingle Target Max Torque Programming Alpha Controller 2 5 1 2 Setup ob Tab Job Tab Screens Tool settings apply to all Tasks Communications ther Full Backur REezstore Auto sequence Tasks aauto Reset Job Auto Sequence Tasks Auto Reset Job Enable Error Proofing auto Sequence Tasks Auto Reset Job aes Error I Programming Options Screens Auto Sequenee Tasks Reset Job Auto Sequence Tasks Auto Reset Job Error arai Auto Tasks Auto Reset Job Errar oe E 15 User Manual Job Tab Screens Options Screens Auto Sequence Tasks ves Auto Sequence Tasks Reset Job Reset Job Enable Error Proofing io 5 Error 2 5 1 3 Setup Task Button Task Tab Screens Options Screens A maximum of 99 tasks can be created Batch Count Batch Count E units Batch Count Units Direction Thread Direction Thread Direction IE Thread Direction Threshold Torque Thread Direction Thread Direct ton aThreshold Torque BIhreshald Torque ao Threshold Threshold 16 Programming Alpha Controller Task Tab Screens Options Screens T
15. E Export J Appendix A Embedded Toolbox 119 User Manual 1 4 1 2 2 4 Thresholds Threshold setup choices include beginning torque threshold angle for Setup torque rate measurement and number of torque readings to average e Jobs Management o Tasks Threshold embedded Toolbox Assembly Technologies Shaw All Jobs Management lob ponfiguration and management Jobs 1 Steps 0 D1 JOB 1 No Steps Duplicate Duplicate 1 General 2 Units 3 Fastener Definition 4 Thresholds At what torque threshold should the controller recognize that the task has begun 0 NM What angle should the torque rate measurement be calculated over What is the number of torque readings to average for the torque rate calculation 5 Audit Definition o amp J epot JE save _ Appendix A Embedded Toolbox QA Alpha Controller 1 4 1 2 2 5 Audit Definition Audit Definition identifies the step for torque and or angle audit Setup e Jobs Management o Tasks Audit Definition embedded Toolbox Assembly Technologies Jobs Management figuration and management Jobs 1 Steps 0 01 JOB 1 No Steps x Duplicate Duplicate 1 General 2 Units 3 Fastener Definition 4 Thresholds 5 Audit Definition What is the torque audit step LAST What is the angle audit step Appendix A Embedded Toolbox 121 User Manual 1 4 1 2 3
16. Screen Programming Alpha Controller Communication Screens Options Screen 2 5 3 Setup Menu 3 Other Other Screens Options Screen Programming changes are stored after exiting current menu 3 EE Keypad Mode alt Count Mode m Count Mode BCount Mode jstop Abort within Limits Programming 51 User Manual Other Screens Options Screen keypad Made PismeLED Keypad Mode 4 Count Mode CoUNT UF Count Mode COUNT 18 Stop Abort within Limits Bstop 4bort within Li COUNT DOWN Mode reS Mode Count Mode BCount Mode dstop Abort within Limits Era u E Password Access Change 52 Programming Alpha Controller Programming Other Screens Options Screen CYCLE HOK TASK SELECTED JOE COMPLETE TASK SELECTED BIT JOB SELECTED BIT MITORGUE OK 53 54 User Manual Other Screens Options Screen F CYCLE B SELECTED B SHSSEMBL Y DETECTEDE CYCLE TASK SELECTED USERS HI ANGLE LOW F CYCLE B SELECTED E SHSSEMBL Y DETECTEDE CYCLE TASK SELECTED Programming Alpha Controller Other Screens Programming Options Screen STORGUE F CYCLE B SELECTED E SHSSEMBL Y DETECTEDE 55 User Manual Other Screens Options Screen F CYCLE B SELECTED B SHSSEMBL Y DET
17. Stop off Time Q SEE Mode MANUAL i Downshi ft Torque Downshift Speed Downshi tt Mode 3 Downshitt Torque Dawnshi ft 20580 Mode 3 Downshift Torque Dawnshi ft ess Downshi Tt Mode Starting Torque ATE Torque x m SERO Tarque ATC Ending Torque d Ending SHE ATC Torque 4 ATC Ending Torque ATC Ending Speed User Manual Strategy AC TC Screens Options Screen ATO Starting Torque zajel ATC Ending Torque 5 Ending Speed Soft Stop d Current Off Time Current Off Time P xd Current Hold Time 2 925 Stop Current ff Time d Current Hold Time Soft Sto Current Off Time Soft Sto j Speed j Power z Acceleration Abort Timer 30 Programming Alpha Controller Strategy AC TC Screens Options Screen Abort Timer j Delay Between Steps Accumulate ngle Abort Timer j Delay Between Steps d Accumulate Angle Abort inse FAbort Timer Delay Between Steps H B Delay Between Steps d Accumulate Angle Accumulate Angle 2 5 1 4 4 Strategy BACK Backoff Strategy BACK Backoff Screens Options Screen DET settings affect only the active Task Snug Torque angle Target High Programming 31 Strategy BACK Backoff Screens Angle Target j High Angle Angle Low Angle 1 Tar
18. Target Controls 8 Soft Stop 9 Step Timers You may specify the time values of certain properties that affect how the step performs over time After how much time should the cycle abort Seconds How much time should elapse between this step and the next Cacandc Appendix A Embedded Toolbox QA Alpha Controller 1 4 1 3 System Management System Management enables custom controller configuration for Setup triggers and tones Setups can be imported exported or saved using the appropriate button System at the bottom of the screen Management 1 4 1 3 1 General General enables naming the controller and specifying keypad mode Setup e System Management o General embedded Toolbox Assembly Technologies v2 0RC2 Shaw All System Management System configuration and management 1 General What name would you like to give to the controller Specify the keypad mode you wish to use Disabled 2 Triggers 3 Lights 4 Tones j 2 Saves Appendix A Embedded Toolbox 131 1 4 1 3 2 Triggers Triggers controls operation action and start mode of the multiple function button MFB embedded Toolbox Assembly Technologies Show All System Management system contour and manabement User Manual Setup e System Management o Triggers MFB Tap controls the operation of the multiple function button on a hand held tool Specify the desired
19. Tool Diagnastics I O Diagnostics 1 4 2 1 Rundown Analysis Rundown Analysis display options include the controller rundown traces summary statistics histogram and x bar range Prior rundown results are shown at screen bottom with results not included in the statistics struck out Use the buttons located at the middle right of screen to swap view options Rundown Trace Statistics Histogram and Xbar range Yellow highlight surrounds active button choice E i G E Appendix A Embedded Toolbox 145 User Manual ss L 1 4 2 1 1 Rundown The Rundown view displays details for current rundown Analyze Click on the information icon to choose either torque or angle data Rundown Analysis After making data selections click the green check to accept or the red x o Rundown to abort Click the information icon again to close EA Em T Settings Statistical Data Set Torque Angle Job 1 Task 1 Population Size 25 Subgroup Size 5 Numberof Bars 20 17 12 Rucl embedded Toolbox Assembly Technologies Runclown Analysis Live and historic rundown analysis Rundown Wm L5 i Subgroup Time Job Task Torque Appendix A Embedded Toolbox QA Alpha Controller 1 4 2 1 2 Trace The Trace view displays a plot of selected tightening variables Click on the information icon to sh
20. Torque Low Angle OK Angle Hi Angle Low Cycle Aborted Stopped Faulted Ready PM Start Trigger MFB Snug Achieved Cycle Stopped Step Bit e Inputs L Ignore Start Select Job Select Task Stop Reset Job Task Select Bit Job Select bit Reverse Disable Task Disable Job Task Verify Job Verify Task Verify Bit Job Verify Bit Reset Result Status Reverse Start Disable Tool M Ignore Start Select Job Select Task Stop Reset Job Task Select Bit Job Select bit Reverse Disable Task Disable Job Task Verify Job Verify Task Verify Bit Job Verify Bit Reset Result Status Reverse Start Disable Tool N Ignore Start Select Job Select Task Stop Reset Job Task Select Bit Job Select bit Reverse Disable Task Disable Job Task Verify Job Verify Task Verify Bit Job Verify Bit Reset Result Status Reverse Start Disable Tool P Ignore Start Select Job Select Task Stop Reset Job Task Select Bit Job Select bit Reverse Disable Task Disable Job Task Verify Job Verify Task Verify Bit Job Verify Bit Reset Result Status Reverse Start Disable Tool R Ignore Start Select Job Select Task Stop Reset Job Task Select Bit Job Select bit Reverse Disable Task Disable Job Task Verify Job Verify Task Verify Bit Job Verify Bit Reset Result Status Reverse Start Disable Tool S Ignore Start Select Job Select Task Stop Reset Job Task Select Bit Job Select bit Reverse Disable Task Disable
21. Type normal timed flash Time STEP BIT Indicates last step of rundown N O N C Bit Binary Binary 1 Outputs not available on 24V Does not apply to 24V Controller Connections and Inputs Outputs 03 Alpha Controller Glossary Abort Timer Acceleration Accept Tone AC TA AC TC AC TM Angle Interval ATC Auto Sequence Tasks BACK Batch Count Downshift Mode Downshift Speed Downshift Torque High Angle High Torque Jobs Low Angle Low Torque Mode Glossary The tightening cycle aborts if the tool does not shutoff before this pre selected time How fast the controller changes the speed of the tool from 0 stopped to the rated speed Controls the tone made from the handle of handheld QPM tools for accepted tightening cycles Allows distinct tones for tools in adjacent workstations Angle Control Torque Averaging Angle Control Torque Control This strategy controls a tool based on angle and Torque Angle Control with Torque Monitor This strategy controls a tool based on angle and monitors the torque limits defined by user Rate Yield and AC TA Angle interval is used to calculate Torque vs Angle Rate A larger interval tends to give a smoother rate Allows Adaptive Tightening Control modes to be selected so that consistent torque can be maintained over a wide range of joints Manual downshift should be used when High Prevailing Torques Prevailing Torque gt 20 of the Tor
22. User Manual 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 Two sets of lights 3 and 7 indicate tool status Two blue lights indicate tool rotation direction disassembly 1 or assembly 2 A single multiple function button 5 can change tool direction and or tasks When the button is used to select the task one of two orange indicators 4 or 6 illuminates to show the active task EA tools have four sets of lights 3 and 7 and an LED 8 that indicates when the tightening cycle count exceeds the PM limit Display and MFP Button for 02 to E34P pistol Models 5 4 Display and MFP Button for E23L to E55L lever Models 8 Display for EA23L to EA34L lever Models 3 4 2 MFP Mode The MFP Mode configures the multiple function button for handheld QPM tools The button can be configured to operate in any of the following modes Disable The button does nothing Pressing the button causes the tool default alarm to beep once Only the assembly blue light 2 illuminates Reverse Disassembly Pressing the button toggles between assembly and disassembly and illuminates the appropriate blue light 1 or 2 All tool status lights 3 and 7 flash when the tool is in disassembly mode Task Select Pressing the button toggles between tasks and illuminates the appropriate orange light 6 or 4 Arm Pressing the
23. You may select a predefined strategy which accounts for most typical joint steps What strategy would you like to use for this step Torque amp Angle What units would you like to use for the torque specifications What is the tool direction of the fastening operation Clockwise CW 5 Audit Step 6 Controls T Slow Seek 8 Finished Save the Job Appendix A Embedded Toolbox 105 User Manual 1 4 1 1 5 Audit Step The Audit Step sets the high and low limits for torque and or angle Setup depending on the strategy selected Free speed of the tool is also set For Quick Start angle limits the snug torque determines the starting point for angle measurement o Audit Step embedded Toolbox Assembly Technologies Quick Start ation d tor Eas 1 Job Name 2 Task Definition 3 Task Name 4 Strategy 5 Audit Step What is the high torque 0 NM What is the low torque What is the snug torque 0 NM What is the high angle 9999 9 gt What is the low angle 6 Controls T Slow Seek 8 Finished Save the Job Appendix A Embedded Toolbox QA Alpha Controller 1 4 1 1 6 Controls Controls enables setting the variables for Setup Wobble e Quick Start Slow Seek Start Delay A Condition Fastener Pre Torque Backout Fastener Release Fastener The default is Slow Seek selected an
24. selection Can be used for job task selection when enabled to do so Numeric Keypad g 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 AGILE QUE amp ANG 2 5 1 Setup Menu 1 J obs The Setup menu programs the controller to operate a spindle or tool Settings are saved per Job with optional Task and Step assignments Most controllers will operate with a single Job Task and Step Tasks control tool operation for tightening a fastener which can have one or more steps Steps are defined by available strategies such as TC AM Torque Control Angle Monitoring The Wizard can be used to setup a Task for simple rundowns Creating a name for Jobs Tasks and Steps is optional but helpful when multiples Jobs and Tasks exist 10 Programming Alpha Controller 2 5 1 1 Wizard Screens Wizard Screens Options Screen The Wizard assists with programming the controller to assign a Task which operates a single spindle To function the Wizard requires a tool to be connected This example shows Torque amp Angle Strategy Selecting another Strategy affects subsequent screen options The wizard automatically appears when there are no configured jobs To access the wizard when jobs exist choose Setup 1 Jobs Manage 1 Add then choose before or aft
25. the menu item using the up down arrows or if available use the keypad to identify the corresponding menu item number Then use the toggle button to expand the dropdown The up down arrows scroll through the choices and the toggle button selects accepts the highlighted choice 2 2 3 Menu Tree EBE BR A menu tree 1 appears beside related menu items E Tabs 1 appear at the top when multiple menu selections exist To navigate between tabs use the left right arrows The active tab is white inactive tabs are grey 2 2 5 Character Scrollbar 1 74 This scrollbar enables adding a z A Z 0 9 space _ amp anda 2z2 period language and or field determines character availability The up arrow 1 Md 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 menu button to accept entry The following screens contain the character scrollbar option Job Name Job Barcode ID Task Name Step Name System General System Users System Date Time System Network System Maintain Displays last torque reading and units 2 when a tool is connected Icons 1 identify controller events see list below Specifies current job 3 The run screen displays unless
26. to give to the task What disassembly speed should be used 9999 RPM What disassembly acceleration should be used 3000 2 Units 3 Fastener Definition 4 Thresholds 5 Audit Definition Appendix A Embedded Toolbox 117 User Manual 1 4 1 2 2 2 Units Units setup choices include NM FTLB INLB INOZ KGM KGCM Setup NCM and NDM e Jobs Management o Tasks Units embedded Toolbox 2 UIR C 1 Assembly Technologies Show All Jobs Management i Job configuration and management Jobs 1 ask Steps 0 01 JOB 1 No Steps Duplicate Duplicate 1 General 2 Units What units would you like to use for the torque specifications 3 Fastener Definition 4 Thresholds 5 Audit Definition E eoo SE Appendix A Embedded Toolbox QA Alpha Controller 1 4 1 2 2 3 Fastener Definition Fastener Definition options include batch counting fastenings number Setup of fastening to be batch counted and tool direction e Jobs Management o Tasks Fastener Definition embedded Toolbox Assembly Technologies 2 0RC2 lob confiauration an C Show All Jobs Management id mana gement Jobs 1 Steps 0 01 New Job 01 New Task No Steps Duplicate Duplicate 1 General 2 Units 3 Fastener Definition How many fastenings will be batch counted What is the tool direction of this task Clockwise 4 Thresholds 5 Audit Definition b Import
27. 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 15 repaired or replaced under the terms of the warranty the warranty period of the repaired or replacement product shall be limited to the remaining portion of the original warranty period Product Services Stanley provides full services for design modification service repair and training on Stanley products Contact STANLEY ASSEMBLY TECHNOLOGIES or their agents for information on training courses to aid users in becoming familiar with operations maintenance or programming of the Stanley DC electric tools and controllers No modification of Stanley tools and controllers can be made without the express permission of STANLEY ASSEMBLY TECHNOLOGIES Refer all service to STANLEY ASSEMBLY TECHNOLOGIES or their representatives Return Material Authorization RMA Procedures A Return Material Authorization or RMA is required before returning any material for warranty or repair service e Contact STANLEY ASSEMBLY TECHNOLOGIES or their agents e Request Customer Service or Repair Services NOTE An RMA can be given without a purchase order However non warranty repairs c
28. 5 Consumption 5 DOA e3 VAC IA i IA 09 a 2 Getting Started Alpha Controller Getting Started Item 1 2 3 4 2 6 8 9 gt p Cc Aa W N Lr c 10 16 Functional Description Red Green Yellow LEDs for Limits Evaluation Display Function Keys with Active Label Above Cursor Keys with Center Button to Expand Lists Maintenance Due and ATC Active LEDs Numeric Keypad to Enter Numbers or Select Options Controller Label and Serial Number Power Switch Power Input USB Port for Data Transfer Optional 24 VDC Input Output Connector Tool Connector Serial Connectors Optional Device Net Connector Optional Profibus Connector Ethernet Connector 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 adjustment
29. BrHlqh Torque Programming 19 User Manual Strategy TC AM Screens Options Screens Torque Target High Torque 9999 911 Low Torque Low Torque j snug Torque High Angle Snug Torque j Hidh Angle 9999 Low Angle Angle High Angle Angle Bailout DRM A Programming Alpha Controller Strategy TC AM Screens Options Screens Angle aH Dos Bailout 9999 SIRE Mode DISABLED Downshift Mode PISABLED H Angle Bailout e 5oft Stop WES h Downshift Mode STSABLEOMIG Downshift Mode soft Stop HE 5 Stop 4 Current Time Current Time Downshift Mode Torque 3 Doawnshift 4 Downshift Torque Dounshi ft speed LDownshift Torque Downshi ft Mode Downshift Speed Downshi ft Mode mm RATE Starting Torque LATE Ending Torque FATE starting Torque ATC Ending Torque iL AT Ending Speed Programming 21 Strategy Screens n stop Lurrent OTT Time Current Hold Time Acceleration j Abort Timer 22 User Manual Ll Screens Ending Torque 3 ATC Ending Paer 1 ATC Starting Torque 4 T ATC Ending Torque d Ending 3 5 Stop 4 Current Off Time Current Hold Time Hold Time Current Ramp Time Current Hold Time Current Ramp Time era
30. ECTEDE CYCLE TASK SELECTED MUG ACHIEVED YCLE STEP BIT E J B SELECTED 56 Programming Alpha Controller Other Screens Programming Options Screen E SELECTED 57 58 Other Screens User Manual Options Screen HI F HI ANGLE LO CYCLE ABORTED 5 Programming Alpha Controller Programming Other Screens Options Screen JOE UERIFY JOB VERIFY ARESET RESULT JOB TENORE START SELECT JOE SELECT TASK TASK SELECT BIT JOB SELECT Bl 59 60 Other Screens User Manual Options Screen JOE UERIFY JOB VERIFY ARESET RESULT JOB TENORE START SELECT JOE SELECT TASK TASK SELECT BIT JOB SELECT Bl Programming Alpha Controller Programming Other Screens Options Screen JOE UERIFY JOB VERIFY ARESET RESULT JOB TENORE START SELECT JOE SELECT TASK TASK SELECT BIT JOB SELECT Bl 61 Multi Functi j Tap Action Action Other Screens I DISABLED HE T5 Lever Push To Start Switch _ Start Input User Manual Options Screen JOB JOB VERIFY ARESET RESULT JOB Multi Function But Tap Action Action ulti Functio
31. Job Task Verify Job Verify Task Verify Bit Job Verify Bit Reset Result Status Reverse Start Disable Tool Software Map 95 User Manual e T Ignore Start Select Job Select Task Stop Reset Job Task Select Bit Job Select bit Reverse Disable Task Disable Job Task Verify Job Verify Task Verify Bit Job Verify Bit Reset Result Status Reverse Start Disable Tool e U Ignore Start Select Job Select Task Stop Reset Job Task Select Bit Job Select bit Reverse Disable Task Disable Job Task Verify Job Verify Task Verify Bit Job Verify Bit Reset Result Status Reverse Start Disable Tool Triggers e Tap Action Disabled Reverse Task Select Arm Reset Reject Job Select Job Reset e Hold Action Disabled Reverse Task Select Arm Reset Reject Job Select Job Reset e Start Input Any All Lever PTS None Lights Lights 1 2 Task Job e Headlight Timer Tones e Accept Tone None Beep Beeeep Tocatta Fifth Turkishmarch Funeralmarch Ninth Michigan Ohio e Reject Tone None Beep Beeeep Tocatta Fifth Turkishmarch Funeralmarch Ninth Michigan Ohio Tool e PM Limit e Temperature Limit e Torsion Factor e Requires Arming No Yes Stats e Population e Subgroup Size Clock e Time e Date 6 1 5 Full Backup Restore Backup Restore Defaults 6 2 Service 6 2 1 Tool 96 About e Model e Serial e Software Version e Max Torque e Max Speed Counters e Odomete
32. Jobs Management o Steps Angle Specification Limits embedded Toolbox Assembly Technologies Show All Jobs Management lob ement antiquratrorn and managen Jobs 1 Tasks 1 lt 01 JOB 1 01 New Step Duplicate Duplicate Duplicate 1 General 2 Strategy 3 Torque Specification Limits 4 Angle Specification Limits What is the target angle What is the high angle limit 3383 8 What is the low angle limit 5 Tool Motor Control 6 Adaptive Tightening Control ATC 1 Target Controls 8 Soft Stop 9 Step Timers Appendix A Embedded Toolbox 125 User Manual 1 4 1 2 3 5 Tool Motor Control Tool Motor Control option identifies tool speed tool acceleration rate to Setup speed downshift torque downshift speed and shutoff mode Coast or Soft Stop e Jobs Management o Steps Tool Motor Control embedded Toolbox Assembly Technologies Show All Jobs Management infiguratian and management Jobs 1 Tasks 1 01 JOB 1 01 New Step Duplicate Duplicate Duplicate 1 General 2 Strategy 3 Torque Specification Limits 4 Angle Specification Limits 5 Tool Motor Control You may change settings that control how the tool reacts while perfoming this step What speed should the tool run 9999 RPM How fast do you want the tool to come up to speed 3000 RPM SEC 6 Adaptive Tightening Control
33. LOGIES SHANGHAI REPRESENTATIVE OFFICE Room 1908 Shanghaimart Tower 2299 Yan An Road West Shanghai 200336 China Tel 011 86 2 1 3208 4550 Fax 011 86 21 6236 0191 www StanleyAssembly com Warranty 101 Appendix A Embedded Toolbox Features Navigation and Menu 1 1 Introduction Embedded Toolbox enables communication to an Alpha controller using a networked computer s web browser To get started point the browser to the controller s IP address 1 2 Installation 12 11 Requirements for Alpha Controllers Ethernet Connection e Javascript enabled Internet browser with Flash 9 for Windows Macintosh or Linux running over an Ethernet TCP IP connection e Adobe Flash Player v9 or above http www adobe com QAI001 Alpha Controller Version 3 0 or above 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 Q0001 Kappa controller 12 12 Requirements for Alpha Controllers Using the Controller Gateway Serial Connection Microsoft Windows XP for serial connection to a controller QA1001 Alpha Controller Version 3 0 or above Q1001 Alpha Controller Version 4 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 c
34. N C Bit BIT task JOB SELECT BIT e DIEI diserte Ds DUNG DISABLE TASK Disable the task N O N C Task DISABLE JOB Disable the job N O N C Job TASK VERIFY ML MM ON inputs JOB VERIFY Verify the selected task to the N OJN C Job 4 inputs TASK VERIFY Verify the selected task to one BIT of the input bits RON Ee ele JOB VERIFY 22 the selected job toone wow C Bit of the input bits RESET RESULT STATUS Clear the result status REVERSE START Put the tool in reverse and start the tool PART ID Set the part identification Length Trigger auto manual DISABLE TOOL Disable the tool PART ID Trigger for part ID Resets Part N O NC TRIGGER ID changed output COT eee Input not available on 24V Does not apply to 24V 82 Controller Connections and Inputs Outputs Alpha Controller Outputs Description IN CYCLE The tool is in cycle N O N C Type normal timed flash Time JOB SELECTED Indicate job select ae C Type normal timed flash Time DISASSEMBLY DETECTED N O N C Type normal timed flash Time TOOL RUNNING The tool is running N O N C Type normal timed flash Time CYCLE OK Self explanatory N O N C Type normal timed flash Time CYCLE NOK Self explanatory N O N C Type normal timed flash Time Controller I O Configuration Options TASK COMPLETE Task complete Indicate a bit of the selected job eke om Ser AMA Ra a ns Senn Sep AMA R
35. O lek Wizard cde 11 2 5 1 2 JOD 15 2 9 1 9 Task y y oer ied 16 2 5 1 4 Setup Step Button Step 1 Step 12 19 2 51 41 orate y OAM u dopo t uuu tM mm 19 2 5 1 4 2 Strategy AG TM oti esent es 23 25 14 3 Strategy Z tsi e t Ie ots 27 2 5 1 4 4 Strategy BACK Backoff 31 2 9 154 5 Strategy RATE uites uu erri ete 35 2 5 1 4 6 Strategy YIELD 39 2 9 1 4 7 Strategy ACTA 43 225125 OCUP Manag E n u 47 2252126 SOUD nan an 47 2 5 2 Setup Menu 2 48 2 5 23 Menus 3 51 2 5 4 Setup Menu 4 Full Backup Restore 65 29 9 OOV CE 66 OOM 66 552 u u s 68 2 9 0 ANANO e D TM dieu E 68 QP MDC Ie iue ird cauta 71 Sal 00 5 uuu uuu aaa cancer cet te ade 71 32 Operar Protection u u l 71 miserius 71 3 2 1 Hearild FETOLIeCIOFL zs dedu
36. REACTION FORCE To Avoid Injury Be alert 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 prepared for the change in direction and or a higher reaction force when a tool is in reverse start lever should be positioned to avoid trapping the operator s hand between the tool and the work piece TOOL MAY NOT SHUT OFF To Avoid Injury e If the tool does not shut off at the end of the tightening cycle contact the person responsible for tool installation or repair Note When the tool does not shut off a stall condition occurs A stall condition can cause a higher than expected torque reaction impulse Ensure tool is properly installed adjusted and in good working order Do not use the power tool if the switch does not turn it on and off Apply the tool to the joint following all recommendations in this manual Check to ensure the drive socket is fully seated and locked into position before connecting power to the tool Prepare to resist the tool s torque reaction Start the tool by depressing the start lever or trigger Release start lever after the cycle is complete QPM DC Electric Tools 75 User Manual 3 5 1 Directional Control WARNING UNEXPECTED REACTION FORCES To Avoid Injury Be prepared when a tool operates in reverse the tool s torque reaction is opposite to the reaction produced when the tool ope
37. Steps 1 4 1 2 3 1 General General identifies the step name Setup e Jobs Management o Steps General embedded Toolbox Assembly Technologies Show All Jobs Management Job configuration and management Jobs 1 Tasks 1 01 JOB 1 01 New Step Duplicate x Duplicate 7 Duplicate 1 General step is a single unit of work performed in a task Each step define the specific work that the controller and the tool should perform What name would you like to give to the step New Step 2 Strategy 3 Torque Specification Limits 4 Angle Specification Limits 5 Tool Motor Control 6 Adaptive Tightening Control T Target Controls 8 Soft Stop 9 Step Timers Appendix A Embedded Toolbox QA Alpha Controller 1 4 1 2 3 2 Strategy Strategy choices include TC AM AC TM AC TC BACKOFF RATE Setup YIELD and AC TA e Jobs Management o Steps Strategy embedded Toolbox Assembly Technologies 42 0RC1 Show All Jobs Management DO r Jernent poantfiguratiarn and manac Jobs 1 Tasks 1 01 JOB 1 01 New Step Duplicate Duplicate Duplicate 1 General 2 Strategy 4 strategy defines the type of interaction and monitoring that the controller and tool will have with the bolt during the execution of the step You may select a predefined strategy which accounts for most typical joint steps or you may choose None to l
38. Time Time Lurrent Hold Time Current Ramp Soft stop d Current Off Time Current Hold li 37 Strategy RATE Screens mn j Abort Timer Acceleration j Abort Timer Between Abort Tiner Delay Between Steps Sa 38 User Manual Options Screen 3221 Hel Current of Time Lurrent Hold Time Current Ramp Time Soft Stop Speed ae Programming Alpha Controller Strategy RATE Screens Options Screen Abort Timer Delay Between Steps Accumulate j Abort Timer j Delay Between Steps d Accumulate Abort Tiner Delay Between Steps j Accumulate ai 2 5 1 4 Strategy YIELD Strategy YIELD Screens Options Screen Step settings affect only the active Task Torque rate strategy Torque Average and Angle Interval configuration 15 set in the Task tab aaa n Yield Target j High Torque Low Torque High Torque Torque Torque Bailout Programming 39 Strategy YIELD Screens Low Torque I Torque Bailout j 5nug Torque Torque Bailout j snug Torque High Angle Snug Torque j High Angle Low Angle High Angle Low Angle j ngle Bailout Low Angle Angle Bailout 40 9999 9E Em x 9993 Downshift Mode DISABLED User Manual Options Screen Programming Alpha Controller Strategy YIELD Screens angle Bailout j Downshift Mode
39. Use the minus button to delete the selected job task or step Use the duplicate button 2491981 task or step 1 4 1 2 1 Jobs Jobs setup includes job name auto sequence task auto reset job enable Setup error proofing and disable reverse on OK options to duplicate the selected job e Jobs Management o Jobs embedded Toolbox Assembly Technologies 2 0 Show Jobs Management a ae i nfiguratian and managemer nf VAS VAL 2 Steps 2 D1 JOB 1 D1 TASK 1 01 SLOW SEEK 02 AUDIT Duplicate Duplicate Duplicate 1 General What name would you like to give to the job JOB 1 What is the barcode ID Would you like to auto sequence the tasks Yes Would you like to auto reset the job Vn Yes Would you like to enable error proofing Appendix A Embedded Toolbox QA Alpha Controller 1 4 1 2 2 Tasks 1 4 1 2 2 1 General General setup includes task name disassembly speed and disassembly Setup acceleration The date of last modification appears at the bottom of the screen e Jobs Management o Tasks General embedded Toolbox Assembly Technologies Show All Jobs Management d Job configuration and manaaement Jobs 1 Steps 0 01 JOB 1 No Steps Duplicate Duplicate 1 General task is a collection of instructions or steps that define how the tool should perform the tightening process What name would you like
40. action for a MFB tap Reverse Specify the desired action for a MFB hold Disabled Specify the start mode you wish to use 3 Lights 4 Tones Appendix A Embedded Toolbox QA Alpha Controller 1 4 1 3 3 Lights Lights identifies mode and headlight timer value Setup e System Management o Lights embedded Toolbox Assembly Technologies l Show All system Management m confiduration and management 1 General 2 Triggers Choose the mode to use for lights 1 2 Job What is the headlight timer value 4 Tones Appendix A Embedded Toolbox 133 User Manual 1 4 1 3 4 Tones Tones sets sound options for accepted and rejected rundowns Setup e System Management o Tones embedded Toolbox Assembly Technologies v2 0RC2 Show System Management system 1 anfigur ation and management 1 General 2 Triggers 3 Lights 4 Tones Specify the tone you wish to hear after an acceptable rundown None Specify the tone you wish to hear after a reject rundown O Eee Appendix A Embedded Toolbox QA Alpha Controller Use the graphical button or table button amp 888 to swap view options Yellow highlight surrounds active button choice Configurations can be added deleted saved imported exported or pues using the button at the of the screen e Input Output 14 1 4 Input Output emb
41. ai a a Self explanatory Self explanatory N O N C Type normal timed flash Time Step Audit Audit 1 Audit 2 ANGLE HIGH Self explanatory ANGLE LOW Self explanatory N O N C Type normal timed flash Time Step Audit Audit 1 Audit 2 N O N C Type normal timed flash Time Step Audit Audit 1 Audit 2 N O N C Type normal timed flash Time Step Audit Audit 1 Audit 2 CYCLE ABORTED The rundown was aborted N O N C Type normal timed flash Time STOPPED was stopped Uy Mie N O N C Type normal timed flash Time FAULTED A fault condition is active N O N C Type normal timed flash Time READY The tool is ready to run N O N C Type normal timed flash Time The tool requires service N O N C Type normal timed flash Time Format float int16 int32 fixed precision Step Audit Audit 1 Audit 2 Format float int16 int32 fixed precision ANON Step Audit Audit 1 Audit 2 FAULT CODE Format float int16 int32 fixed precision Format float int16 int32 fixed precision E START TRIGGER Shows state of start lever or trigger N O N C Type normal timed flash Time MULTIFUNCTION Shows state of multifunction BUTTON N O N C Type normal timed flash Time SNUG ACHIEVED Snug torque is achieved N O N C Type normal timed flash Time CYCLE STOPS N O N C normal timed flash Time complete PART ID CHANGED When the part ID changes N O N C
42. annot 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 short description of the problem 100 Warranty Alpha Controller Contacts STANLEY ASSEMBLY TECHNOLOGIES 5335 Avion Park Drive Cleveland Ohio 44143 2328 USA Tel 1 440 461 5500 Fax 1 440 461 5592 SATinfo stanleyworks com STANLEY ASSEMBLY TECHNOLOGIES 1875 Research Drive Suite 200 Troy Michigan 48092 USA Tel 1 248 824 1100 Fax 248 824 1110 Toll Free Service 877 787 7830 Toll Free Sales 877 709 8006 STANLEY WORKS Ltd FRANCE Outils Portatifs et Systemes d Assemblage Zone Imoparc bat Loire 4 78190 Trappes France Tel 33 1 3050 9100 Fax 33 1 3051 0708 STANLEY GERMANY Inc Frankfurter Strasse 74 D 64521 Gross Gerau Germany Tel 49 0 6152 8052 0 Fax 49 0 6152 8052 22 SATGER stanleyworks com STANLEY TOOLS S r l ITALY Divisione Assembly Technologies 47 Via Parco 20046 Biassono MI Tel 39 039 2389 1 Fax 439 039 2389970 STANLEY ASSEMBLY TECHNOLOGIES Gowerton Road Brackmills Northhampton NN4 7BW England Tel 44 1604 827247 Fax 44 1604 827277 STANLEY ASSEMBLY TECHNO
43. aptive Tightening Control ATC T Target Controls What is the yield target 0 NM What is the TRC target 8 Soft Stop 9 Step Timers Appendix A Embedded Toolbox QA Alpha Controller 1 4 1 2 3 8 Soft Stop Soft Stop enables identifying the current off time hold time and ramp Setup time e Jobs Management o Steps Soft Stop embedded Toolbox Assembly Technologies 9 Jobs Management and management Jobs 1 Tasks 1 Step 01 JOB 1 01 New Step Duplicate Duplicate Duplicate 1 General Strategy 3 Torque Specification Limits 4 Angle Specification Limits 5 Tool Motor Contr ol 6 Adaptive Tightening Control T Target Controls 8 Soft Stop What is the current off time 0 001 Seconds What is the current hold time 0 025 Seconds What is the current ramp time 9 Step Timers Appendix A Embedded Toolbox 129 User Manual 1 4 1 2 3 9 Step Timers Step Timers sets cycle abort time and elapse time between steps Setup e Jobs Management o Steps Step Timers embedded Toolbox gt URC T Assembly Technologies Jobs Management lab cantiqurati n and mana nt Jobs 1 Tasks 1 Ste 91 JOB 1 01 New Step Duplicate Duplicate Duplicate 1 General 2 Strategy 3 Torque Specification Limits 4 Angle Specification Limits 5 Tool Motor Control 6 Adaptive Tightening Control ATC T
44. arget High Torque Low Torque Torque Bailout Snug Torque Angle Target High Angle Low Angle Angle Bailout Downshift Mode Disabled Manual ATC e Manual Downshift Mode e Manual Downshift Speed e ATC Starting Torque e ATC Ending Torque e ATC Ending Speed Soft Stop Yes No e Yes Current Off Time e Yes Current Hold Time e Yes Current Ramp Time Speed Power Acceleration Abort Timer Delay Between Steps Accumulate Angle Yes No e Strategy BACK Snug Torque Angle Target High Angle Low Angle Torque Target High Torque Low Torque Torque Bailout Downshift Mode Disabled Manual ATC e Manual Downshift Mode e Manual Downshift Speed Software Map 91 92 e ATC Starting Torque e ATC Ending Torque e ATC Ending Speed Soft Stop Yes No e Yes Current Off Time e Yes Current Hold Time e Yes Current Ramp Time Speed Power Acceleration Abort Timer Delay Between Steps Accumulate Angle Yes No Strategy RATE Torque Rate Target High Torque Low Torque Torque Bailout Snug Torque High Angle Low Angle Angle Bailout Downshift Mode Disabled Manual ATC e Manual Downshift Mode e Manual Downshift Speed e ATC Starting Torque 96 e Ending Torque e ATC Ending Speed Soft Stop Yes No e Yes Current Off Time e Yes Current Hold Time e Yes Current Ramp Time Speed Power Acceleration Abort Timer Delay Between Steps Accumulate Angle
45. button arms activates the start function but does not start the tool The blue assembly light 2 comes on to show that the tool is armed Reset Reject Pressing the button stops the reject tone 74 QPM DC Electric Tools Alpha Controller 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 Master Counter Records the total number of tightening cycle completed e Cycle Counter Records the number of tightening cycles completed since the last time it was reset e PM Counter Records the number of tightening cycles completed since the last time it was reset e PM Threshold When the PM Counter exceeds the PM Threshold Limit the controller provides a maintenance alert Each time the controller is turned on it reads the tightening cycle counters 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
46. che FE Time Speed d Power Programming Alpha Controller Strategy TC AM Screens Options Screens Acceleration j Abort Timer Between steps Abort Timer j Delay Between Steps d Accumulate Angle Abort Timer belay Between Steps d Accumulate Angle Abort Timer 12 abort Ti ner j Delay Between Steps Delay Between Steps Accumulate Angle Me B Accumulate Angle 2 5 1 4 2 Strategy AC TM Strategy AC TM Screens Options Screen Step settings affect only the active Task STEP Emum Programming 23 Strategy AC TM Screens Snug Torque Angle Target d High Angle High Angle Low Angle High Torque Low Angle j High Torque Torque Torque High Torque ELI EI d Torque Bailout p933 24 User Manual Options Screen Programming Alpha Controller Strategy AC TM Screens Q Torque Bailout EEEE Low Torque mi Downshift Mode DTSRELED Downshift Mode PISABLED H ooft Stop VES Torque Bal lout 2999 5 i Downshift Mode j soft Stop Ott Time Soft Stop Time Programming E Current Hold Time Options Screen Eo Mode T Soft Stop Downsh 1 Mode MANUAL Downshift Torque Dawnshi ft Dawnshift Torque qe Mode tu Dawnshi ft Speed 1 Downshift Torque n ram LDownshift Speed Soft Stop Current Off Time Current Hold Time Current H
47. connecting a power source always ensure the tool or controller is turned off Limit controller access to trained and qualified personnel Lock controller cabinets WARNING ELECTRICAL HAZARD To Avoid Injury Do not use this product near water for example near a washbowl wet basement or the like This product should be located away from heat sources such as radiators or other devices that produce heat This product should not be subjected to vibration or shock or in close contact with water or other liquids To minimize electrical interference place the module as far away from possible sources of electrical noise such as arc welding equipment 4 Getting Started Alpha Controller 14 Plinth 6 152 mm gt 4 102 mm 83 5 mm 0 375 10 mm 18 457 mm 13 305 mm Plinths are used as wall mount brackets for Alpha Controllers This allows for easy installation quick change out and provides for neat cable management Plinths and Alphas can be mounted individually for single tool operation or grouped for multiple applications 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 plinths are mounted next to each other the center to center distance between the mounting holes in different plinths is 2 50 8 mm When plinths are mounted one above another the center to center distance between the
48. cument 8 64KB From localhost s 0 Finished harm your computer If you do not trust the source do not open or o While files from the Internet can be useful some files can potentially 4 save this file What s the risk embedded Toolbox Assembly Technologies Show All Quick Start Parameter confiaur tion Wizard far easy contrall r set 1 Job 2 Task Definition 3 Task Name 4 Strategy 5 Audit Step 6 Controls T Wobble SlowSeek 9 Start Delay 4 0 Condition Fastener 11 Pre Torque 4 2 Backout Fastener 13 Release Fastener 14 Finished Save the Job You have created a job that has a number of tasks associated with it list of the tasks that will be created is shown below Task Bolts 1 Appendix A Embedded Toolbox 115 User Manual 1 4 1 2 obs Management Jobs Management configures tightening cycles with full controller Setup capability to manage jobs tasks and steps The number of configurations appears directly following the name in parenthesis The windows display the items already setup for the controller To define a new setup copy and modify an existing setup step by step setup options are displayed below the highlighted active window e Jobs Management Setups can be imported exported or saved using the appropriate button at the bottom of the screen Use the plus button 7 add a new job task or step
49. d ATC enabled o Controls embedded Toolbox Assembly Technologies Show WPP Mo su 1 Job 2 Task Definition 3 Task Name 4 Strategy 5 Audit Step 6 Controls Select the controls you require to add to the basic strategy _ Wobble Slow Seek _ Start Delay _ Condition Fastener Pre Torque Backout Fastener _ Release Fastener T Slow Seek 8 Finished Save the Job Appendix A Embedded Toolbox 107 1 4 1 1 7 Wobble Set output rotate degrees tool speed and maximum torque embedded Toolbox Re Assembly Technologies w Quick Start 9n larameter configuration Wizard for amp asy 1 Job Name 2 Task Definition 3 Task 4 Strategy User Manual Setup e Quick Start Wobble 5 Audit Step 6 Controls 7 Wobble How many degrees should the output rotate 360 What tool speed should be used 0 RPM What is the maximum torque that should be measured 8 Slow Seek 9 Start Delay 10 Condition Fastener 11 Pre Torque 12 Backout Fastener 13 Release Fastener 14 Finished Save the Job Appendix A Embedded Toolbox QA Alpha Controller 1 4 1 1 8 Slow Seek Set output rotate degrees tool speed and maximum torque Setup e Quick Start Slow Seek embedded Toolbox 2 URC Assembly Technologies Show All Quick Start jeter Co iraton wiza of 1 Job Name 2
50. e NOK Task Selected Job Completed Task Complete Task Selected Bit Job Selected Bit Torque OK Torque Hi Torque Low Angle OK Angle Hi Angle Low Cycle Aborted Stopped Faulted Ready PM Start Trigger MFB Snug Achieved Cycle Stopped Step Bit G Off In Cycle Job Selected Disassembly Detected Tool Running Cycle OK Cycle NOK Task Selected Job Completed Task Complete Task Selected Bit Job Selected Bit Torque OK Torque Hi Torque Low Angle OK Angle Hi Angle Low Cycle Aborted Stopped Faulted Ready PM Start Trigger MFB Snug Achieved Cycle Stopped Step Bit H Off In Cycle Job Selected Disassembly Detected Tool Running Cycle OK Cycle NOK Task Selected Job Completed Task Complete Task Selected Bit Job Selected Bit Torque OK Torque Hi Torque Low Angle OK Angle Hi Angle Low Cycle Aborted Stopped Faulted Ready PM Start Trigger MFB Snug Achieved Cycle Stopped Step Bit J Off In Cycle Job Selected Disassembly Detected Tool Running Cycle OK Cycle NOK Task Selected Job Completed Task Complete Task Selected Bit Job Selected Bit Torque OK Torque Hi Torque Low Angle OK Angle Hi Angle Low Cycle Aborted Stopped Faulted Ready PM Start Trigger MFB Snug Achieved Cycle Stopped Step Bit K Off In Cycle Job Selected Disassembly Detected Tool Running Cycle OK Cycle NOK Task Selected Job Completed Task Complete Task Selected Bit Job Selected Bit Torque OK Torque Hi
51. eave the step unconfigured What strategy do you want to use on this step 3 Torque Specification Limits 4 Angle Specification Limits 5 Tool Motor Control 6 Adaptive Tightening Control T Target Controls 8 Soft Stop 9 Step Timers CET Appendix A Embedded Toolbox 123 1 4 1 2 3 3 Torque Specification Limits Torque Specification Limits choices include target torque high and low torque limits bail out torque limit and minimum snug torque limit and accumulate torque identification Assembly Technologies Show All Jobs 1 01 JOB 1 Duplicate 1 General 2 Strategy 3 Torque Specification Limits What is the target torque 0 NM What is the high torque limit 9999 9 NM What is the low torque limit 4 Angle Specification Limits 5 Tool Motor Control 6 Adaptive Tightening Control ATC T Target Controls 8 Soft Stop 9 Step Timers embedded Toolbox agement 3 24 and managemen Jobs Man lob pcontiguratian Tasks 1 01 New Step Duplicate _ JF CET SEIS Appendix A Embedded Toolbox User Manual Setup e Jobs Management o Steps Torque Specification Limits Duplicate QA Alpha Controller 1 4 1 2 3 4 Angle Specification Limits Angle Specification Limits choices include target angle high and low Setup angle limits bail out angle limit and a check box to accumulate angle e
52. edded Toolbox Input Output input Gut pt ut configuration OK H d 9 Low 24 Yolt Output Bit Width gt Appendix Embedded Toolbox 135 1 4 1 4 1 Configuration Dropdown Use the dropdown to choose a configuration for setup 24 Volt Output 24 Volt Output 24 Volt Input Fieldbus Output Fieldbus Input Modbus TCP Output Modbus TCP Input embedded Toolbox Assembly Technologies Input Output Input Output configuration 24 Volt Input Fieldbus Output Fieldbus Input Modbus TCP Output Modbus TCP Input AA Appendix A Embedded Toolbox User Manual Setup e Input Output QA Alpha Controller 1 4 1 4 2 Add Insert Delete Bit Assignments To add a bit assignment at the end of list click the add button Setup 4 There are eight maximum assignments available for the 24 volt ra To add a bit assignment before a selected bit assignment first select Input Output position with green highlight click a line once using the left mouse button then click the insert button Insert the add button changes to insert To remove a bit assignment highlight and click the delete button embedded Toolbox Assembly Technologies Input Output utput gt x Contact Type 27 Output Type Normal Minimum ON Time Appendix A Embedded Toolbox 137 User Manual 1 4 1 4 3 Func
53. er selected tab strategy Units Thread Direction strategy Units Direction p strategy TORGUE Units Thread Direction High Torque Torque Low Torque MI Torque Torque snug Torque High Angle enug Torque High Angle d EU Programming strategy Units Thread Direction Strategy Units Thread Directi Strategy TORGUE amp ANGLE Units Thread Direction 11 12 Wizard Screens High Angle Low Angle Speed High Angle Low Angle User Manual Options Screen Elobb e Blow Seek H Bass Delay Aingle Target Speed Max Torque L HIzHED HOEELE Angle Target Speed T l MEE Condition Fastener Delay Delay Delay Time Torque i CANCEL E L urIfHRB ETH I Delay Time 8 25 Max Torque f CANCEL F Programming Alpha Controller Wizard Screens Options Screen RHIZHEB CCONDITION IET Down Target Torque Delay Time eam ee Time HI ZARD CONDI TION Delay Time Time Up Angle Target Delay Time Max Time Angle ania Delay T Time Time mle Ear IH IZHED PR TORGUE Torque Target T C Backout Fastener Fastener Release RjBackout Fastener Fastener Release HIZARO EACHKOUT Angle Target Torque Target HIZHED EHCHOLIT DECEM Angle Target Torque Target
54. ers If no then a bolt control option e Quick Start appears at top o Task Definition Assembly Technologies Show All 1 Job Hame 2 Task Definition What is the number of bolts that are to be fastened 1 Do you want all the bolts to be fastened with the same parameters 3 Task 4 Strategy 5 Audit Step 6 Controls T Slow Seek 8 Finished Save the Job Appendix A Embedded Toolbox 103 User Manual 1 4 1 1 3 Task Name Enter the task name to identify this set of fastening parameters Setup e Quick Start o Task Name embedded Toolbox 21 Assembly Technologies Show All Quick Start 1 Job Name 2 Task Definition 3 Task Name What do you want to name this set of fastening parameters Bolt 4 Strategy 5 Audit Step 6 Controls T Slow Seek 8 Finished Save the Job Appendix A Embedded Toolbox QA Alpha Controller 1 4 1 1 4 Strategy Strategy options include Torque Angle and Torque amp Angle Use this Setup screen to also set units and fastening direction e Quick Start o Strategy embedded Toolbox 2 0 1 Assembly Technologies Local Quick Start Parameter configuration wizard for easy controller setup 1 Job 2 Task Definition 3 Task 4 Strategy strategy defines the type of interaction and monitoring that the controller and tool will have with the bolt during the execution of the step
55. et Contact Type 7 Output Type Normal Minimum ON Time Appendix A Embedded Toolbox 139 User Manual 1 4 1 4 5 Screen Examples 1 4 1 4 5 1 24 Volt Output See page 83 for 24 volt assignable Output functions Setup e Input Output embedded Toolbox Assembly Technologies Input Output inr Outp ut contigur ation 24 valt Output gt A gt 7 Output Type Normal Minimum ON Time Appendix A Embedded Toolbox QA Alpha Controller 1 4 1 4 5 2 24 Volt Input See page 82 for 24 volt assignable Input functions Setup e Input Output embedded Toolbox Assembly Technologies Input Output Input Output configuratior Hame Width Start Select Job Select Task Job Select Bit Task Select Bit Job Verify Task Verify c ON gt Contact Type Appendix A Embedded Toolbox 141 User Manual 1 4 1 4 5 3 Fieldbus Output See page 83 for fieldbus assignable Output functions Setup e Input Output embedded Toolbox Assembly Technologies Input Output Input Output configuratior Job Selected Torque Task Selected Torque High Angle Low Parameter Start Trigger Snug Achieved Cycle OK In Cycle Contact Type Output Type Normal Minimum ON Time Appendix A Embedded Toolbox QA Alpha Controller 1 4 1 4 5 4 Fieldbus Inpu
56. et e Server IP e Port e Cell e Station 6 1 4 Other e General Name e Keypad Mode Disabled Task Select Job Select Part ID e Count Mode Count Up Count Down Stop Abort within Limits OK e Users e Add e Manage e 1 Add e 2 Delete e 3 Change Password e 4 Change Access e Outputs e C Off In Cycle Job Selected Disassembly Detected Tool Running Cycle OK Cycle NOK Task Selected Job Completed Task Complete Task Selected Bit Job Selected Bit Torque OK Torque Hi Torque Low Angle OK Angle Hi Angle Low Cycle Aborted Stopped Faulted Ready PM Start Trigger MFB Snug Achieved Cycle Stopped Step Bit e Off In Cycle Job Selected Disassembly Detected Tool Running Cycle OK Cycle NOK Task Selected Job Completed Task Complete Task Selected Bit Job Selected 94 Software Map Alpha Controller Bit Torque OK Torque Hi Torque Low Angle OK Angle Hi Angle Low Cycle Aborted Stopped Faulted Ready PM Start Trigger MFB Snug Achieved Cycle Stopped Step Bit E Off In Cycle Job Selected Disassembly Detected Tool Running Cycle OK Cycle NOK Task Selected Job Completed Task Complete Task Selected Bit Job Selected Bit Torque OK Torque Hi Torque Low Angle OK Angle Hi Angle Low Cycle Aborted Stopped Faulted Ready PM Start Trigger MFB Snug Achieved Cycle Stopped Step Bit F Off In Cycle Job Selected Disassembly Detected Tool Running Cycle OK Cycl
57. f 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 hardware or accessories OEM Products Limited Warranty Some Stanley Assembly Technologies custom engineered systems include compone
58. get High Torque Low Angle j Torque Target Torque Target j High Torque d Low Torque Torque High Torque ELI EI d Torque Bailout 9999 32 User Manual Options Screen Programming Alpha Controller Strategy BACK Backoff Screens Torque Bailout EET Mode Low Torque Downshift Mode Soft Stop Torque Bailout Mode 3 RDownshift Torque iDownshift Speed Soft Stop Time i Current Hold Time Programming 9999 DISABLED HE DISABLED EE mnn Options Screen ls Mode Soft Stop 3 Current Off Time Mode Soft Stop Current 0 1 Time E Mode Downshift Torque Downshift Spee MANUAL Downshitt Mode d Downshift Torque Dawnshi ft 22200 Mode Downshift Torque Dawnshi ft 22200 Soft Stop j Current Off Time Current Hold Time 33 User Manual Strategy BACK Backoff Screens Options Screen Current Dff Time Current Hald Time d burrent Ramp Time Current Off Time Current Hold Time Current OFF Time Current Hold Time Soft Stop Speed Power Power x Acceleration FEP Acceleration j Abort Timer T Acceleration j Abort Timer Between St Delay Between Steps Accumulate Angle Programming Alpha Controller Strategy BACK Backoff Screens Options Screen Abort Timer Delay Between Steps Accumu
59. ha Controller Power Cord 79 4 1 2 Alpha Controller Tool Connector 79 4 1 3 Alpha Controller Serial 80 4 1 4 Alpha Controller Ethernet Connector 80 4 1 5 Alpha Controller Model QA1001 DeviceNet M 80 4 1 6 Alpha Controller Model QA1001 P Profibus Port 81 4 1 7 Alpha Controller Model QA1001 _ V Input and Output COMING GION RU T T eee ee 81 4 2 Assignable Input Output Functions 82 CO S y ee 85 SOI QI S N acus tae ate ab OE ee 89 re 89 I 89 e Ha 89 t 89 MES o T 90 61 3 GomimuhlcatlOFiS 2 3 99 9 9 Mitto iode desde 94 SNR M ONE P 94 6 1 5 Full BaCKUD RESTON E ui odii ea on da n n c ns uu 96 62 CC 96 0 2 T WOO 96 O22 GNE TETTE TT 97 O ANIZO ids 97 PLA 99 Appendix Embedded Toolbox 103 Contents lii Alpha Controller Getting Started This manual is in
60. he X Bar Range view uses the information icon to display a Analyze dropdown showing either torque or angle data Click on the information e Rundown Analysis icon to choose either torque or angle data After making data selections click the green check to accept or the red x to abort Click the information icon again to close Settings Statistical Data Set amp Torque Angle X Bar Range Job 1 m im Task 1 Population Size 23 Subgroup Size 5 Numberof Bars 20 17 Elcl Rucl embedded Toolbox Rundown Analysis 1980 01 01 1 01 52153 s 1950 01 01 1980 01 01 TIE lumt ii ni bide ia 185HD Dl 01 D1 4H 30 Appendix A Embedded Toolbox QA Alpha Controller 1 4 2 2 Tool Diagnostics Tool Diagnostics displays tool torque current temperature angle and Analyze speed Setup and pass fail data for rundowns done while the screen is active are listed Exiting the screen erases the data Tool Diagnostics embedded Toolbox Assembly Technologies Tool Diagnostics Appendix A Embedded Toolbox 153 User Manual 1 4 2 3 1 0 Diagnostics I O Diagnostics displays input and output Analyze Use the graphical button amp or table button to swap view options Yellow highlight surrounds active button choice e I O Diagnostics embedded Toolbox Assembly Technologies Show All I O Diagnostics Input Output ana
61. he 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 orangle tightening cycle was rejected for not reaching either low torque or low angle Red High torque or angle tightening cycle was rejected for exceeding either high torque or high angle Alllights Reverse The next time the start trigger is engaged the tool will release the fastener 76 QPM DC Electric Tools Alpha Controller 3 5 5 Setting Torque Angle and Other Operating Parameters WARNING EXCESSIVE TORQUE CONDITION To Avoid Injury e Only trained and qualified personnel should program controllers e Never set control limits above the maximum rating of the tool e Setting control limits above the maximum rating of the tool can cause high reaction torque e Always test for proper tool operation after programming the controller The Alpha controller can be setup to change tightening parameters from the tool 3 6 Special Application Tools 3 6 1 Exposed Gear Socket Tools WARNING PINCH POINT AT THE EXPOSED GEARS OR TEETH To 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
62. hreshold Torque Statistical Threshold Statistical Threshold Disassembly Speed BEEE oo Acceleration 3898 Disassembly Speed E Disassembly Acceleration 300 Si LOCK Out E Disassembly Acceleration Cycle Lock Dut Audit D LAST Cycle Lock Dut Torque Audit Step Lastia Audit Munt Torque Audit Step AS Torque Audit Step Jangle Audit Step He pangle Audit Step tee Rate Rate Programming Task Tab Screens dangle Audit Step Torque Rate UY Torque Rate Torque Average ms Interval Torque Average ms Angle Interval 18 Torque ludit Step Jangle Audit Step jTorque Rate User Manual Screens Torque Audit Jangle Audit Step Torque Rate AS Torque Audit Jangle Audit Step Rate Jangle audit Step jTorque Rate Torque Average ms Angle Audit Step Torque Rate Programming Alpha Controller 2 5 1 4 Setup Step Button Step 1 Step 12 Step Screens Step 1 Step 12 Options Screens Step settings affect only the active Task Each strategy selection has different configuration 2 Nc Torque Target Torque Target Torque High Torque Torque Target d High Torque 2 5 1 4 1 Strategy TC AM Strategy TC AM Screens Options Screens Step settings affect only the active Task Torque Target Torque Target High Torque 2999 9
63. icable 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 Always ensure drive socket is fully seated and locked into position before connecting power to tool 3 3 2 Suspension Devices Tool suspension devices or bails help support the weight of the tool during tightening operations Attach these devices securely and periodically inspect them for damage or loosening 3 3 3 Cable Installation WARNING ELECTRICAL HAZARD To Avoid Injury e Never use a tool with a damaged cable e Never abuse a cable carry a tool by its cable hang a tool by its cable or pull on a cable to disconnect it from the tool or the controller To ensure superior performance and safe operation use the Stanley cables specifically designed to operate these tools Never use a tool with a damaged cable Never abuse a cable carry a tool by its cable or pull a cable to disconnect it Also keep the cord away from heat sharp edges or moving parts Use cables of appropriate length 60M maximum for each application position and or suspend them in such a way as to prevent tripping and cable damage and to provide good work area maneuverability QPM DC Electric Tools 73
64. include multiple fasteners controlled by one or more tasks 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 When the peak torque recorded fails 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 Controls the operation of the multiple function panel MFP on QPM tools Choices includes MFB Tap Disabled Reverse Task Sel Arm Rst Rej Job Sel 85 Odometer Parameter Set PM Counter PM Counter PM Limit RATE Reject Tone Slow Seek Snug Torque Soft Stop Speed Spindle Steps Strategy System Outputs Task TC AM Thread Direction Threshold Torque Tool Tones Torque Average Torque Calibration Torque Target Trace Trip Counter 86 User Manual Job Rst and MFB Hold Disabled Reverse Task Sel Arm Rst Rej Job Sel Job Rst The default value is Disabled The odometer increments after every in cycle to tracks the total tool cycles It cannot be reset Now referenced as a Task Records the number of tightening cycles completed since the last time it was reset for Planned Maintenance The PM preventative maintenance counter tracks the total too
65. ine mode setups and configuration file exports can be created These files can be imported to a connected controller in the future 1 3 Navigation User Manual A lock unlock icon connects or disconnects the controller An amplifying signal icon EY shows green when connected and red when disconnected NOTE Use the Show All button not the browser s back button to return to the main menu 1 4 Menu Options Quick Start gives wizard capability to configure simple tightening cycles for a specific job Jobs Management configures tightening cycles with full controller capability to manage jobs tasks and steps Systems Management configures system name multiple function button MFB mode keypad mode and tones Input Output configures 24 volt input output fieldbus input output modbus TCP input output using either a table or graphical view Rundown Analysis enables data import export print and analysis including traces statistics historical data and xbar range views Tool Diagnostics shows real time tool parameters such as speed and temperature I O Diagnostics enables real time analysis and stimulus for 24 volt input output fieldbus input output modbus TCP input output Reports shows saves and prints detail controller reports for system Jobs tasks and or combined jobs and tasks Tool Configuration Update upgrades tool configuration information Appendix A Embedded Toolbox Setup e Quick Star
66. ix characters for Angle Torque Status Six characters for Torque eight characters for Time ten characters for Date thirty two characters for VIN two digits for Task L lowfor Torque or Angle two digits for Spindle Number A acceptfor Torque Angle or Overall status H highfor Torque or Angle Always an 5 R replace Torque and rejectfor Overall status The barcode input monitors inter character timing When there is a 500ms gap between characters a complete barcode is assumed When received it flashes the new barcode on the display and logs it with all rundowns until another barcode is received If the incoming barcode is longer than 32 characters then the last 32 characters received is used 4 1 4 Alpha Controller Ethernet Connector Alpha Controllers have a single RJ 5 Ethernet connection located on the bottom of the module for connecting to a plant wide fastening network 4 1 5 Alpha Controller Model QA1001 D DeviceNet Alpha Controllers can have a single Micro DeviceNet M port for connecting the Alpha Controller to a Sigma Interface or to a master controller from another manufacturer In addition error proofing is available through this port Alpha Controllers Micro DeviceNet Connector 80 Controller Connections and Inputs Outputs Alpha Controller 4 1 6 Alpha Controller Model QA1001 Profibus Port Alpha Controllers can have a single Profibus por
67. l cycles until maintenance is required When the PM Counter exceeds the PM Limit the controller provides a maintenance alert RCAM Torque Rate Control This strategy uses an increase in Torque Rate Control to a specified level to indicate a fastening process event Controls the tone made from the handle of handheld QPM tools for rejected tightening cycles Allows distinct tones for tools in adjacent workstations Slow Seek helps engage the socket or fastener at a pre selected speed torque level and angular rotation Once engaged the tightening cycle completes at a higher speed Slow Seek prevents cross threaded fasteners and previously secured fasteners from being counted in a batch The controller begins to monitor the tool for angle at a pre selected threshold torque Any increase in angle after the snug point results in a corresponding increase in the tension or clamp load within the joint Soft stop minimizes the torque impulse to the operator during tool shutoff at the end of the tightening cycle The speed at which the tool operates during the initial portion of the tightening cycle prior to ATC or downshift A spindle represents a connection to a hand held or fixtured tool connected to a controller Instructions to operate a tool defined by available strategies such as TC AM Torque Control Angle Monitoring Identifies what variables will be used to control the tool during a tightening cycle Tool Running In Cycle Cyc
68. late j Abort Timer j Delay Between Steps d Accumulate Abort Tiner Delay Between Steps d Accumulate 2 5 1 4 5 Strategy Strategy RATE Screens Options Screen Step settings affect only the active Task Torque rate strategy Torque Average and Angle Interval configuration 15 set in the Task tab i Torque Rate Target High Torque Low Torque High Torque Torque Torque Bailout Programming 35 Strategy RATE Screens Low Torque I Torque Bailout j 5nug Torque Torque Bailout j snug Torque High Angle Snug Torque j High Angle Low Angle High Angle Low Angle j ngle Bailout Low Angle Angle Bailout 36 9999 9E Em x 9993 Downshift Mode DISABLED User Manual Options Screen Programming Alpha Controller Strategy RATE Screens angle Bailout j Downshift Mode Ex 20 Downshi ft Mode Jd Downshift Torque Dawnshi ft aus stop Current Off Time COU eu Hold Time Programming DISABLED YES Options Screen soft Stop LuUrrent A Soft Stop Time Mode Downshift Torque Dawnshi ft RE Dounshi ft Mode j HDownshift Torque Downshi ft speed Dawnshitft Torque rDounshi ft Mode Downshi ft 80 Soft stop Current Off Time Current Hold
69. le OK Cycle NOK Disassembly Detected Indicate Job also fixed and pulsed Control tool operation for tightening a fastener which can have one or more steps 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 Formerly referenced as Parameter Set Torque Control with Angle Monitoring This strategy controls a tool based on torque and monitors the angle limits defined by user Sets assembly direction to clockwise CW or counter clockwise CCW 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 Distinctive sounds assigned to tool functions Rate Yield and AC TA Number of torque samples averaged for rate calculation Torque samples are taken every millisecond A running average is calculated based on these samples A higher number gives a smoother rate 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 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 A display plo
70. ller 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 1 2 Alpha Controller Tool Connector Alpha controllers use a single 30 pin connector to connect two types of QPM DC electric tool cables patent pending QPM E__ DC electric tool cables use a MIL C 38999 Series III connector The connector is a 17 305 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 Controller Connections and Inputs Outputs 79 User Manual 4 1 3 Alpha Controller Serial Connector Alpha Controllers have two male DB 9 connectors One labeled COM PORT 1 connects a laptop computer for access to Embedded Toolbox software The connection between the computer and the controller is a simple null modem cable Function Transmit Data TP Data Set Ready 9 Ring Indicator A second DB 9 connector COM PORT 2 is setup as 9600 8 N 1 and is not programmable When the box is setup for PFCS protocol over serial the barcode and printout feature 1s disabled 501 PSOL 20 01 1988 00 03 38 0 9A OA Carriage Return r Overall Status A R Angle Status L A H S
71. lysis and stimul us 24 Volt Output Word Bit Width State H e oun C OQ fk C 4 ui La c TENE Appendix A Embedded Toolbox QA Alpha Controller 1 4 2 3 1 Configuration Dropdown Use the dropdown to choose a configuration to view Analyze nt Dutt Diagnostics Fieldbus Output Fieldbus Input Modbus TCP Output Modbus TCP Input embedded Toolbox Assembly Technologies 2 0RCZ2 I O Diagnostics Input Output analysis and stimulus imt 24 volt Output 24 Volt Input Fieldbus Output Fieldbus Input Modbus TCP Output Modbus TCP Input ww C EY 4 a Appendix A Embedded Toolbox 155 User Manual 1 4 2 3 2 Options The options for a selected bit assignment s function appear at screen Analyze bottom Contact Type HO Diagnostics Y Output Type Normal Minimum Time embedded Toolbox Assembly Tachnologles Show I O Diagnostics 24 Yon Output In Cycle Ready Disassembly Detected Job Select Bit Job Select Bit Job Select Bit Job Complete Job Complete oOo Oo Oo Oo Oo Oo amp gt Ooo Oo O D Contact Type Output Type Normal Minimum OM Tine z Appendix Embedded Toolbox QA Alpha Controller 14 3 Report Report 3 Parameter Sheet Parameter Sheet provides a summary for System Jobs Tasks and all Reports J
72. mounting holes in different plinths is 6 152 4 mm 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 Getting Started 5 User Manual 1 4 2 Controller 1 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 2 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 3 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 4 Connect the Alpha Controller to a power source 5 Connect the tool cable to the Alpha controller and press the power switch on the controller 1 4 3 Alpha Controller E Stop Precaution WARNING INTEGRATED E STOP CIRCUIT NOT PRESENT To Avoid Injury When an 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 6 Getting Started Alpha Controller
73. n Bui Action Hold Action Programming Alpha Controller Other Screens pM Screen ae Push To Start Input Action DISABLED 1 jLever Push To Start Switch TE Push To Start Md ca Start Input CHMCEL Headlight Timer E Timer TENTE x ae Reject Tone BReject Tone Taccept Tone Reject Tone esate Tn Reject Tone Programming 63 Other Screens Reject Tone Temperature Limit jTarsion Factor JTorsion Factor jRequires Arming TTeaperature ETIN jTarsion Factor jRequires Arming dTorsion Factor Requires Arming User Manual Options Screen Taccept Tone Reject Tone nccept Tone aReject Tone aReject Tone Temperature jTarsion Factor Requires Arming Programming Alpha Controller Other Screens 1 ir 2668 H ir 2668 2 5 4 Setup Menu 4 Full Backup Restore Full Backup Restore Screens 1 Jobs a Programming Options Screen Options Screen 65 User Manual Full Backup Restore Screens Options Screen EFHLIL TSF i RESTORE p backup Are wou sure EE E To select a file use the up and down arrow keys to scroll through list To change directories highlight Up One Level and then press the center button E Ll BEFHRHULTZZ Fl Are you sure The default button loads current software facto
74. nts 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 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 Warranty 99 User Manual contract price for the products claimed to be defective Some states and countries do not allow the exclusion or limitation of incidental or consequential damages so this specific limitation or exclusion may not apply to you Specification Changes Stanley retains the right to discontinue and or change specifications of any Assembly Technologies products without responsibility for incorporating changes in products already sold Warranty Claims To apply for warranty consideration the original purchaser should take the following action Contact the Stanley Assembly Technologies customer service department
75. nug Torque Angle Target j High Angle Angle Target j High Angle Low Angle Programming 43 Strategy Screens High Angle j Low Angle Hi g Angle j High Torque Low Torque High Torque Torque Torque Bailout Low Torque j Max Torque Bailout Min Torque Bailout Torque Bailout 1 Torque Bailout Downshift Mode _ 44 User Manual Options Screen Programming Alpha Controller Strategy AC TA Screens Min Bailout Downshi ft Made Downshi ft Mode Jd Downshift Torque Dawnshi ft aus stop Current Off Time COU eu Hold Time Programming WaRURL MANUAL Downshi ft Mode Options Screen soft Stop LuUrrent A Soft Stop Time Downshift Torque Dawnshi ft RE Dounshi ft Mode j HDownshift Torque Downshi ft speed Downshi ft Mode 3 Downshift Torque Dawnshi ft Soft stop Current Off Time Current Hold Time Time Lurrent Hold Time Current Ramp Soft stop d Current Off Time Current Hold li MANUAL 45 Strategy AC TA Screens mn j Abort Timer Acceleration j Abort Timer Between Abort Tiner Delay Between Steps Sa 46 User Manual Options Screen Current of Time Lurrent Hold Time
76. ob and Task combinations e Parameter Sheet Use the buttons that appear directly above report to save print scroll through pages and change report views page and width Parameter Sheet jE t Parameter Sheet Alpha Controller Tap Parameter Select MFB Hold Disabled Keypad Mode Reject Tone None Appendix A Embedded Toolbox 157 1 4 4 Service Service i Tool Configuration Update Tool Configuration Update enables upgrading tool configuration information for currently attached tool embedded Toolbox Assembly Technologies Tool Configuration Update Lipd ste tool para nfiauratior 1 Welcome Tool Data Update This component will help you upgrade the configuration information stored in the Stanley tool that is currently attached to the controller 2 Choose File Appendix A Embedded Toolbox User Manual Service Tool Configuration Update QA Alpha Controller embedded Toolbox Assembly Technologies Show All J 1 Welcome 2 Choose File Please select a tool data file This file will be used to update the tool s data Browse Appendix A Embedded Toolbox 159
77. old Time d Current Ramp Time 25 Strategy AC TM Screens Power q Acceleration Acceleration j Abort Timer 1 T Delay Between Steps d Accumulate Angle abort Timer belay Between Steps 26 User Manual el ei Screen stor Current Off Time I Current Hald Time pow Time Lurrent Hold Time Current Ramp Time Soft Stop Speed a Programming Alpha Controller Strategy AC TM Screens Options Screen Abort Timer abort Tiner j Delay Between Steps H f Delay Between Steps Accumulate aik iE B Accumulate 2 5 1 4 3 Strategy AC TC Strategy AC TC Screens Options Screen Step settings affect only the active Task STEP 1 Torque Target j High Torque Low Torque High Torque Torque Torque Bailout Low Torque Torque Bailout Snug Programming 27 User Manual Strategy AC TC Screens Options Screen Torque Bailout j 5nug Torque j Angle Target Snug Torque Jangle Target High Angle 2299 9 Angle Target j High Angle Low Angle j Low Angle Angle Bailout Angle Angle Bailout ji Downshift Mode 28 Programming Alpha Controller Strategy AC TC Screens Angle Bailout j Downshift Mode Ex a Downshift Mode j FDownshift Torque 4 Downshift Speed Programming Options Screen Mode Soft Stop Current Off Time Downshift Mode j soft
78. on may be harmful to your hands arms shoulders or back Use suitable protective equipment and work methods whenever an application presents a hazard Repetitive Motion The use of power tools may involve highly repetitive motions of the 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 15 excessive risk of injury Generally the greater the exposure to a single risk factor or combination of factors the greater the risk for CTDs Forceful exertions and motions Extreme postures and motions Repetitive exertions and motions Intended duration of exertion postures motions vibration and cold Insufficient rest or pauses Work organization risk factors Environmental risk factors These risk factors span job design and content operator training work method work pace work environment proper tool selection and other work place factors beyond the control of the tool QPM DC Electric Tools 71 User Manual 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 g
79. onnected via a serial link 1 2 1 3 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 1 2 1 4 Running the Controller Gateway The installer sets the Controller Gateway to automatically launch each time the computer is started When Controller Gateway is running a small icon appears on the system tray or Windows Task bar typically at the bottom right corner of the screen Right clicking on the Controller Gateway icon displays its menu From the menu select the Auto Connect option Note that Auto Connect 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 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 offl
80. ore 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 Getting Started 1 User Manual 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 2 User Manual Conventions Underlined text indicates glossary terms Menu options appear in Ar al 10 bold italic 1 3 Specifications Layout and Display 34mm beh wim oe 7g 010095 non condensing 220 240 VAC 50 60 Hz 15 service 2
81. other programming functions 4 are in use Run Display Codes indicate why a tightening cycle shutoffs prior to completion Run Display Description Code TIME Tightening time exceeds programmed cycle abort time value STOP Spindle stopped by either the operator or other device 125 Spindle stopped due to torque achieving greater than 125 torque limit for the spindle FAULT Precedes a fault described in 2 3 STALL Spindle in stall status 8 Programming Alpha Controller Alpha Controller Icons Icon Status Description Locked Password required to make changes Unlocked Changes possible automatically re locks in time Busy working Wait Message waiting Check the run screen Warning system not operable Check the run screen T Force on or off Identifies an input output forced on or off Stop No strategy selected 2 3 Faults The display background color in normal operation is white In the event of a fault the display background becomes red and the fault description appears on screen System Faults Overcurrent Fault Logic Voltage Fault Position Feedback Fault Transducer Span Fault Temperature Fault Unrecognized Tool Tool Communications Transducer Current Fault Transducer Zero Fault NO STRATEGY SELECTED Can t run the wizard Unknown Tool 2 4 Log From the main menu run display press the down arrow to view the log of controller events The log lists events by occurrence date and time using the in
82. ow data point information at the location of the vertical cursor Click again to remove the information The right or left arrow keys move the cursor on the X axis to different data points hold the shift key to increase movement Time Torque Angle Speed Speed Command Buss Yoltage Use the dropdown to select variables plotted Torque Time Torque Time Torque Angle Torque Speed Time Speed Commanded Speed Time Buss Voltage Time embedded Toolbox Assembly Technologies 2 0RC1 Rundown Analysis Live and Historic rundown analysis Torque Time Torque Time Torque Angle Torque Speed Time Speed Commanded Speed Time Buss Voltage Time Subgroup Date Time Appendix A Embedded Toolbox F m og A o y 2 O me vi E i E ha a 3 i pem e Rundown Analysis 147 User Manual 1 4 2 1 2 1 Axis Torque vs Time Selected The Trace displayed reflects the rundown selected below the screen Analyze To adjust magnification area position mouse pointer below the x axis e Rundown Analysis pointer changes from an arrow to a hand Next press and hold left mouse button drag left or right to highlight then release to display embedded Toolbox Assembly Technologies Show All Rundown Analysis Torque Porque Time y Ps j
83. 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 72 QPM DC Electric Tools Alpha Controller 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 9596 non condensing and Temperature 32 to 122 F 0 to 50 e Installation maintenance and programming should be performed by qualified personnel Follow all manufacturer installation instructions and applicable regulatory electrical codes and safety codes e 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 e Avoid body contact with electrically energized surfaces when holding a grounded tool e Prior to connecting a power source always ensure the tool or controller is turned off e Limit controller access to trained and qualified personnel Lock controller cabinets Turn controllers off when attaching tools Stanley electric tools must be connected to a controller to operate To ensure superior performance and safe operation use a Stanley controller specifically designed for each tool These instructions are specific to Stanley Electric Tools when used with Stanley Electric Tool Controllers and accessories Some features may not be appl
84. que Set Point TSP High Starting Torque Starting Torque gt 20 of TSP Enables the tool setup for the next task after the batch count is achieved for the prior task in a Job Back Off This strategy functions after Angle Control with Torque Monitor AC TM It loosens the fastener turns it the opposite direction from tightening 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 Defines the number of rundowns required to be completed for each task Disable no downshift Manual Occurs at specified torque ATC automatically adapts to the joint Once the tool reaches the Downshift Torque point the controller changes the operating speed of the tool from the initial Tool Speed to the Downshift Speed The controller changes the operating speed of the tool from the initial Tool Speed to the Downshift Speed at the Downshift Torque level Anytime the peak angle recorded exceeds the High Angle the tightening cycle is recorded as a reject for high angle the high angle light red illuminates and the tightening cycle is given an overall status of NOK 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 Define one or more assembly sequences that can
85. r e PM Counter e Trip Counter Software Map Alpha Controller e Cal e Nominal Cal e Torque Cal e Modified 6 2 2 Controller e About e Model e Serial e Software Version e Servo Version e Update 6 3 Analyze e Results e Cap e Perform e Cam e Export 1 Rundown Data save o 2 Fault Event Data save e Jobl l Job Task e 1 Rundown Data Software Map 97 Alpha Controller Warranty Mechanical Products Limited Warranty STANLEY ASSEMBLY TECHNOLOGIES Stanley warrants its Assembly Technologies mechanical products to the original purchaser to be free from deficiencies in material or workmanship for the useful life of the product Under this lifetime limited warranty Stanley will at its discretion repair or replace any product which upon inspection is acknowledged by Stanley to be defective This limited lifetime warranty shall apply to products which have been used under normal operating conditions for their intended use and shall not apply to products which have been subjected to abnormal wear and tear abuse misuse improper maintenance negligence continued use after partial failure accident alterations or repairs with non genuine Stanley replacement parts Electronic Products Limited Warranty Stanley warrants its Assembly Technologies electronic products to the original purchaser to be free from deficiencies in material or workmanship for a period of one year after the date o
86. r 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 3 Breathing Protection Respirators shall be used where contaminants in the work area present a hazard 3 3 Tool Installation WARNING To Avoid Injury Always wear eye and foot protection when installing equipment Only use equipment and accessories specifically designed to operate with Stanley assembly tools and use them only in the manner for which they are intended Do not install worn damaged or modified equipment that may be unsuitable for safe use Train all operators in the safe and proper use of power tools Operators should report any unsafe condition Store idle tools and accessories in a safe location accessible only by trained persons Disconnect power source air electricity etc from tool prior to making adjustments changing accessories or storing Prior to operation always check and test tools and accessories for damage misalignment binding or any other condition that may affect operation Maintenance and repair should be performed by
87. rates in forward direction The tool can have a higher initial reaction force when loosening a fastener Always stop the tool before changing direction of spindle rotation 3 5 2 Torque Reaction Devices WARNING PINCH POINT BETWEEN TORQUE REACTION BAR AND WORK PIECE To Avoid Injury e Never place any body part between a reaction bar and the work piece e Before starting the tool position the reaction bar firmly against a stationary rigid member that is opposite to the spindle rotation Torque reaction devices absorb tool torque reaction forces Always use reaction devices when high reaction force could injure an operator Some reaction devices may require modification to fit the application Follow all appropriate installation instructions 3 5 3 Tool Temperature WARNING POTENTIAL BURN HAZARD Fixtured tools have higher operating temperatures and do not have additional thermal protection To Avoid Injury Wear thermal protective gloves when handling fixtured tools Stanley electric tools are thermally protected to prevent overheating The thermal protection does not allow the tool to operate if the tool temperature rises abnormally the thermal protector automatically resets when the tool cools down Controller task 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 T
88. rip force consistent with proper control and safe operation e Keep wrists as straight as possible e Avoid repetitive movements of the hands and wrists If wrist pain hand tingling numbness or other disorders of the shoulders arm wrist or finger occur notify supervisor discontinue task reassign user to a different job if relief 15 not found contact experts skilled in treating such disorders Wrist supports torque reaction devices and balancers should be used if it can be determined that such devices can reduce the risk of repetitive motion disorders 3 2 1 Hearing Protection Power tool operators and adjacent personnel may be exposed to excessive sound levels The tool in use is generally only one of many sources of noise that an operator experiences Other tools and machines in the area joint assembly noise work processes and other ambient noise sources all contribute to the sound level operators are exposed to The actual sound level an individual is exposed to and the individual s exposure time over the work day are important factors in determining hearing protection requirements Worker sound level exposure can only be determined at the job site and is the responsibility of tool owners and employers Measure worker sound level exposure and identify high risk noise areas where hearing protection is required Follow federal OSHA state or local sound level statues ordinances and or regulations 3 2 2 Vibration Powe
89. ry defaults 2 5 5 Service 2 5 5 1 Tool Tool Tab Screens Options Screen The odometer increments after every in cycle 2 Controller 66 Programming Alpha Controller Tool Tab Screens Options Screen Software E Torque Max Speed APM Counter aTrip Counter CANCEL E RESET_FH HETRE t 4 a aP x you sure EET 2 tir Counter jJ CANCEL E RESET TRIPS 4 E susntsn ire you sure ng Gee 2 Nominal Cal jToarque Cal Modified Programming 67 User Manual 2 5 5 2 Controller Controller Tab Screens Options Screen The odometer increments after every in cycle Model Serial ER Version Version 2 5 6 Analyze Diag Screens Options Screen Diag displays tool and controller diagnostic information statistics traces and I O status 68 Programming Alpha Controller Diag Screens Options Screen When forcing I O changes during an o Sidus a warning B 22 Clear off Dark on Diag Screens STATS Button Options Screen 1 EXPORT E a Programming 69 70 Diag Screens STATS Button User Manual Options Screen File Name Programming Alpha Controller QPM DC Electric Tools This chapter is intended to promote proper and safe use and gi
90. s 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 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 DC Electric Tools amp Controllers e Install tools in dry indoor non flammable and non explosive environments only Humidity 0 to 9596 non condensing and Temperature 32 to 122 F 0 to 50 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
91. t See page 82 for fieldbus assignable Input functions Setup e Input Output embedded Toolbox Assembly Technologies Input Output input Output configuration llame Width Start Reset Job Reverse Disable Task Task Verify Bit Part ID Reset Result Status lanore Stop gt gt gt att Disable Tool Contact Type Appendix A Embedded Toolbox 143 User Manual 1 4 1 4 5 5 Modbus TCP Output See page 83 for Modbus TCP assignable Output functions Setup e Input Output embedded Toolbox Assembly Technologies Show All Input Output Input Output configuration Hame Tool Running Disassembly Detected Task Select Bit Torque OK Torque High Torque Low Fault Code Start Trigger Step Bit Cycle Stopped Contact Type Output Normal Minimum ON Time Appendix A Embedded Toolbox QA Alpha Controller 1 4 1 4 5 6 Modbus TCP Input See page 82 for Modbus TCP assignable Input functions Setup e Input Output embedded Toolbox Assembly Technologies Input Output Input Output confiauratior Modbus TCP Input Word Bit Select Job Reset Result Status Start Disable Task Job Verify Part ID Stop 23 Ignore Ignore C cr oO BJ CO OC Ch ca a RA x Ignore Contact Type 1 4 2 Analyze Analyze Rundown Analysis
92. t e Jobs Management e System Management e Input Output Analyze e Rundown Analysis e Tool Diagnostics I O Diagnostics Report e Parameter Sheet Service Tool Configuration Update QA Alpha Controller embedded Toolbox 2 0FC1 Assembly Technologies Menu Setup e e Quick Start Jobs Management System Input Output Management Analyze e Rundown Analysis Tool Diagnostics 1 0 Diagnostics Report i Parameter Sheet Service E Ww v Tool Configuration Update 1 4 1 Setup Setup Nr O O Quick Start Jobs Management System Input Output Management Appendix A Embedded Toolbox 101 User Manual 1 4 1 1 Quick Start Quick Start provides a graphical user interface GUI for wizard programming Alpha controllers 1 4 1 1 1 Job Name Enter job name on the opening screen Setup e Quick Start o Job Name embedded Toolbox Assembly Technologies Show All Quick Start rameter Wiza 1 Job This wizard configures fastening parameters for a selected strategy What do you want to name this job New Job 2 Task Definition 3 Task 4 Strategy 5 Audit Step 6 Controls Slow Seek 8 Finished Save the Job Appendix A Embedded Toolbox QA Alpha Controller 1 4 1 1 2 Task Definition Identify the number of bolts to be fastened and whether they will be Setup fastened using the same paramet
93. t for connecting the Alpha Controller to a master controller from another manufacturer Function 3 Data Line 6 Power Supply 9 Empty 4 1 7 Alpha Controller Model QA1001 V Input and Output Connector inputs and outputs are optically isolated 24 VDC e Internal 24 VDC supply Maximum 1 ampere total e External 24 VDC supply Maximum ampere per output The Alpha controller has a MIL C 26482 Series II bayonet connector for 24VDC I O The connector uses a 12 8S insert in the normal position Connector options are listed below Part No 19 pin 24V 1 0 Port Included When all of the inputs are off binary 0 the controller looks to the tool for the parameter selection When the Alpha controller is used with fixtured tools it must use a Remote Start Stop Reverse pendent to the controller to provide basic switching control for the tool Controller Connections and Inputs Outputs 81 User Manual 4 2 Assignable Input Output Functions The following Input Output functions apply to DeviceNET Profibus Modbus TCP and 24V There are 8 maximum inputs and outputs for 24 VDC See Appendix A for assignment of inputs and outputs using Embedded Tool Box Inputs Description Controller 1 0 Configuration Options START N OJN C Latch Y N Timer SELECT JOB Select a job N O N C Job Disable when open Y N SELECT TASK aa Task Disable when open STOP Stop the tool N O N C TASK SELECT One bit in a series to select the N O
94. t of torque versus time or angle of a tightening cycle Records the number of total tool tightening cycles completed since the last time it was reset It is usually used as a supplementary count of the PM Counter Glossary Alpha Controller Units YIELD Glossary The following torque units and associated labels are used with Stanley controllers and tools Abbreviation kgm kgcm ftlb inlb inoz Common Term Newton meter Newton centimeter Newton decimeter Kilogram meter Kilogram centimeter Foot pound Inch pound inch ounce 1 lbfft 1 355 818 135 581 8 13 5582 0 138 255 2 13 825 52 1 12 192 1Nm 1 100 10 0 1019716 10 197 16 0 737 562 1 8 850 745 141 6119 YCAM Yield Control This strategy uses Torque vs Angel Rates as the control variable 87 Alpha Controller Software Map 6 1 Setup 6 1 1 Wizard Strategy Torque Angle Torque amp Angle Units NM FTLB INLB INOZ KGM NCM NDM Thread Direction CW CCW High Torque Low Torque Snug Torque High Angle Low Angle Speed Wobble Angle Target Speed Max Torque Slow Seek Angle Target Speed Max Torque Start Delay Delay Time Max Torque Conditioner Fastener Down Target Torque Delay Time Max Time Up Angle Target Pre Torque Torque Target Delay Between Steps ATC Backout Fastener Angle Target Torque Target Speed Fastener Release Speed Angle Target Max Torque 6 1 2 Job Name Barcode ID Au
95. tended 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 11 Warnings and Cautions Definitions 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 Warning Indicates that death or severe personal injury may result if proper precautions are not taken Caution Indicates that property damage may result if proper precautions are not taken Indicates an electrical hazard This icon appears as a part of a Danger Warning or Caution notice Indicates a general hazard This icon appears as a part of a Danger Warning or Caution notice Indicates that eye protection should be worn This icon appears as a part of a Danger Warning or Caution notice Read and understand all the safety recommendations and all operating instructions before operating tools and controllers Indicates an item of special interest WARNING To Avoid Injury Read and understand all the safety recommendations and all operating instructions bef
96. ternal clock as set by the user Events included in the log are rundowns and faults The data stored for each rundown includes TEE The data stored for each fault includes TL To access the data use the up down cursor keys to scroll Highlight an event and press the toggle key to view the event s data screen Use the up down cursor keys to scroll through the data if there is more than will fit on the screen The data cannot be exported from the log screen This action is performed via the STATS screen under Analyze See 2 5 6 Programming 9 User Manual 2 5 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 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 character selection OQ Toggle Button Selects option for data input accepts changes Data input and when applicable menu
97. tion Palette Bit Function Assignment The Function Palette appears after selecting a bit assignment left click Setup once To assign a function double click it Click the red X button Win the right corner to close window Hama cat in Cytle Sear ted Disassembly Detected Tad Running Lucie LIK Task Selecred Job Complete Task Complete Task Bit Joh Select Bit CIF Torque Hin e Input Output embedded Toolbox Assembly Technologies Input Output Input Output confiauratian Name In Cycle Job Selected Disassembly Detected Tool Running Cycle Cycle Task Selected Job Complete Contact Type 27 Output Type Task Complete Task Select Bit Job Select Bit Torque OK Torque High Minimum ON Time Appendix A Embedded Toolbox Width 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 QA Alpha Controller 1 4 1 4 4 Bit Assignment Options The options for a selected bit assignment s function appear at screen Setup bottom Activate field for changes by pointing to and left clicking field once using mouse pointer then adjust Contact Type N O e Input Output Output Type Normal M Minimum ON Time 0 embedded Toolbox Assembly Technologies 2 Show All Input Output It Output cor 24 alt Output Word Bit Width 105 X um c 9 ndr Yaku ei E QY C6 I insert del
98. to Sequence Tasks Yes No Auto Reset Job Yes No Enable Error Proofing 6 1 2 1 Task Name Batch Count Units NM FTLB INLB INOZ KGM NCM NDM Thread Direction CW CCW Threshold Torque Statistical Threshold Disassembly Speed Disassembly Acceleration Cycle Lock Out Torque Audit Step Last 1 2 3 4 5 6 7 8 9 10 11 12 Angle Audit Step Last 1 2 3 4 5 6 7 8 9 10 11 12 Torque Rate Software Map 89 90 Torque Average Angle Interval Modified 6 1 2 2 Step Name Strategy TC AM Torque Target High Torque Low Torque Snug Torque High Angle Low Angle Angle Bailout Downshift Mode Disabled Manual ATC e Manual Downshift Mode e Manual Downshift Speed e ATC Starting Torque e Ending Torque e ATC Ending Speed Soft Stop Yes No e Yes Current Off Time e Yes Current Hold Time e Yes Current Ramp Time Speed Power Acceleration Abort Timer Delay Between Steps Accumulate Angle Yes No Strategy AC TM Snug Torque Angle Target High Angle Low Angle High Torque Low Torque Torque Bailout Downshift Mode Disabled Manual e Manual Downshift Mode e Manual Downshift Speed Soft Stop Yes No e Yes Current Off Time e Yes Current Hold Time e Yes Current Ramp Time User Manual Software Map Alpha Controller Speed Power Acceleration Abort Timer Delay Between Steps Accumulate Angle Yes No e Strategy AC TC Torque T
99. ve 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 3 2 Operator Protection WARNING ROTATING EQUIPMENT To Avoid Injury e Always wear eye and foot protection when operating installing or maintaining power tools and when in areas where power tools are being used maintained or installed Some applications may require the use of safety glasses and face shields Use eye protection that conforms to ANSI Z87 1 3 and ANSI Z41 PT99M 1 75 C 75 Always stay alert when operating tools and or their accessories Do no operate tools and or their accessories while tired under the influence of drugs alcohol or any other mind altering substance Repetitive work motions or vibrati

Assembly Technologies Alpha Controller User Manual v3.0

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