Академический Документы
Профессиональный Документы
Культура Документы
II
QB Expert Alpha Controller
Table of Contents
3 Programming ���������������������������������������������������������������������30
4.2 Controls
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4.2.1 Menus �������������������������������������������������������������������������������������������������������� 89
4.2.2 Navigation Buttons ������������������������������������������������������������������������������90
4.2.3 Import/ Export Buttons ������������������������������������������������������������������������������90
IV
QB Expert Alpha Controller
Table of Contents
Instruction Manual V
Table of Contents
11 Glossary ����������������������������������������������������������������������������200
VI
QB Expert Alpha Controller
Table of Contents
1
Introduction
What’s Included
Controller Functions and Connections
CE Declaration of Conformity
Regional Notices for Transmitter
Safety
Specifications
Installation Instructions
What’s Included
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
2 STANLEY ASSEMBLY TECHNOLOGIES
Telephone: +1 (440) 461-5500
5335 Avion Park Drive , Cleveland, OH 44143 USA
Email: satinfo@sbdinc.com URL: http://StanleyAssembly.com
3
Item Number Description
1 QB Expert Alpha Controller
2 Plinth for mounting controller
3 Power cord
4 24 V DC I/O mating connector
5 Envelope with Getting Started Documentation
9
POWER USB
8 10
2
ETHERNET SPINDLE
1 19 TOOL
12
11
I/O 17
COM PORT
3 13 14
16
115/230VAC 50/60HZ
10 AMP 1/N/PE~ 15
4
! WARNING ! AVERTISSMENT PROTECTED BY ONE OR MORE OF
THE FOLLOWING US PATENTS:
ELECTRIC SHOCK HAZARD RISQUE DE DECHARGE ELECTRIQUE 5,315,501
To prevent injury Pour empecher des dommages 5,637,968
disconnect power cord debranches le cordon de secteur 6,516,896
before removing cover avant d enlever la couverture
7 6
FIELDBUS OPTIONS
18
Instruction Manual 3
Controller Functions and Connections
1.2 Controller Functions and Connections
This table refers to the picture on the previous page.
Item Number Functional Description
1 Red, Green, Yellow LEDs for Limits Evaluation
2 Programmable and Tool Ready LEDs
3 Display
4 Function Keys with Active Label Above
5 Maintenance Due Indicator
6 Cursor Keys with Center Button to Expand Lists
7 Numeric Keypad to Enter Numbers or Select Options
8 Power Switch
9 Alpha Toolbox Connector
10 USB Port for Data Transfer
11 Tool Connector
12 Plant/ Spindle Network Ethernet Connectors
13 Optional Master DeviceNet Connector
14 Serial Connector
15 Optional Profibus or DeviceNet Connector
16 Power Input
17 19-Pin, 24V DC Input/Output 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 to search the document for the item
of interest.
CAUTION
• To satisfy FCC RF exposure requirements for mobile transmitting devices, a separation distance of 20 cm
(7.87 in) or more should be maintained between the antenna of this device and persons during operation.
To ensure compliance, operations at closer distances than this are not recommended.
Instruction Manual 5
Safety
• cet appareil doit accepter toute interérence, y compris celles susceptibles de provoquer un fonctionnement non
souhaité de l”appareil.
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 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.
WARNING Indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION Indicates that property damage may result if proper precautions are not taken.
Indicates an electrical hazard. This icon appears as a part of a DANGER, WARNING, or CAUTION
notice.
Indicates a fire hazard. This icon appears as a part of a DANGER, WARNING, or CAUTION notice.
Indicates a general hazard. This icon appears as a part of a DANGER, WARNING, or CAUTION notice.
Indicates that eye protection should be worn. This icon appears as a part of a DANGER, WARNING, or
CAUTION notice.
Read and understand all the safety r ecommendations and all operating instructions before operating
tools and controllers.
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.
Instruction Manual 7
Safety
1.5.2 General Power Tool Safety Warnings
These warnings are required by EN 60745.
WARNING
Read all safety warnings and all instructions. Failure to follow the warnings and instructions may result in
electric shock, fire and/ or serious injury.
Save all warnings and instructions for future reference.
The term “power tool” in the warnings refers to mains-operated (corded) power tool or battery-operated
(cordless) power tool.
1. Work Area Safety
a.) Keep work area clean and well lit. Cluttered or dark areas invite accidents.
b.) Do not operate power tools in explosive atmospheres, such as in the presence of
flammable liquids, gases or dust. Power tools create sparks which may ignite the dust or fumes.
c.) Keep children and bystanders away while operating a power tool. Distractions can cause you
to lose control.
2. Electrical Safety
a.) Power tool plugs must match the outlet. Never modify the plug in any way. do not use
any adapter plugs with the earthed (grounded) power tools. Unmodified plugs and matching
outlets will reduce risk of electric shock.
b.) Aoid body contact with earthed or grounded surfaces, such as pipes, radiators, ranges and
refrigerators. There is an increased risk of electric shock if your body is earthed or grounded.
c.) Do not expose tools to rain or wet conditions. Water entering a power tool will inrease the risk
of electric shock.
d.) Do not abuse the cord. Never use the 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 unavaoidable, use a residual current device
(RCD) proteted supply. Use of an RCD reduces the risk of electric shock. The term “residual
current device(RCD)” may be replaced by the term “ground fault circuit interrupter (GFCI)” or “earth
leakage circuit breaker (ELCB)”.
3. Personal Safety
a.) Stay alert, watch what you are doing and use common sense when operating a power tool.
Do not use a power tool while you are tired or under the influence of drugs, alchohol or
medication. A moment of inattention while operating power tools may result in serious personal
injury.
b.) Use personal protective equipment. Always wear eye protection. Protective equipment such
as dust mask, non-skid safety shoes, hard hat, or hearing protection used for appropriate conditions
will reduce personal injuries.
c.) Prevent unintentional starting. Ensure the switch is in the off-position before connecting
to power source adn/ or battery pack, picking up or carrying the tool. Carrying power tools
with your finger on the switch or energising power tools that have the switch on invites accidents.
d.) Remove any adjusting key or wrench before turning the power tool on. A wrench or key left
attached to a rotating part of the power tool may result in personal injury.
Instruction Manual 9
Safety
1.5.3 Safety Instructions for QB Expert Alpha Controllers
WARNING
To Avoid Injury:
• Save these instructions for future reference.
• Read and understand all the safety recommendations and all operating instructions before operating tools
and controllers. Failure to follow all instructions listed below may result in electric shock, fire and/or serious
personal injury.
• Train all operators in the safe and proper use of power tools. Operators should report any unsafe condition
to their supervisor.
• Follow all safety recommendations in the manual that apply to the controllers, tools, battery packs and
chargers being used and the nature of the work being performed.
• Verify that all warning labels illustrated in this manual are readable. Replacement labels are available at no
additional cost from STANLEY Assembly Technologies.
• Only allow suitably qualified personnel to install, program, or maintain this equipment and or system. Follow
all manufacturer installation instructions and applicable regulatory electrical codes and safety codes.
• These persons must be knowledgeable of any potential sources of danger and maintenance measures as set
out in the Installation, Operations, and Maintenance manual.
• This product must be transported, stored, and installed as intended, and maintained and operated with care
to ensure that the product functions correctly and safely.
• Persons responsible for system planning and design must be familiar with the safety concepts of automation
equipment.
• Install tools in dry, indoor, non-flammable, and non-explosive environments only–Humidity: 0 to 95% non-
condensing and T emperature: 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 the outlet and must be earth grounded. Never modify a plug in any way or use
any adaptor plugs.
• Avoid body contact with electrically energized surfaces when holding a grounded tool.
• Prior to connecting a power source, always ensure the tool or controller is turned off.
• Limit controller access to trained and qualified personnel. Lock controller cabinets.
• Only use equipment and accessories specifically designed to operate with STANLEY assembly tools and use
them only in the m
anner for which they are intended.
• Store idle tools and accessories in a safe location accessible only by trained persons.
• Disconnect power source (battery, electricity, etc.) from tool or controller prior to making adjustments,
changing accessories, or storing.
• Prior to operation, always check and test tools and accessories for damage, misalignment, binding or any other
condition that may affect operation. Maintenance and repair should be performed by qualified personnel.
• Do not operate tools in or near explosive environments or in the presence of flammable liquids, gases, dust,
rain or other wet conditions.
• Keep the work area clean, well lit and uncluttered.
• Keep unauthorized personnel out of the work area.
Instruction Manual 11
Installation Instructions
supply voltages. Voltage “sag” is a reduction in voltage which occurs when high current draw causes a voltage
drop in the supply wiring which reduces voltage at the power plug and consequently reduces maximum attainable
tool speed under load. Fuses and breakers are also more likely to blow or trip under these conditions. To minimize
these effects, always connect the system to electric service that meets the recommended supply service ratings.
Please refer to the picutres of a plinth and mounting of the QB Expert Alpha controller on the next two pages.
Plinths connect to each other with four 10-32 machine screws through openings on the top and right side to
threaded openings on the bottom and left side. When 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 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 secure plinths to a wall or other surface. Plinths can be connected using
10-32 threaded holes on the bottom and left side and through holes on the top and right side.
Make sure the bolts of the barrel-latches [5] on the plinth are retracted. Place the lower flange of the QB Expert
Alpha controller [1] into the lip [2] on the plinth.
Align the slot [3] in the flange with the lower mounting-pin [4] on the plinth while placing. Rotate the top of the
controller back towards the plinth.
Place the openings on the upper flange of the controller [6] over the upper mounting pins [7] on the plinth.
Release the bolts on the barrel-latches [5] making sure the bolts enter the two barrels [8] on the controller.
Connect the QB Expert Alpha Controller to a power source.
Connect one end of the tool cable to the tool and the other end to the QB Expert Alpha controller and press the
power switch on the controller.
The controller displays a language list at the first boot up. Press the up/down arrows to select a language, then
press either NEXT from the interactive menu button or use the Toggle button to save the selection.
The controller next prompts for regional settings like Time Zone, Time and Date. Follow the prompts until the run
screen appears indicating the controller is ready for programming and operation.
4.00
[101,6]
2.50
[63,5] n .195 (6-PLACES)
[4,95]
n .375 (6-PLACES)
[9,53]
12.00
[304,8] 18.00
[457,2]
13.00
[330,2]
Plinth 21E204300
Instruction Manual 13
1 4
2
1 3
7 5
6
8
8 7
Instruction Manual 15
QB Expert Alpha Controller
2
Controller Operation
Data Storage
Input and Output Functions
Spoftware
Embedded PLC
Networking
Navigation
Display
Faults
Messages
Data Storage
2 QPM QB Expert Alpha Controller
The QB Expert Alpha controller is a modular, high-end, full-featured controller for QPM DC servo power tools with
torque transducers. It will control any QPM E, EA, EB or EC series servo motor-powered tool. It utilizes closed
loop control of torque, speed and angle so that it can perform various routines for the tool to secure each fastener
with the highest quality results. The high precision torque and angle sensors in the tool provide feedback to the
QB Expert Alpha controller’s digital control circuit. This circuit compares the feedback values to the programmed
values and adjusts the tool’s power and speed values to maintain the programmed speed on the output of the
tool until the fastener has achieved the programmed target torque and/or angle value. Once the programmed
value is sensed the control circuit turns off the tool leaving the fastener with the desired amount of preload or
clamping force.
The QB Expert Alpha controller is certified to IP54 level to withstand the dust, dirt and liquids found in industrial
facilities. Installing into other panels is not necessary.
QB Expert Alpha controllers have an IEEE 802.11b/g/n radio so that the QPM Cordless line of tools may be added
to it as well. Software version 5.2.5 is the first software version to support the QPM cordless tools.
The QB Expert Alpha controller is designed to be a lead controller in a multiple tool system. Multiple systems of
up to 24 spindles can be configured and managed by the QB Expert Alpha controller. Trailing controllers used in
multiple spindle systems can be QB Advanced Alpha or QB Node Alpha or the new QPM Cordless tools.
The QB Expert Alpha controller can be used as a standalone system as it runs its own tool.
2.3 Software
Any computer with a modern web browser connected wirelessly or with an Ethernet cable on the Ethernet
network port, or the ATB port, is used to view the QB Expert Alpha controller’s web-based application called
Alpha Toolbox. Software is not loaded onto a computer to access the data or configure the controller. Alpha
Toolbox updates come with the controller updates.
2.5 Networking
Ethernet and the Internet Protocol using Transport Control Protocol are a powerful and robust means of moving
data from one computer to another. Many end users rely on it to collect information from plant floor equipment.
The QB Expert Alpha controllers support the XML (2.0, 2.1), PFCS, NPL, TOOLSNET, OPEN and FORD protocols.
2.6 Navigation
The QB Expert Alpha controller’s four navigation and input areas facilitate menu navigation, selection and data
input:
–– Interactive Menu buttons
–– Arrows and Toggle button
–– Keypad
–– Touch screen
Labels for the four interactive menu buttons [1] change with menu selection.
5 If the label is blank, the button has no function for the current screen.
The up/down arrows [2] navigate menu and character selections; the left/
right arrows enable backspace and space, as well as navigate between tabs.
The Toggle button [3] switches between modes and selects/accepts choices
(synonymous with OK interactive menu button).
The numeric keypad [4] facilitates data input and menu selection (where
applicable) and Job/Task selection when enabled.
The five LEDs [5] specify status of the fastening cycle for spindle 1:
–– Red indicates high torque/angle;
1
–– Green indicates an OK fastening cycle;
6 –– Yellow indicates low torque/angle;
–– White is programmed by the embedded PLC, and
4 3 –– Blue indicates when the tool is enabled to run.
2 The Orange Wrench icon [6] indicates preventive maintenance is due on the
tool of spindle 1.
2.7 Display
2.7.1 Scroll Bar
A scroll bar appears on the right of the screen when more items are available than the display allows to view at
one time. The black scroll bar indicates which list items are currently displayed. No scroll bar means all items are
currently displayed.
To navigate between menu items, use the up/down arrows or, if available, use the keypad to identify the
corresponding menu item number.
2.7.2 Dropdown
A dropdown arrow appears to the right of menu items with multiple choices. To view choices, highlight the menu
item using the up/down arrows then use the Toggle button to expand the dropdown. Use up/down arrows to
scroll and the toggle or interactive menu button to select/accept.
Instruction Manual 19
Display
2.7.3 Menu Tree
A menu tree appears beside related menu items.
2.7.4 Tabs
Tabs appear at the top when multiple menu selections exist. To navigate between tabs, use the left/right arrows.
The active tab is white; inactive tabs are grey.
1 10 6 7
2 4
8 3
11
9
Icons identify events [1], see list below. Displays last torque and angle readings with units, when a tool is connected
[2]. Up/down arrows next to the torque or angle value indicate the last fastening cycle NOK status whether it
exceeded (up) or did not achieve (down) torque or angle limits.
Identifies the active Job [6] and active Task [7]. Identifies Target batch 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 applicable [8].
The display also has the current time [10] for the specified region and fastening cycle history in the Fastening cycle
Log [9].
This [11] portion of the screen changes to an orange bar with white background when either Limit Rejects or Job
Timer parameters are used. The orange bar increments in one division of the width equal to the Reject Count value
each time a NOK cycle occurs. This bar also acts 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 display background color turns red in the event of a fault; see section “2.8 Faults” on page 25.
The run display changes to indicate the step in which the tool stopped (providing it did not stop during the audit
step).
5
The Fastening Cycle Log [9] lists the fastening cycles that have occurred in the QB Expert Alpha controller. While
viewing the Run Display press the down arrow to access the Fastening Cycle Log.
Use the up/down arrow keys to scroll through the data listed chronologically (newest at the top, oldest at the
bottom). Each line identifies a fastening cycle. The first column indicates the fastening cycle status or shutoff
code. The second column indicates the achieved torque during the fastening cycle. The third column indicates the
achieved angle during the fastening cycle. The fourth column indicates the working bolt count.
Instruction Manual 21
Display
Use the up/down arrow keys and the interactive OK button, or the Toggle button, or the number keys, to select
the action required.
Export Rundowns will transfer all fastening cycle data to the USB memory stick after choosing a file name.
Export Trace will transfer fastening cycle trace data to the USB memory stick after choosing a file name. Choose
between the selected trace, the number of traces in the population size or all traces to be exported. When
exporting the SELECTED trace it exports as a comma seperated value file. If POPULATION or ALL are selected the
appropriate number of traces are placed into a zip file before exporting. If selecting All, be aware it will take a
significant amount of time before all traces are put into the zip file and exported.
Delete Rundowns will delete all fastening cycle and trace data from the QB Alpha Expert controller. This action
cannot be undone.
Press the interactive YES button to 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 write a new file name if required. Press the interactive OK
button or the Toggle button to accept the file name.
Instruction Manual 23
Display
2.7.7.3 Fastening Cycle Trace
Press the interactive TRACE button after scrolling through the log and highlighting a particular line. A Torque vs.
Time trace screen is drawn for the highlighted line.
Press the third interactive menu button to change the trace axes.
Use the up/down arrow keys and the interactive OK button or the Toggle button, or the number keys, to select
the type required.
1. Torque – Torque vs. time
2. Angle – Angle vs. time
3. Torque/Angle – Torque vs. Angle
4. Speed – Tool Speed vs. time.
Press the interactive BACK or EXIT buttons to leave the trace screen.
2.8 Faults
The display background color in normal operation is white. In the event of a fault, the spindle display and the time
display backgrounds turn red and the fault description appears on screen. The background color reverts to original
only when the fault is cleared.
Instruction Manual 25
Messages
This fault is asserted when the tool temperature detector has reached the
Temperature Fault! temperature limit set by the Temperature Limit parameter. It resets after detected
temperature has dropped by 5°C.
The controller is communicating to the tool but does not recognize the model
Unrecognized Tool!
number written in the tool memory board.
Tool Communications! The controller is not communicating to a tool.
Transducer current has fallen outside nominal values. For EA, EB and EC series
Transducer Current Fault!
tools that is 4.16 mA +/- 75% (1 to 7mA).
The wrong tool type has been connected to the controller. The Alpha controller
Unsupported Tool!
cannot run the tool that is connected.
The CPU has lost communication to the DSP on the Logic board. This may
Servo Connection Fault!
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.
Used for Toyota PI protocol only. Controller has lost communications to the PI
Communication Fault
box.
Used for Toyota PI protocol only. Controller and PI box have a bolt count
Count Fault
mismatch.
Used for Toyota PI protocol only. More Fastening cycles were performed than the
Program Fault
PI box expected.
Tool Update Failed Controller failed to update the tool configuration.
PLC Message A user defined message controlled by the internal PLC.
Invalid PLC File Appears when an invalid PLC file is imported into the controller.
Appears when the Expert is identifying a trailing spindle when the trailing
Identifying Spindle
spindle connects or when the interactive IDENTIFY button is pressed.
Instruction Manual 27
QB Expert Alpha Controller
3
Programming
SETUP Area
SERVICE Area
ANALYZE Area
SETUP Area
3 Programming
WARNING
EXCESSIVE TORQUE CONDITION
To Avoid Injury:
• Only trained and qualified personnel should program controllers.
• Never set control limits above the maximum rating of the tool.
• Setting control limits above the maximum rating of the tool can cause high reaction torque.
• Always test for proper tool operation after programming the controller.
The controller uses three main menus to display information and enable programming:
–– SETUP menu
–– SERVICE menu
–– ANALYZE menu
Fields with bold font are editable. Fields with gray font are not editable.
To begin programming a tool strategy, press the SETUP interactive menu button.
1. Jobs – use to perform tool strategy programming such as torque and speed parameters.
2. Communications – use to program Ethernet, serial port, fieldbus and network protocol options.
3. Other – use to set parameters for all 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.
If no tool is attached or if at least one Job exists, the Job tab appears allowing for expert user programming.
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.
Strategy • TORQUE - Torque Control/ Angle Monitor (TC/AM)
• ANGLE - Angle Control/ Torque Monitor (AC/TM)
• TORQUE & ANGLE - Torque Control/ Angle Control (TC/AC)
The number of fasteners required to be secured in a Task. Typically used with an error
Batch Count proofing scheme and remote input and output device. Acceptable values are between 1
and 99. The default value is 1.
Instruction Manual 31
SETUP Area
Tool operating units: = 1 FT LB = 1 NM
• NM, Newton Meters 1.355818 1
• FT LB, Foot Pounds 1 0.7375621
• IN LB, Inch Pounds 12 8.850745
Units • IN OZ, Inch Ounces 192 141.6119
• KG M, Kilogram Meters 0.1382552 0.1019716
• KG CM, Kilogram Centimeters 13.82552 10.19716
• N CM, Newton Centimeters 135.5818 100
• N DM, Newton Decimeters 13.55818 10
Use CW (clockwise) for tightening right hand fasteners. Use CCW (counter-clockwise) for
Thread Direction
tightening left hand fasteners.
To modify a parameter, select the parameter using the up/down arrow keys then press the Toggle button. Enter
the appropriate value then press the TOGGLE button. After all parameters/ selections/options 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.
TC/AM Selected
The maximum allowed torque during this step. The Wizard uses the rated torque for the
High Torque
connected tool.
The minimum allowed torque during this step. The Wizard uses zero as the low torque
Low Torque
limit of the strategy.
The speed of the tool’s output in Revolutions Per Minute (RPM). The Wizard uses the
Speed
maximum speed of the connected tool.
AC/TM Selected
Snug Torque The point in this step when the controller begins to monitor the tool’s output angle.
The maximum allowed angle in degrees during this step. The Wizard chooses the
High Angle
maximum value as default.
AC/TC Selected
See parameter definitions from the other selected strategies.
The Audit step is now defined. The Wizard uses the median value, between the High and Low parameters, as the
Target. It also calculates and programs other parameters automatically, including: Snug Torque, Threshold Torque,
Statistical Torque and High Angle Bailout. 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 to your application. Press the NEXT interactive
menu button to view the option screens for each specific control chosen. The Wizard makes assumptions,
calculates and presents specific values. Modify these values if necessary.
Not Selected
Selected
Instruction Manual 33
SETUP Area
Creates a Smart Step with an Angle Control/Torque Monitoring strategy that rotates the
fastener in the opposite direction as the Audit step is programmed. The fastener threads
align with the locking device threads before standard forward rotation and high speed
are applied (prevents cross-threads). If selected, this is the first step in the tool strategy.
Options include:
The number of degrees of rotation the socket turns during this step.
Angle Target
Wobble The Wizard uses 360˚ by default.
The speed of the tool’s output in Revolutions Per Minute (RPM). The
Speed
Wizard uses 60 RPM as default.
The maximum allowed torque during this step. A low value is
Max Torque calculated by the Wizard to detect cross-threads and double hits (Re-
hits).
Creates a Smart Step with an Angle Control/Torque Monitoring strategy that rotates the
fastener in the same direction as the Audit step is programmed. The flats of the socket
align with the flats on the fastener before standard forward rotation and high speed are
applied. Using Slow Seek as a first step also allows for cross-thread and re-hit detection. If
selected, this is the first step AFTER Wobble. Options include:
The number of degrees of rotation the socket turns during this step.
Slow Seek Angle Target
The Wizard uses 180˚ by default.
The speed of the tool’s output in Revolutions Per Minute (RPM). The
Speed
Wizard uses 60 RPM as default.
The maximum allowed torque during this step. A low value is
Max Torque calculated by the Wizard to detect cross-threads and double hits
(Re-hits).
In some fastening situations, the initial fastening cycle torque is as high as or higher than
the target torque specification limit for the joint. In other cases, such as thread rolling
or forming, overcoming friction in getting the fastener started causes the high initial
torque. In order to compensate for this high initial torque, the Self Tap control allows the
controller to drive the tool for a specified amount of angle at the start of a fastening cycle.
Creates a Smart Step with an Angle Control/Torque Monitoring strategy in the same
direction as the Audit step is programmed. If selected, this is the first step AFTER Slow
Seek. Options include: Snug Torque, Angle Target, Speed, Max Torque.
Self Tap The point in this step when the controller begins to monitor the tool’s
Snug Torque
output angle.
The number of degrees of rotation the socket turns during this step.
Angle Target
The Wizard uses 800˚ by default.
The speed of the tool’s output in Revolutions Per Minute (RPM). The
Speed
Wizard uses the rated speed of the tool in RPM as default.
The maximum allowed torque during this step. The Wizard uses the
Max Torque
tool’s rated torque to prevent any interference.
The pre-torque runs the fastener to a preliminary torque level and suspends the fastening
cycle for a period of time. After a time delay, the Audit step begins. Creates a Smart Step
with a Torque Control/Angle Monitoring strategy in the same direction as the Audit step is
programmed. If selected, this is the first step AFTER Self Tap. Options include:
Pre-Torque The Target Torque for this step. The Wizard uses the Audit step’s
Torque Target
Low Torque value by default.
Delay Between The time period to suspend the tool strategy before continuing
Steps entered in seconds. The Wizard uses 0.05 seconds as default.
Instruction Manual 35
SETUP Area
AC TM AC TC
Creates a Torque Control/ Angle Monitor Strategy step AFTER the Audit step and will make
the Torque Recovery step the Audit step. The torque parameters of the Torque Recovery
step are the same as the Audit step. Sets Merge Torque to Yes. Sets Accumulate Angle to
Yes. Sets Torque Display to Final for both steps.
TC AM This is the value for the Delay Between Steps of the Audit step prior
Relaxation Time to running the Torque Recovery step. The Wizard uses 0.05 seconds
as default.
The Speed of the tool’s output in Revolutions Per Minute (RPM)
Speed during the Torque Recovery step. The Wizard uses 10 RPM as
Torque Recovery default.
If the achieved angle in the Torque Recovery step exceeds the
Rotation Threshold the torque and angle values displayed and saved
are the final torque and final angle of the Torque Recovery step.
Rotation If the achieved angle in the Torque Recovery step does not exceed
Threshold the Rotation Threshold in the Torque Recovery step, the torque and
angle values displayed and saved are the final torque and final angle
of the Audit step.
The Wizard uses 0 degrees as default.
In some fastening situations sockets become stuck on the fasteners. This step reverses
the tool and releases the socket without loosening the fastener. Creates an Angle Control
or Torque Control (AC/TC) strategy Smart Step that rotates the fastener in the opposite
direction of the Audit step. Options include:
The number of degrees of rotation the socket turns during this step.
Angle Target
Fastener Release The Wizard uses 50˚ by default.
The speed of the tool’s output in Revolutions Per Minute (RPM). The
Speed
Wizard uses the rated speed of the tool in RPM as default.
The maximum allowed torque during this step. The Wizard uses
Max Torque
50% of the rated torque of the tool by default.
The Job tab screen appears. This allows manual editing of parameters prior to saving Wizard programming. To
save, press the EXIT interactive menu button.
Press the YES interactive menu button to save changes. This saves the parameters and opens the Run screen.
There can be more than one Job. Use the left/right arrow keys to select the tab/Job for modifying.
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. When using the PFCS
Name
protocol a Machine ID value must be entered here. This name will appear on the Run
screen when the Job is selected.
Instruction Manual 37
SETUP Area
This is a mask that when equal to an incoming PART ID (barcode scan) this Job is selected
as the active Job. The PART ID can come from the USB port, serial port, a network
protocol, a fieldbus input, the internal PLC or the keypad itself. Use periods (.) to mask
the negligible portions of the PART ID; use the exact characters in their exact PART ID
Barcode Id positions to select the Job.
Example: If a PART ID is 123ABC and if the 3A determines when this Job is to run (the
third and fourth positions), then enter “..3A..” as the parameter value. Notice that the
periods (.) match the length of the expected PART ID.
Setting this parameter to Yes will allow the selected Job’s bolt count to increment on both
Increment Count
OK and NOK fastening cycles. If set to No the Job’s bolt count will increment only on OK
on NOK
fastening cycles.
When set to Yes, the QB Expert Alpha controller automatically sequences from Task 1
Auto Sequence
through each Task to the final Task in the Job after the fastener count in each Task is
Tasks
complete. The value of No requires an input to select the Task to run within a Job.
The value of Yes resets the Job automatically after the Batch Count has been met. The tool
Auto Reset Job will not disable with Error Proofing enabled. The value of No requires an Input to Reset
the Job.
This identifies whether the tool disables after each Task has
completed. This requires a Reset Job, Task Select or Task Select Bit
input to select an incomplete Task which enables the tool for an
incomplete Task only. If Auto Sequence Task is used, the tool re-
enables when the active Task switches to an incomplete Task.
Disable
Yes disables the tool when the active Task is
Assembly
complete. If an input switches the controller to a
On Task completed Task, the tool is disabled. If an input
Complete switches the controller to an incomplete Task, the
tool is enabled to complete the Task. No will not
disable the tool when the active Task is complete.
A value of YES invokes the Job Timer. The Job Timer starts when the first bolt of the batch
count exceeds Threshold Torque (In Cycle) and stops when the programmed number of
seconds has elapsed. If the timer times out before the batch count is complete the Job is
Enable Job set to complete, the tool is disabled and the Job Complete output is energized.
Timer
A value of No disables the Job Timer.
Job Timer Value is in seconds. Maximum is 9999.9 seconds, minimum is 1 seconds.
Instruction Manual 39
SETUP Area
3.1.2.1 Manage Button (Jobs)
Press the MANAGE interactive menu button to Add, Delete, Copy or Paste Jobs.
The Manage interactive button enables Jobs to be added, deleted, copied to the clipboard and pasted into another
Job, imported or Exported using a USB memory stick.
Adds a Job to the controller. If a tool is attached, the Wizard begins for easy setup of
parameters. If a tool is not attached, the Jobs tab appears for manual parameter setup.
Add
Jobs do not have to be added sequentially. A Job can be added before or after the one
that is selected. Jobs renumber automatically after being added. Make a selection and
press the OK interactive 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.
Overwrites the selected Job with the values residing in the Clipboard.
Paste To copy/ move a Job: first create a new Job where it is needed, then copy the Job to be
moved, then paste it into the new Job created and delete the original if required.
Imports the selected Job file from the USB memory stick and overwrites all Jobs in the
controller.
Import Insert a USB memory stick into the USB port on the bottom of the controller. Use the up
and down arrow keys to select Import. Scroll through the files on the USB memory stick
until the desired file is selected. Press the OK interactive menu button to import the file.
Press EXIT then YES to save the file.
Export 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
write a new file name. Press the interactive OK button or the Toggle button to accept the
file name. Press again to save the file to the USB memory stick.
Press the EXIT interactive menu button to save changes and return to the Run screen. See section “3.1.2.6 Exit”
on page 52
Name the Task to define the operation performed (15 character maximum). Use the up/
Name
down arrows for letters or use the numeric keypad.
This is the number of OK fastening cycles the Task is required to count before it is
Batch Count
completed OK. Zero is not allowed. The default value is 1. The maximum is 99.
Instruction Manual 41
SETUP Area
Limits the number of NOK (Not OK) fastening cycles in a Task. If the limit is achieved the
tool is disabled. Use Reset Job, Task Select or Task Select Bit inputs to recover. Yes turns
this function on and increases the Task menu to insert the Reject Count parameter. No
turns this function off. The default value is No.
Limit Rejects
Reject Count The maximum number of NOK fastening cycles allowed during this
Task. The default value is 3.
Operating torque units. See section “3.1.1.1 Wizard Screens” on page 31 for a list of
Units available units. Each Task does not have to use the same operating torque units as the
other Tasks. The default value is Nm.
For tightening a right-hand fastener use clockwise (CW). Use counter-clockwise (CCW) for
Thread Direction
left-hand fasteners. The default value is clockwise (CW).
The torque level during the fastening cycle when the In Cycle output transitions high. Data
Threshold
is not stored, or available to Alpha Toolbox, unless Threshold Torque is exceeded during
Torque
the fastening cycle. A good starting point is 20% of Target Torque. The default value is 0.
The torque level required to be exceeded before the fastening cycle data is included into
Statistical Torque
Statistics or sent via a network protocol. The default value is 0.
The speed of the tool during (Reverse) operation in RPM (revolutions per minute). The
Disassembly
default value is 9999. To limit the speed of the tool reduce this parameter to a value less
Speed
than the maximum speed of the tool.
Disassembly The rate at which the tool gets to Disassembly Speed in RPM/s (revolutions per minute per
Acceleration second). The default value is 3,000.
This is a timer, in seconds, that activates after the tool has reached its target. While active,
Cycle Lock-Out
the tool is disabled.
This section sets values used in determining fastening cycle torque rate used in the Rate
Control or Yield Control strategies.
Number of Torque samples averaged for the Rate calculation.
Calculates a running average from torque samples taken every
Torque Rate Torque Average
millisecond. A higher number gives a smoother Rate. The default
value is 10 m sec.
Used to calculate the Torque vs. Angle Rate. Larger intervals may give
Angle Interval
a smoother Rate. The default value is 20°.
A value that is changed by the controller to indicate the date and time parameter values
Modified
were last changed in this Task or associated Steps.
Adds a Task to the controller. If a tool is attached, the Wizard begins for easy setup of
parameters. If a tool is not attached the Tasks tab appears for manual parameter setup.
Add
Tasks do not have to be added sequentially. A Task can be added before or after the one
that is selected. Tasks renumber automatically after being added. Make a selection and
press OK to add a Task, or CANCEL to not add a Task
Delete Deletes the selected Task from the controller. Tasks cannot be recovered once deleted.
Copy Copies the selected Task and its associated Steps to the Clipboard.
Overwrites the selected Task with the values residing in the Clipboard.
Paste 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 screen. See section “3.1.2.6 Exit”
on page 52.
Press the BACK interactive menu button to return to the Job level.
Step settings only affect the selected Job and Task. There can be only one Audit step per Task. Each Step is
Instruction Manual 43
SETUP Area
represented by its own tab. Use the left/right arrow keys to select the tab/Step for modifying. There are a
maximum of 12 Steps in each Task.
The parameters for all strategy types are listed. Not all parameters are shown on the display at one time. Use the
scroll
AC TMbar on the display toACview
TC more parameters.
Provides an identifier for the step (15 characters maximum). Use the up/down arrows for
Name
letters or use the numeric keypad.
Identifies values used to control the tool during a Step and to control the Step’s direction.
Strategies include:
TC / TC
AMAM Torque Control with Angle Monitor. The controller shuts off the tool
when the target torque value is achieved. The controller also monitors
angle which can indicate changes in joint rate. Audit Step torque and
Strategy angle results must fall within their specified limits for the fastening
(Standard) cycle to be acceptable (OK).
AC AC TM
/ TM AC TC
Angle Control with Torque Monitor. The controller shuts off the tool
when the target angle value is achieved after a selected snug torque
AC/TA value. The controller also monitors torque. Audit Step torque and
angle readings must fall within their specified limits for the fastening
cycle to be acceptable.
AC TM AC TC
AC / TC Angle Control and
TC AM 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 occurs. Audit
AC TM AC TC Step final torque and angle results must fall within their specified
limits for the fastening cycle to be acceptable. The controller also
shuts off the tool when it determines that target torque and angle
TC AM
cannot be reached (i.e. Bailout limits have been achieved).
AC/TA
Angle Control or Torque Control. The controller shuts off the
Strategy tool when either a target torque value or a target angle value is
(Advanced) achieved after a selected snug torque value occurs. Bailouts are set
to the targets. Audit Step final torque and angle results must fall
TC AM
within their specification limits for the fastening cycle to be judged
acceptable.
AC AC/TA
/ TA Angle Control with Torque Average. The controller performs a
standard Angle Control strategy with the exception that the torque
results are the average torque achieved during the step.
/TA
AC/TA YC / AM Yield Control with Angle Monitor. The controller shuts off the tool
when the falling target rate value is achieved after a selected snug
AC/TA torque value. The controller also monitors angle. Audit Step torque
and angle readings must fall within their specified limits for the
fastening cycle to be acceptable.
Strategy TC AM
(Advanced) BACK OFF Reverse Angle Control or Torque Control. The controller runs the tool
in the opposite direction and shuts off the tool when either a lowering
target torque value or a target angle value. Torque has priority over
Angle.ACWhich
TM means theACtool
TC will shut off if torque target is reached
before the angle target. Audit Step torque and angle readings must
fall within their specification limits for the fastening cycle to be judged
acceptable.
AC TM AC TC
PC / TM Position Control with Torque
TC AM Monitor. The controller shuts off the tool
when the tool zero position is achieved after a selected snug torque
value. The controller also monitors the torque. Audit Step torque and
angle readings must fall within their specified limits for the fastening
cycle to be acceptable.
AC/TA
The torque at which the controller shuts off the tool. Should be greater than Low Torque
Torque Target
and lower than High Torque. Units are the selected torque units.
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
High Torque
LED on the front panel and tool illuminates. Must be greater than Torque Target and less
than or equal to the rated torque marked on the tool. Units are the selected torque units.
The minimum peak torque for an acceptable fastening cycle. If the actual torque does not
reach this limit, the fastening cycle is flagged as NOK and the YELLOW LED on the front
Low Torque
panel and tool illuminates. Must be less than the Torque Target. Units are the selected
torque units.
Selects which achieved torque value to store, display and use to compare against limits
Torque Display for fastening cycle status. PEAK will choose the peak torque during the step, FINAL will
choose the torque at peak angle during the step.
Yes carries the angle over from the previous step. The angle value is from the previous
Accumulate
step’s Snug Torque to this active step’s peak angle. No turns this function off. The default
Angle
is NO requiring a Snug Torque value for this step.
The point in the step when the controller begins to monitor the tool’s output angle. Should
Snug Torque be greater than 0 and less than Low Torque. A value of 50% of Torque Target is a good
starting point. Units are the selected torque units.
Instruction Manual 45
SETUP Area
The angle at which the controller shuts off the tool after a selected Snug Torque value.
Angle Target Should be greater than Low Angle and lower than High Angle. Units are degrees of
rotation.
The maximum peak angle for an acceptable fastening cycle (required for all steps). If the
actual angle exceeds this limit the fastening cycle will be flagged as NOK and the RED
High Angle
LED on the front panel and tool illuminates. Must be greater than Low Angle. Units are
degrees of rotation.
The minimum peak angle for an acceptable fastening cycle. If the achieved angle does
not reach this limit the fastening cycle will be flagged as a NOK and the YELLOW LED on
Low Angle
the front panel and tool illuminates. Must be less than High Angle. Units are degrees of
rotation.
Resets the achieved angle value to zero if torque drops below Snug Torque during the
Angle Reset
step.
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 selected torque units.
Bailout on High
Torque
Torque Bailout The torque value at which the tool will shutoff during an Angle
Control strategy if the tool has not reached target angle.
Yes will shutoff the tool when the High Angle parameter is exceeded during any Torque
Control strategy. No will cause the tool to stop when the Angle Bailout parameter is
exceeded during any Torque Control strategy. Requires the Angle Bailout value to be set.
Should be set equal to or above High Angle. Units are degrees of rotation.
Bailout on High
Angle
Angle Bailout The angle value at which the tool will shutoff during an Torque
Control strategy if the tool has not reached target torque.
Monitor Torque
Window
Upper Torque Defines the high torque limit for the window.
Lower Torque Defines the low torque limit for the window.
Upper Angle Defines the low angle limit for the window referenced from when the
Snug Torque value.
Lower Angle Defines the high angle limit for the window referenced from when the
Snug Torque value.
Provides Torque Rate Monitoring during the step between a Rate Threshold to final torque
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.
Monitor Torque Rate Threshold Defines the torque at which this monitoring begins
Rate
The maximum peak rate for an acceptable fastening cycle. If the
High Rate actual rate exceeds this limit the fastening cycle will be flagged as
NOK and the RED LED on the front panel and tool illuminates.
The minimum peak rate for an acceptable fastening cycle. If the actual
Low Rate rate does not achieve this limit the fastening cycle will be flagged as
NOK and the YELLOW LED on the front panel and tool illuminates.
Correlation coefficient for least square fit (straight line) of the torque
rate curve. A higher number correlates to a straighter line. If any
Deviation Limit point exceeds the Deviation Limit the fastening cycle will be flagged
as NOK and the RED and YELLOW LEDs on the front panel and tool
illuminates.
Instruction Manual 47
SETUP Area
The controller shuts off the tool if the achieved torque drops below the peak torque by a
defined percentage. YES turns this monitoring on. NO turns this monitoring off.
Bailout on
Torque Drop The value, as a percentage of running peak torque, the torque must
Torque Drop
drop before the controller shuts off the tool.
Torque The torque at which this monitoring begins.
Threshold
The amount of angle the tool’s output must rotate where the torque
Filter drop must be maintained before the fastening cycle is ended with a
shutoff code of TD.
The velocity of the output of the tool before any Downshift Mode activates (required for
Speed
any step). Units are RPM. Must be greater than 0. Default is 9999.
The rate the tool ramps up to Speed in RPM/s (revolutions per minute per second). Should
Acceleration
be greater than 1,000 RPM/s. The default is 3,000 RPM/s.
Stops the tool when the time has elapsed from the start of the step. The value should be
Abort Timer
long enough to complete the fastening cycle during this step.
Delay Between The time the tool delays before proceeding with the next step in the Task. Entered in
Steps seconds.
The maximum power available to the tool to perform the fastening cycle. Required for
Power all steps. Units are percent of maximum rated torque of the tool. Should not be less than
100%.
The maximum current for an acceptable fastening cycle. If the achieved tool current
High Current exceeds this limit the fastening cycle is flagged as NOK and the RED LED on the front
panel and tool illuminates. Must be greater than Low Current. Units are percent.
Instruction Manual 49
SETUP Area
The minimum current for an acceptable fastening cycle. If the actual tool current does not
Low Current reach this limit the fastening cycle is flagged as a NOK and the YELLOW LED on the front
panel and tool illuminates. Must be less than High Current. Units are percent.
This controls how the tool is turned off AFTER reaching target torque. This is designed as
an ergonomic benefit to ease operator discomfort with direct-drive tools.
Soft Stop
Carries the torque over from one step to another as if the two steps were actually one
Merge Torque
step.
The rising slope rate at which the controller shuts off the tool. Units are the selected
Rate Target
torque units/degrees of rotation.
The falling slope rate at which the controller shuts off the tool. Units are the selected
Yield Target
torque units/degrees of rotation.
A combination of the High Torque and Bailout on High Torque parameters. Used in Angle
Max Torque
Control Smart Steps only.
The number of degrees from Tool Zero Position where the controller will shut off the tool
Position Target
during a Position Control / Torque Monitor strategy after achieving Snug Torque.
Steps do not have to be added sequentially. A Step can be added before or after the one
that is selected. Steps renumber automatically after being added. Make a selection and
press OK to add a Step, or CANCEL to not add a Step.
Add
Use the Up and Down arrow to select the option required then press the interactive OK
button.
STRATEGY creates a step using a strategy from the list above. Only Strategy steps can be
assigned as audit steps.
WOBBLE, SLOW SEEK, SELF TAP, PRE-TORQUE, BACKOUT and 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.
Overwrites the selected Step with the values residing in the Clipboard.
Paste To copy/ move a Step: first create a new Step where it is needed, than copy the Step to be
moved, then paste into the new Step created and delete the original if required.
Press the EXIT interactive menu button to save changes and return to the Run screen. See section “3.1.2.6 Exit”
on page 52.
Press the BACK interactive menu button to return to the Task level.
Instruction Manual 51
SETUP Area
3.1.2.6 Exit
Programming changes are stored after exiting current menu. Alert Operator(s) to any changes in tool behavior
before saving.
Press the YES interactive menu button to save the changes and exit the programming mode.
Press NO to discard the current changes and exit the programming mode.
Press CANCEL to not exit the programming mode and continue modifying parameters.
This is the MAC id of the Ethernet port on the Alpha controller. This
Physical
value comes from the Ethernet board inside and cannot be changed.
To enable wireless communications for the Expert Alpha controller, type in an SSID value, type in a PASSWORD
and choose the applicable REGION.
Off - Disables the radio in the Network Node Alpha controller.
Low - Enables the radio in the Network Node Alpha controller at a low power level.
Radio
Medium - Enables the radio in the Network Node Alpha controller at a medium power level.
High - Enables the radio in the Network Node Alpha controller at a high power level.
Instruction Manual 53
SETUP Area
Name This parameter sets the Service Set Identifier (SSID) for the access point in the QPM Expert
Alpha controller.
The maximum number of case sensitive, alphanumeric (ASCII) characters is 32. It is
recommended to use a value that best defines the station under test from other stations.
Use the up and down arrows on the keypad to insert characters. Use the right arrow to move
the cursor for the next character.
If left blank the default SSID for the QPM Expert Alpha controller is QB-serialnumber, where
serialnumber is the serial number of the controller; i.e. QB-032014007.
Password This parameter sets the encryption key needed to connect a wireless device to the access
point in the QPM Expert Alpha controller. Must be a minimum of 8 characters and no longer
than 63 printable characters or 64 hexadecimal digits.
Use the up and down arrows on the keypad to insert characters. Use the right arrow to move
the cursor for the next character.
This parameter can be left blank.
Region Select from the drop-down list the region of the world where the tool is operating. This
selects the correct frequency channels allowed by that region.
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.
Instruction Manual 55
SETUP Area
Choose which type of PFCS communications to be used.
BASIC This is the standard protocol used at Chrysler facilities.
This is the enhanced protocol used at Fiat facilities. The controller is
BASIC NPL enabled by the network, performs many operations until disabled by
Type
the network.
This is the enhanced protocol used at Fiat facilities. The controller
SMART NPL is enabled for a specific Job by the network, after successfully
completing the job the controller disables itself.
This port is used by the PFS system to select the Job number on the Alpha controller.
Enable or Disable this port as required. When enabled type the port number.
The required virtual port on which the Alpha will communicate to the
Port Number plant network. Must be a different port number than the Solicited
Port.
Required for Smart or Basic NPL. May be used for Basic PFCS. The
Machine ID
Machine ID for the port.
Wait to Time period in seconds between a disconnect and an attempt to
Unsolicited Port Connect reconnect.
The time period in seconds where the controller waits for a reply to a
Wait for Data
request sent to the server.
The time period to wait between when the controller sends data to
Wait for ACK the server and it should receive an acknowledgment. If no ACK in this
time period the data sent again 3 times.
The time in seconds for an inactivity timeout between messages when
Keep Alive
the controller sends a KEEP ALIVE message to ensure cable integrity.
There are OPTIONS which can be adjusted based on plant Systems requirements.
Rundown Data Specify the PART ID as VIN or AVI.
Options Select YES to allow the controller to buffer the fastening cycle data
Buffer While
while the controller is off line (disconnected from the network). NO
Offline
means the controller will not buffer data for network retrieval.
Change these parameter values as required by Systems department. Units are in seconds.
Wait to Time period between a disconnect and an attempt to reconnect.
Connect
The time period where the controller waits for a reply to a request
Wait for Data
sent to the server.
Timers
The time period to wait between when the controller sends data to
Wait for ACK the server and it should receive an acknowledgment. If no ACK in this
time period the data sent again 3 times.
The time for an inactivity timeout between messages when the
Keep Alive
controller sends a KEEP ALIVE message to ensure cable integrity.
This is the installed version of the PFCS protocol. Check with the Chrysler’s Systems group
PFCS Version
to determine if this has been approved for use in the facility.
Instruction Manual 57
SETUP Area
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.
The required virtual port on which the Alpha will communicate to the plant network.
Port
Normally 4545.
Cell Type the cell number where this Alpha controller resides.
Yes causes the Alpha controller to buffer data for 100 fastening cycles when the server
Buffer While Off
connection is lost. Upon reconnection, the buffered data transmits to the server. No does
Line
not buffer any data when the server connection is lost.
Send Fastener Yes sends the FASTENER REMOVED message when the Alpha controller detects a
Removed tightened fastener is removed. No stops the message from transmitting.
This is the number of times the Alpha controller sends a message to the server when no
Number of Tries
ACK message is received.
Max The maximum number of connections the Alpha controller allows the server. The Alpha
Connections cannot have more than 10 connections.
Wait for Ack The time in seconds to wait for an ACK before retransmitting information.
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.
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.
Instruction Manual 59
SETUP Area
3.1.3.7 XML Tab
The plant’s IT department must provide these values to allow the Alpha controller to communicate on the XML
protocol network.
Enable or Disable XML communications as required. Once enabled select the correct
software and results server and ports.
Now supports version 2.0 and 2.1. Choose the correct one for the
Version
facility.
XML Results Server Type the IP Address of the Results Server on the network.
Communications
The virtual port on the XML protocol network server where the Alpha
Results Port
controller transmits messages.
The virtual port where the Alpha controller receives commands from
Command Port
the XML protocol network server.
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.
To set the DeviceNet network’s communication rate use the up/down arrows to select Baudrate. Press the
Toggle button. Choices include: 125 K bits/s, 250 K bits/s and 500 K bits/s. Use the up/down arrows to choose
the baud rate and press the OK interactive menu button.
If no trailing devices are listed then they have to be added. They can be added in two different ways. They
can be added manually using ADD function or automatically by using the SCAN function. Both functions are
accessed with the MANAGE interactive menu button.
EDIT This edits the selected device that has already been added to the controller.
This adds a device for the Expert to control. Set the options for the devices added in the
Scanner dialog box.
Delete This deletes the selected device from the controller’s DeviceNet network.
Import This imports a scanner.json file on the USB memory stick.
Scans the DeviceNet network and adds any devices it finds to the controller. After adding
Scan
the user must use EDIT to modify the options for the device.
Use the right arrow to move to the next tab or press EXIT to save the changes and return to the Run screen. See
Instruction Manual 61
SETUP Area
section “3.1.2.6 Exit” on page 52.
3.1.3.9.1 DeviceNet
This tab appears on Alpha controllers only when the DeviceNet port option is installed and sets the communications
parameters for the Alpha controller on a DeviceNet network.
Sets the Alpha controller’s communication rate on the DeviceNet network. Choices
Baudrate
include: 125 K bits/s, 250 K bits/s and 500 K bits/s.
Mac Id Sets the Alpha controller’s node number on the DeviceNet network.
The Expert Alpha controller automatically 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.
3.1.3.9.2 Ethernet/IP
This tab appears on the Alpha controllers only when the Ethernet/IP option is installed and sets the communications
parameters for the Alpha controller on a EthernetIP network.
This is the MAC id of the EthernetIP port on the Alpha controller. This
Physical
value comes from the EthernetIP board inside and cannot be changed.
The Alpha controller 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.
3.1.3.9.3 Profinet
This tab appears on the Alpha controllers only when the PROFINET option is installed.
Instruction Manual 63
SETUP Area
This information is received when connecting the Alpha controller to PROFINET control
device using its optional RJ-45 jack and cannot be modified.
PROFINET I/O IP Address The IP Address of the Alpha controller’s Profinet port.
Device
Subnet Mask The Subnet address of the Alpha controller’s Profinet port.
Gateway The Gateway address to a connecting network.
This is the name of given to the controller for lookup by the controlling PLC to determine
the IP Address of the Profinet port on the Alpha controller. Valid device names are
defined in the PROFIBUS standard, but in general must obey the following rules:
• The device name can consist of one or more labels, each separated by a period (.).
• Each label consists of numbers and lower-case letters, and may have embedded
hyphens (-).
Name • Each label can be up to 63 characters long, and the total device name can be up to
240 characters long.
The following examples are valid device names:
• rmc150e
• rmc150e-1
• rmc150e-1.company.com
This is the MAC id of the RJ45 jack on the Alpha controller. This value comes from the
Physical
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.
3.1.3.9.4 Profibus
This tab appears on Alpha controllers only when the Profibus port option is installed.
This tab sets the communications parameters for the Alpha controller on a Profibus network.
Sets the baud rate for the Alpha on the Profibus network. The choices are:
Baudrate
Sets the node number of the Alpha controller on the Profibus network. Values can be
Bus Address
from 0 to 126.
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.
Compatibility
Sets the order of the Inputs and Outputs as listed in the GSD file.
GSD Order
Choices are Outputs First or Inputs First.
Instruction Manual 65
SETUP Area
Determines whether or not the Alpha controller will automatically select which type of
I/O modules to setup based on the assignable I/O created in section “3.1.4.3 I/O Tab” on
page 69. If NO is selected the user must enter the I/O modules manually.
Type the number of modules desired. The modules will be created.
Output
User must select the number of BYTES or WORDS that make up each
Modules
module and if it has consistency or not.
Automap
Type the number of modules desired. The modules will be created.
Input Modules User must select the number of BYTES or WORDS that make up each
module and if it has consistency or not.
If YES is selected the Alpha will create the I/O modules. User must select if Consistency is
desired or not. NO will select without consistency, YES will select with consistency.
The Alpha controller has no default I/O on the Profibus bus. The I/O must be assigned before a GSD file can be
obtained. See Section “3.1.4.3 I/O Tab” on page 69 to assign and configure the Profibus I/O.
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 or press EXIT to save the changes and return to the Run screen. See
section “3.1.2.6 Exit” on page 52.
Select the appropriate user from the drop-down and then type in the correct password for the selected user.
The parameter value will be modified if the logged in user has sufficient privileges. Otherwise the controller will
display the Insufficient Privileges screen and the parameter value will not be modified.
Instruction Manual 67
SETUP Area
The controller automatically re-locks the system 15 minutes after the last keypad input. Press the LOGOUT button
to re-lock the controller when finished modifying parameters. When the controller is locked the lock icon appears,
the LOGOUT button disappears and the controller is password protected.
To add a user, press the MANAGE interactive menu button.
Adding users is a two step process. First add user by choosing option 1. Add:
Name user, enter password, enter password again to verify and press OK.
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-administrators choose NO, then press OK.
Select the Access level for non-administrators.
Options include:
NONE denies access.
LOCAL allows access from the keypad.
REMOTE allows access from a computer via Alpha Toolbox.
BOTH allows access from the keypad and a computer.
There is no overlap between areas. Select more than one area for access if required.
Press OK to save.
To delete a user press the MANAGE button and select option 2. Delete. Confirm deletion by pressing OK. This
action requires the Administrator password; once entered, user is deleted.
Import – Users can be entered from a backup file. Connect a USB memory stick to the USB port, scroll to desired
file and press 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.
3.1.4.3.1 Outputs
The 24V DC Connector has pins C through K designated as Outputs 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. A list of
available output functions displays. See section “6.12 Assignable Input and Output Functions” on page 120 for
the complete list and descriptions.
Highlight function to assign to the selected pin and press the NEXT button. An Output functions can be assigned
to more than one pin.
The selected Output function must then be configured. See section “6.12.2 Output Descriptions” on page 129
for configuration options and descriptions. After modifying press FINISH.
Instruction Manual 69
SETUP Area
3.1.4.3.2 Inputs
The 24V DC Connector has pins L through U designated as Inputs to 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. A list of
available Input functions displays. See section “6.12 Assignable Input and Output Functions” on page 120 for
the complete list and descriptions.
Highlight the function to assign to the selected pin and press the Toggle button. An Input function can be assigned
to more than one pin.
The selected Input function must then be configured. See section “6.12.1 Input Descriptions” on page 123 for
configuration options and descriptions. After modifying press FINISH.
3.1.4.3.3 Fieldbus
Unlike the 24V DC inputs and outputs the fieldbus buses do not have any pre-assigned I/O functions. After
selecting a fieldbus, such as ModbusTCP Output, 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 function must then be configured. See section “6.12.1 Input Descriptions” on page 123 or
“6.12.2 Output Descriptions” on page 129 for configuration options and descriptions. Each fieldbus function has
its own unique configuration parameters. After modifying press FINISH.
If this is the first one bit wide function added to the bus then an entire byte will be added with the remaining bits
assigned as IGNORED or NOT USED. These functions will have a bit length of 7 to fill out the byte.
To continue adding functions choose the next bit that is IGNORED or NOT USED and press the Toggle button.
Each time a function is added the IGNORED or NOT USED functions will decrease their bit length until all bits in a
If the highlight is on an IGNORED or NOT USED or last bit of a byte the Add After Selection window appears. If
the highlight is on bit 0 the Add Before Selection window appears. If the highlight is on a bit in the middle of a
byte the Can’t Add! window appears. Press the OK button after one of these windows appears.
The new byte will be added either before or after the highlighted byte. Be sure to highlight the correct part of the
byte before adding a new byte where required.
Select the desired function and press the NEXT button. Modify the configuration settings then press the FINISH
button. A new byte, word or double word will be added to match the length of the new function.
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.
Instruction Manual 71
SETUP Area
Tap Action Defines the operation when the MFB on the tool is tapped (pressed quickly).
Hold Action Defines the operation when the MFB on the tool is held for one second.
Defines which input starts the tool. In all cases, the 24V DC Start input is always available
to start the tool.
Any Either the tool trigger or tool push-to-start switch starts the tool.
Start Mode Requires that both the tool trigger and the tool push-to-start switch
All
must be activated to start the tool.
Lever Only the trigger on the tool starts the tool.
PTS Only the push-to-start switch on the tool starts the tool.
Neither the tool trigger nor the tool push-to-start switch starts the
None
tool.
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.
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.
The PLAY Button when pressed will preview the selected tone. A tool needs to be connected to the controller to
perform this action.
The STOP button will end the preview.
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.
When the PM Counter in the tool exceeds this threshold, the preventive maintenance
PM Limit indicator on the front panel illuminates indicating it is time to perform maintenance on the
attached tool.
Temperature Identifies the threshold, in degrees Celsius, for tool shut off. This is caused by excessive
Limit duty cycle on the tool.
See Appendix A – Torsion Compensation for an explanation of this parameter and how to
Torsion Factor
determine a correct value. Otherwise, use the default (zero).
Forces the Tap Action on the MFB to Arm. See section “5.2.5 MFB Mode” on page 104.
Requires Arming
Tubenut tools require arming as a factory setting.
Sets the torque level at which the tubenut stops when it returns home. The value is a
Dog Torque
percentage of the rated torque of the tool; where 0.1 = 10%.
Home Speed Sets the speed of the tubenut tool when it returns home.
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.
Instruction Manual 73
SETUP Area
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.
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.
Press the SYNC interactive button in Alpha Toolbox to set the controller to the connected computer’s date and
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 “3.1.2.6 Exit” on page 52.
Ladder logic for the embedded PLC can be created or edited using Alpha Toolbox. See section “7.3 PLC Editor”
on page 155.
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 “3.1.2.6 Exit” on page 52.
Press EXIT to save the changes and return to the Run screen. See section “3.1.2.6 Exit” on page 52.
3.2.1 Tool
All tool parameters are stored in the tool memory board in the tool’s handle. This area reads/writes values to the
tool memory board, not to the controller. Updating the tool’s configuration and firmware is managed here.
Instruction Manual 75
SERVICE Area
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.
Odometer – Cannot be reset. Indicates the total number of OK Fastening cycles the attached 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 EXIT to save the changes and return to the Run screen. See
section “3.1.2.6 Exit” on page 52.
This is a calculated value based on the torque output of the motor, the gear ratios and
Nominal Cal
efficiencies. This is a reference value only and cannot be modified.
Choose which transducer will be used as the primary transducer for control and data
Primary
collection. This parameter is only available when a tool with a redundant transducer is
Transducer
attached.
This is the specific torque calibration value for the tool. Enter a new value after performing
Torque Cal a lab certification. The Torque Cal should not deviate from the Nominal Cal value by more
than 20%.
ENABLE or DISABLE the redundant transducer to check the primary transducer’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 disable the redundant transducer and
Redundant select T1 as the Primary Transducer. Calibrate the tool normally. Then select T2 as the
Transducer Primary Transducer and calibrate the tool normally. Enable the redundant transducer if
required. Choose the correct Primary Transducer.
This is the specific tolerance value for the redundant transducer to
check against the primary transducer. Units are percentage of Max
Tolerance
Torque of the tool. This parameter is only available when a tool with a
redundant transducer is attached.
Instruction Manual 77
SERVICE Area
ENABLE or DISABLE the redundant angle sensor to check the primary angle sensor’s
operation. This parameter is only available when a tool with a redundant transducer is
attached. When enabled the controller compares the redundant angle sensor’s signal to
the primary angle snesor’s signal continuously, even at rest. If the difference in the values
Redundant
exceeds the Tolerance the controller stops the tool with a shutoff code of A1 ≠A2.
Angle
This is the specific tolerance value for the redundant angle sensor to
Tolerance check against the primary angle sensor. Units are defrees of rotation
of the tool.
A value that is changed by the controller to indicate the date and time the tool was last
Modified
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 managed here.
Instruction Manual 79
ANALYZE Area
during troubleshooting operations.
Transducer Health – The thickness of the vertical line within the horizontal bar indicates transducer health (a
thicker line means less healthy). Once 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 Fastening cycle.
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 instantaneous temperature of the tool’s stator windings. Temperature is not
measured during tool operation. This interacts with the Temperature Limit parameter. See section “3.1.4.7 Tool
Tab” on page 73.
Tool Output Angle – Identifies the number of circular degrees of rotation on the tool output. Resets at each start.
Tool Output Speed – Identifies the real time speed of the tool output.
The IDENTIFY interactive menu button will flash the red, yellow and green status lights on the selected tool and
controller to distinguish it from another.
The Identify Spindle dialog box will 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.
This tab plots a torque verses time curve after every fastening cycle. The Y-axis is auto-scaled from 0 to maximum
torque of the data. The X-axis has a variable scale to include the entire fastening cycle.
Use the TORQUE interactive menu button to choose how to view the trace.
Instruction Manual 81
ANALYZE Area
Alpha controllers maintain both sample and population statistics. Sample statistics are calculated using the last
completed 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.
The statistics are calculated for Torque and Angle. Data is filtered by Task. Press the interactive
menu button and choose the Job and Task under analysis.
Instruction Manual 83
ANALYZE Area
The details provide the Date and Time the event occurred.
Source – Shows where the user changed the values. Controller means the keypad was used, aTB means the Alpha
Toolbox was used.
Details – Shows which part of the controller the changes were made.
Press the BACK interactive menu button to return the LOG screen.
Press the MANAGE interactive menu button to export Log Data to the USB memory stick or to clear the event log.
Connect a USB memory stick to the USB port on the bottom of the Alpha controller. Use the up/down arrows and/
or the numeric keypad to select option.
Use the up/down arrows and/or the numeric keypad to type a file name. Pressing the OK interactive menu button
saves the data to the USB memory stick.
After the file is saved, 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.
Each 24V DC connector pin is represented. Pin A is for supplying 24V DC to the I/O functions. Pin V is the
24VDC Return to complete the current loop. Pin B is the bus for the Outputs. See section “6.11 Input and Output
Connector” on page 116 for a schematic. Pins L through U are for Inputs. Pins C through K are for Outputs. See
section “3.1.4.3 I/O Tab” on page 69 to assign functions to the pins.
Move the horizontal bar/cursor under a pin and press the 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 indicates the pin is
forced ON.
Choose the YES interactive menu button to remove the force(s) and return to the run screen. Choosing the NO
interactive menu button 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.
Press EXIT to save the changes and return to the Run screen. See section “3.1.2.6 Exit” on page 52.
Instruction Manual 85
QB Expert Alpha Controller
4
Alpha Toolbox
Connection
Controls
Editing Parameters
Trace Data
Icons and Security
Connection
4 Alpha Toolbox
Each Alpha Controller has an Alpha Toolbox port for the purposes of local configuration, backup of parameters
and data, restoring parameters and performing updates. The Alpha Toolbox port on the leading spindle provides
access to all spindles if in a multiple spindle configuration. The Alpha Toolbox port is not used on a network.
If configuration and data collection over an Ethernet network is required the normal Network port, and its IP
Address, is used.
WARNING
NETWORK INTERRUPTION
To Avoid Issues:
• Never connect an Alpha Toolbox port to a plant network.
The Alpha Toolbox port provides an easy connection with a computer. It has a DHCP server and a DNS server built
in. The controller has its own private IP Address and will provide a private IP Address to the computer to create
its own network. Knowledge of the IP Address is not required.
4.1 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 type http://ATB.QPM into the uniform resource locator bar.
The controller’s web server will provide the Alpha Toolbox screens and controls.
4.2 Controls
The menus on the left coincide with the interactive menu buttons on the controller’s run screen. See section “3
Programming” on page 26 for descriptions on these menu items.
The controller display windows on the right mimic the controller run screen. See section “2.7 Display” on page
15 for a description of the items on these windows. Normally only one window is displayed. When connected
to a leading controller on a multiple spindle system all the spindles’ windows will appear on the Alpha Toolbox
run screen with a scroll bar, if necessary, to view them all.
A yellow box will cover the display if there is a message until the condition is cleared.
The active spindle number is displayed in the upper right hand corner and the controller display window for the
active spindle will be a darker color than the others.
To switch between spindles click on the controller 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 appropriate
buttons. Underneath the black bar on the left are the controls for the area. The Add, Delete, Copy, Paste buttons
are the same as the MANAGE interactive menu button on the controller for each particular area. The windows
below that are the tabs that correspond to each area. The area on the right displays the parameters for each area.
See section “3 Programming” on page 26 for descriptions on these menu items and parameters and how to
Instruction Manual 89
Editing Parameters
use them.
The Home button brings up the Alpha Toolbox run screen. Any others such as ,
and will send the user back one screen.
It is important to understand that the JSON files are specific to a controller area. If the Import button is clicked
while in the Jobs area the imported file must be a Jobs.json file. If a different file, such as an IO.json file, 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 file.
They contain the parameters from the active area only. They cannot be used in the Restore function.
When the parameter is clicked once the screen is selected for editing and the background for the value box turns white.
When finished entering the value press the computer’s Enter or Tab keys to set the value. The “Save Changes” dialog box
opens. Click Apply to save the changes to the controller. Click Cancel to discard the changes.
4.3.1.1.1 Parameters
Parameters for areas of the controller or the whole controller can be retrieved in separate files. The Export button
is explained above for retrieving parameters from the areas of the controller. This section explains a complete
backup of the controller’s parameters.
Click on the Setup>Full Backup / Restore menu from the Home screen in Alpha Toolbox.
Click on the Backup menu. The params.json file is immediately transferred to the computer. Be sure to understand
the browser setting to know where the file is saved.
Click on the Rundowns menu. The rundowns.csv file is immediately transferred to the computer. Be sure to
understand the browser setting to know where the file is saved.
The CSV file has headings for all of the columns that are obvious with the exception of column A “ID” and column
G “SOC”.
The ID column header will have numbers in front of the words ID. The syntax is n:Next_Rundown_Number[space]
ID. The column contains unique numbers for each fastening cycle. When the controller is defaulted this value
starts at 0 and runs to 4 billion before starting at 0 again.
Instruction Manual 91
Trace Data
SOC is short for Shutoff Code. This column will contain numbers representing the reason the tool shutoff. Here
are the values for the numbers, see section “2.7.7.2 Shutoff Codes” on page 19 for a description:
1 = ”TORQUE” 2 = ”ANGLE”
3 = ”TORQUE/ ANGLE” 4 = ”CURRENT”
5 = ”TORQUE BAILOUT” 6 = ANGLE BAILOUT”
7 = ”MINIMUM TORQUE BAILOUT” 16 = ”RATE MONITOR”
32 = ”YIELD MONITOR” 128 = "TIME"
129 = "STOP" 130 = ">115%"
131 = "FAULT" 132 = "STALL"
133 = "CAN" 134 = "SYNC"
135 = "T1≠T2" 136 = "TD"
137 = "YIELD" 138 = "[T]"
139 = “Rate” 140 = “I”
141 = “A1≠A2
This same file can be saved to a USB memory stick from the controller’s USB port.
A list of rundowns appears on the left. Click on the rundown that corresponds to the trace to be retrieved. The
selected rundown turns blue.
Click on the Export button and the trace#.csv file will download to the computer. Be sure to understand the
browser setting to know where the file is saved. The file will be numbered (#) with the unique rundown ID
4.4.1.1.1 Rundowns
There is a trace file for each fastening cycle. Each fastening cycles is represented by a controller run screen with
a miniature trace box. The trace box contains an actual representation of the trace for the fastening cycle. The
trace in the box will change depending on the values chosen for the X, Y1 and Y2 axes. See section “2.7 Display”
on page 15 for a description on the other elements of the run screen.
The run screen background can be green, red or blue. Green indicates 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 the fastening cycle. The trace will draw on the right
of the Trace screen. If the top most fastening cycle is selected any new fastening cycle will pop into the top of the
list and be selected automatically. If a different fastening cycle is selected any new fastening cycle will pop into
the top of the list but will not be selected automatically.
Click on the miniature trace box to lock the trace for viewing. More than 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.
Selected and locked fastening cycles will move down the list as new ones come into the list. Use the scroll bar to
view or unlock older traces.
4.4.1.1.2 Information
Click on the Information button to display information about the selected fastening cycle. The left side of the
Trace screen will change to display this information.
Instruction Manual 93
Trace Data
Time – The time in milliseconds the point occurred in the fastening cycle from start.
Torque – The torque achieved at the mouse hover point.
Angle – The angle achieved at the mouse hover point.
Speed Command – The commanded speed at the mouse hover point.
Speed – The actual tool speed achieved at the mouse hover point.
Bus Voltage – The actual DC Bus voltage achieved at the mouse hover point.
Current Command – The commanded current at the mouse hover point.
Current – The actual tool current achieved at the mouse hover point.
Torque Rate – The actual torque rate achieved at the mouse hover point. This values is derived by using the
Torque Rate algorithm associated with the parameters Torque Average (ms) and Angle Interval.
4.4.1.1.4 Print
Clicking the Print button will open the printer dialog. This window allows the user to modify printer parameters
and displays what is to be printed. The currently selected Y axis values are printed separately in their 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 the selected trace it
exports as a comma seperated value file. If POPULATION is selected the appropriate number of traces are placed
into a zip file before exporting.
The exported trace file is a comma separated values file and contains four sections. They are the identifier section,
the step values sections, the trace values section and the events section.
The identifier section repeats some of the same information from the fastening cycle record so it can be correlated
with the trace file. This information is displayed when the Information button is clicked.
The step values section provides the torque, angle and current values for each step in the fastening cycle. The
fastening cycle file has only the audit step for each record. If the values for each individual step are required this
is the place from which to parse the information.
The trace values section provides the captured X and Y axes information to draw the graph.
The events section marks the time at which the events occur so they can be entered on the graph.
Instruction Manual 95
Trace Data
4.4.1.1.6 Import
Click the Import button to import a saved trace file for analysis. The file is placed at the top of the fastening cycle
list and be treated as if it were just received from the controller. It will travel down there list as new fastening
cycles are received. When the user navigates away from the Trace screen the imported files are removed from
the list.
4.4.1.2 Graph
1/20/15, 3:08 PM
1.2
0.8
0.6
0.4
0.2
NM vs deg
-1,000 -500 0 500 1,000
-0.2
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. The Angle value is not available if the X axis has Angle selected.
http://10.114.17.44/pages/print-trace.html Page 1 of 1
Preset Selector
Event
Event
Angle Window
The Y axes field selectors are at the top of each axis. The X axis field selector is at the bottom center of the screen.
An axes presets selector is at the top center of the screen.
Data for the trace is collected every millisecond from start to finish of the fastening cycle. Once the number of data
points exceeds ~2000 the graph is automatically scaled between event points for graph and file manageability
while ensuring a high resolution around the event 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 Master Detail icon arrow in the bottom right corner of the screen allows the user to zoon in on a graph.
Instruction Manual 97
Trace Data
Slide the left arrow bubble to the right or the right arrow bubble to the left to change the screen zoom. The graph
window will follow and display only the area indicated in white.
Hover the mouse over the zoomed, white to change the mouse cursor to four arrows. Click and drag the white
area to move the zoom to different areas of the 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.
4.4.2 Events
The dots on the graphs indicate events that occurred during the fastening cycle. Events are things such as
4.4.2.2.1 Overlay
Multiple fastening cycle graphs can be layered on top of one another. Click the Rundown button at the top of
the left window in the Trace screen. Click on the miniature trace box to lock the trace for viewing. More than
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 cycles will move down the list as new ones come into the list. Use the scroll bar to
view or unlock older traces.
Instruction Manual 99
Icons and Security
users to view the contents of the controller at any one time. There are icons on the bottom of the Alpha Toolbox
screen to indicate user status.
Locked
Unlocked
Wireless is Active
While viewing parameters in Alpha Toolbox the Locked icon will appear in the botom of the Screen. When 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.
These same icons and their behaviors are mimicked on the controller display so the local user can see when a
remote user is editing and vice versa.
5
Tool Operation
Display
Multiple Function Button
Start Trigger Switch
Tool Memory
Worklights
Tool Operation
Special Application Tools
Tool Specifications
5 QPM DC Electric Tools
This chapter promotes proper and safe use and gives guidance to owners, employers, supervisors and others
responsible for training and safe use by operators. DC electric tools from STANLEY Assembly Technologies are
intended for use in industrial threaded fastening or precision position and or adjustment applications only. Some
instructions may not apply to all tools. Please contact your STANLEY Sales Engineer for information or assistance
on STANLEY training for assembly tool operation.
Noise Level: A-weighted emission sound pressure level at the work station < 70dBA (ref 20μPa) as determined
according to ISO 15744-2002.
Vibration Level: Weighted root mean square acceleration value at the handle < 2.5 m/s2 as determined according
to ISO 8662.
STANLEY ASSEMBLY TECHNOLOGIES hereby declares the following sound and vibration emission levels as
required by the Machinery Directive 98/37/EC.
A-weighted emission sound pressure level at the work station LpA (ref 20µPa) 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/s².
* Operating conditions for all measurements: full rated speed, no load, rated supply voltage or pressure.
A-weighted emission sound power level LWA: not required, declared sound pressure emission levels are below
85dBA.
C-weighted peak emission sound pressure level LpCpeak: not applicable to these products.
Uncertainty KpA, KWA, KpCpeak: not relevant, declared levels are maximum values.
WARNING
To Avoid Injury:
This information is provided to assist in making rough estimates of sound and vibration exposure levels in
the workplace. The declared emission values were obtained by laboratory type testing in accordance with the
stated standards. Levels measured in individual workplaces may be higher.
The actual exposure levels and risk of harm experienced by an individual user depends upon the work
piece, workstation design, duration of exposure, and the physical condition and work habits of the user. To
help prevent physical impairment, a program of health surveillance is highly recommended to detect early
symptoms which may relate to sound and/or vibration exposure, such that appropriate preventive measures
may be taken.
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, numbness or
blanching of the fingers.
• Wear vibration damping gloves if it can be determined that they reduce the risk of vibration disorders without
introducing other hazards.
CAUTION
• Inspect square drives and detent pins prior to use. Missing or damaged items should be replaced before use.
To ensure superior performance and safe operation, use the STANLEY cables specifically designed to operate
these tools.
Never use a tool with a damaged cable. Never abuse a cable, carry a tool by its cable or pull a cable to disconnect
it. Also, keep the cord away from heat, sharp edges, or moving parts.
Use cables of appropriate length (60M maximum) for each application; position and or suspend them in such a
way as to prevent tripping and cable damage, and to provide good work area maneuverability.
Odometer Counter Records the total number of fastening cycle the tool has completed during its
lifetime.
Trip Counter Records the number of fastening cycles the tool completed since the last reset to
zero.
PM Counter Records the number of fastening cycles the tool completed since the last reset to
zero. Interacts with PM Threshold.
PM Threshold A static value set by the 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.
6 3
5
7
5.2.4 Tool Status Lights
Handheld tools from STANLEY ASSEMBLY TECHNOLOGIES have three (green, yellow, and red) status lights. The
status light mirror or copy the status lights on the controller.
Green Tightened to specified limits The Fastening cycle meets all of the specified parameters.
The Fastening cycle was rejected for not achieving either low
Yellow Low torque or angle
torque or low angle.
The Fastening cycle was rejected for exceeding either high torque
Red High torque or angle
or high angle.
The next time the start trigger is engaged the tool will remove the
All lights Reverse
fastener.
5.2.6 Worklights
There are two worklights located above the MFB, below the motor on pistol type tools, but is opposite the start
trigger switch on standard tools. The worklights are activated when the trigger switch is depressed, and will
automatically turn off after the programmed amount of seconds after the trigger switch is released. If the trigger
switch remains depressed, the worklights will remain on.
! NOTE: The worklights are for lighting the immediate work surface and are not intended to be used as a flashlight.
Clockwise is the normal direction for securing a fastener, however a fastener can have left hand threads which
requires the tool’s output to turn counter-clockwise to secure the fastener. The direction of rotation to secure a
fastener is programmed in the controller.
If a reverse, or disassembly, operation is required the operator must press the MFB to change the tool’s mode to
reverse. Then the start trigger switch is pressed to run the tool in reverse. While the tool is in reverse mode, the
blue disassembly ready light [1] will illuminate if the tool is ready to run, all the tool’s display status lights [3] and
[6] will flash and the tool’s noise maker will emit a tone that alternates between on and off.
To return the direction of rotation to forward, or assembly, the operator must press the MFB again. The blue
assembly ready light [2] will illuminate if the tool is ready to run, the tool’s status lights will no longer flash and
the alternating tone will stop.
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’s MFB.
Exposed gear socket tools are designed to fit into tight spaces where other tools do not fit. These tools have
exposed gears or ratchet teeth. It is recommended to use the MFB ARMING feature for these types of tools.
Controller Connections
6 Power Cord
Tool Connector
USB Connector
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
Power Cord
6 Alpha Controller Connections
Each Alpha Controller has a different combination of connectors. These connectors serve several purposes, such
as:
• Power
• Tool Connections
• Discrete inputs and outputs
• Communications ports
• Fieldbus ports
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 in the normal
position.
The barcode input monitors inter-character timing. When there is a 500 msec gap between characters, a complete
barcode is assumed. When received, the controller logs it with all fastening cycles until another barcode is received
or until the controller power is cycled. If the incoming barcode is longer than 32 characters, then the last 32
characters received are used.
The following virtual ports are used for the various protocols of the controller:
Listen/ Internet
Port Use Description
Transmit Protocol
Browser access to the embedded web server for
80 HTTP Listen/transmit TCP/IP
configuration and analysis; browser can use port proxy.
502 ModbusTCP Listen/transmit TCP/IP ModbusTCP I/O traffic
4545 OPEN Listen/transmit TCP/IP OPEN protocol traffic; port is assignable by end user.
XML
4700 Listen TCP/IP XML commands to controller; port is assignable by end user.
Command
4710 XML Result Transmit TCP/IP XML response from controller; port is assignable by end user.
6575 Toolsnet Listen/Transmit TCP/IP Toolsnet protocol traffic; port is assignable by end user.
≥10000 PFCS Listen/Transmit TCP/IP PFCS messaging traffic in Chrysler facilities
1 Drain
2 V+
3 V-
4 CAN H
5 CAN L
Alpha Controllers Mini DeviceNet™
Connector
1 Drain
2 V+
3 V-
4 CAN H
5 CAN L
Alpha Controllers Micro DeviceNet™
Connector
Max 5 30 11 30 30 30
24 volt
Min -3 ND 5 2 11 6
The Alpha controller has a MIL-C-26482 Series I plug connector with cable clamp and solder cup pins.
! NOTE: One I/O mating connector (P/N 21C104800) is included with each Alpha controller. Optional crimp style
mating connectors, crimp tools, round connector-to-terminal strip and pig-tail I/O cables are also available.
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
21C2020XX schematic
When the Alpha controller is used with fixtured tools, it must use a Remote Start/Stop/Reverse pendent to the
controller to provide basic switching control for the tool.
Pin descriptions are shown in the following table:
Pin # Description PLC Address Pin # Description PLC Address
Schematics of the Inputs, Outputs and other pins, with cabling, are shown below:
DISABLE TOOL Disable tool (will complete running if it is in cycle) Contact Type , Spindle
JOB VERIFY Verify the selected job to the inputs Contact Type, Job, Spindle
JOB VERIFY (BIT) Verify the selected job to one of the input bits in a series Contact Type, Bit, Mode, Spindle
RESET RESULT STATUS Clear the result status Contact Type , Spindle
SET ZERO POSITION Used to set Zero Position for Position Control Strategy Contact Type, Spindle
START REVERSE Put the tool in reverse and start the tool Contact Type , Spindle
TASK VERIFY Verify the selected task to the inputs Contact Type, Task, Spindle
Verify the selected task to one of the input bits in a
TASK VERIFY (BIT) Contact Type, Bit, Mode, Spindle
series
* Input not available on 24V
ANGLE HIGH Fastening cycle Angle exceeded High limit Contact Type, Type, Time, Step, Spindle
ANGLE LOW Fastening cycle Angle under Low limit Contact Type, Type, Time, Step, Spindle
ANGLE OK Fastening cycle Angle was within limits Contact Type, Type, Time, Step, Spindle
*ANGLE STATUS Angle status of last fastening cycle Data Type, Step, OK, Low, High, Spindle
CYCLE ABORTED The fastening cycle was aborted/stopped Contact Type, Type, Time, Spindle
CYCLE NOK Fastening cycle was NOK Contact Type, Type, Time, Spindle
CYCLE STOPPED Shut off code is STOP Contact Type, Time, Spindle
DISASSEMBLY DETECTED A tightened fastener removed has been loosened Contact Type, Type, Time, Spindle
IN REVERSE The tool mode is Reverse Contact Type, Type, Time, Spindle
JOB COMPLETE Job complete (all bolts in job are OK) Contact Type, Type, Time, Job, Spindle
JOB SELECTED Indicates a specific job is selected Contact Type, Type, Time, Job, Spindle
JOB SELECTED (BIT) A bit to indicate the selected job in a series of bits Contact Type, Bit, Mode, Spindle
MULTI-FUNCTION
Shows the state of the multifunction button Contact Type, Type, Time, Spindle
BUTTON
NOT USED Output is not in use None
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 STATUS Overall status of last fastening cycle Data Type, OK, NOK, Spindle
*RUNDOWN UNITS Torque Units of last fastening cycle Data Type, Spindle
SNUG ACHIEVED Is set when Snug torque exceeded Contact Type, Type, Time, Spindle
START TRIGGER Shows the state of the tool trigger Contact Type, Type, Time, Spindle
STEP BIT Indicates last step of fastening cycle in a series of bits Contact Type, Bit, Mode, Spindle
TASK COMPLETE Task complete (all bolts in task are OK) Contact Type, Type, Time, Task, Spindle
TASK SELECTED Indicates a specific task is selected Contact Type, Type, Time, Task, Spindle
TASK SELECTED (BIT) A bit to indicate the selected task in a series of bits Contact Type, Bit, Mode, Spindle
TOOL RUNNING The tool is running Contact Type, Type, Time, Spindle
TORQUE HIGH Fastening cycle Torque exceeded High limit Contact Type, Type, Time, Step, Spindle
TORQUE LOW Fastening cycle Torque under Low limit Contact Type, Type, Time, Step, Spindle
TORQUE OK Fastening cycle Torque was within limits Contact Type, Type, Time, Step, Spindle
TORQUE STATUS Torque status of last fastening cycle Data Type, Step, OK, Low, High, Spindle
CURRENT 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.
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 functions, see
REVERSE START.
When removed, from any input type, the controller places the tool into Forward (assembly) mode.
REVERSE Size: 1 bit
Configuration:
Contact Type: Normally Open (N.O.), Normally Closed (N.C.)
Spindle: Type the spindle number for the tool to be put into reverse.
When asserted, on any input type, the controller makes this input’s Job the active Job.
When removed either nothing happens or if “Disable when open” is set to yes, then the tool becomes disabled.
Size: 1 bit
Configuration:
Contact Type: Normally Open (N.O.), Normally Closed (N.C.)
SELECT JOB
Job: Type the job number to select when this input is asserted.
Disable when open:
Yes – Disables the tool when this input is removed.
No – Does not disable the tool upon input removal.
Spindle: Spindle: Type the spindle number in which the job is to be selected.
Bit Number 4 3 2 1 0
Weighted
16 8 4 2 1
Value
Binary
1 0 1 0 1
Number
SELECT TASK 24V DC Pins
(BIT) R P N M L
(example)
To select task #21 on the controller 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:
Contact Type: Normally Open (N.O.), Normally Closed (N.C.)
Bit: Type the number of this bit, in the binary number scheme, to select tasks.
Mode: All TASK SELECT 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.
Spindle: Spindle: Type the spindle number in which the task is to be selected.
When asserted, on any Input type, the Zero Position for the tool is set. This Zero Position is used in the Position
Control strategy to stop the tool at the Zero Position after meeting the Snug Torque value.
Size: 1 bit
SET ZERO
POSITION Configuration:
Contact Type: Normally Open (N.O.), Normally Closed (N.C.)
Spindle: Type the spindle number in which the Zero Positions is to be set.
7
Embedded PLC
Rack Layout
Supported Instructions and File Types
PLC Editor
Converting a RSS File
“Rack” Layout
7 Embedded PLC
Each Alpha Controller has an internal software PLC. This PLC serves to enhance the integration of the Alpha
controller into an end user’s plant. The PLC emulates the Allen Bradley SLC-504 controller and uses many of the
same layouts, addressing structures and commands. Alpha Toolbox has a PLC editor but RSLogix500 can also be
used to program ladder logic for the embedded PLC.
The 24V DC I/O Module in slot 0 reflects the physical I/O on the Alpha.
The 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 Alpha. The optional DeviceNet Scanner card in slot #3 can be
configured to auto-map the devices connected to it. This card uses the M-5 DeviceNet connector on the bottom
of the Alpha if this option is ordered.
O0 OUTPUT
I1 INPUT
B3 BINARY
T4 TIMER
C5 COUNTER
R6 CONTROL
N7 INTEGER
ST14 STRING
Instructions Description
Absolute
ABS
Calculates the absolute value of the source and places the result in the destination.
The Add Branch button adds a branch to the rung or around an instruction.
The List of Instruction buttons add the instruction to the ladder logic. Use the mouse to click, hold and drag the
instruction to the desired spot on the ladder. When an instruction 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.
Integers are stored in N7:X files and must be a Decimal number in the range from 32767 to -32768. Strings are
stored in ST14:X files and their values must be ASCII characters. Maximum string length is 80 characters plus a
carriage return and line feed (CRLF). When string files are written they are displayed in capital letters, but if they
were writen in lower case they will be stored in lower case.
The Add Rung button adds another rung to the bottom of the ladder.
Zoom In and Out allows the user to adjust the size of the view.
To move a rung, select the rung by clicking it with 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 all items on the ladder. Select the item by clicking it with the mouse and
then click the Add Description icon. Type in a description and click the green check icon to save it or the red X
icon to discard it.
While editing the ladder the Save or Cancel dialog box appears. Press the Apply button to save the changes.
Press the Cancel button to discard the changes. When adding Initialization Files the window must first be saved
by clicking Apply and then the ladder logic must be saved by clicking Apply again.
Clicking a field will select the box and open its value edit window along with showing the Delete and Add
Description icons.
Type the required values for the field and press the Enter key on the computer’s keyboard. This saves the field
value in the box. Click on Apply in the Save or Cancel dialog window to save the ladder logic.
Paste the information into a text editor. RSLogix500 adds characters to certain addresses which are carried over
to the paste operation. The Alpha controller does not support these added characters. They must be removed
or converted to the appropriate address 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 file using the .json extension and choose “All Files” under Save as type in the Save window.
To provide a version, put another JSON parameter tag after the logic or name tag and before the ending brackets.
The new tag is”702”: “VERSION”. There is a 15 character limit to this parameter.
8
Multiple Spindle
Connection
Disconnect
Synchronization
Networking
Connection
8 Multi-Spindle
Expert Alpha controllers can be managers (leaders) to twenty-three other Advanced or Node Alpha controllers or
QPM Cordless tools (if the Expert is a wireless version). An Ethernet cable connection between them creates a
multiple spindle system. The Expert manages all I/O connections and ladder logic for the multiple spindle system.
8.1 Connection
The lead and trailing controllers are connected via a standard Ethernet cable to their Ethernet ports, or via IEEE
802.11b/g/n for a QPM Cordless Tool. They must follow all the same addressing requirements on this Spindle
Network that a standard Ethernet network requires. The Ethernet cable can be connected at any time. However,
no communication will happen until the IP Addresses are entered into each of the controllers connected.
For QPM Cordess Tools follow the pairing instructions in the QPM Cordless Tool manual 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 acknowledge the addition. The lead
controller will display the Add New Spindle dialog box. Select the spindle number for the added controller. Before
acknowledgement the trailing controller trying to connect will:
• flash the red, green and yellow status lights on the controller and the tool
• flash the QPM light on the face of the controller and
• display the Identify Spindle message window.
Press the Yes interactive menu button to accept the new spindle connection. Press the No interactive menu
button to decline the new spindle connection. After connection the lead spindle will add the new spindle as a tab
on the run screen. It will also add and select the ALL tab to show both spindles’ run screen on the lead controller.
See section “2.7 Display” on page 15 for a description of the elements on the run screen.
Each spindle must be programmed individually. The ony way to copy programming from one spindle to another
is to Export a Jobs file from one controller and Import it to another. To program the spindles from the keypad
press the right or left arrow keys to select the desired spindle tab and program as normal. See section “3
Programming” on page 26.
The All tab provides the SETUP interactive menu button. The User, Regional and Clock settings for all controllers
move here. These settings are global for all controllers in the multiple spindle systems. On connection, or
when they are changed, the lead controller’s users and passwords 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. If the trailing spindle gets disconnected
then reconnected there is no need to acknowledge the connection again. However, if a trailing controller is
removed (fforgotten) and a different controller is attached the different controller must then be acknowledged
before it is added to the system. If a trailing controller is offline or disconnected the spindle’s tab on the lead
controller’s display will turn red. The lost spindle’s display on Alpha Toolbox will turn red as well. When the
spindle comes back online the red will turn to the normal color.
Use the right arrow to select the tab with the disconnected spindle. The color change to red and blue from the
normal grey and black make it obvious that the trailing spindle is not connected.
The lead controller’s QPM logo will blink if it had a trailing controller connected and the trailing controller goes
offline or is disconnected.
The trailing controller’s QPM logo will blink if it has a value in the Master IP Address parameter and is not
connected to a controller with the specified IP Address.
Forget the trailing spindle to stop the logo from blinking on the lead controller. Delete any values in the Master
IP Address in the trailing controller to stop the logo from blinking. See section “8.2 Disconnect” on page 172.
8.2 Disconnect
When the multiple spindle mode is no longer required remove the Ethernet cable between the two controllers.
On the lead spindle navigate to the trailing spindle tab by pressing the right arrow while on the run screen. The
disconnected spindle run screen is red. Press the FORGET interactive 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 fastening situations require that two or more fasteners are secured simultaneously which even out the
distributed clamp loads on each of the fasteners in the assembly. In a tool control controller such as the Alpha,
this is known as synchronization. An Expert Alpha controller can synchronize its tool operation with other Alpha
controllers over the spindle network so that they start each step of a multi-step strategy at the same time. The
tools are synchronized so all spindles complete a given step before continuing on with the subsequent step(s).
When multiple Alpha controllers are synchronized, the tool strategy parameters are the same for each. This
allows each fastener in the assembly to be driven to the final target in the same manner at a controlled pace. For
each step to be synchronized the Delay Between Steps parameter must be greater than zero for each controller.
8.3.1 Operation
The fixtured tools must be started with a remote start switch connected to the START input of the lead Alpha. The
lead controller will apply a start to the synchronized trailing spindles in the system.
When the remote start switch is depressed all tools will start. All tools will run the first step in the selected Job/
Task. Once each tool has completed the first step it will stop and wait for all tools to finish the step. If all tools
finished the step OK then all tools start the next step in the multi-step strategy. This process continues until all
steps are complete or any tool times out or is stopped or aborted.
All multi-step rules still apply in that the tool must meet the programmed OK window to move on to the next
step. If a tool fails a step it will stop which causes all other tools to stop immediately. Once they stop the In-Cycle
indicator on the run screen will go away and a SYNC shutoff code is indicated for all controllers except the one
that failed to complete a step OK. All tools will be stopped immediately if any single tool is stopped due to an
abort event.
When in synchronization mode any Reverse, Job Select, Task Select or PartID input from any of the synchronized
spindles will cause all spindles to react to 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 retry fastening cycles or to perform a recovery operation. The logic for
these recovery operations can become very complex especially if Error Proofing is enabled and the user wishes to
maintain equal bolt counts on the controllers.
It is important to understand that the START: ALL input cannot be used to start individual spindles for forward or
reverse operations if a spindle is disabled through the STOP command. Individual Starts, Stops and Reverses must
be applied to the spindles required to run in recovery operations.
8.4 Networking
WARNING
NETWORK INTERRUPTION
To Avoid Issues:
• Never connect an Alpha Toolbox port to a plant network.
• Never connect the SPINDLE port to a plant network.
The lead controller in a multiple spindle system can communicate to a plant network via the embedded protocols,
see section “3.1.3 COMMUNICATIONS Menu” on page 48. The lead controller will collect and transmit the
fastening cycle data after each fastening cycle from each controller in the system via the selected protocol.
Connecting the multiple spindle lead Expert controller to a facility network using the ETHERNET port. Use
customer’s supplied values and enter the IP Address, Subnet Mask and Gateway into the lead Expert controller.
9
Maintenance
Scheduled Maintenance
Diagnostics and Troubleshooting
Fault Guide
Message Guide
Parts List
Scheduled Maintenance
9 Maintenance
There are no user serviceable components within the QB Expert Alpha controller. That does not mean that there
are no maintenance requirements or actions to be taken to insure optimal performance of the controller.
WARNING
To Avoid Injury:
• Trained, qualified personnel should perform all repairs.
• Always wear eye protection when servicing equipment.
• Replace worn or damaged components and equipment that are unsuitable for safe operation immediately.
• Always test controller after repair or replacement of parts to assure they function properly. Never test a
partially assembled controller.
• Never modify the tool or controller electrical system.
• Never remove guards and safety devices.
• Always disconnect the tool before repairing the controller.
WARNING
To Avoid Injury:
• Unauthorized opening of equipment and improper repairs can result in loss of life or severe personal injury
as well as substantial property damage.
• Remove conductive 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 lists of
the installation, operation, and maintenance manual or drawings.
Tool Disabled:
System
Wait until the Wait until the
The controller is Initializing
controller has controller has
in the process of message on display
finished the boot finished the boot
booting when the operator
up process up process
pressed the tool’s
Tool Disabled start trigger
Continued Wait for the timer Tool Disabled: Wait for the timer
to reset. Cycle Lock-out to reset.
The Cycle Lock-out message on display
timer is active Change the Cycle when the operator Change the Cycle
Lock-out timer pressed the tool’s Lock-out timer
value. start trigger value.
Tool Disabled:
Reject Count
Exceeded message
Reject Count
Reset the Job on display when Reset the Job
Exceeded
the operator
pressed the tool’s
start trigger
Tool Disabled: Retrain operator on
Retrain operator on Internal PLC proper process to
Logic criteria insure the internal
proper process to message on display
not met for tool PLC logic is met.
insure the internal when the operator
operation
PLC logic is met pressed the tool’s Delete the PLC
start trigger program.
Users may order installation and repair parts directly from STANLEY, or their agents.
Device Description Item Number
Label, Warning, Pinch Point X5557
Tool Label, Warning, Reaction Point X5571
Label, Warning, Tubenut X5556
10 Appendix A
Torsion Compensation
Angle Validation
Torsion Factor
10 Torsion Compensation
10.1 Torsion Factor
For all STANLEY electric assembly tools, the angle information is based on the rotation of the resolver, which
is directly attached to the rotor. This information is used for motor commutation, and it also serves as an angle
encoder. The rotation of the tool output can be determined by dividing the rotor angle by the total gear ratio for
the tool.
All things can deflect when loaded. Just as a long steel bar attached to a socket to produce high torque will
deflect, likewise the gears within an assembly tool will deflect when subjected to the torque loads. In effect, the
gears act as a torsion spring between the rotor and the socket, and it is the deflection of this spring that can give
false angle data. In addition to the angular deflection within the gears of the tool, there can also be deflection of
the parts of the joint.
Whenever this deflection is present in the tool or the joint or the tool mounting device, the angle information
derived from the resolver will indicate a larger angle than the tool output actually rotates. This error is directly
proportional to the torque level. That is, the deflection at 40 NM will be twice that at 20 NM.
In a torque vs. angle curve of a fastening cycle, at the end when the torque reaches its maximum value, the
angle will also be at its maximum value. After shut off, as the torque falls to zero, the angle should remain at
its maximum value. But in the typical torque vs. angle curve, as the torque falls to zero, the angle also appears
to fall some amount. This is not because the fastener is being loosened. It is actually the resolver indicating that
the angular deflection of the gears is relaxing to the neutral position. In this case, the maximum angle indicated
at the maximum torque was incorrect. The resolver indicated more angle than the tool output actually rotated.
To correct for this slight error in angle data, the Alpha controller has a STANLEY-exclusive solution. The Torsion
Factor allows the user 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), 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, at 15 NM, the
controller will subtract 1.5 degrees from the angle reading for that sample. At 30 NM, the controller will subtract
three degrees for that sample.
The easiest way to determine the correct value for the Torsion Factor is to look at a torque vs. angle trace
with Torsion Factor set to zero. The amount of degrees that the socket appears to loosen after the maximum
torque, divided by that maximum torque is the Torsion Factor. For example, consider a torque vs. angle trace
that indicates a maximum torque of 40 NM, and the maximum angle at this torque of 50 degrees. But the angle
appears to loosen by four degrees as the torque drops to zero. The Torsion Factor can be determined by dividing
four degrees by 40 NM to arrive at a Torsion Factor of 0.1 degrees per NM. When this value is entered into the
Torsion Factor parameter, each angle reading will be corrected by this factor. When this factor is set correctly, any
torque vs. angle trace will now indicate no apparent loosening of the fastener as the torque drops to zero after
shut off; which is exactly as it should be.
11 Glossary
11 Glossary
Abort Timer The Fastening cycle aborts if the tool does not shutoff before this pre-selected time.
How fast the controller changes the speed of the tool from 0 (stopped) to the rated
Acceleration speed.
Controls the tone made from the handle of handheld QPM tools for accepted Fastening
Accept Tone cycles. Allows distinct tones for tools in adjacent workstations.
Allows Adaptive Tightening Control modes to be selected, so that consistent torque can
be maintained over a wide range of joints. Manual downshift should be used when:
ATC • High Prevailing Torques – Prevailing Torque > 20% of the Torque Set Point (TSP).
• High Starting Torque –Starting Torque > 20% of TSP.
The number of Fastening cycles required to be within specified limits to complete a
Batch Count batch. The Run display shows the batch count and number of complete Fastening cycles.
Disable: no downshift; Manual: Occurs at specified torque; ATC automatically adapts to
Downshift Mode the joint.
Once the tool reaches the Downshift Torque point, the controller changes the operating
Downshift Speed speed of the tool from the initial Tool Speed to the Downshift Speed.
The controller changes the operating speed of the tool from the initial Tool Speed to the
Downshift Torque Downshift Speed at the Downshift Torque level.
High Angle Anytime the peak angle recorded exceeds the High Angle, the Fastening cycle is recorded
as a reject for high angle, the high angle light (red) illuminates and the Fastening cycle is
given an overall status of NOK.
Anytime the peak torque recorded exceeds the High Torque, the Fastening cycle is
High Torque recorded as a reject for high torque, the high torque light (red) illuminates and the
Fastening cycle is given an overall status of NOK.
Anytime the peak angle recorded during the Angle Audit Step fails to reach the Low
Low Angle 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.
When the peak torque recorded fails to reach the Low Torque, the Fastening cycle is
Low Torque recorded as a reject for low torque, the low torque light (yellow) illuminates and the
Fastening cycle is given an overall status of NOK.
Controls the operation of the multiple-function panel (MFP) on QPM tools.
MFP Mode The choices for handheld tools are Disable, Reverse (Disassembly), Parameter Select,
Arming and Reset Reject. The default value is Disable.
Records the number of Fastening cycles completed since the last time it was reset for
PM Counter Planned Maintenance.
PM Limit When the PM Counter exceeds the PM Limit, the controller provides a maintenance alert.
A Parameter Set is a collection of instructions that define how the tool should perform
Parameter Set the tightening process. It may be selected from the keypad or 24V device such as a
socket tray.
Controls the tone made from the handle of handheld QPM tools for rejected Fastening
Reject Tone cycles. Allows distinct tones for tools in adjacent workstations.
Slow Seek helps engage the socket or fastener at a pre-selected speed, torque level and
angular rotation. Once engaged, the Fastening cycle completes at a higher speed. Slow
Slow Seek Seek prevents crossthreaded fasteners and previously secured fasteners from being
counted in a batch.
The controller begins to monitor the tool for angle at a preselected threshold torque. Any
Snug Torque increase in angle after the snug point results in a corresponding increase in the tension
or clamp load within the joint.
Soft stop minimizes the torque impulse to the operator during tool shutoff at the end of
Soft Stop the Fastening cycle.
Thread Direction Sets assembly direction to clockwise (CW) or counter clockwise (CCW).
Sets the point at which the tool is "In Cycle". When the tool is "In Cycle" the tool and
Threshold Torque controller Fastening cycle status lights turn off, the controller displays dashes (-) for data,
and the "In Cycle" output is turned on.
Tool Tones Distinctive sounds assigned to tool functions.
Determines how torque values are assigned to the electrical signals from the torque
Torque Calibration transducer on the tool. This value is unique to each tool and changes over time.
When the tool is being controlled for torque, the torque target instructs the controller
Torque Target 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.
Records the number of Fastening cycles completed since the last time it was reset. It is
Trip Counter usually used as a supplementary count of the PM Counter.
The following torque units and associated labels are used with STANLEY controllers and
tools. The labels are derived from SP811, SI Unit rules and style conventions from the
National Institute of Standards and Technology
12 Limited Warranty
! NOTE: An RMA can be given without a purchase order. However, non-warranty repairs cannot be performed until
a written purchase order or credit card authorization is received.
Have the following information available for the person answering the telephone to obtain an RMA:
• Company name and address.
• A contact name and telephone number. If possible, have facsimile and pager numbers (if any) available.
• The STANLEY model number, serial number, and description for the item
• A short description of the problem.