Stanley QB Expert Instruction Manual Download Page 190

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QB Expert Alpha Controller

182

Diagnostics and Troubleshooting

Fault

Possible Cause

Probable Solution

Major Consideration

That Led to Solution

To Clear/Reset from

Fault Condition

GFI Fault!

Defective tool,
cable, or controller

Replace defective
tool, cable, or
controller

Exchanging
known good
tools controllers
and cables can
determine which
caused a failure

Replace defective
tool, cable, or
controller.
If the controller
is found to be
defective, return to
STANLEY Assembly
Technologies for
repair.
If the tool is
found to be
defective, repair
it by replacing the
motor.

Defective Tool

Replace defective
tool

Use an ohmmeter
or the motor tester
to check:
Phase-to-phase
values; they should
be equal.
Phase-to-ground;
they should be >2
Megohms.

Replace defective
tool

Logic Voltage Fault!

Insufficient AC
input power

Repair incoming
power system

Use a voltmeter
to test for proper
voltage WHILE the
tool is running.
Check for proper
grounding at the
receptacle.

Repair incoming
power system

Defective triple
power supply or
logic board inside
controller

Return controller
for repair

Logic Voltage Fault!
appears on display

Return for repair

Summary of Contents for QB Expert

Page 2: ...1 5 Safety 6 1 5 1 Warnings and Cautions 6 1 5 2 General Power Tool Safety Warnings 8 1 5 3 Safety Instructions for QB Expert Alpha Controllers 10 1 6 Specifications 11 1 6 1 Physical and Environmental Ratings 11 1 6 2 Electric Service Ratings 11 1 6 3 E Stop Precaution 11 1 6 4 Tool Speed and Torque Scatter Versus Electric Supply 11 1 6 5 Tool Temperature Versus Electric Supply 11 1 7 Installatio...

Page 3: ... Messages 26 3 Programming 30 3 1 SETUP Area 30 3 1 1 JOBS Wizard 30 3 1 2 JOBS Manual Programming 37 3 1 3 COMMUNICATIONS Menu 52 3 1 4 OTHER Menu 66 3 1 5 RESTORE FACTORY DEFAULTS Menu 74 3 2 SERVICE Area 75 3 2 1 Tool 75 3 2 2 Controller 78 3 3 ANALYZE Area 79 3 3 1 TOOL Tab 79 3 3 2 TRACE Tab 81 3 3 3 STATS Tab 82 3 3 4 LOG Tab 83 3 3 5 I O Tab 84 4 Alpha Toolbox 88 4 1 Connection 88 4 2 Contr...

Page 4: ...tion 107 5 1 7 Sockets and Adapters 107 5 1 8 Cable Installation 108 5 2 QPM Tool Controls and Operation 108 5 2 1 Start Trigger Switch 108 5 2 2 Tool Memory 108 5 2 3 Display and Multiple Function Button 109 5 2 4 Tool Status Lights 110 5 2 5 MFB Mode 110 5 2 6 Worklights 111 5 2 7 Program Selection 111 5 2 8 Directional Control 111 5 2 9 Tool Temperature 111 5 2 10 Setting Torque Angle and Other...

Page 5: ...iceNet Connector 121 6 9 Profibus Connector 121 6 10Leading DeviceNet Connector 122 6 11 Input and Output Connector 122 6 12 Assignable Input and Output Functions 126 6 12 1 Input Descriptions 129 6 12 2 Output Descriptions 135 6 13 MODBUS TCP 146 6 13 1 Example Map 148 7 Embedded PLC 152 7 1 Rack Layout 152 7 1 1 Addressing Scheme 152 7 2 Supported Instructions and File Types 153 7 3 PLC Editor 1...

Page 6: ...1 Connection 170 8 2 Disconnect 172 8 3 Synchronization 172 8 3 1 Operation 173 8 3 2 Recovery 173 8 4 Networking 173 8 5 Fastening Cycle Data 174 9 Maintenance 178 9 1 Scheduled Maintenance 178 9 2 Diagnostics and Troubleshooting 178 9 2 1 Fault Guide 181 9 3 Message Guide 189 9 4 Parts List 192 10 Torsion Compensation 196 10 1 Torsion Factor 196 10 2Angle Validation 196 11 Glossary 200 12 Limite...

Page 7: ...204 12 2Electronic Products Limited Warranty 204 12 3Software Products Limited Warranty 204 12 4OEM Products Limited Warranty 204 12 5General Terms 204 12 6Specification Changes 205 12 7 Warranty Claims 205 12 8Product Services 205 12 9Return Material Authorization RMA Procedures 205 ...

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Page 9: ... QB Expert Alpha Controller Introduction What s Included Controller Functions and Connections CE Declaration of Conformity Regional Notices for Transmitter Safety Specifications Installation Instructions ...

Page 10: ...ed with the QB Expert Alpha controller is a power cord plinth for mounting documentation in the envelope and a mating connector for the I O port The mating connector is included so the end user may connect wires to the controller s I O port to their requirements STANLEY ASSEMBLY TECHNOLOGIES 5335 Avion Park Drive Cleveland OH 44143 USA Telephone 1 440 461 5500 Email satinfo sbdinc com URL http Sta...

Page 11: ...g cover WARNING AVERTISSMENT RISQUE DE DECHARGE ELECTRIQUE Pour empecher des dommages debranches le cordon de secteur avant d enlever la couverture PROTECTED BY ONE OR MORE OF THE FOLLOWING US PATENTS 5 315 501 5 637 968 6 516 896 115 230VAC 50 60HZ 10 AMP 1 N PE FIELDBUS OPTIONS 1 2 3 4 5 6 7 8 11 13 16 10 12 14 15 17 9 18 19 See Description on next page ...

Page 12: ...utput Connector 18 Optional Fieldbus Ethernet Connectors 19 Indicates WiFi Enabled when present Information about these items is discussed elsewhere in this manual Use the Table of Contents to find the page for the item of interest If this is an electronic document you are reading click on the item in the Table of Contents and it will link you directly to the page Or press CNTRL F on the keyboard ...

Page 13: ...e to radio communications However there is no guarantee that interference will not occur in a particular installation If this equipment does cause harmful interference to radio or television reception which can be determined by turning the equipment off and on the user is encouraged to try to correct the interference by one or more of the following measures reorient or relocate the receiving anten...

Page 14: ...n below As of the date of this document only France has a restriction The restriction is that if the radio is operated outdoors in the 2450 2483 5 MHz band the power must be limited to 10 mW instead of 100 mW This device is not intended for outdoor use 1 5 Safety 1 5 1 Warnings and Cautions The safety notices and warnings for protection against loss of life the users or service personnel or for th...

Page 15: ...rollers Indicates an item of special interest Indicates a pinch point hazard This icon appears as a part of a DANGER WARNING or CAUTION notice Indicates an open wrench pinch point hazard This icon appears as a part of a DANGER WARNING or CAUTION notice Indicates an environmental hazard Do not throw equipment into the normal housekeeping refuse bin ...

Page 16: ...he cord for carrying pulling or unplugging the power tool Keep cord away from heat oil sharp edges or moving parts Damaged or entangled cords increase the risk of electric shock e When operating a power tool outdoors use an extension cord suitbable for outdoor use Use of a cord suitable for outdoor use reduces the risk of electric shock f If operating a power tool in a damp location is unavaoidabl...

Page 17: ...g any adjustments changing accessories or storing power tools Such preventive safety measures reduce the risk of starting the power tool accidentally d Store idle power tools out of the reach of children and do not allow persons unfamiliar with the power tool or these instructions to operate the power tool Power tools are dangerous in the hands of untrained users e Maintain power tools Chek for mi...

Page 18: ...rrectly and safely Persons responsible for system planning and design must be familiar with the safety concepts of automation equipment Install tools in dry indoor non flammable and non explosive environments only Humidity 0 to 95 non condensing and Temperature 32 to 122 ºF 0 to 50 ºC Do not install worn damaged or modified equipment that may be unsuitable for safe use Controller plugs must match ...

Page 19: ...esult in personal injury or substantial damage to property an E stop circuit is required An E stop circuit must be created in the external electrical service supply line 1 6 4 Tool Speed and Torque Scatter Versus Electric Supply The minimum electric supply voltage required to attain catalog speeds is 104V AC or 208V AC depending which supply voltage system is used Supply voltages above these minim...

Page 20: ...ed next to each other the center to center distance between the mounting holes in different plinths is 2 50 8 mm When mounting plinths are place one above another the center to center distance between the mounting holes in different plinths is 6 152 4 mm Install the QB Expert Alpha Controller either directly to the wall or to a plinth part number 21E204300 Fasteners through four mounting holes sec...

Page 21: ...Introduction Instruction Manual 13 4 00 101 6 6 06 154 n 195 6 PLACES 4 95 n 375 6 PLACES 9 53 12 00 304 8 13 00 330 2 18 00 457 2 2 50 63 5 Plinth 21E204300 ...

Page 22: ... QB Expert Alpha Controller 14 5 7 8 5 7 6 8 1 2 4 1 3 Mounting QB Alpha Expert Controller onto Plinth ...

Page 23: ...Introduction Instruction Manual 15 ...

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Page 25: ...2 QB Expert Alpha Controller Controller Operation Data Storage Input and Output Functions Spoftware Embedded PLC Networking Navigation Display Faults Messages ...

Page 26: ... as a standalone system as it runs its own tool 2 1 Data Storage Data associated with 30 000 fastening cycle results and 10 000 traces is stored in the QB Expert Alpha controller This data is retrieved with a USB memory stick or Alpha Toolbox SPC analysis is performed by the QB Expert Alpha controller on the stored data 2 2 Input and Output Functions Bolt Count or Error Proofing functions are an i...

Page 27: ...ble and Job Task selection when enabled The five LEDs 5 specify status of the fastening cycle for spindle 1 Red indicates high torque angle Green indicates an OK fastening cycle Yellow indicates low torque angle White is programmed by the embedded PLC and Blue indicates when the tool is enabled to run The Orange Wrench icon 6 indicates preventive maintenance is due on the tool of spindle 1 2 7 Dis...

Page 28: ...ive character 2 displayed between Use the QB Expert 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 the next character Push Toggle button or OK interactive menu button to accept entry The following screens contain the character scrollbar option ALL Job Name Task Name Step Name System Name Gener...

Page 29: ...ts as a progress bar for the Job Timer to indicate the progress of the timer The time display 10 will change in the following manner When a Part ID is received the time will change to the Part ID for 5 seconds and then return to the clock If the Job or Task has been selected the Job Name Task Name appear on the screen until the batch count Job has been completed and then returns to the clock The d...

Page 30: ... delete the data Press the interactive NO button to cancel the delete action Use the following sequence to save a Rundown or Trace file Insert a USB memory stick into the USB port on the bottom of the QB Expert Alpha controller Use the down arrow to select the Name field Use the Toggle button to enter edit mode Use the left arrow to delete the name Use the up down arrows or the numeric keypad to w...

Page 31: ...to return to the Fastening Cycle Log 2 7 7 2 Shutoff Codes Shutoff Codes on the display indicate why a fastening cycle terminates prior to completion Shutoff Code Description TIME Fastening cycle time exceeds programmed Cycle Abort time value STOP Spindle stopped by either the operator or other device 115 Spindle stopped due to torque achieving greater than 115 torque limit for the tool FAULT The ...

Page 32: ...ypad A Job Task window opens Use the numbers on the keypad to type in a Job Task to be selected to run Use the toggle or interactive OK button to accept and switch controller operation to the selected Job Task number When the Keypad Mode is set to PART ID see 3 1 4 1 General Tab on page 60 at the run screen press the Toggle button or a number on the keypad A PART ID window opens Use the up down ar...

Page 33: ... reverts to original only when the fault is cleared Here is a list of the Faults in the QB Expert Alpha controller Overcurrent Fault Total Current the controller software limits the current applied to any tool based on what the tool can handle This fault is asserted if the total current applied is greater than allowed GFI Fault The Ground Fault Interrupter has exceeded its current trip point A cur...

Page 34: ...ard This may happen on a reboot after and upgrade as the CPU resets before the DSP Spindle Communications The lead controller loses communications with a trailing spindle controller 2 9 Messages Messages appear on the screen when certain non critical conditions exist They may appear on any screen at any time Communication Fault Used for Toyota PI protocol only Controller has lost communications to...

Page 35: ... a Batch count has been met or the Job has not been reset Reset with a Job Reset input Stop Issued An Input is disabling the tool remove the Stop input May also be caused by Job Task Verify inputs not matching selected Job Task System Initializing The controller is booting up please wait Cycle Lock out The Cycle Lockout timer is active wait for it to reset Reject Count Exceeded Indicates the Rejec...

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Page 37: ...3 QB Expert Alpha Controller Programming SETUP Area SERVICE Area ANALYZE Area ...

Page 38: ... other features including system level users passwords I O and tool functions 4 Restore Factory Defaults use to backup restore delete programming and return controller to factory defaults To access press the corresponding menu number on the keypad or use the up down arrow keys to highlight then press the Toggle button 3 1 SETUP Area This area changes the settings of the Job s Tasks Steps tool stra...

Page 39: ...Y non Smart step step When complete the Wizard will have created the Job Task and appropriate steps based on programming input Strategy Identifies the values used for controlling the tool during the a step Choose the strategy required for the Audit step of the Job and Task being programmed See section 3 1 2 4 Step Button on page 43 for an explanation of the strategies TORQUE Torque Control Angle M...

Page 40: ...ns are finished press the NEXT interactive menu button to advance through the Wizard Repeat for subsequent windows Press the PREV interactive menu button to move back to previously programmed screens within the Wizard Press the CANCEL interactive menu button at any time to stop Wizard operation High Torque The maximum allowed torque during this step The Wizard uses the rated torque for the connect...

Page 41: ...ilout Change these values after saving Wizard programming if desired Next select the controls Smart Steps specific to your application Multiple step strategies are ways of using more than one step to meet the requirements of a difficult joint The following features are available through multiple strategies programmed via the Wizard Use the Toggle button to select or deselect the controls specific ...

Page 42: ... turns during this step The Wizard uses 180 by default Speed The speed of the tool s output in Revolutions Per Minute RPM The Wizard uses 60 RPM as default Max Torque The maximum allowed torque during this step A low value is calculated by the Wizard to detect cross threads and double hits Re hits Self Tap In some fastening situations the initial fastening cycle torque is as high as or higher than...

Page 43: ...xt sequential step Triggered when the tool meets the Down Torque Target and entered in seconds The Wizard uses 0 05 seconds by default Max Time The maximum time permissible to have the tool energized during this step Entered in seconds Angle Target The target angle for the Back off step The Wizard uses 360 by default Pre Torque The pre torque runs the fastener to a preliminary torque level and sus...

Page 44: ...ring partial removal of the fastener before additional components can be added to the joint Creates a Back off strategy Smart Step after the Audit step The tool stops after achieving either the angle or torque target If selected this is the first step AFTER the Audit step Options include Angle Target The number of degrees of rotation the socket turns during this step The Wizard uses 1800 by defaul...

Page 45: ... according to the plant integration scheme desired and then program Task s and Step s to create the tool strategy Job settings apply to all Tasks and Steps within the Job There can be up to 255 Jobs per Alpha controller Select Jobs by pressing the SETUP interactive menu button on the Run screen Press 1 or highlight Jobs selection and press the Toggle button There can be more than one Job Use the l...

Page 46: ...alue Notice that the periods match the length of the expected PART ID Increment Count on NOK Setting this parameter to Yes will allow the selected Job s bolt count to increment on both OK and NOK fastening cycles If set to No the Job s bolt count will increment only on OK fastening cycles Auto Sequence Tasks When set to Yes the QB Expert Alpha controller automatically sequences from Task 1 through...

Page 47: ...other two events is met On All Fasteners Removed Yes does not allow the use of Disassembly mode after all fasteners have been removed i e accumulated count is back to zero No allows the use of Disassembly mode after all fasteners have been removed unless the logic of the above two events is met Disable Assembly This identifies whether the tool disables after each Task has completed This requires a...

Page 48: ...e menu button to add a Job or CANCEL to not add a Job Delete Deletes the selected Job from the controller Jobs cannot be recovered once deleted Copy Copies the selected Job and its associated Tasks and Steps to the Clipboard Paste Overwrites the selected Job with the values residing in the Clipboard To copy move a Job first create a new Job where it is needed then copy the Job to be moved then pas...

Page 49: ...o the Run screen See section 3 1 2 6 Exit on page 52 3 1 2 2 Task Button Press the TASK interactive menu button to setup the parameters of the Tasks and Step s inside the selected Job Task settings apply to all Steps inside the Task The maximum number of Tasks in the Expert Alpha controller is 255 Share these Tasks between the programmed Jobs There can be up to 99 Tasks per Job Select Tasks by pre...

Page 50: ...d before the fastening cycle data is included into Statistics or sent via a network protocol The default value is 0 Disassembly Speed The speed of the tool during Reverse operation in RPM revolutions per minute The default value is 9999 To limit the speed of the tool reduce this parameter to a value less than the maximum speed of the tool Disassembly Acceleration The rate at which the tool gets to...

Page 51: ...d Copy Copies the selected Task and its associated Steps to the Clipboard Paste Overwrites the selected Task with the values residing in the Clipboard To copy move a Task first create a new Task where it is needed than copy the Task to be moved then paste into the new Task created and delete the original if required Press the EXIT interactive menu button to save changes and return to the Run scree...

Page 52: ...udit Step torque and angle readings must fall within their specified limits for the fastening cycle to be acceptable Strategy Advanced AC TC Angle Control and Torque Control This strategy enables precision control for both torque and angle on critical joints The controller shuts off the tool when both a target torque value and a target angle value are achieved after a selected snug torque value oc...

Page 53: ...table Torque Target The torque at which the controller shuts off the tool Should be greater than Low Torque and lower than High Torque Units are the selected torque units High Torque The maximum peak torque for an acceptable fastening cycle required for all steps If the actual torque exceeds this limit the fastening cycle will be flagged as NOK and the RED LED on the front panel and tool illuminat...

Page 54: ...ue to zero if torque drops below Snug Torque during the step Bailout on High Torque Yes will shutoff the tool when the High Torque parameter is exceeded during any Angle Control strategy No will shutoff the tool when the Torque Bailout parameter is exceeded during any Angle Control strategy Requires the Torque Bailout value to be set Should be set equal to or above High Torque Units are the select...

Page 55: ...orque of the step AVERAGE will provide the average torque rate during the step INSTANT will provide the instantaneous rate at the step target Only available during Torque Control strategies NO disables this monitoring The shutoff code is RATE Rate Threshold Defines the torque at which this monitoring begins High Rate The maximum peak rate for an acceptable fastening cycle If the actual rate exceed...

Page 56: ...off the tool Torque Threshold The torque at which this monitoring begins Filter The amount of angle the tool s output must rotate where the torque drop must be maintained before the fastening cycle is ended with a shutoff code of TD Speed The velocity of the output of the tool before any Downshift Mode activates required for any step Units are RPM Must be greater than 0 Default is 9999 Acceleratio...

Page 57: ...led torque rate The default values can be modified for when the algorithm starts monitoring rate Threshold Low when it stops monitoring rate Threshold High and the tool speed after the algorithm ends Minimum Speed The torque units are a percent of Target Torque The speed values are a percent of maximum speed of the tool Abort Timer Stops the tool when the time has elapsed from the start of the ste...

Page 58: ...elected torque units Min Torque Bailout Determines when to stop the tool based on dropping below a minimum torque value during the Angle Control Torque Averaging strategy Units are the selected torque units Torque Compensation Yes will use the average torque achieved during an Angle Control Torque Averaging strategy as the zero torque for the next immediate step only Merge Torque Carries the torqu...

Page 59: ...nd RELEASE selections create Smart Steps in their required order Smart Steps cannot be audit steps See section 3 1 1 1 Wizard Screens on page 31 for a description of these Smart Steps Delete Deletes the selected Step from the Task Steps cannot be recovered once deleted Copy Copies the selected Step to the Clipboard Paste Overwrites the selected Step with the values residing in the Clipboard To cop...

Page 60: ...xit the programming mode Press CANCEL to not exit the programming mode and continue modifying parameters 3 1 3 COMMUNICATIONS Menu This area changes the setting of the Ethernet Serial and fieldbus Communications port s located on the bottom of the Alpha Users must have COMMUNICATIONS SETUP or ADMINISTRATOR access level to modify values in this area Select Communications by pressing the SETUP inter...

Page 61: ...button have the controller initiate a GET IP ADDRESS request to the network Use the right arrow to move to the next tab or press EXIT to save the changes and return to the Run screen See section 3 1 2 6 Exit on page 52 3 1 3 2 WIFI Tab Use these parameters to setup the access point to connect QPM Cordless tools to the Expert Alpha controller The access point may also be used to connect computers o...

Page 62: ... SHOW Button Normally the password displays as dots when typed To see the password press the SHOW interactive menu button 3 1 3 2 2 PAIR Button Press the PAIR interactive menu button to initiate the pairing mode to a QPM Cordless Tool This will switch the access point to a pairing SSID while the Expert Alpha controller is in pairing mode To pair a QPM Cordless Tool after pressing the PAIR button e...

Page 63: ...this port to the Chrysler network OPEN Connects this port to a network using the OPEN protocol with serial messaging PLC The internal PLC takes over communications on this port Baud rate and Parity of the Serial port may be changed for PLC communications Set these values according to the requirements of the end user Baudrate The data transmission rate in bits second for communication Parity Used t...

Page 64: ...time period to wait between when the controller sends data to the server and it should receive an acknowledgment If no ACK in this time period the data sent again 3 times Keep Alive The time in seconds for an inactivity timeout between messages when the controller sends a KEEP ALIVE message to ensure cable integrity Unsolicited Port This port is used by the PFS system to select the Job number on t...

Page 65: ...ults are sent as they happen TR Final fastening cycle in Job is sent as ER Options There are OPTIONS which can be adjusted based on plant Systems requirements Rundown Data Specify the PART ID as VIN or AVI Buffer While Offline Select YES to allow the controller to buffer the fastening cycle data while the controller is off line disconnected from the network NO means the controller will not buffer ...

Page 66: ... is lost Send Fastener Removed Yes sends the FASTENER REMOVED message when the Alpha controller detects a tightened fastener is removed No stops the message from transmitting Number of Tries This is the number of times the Alpha controller sends a message to the server when no ACK message is received Max Connections The maximum number of connections the Alpha controller allows the server The Alpha...

Page 67: ...ler resides Station Type the Station number where this Alpha controller resides Station Name Type the Station name where this Alpha controller resides Trace Selects the types of traces that are sent to the server None No traces are sent to the server All All traces are sent to the server OK Only OK fastening cycle traces are sent to the server NOK Only NOK fastening cycle traces are sent to the se...

Page 68: ... to the next tab or press EXIT to save the changes and return to the Run screen See section 3 1 2 6 Exit on page 52 3 1 3 8 SCANNER Tab This tab appears on Alpha controllers only when the leading DeviceNet port option is installed and sets the communications parameters for the Alpha controller s DeviceNet network This allows the Expert Alpha controller to control devices on its own DeviceNet netwo...

Page 69: ...sumed Length The number of bytes consumed by the device Output The output address of the device for embedded PLC logic Controller generated Produced Length The number of bytes produced by the device Input The input address of the device for embedded PLC logic Controller generated Delete This deletes the selected device from the controller s DeviceNet network Import This imports a scanner json file...

Page 70: ...ally detects the type of communications controlled by the device in the connected network The Alpha controller has no default I O mapped on the DeviceNet bus The I O must be assigned before an EDS file can be obtained See Section 3 1 4 3 I O Tab on page 69 to assign and configure the DeviceNet I O 3 1 3 9 1 1 EDS Button Press the EDS interactive menu button to create an EDS file equivalent to the ...

Page 71: ...oller has no default I O mapped on the Ethernet IP bus The I O must be assigned before an EDS file can be obtained See Section 3 1 4 3 I O Tab on page 69 to assign and configure the Ethernet IP I O 3 1 3 9 2 1 EDS Button Press the EDS interactive menu button to create an EDS file equivalent to the Ethernet IP I O map created Connect a USB memory stick to the USB port on the bottom of the Alpha con...

Page 72: ...al This is the MAC id of the RJ45 jack on the Alpha controller This value comes from the Ethernet board inside and cannot be changed The Alpha controller has no default I O on the PROFINET bus The I O must be assigned before a GSD XML file can be obtained See Section 3 1 4 3 I O Tab on page 69 to assign and configure the PROFINET I O 3 1 3 9 3 1 GSD Button Press the EDS interactive menu button to ...

Page 73: ... device Bus Address Sets the node number of the Alpha controller on the Profibus network Values can be from 0 to 126 Compatibility Sets the compatibility mode of the Profibus card The selections are Q QA or QB This provides the same identification to the PLC as if the QB controller is a Q or QA controller GSD Order Sets the order of the Inputs and Outputs as listed in the GSD file Choices are Outp...

Page 74: ...lt Pressing the OK interactive menu button saves the file to the USB memory stick Use this controller generated GSD file in the PLC connected to the Alpha controller If the Profibus I O map is changed a new GDS file must be generated Use the right left arrow to move to the next tab or press EXIT to save the changes and return to the Run screen See section 3 1 2 6 Exit on page 52 3 1 4 OTHER Menu T...

Page 75: ...controller s screen or turn off the Cordless Tool Minimum value is 1 maximum value is 60 default value is 10 Running a tool pressing a button or the touch screen connecting with Alpha Toolbox changing the state of I O are all operations that will wake up the controller Press the Start Trigger Switch on the Cordless Tool to recover from power saving mode Use the right arrow to move to the next tab ...

Page 76: ...Second manage the users access by selecting the new user Press the MANAGE interactive menu button and select option 4 Change Access One user must be an Administrator Administrator rights give a user full access to the controller This enables all privileges including restoring factory defaults deleting logs and adding users To assign the selected user as an Administrator choose Yes for non administ...

Page 77: ...ess IMPORT The new users display on the User list Export To backup Users connect a USB memory stick to the USB port name the file then press SAVE Press OK to save Use the right arrow to move to the next tab or press EXIT to save the changes and return to the Run screen See section 3 1 2 6 Exit on page 52 3 1 4 3 I O Tab Press the BUS interactive menu button then the up down arrows to select the I ...

Page 78: ... the required amount of bytes to be used must be added so that functions can be assigned to the individual bits bytes or words Press the Toggle button to add a function assignment Highlight the function to assign to the selected pin and press the Toggle button A function can be assigned to more than one pin The fieldbus functions are an expanded list of the 24V DC bus functions The selected Input ...

Page 79: ...iguration settings then press the FINISH button A new byte word or double word will be added to match the length of the new function 3 1 4 3 4 Manage Button Edit Modifies the highlighted function To edit a function or its configuration highlight the function then press the MANAGE button Then choose Edit Choose the same function or a different one then press the NEXT button Modify the configuration...

Page 80: ...4 5 Lights Tab Lights 1 2 Defines whether the lights indicate a Job or Task Headlight Timer Sets the time the tool s headlights remain on in seconds after the trigger is pressed Enable Tool Light Timer Yes enables the timer and the tool s Red Green and Yellow status lights will illuminate for the period of time specified after a fastening cycle and then extinguish If No is selected the time is dis...

Page 81: ...off This is caused by excessive duty cycle on the tool Torsion Factor See Appendix A Torsion Compensation for an explanation of this parameter and how to determine a correct value Otherwise use the default zero Requires Arming Forces the Tap Action on the MFB to Arm See section 5 2 5 MFB Mode on page 104 Tubenut tools require arming as a factory setting Dog Torque Sets the torque level at which th...

Page 82: ...next tab or press EXIT to save the changes and return to the Run screen See section 3 1 2 6 Exit on page 52 3 1 4 11 PLC Tab If a PLC logic file is running the Name Version and Length parameters are identified If a PLC file is not running the Name Version and Length are blank Press the MANAGE interactive menu button to Import Export or Delete a PLC file Connect a USB memory stick in the USB port f...

Page 83: ... 1 1 UPDATE Interactive Menu Button Use this button to change the tool configuration or to update the firmware in the tool Change the tool configuration Download a configuration INI file from the Internet and transfer it to a USB memory stick Insert the USB memory stick into the USB port Press the UPDATE interactive menu button to open the file browse window Use the up and down arrows to find and ...

Page 84: ...hed tool has performed over its lifetime PM Counter Causes the preventive maintenance indicator to illuminate on front panel and tool when this value exceeds the PM Threshold Trip Counter Counts the number of OK fastening cycles between resets Use the RESET interactive menu button to reset back to zero either the PM Counter or the Trip Counter Use the right arrow to move to the next tab or press E...

Page 85: ...s operation This parameter is only available when a tool with a redundant transducer is attached When enabled the controller compares the redundant transducer s signal to the primary transducer s signal continuously even at rest If the difference in the values exceeds the Tolerance the controller stops the tool with a shutoff code of T1 T2 To calibrate a tool with a redundant transducer first disa...

Page 86: ...sensor to check against the primary angle sensor Units are defrees of rotation of the tool Modified A value that is changed by the controller to indicate the date and time the tool was last calibrated Press EXIT to save the changes and return to the Run screen See section 3 1 2 6 Exit on page 52 3 2 2 Controller This tab displays the controller information Updating the controller s firmware is man...

Page 87: ...file is complete and written to permanent memory The controller auto reboots When the run screen appears the controller is updated and ready During the file transfer process a file error can cause the transfer to abort and the error message appears Contact your STANLEY representative if this happens The Invalid File screen appears if the update file is for a different controller Contact your STANL...

Page 88: ...cle Transducer Current The transducer is powered with a constant current value This current should be present and not varying See section 2 8 Faults on page 21 for limits Controller DC Bus voltage The bus should always be approximately 320V DC Controller AC Supply Voltage Frequency See section 1 6 2 Electric Service Ratings on page 8 for controller AC volts specification Tool Temperature Indicates...

Page 89: ... appear when identifying is active Press the OK interactive menu button to clear and stop the flashing lights Use the right arrow to move to the next tab or press EXIT to save the changes and return to the Run screen See section 3 1 2 6 Exit on page 52 3 3 2 TRACE Tab Press the right arrow to enter the Trace area of the controller This tab plots a torque verses time curve after every fastening cyc...

Page 90: ...d subgroup of fastening cycles for a given Task The subgroup size is set using Subgroup Size Population statistics are calculated using all of the fastening cycles for a given Task up to the population To be included in sample or population statistics a rundown must exceed the Task s Threshold Torque and Statistical Torque and the fastening cycle must not be marked as a STOP or ABORT shutoff code ...

Page 91: ...r capability index R bar Identifies the average range of a constant size subgroup series 3 sigma Displays the sample estimated Standard Deviation times three X bar Displays the value s average mean Performance This section shows the performance statistics for the selected Job and Task Pp Shows a performance index of a stable process Ppk Shows a performance index of a stable process typically defin...

Page 92: ...ed press the OK button to return to the LOG screen Press the MANAGE interactive menu button to clear the data Press OK to clear the data or press CANCEL to return to the LOG screen Press YES to clear the data NO to return to the LOG screen Use the right arrow to move to the next tab or press EXIT to save the changes and return to the Run screen See section 3 1 2 6 Exit on page 52 3 3 5 I O Tab Thi...

Page 93: ... ON interactive menu button to force it on press the OFF interactive menu button again to force it off When the force is no longer required press the REMOVE button to remove the force and return the pin to system control When forcing I O changes during operation the system provides a warning first A clear pin icon with a small F indicates the pin is forced OFF A green pin icon with a small F indic...

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Page 95: ...4 QB Expert Alpha Controller Alpha Toolbox Connection Controls Editing Parameters Trace Data Icons and Security ...

Page 96: ... Connection Connect a computer to the Alpha Toolbox port using a standard CAT 5 5E or 6 Ethernet cable It does not matter if the cable is straight through or crossover The computer s Ethernet port must be set to DHCP rather than a static IP Address Observe the computer s notifications to determine when the controller has provided the IP Address Open a web browser any current browser will do and ty...

Page 97: ...roller display window for the desired spindle Once a spindle is selected it becomes the active spindle and all menu items on the left belong to the active spindle 4 2 1 Menus Click on a menu item to view or edit that area of the controller The menu item s window appears with its own controls The black bar at the top of the Alpha Toolbox screen provides a navigation button as well as area appropria...

Page 98: ...is imported the file will delete all jobs currently in the controller since there is no Jobs information in the IO file There is no recovery other than importing the correct file for the active area The Export button will download the JSON file for the active area to the computer Be sure to understand the browser setting to know where the file is saved These files are different from the Backup fil...

Page 99: ...sure to understand the browser setting to know where the file is saved 4 3 1 1 2 Fastening Cycle Data The Expert Alpha controller stores resultant audit data for 30 000 fastening cycles on a first in first out basis Click on the Full Backup Restore menu from the Home screen in Alpha Click on the Rundowns menu The rundowns csv file is immediately transferred to the computer Be sure to understand th...

Page 100: ...I 141 A1 A2 This same file can be saved to a USB memory stick from the controller s USB port 4 4 Trace Data The Expert Alpha controller stores resultant audit data for 10 000 fastening cycles on a first in first out basis Click on the Analyze Trace menu from the Home screen in Alpha Toolbox Select the Rundowns button to display the rundowns A list of rundowns appears on the left Click on the rundo...

Page 101: ...ndicates the fastening cycle status is OK Red indicates the fastening Cycle status of NOK Blue indicates the fastening cycle selected for display on the right of the Trace screen Information Point Details print or export The most recent fastening cycle will always be at the top of the list A scroll bar is provided to view older fastening cycles Click on the torque value in the run screen to select...

Page 102: ...orking bolt of the Task during this fastening cycle Tool Model The model number of the tool performing the fastening cycle Tool Serial The serial number of the tool performing the fastening cycle Tool Temperature The temperature of the tool at the tool shutoff Steps The steps performed during the fastening cycle The step s strategy type peak Torque Current Angle Torque Rate and Deviation achieved ...

Page 103: ...ir own box on the same page The X axis is either Time or Angle depending on the current selection If no physical printer is attached choose an installed PDF printer to save as a PDF file 4 4 1 1 5 Export Click the Export button to save the selected fastening cycle trace file to the computer Choose between the selected trace the number of traces in the population size to be exported When exporting ...

Page 104: ...ed from the list 4 4 1 2 Graph The selected fastening cycle graph plot is drawn in the window on the right in the Trace screen There are two Y axes and one X axis The values for the axes can be selected By default the Y1 axis is Torque while the Y2 Axis is None and the X axis is Angle The graph for each Y axes value has its own color The value selected on one Y axis is not available to the other T...

Page 105: ...points Event points are things such as Threshold Exceeded ATC Active and Control Point target achieved The X axis zero point for Time is when the achieved torque reaches or exceeds Task s Threshold Torque value The X axis zero point for Angle is when the achieved torque reaches or exceeds the audit step s Snug Torque value Time and Angle values between start and the zero point are negative The Mas...

Page 106: ...e graph Double click the zoomed white area to return the graph to normal Click the arrow in the bottom right corner of the Master Detail to reduce the window to its icon 4 4 1 2 1 Points on Graph Crosshairs and a point information box appear at the point where the mouse hovers over the graph The X and Y axes information is presented in the point information box Move the mouse alonteh the X and Y a...

Page 107: ...han one trace may be locked Each locked trace will draw on the right and overlay on top of each other They will be represented by dotted lines rather than a solid line The zero point of the X axis of Time for each graph in overlay view is the programmed Threshold Torque Change the X axis from Time to Angle and the zero point changes to the programmed Snug Torque Selected and locked fastening cycle...

Page 108: ...hen the user begins to edit any parameter the Locked icon changes to an Unlocked icon Alpha Toolbox supports user security If users are programmed into the controller the user must have Remote rights to make edits using Alpha Toolbox If user1 is editing parameters the Locked icon and the Other User Editing icon will appear for user2 The controller supports 5 simultaneous Alpha Toolbox connections ...

Page 109: ...Instruction Manual 101 ...

Page 110: ......

Page 111: ...5 QB Expert Alpha Controller Tool Operation Display Multiple Function Button Start Trigger Switch Tool Memory Worklights Tool Operation Special Application Tools ...

Page 112: ...Pa of 70dBA Value determined according to ISO 15744 2002 using as basic standards ISO 3744 and ISO 11203 Weighted emission root mean square acceleration level at the handle Value determined according to ISO 8662 single axis of 2 5 m s 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 s...

Page 113: ...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 too...

Page 114: ...low federal OSHA state or local sound level statues ordinances and or regulations 5 1 4 Vibration Power tools can vibrate during use To minimize the possible effects of vibration Keep hands and body dry Avoid anything that inhibits blood circulation such as tobacco cold temperatures and certain drugs Operators should notify their employer when experiencing prolonged symptoms of pain tingling numbn...

Page 115: ... 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 t...

Page 116: ... devices securely and periodically inspect them for damage or loosening 5 1 8 Cable Installation WARNING ELECTRICAL HAZARD To Avoid Injury Never use a tool with a damaged cable 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 specificall...

Page 117: ...e end user When the PM Counter exceeds the PM Threshold Limit the controller provides a maintenance alert The alert is an orange indicator on the front of the controller and on the tool The controller reads the fastening cycle counters from the tool on each power up 5 2 3 Display and Multiple Function Button Handheld QPM tools have a display and a multiple function button MFB Two sets of lights 3 ...

Page 118: ...ultiple function button for handheld QPM tools The button can be configured to operate in any of the following modes Disable The button does nothing Reverse Disassembly Pressing the button toggles between assembly and disassembly and illuminates the appropriate blue light 1 or 2 All tool status lights 3 and 7 flash when the tool is in disassembly mode Job Task Select Pressing the button toggles be...

Page 119: ... 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 Always stop the tool before changing direction of spindle rotation Clockwise is the normal direction for securing a fastener however a fastener can have left hand threads which requires the tool s output to ...

Page 120: ...ontrol limits above the maximum rating of the tool can cause high reaction torque Always test for proper tool operation after programming via the controller CAUTION Ensure fastener and or system will withstand the level of torque generated by the tool Excessive torque may cause breakage and possible personal injury The Alpha controller can be setup to change tightening Jobs or Tasks from the tool ...

Page 121: ...ut nutrunners are used for installing tube fittings 5 3 2 1 General Sequence of Operation Place nutrunner socket around the tube and onto the nut Press the MFB to ARM the start function if this is programmed Depress start trigger to start the tool s tightening strategy The tool stops after reaching torque Release the start trigger and lift the tool from the nut All tool status lights flash to indi...

Page 122: ...as elapsed Homing Mode Tool will run in Normal Homing mode when operator presses the start trigger switch Homing Mode Tool will run in Normal Homing mode when operator presses the start trigger switch Required Assembly Mode Operator must ARM the tool by pressing the MFB once quickly Operator must start the tool before ARM times out When the start trigger switch is released the tool switches to Hom...

Page 123: ...Instruction Manual 115 Tool Operation ...

Page 124: ......

Page 125: ...ector Serial Connector Alpha Toolbox Ethernet Connector Facility Spindle Network Ethernet Connectors Ethernet IP or Profinet Connectors Trailing DeviceNet Connector Profibus Connector Leading DeviceNet Connector Input and Output Connector Assignable Input and Output Functions MODBUS TCP ...

Page 126: ... tool cable QPM EA DC electric tool cables use a MIL C 38999 Series III connector The connector is a 17 30S with the insert clocked in the B position 30 pin Tool Connector 6 2 2 E Tools Alpha controllers use a single 30 pin connector to connect one QPM EA DC electric tool cable QPM EA DC electric tool cables use a MIL C 38999 Series III connector The connector is a 17 30S with the insert clocked i...

Page 127: ...uter and the controller is a null modem cable Communication functions can be selected for the serial port See section 3 1 3 3 Serial Tab on page 50 DB 9 Connector Pins Pin Function Pin Function Pin Function 1 Carrier Detect 4 Data Terminal Ready 7 Request to Send 2 Receive Data 5 Signal Ground 8 Clear to Send 3 Transmit Data 6 Data Set Ready 9 Ring Indicator The controller uses only pins 2 3 and 5...

Page 128: ...ork Ethernet Connectors Expert Alpha controllers have two RJ 45 Ethernet connections located on the bottom of the controller for connecting to a facility network or spindle network The facility network can consist of the controller and a PC or a plant wide fastening network The second Ethernet connector is available to provide connections to another Alpha to create a spindle network The single IP ...

Page 129: ...ed internally and have the same IP Address Two ports are provided so that controllers may be daisy chained together to create the fieldbus network rather than sending a cable from each controller back to a switch Ethernet IP or Profinet Controller Network 6 8 Trailing DeviceNet Connector Alpha controllers can have a single Mini DeviceNet port for connecting the Alpha Controller to a Leading contro...

Page 130: ... relays and contacts The Alpha has an internal 24V DC power supply that can be used to provide the I O signals an external 24V DC power supply may be used instead The following are amperage ratings Internal 24V DC supply Maximum 1 ampere total External 24V DC supply Maximum 1 ampere per output The Alpha controller s Input circuits conform to the IEC 61131 2 standard for PLCs LIMITS per IEC 61131 2...

Page 131: ...pha 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 Pin descriptions are shown in the following table Pin Description PLC Address Pin Description PLC Address C Output O 0 0 0 L Input I 0 0 0 D Output O 0 0 1 M Input I 0 0 1 E Output O 0 0 2 N Input I 0 0 2 F Output O 0 0 3 P Input I 0 0 3 G Out...

Page 132: ...Input and Output Connector QB Expert Alpha Controller 124 Inputs example ...

Page 133: ...Controller Connections Instruction Manual 125 Outputs Sourcing example ...

Page 134: ...the same time If more than one type of Input uses a particular function the controller responds to an input when a function is asserted on any one of those inputs It is important to understand how the Alpha controller and the internal PLC responds to the rising and falling edges of input functions as they are asserted or removed not while the levels are high or low The STOP bit is an exception it ...

Page 135: ...ECT TASK BIT One bit in a series to select the task Contact Type Bit Mode Spindle SET ZERO POSITION Used to set Zero Position for Position Control Strategy Contact Type Spindle START Start the tool Contact Type Latch Time Spindle START REVERSE Put the tool in reverse and start the tool Contact Type Spindle STOP Stop the tool Contact Type Spindle TASK VERIFY Verify the selected task to the inputs C...

Page 136: ...e READY The tool is ready to run Contact Type Type Time Spindle RUNDOWN BOLT Accumulated Bolt Count of last fastening cycle Data Type Spindle RUNDOWN DAY Day of last fastening cycle Data Type Spindle RUNDOWN HOUR Hour of last fastening cycle Data Type Spindle RUNDOWN JOB Job of last fastening cycle Data Type Spindle RUNDOWN MINUTE Minute of last fastening cycle Data Type Spindle RUNDOWN MONTH Mont...

Page 137: ...sert on the transition only Job or Task selection can come from multiple inputs at once including the MFB There is no priority each one is equal The Alpha controller switches its active Job or Task with each input change The last one to change becomes the active Job or Task Spindle Indicates to which spindle in the multi spindle system this function applies Inputs Description DISABLE JOB When asse...

Page 138: ...nput bus the controller verifies the selected and active job is equal to this input s job Use the BIT parameter under Configuration to select the job number to verify If there is a mismatch between the active job number and this input s job number the tool is disabled This is one bit of a binary number created by many of these bits See SELECT TASK BIT to understand how to use bits to create binary...

Page 139: ...NT LOW When removed nothing happens Size 1 bit Configuration Contact Type Normally Open N O Normally Closed N C Spindle Type the spindle number in which the result status is to be reset REVERSE When asserted on any input bus the tool is placed in Reverse disassembly mode This does NOT run the tool in Reverse mode it changes the tool mode from Forward to Reverse If one input is required to do both ...

Page 140: ...ed Binary Creates a decimal number equivalent to the weighted value of this binary bit s Binary 1 Creates a number equivalent to the weighted value of this binary bit s and adds the value of one 1 to that number Spindle Spindle Type the spindle number in which the job is to be selected SELECT TASK When asserted on any input type the controller makes this input s Task the active Task When removed e...

Page 141: ...oller at least five inputs are assigned as TASK SELECT BIT Each would then be given a bit number to have a series of bits with different weighted values For example on the 24 VDC input pin L is bit 0 pin M is bit 1 pin N is bit 2 pin P is bit 3 and pin R is bit 4 Therefore to select task 21 assert pins L N and R Size 1 bit except on fieldbus where it can be any size to fit the need Configuration C...

Page 142: ...The Latch function is off Spindle Type the spindle number for tool to be started START REVERSE When asserted on any input bus the tool mode is switched to Reverse Disassembly AND the tool is started This is different from the REVERSE input function in that REVERSE puts the tool into Reverse mode only When removed the tool stops and switches back to Forward mode Size 1 bit Configuration Contact Typ...

Page 143: ...s It is recommended to configure them immediately once the output functions are assigned to a pin Contact Type The Contact Type can be Normally Open N O or Normally Closed N C Sourcing Outputs PNP type If an output s contact type is normally open and the output is asserted the output pin transitions from 0V DC to 24V DC If an output s contact type is normally closed and the output is asserted the ...

Page 144: ...p Audit Audit 1 Audut 2 Output Type Normal Timed Flash Minimum ON Time Time Period Spindle Type the spindle number from which the angle status comes ANGLE LOW Asserts at the end of a fastening cycle when the achieved angle value is below the Low Angle limits for the Audit step Resets when the tool is commanded to start again Can also be reset with the RESET RESULTS STATUS input Size 1 bit Configur...

Page 145: ...Value Spindle Type the spindle number from which the angle status comes BOLT This output is the value of the active accumulated bolt count As the bolt count changes so does this output Size Can be any size from 0 to 32 bytes depending on Data Type Configuration Data Type Float Int8 Int16 Int32 Fixed Point String Spindle Type the spindle number from which the bolt status comes CONSTANT This value i...

Page 146: ...ool is commanded to run again Can also be reset with the RESET RESULTS STATUS input Size 1 bit Configuration Contact Type Normally Open N O Normally Closed N C Output Type Normal Timed Flash Minimum ON Time Time Period Spindle Type the spindle number from which the cycle status comes CYCLE STOPPED Asserts when the tool shuts off due to a loss of Start signal or the operator released the trigger be...

Page 147: ...FAULTED Asserts when there is a fault on the controller Resets when the fault clears Size 1 bit Configuration Contact Type Normally Open N O Normally Closed N C Output Type Normal Timed Flash Minimum ON Time Time Period Spindle Type the spindle number from which the fault comes IN CYCLE Asserts during the fastening cycle when the achieved torque value exceeds the Threshold Torque value Resets when...

Page 148: ...bit in a series of bits to create a binary number As jobs change so will the binary number created from these bits Size 1 bit Configuration Contact Type Normally Open N O Normally Closed N C Bit Type the number this bit to be in the binary number scheme for selected jobs Mode All JOB SELECTED BITs must be the same mode modes cannot be mixed Binary Creates a decimal number equivalent to the weighte...

Page 149: ... Closed N C Output Type Normal Timed Flash Minimum ON Time Time Period Spindle Type the spindle number from which the signal comes READY Asserts when there is no fault on the controller and the tool is ready to run This output resets when the tool is disabled The blue light on the controller and tool will illuminate when this output is on Size 1 bit Configuration Contact Type Normally Open N O Nor...

Page 150: ...es depending on Data Type Configuration Data Type Float Int8 Int16 Int32 Fixed Point String Spindle Type the spindle number from which the signal comes RUNDOWN MONTH This is the month value of the last fastening cycle date It asserts when the fastening cycle is complete before the IN CYCLE bit resets The value resets to zero 0 when the tool is commanded to run again Size Can be any size from 0 to ...

Page 151: ...ts when the fastening cycle is complete after the IN CYCLE bit resets The value resets to zero 0 when the tool is commanded to run again Size Can be any size from 0 to 32 bytes depending on Data Type Configuration Data Type Float Int8 Int16 Int32 Fixed Point String Spindle Type the spindle number from which the signal comes RUNDOWN UNITS This is the numeric equivalent value of the torque units of ...

Page 152: ...ze to fit the need Configuration Contact Type Normally Open N O Normally Closed N C Bit Type the number this bit will be in the binary number scheme for steps Mode All STEP BITs must be the same mode no mixing of modes allowed Binary Creates a decimal number equivalent to the weighted value of this binary bit s Binary 1 Creates a number equivalent to the weighted value of this binary bit s and add...

Page 153: ...value of one 1 to that number Spindle Type the spindle number from which the signal comes TOOL RUNNING Asserts anytime the tool is energized Resets when the tool is commanded to stop Size 1 bit Configuration Contact Type Normally Open N O Normally Closed N C Output Type Normal Timed Flash Minimum ON Time Time Period Spindle Type the spindle number from which the signal comes TORQUE This output is ...

Page 154: ...ue for High is then this output value is The OK User Defined Value is selected when the achieved torque for the defined step are within specified limits The Low User Defined Value is selected cycle when the achieved torque for the defined Step is below the Low Torque limit The High User Defined Value is selected when the achieved torque for the defined step is above the High Torque limit It assert...

Page 155: ...late the external PLC addressing to the controller s inputs and outputs Memory Type Controller I O Type External PLC Address Data Type External PLC Read Write 1 Coil Input 10001 20256 Bit Read Write 2 Input Output 20001 20256 Bit s Read 3 Holding Register Input 30001 30256 Mixed Read Write 4 Input Register Output 40001 40256 Mixed Read 5 Force Single Coil Input 50001 50256 Bit Read Write 6 Single ...

Page 156: ...ction code 03 0x03 can only transmit a 16 bit register not the individual bits within a register The PLC will need to send the 16 bit register and the Alpha controller will parse the individual bits after receipt Controller Outputs External PLC Alpha Controller Address Modbus Output Assigned Function Length Bits 40001 0 0 0 Fault 1 40001 1 0 1 Ready 1 40001 2 0 2 Tool Running 1 40001 3 0 3 In Cycl...

Page 157: ...Controller Connections Instruction Manual 149 ...

Page 158: ...MODBUS TCP QB Expert Alpha Controller 150 ...

Page 159: ...7 QB Expert Alpha Controller Embedded PLC Rack Layout Supported Instructions and File Types PLC Editor Converting a RSS File ...

Page 160: ...Trailing Fieldbus card in slot 2 uses the M 12 DeviceNet connector on the bottom of the Alpha when the DeviceNet option is ordered The DB 9 connector is used when Profibus is ordered The RJ 45 jacks are used when Ethernet IP or Profinet are ordered The ModbusTCP card in slot 1 comes installed as standard equipment on Expert Alpha controllers Each uses the RJ 45 ETHERNET jack on the bottom of the A...

Page 161: ...Output Energize AEX String Extract GEQ Greater Than or Equal OTL Output Latch AIC Integer to String GRT Greater Than OUT Output Unlatch AND And LEQ Less Than or Equal RES Reset ARD ASCII Read Characters LES Less Than RTO Retentive Timer ASC String search LIM Limit Test SOR Start of Rung ASR ASCII String Compare MEQ Masked Comparison for Equal SUB Subtract AWT ASCII Write MOV Move TOF Timer Off Del...

Page 162: ...act startis at the indexed position If the index plus the number is greater than the total characters in the source string the destination string will be the characters from the index to the end of the source string Destination is the string function ST14 X where the extracted string is stored AIC Integer to String Converts an integer value between 32 768 and 32 767 to an ASCII string AND Performs...

Page 163: ...gth and upper lower case characters If two strings are identical the rung is true if there are any differences the rung is false AWT ASCII Write Writes a source string to the designated channel Provides a Result integer for the status of the write Channel 0 Serial port Channel 1 Display Channel 2 Ethernet The internal PLC supports reading from and writing to the Network Ethernet port on the Expert...

Page 164: ...truction is enabled CTU Count Up Counts false to true rung transitions When rung conditions for a CTU instruction have made a false to true transition the accumulated value is incremented by one count provided that the rung containing the CTU instruction is evaluated between these transitions The accumulated value is retained when the rung conditions again become false The accumulated count is ret...

Page 165: ... Use the GRT instruction to test whether one value source A is greater than another source B If the value at source A is greater than the value at source B the instruction is logically true If the value at source A is less than or equal to the value at source B the instruction is logically false LEQ Less Than or Equal Use the LEQ instruction to test whether one value source A is less than or equal...

Page 166: ...lpha controllers Proper syntax is required Text editor syntax MSG XXXXH HW LW where is spindle number XXXXH is the command HW is High Word and LW is Low Word High Words and Low Words contain information provided by the instruction The user must be trained by a STANLEY trainer to use this instruction MOV Move This output instruction moves the source value to the destination location As long as the ...

Page 167: ...bit when rung conditions are evaluated as true OTL Output Latch OTL is a retentive output instruction OTL can only turn on a bit while OTU can only turn off a bit This instruction is usually used in pair with the OTU instruction The program can examine a bit controlled by OTL instructions as often as necessary When rung conditions become false after being true the bit remains set and the correspon...

Page 168: ...ion SOR Start of Rung Marks the beginning of a new rung SUB Subtract Use the SUB instruction to subtract one value source B from another source A and place the result in the destination TOF Timer Off Delay Use the TOF instruction to turn an output on or off after its rung has been off for a preset time interval The TOF instruction begins to count millisecond intervals when the rung makes a true to...

Page 169: ...bit 15 rung conditions are true rung conditions go false XIC Examine If Closed Use the XIC instruction in the ladder program to determine if a bit is on When the instruction is executed if the bit addressed is on 1 then the instruction is evaluated as true When the instruction is executed if the bit addressed is off 0 then the instruction is evaluated as false XIO Examine If Open Use the XIO instr...

Page 170: ...starts moving Add Points appear to show all the available places to add the instruction on the ladder Or click on a branch or other instruction in the ladder and then click an instruction button in the list of instructions to add to the ladder Undo removes the last item or action and reverting to a previous state Revert back to any previous state since the last save by clicking Undo multiple times...

Page 171: ...the mouse and clicking on one of the green move icons The rungs may be moved up or down in single steps using the single arrow icons or to the top or bottom using the multiple arrow icons The red circle with the X delete icon is available for all items on the rung Select the item to be deleted by clicking it with the mouse and then click the delete icon The Add Description icon is available for al...

Page 172: ...ns that are exclusive to the Alpha controller One is MON or Monitor the other is MSG or Message MON monitors for events in the Alpha s CPU and can be used as a trigger to activate a rung MSG is an output and inserts commands directly into the Alpha s CPU When used in a multiple tool application on the leading Alpha MON and MSG can interact with the trailing Alpha s CPUs These instructions require ...

Page 173: ...ddress before saving the file for use in the Alpha See section 7 4 1 Invalid Characters on page 166 This must now be converted to a JSON file Type the following BEFORE the first SOR in the pasted logic in the text editor CRLF TAB plc TAB CRLF TAB TAB 1 TAB CRLF TAB TAB TAB 700 TAB Then type the following AFTER the last EOR in the pasted logic in the text editor CRLF TAB TAB CRLF TAB CRLF Save the ...

Page 174: ... support this pound sign Find another way to program without using substitutions 7 4 2 Predefining String or Integer Files To use predefined strings or integers type the string or integer file address and its value before the logic in the file There must be a space between the address and the value For Strings the value must be encapsulated within backslash and double quotes There must be a space ...

Page 175: ...Embedded PLC Instruction Manual 167 ...

Page 176: ......

Page 177: ...8 QB Expert Alpha Controller Multiple Spindle Connection Disconnect Synchronization Networking ...

Page 178: ...ual otherwise to connect Advanced and Node controllers to the Expert connect the Ethernet cable as follows Using the keypad or Alpha Toolbox on the trailing controller set the Obtain IP Address From Network parameter to YES Exit and save the setting The Expert will then provide the IP Addresses to the trailing controller Once the trailing controller connects to the lead controller the user must ac...

Page 179: ...sswords will overwrite the trailing controllers users and passwords to match When the trailing spindle is disconnected it will retain the lead spindle s users and passwords Alpha Toolbox will also display all spindles on its Home screen See Section 4 3 Editing Parameters on page 84 to edit the parameter via Alpha Toolbox Once a specific controller is connected the lead controller will remember it ...

Page 180: ...e menu button to delete the trailing spindle connection The Spindle Delete message appears Press the Yes interactive menu button to delete the spindle The spindle deletes and the run screen will return to a normal single spindle run screen if that was the only trialing spindle On the trailing spindle delete the values in the Master IP Address parameter EXIT and save 8 3 Synchronization Many fasten...

Page 181: ... the input All spindles are required to maintain the same number of accumulated bolt count If one spindle has a bolt count different from the other the controllers will not run from the START ALL input Individual spindles must be ran in recovery operations to get all spindles on the same bolt count to continue or reset the Job to recover 8 3 2 Recovery In certain stations the system is allowed to ...

Page 182: ...cle is entered as a line in the fastening cycle record in each controller in the system for its own spindle However when a system is ran in Synchornized mode the fastening cycle records get an additional column labled Mult ID This Multi ID is the same in each spindle in the muti tool system for the same fastening cycle ran This allows the user to correlate the same run in each file ...

Page 183: ...Multiple Spindle Instruction Manual 175 ...

Page 184: ... QB Expert Alpha Controller 176 ...

Page 185: ...9 QB Expert Alpha Controller Maintenance Scheduled Maintenance Diagnostics and Troubleshooting Fault Guide Message Guide Parts List ...

Page 186: ...e jewelry including rings and watches before repairing controllers or electric tools Before opening of equipment always remove the power plug or open the disconnecting switch Certain parts of this equipment could have dangerously high voltage levels that are accessible with the cabinet door open Only use parts or components that are contained in the spare parts list or listed in the spare parts li...

Page 187: ...just No bolt count on the Run screen for the selected Job Task Create new strategy Cycle Abort set to zero 0 Set higher amount on Cycle Abort Torque Target set to zero 0 on torque control strategy Set higher amount on Torque Target Angle Target set to zero 0 on angle control strategy Set higher amount on Angle Target Tool Speed set to zero 0 Set higher amount on Tool Speed Power set to zero 0 Set ...

Page 188: ...t is on plugged in and there is power at the source Return for repair Completed Rundown Zero for Torque and Angle Readings Incorrect Audit Step Verify Adjust Torque Audit Step and or Angle Audit Step set on undefined step Set Torque Audit Step and or Angle Audit Step on the actual desired audit step Completed Rundown No Torque and Angle Readings Threshold Torque set too high Verify Adjust Tool ran...

Page 189: ...t Fault Defective tool cable or controller Replace defective tool cable or controller Exchanging known good tools controllers and cables can determine which caused a failure Replace defective tool cable or controller If the controller is found to be defective return to STANLEY Assembly Technologies for repair If the tool is found to be defective repair it by replacing the motor or gearing or head ...

Page 190: ...Assembly Technologies for repair If the tool is found to be defective repair it by replacing the motor Defective Tool Replace defective tool Use an ohmmeter or the motor tester to check Phase to phase values they should be equal Phase to ground they should be 2 Megohms Replace defective tool Logic Voltage Fault Insufficient AC input power Repair incoming power system Use a voltmeter to test for pr...

Page 191: ... cable and connected directly to the controller which then cleared the error Fault condition resets when cable length is reduced Transducer Span Fault Torque Cal set to a non standard value i e greater than 20 variance from Nominal Cal Set Torque Cal to the specific torque calibration value for the tool Read the Nominal Torque Cal value from the tool and compare it to the specific Torque Cal May r...

Page 192: ...Torque Cal value from the tool and compare it to the specific Torque Cal May require tool recertification Tool gear case binding Remove the object wrapped around gear case Open gear case and inspect for wrong components or components are in backward ANALYZE screen shows a zero offset on the transducer health meter Remove the object wrapped around gear case Reassemble gear case with proper componen...

Page 193: ...ure reaches and stays above programmed set point for 8 minutes This error automatically resets when temperature drops and stays below trip point for 8 minutes on QPM tools It can also be reset by cycling power however if the tool has not cooled down this error will reappear in 8 minutes For fixtured tools turn off Soft Stop Inefficient Rundown Strategy Contact STANLEY Assembly Technologies for hel...

Page 194: ...are different than normal Perform maintenance on tool open and inspect tool head and gearing replace any worn or broken parts Reduced incoming voltage The type of joint hard or soft can cause see Excessive Duty Cycle cause above switch from 115 V AC to 230 V AC or correct reduced incoming voltage problem When tested with a voltmeter or as observed on the ANALYZE screen incoming voltage is 90 of no...

Page 195: ...ANLEY Assembly Technologies for repair If the tool is found to be defective see the next row for troubleshooting and repair Tool Memory Board failure Replace the Tool Memory Board Tool found to be defective Replace and reprogram the Tool Memory Board in the handle of the tool Defective tool Re engage and lock pins in connector in handle Visual mechanical inspection of pins in tool handle connector...

Page 196: ...ol failure Replace transducer transducer cable in tool View transducer health current and torque output meters on ANALYZE screen and determine if values are in normal range Tool found to be defective Open tool handle and check transducer cable connections to ensure tightness and the wiring is not damaged Remove motor housing sleeve and check blue transducer wire for damage Remove the gear pack fro...

Page 197: ...Message Guide Message Possible Cause Probable Solution Major Consideration That Led to Solution To Clear Reset from Message Condition Communication Fault Cable has disconnected from controller or PI box Reconnect cable Visual inspection Reconnect cable Count Fault Operator backed out a fastener Re fasten loosened fastener Actual bolt count on display is less than required Re fasten loosened fasten...

Page 198: ...een Press OK Tool Disabled An unprogrammed Task has been selected Select a different Task Tool Disabled Undefined Task message on display when the operator pressed the tool s start trigger Program the selected Task or select another Task that is already programmed A non valid Job Task has been selected Select a different Job Task Tool Disabled Invalid Job Task message on display when the operator ...

Page 199: ... the controller has finished the boot up process Tool Disabled System Initializing message on display when the operator pressed the tool s start trigger Wait until the controller has finished the boot up process The Cycle Lock out timer is active Wait for the timer to reset Change the Cycle Lock out timer value Tool Disabled Cycle Lock out message on display when the operator pressed the tool s st...

Page 200: ... reset the NOK fastening cycle Tool Disabled Not Armed message appears on display whenever the operator presses the tool s start trigger Reset Reject is programmed Press the MFB to acknowledge and reset the NOK fastening cycle Change the MFB parameter to not require Reset Reject 9 4 Parts List WARNING To Avoid Injury Only use approved replacement parts when repairing controllers Using unapproved p...

Page 201: ...Instruction Manual 193 Maintenance ...

Page 202: ...QB Expert Alpha Controller 194 ...

Page 203: ...10 QB Expert Alpha Controller Appendix A Torsion Compensation Angle Validation ...

Page 204: ...oint components or the tool mounting device and this factor is used to correct the angle reading throughout the fastening cycle This factor is entered as Degrees per NM and its default value is zero If the default value is used there will be no angular correction If a value of 0 1 is used each angle data point every millisecond will be modified by subtracting 0 1 times the torque value For example...

Page 205: ...chronized exactly For example if a brake line fitting requires six NM plus 40 degrees pre torque the joint to seven NM first Then change to an Angle Control strategy with six NM snug torque plus 40 degrees angle target and reset the external torque angle monitor Then as the tool is run in this angle control mode the tool will start counting angle as soon as it has six NM which might have been five...

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Page 207: ...11 QB Expert Alpha Controller Glossary ...

Page 208: ...s given an overall status of NOK Low Angle Anytime the peak angle recorded during the Angle Audit Step fails to reach the Low Angle the Fastening cycle is recorded as a reject for low angle the low angle light yellow illuminates and the Fastening cycle is given an overall status of NOK Low Torque When the peak torque recorded fails to reach the Low Torque the Fastening cycle is recorded as a rejec...

Page 209: ... tool This value is unique to each tool and changes over time Torque Target When the tool is being controlled for torque the torque target instructs the controller when to shutoff the tool The torque target should be greater than Low Torque and less than High Torque and is required for torque control Trace A display plot of torque vs time or angle of a Fastening cycle Trip Counter Records the numb...

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Page 211: ...chanical Products Limited Warranty Electronic Products Limited Warranty Software Products Limited Warranty OEM Products Limited Warranty General Terms Specification Changes Warranty Claims Product Services Return Material Authorization RMA Procedures ...

Page 212: ...y 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 r...

Page 213: ...ervices 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 A...

Page 214: ... 9100 Fax 33 1 3051 0708 Email Vahid Amirzadeh sbdinc com Germany STANLEY Engineered Fastening Germany Max Eyth Str 1 35394 Giessen Germany Tel 49 0 641 405 728 Fax 49 0 641 405 383 Email Vahid Amirzadeh sbdinc com India STANLEY Engineered Fastening India 6th Floor Apex Towers No 54 2nd Main Road R A Puram CHENNAI 600 028 India Tel 91 44 4343 7100 Fax 91 44 4306 0768 Email Rajesh Patil sbdinc com ...

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