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Assembly Technologies Alpha Controller User Manual v3.1

1. Ira a 1 78 SA2 NID AION 79 3 2 3 Breathing Protection 79 3 9 UOONIMSTANAUON u y y uu iode A 79 3 3 1 Sock els ANG AOaDIGES uen dit re ovrt e e eee tet 79 3 3 2 Suspension Devices 80 9 9 9 Cable TInstallaliof ssisceeie t eese Eme tonite 80 ee E LIE UI LE tue 80 3 4 1 Display and Multiple Function Button for Hand Held Tools 80 9 4 2 MEP MOGG u uu u 81 9 4 9 TOOLMOMO 81 3 4 4 Tightening Cycle Counters 81 35 MOON QDS FAO pis tosh 82 3 521 vs beetle tenias 82 3 5 2 Torque Reaction Devices 82 3 5 9 TemperalUl G 83 9 5 4 FOO SlalnsS LighiSuu u u 83 3 5 5 Setting Torque Angle and Other Operating Parameters 83 3 6 Special Application 83 3 6 1 Exposed Gear Socket Tools 83 39 5 2 ODO TUT N lruniiersu uum y u etn kas 84 Controller Connections and Inputs Outputs
2. 109 aloes E oq Nod iro 111 VV AMM AMY toa NOCTES 115 Getting Started Aloha Controller Getting Started This manual is intended to promote proper and safe use and give guidance to owners employers supervisors and others responsible for training and safe use by operators and maintainers Please contact your Stanley Sales Engineer for further information or assistance on Stanley training or assembly tool operations 1 1 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 opera
3. 85 4 1 Alpha Controller Connections 85 4 1 1 Alpha Controller Power Cord 85 4 1 2 Alpha Controller Tool Connector 85 4 1 3 Alpha Controller Serial 86 4 1 4 Alpha Controller Ethernet Connector 87 4 1 5 Alpha Controller Model QA1001 _D_ DeviceNet M 87 4 1 6 Alpha Controller Model QA1001 P Profibus Port 87 4 1 7 Alpha Controller Model QA1001 _ V Input and Output Coli sio ere erent terrence TO 88 4 2 Assignable Input Output Functions 88 2 2a EN 6 ol Rc T TES 90 42 2 OU Ut DescriDIiOliSis 96 S0 Wale 99 Bel 99 Tl 222112 99 Dilek ana 99 ou E E 99 SEM E 100 GoOrmimublledtlOEiS 104 NE Rog 104 5 1 5 Full BacKup HeSIOLG 106 SP MEME iue N 106 Da I a s 106 5 2 2 tas 107 D 9 107 Contents User Manual Appendix A Embedded Toolbox
4. Disable when open Yes Will disable the tool when this input 15 removed No Will not disable the tool upon input removal When asserted on any input type the controller will stop the tool It will also keep the tool from running while it is applied When removed nothing will happen other than the tool will be allowed to run The size of this input function is 1 bit Configuration Contact Type Normally Open N O Normally Closed N C When asserted on any input the controller will reset the accumulated bolt count back to zero for the active job and act as a Part Entry to re enable the tool if disabled The tool could be disabled due to Error Proofing having been enabled and the accumulated bolt count equal to target bolt count When removed nothing will happen The size of this input function is 1 bit Configuration Contact Type Normally Open N O Controller Connections andInputs Outputs att tt 8 Connections and Inputs Outputs 91 User Manual Inputs Description Normally Closed N C TASK When asserted or removed on any input type the controller will select a task This is one SELECT BIT bit in a series of bits to create a binary number The number created by this and other TASK SELECT BIT inputs will determine which task will become the active task for the tool to run You will need to have more than one input assigned as a TASK SELECT BIT in order to create a number greater
5. Dounshi ft Mode 1 Downshift Torque Downshi ft Soft stop Current Off Time Current Hold Time 3 Current Off Time Current Hold Current OFF Time Current Hold Time Current Ramp Ti stop Dff Time i Hold Time Current 09 Time Current Hold Time Current Ramp Time T Soft Stop Speed Power Aloha Controller Strategy AC TA Screens or Tier Abort Timer Acceleration Abort Timer q Delay Between Abort Timer j Delay Between Steps Accumulate Angle Abort Timer oj Delay Between Steps Accumulate Angle Abort Timer j Delay Between Steps Accumulate Angle Programming Options Screen Abort Timer j Delay Between Steps j Accumulate Angle 39 User Manual 2 5 1 4 6 Strategy RC AM Strategy RC AM Screens Options Screen Step settings affect only the active Task Torque rate strategy Torque Average and Angle interval configuration is set in the Task tab Torque Rate Target q High Torque Low Torque High Torque j Low Torque d Torque Bailout Low Torque Torque Bailout q Snug Torque Torque Bailout j Snug Torque High me 40 Programming Aloha Controller Strategy RC AM Screens Options Screen Snug Torque High Angle Low Angle EE elpt E Jangle Bailout 9399 3 Angle E Downshift Mode DTSRBLED Downshift Mode bangle Bailout
6. 4 LATE Ending Speed p stop Lurrent OTT Time Current Hold d Current OTT Time Current Hold Time Current Ramp Time Soft Stop Current Off Time Current Hold Time 00 Time Lurrent Hold Time Current Ramp Time Soft Stop Speed j Power Programming Aloha Controller Strategy AC TM Screens Options Screen ae Abort Timer j Delay Between Steps Accumulate Abort Timer j Delay Between Steps Accumulate Angle Abort Timer D Abort Te 1 Between Steps Between Steps Accumulate Angle B Accumulate Angle 2 5 1 4 3 Strategy AC TC Strategy AC TC Screens Options Screen Step settings affect only the active Task Torque Target High Torque Low Tor oue Programming 27 User Manual Strategy AC TC Screens Options Screen High Torque j Low Torque Torque Bailout Low Torque u Torque Bailout 5999 q Snug Torque Torque Bailout j snug Torque q Angle Target Snug Torque j Angle Target High Angle Angle Target j High Angle Angle 28 Programming Aloha Controller Strategy AC TC Screens Options Screen High Angle Angle angles Bailout Low Angle j Angle Bailout d Downshift Mode Angle Bailout Downshift Mode Soft Stop Downshift Mode ET B Daoenshift Mode Downshi tt Torque x B Soft Stop d Downshift 3 F Downshift Mode Soft Stop
7. High Angle Angle Bailout MW Programming Aloha Controller Strategy TC AM Screens Low Angle Angle Bailout EET Mode Angle Bailout Downshift Soft Stop Downshift Mode soft Stop Current Time Programming 9999 B DISABLED DISABLED WES Options Screens Downshift Mode 1 507 Stop Lurrent OTT d Downshift Mode Torque 3 Doawnshift Downshitt Torque Downshi tt speed ET Mode Downshitt Torque 4 Doawnshift Speed Downshi ft Made m RATE Starting Torque LATE Ending Torque starting Torque ATC Ending Torque iL AT Ending Speed 21 Strategy TC AM Screens n stop Lurrent OTT Time Current Hold Time Acceleration j Abort Timer 22 User Manual I Screens Ending Torque 4 Ending SEES 1 ATC Starting Torque 4 ATC Ending Torque ii ATO Ending 3 5 Stop 4 Current Off Time Current Hold Time Hold Time Current Ramp Time Current Hold Time Current Ramp Time Time Speed d Power Programming Aloha Controller Strategy TC AM Screens Options Screens Acceleration j Abort Timer s Between Steps Abort Timer belay Between Steps d Accumulate Angle Abort Timer belay Between Steps d Accumulate Angle Abort Timer a
8. User Manual 2 2 2 Dropdown 1 dropdown 1 arrow appears to the right of menu items with multiple choices To view these choices first select the menu item using the up down arrows or use the keypad to identify the corresponding menu item number Then use the toggle button to expand the dropdown The up down arrows scroll through the choices and the toggle button selects accepts the highlighted choice 2 2 3 Menu Tree EHE dii A menu tree 1 appears beside related menu items mes 2 2 4 Tabs 1 T 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 p F This scrollbar enables adding a z A Z 0 9 space _ amp anda 2 period language and or field determines character availability The up arrow 1 3 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 2 2 6 Run Display Icons 1 identify controller events see list below Displays last torque reading and units 2 when a tool is connected Specifies target bolt count 3 of active job The run screen di
9. 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 82 QPM DC Electric Tools Aloha Controller 3 5 3 Tool Temperature WARNING POTENTIAL BURN HAZARD Fixtured tools have higher operating temperatures and do not have additional thermal protection To Avoid Injury Wear thermal protective gloves when handling fixtured tools Stanley electric tools are thermally protected to prevent overheating 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 The status light mirror or copy the status lights on the controller or control panel Green Tightened to The tightening cycle meets all of the specified parameters specified limits Yellow Low torque or angle tightening cycle was rejected for not reaching either low torque or low angle Red High torque or a
10. 4 Assembly Technologies Alpha Controller User Manual v3 1 Important Safeguards For your protection please read these instructions completely and keep this manual for future reference Carefully observe and comply with all warnings cautions and instructions placed on the equipment or described in this manual THE STANLEY WORKS ALL RIGHTS RESERVED www stanleyAssembly com QA Alpha V 3 1 0608 User Manual Contents Genting RETE 1 11 Warnings and Cautions ener xk sms 1 1 2 User Manual Conventions 2 1 3 Specifications Layout and Display 2 1 4 Installation Instructions 4 1 451 5 68 1 TRE TT 6 1 4 3 Alpha Controller E Stop Precaution 6 ENTE UU T 2 1 QA Alpha Controller Navigation and Programming 7 22 WIS o i E 7 oO rio 7 2 2 2 DrOPJOW eerren 8 229 MENU Ed 8 a IDE DE LI 8 2 2 5 Gharaeter 8 2 2 O RUN 8 29 9 2 E0012 9 2 Alpha Controller Programming 10 2 5 1 Setup Menu 1 Jobs 11 2 59 1 WIZard SCreeris
11. 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 101 102 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 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 YIELD Yield Target High Torque Low Torque Torque Bailout Snug Torque User Manual Software Map Aloha 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 Of
12. 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 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 St
13. 2999 7 L Soft Stop Downshift Mode B Daoenshift Mode j FDownshift Torque Soft Stop Downshift Speed Current Off Time Downshift Mode j soft Stop Current Off Time Programming 41 User Manual Strategy RC AM Screens Options Screen _ we Mode DE Downshift Torque ef Dawnshi ft 6 Dawnshitft Torque Downshi ft Mode Downshi ft Dawnshift Torque Downshift Mode Dawnshi ft L Stop Current Off Time Current Hold Time Soft stan Jd Current Off Time Current Hold n Lurrent Hold Time Current Ramp Time Soft ston ai Current Off Time Current Hold n current Time P Hald Time Ramp Time E Soft Stop Speed Power Programming Aloha Controller Strategy RC AM Screens Abort Timer Acceleration Abort Timer q Delay Between Abort Timer j Delay Between Steps Accumulate Angle Abort Timer oj Delay Between Steps Accumulate Angle Abort Timer j Delay Between Steps Accumulate Angle Programming Options Screen Abort Timer j Delay Between Steps j Accumulate Angle 43 User Manual 2 5 1 4 7 Strategy YC AM Strategy YC AM Screens Options Screen Step settings affect only the active Task Torque rate strategy Torque Average and Angle Interval configuration is set in the Task tab Yield Target q
14. Current Off Time Downshift Mode TL Torque Dawnshi ft epus poe Torque Dawnshi ft Spe Programming 29 User Manual Strategy AC TC Screens Options Screen Mode Dawnshift Torque Dawnshi ft Downshi tt Mode ATC Starting Torque Ending Torque x 3 RATE enm Torque ATC Ending Torque i Ending Speed Torque ATC Ending Torque Ending dn ATE Serm Torque 4 ATC Ending Torque i Ending 0088 Stop ston Current Off Time Current Off Time d Current Hold Time Current Hold Time 30 Stop Current ff Time i Lurrent Hold Time Soft Stop d Current Off Time Current Hold Time Current Hold Time Current Ramp Time Soft Stop Speed Power Programming Aloha Controller Strategy AC TC Screens Options Screen Power Acceleration Acceleration j Abort Timer Abort Timer j Delay Between Steps Accumulate Angle Abort Timer j Delay Between Steps d Accumulate Angle Abort Timer Tiner j Delay Between Steps B Delay Between Steps d Accumulate Angle d Programming 31 User Manual 2 5 1 4 4 Strategy BACK Backoff Strategy BACK Backoff Screens Options Screen DET settings affect only the active Task Snug Torque bangle Target High Angle Target High Angle p Low Angle L
15. 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 Bit Software Map Aloha Controller 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 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 G Off In Cycle Job Selected Disassembly Detected Tool Running Cycle OK Cycle NOK Task Selected Job Completed Task Complete Task Selected Bit
16. Manual Options Screen Programming Aloha Controller QPM DC Electric Tools This chapter is intended to promote proper and safe use and give guidance to owners employers supervisors and others responsible for training and safe use by operators 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 STANLEY ASSEMBLY TECHNOLOGIES hereby declares the following sound and vibration emission levels as required by the Machinery Directive 98 37 EC Product A weighted emission sound pressure level at the Weighted emission root mean work station L 4 ref 20uPa square acceleration level at the Value determined according to ISO 15744 2002 handle Value determined using as basic standards ISO 3744 and according to ISO 8662 single ISO 11203 axis EO E2 EA2 E3 EA3 lt 70dBA lt 2 5 m s F4 and E5 electric tools Operating conditions for all measurements full rated speed no load rated supply voltage or pressure A weighted emission sound power level Lwa not required declared sound pressure emission levels are bel
17. TASK N O N C Task Disable when open STOP Stop the tool N O N C TASK SELECT BIT One bit in a series to select the task N O N C Bit JOB SELECT BIT One bit in a series to select the job N O N C Bit DISABLE TASK Disable the task N O N C Task DISABLE JOB Disable the job N O N C Job TASK VERIFY Verify the selected task to the inputs N O N C Task JOB VERIFY Verify the selected job to the inputs N O N C Job TASK VERIFY BIT the selected task to one of the NO Bit input bits in a series JOB VERIFY BIT input bits in a series RESET RESULT STATUS Clear the result status N O N C REVERSE START Put the tool in reverse and start the tool N O N C DISABLE TOOL Disable tool will complete running if NOJNC it is in cycle PART ID Sets the part identification Length Trigger Trigger for PART ID Resets PART PARTID TRIGGER ID CHANGED output N O N C Input not avallable on 24V Outputs Description Configuration Options Output is turned off Output is not assigned IN CYCLE The tool is in cycle N O N C Type Time JOB SELECTED Indicates a specific job is selected N O N C Type Time Job DISASSEMBLY A tightened fastener removed has TOOL RUNNING The tool is running N O N C Type Time CYCLE OK Rundown was OK N O N C Type Time CYCLE NOK Rundown was NOK N O N C Type Time TASK SELECTED Indicates a specific task is selected N O N C Type Time Task JOB COMP
18. Torque ingle Target Max Torque CANCEL E Programming Aloha Controller 2 5 1 2 Setup ob Tab Job Tab Screens Tool settings apply to all Tasks Commun cations Other Full Backur Festore Auto sequence Tasks aauto Reset Job Auto Sequence Tasks Auto Reset Job j 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 APAE Errar oe E 15 User Manual Job Tab Screens Options Screens Auto Sequence Tasks ves 8 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 TASK if H Batch Count Batch Count ix Units Batch Count Units es Direction Thread Direction Thread Direction dE Thread Direction Threshold Torque Thread Direction Thread Direct ton aThreshold Torque Threshold Torque een Threshold polar ete Threshold 16 Programming Aloha Controller Task Tab Screens Options Screens Threshold Torque Statistical Threshold Statistical Threshold C EN Disassembly Speed BEEE ooo Acceleration 3898 L sss Disasse
19. areas where hearing protection is required Follow federal OSHA state or local sound level statues ordinances and or regulations 3 2 2 Vibration Power tools can vibrate during use To minimize the possible effects of vibration e Keep hands and body dry e Avoid anything that inhibits blood circulation such as tobacco cold temperatures and certain drugs e Operators should notify their employer when 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
20. asserted or removed not while it is being held on or off It is important to understand the controller responds to the rising and falling edges of input functions as they are asserted or removed not while the levels are high or low The STOP bit is an exception it is a true OR function rather than working off the transition One type of Input does not have priority over the other The controller will respond to the first change in status of an input function no matter which Input connection makes the change If more than one type of Output shares a particular output function that function is asserted on all types of Output The table below lists the available input and output functions gives a brief description and indicates the configuration options for each The configuration options are an important aspect of the I O functions as they add powerful multiple dimensions to each function not previously seen in Stanley tool controllers These new dimensions allow integration of these controllers in unique ways providing an amazing amount of flexibility Please see the full description of each function in the section following this table See Appendix A for assigning of inputs and outputs using Embedded Tool Box Inputs Description Configuration Options IGNORE Input is ignored Input is not assigned 88 Controller Connections and Inputs Outputs Aloha Controller SELECT JOB Select a job N O N C Job Disable when open SELECT
21. cleared Source the source of the fault the list of sources 1s below Tool Servo DSP Controller PC 104 Embedded Toolbox PC State asserted or cleared Use the down arrow to access the data Once viewing the Log Screen use the up down arrows to scroll To view the event s detail screen highlight an event and press the toggle button Use the up down arrows to scroll through the data if there is more than will fit on the screen Data cannot be exported from the log screen This action is performed using the EXPORT button found via the STATS button under Analyze see section 2 5 6 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 NEN Up Down Arrow Keys Scroll through menu selection and character selection 9 Selects option for data input accepts changes 2 5 U
22. input to do both functions is desired see the input function REVERSE START When removed from any input type the controller will place the tool into Forward assembly mode The size of this input function is 1 bit Configuration Contact Type Normally Open N O Normally Closed N C DISABLE When asserted on any input type the controller will disable the tool while this specific task TASK is selected This will act like a STOP to stop the tool during use Use the Task parameter under Configuration to select the task to be disabled when this input is asserted When removed the tool will be allowed to run while this specific task is selected The size of this input function is 1 bit Configuration Contact Type Normally Open N O Normally Closed N C Task Type in the task number you wish to disable when this input is asserted DISABLE When asserted on any input type the controller will disable the tool while this specific job JOB is selected This will act like a STOP to stop the tool during use Use the JOB parameter under Configuration to select the job to be disabled while this input is asserted When removed the tool will be allowed to run while this specific job is selected The size of this input function is 1 bit Configuration Contact Type Normally Open N O Normally Closed N C Job Type in the job number you wish to select when this input is asserted TASK When asserted on any input type the control
23. is normally open the input is asserted when 24 VDC is applied to the 24 VDC connector input pin or when the fieldbus bit transitions from low to high If an input s contact type is normally closed the input is asserted when the 24 VDC is removed from the 24 VDC connector input pin or when the fieldbus bit transitions from high to low Inputs Description IGNORE The pin or bit that is assigned as IGNORE means the input will do nothing when asserted This is essentially a placeholder For fieldbus the length of this input function may be set to any size that meets the need When asserted on any input type the tool will start and run the currently selected job task This input is overridden by the STOP input If STOP is used and a tool restart is required remove the STOP remove the START then re assert the START If the tool is required to operate in Disassembly mode remove the START assert the REVERSE input and then re assert the START When removed from any type of Input the tool will stop Even if a second START input is active the tool will stop when any START is removed The size of this input function is 1 bit Configuration Contact Type Normally Open N O 90 Controller Connections and Inputs Outputs Aloha Controller Inputs SELECT JOB SELECT TASK STOP RESET JOB Description Normally Closed N C Latch This is applicable to external inputs only This is not applicable to the trigger on th
24. 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 mounting holes in different plinths 1 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 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 person
25. sce igi teens 11 2 5 122 MOD 15 2 9 9 Setup TASK BULOEI uus tata catt 16 2 5 1 4 Setup Step Button Step 1 Step 12 19 2 5 1 4 1 Strategy TC AM anal ou a 19 2 5 1 4 2 Orate AG 23 2 9 1549 Strategy AG I O ua een do apes ud und 27 2 5 1 4 4 Strategy BACK Backoff 32 2 5 1 4 5 Strategy RATE iiie t tte 40 2 5 1 4 6 BO DS ee eee 44 2 5 1 4 7 Strategy AC TA 36 2 5 1 5 Setup Manage 40 282126 52 2 5 2 Setup Menu 2 Communications 52 25 9 SELUD MENE Qasi 56 2 5 4 Setup Menu 4 Full Backup Restore 71 2i5 5 OOSFVICOSQSssesasayasassqpussascqpuqqawsqauscayaqayasasauspasayauspasayasayssayassps 72 2 5 5 00 EE 72 73 E 74 OPM DO leet TOO T OE 77 9 TOOMSPSCHICAUON S efto ei mi ctos i oi efe eie 77 32 Operator 77 Repetitive Motion 78 li Getting Started Aloha Controller
26. than one The maximum number of tasks required will determine the maximum number of inputs requiring this input function assignment In binary numbers the digit furthest to the right is the ones digit the next digit to the left is the twos digit next comes the fours digit then the eights digit and so on The integer equivalent to a binary number can be found by summing all the weighted values of the selected digits For example the binary number 10101 is equivalent to the integer 21 The math is 1 4 16 21 where the digits that are high one are added together and the digits that are low zero are ignored Bit Number 4 3 2 0 Weighted Value 16 8 4 1 Binary Number 1 0 1 1 24 VDC Pins example R In order to select task 21 the controller you would need at least 5 inputs assigned as TASK SELECT BIT Each would then have to be given a bit number in order to have a series of bits with different weighted values For example on the 24 VDC input pin L is bit 0 pin is bit 1 pin N is bit 2 pin P is bit 3 and pin 1 bit 4 Therefore to select task 21 you would have to assert pins L N and R The size of this input function is 1 bit except on fieldbus where it can be any size to fit the need Configuration Contact Type Normally Open N O Normally Closed N C Bit Type in the number you wish this bit to be in your binary number scheme to select tasks Mode All TASK SELECT BITs must be t
27. 10 11 12 Torque Rate Software Map 99 e Torque Average e Angle Interval e Modified 5 1 2 2 Step e Name e Strategy TC AM 100 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 Aloha Controller Speed Power Acceleration Abort Timer Delay Between Steps Accumulate Angle Yes No e Strategy AC TC Torque Target 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
28. A is required before returning any material for warranty or repair service e Contact STANLEY ASSEMBLY TECHNOLOGIES or their agents e Request Customer Service or Repair Services NOTE An RMA can be given without a purchase order However non warranty repairs cannot be performed until a written purchase order or credit card authorization is received e Have the following information available for the person answering the telephone to obtain an RMA e Company name and address e A 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 116 Warranty Aloha 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 D
29. Abort Timer j Delay Between Steps Accumulate Angle Programming Options Screen Abort Timer Delay Between Steps Accumulate Angle 35 User Manual 2 5 1 4 5 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 is set in the Task tab Snug Torque j Angle Target d High Angle 3939 Angl Target High Angle 2999 9 Low Angle u High Angle Low Angle Torque Angle EJ High Torque m Low 36 Programming Aloha Controller Strategy AC TA Screens High Torque Torque ler age Bailout Low Torque j Max Torque Bailout Min Torque Bailout Torque Bailout j Min Torque Bailout d Downshift Mode Min Torque Bailout j Accumulate Torque d Downshift Mode Accumulate Torque PATE Star Mode Downshift Mode j FDownshift Torque 4 Downshift Spe Programming CL ATE 2 MANUAL Options Screen ACCUMUT ate Torque pk d Downshift Mode NETS ATG Starting Res _FDowunshift Mode 1 507 Stop LUrrent 37 User Manual Strategy AC TA Screens Options Screen DOE DUE Soft Stop 4 Current Off Time Downshi ft Mode Downshift Torque l 0850 Dounshi ft Mode 1 Downshift Torque Downshi ft speed
30. High Torque Low Torque High Torque FEEEBE Low Torque alt Torque Bailout Low Torque Torque Bailout q Snug Torque Torque Bailout j snug Torque d High Angle 44 Programming Aloha Controller Strategy YC AM Screens Options Screen Snug Torque High Angle Low Angle EE elpt E Jangle Bailout 9399 3 Angle E Downshift Mode DTSRBLED Downshift Mode bangle Bailout 2999 7 L Soft Stop Downshift Mode B Daoenshift Mode j FDownshift Torque Soft Stop Downshift Speed Current Off Time Downshift Mode j soft Stop Current Off Time Programming 45 User Manual Strategy YC AM Screens Options Screen _ o Mode DE Downshift Torque ef Dawnshi ft 6 Dawnshitft Torque Downshi ft Mode Downshi ft Dawnshift Torque Downshift Mode Dawnshi ft L Stop Current Off Time Current Hold Time Soft stan Jd Current Off Time Current Hold n Lurrent Hold Time Current Ramp Time Soft ston ai Current Off Time Current Hold n current Time P Hald Time Ramp Time E Soft Stop Speed Power Aloha Controller Strategy YC AM Screens or Tier Abort Timer Acceleration Abort Timer q Delay Between Abort Timer j Delay Between Steps Accumulate Angle Abort Timer oj Delay Between
31. LETE obate EOIN ES Tope Tine To TASK COMPLETE Complete r mam Tine Tak TASK SELECTED A bit to indicate the selected task in N O N C Bit Mode BIT a series of bits Controller Connections and Inputs Outputs User Manual JOB SELECTED A bit to indicate the selected job in N O N C Bit Mode BIT a series of bits TORQUE OK Rundown Torque was within limits N O N C Type Time Step TORQUE HIGH m Torque exceeded High N O N C Type Time Step TORQUE LOW Rundown Torque under Low limit N O N C Type Time Step ANGLE OK Rundown Angle was within limits N O N C Type Time Step ANGLE HIGH m Rng lsrexceeded Migh N O N C Type Time Step ANGLE LOW Rundown Angle under Low limit N O N C Type Time Step CYCLE ABORTED The rundown was aborted stopped N NONC Tme Time N C NONC Tme Time Time STOPPED A STOP input is asserted N O N C Type Time Shows the state of the SNUG ACHIEVED Is set when Snug torque exceeded N O N C Type Time CYCLE STOP Shut off code is STOP N O N C Time PART ID CHANGED Controller has read the PART ID N O N C Type Time STEP BIT Indicates last step of rundown in a N O N C Bit Mode series of bits Outputs not available on 24 VDC 4 2 1 Input Descriptions Each of the single bit input functions has a Configuration setting of Contact Type The Contact Type can be Normally Open N O or Normally Closed N O If an input s contact type
32. Manual Options Screen factory defaults xml JD io_function xm mu rs Tie 8 z i RESTORE ae Ore vou sure ES eens a 4 22 agno c oc oc ao 4 4 M NS wuunmunanaunanananananana wuununununanuaunwunanuanaaqa wumumunanananananananan Programming Aloha Controller Other Screens Options Screen 21 28 35 B 11 2668 2 5 4 Setup Menu 4 Full Backup Restore Full Backup Restore Screens Options Screen Jobs Communications Other EFHLULTZE 5 TYITUE zs n a _ Complete CMM 5 fil Ie Are vou sure ER aS x PIA Ip ce Complete z 5 s select file use the up and down arrow Programming 71 Full Backup Restore Screens 2 5 5 Service 2 5 5 1 Tool User Manual Options Screen keys to scroll through list To change directories highlight Up One Level and then press the center button mann EE LEE ER a fart r pe ee Iz s a um Complete ES Lt fo EE u c vost s The default button loads current software factory defaults Tool Tab Screens Options
33. OK TASK SELECTED JOB COMPLETE TASK COMPLETE TASK SELECTED BIT JOB SELECTED BIT TORQUE OK TORQUE LOW ANGLE OK ANGLE HIGH ANGLE LOW CYCLE ABORTED STOPPED FAULTED READY TORQUE 96 Controller Connections and Inputs Outputs Aloha Controller Outputs Description START TRIGGER MFB SNUG ACHIEVED PART ID CHANGED Controller Connections and Inputs Outputs 97 Aloha Controller Software Map 5 1 Setup 5 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 Backoff Fastener Angle Target Torque Target Speed Fastener Release Speed Angle Target Max Torque 5 1 2 Job Name Barcode ID Auto Sequence Tasks Yes No Auto Reset Job Yes No Enable Error Proofing 5 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
34. Screen The odometer Increments after every In cycle B Version Max Torque Max Speed d EXIT Odo APM Counter Trip Counter 72 SERVICE zZLontroaller Programming Aloha Controller Tool Tab Screens Options Screen fu oray s a Ttt NN RESET EPH Lousts Are you sure fu shy e V sar t t ss se ort Non nere mE s ghar RESET TRIP vou sure eer AY Nominal Cal jToarque Cal Modified ite EXIT gt La2illpdate tool 2 5 5 2 Controller Controller Tab Screens Options Screen The odometer increments after every in cycle SETUP Programming 73 User Manual Controller Tab Screens Options Screen a i EE SS Model 3 j serial Software version Serwo 2 5 6 Analyze Diag Screens Options Screen Analyze displays tool and controller diagnostic information statistics traces and I O status When forcing I O changes during an operation the warning w DR 2 Comet UN Clear off Dark on Diag Screens STATS Button Options Screen 74 Programming Aloha Controller Diag Screens STATS Button Options Screen YeFault Event Data E _ ELT ee 6 File Name Programming 75 76 Diag Screens STATS Button User
35. Steps Accumulate Angle Abort Timer j Delay Between Steps Accumulate Angle Programming Options Screen Abort Timer j Delay Between Steps j Accumulate Angle 47 User Manual 2 5 1 4 8 Strategy BACKOFF Strategy BACKOFF Screens Options Screen Step settings affect only the active Task Torque rate strategy Torque Average and Angle interval configuration is set in the Task tab Snug Torque j Angle Target d High Angle 3939 Angl Target t High Angle 2999 9 Low Angle u High Angle Low Angle Torque Angle High Torque m Low 48 Programming Aloha Controller Strategy BACKOFF Screens High Torque Torque uM Bailout Torque Torque Bailout d Downshift Mode Torque Bailout j Downshift Mode d ATC Starting Downshift Mode eee Torque poet Programming Options Screen Dounshi ft Mode Stop Downshift Mode Soft Stop Current Off Time Downshift Mode Torque Dawnshi ft Ep Downshift Mode Torgue Dawnshi ft spe 49 Strategy BACKOFF Screens stop Lurrent OTT Time Current Hold Time rower tion j Abort Timer 50 User Manual Options Screen Dounehi tt Mode Dawnshitft Torque Dawnshi ft 22200 MANUAL EUM bp stop Lurrent OTT Time Current Hold d Current OTT Time Current Hold Time Curre
36. T RESET RESULT STATUS REWERSE START E JOB UERIFV Programming Aloha Controller Other Screens Munti Function Button Action REVERSE Hold Action DISABLED RR Hold Action Lever f Push To Start Switch eStart Input ANY Programming UERIFV RESET RESULT am REVERSE START Multi Function E T Hold Tar TES Lever Push To a Start Input 67 User Manual Other Screens Options Screen _ Mold Action _ DIERBLED J jLever Push To Start Switch H p Push To Start Swijtb start Input JTS ARLE Sh H LIGHTS HEB Lights 1 2 JOE Mif Lights 1 2 JHeadlight Timer BHeadlight Timer Headlight Timer pnm pur pnm pees Tone BReject Tone Taccept Tone aReject Tone TURE ILSHMARCHE faccept Tone F NERHLMRECHE aReject Tone St pom IEEE Reject Tone Reject Tone 68 Programming Aloha Controller Other Screens Temperature Limit Torsion Factor TTeaperature EUN jTarsion Factor jRequires Arming Temperature ian jTarsion Factor jRequires Armin Temperature ERE jTarsion Factor jRequires Arming Subgroup Size Programming Options Screen Taccept Tone Reject Tone Taccept Tone Reject Tone MICHIGAH Temperature ECTS jTarsion Factor iRequires Arming 69 70 Other Screens 11 2668 User
37. TED READY BMF SHUG ACHIEVED OFF CYCLE E SELECTED SASSEMBLY CYCLE TASK SELECTED Programming Aloha Controller Other Screens Programming Options Screen HI ANGLE LOW B MUG ACHIEVED YCLE STOPPED BIT F CYCLE SELECTED B SHSSEMBL Y DETECTEDE CYCLE HOK TASKE SELECTED HI ANGLE LOW 59 Other Screens 60 User Manual Options Screen CYCLE HOK TASKE SELECTED Toole TASK SELECTED Programming Alpha Controller Other Screens Programming Options Screen 5 HI ANGLE LOW COMPLETE 61 62 User Manual Other Screens Options Screen Aone COMPLETE HI M HI ANGLE LOW CYCLE ABORTED STOPPED Programming Aloha Controller Other Screens Options Screen EEENTi HI ANGLE LO CYCLE ABORTED STOPPED MUG ACHIEVED YCLE STOPPED STEP BIT JOE UERIFV JOB VERIFY BIT tl RESET RESULT 5 REVERSE START i Programming 63 64 Other Screens User Manual Options Screen JOE UERIFV BIT 4 RESET RESULT STATUS REWERSE START 5 JOB Programming Aloha Controller Other Screens Programming Options Screen JOE UERIFV BIT RESET RESULT Piel REWERSE START JOB 65 66 Other Screens User Manual Options Screen JOE UERIFV BI
38. al 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 Aloha Controller 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 1 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 A scroll bar appears when more items are available than space within the 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 or use the keypad to identify the corresponding menu item number Programming
39. and test tools and accessories for damage misalignment binding or any other condition that may affect operation Maintenance and repair should be performed by qualified personnel Do not operate tools in or near explosive environments or in the presence of flammable liquids gases dust rain or other wet conditions Keep the work area clean well lit and uncluttered Keep unauthorized personnel out of the work area DC Electric Tools amp Controllers e Install tools in dry indoor non flammable and non explosive environments only Humidity 0 to 95 non condensing and Temperature 32 to 122 F 0 to 50 Installation maintenance and programming should be performed by qualified personnel Follow all manufacturer installation instructions and applicable regulatory electrical codes and safety codes Tool and controller plugs must match the outlet This equipment must be earth grounded Never modify a plug in any way or use any adaptor plugs Avoid body contact with electrically energized surfaces when holding a grounded tool Prior to connecting a power source always ensure the tool or controller is turned off Limit controller access to trained and qualified personnel Lock controller cabinets Turn controllers off when attaching tools Stanley electric tools must be connected to a controller to operate To ensure superior performance and safe operation use a Stanley controller specifically designed for each tool These instructio
40. art 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 Job Task Verify Job Verify Task Verify Bit Job Verify Bit Reset Result Status Reverse Start Disable Tool Software Map 105 User Manual 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 Sel
41. ary number scheme to verify a job Mode All JOB VERIFY BITs must be the same mode no mixing of modes allowed Binary Will create a decimal number equivalent to the weighted value of this binary bit s Binary 1 Will create a number equivalent to the weighted value of this binary bit s and add the value of one 1 to that number RESET When asserted on any input type the controller will reset to 0 zero any rundown results RESULT status output bits on the same type of I O Meaning if this were asserted on DeviceNet only STATUS the DeviceNet output status bits will be reset Output status bits on other types of I O will remain in their original state The list of status bits that will reset are CYCLE OK CYCLE NOK TORQUE OK TORQUE HIGH TORQUE LOW ANGLE OK ANGLE HIGH ANGLE LOW CYCLE ABORTED CYCLE STOP When removed nothing will happen The size of this input function is 1 bit Configuration Contact Type Normally Open N O 94 Controller Connections and Inputs Outputs Aloha Controller Inputs Description MEM Normally Closed N C REVERSE START DISABLE TOOL PART ID TRIGGER PART ID When asserted on any input type the controller will switch the tool mode to Reverse Disassembly AND start the tool This 15 different from the REVERSE input function in that the REVERSE input function puts the tool into Reverse mode only When removed the tool will stop and switch back to Fo
42. b S WIZHED strategy TORGUE ANGLE Units Thread Direction Strategy TORQUE 22 Units Thread Direction High Torque Low Torque snug Torque Low Torque TIE snug Torque aM High Angle 9999 Snug Torque High Angle Low Angle Programming Units Strategy Thread Direct strategy Units Thread Direction Strategy TORQUE amp RNGLE Units Thread Direction 11 12 Wizard Screens High Angle Low Angle peed x Condition Fastener User Manual Options Screen Angle Target Speed Max Torque Angle Target Speed Max Torque Bl5tart Delay Eondition Fastenerk lPra Tarque Delay Time Max Torque L urizHEB ETH E Delay Time Max Torque Programming Aloha Controller Wizard Screens l T C lBackout Fastener Fastener Release Programming Options Screen Target Delay Time Max Time CANCEL P Delay Time Hax Time Up Angle Target Delay Time Max Time REOS Angle Target HI ZARO TOHDI TI ON Delay Time Max Time P PLEME asa HIZARO PRE TORGUE Torque Target RjBackout Fastener Fastener Release ngle Target Torque Target 14 User Manual Wizard Screens Options Screen HI ZARO BACKOUT ingle Target Torque Target ingle Target Max Torque ingle Target Max
43. bort Timer j Delay Between Steps P Delay Between Steps Accumulate Angle We B Accumulate 2 5 1 4 2 Strategy AC TM Strategy AC TM Screens Options Screen Step settings affect only the active Task ACTH Programming 23 Strategy AC TM Screens Snug Torque Angle Target High Angle High Angle Low Angle Torque Low Angle j High Torque Low Torque Torque High Torque ELI EI d Torque Bailout 5999 93 24 User Manual Options Screen Programming Aloha Controller Strategy AC TM Screens Torque Bailout EET Mode Low Torque Mode Soft Stop Torque Bailout EEEREN Downshift Mode j soft Stop Ott Time Programming 9999 Bl DISABLED HE DISABLED WES fi Options Screen Mode T Soft Stop Downshift Torque Dawnshi ft qe Made Downshift Torque Dawnshi ft s Downshitt Mode Downshift Torque Downshift Speed Downshi Tt Mode Starting Torque ze ATC ae Starting Torque j ATC Ending Torque 3 Ending Speed starting Torque Ending Torque J ATC Ending Speed L MANUAL Mji u 25 Strategy Screens stop Lurrent OTT Time Current Hold Time rower tion j Abort Timer 26 User Manual Screen ATE starting Torque d FATE Ending Torque
44. e the last time it was reset It is usually used as a supplementary count of the PM Counter Glossary Aloha Controller Units The following torque units and associated labels are used with Stanley controllers and tools Abbreviation Term 1 Ibfft 1 Nm Nm Newton meter 1 355 818 1 Newton centimeter 135 581 8 100 Ndm Newton decimeter 13 5582 10 kgm Kilogram meter 0 138 255 2 0 101 971 6 Kilogram centimeter 13 825 52 10 197 16 ftlb Foot pound 1 0 737 562 1 inlb Inch pound 12 8 850 745 inoz inch ounce 192 141 6119 YIELD YCAM Yield Control This strategy uses Torque vs Angel Rates as the control variable Warranty Glossary 113 Aloha 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
45. e tool handle Yes when selected causes the START input to latch internally after a time period has elapsed This means the physical START input can be removed without stopping the tool The tool will run until the currently active task is complete or times out A TIME parameter becomes available to set how long the START input must be applied in seconds before the Latch becomes active No when selected turns the Latch function off When asserted on any input type the controller will make the job assigned specifically to this input the active job When removed either nothing will happen or if Disable when open is selected as yes then the tool will be disabled The size of this input function is 1 bit Configuration Contact Type Normally Open N O Normally Closed N C Job Type in the job number you wish to select when this input is asserted Disable when open Yes Will disable the tool when this input is removed No Will not disable the tool upon input removal When asserted on any input type the controller will make the task assigned specifically to this input the active task When removed either nothing will happen or if Disable when open is selected as yes then the tool will be disabled The size of this input function is 1 bit Configuration Contact Type Normally Open N O Normally Closed N C Task Type in the job number you wish to select when this input 1 asserted
46. ect 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 Lever PTS None Lights Lights 1 2 Task Job e Headlight Timer Tones e Accept Tone None Beeeep Tocatta Fifth Turkishmarch Funeralmarch Ninth Michigan Ohio e Reject Tone None 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 5 1 5 Full Backup Restore Backup Restore Defaults 5 2 Service 5 2 1 Tool 106 About e Model e Serial e Software Version e Max Torque e Max Speed Counters e Odometer e PM Counter e Trip Counter Software Map Aloha Controller e Cal e Nominal Cal e Torque Cal e Modified 5 2 2 Controller e About e Model e Serial e Software Version e Servo Version e Update 5 3 Analyze e Results e Cap e Perform e Cam e Export 1 Rundown Data save 2 Fault Event Data save e Jobl 1 Job Task e 1 Rundown Data 107 Aloha Con
47. ee TASK SELECT BIT to understand how to use bits to create binary numbers When removed verification will not happen The size of this input function is 1 bit except on fieldbus where it can be size any size to fit the need Configuration Contact Type Normally Open N O Normally Closed N C Bit Type in the number you wish this bit to be in your binary number scheme to verify a task Mode All TASK VERIFY BITs must be the same mode no mixing of modes allowed Binary Will create a decimal number equivalent to the weighted value of this binary bit s Binary 1 Will create a number equivalent to the weighted value of this binary bit s and add the value of one 1 to that number JOB VERIFY When asserted on any input type the controller will verify the active job number is equal to BIT the job number selected by this input Use the BIT parameter under Configuration to select the job number to verify If there is a mismatch between the active job and the selected job the tool will be disabled This is one bit of a binary number created by many of these bits See TASK SELECT BIT to understand how to use bits to create binary numbers When removed verification will not happen The size of this input function is 1 bit except on fieldbus where it can be any size to fit the need Configuration Contact Type Normally Open N O Normally Closed N C Bit Type in the number you wish this bit to be in your bin
48. f 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 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 Software Map 103 User Manual e Accumulate Angle Yes No 5 1 3 Communications Obtain IP From Network No Yes e IP Address e Subnet Mask e Gateway e DNS e Physical Serial e Serial Port 1 Barcode Printer Barcode Printer ETB e Serial Port 2 Barcode Printer Barcode Printer Toyota PFCS Open PFCS e Server IP e Port e Time Out Open e Port e Cell e Buffer while off line Toolsnet e Server IP e Port e Cell e Station 5 1 4 Other e General e Name 104 e Keypad Mode Disabled Task Select Job Select Part ID e Count Mode Count Up Count Down e Stop Abort within Limits OK Users e Add e Manage e 1 Add e 2 Delete e 3 Change Password e 4 Change Access Outputs e C Off In Cycle Job Selected Disassembly Detected Tool Running Cycle OK
49. for each application position and or suspend them in such a way as to prevent tripping and cable damage and to provide good work area maneuverability 3 4 QPM Tools 3 4 1 Display and Multiple Function Button for Hand Held Tools Handheld QPM tools have a display and a multiple function button Two sets of lights 3 and 7 indicate rundown status Two blue lights indicate tool rotation direction disassembly 1 or assembly 2 A single multiple function button 5 is programmable to perform different functions when it is either tapped or held for 2 seconds A short list of functions that are programmable include changing tool direction selecting tasks or jobs or arming for tubenut operation See section 3 4 2 for a complete list When the button is used to select the task or job one of two orange indicators 4 or 6 illuminates to show the active task or job EA tools have four sets of lights 3 and 7 and an LED 8 that indicates when the Preventive Maintenance PM count exceeds the PM limit Display and MFP Button for E02P to E34P pistol Models Display and MFP Button for E23L to E55L lever Models 8 Display for EA23L to EA34L lever Models 80 QPM DC Electric Tools Aloha Controller 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 with either a tap or a 2 second hold You may program one function fo
50. hall not apply to products which have been modified misused improperly handled improperly maintained or used with non compatible hardware or accessories OEM Products Limited Warranty Some Stanley Assembly Technologies custom engineered systems include components manufactured by others The limited warranties of each individual manufacturer shall apply to these components and Stanley makes no representation or warranty of any kind expressed or implied with respect to such components 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 115 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 Technol
51. he same mode no mixing of modes allowed Binary Will create a decimal number equivalent to the weighted value of this binary bit s Binary 1 Will create a number equivalent to the weighted value of this binary bit s and add the value of one 1 to that number JOB SELECT When asserted or removed on any input type the controller will select a job This is one bit BIT of a binary number created by many of these bits See TASK SELECT BIT function description for explanation of this bit keeping in mind this is referenced to jobs not tasks The size of this input function is 1 bit except on fieldbus where it can be any size to fit the need Configuration Contact Type Normally Open N O Normally Closed N C Bit Type in the number you wish this bit to be in your binary number scheme to select jobs Mode All JOB SELECT BITs must be the same mode no mixing of modes allowed Binary Will create a decimal number equivalent to the weighted value of this binary bit s Binary 1 Will create a number equivalent to the weighted value of this binary bit s and add the value of one 1 to that number REVERSE When asserted on any input type the controller will place the tool in Reverse disassembly mode This will NOT run the tool in Reverse mode it simply changes the tool mode from 92 Controller Connections and Inputs Outputs Aloha Controller Inputs Description Forward to Reverse If one
52. ified above and take appropriate action Some measures which may reduce the risk of CTDs e Use minimum hand grip force consistent with proper control and safe operation e Keep wrists as straight as possible e Avoid repetitive movements of the hands and wrists e f 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 1 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 1 the responsibility of tool owners and employers 78 QPM DC Electric Tools Aloha Controller Measure worker sound level exposure and identify high risk noise
53. ioned 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 3 5 1 Directional Control WARNING UNEXPECTED REACTION FORCES To Avoid Injury Be prepared when tool operates in reverse the tool s torque reaction is opposite to the reaction produced when the tool operates in forward direction The tool can have a higher initial reaction force when loosening a fastener e Always stop the tool before changing direction of spindle rotation 3 5 2 Torque Reaction Devices WARNING PINCH POINT BETWEEN TORQUE REACTION BAR AND WORK PIECE To Avoid Injury e Never place any body part between a reaction bar and the work piece
54. ions Layout and Display 34mm beh Weight oe 7g Humidity 010095 non condensing 220 240 VAC 50 60 Hz 15 service 25 Consumption 5 Jsa DOA oa i IA 09 i7 2 Getting Started Aloha Controller Getting Started Item 1 2 3 4 5 6 8 9 L3 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
55. ivisione Assembly Technologies 47 Via Parco 20046 Biassono MI Tel 39 039 2389 1 Fax 39 039 2389970 STANLEY ASSEMBLY TECHNOLOGIES Gowerton Road Brackmills Northhampton NN4 7BW England Tel 44 1604 827247 Fax 44 1604 827277 STANLEY ASSEMBLY TECHNOLOGIES SHANGHAI REPRESENTATIVE OFFICE Room 1908 Shanghaimart Tower 2299 Yan An Road West Shanghai 200336 China Tel 011 86 2 1 3208 4550 Fax 011 86 21 6236 0191 www StanleyAssembly com Warranty 117
56. ixed decimals torque status H HIGH L LOW torque result laststep ran or audit step whichever is smaller decimals are tool units dependant job number pindle number 1 MASTER 2 SLAVE e Barcode this will only read a read code scanner e Printer this will only print after a rundown occurs see string below e PFCS use this to connect to a Chrysler PFS system Toyota use this to connect to a Toyota PI box e Open use this to connect to an Open protocol serial network Version 3 1 4 1 126 2 06 09 2008 10 20 19 barcode second minute hour year day month x 5 The above format has the following issues e Spindle number is not programmable e Task number is not present e Torque angle results and status are not always from the audit step e There is no distinction between no angle and 0 0 degrees 86 Controller Connections and Inputs Outputs Aloha Controller Version 3 0 501 PSOL 01 01 1988 00 03 38 0 9A OA T Carriage Return r Overall Status A R Angle Status L A H Six characters for Angle Torque Status R 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 status two digits for Spindle Number A acceptfor Torque Angle or Overall status highfor Torque or A
57. j Subnet Mask Gateway EDE J Fhysical ow Port 1 0 Port 2 53 Communication Screens Port Buffer While Off Line send Fastener Removed 54 User Manual Options Screen Programming Aloha Controller Communication Screens Buffer While Off Line send Fastener Removed Programming Options Screen 55 User Manual Communication Screens Options Screen EXIT save changes 2 5 3 Setup Menu 3 Other Other Screens Options Screen Programming changes are stored after exiting current menu Jobs CANCEL E Keypad Mode Count Mode Mode Count Mode jstop Abort within Limits H H TRE PERE SA Keypad Moda Keypad Moda Count Mode Count Mode within Limits Stop Abort within Li COUNT DOWN Keypad Node Pree u Keypad Mode Count Mode BCount Mode jstop Abort within Limits 56 Programming Aloha Controller Other Screens Options Screen F GENERAL USERS S Defined Add 2 Delete 5 Chanae Password 4 Chanae Access 5 Change Password 4 Chanae Access O CHHCEL Password Access Administrator Programming 57 58 User Manual Other Screens Options Screen SSS Fecess Administratar OFF CYCLE SELECTED SASSEMBLY ET ORGUE ERIERAL SIFAUL
58. ler will verify the active task number is equal VERIFY to the task number selected by this input Use the TASK parameter under Configuration to select the task number to verify If the wrong task is selected the tool will be disabled When removed verification will not happen The size of this input function is 1 bit Configuration Contact Type Normally Open N O Normally Closed N C Task Type in the task number you wish to verify when this input is asserted JOB VERIFY When asserted on any input type the controller will verify the active job number is equal to the job number selected by this input Use the JOB parameter under Configuration to select the job number to verify If the wrong job is selected the tool will be disabled When removed verification will not happen The size of this input function is 1 bit Configuration Contact Type Normally Open N O Normally Closed N C Job Type in the job number you wish to verify when this input is asserted TASK When asserted on any input type the controller will verify the active task number is equal VERIFY BIT to the task number selected by this input Use the BIT parameter under Configuration to select the task number to verify If there is a mismatch between the active task and the Controller Connections and Inputs Outputs 93 User Manual Description selected task the tool will be disabled This is one bit of a binary number created by many of these bits S
59. lert 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 Cycle OK Cycle NOK Disassembly Detected Indicate Job also fixed and pulsed Control tool operation for tightening a fastene
60. mbly Speed E Disassembly Acceleration 3006 LOCK Out Disassembly Acceleration Cycle Lock Dut ee Audit D LAST Cycle Lock Dut Torque Audit Step Lastia Audit Wapu 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 Torque Rate Torque Average ms Interval Torque Average ms Angle Interval BED 18 User Manual Screens Torque ludit Step Jangle Audit Step jTorque Rate Torque Audit Jangle Audit Step Torque Rate AS Torque Audit Jangle Audit Step lege Rate Jangle audit Step Torque Rate Torque Average ms Angle Audit Step Torque Rate Programming Aloha 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 options Torque Target 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 d High 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 Low Angle
61. ngle 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 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 User Manual 3 6 2 Tubenut Nutrunners WARNING PINCH POINT AT THE EXPOSED GEARS OR TEETH To Avoid Injury e Never place body parts or clothing near the socket opening Dress properly Do not wear loose fitted clothing or jewelry e Follow the Tubenut Nutrunner Sequence of Operation Tubenut nutrunners are used for installing tube fittings Tuben
62. ngle status reglacefor Torque status and rejectfor Overall status Always an S The barcode input monitors inter character timing When there is a 500ms gap between characters a complete barcode is assumed When received the controller logs it with all rundowns until another barcode is received or until controller power 15 cycled If the incoming barcode 1 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 45 Ethernet connection located on the bottom of the module for connecting to an Ethernet network This network can consist of the controller and a PC all the way up to a plant wide fastening network 4 1 5 Alpha Controller Model QA1001 D DeviceNet Alpha Controllers can have a single Mini DeviceNet M port for connecting the Alpha Controller to a master controller such as a PLC o Alpha Controllers Mini DeviceNet Connector 4 1 6 Alpha Controller Model QA1001 P Profibus Port Alpha Controllers can have a single Profibus port for connecting the Alpha Controller to a master Profibus controller from another manufacturer 3 Data Line Power Supply Empty Controller Connections and Inputs Outputs 87 User Manual 4 1 7 Alpha Controller Model QA1001 V Input and Output Connector All 24 VDC inputs and outputs are optically isolated e Internal 24 VDC supply Maximum 1 ampere total e External 24 VDC
63. ns are specific to Stanley Electric Tools when used with Stanley Electric Tool Controllers and accessories Some features may not be applicable performance may be degraded and some safety systems may not be available when tools are connected to non Stanley controllers and accessories 3 3 1 Sockets and Adapters Use only industrial grade sockets and adapters power bit and power or impact socket type Replace worn or damaged sockets that are unsuitable for safe operation immediately QPM DC Electric Tools 79 User Manual Always ensure drive socket is fully seated and locked into position before connecting power to tool 3 3 2 Suspension Devices Tool suspension devices or bails help support the weight of the tool during tightening operations Attach these devices securely and periodically inspect them for damage or loosening 3 3 3 Cable Installation WARNING ELECTRICAL HAZARD To Avoid Injury e Never use a tool with a damaged cable e Never abuse a cable carry a tool by its cable hang a tool by its cable or pull on a cable to disconnect it from the tool or the controller To ensure superior performance and safe operation use the Stanley cables specifically designed to operate these tools Never use a tool with a damaged cable Never abuse a cable carry a tool by its cable or pull a cable to disconnect it Also keep the cord away from heat sharp edges or moving parts Use cables of appropriate length 60M maximum
64. nt Ramp Time Soft Stop Current Off Time Current Hold Time 00 Time Lurrent Hold Time Current Ramp Time Soft Stop J Speed j Power Programming Aloha Controller Strategy BACKOFF Screens Options Screen Acceleration abort Timer DELE Between eters Abort Tiner Delay Between Steps Accumulate Angle Abort ICE j Delay Between Steps Accumulate Angle Tiner J Abort Tiner Delay Between Steps E Delay Between Steps Accumulate XE late all 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 Delete Paste Programming 51 User Manual SI ur 2 5 1 6 Setup Exit Exit Screens Options Screen Programming changes are stored after exiting current menu a HE 2 5 2 Setup Menu 2 Communications Communication Screens Options Screen Programming changes are stored after exiting current menu 52 Programming Aloha Controller Communication Screens Dbtain IIF Address Subnet Mask EMI AE ERRCO DE PRIHTER Programming Options Screen IP Address Subnet Mask Obtain IP From Network 1 Address _ HH subnet Mask Address
65. ogies products without responsibility for incorporating changes in products already sold Warranty Claims To apply for warranty consideration the original purchaser should take the following action Contact the Stanley Assembly Technologies customer service department to obtain a Return Authorization Number and Warranty Claim Report Form Package the product including proof of purchase and the completed warranty claim form Note the Return Authorization Number on the exterior of the package 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 RM
66. ow 85dBA C weighted peak emission sound pressure level Lpcpeak not applicable to these products Uncertainty Kwa not relevant declared levels are maximum values WARNING To Avoid Injury This information is provided to assist in making rough estimates of sound and vibration exposure levels in the workplace The declared emission values were obtained by laboratory type testing in accordance with the stated standards Levels measured in individual workplaces may be higher The actual exposure levels and risk of harm experienced by an individual user depends upon the work piece workstation design duration of exposure and the physical condition and work habits of the user To help prevent physical impairment a program of health surveillance is highly recommended to detect early symptoms which may relate to sound and or vibration exposure such that appropriate preventive measures may be taken QPM DC Electric Tools 77 User Manual 3 2 Operator Protection WARNING ROTATING EQUIPMENT To Avoid Injury e Always wear eye and foot protection when operating installing or maintaining power tools and when in areas where power tools are being used maintained or installed Some applications may require the use of safety glasses and face shields Use eye protection that conforms to ANSI Z87 1 3 and ANSI Z41 PT99M 1 75 C 75 Always stay alert when operating tools and or their accessories Do no opera
67. ow Angle 1 Target Torque Angle 1 Target d High Torque 32 Programming Aloha Controller Strategy BACK Backoff Screens Options Screen Torque Target j High Torque 2533 35 Q Torque U EE FE E j Torque Bailout 5999 3 zu Downshift Mode 5 Downshift Mode Torque Bailout EEE L Soft Stop Downshift Mode B Dowenshift Mode j FDownshift Torque Soft Stop Downshift Speed Current Off Time Downshift Mode j soft Stop Current Off Time Programming 33 User Manual Strategy BACK Backoff Screens Options Screen _ we Mode manual DE Downshift Torque ef Dawnshi ft 6 Dawnshitft Torque Downshi ft Mode Downshi ft Dawnshift Torque Downshift Mode LA Dawnshi ft 22200 Stop Current Off Time Current Hold Time Soft stop Jd Current Off Time Current Hold n Lurrent Hold Time Current Ramp Time Soft ston d Current Off Time Current Hold n current Time P Hald Time Ramp Time Soft Stop Speed Power 34 Programming Aloha Controller Strategy BACK Backoff Screens or Tier Abort Timer Acceleration Abort Timer q Delay Between Abort Timer j Delay Between Steps Accumulate Angle Abort Timer oj Delay Between Steps al Accumulate Angle
68. r tap and a second function for hold Disable default The button does nothing Pressing the button causes the tool alarm to beep once Only the assembly blue light 2 illuminates Reverse Pressing the button toggles between assembly and disassembly and Disassembly illuminates the appropriate blue light 1 or 2 All tool status lights 3 and 7 flash when the tool is in disassembly mode Job or Task Select Pressing the button toggles between job 1 and job 2 or task 1 and task 2 and illuminates the appropriate orange light 6 or 4 Arm Pressing the button arms activates the start function but does not start the tool The tool is allowed to start once the button 1 pressed This arming is active for 5 seconds If the tool is not run within 5 seconds it will disarm automatically The blue assembly light 2 comes to show that the tool 15 armed and will go off when the tool is disarmed When Reset Reject is selected and the rundown status is NOK red or yellow light illuminated the tool becomes disabled and the reject tone will continue to sound until the MFP is pressed Pressing the button stops the reject tone and re enables the tool Job Reset Pressing the button will reset the accumulated bolt count back to zero for the active job and act as a Part Entry to re enable the tool if disabled Reset Reject 3 4 3 Tool Memory QPM tools have an onboard tool memory that stores tool identification calibration factors and
69. r 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 include multiple fasteners controlled by one or more tasks Anytime the peak angle recorded during the Angle Audit Step fails
70. r 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 plot of torque versus time or angle of a tightening cycle Records the number of total tool tightening cycles completed sinc
71. red in the controller or sent out via the serial port or Ethernet This input function is NOT available on the 24 VDC type of I O The size of this input function can be any size from 0 to 32 bytes When removed nothing will happen Configuration Length Type in the length of the expected data string in bits Trigger Manual A handshake must be performed in order for the controller to read the new PART ID The definition of a handshake is as follows The external PLC verifies the PART ID CHANGED output is low 0 2 The external PLC writes the data into the PART ID fieldbus input 3 The PLC sets the PART ID TRIGGER input high 1 to indicate the new PART ID data has been written and is ready for the controller to read it 4 The controller will read the PART ID data into its memory and set the PART ID CHANGED output high 1 to indicate the data has been read 5 The PLC reads the high level on the PART ID CHANGED output then sets the PART ID TRIGGER input to low 0 6 The controller will set the PART ID CHANGED output to low 0 Auto The controller will read the PART ID when it 5 automatically no Controller Connections andInputs Outputs 5 Connections and Inputs Outputs 95 User Manual Inputs Description BEEN handshake required 4 2 2 Output Descriptions Outputs Description pore JOB SELECTED DISASSEMBLY DETECTED TOOL RUNNING CYCLE OK CYCLE N
72. rward mode The size of this input function is 1 bit Configuration Contact Type Normally Open N O Normally Closed N C When asserted on any input type the controller will prevent the tool from running It does NOT stop the tool if the tool is running but will prevent it from running when the next START signal is applied The START input can come from any type of I O or the tool trigger When removed the tool is allowed to run after the next START input The size of this input function is 1 bit Configuration Contact Type Normally Open N O Normally Closed N C When asserted on any fieldbus input type the controller will read the new PART ID input and place the data into the Part ID buffer This data is added to the rundown data and stored in the controller or sent out via the serial port or Ethernet This input function is NOT available on the 24 VDC type of I O Also the PART ID CHANGED output will go high This lets the PLC programmer know the controller has read the new PART ID See PART ID input function for explanation of handshake between controller and external PLC When removed the PART ID CHANGED output goes low The size of this input function is 1 bit Configuration Contact Type Normally Open N O Normally Closed N C When asserted on any fieldbus input type the controller will read the new PART ID input and place the data into the Part ID buffer This data is added to the rundown data and sto
73. s equipment must be earth grounded Never modify a plug in any way or use any adaptor plugs Avoid body contact with electrically energized surfaces when holding a grounded tool Prior to connecting a power source always ensure the tool or controller is turned off Limit controller access to trained and qualified personnel Lock controller cabinets WARNING 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 Aloha 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
74. s 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 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 85 User Manual 4 1 3 Alpha Controller Serial Connector Alpha Controllers have two male DB 9 connectors The setup is 9600 baud rate 8 data bits No Parity and 1 Stop bit and is not programmable The connection between the computer and the controller is a simple null modem cable The one that is labeled COM PORT 1 has the intended purpose of connecting a laptop computer for access to Embedded Toolbox software Other communication functions can be selected for the serial port besides Embedded Toolbox Those choices are Barcode Printer Barcode or Printer Function Transmit Data Data Set Ready Ring Indicator A second DB 9 connector COM PORT 2 is available if needed It also has options for different communication functions The list includes Barcode Printer This will read a barcode scanner and print the rundowns after they occur see string below x overall status R NOK angle status L LOW angle result laststep ran or audit step whichever is smaller f
75. sed data input menu selection job task selection Numeric Keypad and for entering PART ID a 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 10 Programming Aloha Controller 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 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 after selected ta
76. splays unless other programming functions 4 are in use Shows active job 5 and active task 6 Tool Shutoff Codes indicate why a tightening cycle shutoffs prior to completion Tool Shutoff Description Code TIME Tightening time exceeds programmed cycle abort time value STOP Spindle stopped by either the operator or other device before completing cycle 125 Spindle stopped due to torque achieving greater than 125 torque limit for the spindle FAULT Faults are described in section 2 3 STALL Spindle is in a stall status Alpha Controller Icons Icon Status Description Locked Password required to make changes Unlocked Changes possible automatically re locks in time fe Busy working Please wait for controller to finish working Warning system not operable Check the run screen Force on or off Identifies an input output forced on or off Programming Aloha Controller Stop Tool Operation No strategy selected Bolt count has been met needs reset An Input is disabling the tool Reset Reject has is enabled and active 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 the screen Over current Fault Logic Voltage Fault Position Feedback Fault Transducer Span Fault Temperature Fault Unrecognized Tool Tool Communications Transducer Current Fault Transducer Zero Fault Internal Fault Uns
77. 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 PartNo 19 24V I O Port Included 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 4 2 Assignable Input Output Functions The following Input Output I O functions apply to DeviceNET Profibus Modbus TCP EthernetIP and 24V There is a maximum of eight inputs and eight outputs for the 24 VDC I O connector There is a maximum of 512 bytes of input and 512 bytes of output on each Fieldbus used with the controller with the exception of DeviceNet which is limited to 256 bytes of both inputs and outputs Ninety nine is the maximum number of I O functions that can be assigned to each type of input or output Each I O function can have a length of one bit all the way up to 32 bits You must keep track of the lengths for each I O function you assign to stay within the maximum length of the type of I O you are using More than one type of I O connection can be used at the same time For instance the controller can use the 24 VDC I O connector AND Modbus TCP on Ethernet AND DeviceNet all at the same time If more than one type of Input uses a particular input function the controller will respond to an input when it is
78. te tools and or their accessories while tired under the influence of drugs alcohol or any other mind altering substance Repetitive work motions or vibration may be harmful to your hands arms shoulders or back Use suitable protective equipment and work methods whenever an application presents a hazard Repetitive Motion The use of power tools may involve highly repetitive motions of the fingers hands wrists and shoulders These repetitive motions can lead to cumulative trauma disorders CTD Many personal and workplace factors can contribute to these disorders Currently available data have identified the following risk factors These risk factors are not necessarily causation factors of CTDs The mere presence of a risk factor does not necessarily mean there is excessive risk of injury Generally the greater the exposure to a single risk factor or combination of factors the greater the risk for CTDs Forceful exertions and motions Extreme postures and motions Repetitive exertions and motions Intended duration of exertion postures motions vibration and cold Insufficient rest or pauses Work organization risk factors Environmental risk factors These risk factors span job design and content operator training work method work pace work environment proper tool selection and other work place factors beyond the control of the tool manufacturer Tool owners and employers should analyze jobs for all of the risk factors ident
79. tightening cycle counters Memory parameters include e Model Number Serial Number Torque Cal calibration factor Angle Cal calibration factor Tightening cycle counters 3 4 4 Tightening Cycle Counters QPM tools have onboard counters that record the number of tightening cycles completed by the tool e Odometer Records the total number of tightening cycle completed e Trip Counter Records the number of tightening cycles completed since the last reset e PM Counter Records the number of tightening cycles completed since the last reset e PM Threshold 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 from the Tool Memory Board QPM DC Electric Tools 81 User Manual 3 5 Tool Operation WARNING ROTATING SPINDLE To Avoid Injury e Always wear eye and foot protection when operating and when in areas where power tools are being used e Keep all body parts and clothing away from the rotating end of the tool Dress properly Do not wear loose fitted clothing or jewelry TORQUE REACTION FORCE To Avoid Injury Be alert 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 The start lever should be posit
80. ting tools and controllers Indicates an item of special interest WARNING To Avoid Injury Read and understand all the safety recommendations and all operating instructions before operating tools and controllers Save these instructions for future reference Train all operators in the safe and proper use of power tools Operators should report any unsafe condition to their supervisor Follow all safety recommendations in the manual that apply to the tools being used and the nature of the work being performed Verify that all warning labels illustrated in this manual are readable Replacement labels are available at no additional cost from STANLEY ASSEMBLY TECHNOLOGIES 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 Arial 10 bold italic 1 3 Specificat
81. 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 Job Rst and MFB Hold Disabled Reverse Task Sel Arm Rst Rej Job Sel Job 111 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 112 User Manual 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 tool cycles until maintenance 1 required When the PM Counter exceeds the PM Limit the controller provides a maintenance a
82. troller Appendix A Embedded Toolbox Appendix A Embedded Toolbox 109 Aloha 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 Torque Set Point TSP High Starting Torque Starting Torque gt 20 of TSP Enables the tool setup for the next task afte
83. unsafe condition Store idle tools and accessories in a safe location accessible only by trained persons Disconnect power source air electricity etc from tool prior to making adjustments changing accessories or storing Prior to operation always check and test tools and accessories for damage misalignment binding or any other condition that may affect operation Maintenance and repair should be performed by qualified personnel Do not operate tools in or near explosive environments or in the presence of flammable liquids gases dust rain or other wet conditions Keep the work area clean well lit and uncluttered Keep unauthorized personnel out of the work area 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 e 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 95 non condensing and Temperature 32 to 122 F 0 to 50 C Installation maintenance and programming should be performed by qualified personnel Follow all manufacturer installation instructions and applicable regulatory electrical codes and safety codes Tool and controller plugs must match the outlet Thi
84. upported 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 internal clock as set by the user Events included in the log are rundowns and faults The data stored for each rundown includes Torque the torque value achieved from Audit step or last step performed if the Threshold Torque has been exceeded Angle the angle value achieved from Audit step or last step performed if the Snug Torque has been exceeded Date controller date when rundown was performed Time controller time when rundown was performed Job the job number which the rundown was performed Task the task in which the rundown was performed Status the overall status of the rundown SOC shutoff code other than normal see section 2 2 6 for a list of Shutoff Codes Bolt which bolt being fastened used only during error proofing operations Step the step achieved at shutoff not necessarily the final step in the task Part ID the number stored in the Part ID buffer could be from a barcode scan or received over the serial port Fieldbus Ethernet or keypad The data stored for each fault includes Event the name of the fault see section 2 3 for a list of faults Date controller date when fault was asserted cleared Programming User Manual Time controller time when fault was asserted
85. ut Sequence of Operation QPM Tools e Place nutrunner socket on fastener e Press the button on the multiple function panel to the start function not required in modes 0 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 84 QPM DC Electric Tools Aloha 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 Controller Connections 4 1 1 Alpha Controller Power Cord Alpha Controllers use an IEC 60320 style connector The power source connector for the power cord is based on customer requirements The power cord should be rated at either 15A 125V for 115 V or 10A 250V for 230 V use of the controller 4 1 2 Alpha Controller Tool Connector Alpha controller
86. with non genuine Stanley replacement parts Electronic Products Limited Warranty Stanley warrants its Assembly Technologies electronic products to the original purchaser to be free from deficiencies in material or workmanship for a period of one year after the date of shipment Under this limited warranty Stanley will at its discretion repair or replace any product which upon inspection is acknowledged by Stanley to be defective This warranty shall apply to products which have been 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 s

Assembly Technologies Alpha Controller User Manual v3.1

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