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PSI-C/C2 Controller - Stanley Engineered Fastening

1. J I8 VSlIcl HOLVd HOLVd Schematic NENNEN NNNM Pin Description Pin Description 1 OUTPUT COMMON BUS 6 DISABLE TOOL 2 CYCLE OK 7 BATCH REJECT RESET 3 CYCLE NOK 8 MANUAL WRENCH ACCEPT 4 BATCH OK 9 PSET Select BIT 3 5 10 PSET Select BIT 2 11 PSET Select BITI 12 INPUT COMMON BUS Connector Plug Part No 24X500537 The PSI C I O terminal strip is located externally on the bottom of the PSI C Certain remote connections are also accessible via the RJ45 socket located on the right side bottom panel and can be easily accessed using the ROI Remote Operator Interface Standard I O is optically isolated and relay operated using dry contacts normally open I O must be powered from a remote source Installation and Use 19 User Manual Standard INPUTS are Disable Part Not Present and Batch Clear Reset Input terminals 9 10 and 11 are used to select Parameter Sets according to the following table Pin9 Pinl10 Pinll Parameter Set Binary 1 Off Off Off Keypad Selects Off Off On 1 2 Off On Off 2 3 Off On On 3 4 On Off Off 4 5 On Off On 5 6 On On Off 6 7 On On On 7 8 When all three inputs are OFF the c
2. Assembly Technologies PSI C C2 Controller User Manual Software Version PCX 2 0 0 Important Safeguards For your protection please read these instructions completely and keep this manual for future reference Carefully observe and comply with all warnings cautions and instructions placed on the equipment or described in this manual 2011 StanleyBlack amp Decker Inc ALL RIGHTS RESERVED www StanleyAssembly com User Manual Contents GETING c 1 1 4 Warnings and Cautions 1 1 2 Qualified Personnel 1 D E AUI E E A AAT 2 1 4 UC HOT 2 1 5 Electrical Safety 2 1 6 SpeciticallOliS 3 1 6 1 Layout and Operator 4 Installatiori and tissue testa ias net p PIS 5 2 1 Air Supply Requirement 5 22 OUTING ak 5 2 3 Tool Compatibility uapa ta sai 6 2 3 1 Transducer Pulse and Impact Tools 6 2 4 Main Menu and Application Programming 7 2 4 1 Check HITIBSS 7 2 42 Parameter Set up 8 2 4 2 1 Calibration Correlation 8 2 4 2 1 1 Correlation Procedur
3. 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 STANLEY ASSEMBLY TECHNOLOGIES 1 2 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 Getting Started 1 User Manual 1 3 Safe Use 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
4. 1 1 1 Begin measuring data vt 2 3 2 Message Type 13 4 4 1 Revision At 5 16 12 Time Date 17 22 6 FF0101 or PPO101 23 23 1 Torque Pass Fail DEY 24 28 5 Torque High Limit 01000 100 0 29 33 5 Torque Low Limit 01000 100 0 34 38 5 Torque Final 01000 100 0 39 40 1 Pulse Angle Pass Fail EPS Op ik 40 44 5 Pulse Angle Max Limit 00005 5 45 49 5 Pulse Angle Min Limit 00005 5 50 54 5 Pulse Angle Final 00005 5 55 55 1 UNITS L SS 56 537 2 Current Pset 01 08 58 59 2 Batch Count 01 99 60 61 2 Current Count 01 99 62 63 2 Filter 01 64 64 68 5 Transducer Cal 01000 100 0 69 73 5 Target Torque 01000 100 0 74 78 5 Angle Target 00000 99999 79 83 Transducer Zero 00000 04095 84 88 5 Adc Tq Shutoff 00000 04095 89 93 5 Adc Tq Final 00000 04095 94 94 a Early Release VY E XN 95 134 40 Barcode ASCII 135 150 16 Controller Name ASCII 151 155 5 Packet Number 00000 65535 156 156 1 End of Data r 0x0D 257 Networking The PSI C is Ethernet Network capable through an optional Ethernet Network card 1 Ethernet TCP IP This optional card part 24B500502 must be factory programmed for Ethernet It is accessed via an RJ45 port located on the bottom panel of the enclosure The Ethernet card communicates using TCP IP and can be configured to utilize communication software programs 2 PFCS Chrysler PFCS is available in both Serial RS 232 and Ethernet formats If the PFCS Ethernet net
5. Scroll UP or DOWN to set the MIN PULSE CT The setting can be tested at this point Watch the screen and run some good and bad cycles Adjust MIN PULSE CT setting until satisfied Press ENTER to activate CYCLE COUNTER This allows a maintenance cycle counter to be set that counts down from a selectable number of cycles Once this number of cycles is achieved a MAINTENANCE REQUIRED screen appears so that normal pulse tool maintenance can be performed Press ENTER and UP SET DWN CLEAR appears Press UP and CYCLES appear Scroll UP to set the number of cycles to count BATCH COUNT Press ENTER to adjust the BATCH COUNT or the total fasteners to be run successfully on the part Press ENTER and scroll UP or DOWN to alter the fastener COUNT per BATCH BATCH TIMER Press ENTER to adjust the BATCH TIME or the total cycle time for all fasteners to be run successfully on the part Zero is equal to OFF or no timer Press ENTER and scroll UP or DOWN to alter the number of SECONDS allowed for the BATCH If all fasteners are not successfully tightened in the allotted time a Batch NOK occurs TARGET TORQUE HI LIMIT LOW LIMIT Adjust the torque target high or low limit if the specification changes 12 PSI C Controller Function LOW LIMIT GRN ON Description Use the ENTER button to toggle ON OFF whether the green OK LED light turns ON after the LOW LIMIT is crossed If OFF is chosen the green LED turns
6. Stanley controllers are intended for use in industrial threaded fastening or precision position and or adjustment applications only Some instructions may not apply to all applications Please contact your Stanley Sales Engineer for further information or assistance on Stanley training or assembly tool operations 1 4 Introduction The PSI C Controller provides closed loop torque control and torque validation available with date and time stamp It is easy to program has common network ready hardware available and uses industry standard protocols The PSI C Controller provides precise torque control as well as multiple parameter set capability and Poke Yoke error proofing to compatible transducer pulse tools With the available DTU up to 576 fastening cycles are stored STATISTICS calculated with DATE TIME and easily transfers to Microsoft Windows Excel Compact in design the PSI C Controller provides operator feedback via a large digital display for parameter set identification as well as torque and joint condition status and color LEDs for fastener counting There are OK NOK indicator lights for finished cycle or batch evaluation for in and out of spec conditions Available with eight parameter sets allowing different counts and application set ups one tool can be set to perform various applications using its full torque range The PSI C2 offers all the same functionality as the PSI C with the added benefits of running the PSI series tools
7. PSI C has a two line main display This shows the final TORQUE Parameter or PSET the BATCH or fastener COUNT and the BATCH TIMER BATCH COUNT represents the number of fasteners that the PSI C has been programmed to count per BATCH LED lights change to GREEN upon reaching an OK or GOOD fastening cycle Outputs and CYCLE lights on the tool if applicable fire automatically CYCLE lights on the tool can be fired after crossing the LOW LIMIT or when TARGET TORQUE is achieved The BATCH light on the PSI C and internal outputs also fire automatically Running the next cycle clears these lights and resets outputs automatically Select MOMENTARY from the ADMIN MENU to clear the cycle lights and reset the outputs after two seconds 18 PSI C Controller 2 5 3 Inputs Outputs I O Output signal lines are switched by closing normally open relay contacts These relays conform to VDE0435 UL508 and CSA22 2 Signal power is customer supplied and may be AC or DC up to 48 volts The maximum current capacity of the relay circuitry is seven amps per contact with seven amps total Inputs are optically decoupled from other circuitry These signals must be between 12 and 24 volts DC The design will accept DC input signals of either polarity 1 2 4 5 6 7 8 9 10 11 12 Z 2 Z S O O O O NS Z Wd SZ SZ SZ Se J T SN S N
8. but LOW TQ or TQ NOT REACHED is received check for e Target torque is above the capacity of the tool e The pulse mechanism is not adjusted to the maximum e Insufficient supply air pressure Check pressure when free running tool air pressure should not drop more than 10 psi from the static air pressure available e Incorrect NOMINAL CAL VALUE was entered 2 4 2 1 1 Correlation Procedure 1 From this RUN screen without clearing the last reading access the ADMIN functions via the ADMIN key Quickly press the ADMIN key to display options 2 Use the UP or DOWN keys to scroll through and find the CORRELATION option Press the ENTER button 3 MANUAL or AUTO CAL can be selected Press the UP key or DOWN key accordingly AUTO CAL allows the entry of the master torque reading to be entered by scrolling up or down until the master value is entered NOTE Adjust using AUTO CAL by setting the MASTER reading to about 60 70 of the actual measured torque Repeat as needed until the two readings correlate 4 Press ENTER and note the new Correlation Value which is calculated automatically 5 Press the BACK button to return to run screen 6 Repeat this process until the readings from the master and the PSI C match within 2 or as required by your ISO procedures Installation and Use 9 User Manual 2 4 2 2 Operation Flowchart Initial Set up PSI C AS Use the UP DWN arrows to find the parameter set desired Press
9. on when TARGET TQ is achieved Scroll to the next ADMIN function Press the BACK button to return to the RUN screen CYCLE DELAY This setting determines the off time between the end of one run down and tool reset for the next cycle The total range of adjustment is between 10 and 1000 counts This relates to 25 second to four seconds of off time The default value of 100 keeps the tool off for about one half second before allowing the operator to press the trigger for the next fastener If this is too slow adjust by using the UP DWN buttons the value down to approximately 60 80 Any lower may be too quick and may not allow the operator enough time to release the trigger A higher value causes the tool to reset slower TIME DATE Sets TIME and DATE Press UP to SET Scroll to change Press ENTER Press DOWN to exit DATA Allows the download of all data stored on optional DTU Data Transfer Unit Press ENTER and then DOWN to download all RS232 serial data through RJ45 serial port Press UP to CLEAR all DATA I O Latched or Momentary Allows the outputs to be latched until the next cycle starts or momentary which turns the outputs off two seconds after the completion of the cycle Toggle by pressing ENTER Scroll UP or DOWN to move to the next option ADMIN LOCK ON OFF Initially turning this feature ON allows the entry of a four button code using the existing four keys in a programmable order Once this is done
10. or another pre determined value Scroll to alter Press ENTER to activate change PULSE DELAY The PSI C can ignore the initial pulses from the tool This is required to eliminate any pulse spiking from the initial pulse s This can happen due to the high free speed of the tool This is defaulted to one 1 pulse Adjust to a higher number to cover worst case applications such as hard joints and loose sockets extensions DOWNSHIFT This allows the end of the fastening cycle to be slowed down in order to control torque over shoot TORQUE appears when ENTER is pressed showing the TARGET TQ Scroll down to set the TORQUE to initiate DOWNSHIFT Press ENTER PSI appears Scroll to the PSI level which the tool will run until TARGET is achieved MAX PULSE COUNT This sets a maximum allowable PULSE COUNT before the cycle is REJECTED If a strip or cross thread occurs this can help detect the bad cycle It can also detect a failing pulse pack unit Press ENTER and LAST RUN and MAX PULSE CT setting appears The setting can be tested at this point Watch the screen and run some good and bad cycles Adjust MAX PULSE CT setting until satisfied Press ENTER to activate MIN PULSE COUNT This sets a minimum allowable PULSE COUNT before the cycle is REJECTED If a previous tightened fastener or a cross thread occurs this can detect the bad cycle Press ENTER and pulse counts from the LAST RUN then the MIN PULSE CT setting appears
11. the tool 1 The pulse unit adjustment screw in the tool must be set for the highest output of the tool or at least the high limit of your application Adjust the screw fully clockwise until it seats then back it out approximately 1 2 turns or until the operation of the tool is uniform and smooth when pulsing 2 Check the maximum torque of the tool to insure that it can obtain the torque required 3 Install and attach the GEMINI air hose transducer cable to the bottom of the PSI C and the tool Air hose and transducer cable versions depend upon the PSI C and tool being used 4 Upon power up hold down both the ENTER and BACK keys simultaneously until the display reads CLEAR COMPLETE This returns all settings to the factory defaults Observe the display to determine both the type of software and code revision date installed 5 The PSI C automatically zeros and checks the tool s transducer then shows PSET 1 NOT SET UP 6 Press the ENTER key left key after controller power up to display the MAIN MENU Use the UP DOWN key to scroll through the MAIN MENU 2 4 1 Check Harness Installation and Use 7 User Manual 2 4 2 Parameter Set up PSET 1 NOT SET UP Select the PSET desired by scrolling up or down press ENTER NOMINAL CAL A default value of the transducer s nominal calibration setting appears on screen The tool has its nominal cal value stated on the tool NOTE The cal value is only correct if sensitivity is correct
12. this programmed button order must be entered every time the ADMIN MENU is accessed through the ADMIN button Turning this OFF allows entry to the ADMIN MENU without a four button code SENSITIVITY Sets the level of sensitivity for the transducer circuit to reduce the negative effects of loose sockets poor alignment and or electrical noise from affecting the torque readings Default setting 15 seven 7 for most impact tools and 14 for pulse tools NOTE A change to the SENSITIVITY setting requires an adjustment or resetting of the CALIBRATION VALUE ETHERNET Allows entry of the UNIT IP ADDRESS Scroll UP or DOWN to change Press ENTER After changing the settings under ETHERNET it is necessary turn the power to the PSI C off and on PRETORQUE Allows the setup of a two step fastening procedure This is used for wheels cylinder heads or any assembly that requires a snug torque before a final torque to compensate for relaxation Press ENTER Scroll UP to choose PRETORQUE This is usually 50 60 of the specified final torque Press ENTER NOTE BATCH COUNT must be programmed for correct sequencing The Run Screen now shows PTQ when running PRETORQUE or snug torque PRETORQUE all fasteners When the PRETORQUE BATCH is finished OK The Run Screen changes to show TQ Final Torque all fasteners NOTE MIN PULSE COUNT may need to be adjusted to accept final torque while still rejecting a REHIT fastener RAMP Installat
13. 04095 oOo SY QE UN ASCII ASCII 00000 65535 r 0x0D Retries 3 Notes After thr retries the unit will close the connection Message Keep Alive Start End Length Field Format 1 1 Begin measuring data DS 2 3 2 essage Type TOGN 4 4 1 Revision 5 20 16 Controller Name ASCII 21 24 End of Data Nr 0x0D Direction Controller to Host Retries 3 Notes Sent every 30 Seconds After thr close the connection retries the unit will Message Acknowledgement Start End Length Field Format 1 1 T Begin measuring data UNI 2 4 3 essage Type 98R 5 5 1 End of Data Nr 0x0D Direction Host to Controller Notes Sent in reply to Final Data or Keep Alive messages 2 5 8 Troubleshooting and Adjustments 2 5 8 1 Transducer Calibration If the controller does not correlate once the NOMINAL CAL VALUE of the tool is programmed check the cable and connections Substitute a known good cable and then a known good tool to determine if the tool s wiring transducer or cable is defective Should the transducer set up correctly but the torque value not agree with your MASTER Check that the NOM CAL of the tool is correctly entered Perform a CORRELATION routine described previously 24 PSI C Controller Any added square drive extension including a rotary transducer causes efficiency loss and thus torque loss at the fastener Use only eCoDrive sockets and e
14. 3 Excessive Cycle Time 25 26 Service and Maintenance 25 27 PSI C Controller Assembly PSI C 26 2 8 PSI C HI Flow Controller Assembly PSI C H 27 PSI C Controller Getting Started 1 1 Warnings and Cautions The safety notices and warnings for protection against loss of life the users or service personnel or for the protection against damage to property are highlighted in this document by the terms and pictograms defined here The terms used in this document and marked on the equipment itself have the following significance Indicates that death or severe Indicates a general hazard This Danger personal injury will result if icon appears as a part of a proper precautions are not taken Danger Warning or Caution notice Indicates that death or severe Indicates that eye protection Warning personal injury may result if should be worn This icon proper precautions are not taken appears as a part of a Danger Warning or Caution notice Indicates that property damage Read and understand all the Caution may result if proper precautions safety recommendations and all are not taken operating instructions before operating tools and controllers Indicates an electrical hazard This icon appears as a part of a Danger Warning or Caution notice Indicates an item of special interest
15. BLY TECHNOLOGIES Outils Portatifs et Systemes d Assemblage Zone Immoparc Route De Chartres B timent Loire 4 78190 Trappes Cedex France Tel 33 130 50 91 00 Fax 33 130 51 07 08 SATinfo stanleyworks com STANLEY DEUTSCHLAND GmbH Division Assembly Technologies Frankfurter StraBe 74 D 64521 Gro Gerau Germany Tel 49 6152 8052 0 Fax 49 6152 8052 22 SATGER stanleyworks com STANLEY ASSEMBLY TECHNOLOGIES Divisione SWK UTENSILERIE s r l Via Parco 47 20046 Biassono Italy Tel 39 039 238 9950 Fax 39 039 238 9970 SATinfo stanleyworks com www StanleyAssembly com Installation and Use 29
16. ENTER to select 30 ed meer Continued on Next Page 10 PSI C Controller Operation Flowchart Continued hl This is the RUN screen 2 4 3 Test Run a few normal fasteners The PSI C shuts off the tool Release the trigger the PSI C resets the internal shut off valve If you leave the trigger pressed the tool turns back on Check torque results The system is not defaulted for REHIT error detection i e re hitting an already tightened fastener Set up this feature using MIN PULSE COUNT in the ADMIN MENU Adjust ADMIN functions for the system to detect a REHIT fastener and error or display as a fault Run the tool in free air release the trigger and the program should ignore the run display LOW TQ or ABORT Slip off or strip out a fastener and the display should ignore error or read SLIP If the results obtained are not correct press ENTER and re program the application or go to the ADMIN functions via the ADMIN key Use the BACK key to return 2 5 ADMIN Functions From the RUN screen access the ADMIN functions via the ADMIN key Quickly press the ADMIN key scroll through the functions using the UP and DOWN buttons the following options display NOTE After adjusting function s press ENTER to accept the change then press the BACK UP key until the run screen appears Function Description CORRELATION Provides an easy transducer correlation to an independen
17. OSE SSR Hey a AUX RJ 45 REMOTE KEYPAD LIGHTS etc NETWORK CONNECTOR Serial Ethernet 3 8 AIR OUTPUT GEMINI HOSE CONNECT 1 2 NPT AIR INPUT VO SCHEMATIC o gt PSI C Controller Installation and Use WARNING To Avoid Injury Always wear eye and foot protection when installing equipment Keep the work area clean well lit and uncluttered Keep unauthorized personnel out of the work area Do not install worn damaged or modified equipment that may be unsuitable for safe us Train all operators in the safe and proper use of power tools Operators should report any unsafe condition Install tools in dry indoor non flammable and non explosive environments only 2 1 Air Supply Requirement A supply of compressed dry filtered air is required to run the pulse or impact tools connected to a PSI C controller Please check the individual tool specification for air flow and pressure requirements Most tool specifications are based on 90 psi 6 Bar for full range operation However the PSI C controller will operate at any level as long as the air pressure and volume are sufficient for the tool to reach the required torque The supply air hose should be a inch 15mm or 3 8 inch 10 mm inside diameter with no restrictions fittings smaller than 3 8 inch inside diameter If the air pressure and volume are insufficient the performance of the tool suffers and the full torque range of the tool will not be realiz
18. able Network 38 2 24R500102 Pan Head Screw 4 40 x 3 8 39 1 248500325 Cap Plug Part of Printer Assembly 10780 optional TE Used with Network Card 28 PSI C HI Flow Controller Assembly PSI C H Item Qty Part Description 1 1 24 500178 Enclosure Molded Plastic 2 1 24X500195 Overlay Keypad 3 1 248500165 Main Board Assembly 4 1 248500229 Pre Amp Board Assembly 5 4 24R500299 Screw Pan Head High Low 8 x V2 6 1 24X500193 Bottom Panel Cover 7 1 24X500025 Valve 3000 9 1 24X500008 12 OD Tube 10 1 24X500064 Bulkhead Output 3 8 Tube 11 1 24X500192 Bulkhead Input 2 3 8 12 1 248500268 90 Degree Fitting V2 1 2 Tube 13 1 24X500018 90 Degree Fitting BARB 14 1 248500289 Reducer Bushing 3 8 14 15 1 246500257 3 8 OD Tube Instal
19. e 9 2 4 2 2 Operation Flowchart Initial Set up PSI C 10 J 11 25 ADMIN Functions rd decet 11 2 5 1 Operation Flowchart Basic ADMIN MENU 14 2 5 2 Error Proofing OK NOK 17 2 5 2 4 EUROS k Saa q aS 18 2 5 2 2 Normal Operation Run Mode 18 25 3 Inputs Outputs I O 19 2 5 4 RJ45 Auxiliary Connector 20 25 5 Data Collection and Download 20 256 SaerialPort 21 2 15 22 2 5 7 1 Standard Ethernet Protocol 23 2 5 7 1 1 Theory of Operation 23 25 7 Nick Packets stein reti bn osea ii 23 2 5 8 Troubleshooting and Adjustments 24 2 5 8 1 Transducer Calibration 24 2 5 8 2 Set up Problems 25 2 5 8 3 Other Concerns 25 2 5 8 3 1 Air Hose Lengih 25 2 5 8 3 2 Air Pressure and Volume 25 2 5 8 3
20. e error condition of the last failed cycle on the second line of the display 2 6 Service and Maintenance The PSI C requires no scheduled adjustments or maintenance Ensure that the air supply is clean and filtered and that any lubricator if used is installed after the box If a lubricator is installed before the controller adjust it to the minimum setting Any moisture present in the input air can foul the main valve and render the controller inoperable Should service be required contact your local distributor or Stanley Assembly Technologies Installation and Use 25 User Manual 27 PSI C Controller Assembly PSI C 39 13 D 3 9 23 AN Lo 20 20 Item Qty Part No Description 1 1 24E500178 Enclosure Molded Plastic 2 1 24X500195 Overlay Keypad 3 1 24B500165 Main Board Assembly 4 1 24B500229 Pre Amp Board Assemb
21. ed If the PSI C controller does not receive sufficient air volume the tool may operate erratically and the controller indicates a bad cycle or no change on the display Install the PSI C controller with an air filter before the air inlet to the controller If a lubricator is used it can be installed before the controller or between the controller and the tool The lubricator must be a free flowing design and not smaller than inch NPT NOTE Some lubricators act as a check valve and will not allow air flow back thru the lubricator This type is not recommended for use with the PSI C The air hose cable for the AH AM AT and AP series of tools is called the GEMINI The GEMINI air hose includes an integral transducer cable and is available in 3 8 inch I D coiled or straight and available in many lengths A separate transducer cable is also available Prevent any unnecessary restrictions elbows swivels etc between the controller and the tool to prevent air flow volume restrictions 2 2 Mounting Installation and Use 5 User Manual 60 45 Typical Assembly Line Installation WARNING To Avoid Injury e Shutoff valve must be in the closed position until the air lines are installed and properly terminated e Donotconnect power to the PSI C Controller until all air line connections are secured Su
22. g 7 815 8 24 wide X 14 43 height X 6 38 depth Six Discrete 12 24V Optically Isolated Inputs with screw lug terminals Inputs Inputs available Batch Reset Manual Wrench Accept Parameter Select 3 and Disable Four Dry Contact Relays with screw lug terminals Outputs Outputs available Cycle Accept Reject Batch Accept Reject CE UL amp VED rated up to 7 amps at 48V AC DC Internal Thermal Printer for documentation of cycle data onto individual labels 2 x 4 adhesive backed Dual Line 0 5 LCD backlit 16 character Up Down Enter Menu Back and ADMIN Five button keypad Back button Momentary for Batch reset hold down two seconds for override LED Indicator CYCLE OK NOK and BATCH OK NOK Indicators Separate IP address with buffered memory provides asynchronous network communication Supports standard Windows based TCP IP 10baseT protocol female RJ 45 connector Expands PSI C functions to use eight 8 parameter sets Storage memory of fastening cycle data 72 readings PSET Statistics and date time information Printer optional Ethernet optional DTU Data Transfer Unit optional Getting Started 3 User Manual 1 6 1 Layout and Operator Interface Two Line Results Display Enter key Cycle OK Green NOK Red Lights Admin Key Batch OK Green NOK Red Lights Up Down Scroll Keys BACK Key POWER SOCKET POWER SOCKET 16 VAC Ferunt m DC Suppl 1O CONNECTOR ae eee GEMINI H
23. ion and Use ON OFF can be chosen to enable increased air pressure from the START PSI upon reaching THRESHOLD The START PSI default value is 40 PSI This is to control the rundown speed and prevent torque scatter When the tool runs a fastener the PSI is RAMPED up to maximum PSI until the TARGET TQ is achieved the speed at which this PSI is fixed Press the ENTER button to choose option Scroll to the next ADMIN function Press the BACK button to return to the RUN screen 13 User Manual e 2 5 1 Operation Flowchart Basic ADMIN MENU Y A gt E EIE gt 4 gt Continued Below Continued Below e e wem a Q EEN o o praem Ezz m PSI C Controller Operation Flowchart Continued Continued Below Ij Continued on Next Page Installation and Use 15 User Manual Operation Flowchart Continued Q gt Q gt Continued Below Jd Continued Below 16 cl Bd Mt ki kl e Continued On Next Page PSI C Controller Operation Flowchart Continued After changing the ETHERNET settings it is necessary to cycle power on the PSI C FEET 2 5 2 Error Proofing Error proofing is one of the most important features of the PSI C controller Once an application has been setup the PSI C controls the torque applied and discerns between a fastening cycle pass OK and error NOK Ins
24. lation and Use User Manual Item Qty Part No Description 16 1 24C501500 Harness Transducer 17 1 24X500029 Harness ITV Valve 18 1 24X500194 Rear Panel Cover 19 6 24R500298 Screw Pan Head High Low 10 x 2 20 1 24X500211 Access Panel Front DTU 21 1 24R500028 Label Logo Bubble 22 4 246500224 Rivet Finger 23 1 24K500172 DTU Data Transfer Unit optional 24 1 24X500196 Printer Housing 25 1 248500225 Printer Board 26 1 24X500331 Printer Head 27 4 248500332 Screw Pan Head 2 x 3 8 28 4 248500299 Screw Pan Head High Low 8 x V2 29 1 24X500544 Harness Cable Printer Data Power 30 4 24X500197 Spindle Paper Roll Printer 31 4 24X500198 Washer Spindle Printer 32 4 248500298 Screw Pan Head High Low 10 x 1 2 33 1 24X500147 Labels Printer Case of 20 optional 34 1 24X500092 Power Supply Standard 36 1 248500032 Network Card Option Serial 1 248500502 Network Card Option Ethernet 8 37 1 246500400 RJ45 Cable Network 38 2 248500102 Pan Head Screw 4 40 x 3 8 39 1 24R500325 Cap Plug ek 28 Part of Printer Assembly 24X500173 optional Used with Network Card PSI C 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 ASSEM
25. ly 5 4 24R500299 Screw Pan Head High Low 8 x 2 6 1 24X500193 Bottom Panel Cover 7 1 24W510085 Valve 2000 9 1 24X500008 1 2 OD Tube 10 1 24X500064 Bulkhead Output 3 8 Tube 11 1 24X500192 Bulkhead Input 1 2 3 8 12 1 24X500328 90 Degree Fitting 3 8 Tube 13 1 24X500018 90 Degree Fitting 14 BARB 15 1 248500257 3 8 OD Tube 16 1 24C501500 Harness Transducer 17 1 24X500029 Harness Valve 18 1 24X500194 Rear Panel Cover 19 6 24R500298 Screw Pan Head High Low 10 x 2 20 1 24X500211 Access Panel Front DTU 21 1 246500028 Label Logo Bubble 22 4 24R500224 Rivet Finger 23 1 24K500172 DTU Data Transfer Unit optional i 24 1 24X500196 Printer Housing 25 1 248500225 Printer Board 26 1 24X500331 Printer Head 27 4 24R500332 Screw Pan Head 2 x 3 8 i 28 4 24R500299 Screw Pan Head High Low 8 x 2 PSI C Controller Item Qty Part No Description 29 1 24X500544 Harness Cable Printer Data Power 30 4 24X500197 Spindle Paper Roll Printer 31 4 24X500198 Washer Spindle Printer s 32 4 24R500298 Screw Pan Head High Low 10 x 1 2 33 1 24X500147 Labels Printer Case of 20 optional 34 1 24X500092 Power Supply Standard 36 1 248500032 Network Card Option Serial 1 248500502 Network Card Option Ethernet ui 37 1 24C500400 RJ45 C
26. ly programmed Refer to the calibration run off sheet supplied with the tool If required engineering units are different than those shown calculate the full scale in units and then scroll up or down to change the value on the screen Press the ENTER key and the PSI C automatically checks and sets the ZERO and MAX values of the transducer connected TARGET TORQUE Enter the application s target torque by scrolling up or down press ENTER HIGH LIMIT Scroll to set the upper torque specification press ENTER LOW LIMIT Scroll to set the low limit torque specification press ENTER BATCH COUNT Scroll up to set the number of fasteners per assembly to use the PSI C to count fasteners Set this number to zero to stop the PSI C from counting fasteners BATCH TIME Scroll to the number of seconds adequate to tighten all of the fasteners per assembly Set this to zero if there is no time limit BATCH time starts upon completion of the first in a group of fasteners 2 4 2 1 Calibration Correlation After the initial set up is complete the system may need to adjust correlation to the application using an approved method It is very important that the final calibration be performed using the same method and equipment that will be used to evaluate the results in production Some rotary transducers are compatible with pulse tools and can be used just behind the socket as the master transducer However it must be understood that the residual torque mea
27. mes If an acknowledgement packet is not received the controller disconnects from the server and attempts a new connection If the network card has not transmitted a final data packet within two minutes of the last one it sends a Keep Alive message to the server to keep the connection open 2 5 7 1 2 Packets Message Cycle Rundown Data Psi C C2 Start End Length Field Format 1 1 1 Begin measuring data UT 2 3 2 Message 13 4 4 1 Revision 5 16 12 Time Date 17 22 6 FF0101 or PP0101 23 23 1 Torque Pass Fail P or F 24 28 5 Torque High Limit 01000 100 0 29 33 5 Torque Low Limit 01000 100 0 34 38 5 Torque Final 01000 100 0 39 40 1 Pulse Angle Pass Fail o 40 44 5 Pulse Angle Max Limit 00005 5 45 49 5 Pulse Angle Min Limit 00005 5 50 54 5 Pulse Angle Final 00005 5 55 59 1 Strategy Oe Gee 56 57 2 Current Pset 01 08 58 59 2 Batch Count 01 99 Installation and Use 23 60 62 64 69 74 79 84 89 94 95 135 151 156 Direction 61 63 68 73 78 83 88 93 94 134 150 155 156 i gt ON O Controller to Host Current Count Sensitivity Transducer Cal Target Torque Angle Target Transducer Zero Adc Tq Shutoff Adc Tq Final Early Release Barcode Controller Name Packet Number End of Data User 1 99 1 64 1000 100 0 1000 100 0 0000 99999 0000 04095 0000 04095 0000
28. ned fastener or a cross thread occurs a NOK results The system default is zero 0 pulse counts which means all rundowns which result in a final torque between LOW LIMIT and HIGH LIMIT will be OK MAX PULSE COUNT If a strip or cross thread occurs this can cause too many pulses and a bad cycle This error can also occur if the pulse pack in the tool is in need of service or failing Slip off or cam out If the socket or screwdriver bit slips off the fastener the controller will not count the cycle or alarm this condition as TQ LOW if the THRESHOLD has not been crossed Short cycle premature cycle abort This feature insures that only attempts to tighten fasteners are counted The controller will not count the cycle or alarm this condition as TQ LOW if the THRESHOLD has not been crossed NOTE The PSI C ignores no load running of the tool unless THRESHOLD is crossed 2 5 2 2 Normal Operation Run Mode When operating in the RUN mode the UP DOWN keys allow the operator to change between parameter sets unless the PSET LOCK OUT is activated PSET LOCK OUT is recommended when only one PSET is being utilized Pressing the BACK button clears the batch The BATCH NOK output fires and turns on the red BATCH LED Pressing and holding the BACK button for one to two seconds puts the PSI C in OVER RIDE mode OVER RIDE means that the system has full power without any torque control or shut off capabilities The
29. ontroller returns to manual keypad selection Choose Binary mode using the ADMIN button Standard OUTPUTS are Batch NOK Batch OK Cycle OK and Cycle NOK NOTE Remote Batch Reset is available by holding the OVERRIDE button for one 1 second then pressing the UP button once 2 5 4 RJ45 Auxiliary Connector Located on the right side of the bottom panel the RJ45 connector provides access to the following functions Cycle Accept Reject indicator lights UP button DOWN button and RESET OVERRIDE button 2 5 5 Data Collection and Download If the PSI C has the DTU Data Transfer Unit Part 24K500172 all parameter values and fastening cycle data from the last 72 readings per Parameter Set is stored in the memory of the DTU The Data Transfer Kit part 24 500340 can be used to download this data to a Microsoft Excel spreadsheet The kit includes the Data Transfer Software Program and all cables and adapter required An RS232 serial bus is ported through the RJ45 connector located on the left side of the bottom panel of the PSI C The data is sent through this serial output directly into a Windows Excel file An RJ45 patch cable and RJ45 F to DB9 S adapter are required to output serial data The data cable configuration is shown below RJ45 PATCH CABLE DATA X FER C SOFTWARE x USB SERIAL ADAPTER ADAPTER IF REQ D 20 PSI C Controller Data Collection Transfer Kit Part 24K500340 Once
30. pply air energizes the outlet port when electrical power is supplied to the PSI C Controller 23 Tool Compatibility 2 3 1 Transducer Pulse and Impact Tools In addition to the PSI series of transducer pulse and impact tools the PSI C controller is available to control all other major brands of Transducer Pulse tools including URYU and Yokota IR 6 PSI C Controller Make certain that the range of the tool being used is capable of the torque required If prevailing torque is present or the joint is very soft then an over sized tool may be required NOTE With ALL pulse tools large heavy sockets loose fitting or worn sockets extensions and universal sockets WILL reduce the efficiency of the tool and increase torque scatter All PSI tools should be equipped with EcoDrive sockets and extensions for the AH and AM tools or the Taper Lock sockets and extensions for all AP and AT tools Performance and capability statements or claims are not ensured without these speciality sockets and attachments Oversize the tool as needed to prevent premature tool wear and long cycle times Prevailing torque and torque losses due to loose and or worn sockets and extensions will reduce tool life increase cycle times and increase torque scatter AT60PB 675 70 24 Main Menu and Application Programming WARNING To Avoid Injury e For maximum tool life do not use the tool higher than 90 of the maximum torque output of
31. sured once the rotary transducer is removed from the drive train will change because of the dynamics change caused by removing the transducer weight speed and losses NOTE 9 Rotary transducers are not compatible with the AM A AP AH or AT series tools Include any extensions that will be used in the application as it will affect the final torque if the set up is changed This method calibrates to the dynamic torque If the fastener torque will be judged using static torque a digital torque wrench can also be used to calibrate the PSI C after the fastener has been tightened Using this method ensures more effective control and correlation of the residual torque on the fastener This method compensates for the effects of initial torque relaxation in the fastened joint When testing for repeatability and accuracy a TVM measures dynamic applied torque AT THE FASTENER without influence of operator input Run the tool on the fastener until the PSI C controller shuts off the tool then release the trigger PSI C Controller For both OK and cycles check the master transducer reading or the residual torque reading from the torque wrench versus the reading on the PSI C controller These numbers generally vary Use CORRELATION under ADMIN to bring the two readings into correlation see Correlation Procedure below A few more fasteners may be run to check the reading consistency between the two If the program completes this cycle
32. t measuring system or torque wrench When using a torque transducer system make a rundown and compare the torque reading from the controller to the independent system The torque reading from the last rundown appears in the top line of the display as TQ By scrolling up or down enter the value from the independent measurement in the bottom line of the display as REF TQ This changes the transducer calibration value by the percent difference of the two Future readings should agree with the independent system Installation and Use 11 Function START PSI ADJUST User Manual Description Enables changes to be made to the tool s starting PSI level air pressure This is called START PSI because the PSI C default setting operates from this start value In order to reach TARGET TQ as quickly as possible adjust this to a higher level and or enable RAMP SPEED see below PRE TRIGGER This allows an early tool shut off in order to control any torque over shoot that may occur in certain difficult applications Press the ENTER button and two values will appear The A value in the amount of over torque that occurred from the last rundown The PT value is the amount of pre trigger torque Scroll UP to set the amount of pre trigger desired then press ENTER to activate this feature THRESHOLD This is the torque setting where the PSI C deems that a fastening event has begun This is automatically set to 3096 of the TARGET TQ
33. tallation and Use 17 2 5 2 1 Error LOW TORQUE or Short Cycle User Manual Description If the tool has run many cycles and the pulse oil or the air motor needs maintenance the tool may not be able to reach torque The operator may be stopping the cycle prior to completion of the fastening to TARGET TQ This sometimes occurs when the operator anticipates the end of cycle and releases the trigger prematurely before the PSI C controller has shut off the tool If LOW LIMIT GRN ON is chosen in the ADMIN MENU and the operator releases the trigger after the LOW LIMIT has been passed then a PASS results even though TARGET TORQUE has not been achieved HIGH TORQUE This can occur if joint conditions change to a harder type joint than the original or the PSI has been adjusted to increase the tool speed beyond what can be controlled consistently on the application This can also occur if the CAL VALUE is incorrect RE HIT This occurs whenever the tool is applied to a pre tightened fastener This is not a defaulted error condition It must be set up through the MIN PULSE COUNT in the ADMIN MENU Once set up correctly an NOK displays when the tool is cycled on a previously tightened fastener If a REHIT is accepted the MIN PULSE COUNT feature should be adjusted MIN PULSE COUNT If a MIN number of PULSES is not achieved before TARGET TORQUE is reached an error occurs Once set up correctly if a previous tighte
34. the Data Collection Cable Assembly is correctly assembled open the Data Collection software program Select the COM Port Go into the ADMIN MENU of the PSI C and scroll to DATA Press ENTER Press DOWN to download all data from the current Parameter Set Name and save the Microsoft Excel Spreadsheet Press UP to clear all DATA The data format is as follows NOMINAL CAL VALUE NM 125 1 MIN 21 TARGETTQ 21 HILIMIT 24 MAX LO LIMIT 18 21 6 THRESHOLD 10 5 AVG MIN PULSES 0 21 1633 PULSES 500 DOWNSHIFT 21 0 6 DOWNSHIFT PSI 44 STD DEV START PSI 44 0 182857271 NUMBER OF BOLTS 1 SENSITIVITY 7 6 SIGMA 1 097143627 6 SIGMA 0 051841721 5 171003317 CPR NUMBER OF READINGS STORED 30 0 008640287 READING TIME DATE RESULT 03 28 08 4 19 22 21 0 03 28 08 4 19 24 21 1 03 28 08 4 19 26 21 0 03 28 08 4 19 28 21 1 Internal Wiring for RJ45 DB9F Adapters RJ45 Pin DB9 Pin Data Collection RJ45 Serial Adapter to DB9F 2 gt Part 24K500496 3 E Network Serial Protocol PFCS Check amp 5 5 Cooper Cart RJ45 Adaptor to DB9F 6 2 Part 24K500497 3 3 2 5 6 Serial Port If no network card is installed in the PSI C then the serial port will provide an output string after each rundown that passes the Threshold Torque value Here is a sample of the output string Installation and Use 21 User Manual Message Cycle Rundown Data Start End Length Field Format
35. troller must not fall below 75 PSI when the tool is pulsing or coming to final torque If the facilities air pressure falls more than 10 PSI from static reading when a tool is free running then the plant air volume may not be sufficient for the application and a tool with more torque capacity may be required 2 5 8 3 3 Excessive Cycle Time If torque scatter is excessive or the cycle time is too long suspect the socket and or extension Worn or broken sockets can cause erratic torque long cycle times and excessive pulsing Extensions can rob the torque from a tool and stop it from reaching the fastener If increasing the air pressure and torque target does not shorten the cycle time or correct the scatter issue then remove the extension shorten the extension or switch to the eCoDrive Fat Boy extension For any problem other than a bad socket extension substitute a known good cable first then a known good tool then a known good PSI C controller in that order One of these or a combination will correct the issue Send the problematic part in for repair Please contact your Stanley Sales Engineer for assistance If a CYCLE error displays often after a rundown check the following settings in the ADMIN MENU MIN PULSE COUNT MAX PULSE COUNT PULSE DELAY LOW HIGH LIMITS THRESHOLD and TARGET TORQUE Refer to ADMIN functions section in this manual for proper setup and definitions of these features The display will continue to indicate th
36. with memory or an absolute position sensor for controlling monitoring angle rotation of the fastener This manual uses the name PSI C in the text This name PSI C is for both the PSI C and C2 controller Any differences will be specifically called out 1 5 Electrical Safety The issue of operator safety is of maximum importance from both the attitude of ergonomic comfort as well as electrical safety The PSI C controller operates from low voltage external AC or DC power The standard configuration utilizes a CE approved power supply that is UL listed It consists of a wall mount 120VAC transformer with 16VAC at 1 Amp power output See Table 1 below for the appropriate power supply for your country mm Japan 100 VAC 1 Amp 24X500143 Australia 240 VAC 1 Amp 24X500144 United Kingdom 240 VAC 1 Amp 24X500145 Europe 220 VAC 1 Amp 24X500146 U S A 110 VAC 1 Amp 24X500092 Table 1 PSI C Controller WARNING ELECTRICAL HAZARD To Avoid Injury e Plug power cord into a grounded outlet that conforms to National Electric Code standards e not defeat the grounding pin on plug or substitute a cable that does not conform to the power and safety requirements of system 1 6 Specifications Specification JE Description External Wall Mount Transformer to 16 50 Hz 1 AMP 50 scfm 6 bar pressure 87psi ae Temperature 0 to 50 degrees Celsius pan Humidity 0 95 non condensing 3 5 k
37. work card has not been factory installed and the PSI C is being converted to PFCS communication follow the instructions below PFCS Ethernet network card Remove jumpers from main control board JP1 and JP2 PFCS Serial network card Remove all jumpers from main control board JP1 and install jumpers onto all positions on JP2 The following JUMPER arrangements must be installed on the PSI C main board DATA or NETWORK Configurations Data Collection and Download Std JP1 Install Jumpers 1 2 Configuration JP 2 Install Jumpers 2 3 5 Network Card Serial Protocols PFCS amp Std JP 1 No Jumpers Installed Serial J JP 2 Install All Jumpers Network Card Ethernet Protocols PFCS JP 1 No Jumpers Installed Ethernet JP 2 No Jumpers Installed 22 PSI C Controller DATA or NETWORK Configurations Install Cable Part 24C500400 From Network Card Board To J6 JP 1 Install Jumpers 1 2 Printer Installation Part 24X500173 JP 2 Install Jumpers 2 3 5 Cable Part 24X500544 From Printer To J8 48 PRINTER JACK DATA POWER JP1 JUMPER PINS JP2 JUMPER PINS J6 RJ45 NETWORK JACK 2 5 7 1 Standard Ethernet Protocol 2 5 7 1 1 Theory of Operation The PSI C standard Ethernet protocol supports three messages on port 4240 Every time the controller has a result OK NOK the network card sends a cycle data packet to the server The network card attempts to send this packet three ti
38. xtensions for maximum efficiency 2 5 8 2 Set up Problems The inability for the controller or tool to set up correctly may be due to too a bad cable connection or wiring within the tool to the connector This may be indicated by the controller screen reading XDUCER FAIL or CALIBRATION FAILED Check cable connections at the PSI C and at the tool Change the cable if this does not correct the fault 2 5 8 3 Other Concerns 2 5 8 3 1 Tool Air Hose Length The PSI C is designed to operate a tool with an 8 25 long 3 8 inside diameter air hose However the controller adjusts to any reasonable hose length provided that the pressure drop and restrictions do not affect the airflow volume With a longer hose the system may require a longer dwell time between fasteners See CYCLE DELAY under ADMIN functions If the tool is changed the torque should be checked and the system calibrated with the new tool to ensure proper function 2 5 8 3 2 Air Pressure and Volume Clean air at 90 psi with sufficient air volume is required in cases where the tool is being used at or above 90 of its rated capacity The air pressure required for a particular application varies depending on the tool and the torque required If the tool is used at gt 90 of its specified output then the available air pressure is critical in order to achieve torque If the PSI C setup requires 75 PSI to achieve torque with a particular tool then the input air pressure to the con

PSI-C/C2 Controller - Stanley Engineered Fastening

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