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Stanley Theta Controller, User Manual

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Theta Controller  

Getting Started 

 

1 

Getting Started 

This manual is intended to promote proper and safe use and give guidance to owners, employers, 
supervisors, and others responsible for training and safe use by operators and maintainers. Please 
contact your Stanley Sales Engineer for further information or assistance on Stanley training or 
assembly tool operations. 

1.1

 

EC Directives 

The QPM tightening systems are designed and built, in whole or in part, using the following 
standards and or directives. 

2006/42/EC Machinery Directive 

Standard  

Title / Description 

EN292-1,2 

 

Safety of Machinery - Basic Concepts

 

EN14121-1 

 

Safety of Machinery - Principles of Risk Assessment

 

EN50178 

 

Electronic Equipment for Use in Power Installations

 

EN60204-1 

 

Safety of Machinery, Part 1 - Electrical Equipment of Machines

 

EN60745-1 

 

Hand-Held Motor-Operated Electric Tools - Safety

 

89/336/EEC Electromagnetic Compatibility Directive 

Standard  

Title / Description 

EN55011 

 

Conducted and Radiated Emissions

 

EN61000-3-2 

 

Current Harmonics

 

EN61000-3-3  

Voltage Fluctuation and Flicker 

EN61000-4-3

 

Radiated Immunity

 

EN61000-4-4 

 

Fast Burst Transients

 

EN61000-4-5 

 

Surge

 

EN61000-4-6  

Conducted Immunity 

EN61000-4-8  

Magnetic Immunity 

EN61000-4-11  

Voltage dips/interruptions 

EN61000-4-2 

Electrostatic Discharge Immunity 
Level 4: Contact Discharge 8 KV, Air Discharge 15 KV 

1.2

 

Warnings and Cautions 

The safety notices and warnings for protection against loss of life (the users or service personnel) 
or for the protection against damage to property are highlighted in this document by the terms and 
pictograms defined here. The terms used in this document and marked on the equipment itself 
have the following significance: 

Danger 

Indicates that death or severe 
personal injury will result if 
proper precautions are not taken. 

 

Indicates a general hazard. This 
icon appears as a part of a 
Danger, Warning, or Caution 
notice. 

Warning 

Indicates that death or severe 
personal injury may result if 
proper precautions are not taken. 

 

Indicates that eye protection 
should be worn. This icon 
appears as a part of a Danger, 
Warning, or Caution notice. 

Caution 

Indicates that property damage 
may result if proper precautions 
are not taken. 

 

Read and understand all the 
safety recommendations and all 
operating instructions before 
operating tools and controllers. 

Summary of Contents for Theta Controller

Page 1: ...ur protection please read these instructions completely and keep this manual for future reference Carefully observe and comply with all warnings cautions and instructions placed on the equipment or described in this manual 2009 THE STANLEY WORKS ALL RIGHTS RESERVED www StanleyAssembly com ThetaUser070709 ...

Page 2: ...r Scrollbar 9 2 5 6 Run Display 9 2 6 Faults 10 2 7 Messages 11 2 8 Theta Controller Programming 12 2 8 1 Setup Menu 1 Jobs 13 2 8 1 1 Wizard Screens 13 2 8 1 2 Setup Job Tab 17 2 8 1 3 Setup Manage Button Job 19 2 8 1 4 Setup Task Button 19 2 8 1 5 Setup Step Button 21 2 8 1 6 Setup Manage Button Step 23 2 8 1 7 Setup Exit 23 2 8 2 Setup Menu 2 Communications 24 2 8 3 Setup Menu 3 Other 25 2 8 3 ...

Page 3: ...ools 41 3 4 1 Display and Multiple Function Button for Hand Held Tools 41 3 4 2 MFB Mode 41 3 4 3 Tool Memory 42 3 4 4 Tightening Cycle Counters 42 3 5 Tool Operation 43 3 5 1 Directional Control 43 3 5 2 Torque Reaction Devices 43 3 5 3 Tool Temperature 44 3 5 4 Tool Status Lights 44 3 5 5 Tool Audible Device 44 3 5 6 Setting Torque Angle and Other Operating Parameters 44 3 6 Special Application ...

Page 4: ...User Manual iv 4 2 2 Output Descriptions 53 Glossary 55 Appendix A Controller Gateway 57 Appendix B Torsion Compensation 58 Warranty 60 ...

Page 5: ...r EN61000 4 3 Radiated Immunity EN61000 4 4 Fast Burst Transients EN61000 4 5 Surge EN61000 4 6 Conducted Immunity EN61000 4 8 Magnetic Immunity EN61000 4 11 Voltage dips interruptions EN61000 4 2 Electrostatic Discharge Immunity Level 4 Contact Discharge 8 KV Air Discharge 15 KV 1 2 Warnings and Cautions The safety notices and warnings for protection against loss of life the users or service pers...

Page 6: ...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...

Page 7: ...ive Label Above 4 Cursor Keys with Center Button to Expand Lists 5 Maintenance Due and ATC Active LED s 6 Numeric Keypad to Enter Numbers or Select Options 7 Controller Label and Serial Number 8 Power Switch 9 Power Input 10 24 VDC Input Output Connector 11 20A Fuse MDA 20 P N 21R201007 12 Serial Connector for Laptop 13 Tool Connector 14 Serial Connector for Network Protocols ...

Page 8: ...nstallation maintenance and programming should be performed by qualified personnel Follow all manufacturer installation instructions and applicable regulatory electrical codes and safety codes Tool and controller plugs must match the outlet This equipment must be earth grounded Never modify a plug in any way or use any adaptor plugs Avoid body contact with electrically energized surfaces when hold...

Page 9: ...ide to threaded openings on the bottom and left side When mounting plinths are placed next to each other the center to center distance between the mounting holes in different plinths is 2 50 8 mm When mounting plinths are place one above another the center to center distance between the mounting holds in different plinths is 6 152 4 mm ...

Page 10: ... 7 on the plinth Release the bolts on the barrel latches 5 making sure the bolts enter the two barrels 8 on the controller 6 Connect the Theta Controller to a power source 7 Connect the tool cable to the Theta controller and press the power switch on the controller 8 The controller displays a language list at the first factory boot up Press the up down arrows to select a language then press either...

Page 11: ...ts Bolt Count and Error Proofing functions are an integral part of the Theta controller s functions Its four inputs and four outputs on the 24 VDC connector support these functions to provide advanced plant integration by external devices such as a PLC The inputs and outputs are assignable and configurable 2 2 Software The Controller Gateway connects to the Theta s COM 1 via a serial connection an...

Page 12: ...pad 4 facilitates data input and menu selection where applicable and job step selection when enabled 2 5 Display 2 5 1 Scroll Bar A scroll bar appears when more items are available than space within the display allows The up arrow 1 and down arrow 3 direct scrolling The black white scroll bar 2 indicates which list items are currently displayed No scroll bar means all items are currently displayed...

Page 13: ...ob 6 and active Task 7 Identifies Target bolt count 3 and Accumulated bolt count 4 for the active Job The side scroll bar indicates events are available in the Event Log Press the down arrow to view the events The number of fastening cycle attempts indicator is below the bolt count box The run screen displays unless other programming functions 5 are in use A Shutoff code is also displayed when app...

Page 14: ...sk Network Protocol The plant control system is issuing a Stop via a network protocol Wait for the protocol to remove the Stop command Error Proofing Bolt count has been met Reset with a Job Reset input Stop Issued An Input is disabling the tool Remove the Stop input Invalid Job The selected Job is wrong based on the validation inputs System Initializing The controller is booting up please wait Cy...

Page 15: ... temperature detector has reached the temperature limit set by the Temperature Limit parameter It resets after detected temperature has dropped by 5 C Unrecognized Tool The controller is communicating to the tool but does not recognize the model number written in the tool memory board Tool Communications The controller is not communicating to a tool Transducer Current Fault Transducer current has ...

Page 16: ...r features including system level users passwords I O and tool functions 4 Restore Factory Defaults use to backup restore delete programming and return controller to factory defaults To access press the corresponding menu number on the keypad or use the up down arrow keys to highlight then press the Toggle button Icon Legend Icon Description Navigation Menu Buttons Press to activate menu option no...

Page 17: ...th programming the controller to assign a Job which consists of one Audit Step with optional Smart Steps To function the Wizard requires a tool to be connected It automatically appears when there are no configured jobs or when adding a new job The Wizard presents programming parameters and gives a list of strategy controls These controls are explained further in this section Strategy TORQUE TC AM ...

Page 18: ...rque Threshold Torque Statistical Torque and High Angle Bailout Change these values after saving Wizard programming if desired Press the PREV interactive menu button to move back to previously programmed screens within the Wizard Next select the controls specific to your application Option screens appear for each specific control chosen The Wizard makes assumptions and calculates specific values m...

Page 19: ... which the final tool strategy is programmed This allows the flats of the socket to align with the flats on the fastener before a standard forward rotation and high speed are applied Using Slow Seek as a first step also allows for cross thread detection If selected this is the first step after Wobble If Wobble is not selected this is the first step in the tool strategy Slow Seek options include An...

Page 20: ... the tool strategy before continuing If SYNCHRONIZE is used the tool waits here until all synchronized tools have completed this step before continuing ATC Adaptive Tightening Control is not a strategy or a step It is an algorithm that modifies the tool s speed as the torque rises Select this instead of a downshift as an option to increase tool capability There are no options with this selection T...

Page 21: ...lect Jobs by pressing the SETUP button on the run screen Press 1 Jobs or highlight selection and press Toggle button Name Name the Job to define the operation performed 15 character maximum Use the up down arrows to spell with letters or use the numeric keypad Barcode Id This is a mask that when equal to an incoming PART ID selects this Job as the active Job The PART ID can come from the serial po...

Page 22: ...other two events is met On Job Complete Yes does not allow the use of Disassembly mode after the active Job is complete accumulated count equals target count No allows the use of Disassembly mode after a Job is complete unless the logic of the other two events is met On All Fasteners Removed Yes does not allow the use of Disassembly mode after all fasteners have been removed i e accumulated count ...

Page 23: ...ess OK to add a Job or CANCEL to not add a Job Delete Deletes the selected Job from the controller Jobs cannot be recovered once deleted Copy Copies the selected Job and its associated Tasks and Steps to the Clipboard Paste Overwrites the selected Job with the values residing in the Clipboard To move a Job first create a new one where it is needed next copy the Job to be moved then paste it into t...

Page 24: ... via a network protocol Disassembly Speed The speed of the tool during Reverse operation in RPM revolutions per minute Disassembly Acceleration The rate at which the tool gets to Disassembly Speed in RPM s revolutions per minute per second Cycle Lock Out This is a timer in seconds that activates after the tool has reached its target While active it disables the tool Synchronization Yes turns on th...

Page 25: ... LED on the front panel and tool illuminates Must be less than the Torque Target Snug Torque The point in this step when the controller begins to monitor the tool s output angle Should be greater than 0 and less than Low Torque A value of 50 of Torque Target is a good starting point High Angle The maximum peak angle for an acceptable tightening cycle required for this step If the actual angle exce...

Page 26: ... proceeding with the next step in the Task Entered in seconds Power The maximum power available to the tool to perform the tightening cycle required for this step Units are percent of maximum rated torque of the tool Should not be less than 100 Soft Stop This controls how the tool is turned off AFTER reaching target torque This is designed as an ergonomic benefit to ease operator discomfort with d...

Page 27: ...curs first followed by Slow Seek Self Tap Pre Torque then the audit step and finally Backout Smart Steps are not required to run a tool strategy however they may help Add and modify the appropriate Smart Step s for the application See section 2 8 1 1 Wizard Screens for a description of the Smart Steps Delete Removes selected step from tool strategy Copy Copies selected step to clipboard Paste Over...

Page 28: ...A Toyota an error proofing protocol used in handheld tool applications in Toyota facilities OPEN An error proofing data collection protocol used in tool applications at Ford Honda and other facilities This protocol can be used by others as it does not take special equipment like the Toyota protocol The Theta controller supports the following MID s Rev 1 only on the OPEN protocol MID Description 1 ...

Page 29: ... 8 3 Setup Menu 3 Other Other Screens Options Screen This area sets the parameters for all other Theta features including system level users passwords I O and tool functions Each category is represented by its own tab Use the left right arrows to select the tabs category for modification Users must have ADMINISTRATOR or SETUP access level to modify values in this area Select Other by pressing the ...

Page 30: ... for further information 2 8 3 2 Users Tab To add a user press the MANAGE interactive menu button A maximum of eight users with unique passwords can be added Passwords can contain any character symbol or number combination maximum length of 16 If users are assigned one must be an Administrator If the lock icon appears the controller is password protected The controller automatically re locks the s...

Page 31: ...meters under the Input Output and Trigger tabs in the Other area Tool Users at this level can modify parameters under the Tool tab in the Other area as well as set Preventive Maintenance Threshold and reset the PM and Cycle counters in the SERVICE menu Diagnostics Users at this level can force Inputs or Outputs ON or OFF and REMOVE forces in the I O tab of ANALYZE Communications Users at this leve...

Page 32: ...uts from the controller The pin assignments are selectable on this tab Use the up down arrows to select the pin to assign then press the Toggle button or the EDIT interactive menu button A list of available output elements displays See section 4 2 Assignable Input Output Functions for a complete list and descriptions Highlight an element to assign to the selected pin and press the NEXT interactive...

Page 33: ...ment can be assigned to more than one pin See section 4 2 Assignable Input Output Functions for configuration options and descriptions Configure the selected input element After modifying press the FINISH interactive menu button Use the right arrow to move to the next tab or press EXIT to save the changes and return to the Run screen See section 2 8 1 7 Setup Exit for further information 2 8 3 4 T...

Page 34: ... Setup Exit for further information 2 8 3 5 Lights Tab Sets the time the pistol tool headlights remain on in seconds after the trigger is pressed Use the right arrow to move to the next tab or press EXIT to save the changes and return to the Run screen See section 2 8 1 7 Setup Exit for further information 2 8 3 6 Tones Tab The alarm in the tool handle can emit different tones based on the status ...

Page 35: ...he front panel illuminates indicating it is time to perform maintenance on the attached tool Temperature Limit Identifies the threshold in degrees Celsius for tool shut off This is caused by excessive duty cycle on the tool Torsion Factor See Appendix B for an explanation of this parameter and how to determine a correct value Otherwise use default of zero Requires Arming Forces the Tap Action on t...

Page 36: ... 24 hour clock Date mm dd yyyy m month d day y year Use the left arrow to move to the next tab or press EXIT to save the changes and return to the Run screen See section 2 8 1 7 Setup Exit for further information 2 8 4 Setup Menu 4 Restore Factory Defaults Restore Factory Defaults Screens Options Screen Select Restore Factory Defaults by pressing the SETUP interactive menu button on the Run screen...

Page 37: ...currently attached to the controller Only the Serial value field is editable If there is no serial number enter one can only be entered one time Use the right arrow to move to the next tab or press EXIT to save the changes and return to the Run screen See section 2 8 1 7 Setup Exit for further information 2 8 5 1 2 Counters Tab Each of the three counters increments at the same time after an OK tig...

Page 38: ...al This is a calculated value based on the torque output of the motor the gear ratios and efficiencies This is a reference value only and cannot be modified Torque Cal This is the specific torque calibration value for the tool Enter a new value after performing a lab certification The Torque Cal should not deviate from the Nominal Cal value by more than 20 Press EXIT when finished modifying the va...

Page 39: ...he zero point of the line reaches the tick mark on either side of center the transducer needs to be replaced Transducer Torque Provides a live transducer torque value during the tightening cycle Transducer Current The transducer is powered with a constant current value This current should be present and not varying See section 1 3 Specifications Layout and Display for limits Controller DC Bus volt...

Page 40: ...oller Input and Output Connector for a schematic Pins 3 through 6 are for Inputs Pins 7 through 14 are for Outputs See section 2 8 3 3 I O Tab to assign elements to the pins If an Input or Output pin icon is Clear it is OFF If the pin icon is Dark the pin is ON There is a horizontal cursor under the pins Use the cursor keys to move the cursor The bottom left corner of the screen indicates cursor l...

Page 41: ... Options Screen Choose Yes to remove the force s and return to the run screen Choosing No does NOT remove the force s it returns to the run screen The system runs with forces applied until they are removed or until the controller s next power cycle ...

Page 42: ...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 EC0 EC1 EC2 EC3 EC4 and EC5 electric tools 70dBA 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 dec...

Page 43: ... exertion postures motions vibration and cold Insufficient rest or pauses Work organization risk factors Environmental risk factors These risk factors span job design and content operator training work method work pace work environment proper tool selection and other work place factors beyond the control of the tool manufacturer Tool owners and employers should analyze jobs for all of the risk fac...

Page 44: ...operation Maintenance and repair should be performed by qualified personnel Do not operate tools in or near explosive environments or in the presence of flammable liquids gases dust rain or other wet conditions Keep the work area clean well lit and uncluttered Keep unauthorized personnel out of the work area DC Electric Tools Controllers Install tools in dry indoor non flammable and non explosive ...

Page 45: ...le Function Button for Hand Held Tools Handheld QPM tools have a display and a multiple function button MFB Two sets of lights 3 and 7 indicate tightening cycle status Two blue lights indicate tool rotation direction disassembly 1 or assembly 2 A single multiple function button 5 can change tool direction and or parameter sets When the button is used to select the Job one of two orange indicators ...

Page 46: ...he rejected fastening cycle and wishes to repair it Once the tool has run in REVERSE and passes Threshold Torque value it can be placed in Forward for normal operation 3 4 3 Tool Memory QPM tools have an onboard tool memory that stores tool identification calibration factors and tightening cycle counters Memory parameters include Model Number Serial Number Torque Cal calibration factor Angle Cal c...

Page 47: ... tool if the switch does not turn it on and off Apply the tool to the joint following all recommendations in this manual Check to ensure the drive socket is fully seated and locked into position before connecting power to the tool Prepare to resist the tool s torque reaction Start the tool by depressing the start lever or trigger Release start lever after the cycle is complete 3 5 1 Directional Co...

Page 48: ...for exceeding either high torque or high angle All lights Reverse The next time the start trigger is engaged the tool will remove the fastener 3 5 5 Tool Audible Device The tool also has an audible device designed to be operator aid The Theta controller pulses the audible device when the tool is in the Reverse direction There is no audible indication of OK or NOK tightening cycles 3 5 6 Setting To...

Page 49: ...benut nutrunners are used for installing tube fittings Tubenut Sequence of Operation QPM Tools Place nutrunner socket on fastener Press the MFB to arm the start function Depress start lever The tool runs the selected Job The tool stops after reaching torque Release the lever and lift the tool from the fastener All tool status lights flash to indicate that the tool will now run in reverse to open t...

Page 50: ... and prevents dirt and water from entering the controller 4 1 Theta Controller Connections 4 1 1 Theta Controller Power Cord Theta Controllers use an IEC 60320 style connector The power source connector for the power cord is based on customer requirements The power cord should be rated at either 15A 125V for 115 V or 10A 250V for 230 V use of the controller 4 1 2 Theta Controller Tool Connector Th...

Page 51: ...tus A OK H HIGH L LOW torque result last step ran or audit step whichever is smaller decimals are tool units dependant job number spindle number The barcode input monitors inter character timing When there is a 500ms gap between characters a complete barcode is assumed When received the controller logs it as PART ID with all fastening cycles until another barcode is received or until controller po...

Page 52: ...oller to provide basic switching control for the tool The table below shows the I O pin description for the Theta controller Pin Description Pin Description 1 24V Return 9 Output 1 N C 2 Input Common Bus 10 Output 1 N O 3 Input 0 11 Output 2 N C 4 Input 1 12 Output 2 N O 5 Input 2 13 Output 3 N C 6 Input 3 14 Output 3 N O 7 Output 0 N C 15 24 V Supply 8 Output 0 N O 16 Output Common Bus Inputs Sou...

Page 53: ...Theta Controller Theta Controller Connections 49 Inputs Sinking example Outputs Sourcing example ...

Page 54: ... configuration options are an important aspect of the I O functions as they add powerful multiple dimensions to each function not previously seen in Stanley tool controllers These new dimensions allow integration of these controllers in unique ways providing an amazing amount of flexibility Please see the full description of each function in the section following this table Inputs Description Conf...

Page 55: ...m the load must be wired to Pin 1 Sinking Inputs PNP type If Pin 1 is wired to Pin 2 to supply the inputs a connection to 24 V must be applied to assert the input The return from the load must be wired to Pin 15 Inputs Description IGNORED The pin that is assigned as IGNORE means the input does nothing when asserted This is essentially a spare input START When asserted the tool starts and runs the ...

Page 56: ...b selection follows the operator s assigned binary number scheme Mode All SELECT JOB 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 adds the value of one 1 to that number REVERSE When asserted the controller places the tool...

Page 57: ...rwise it remains asserted until a reset condition occurs Timed The output asserts for this period of time then resets on its own without waiting for the reset condition to occur Time Units are in seconds Flash The output flashes for as long as it is asserted Period Sets the flashing On and Off times which are equal Units are in seconds Outputs Description NOT USED The pin that is assigned as OFF m...

Page 58: ...ntroller is energized and there are no faults and there is nothing disabling the tool such as Error Proofing or a Stop input See section 2 5 6 Run Display for the conditions that can Stop Tool Operation Resets when the controller is turned off or there is anything stopping the tool from operating The size of this output function is 1 bit Configuration Contact Type Output Type SYNC OUT Asserted whe...

Page 59: ...ycle is recorded as a reject for high torque the red light illuminates and the tightening cycle is given an overall status of NOK Low Angle Anytime the peak angle recorded during the Angle Audit Step fails to reach the Low Angle the tightening cycle is recorded as a reject for low angle the yellow light illuminates and the tightening cycle is given an overall status of NOK Low Torque When the peak...

Page 60: ...ue values are assigned to the electrical signals from the torque transducer on the tool This value is unique to each tool and changes over time Torque Target When the tool is being controlled for torque the torque target instructs the controller when to shut the tool off The torque target should be greater than Low Torque and less than High Torque and is required for torque control Trace A display...

Page 61: ...to automatically launch each time the computer is started When Controller Gateway is running a small icon appears on the system tray or Windows Task bar typically at the bottom right corner of the screen Right clicking on the Controller Gateway icon displays its menu From the menu select the Auto Connect option NOTE Auto Connect is the default option this means that double clicking the Controller ...

Page 62: ...a Stanley exclusive solution The Torsion Factor allows the operator to input a value that compensates for the torsional spring rate of any part of the fastening system the gears of the tool the joint components or the tool mounting device this factor is used to correct the angle reading throughout the fastening cycle Enter this factor as Degrees per NM its default value is zero If the default valu...

Page 63: ... Even if the tool s transducer and the external transducer do not exactly agree near the snug torque they will both start counting angle just before the fastener starts to rotate so their zero angle will be synchronized exactly For example if a brake line fitting requires 6 NM plus 40 degrees pre torque the joint to 7 NM first Then change to an Angle Control strategy with 6 NM snug torque plus 40 ...

Page 64: ...ndling overload abuse misuse improper maintenance use with improper accessories or where alterations have been made Software Products Limited Warranty Stanley warrants its Assembly Technologies software products to the original purchaser to be free from deficiencies in material or workmanship for a period of one year after the date of shipment Under this limited warranty Stanley will at its discre...

Page 65: ...the warranty the warranty period of the repaired or replacement product shall be limited to the remaining portion of the original warranty period Product Services Stanley provides full services for design modification service repair and training on Stanley products Contact STANLEY ASSEMBLY TECHNOLOGIES or their agents for information on training courses to aid users in becoming familiar with opera...

Page 66: ...nfo stanleyworks com STANLEY DEUTSCHLAND GmbH Division Assembly Technologies Frankfurter Straße 74 D 64521 Groß 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 MI Italy Tel 39 039 238 9950 Fax 39 039 238 9970 SATinfo stanleyworks com STANLEY ASSEMBLY TECHNOLOGIES Rm 202 Building 1...

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