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Instruction Manual

QB Expert Alpha Controller


Software Version 5.2.8

English - Original Document - Revision C


© 2016 STANLEY Black and Decker, Inc. All rights reserved.
Table of Contents

1 Getting Started �����������������������������������������������������������������������2

1.1 What’s Included ������������������������������������������������������������������������������ 2

1.2 Controller Functions and Connections ���������������������������������������������� 4

1.3 CE Directives (Europe) �������������������������������������������������������������������� 4


1.3.1 Machinery Directive Compliance �������������������������������������������������������4
1.3.2 RoHS Compliance ��������������������������������������������������������������������������������5
1.3.3 WEEE Compliance ��������������������������������������������������������������������������������5
1.4 Regulatory Notices for Radio Transmitter ���������������������������������������������� 5
1.4.1 FCC Notice (USA) ��������������������������������������������������������������������������������5
1.4.2 Canadian Compliance Notice ��������������������������������������������������������������������5
1.4.3 CE Notice (Europe) ��������������������������������������������������������������������������������6
1.5 Safety ���������������������������������������������������������������������������������������������������� 6
1.5.1 Warnings and Cautions ��������������������������������������������������������������������������������6
1.5.2 General Power Tool Safety Warnings �������������������������������������������������������8
1.5.3 Safety Instructions for QB Expert Alpha Controllers ����������������������������� 10
1.6 Specifications
����������������������������������������������������������������������������������������� 11
1.6.1 Physical and Environmental Ratings ����������������������������������������������������� 11
1.6.2 Electric Service Ratings ������������������������������������������������������������������������������ 11
1.6.3 E-Stop Precaution ������������������������������������������������������������������������������ 11
1.6.4 Tool Speed and Torque Scatter Versus Electric Supply ����������������������������� 11
1.6.5 Tool Temperature Versus Electric Supply ����������������������������������������������������� 11
1.7 Installation Instructions ������������������������������������������������������������������� 12

2 QPM QB Expert Alpha Controller ������������������������������������ 18

2.1 Data Storage ����������������������������������������������������������������������������������������� 18

2.2 Input and Output Functions �������������������������������������������������������� 18

2.3 Software ����������������������������������������������������������������������������������������� 18

2.4 Embedded PLC ����������������������������������������������������������������������������� 18

2.5 Networking ����������������������������������������������������������������������������������������� 18

2.6 Navigation ����������������������������������������������������������������������������������������� 19

II
QB Expert Alpha Controller
Table of Contents

2.7 Display ����������������������������������������������������������������������������������������� 19


2.7.1 Scroll Bar ������������������������������������������������������������������������������������������� 19
2.7.2 Dropdown ������������������������������������������������������������������������������������������� 19
2.7.3 Menu Tree ������������������������������������������������������������������������������������������� 20
2.7.4 Tabs �������������������������������������������������������������������������������������������������������� 20
2.7.5 Character Scrollbar ������������������������������������������������������������������������������ 20
2.7.6 Run Display ������������������������������������������������������������������������������������������� 20
2.7.7 Fastening Cycle Log ������������������������������������������������������������������������������ 21
2.7.8 Keypad Mode ������������������������������������������������������������������������������������������� 24
2.7.9 Controller Display Icons ������������������������������������������������������������������������������ 24
2.8 Faults ��������������������������������������������������������������������������������������������������� 25

2.9 Messages ����������������������������������������������������������������������������������������� 26

3 Programming ���������������������������������������������������������������������30

3.1 SETUP Area ����������������������������������������������������������������������������������������� 30


3.1.1 JOBS: Wizard ������������������������������������������������������������������������������������������� 30
3.1.2 JOBS: Manual Programming ������������������������������������������������������������������ 37
3.1.3 COMMUNICATIONS Menu ������������������������������������������������������������������ 52
3.1.4 OTHER Menu �������������������������������������������������������������������������������������������66
3.1.5 RESTORE FACTORY DEFAULTS Menu ����������������������������������������������������� 74
3.2 SERVICE Area ����������������������������������������������������������������������������� 75
3.2.1 Tool �������������������������������������������������������������������������������������������������������� 75
3.2.2 Controller ������������������������������������������������������������������������������������������� 78
3.3 ANALYZE Area ����������������������������������������������������������������������������� 79
3.3.1 TOOL Tab ������������������������������������������������������������������������������������������� 79
3.3.2 TRACE Tab ������������������������������������������������������������������������������������������� 81
3.3.3 STATS Tab ������������������������������������������������������������������������������������������� 82
3.3.4 LOG Tab ������������������������������������������������������������������������������������������� 83
3.3.5 I/O Tab ��������������������������������������������������������������������������������������������������������84

4 Alpha Toolbox ���������������������������������������������������������������������88


4.1 Connection �����������������������������������������������������������������������������������������������������������������88

4.2 Controls
������������������������������������������������������������������������������������������������������������������������������88
4.2.1 Menus �������������������������������������������������������������������������������������������������������� 89
4.2.2 Navigation Buttons ������������������������������������������������������������������������������90
4.2.3 Import/ Export Buttons ������������������������������������������������������������������������������90

Instruction Manual III


Table of Contents

4.2.4 Manage Buttons ������������������������������������������������������������������������������90


4.3 Editing Parameters ����������������������������������������������������������������������������� 90
4.3.1 Parameter and Data Retrieval ������������������������������������������������������������������ 91
4.4 Trace Data ����������������������������������������������������������������������������������������� 92
4.4.1 Analyzing Traces ������������������������������������������������������������������������������ 93
4.4.2 Events ��������������������������������������������������������������������������������������������������������98
4.5 Icons and Security ����������������������������������������������������������������������������� 99

5 QPM DC Electric Tools ��������������������������������������������������104

5.1 Tool Specifications ��������������������������������������������������������������������������� 104


5.1.1 Operator Protection ���������������������������������������������������������������������������� 105
5.1.2 Repetitive Motion ���������������������������������������������������������������������������� 105
5.1.3 Hearing Protection ���������������������������������������������������������������������������� 105
5.1.4 Vibration ����������������������������������������������������������������������������������������� 106
5.1.5 Breathing Protection ���������������������������������������������������������������������������� 106
5.1.6 Tool Installation ����������������������������������������������������������������������������������������� 107
5.1.7 Sockets and Adapters ���������������������������������������������������������������������������� 107
5.1.8 Cable Installation ���������������������������������������������������������������������������� 108
5.2 QPM Tool Controls and Operation ������������������������������������������������������ 108
5.2.1 Start Trigger Switch ���������������������������������������������������������������������������� 108
5.2.2 Tool Memory ����������������������������������������������������������������������������������������� 108
5.2.3 Display and Multiple Function Button ��������������������������������������������������� 109
5.2.4 Tool Status Lights ���������������������������������������������������������������������������� 110
5.2.5 MFB Mode ����������������������������������������������������������������������������������������� 110
5.2.6 Worklights ����������������������������������������������������������������������������������������� 111
5.2.7 Program Selection ���������������������������������������������������������������������������� 111
5.2.8 Directional Control ���������������������������������������������������������������������������� 111
5.2.9 Tool Temperature ���������������������������������������������������������������������������� 111
5.2.10 Setting Torque, Angle, and Other Operating Parameter ��������������������������� 112
5.2.11 Assembly (Forward) Operation ���������������������������������������������������������������� 112
5.2.12 Disassembly (Reverse) Operation ��������������������������������������������������� 112
5.3 Special Application Tools ������������������������������������������������������������������ 112
5.3.1 Exposed Gear Socket Tools ���������������������������������������������������������������� 112
5.3.2 Tubenut Nutrunners ���������������������������������������������������������������������������� 113

6 Alpha Controller Connections ����������������������������������������� 118

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QB Expert Alpha Controller
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6.1 Power Cord ����������������������������������������������������������������������������������������118

6.2 Tool Connector ����������������������������������������������������������������������������118


6.2.1 EA, EB and EC Tools ���������������������������������������������������������������������������� 118
6.2.2 E Tools ������������������������������������������������������������������������������������������������������ 118
6.3 USB Connector ����������������������������������������������������������������������������118

6.4 Serial Connector ���������������������������������������������������������������������������� 119

6.5 Alpha Toolbox Ethernet Connector ������������������������������������������� 120

6.6 Facility/ Spindle Network Ethernet Connectors ��������������������������������� 120

6.7 Ethernet/IP or Profinet Connectors ��������������������������������������������121

6.8 Trailing DeviceNet™ Connector �������������������������������������������������������121

6.9 Profibus Connector ����������������������������������������������������������������������������121

6.10 Leading DeviceNet Connector ������������������������������������������������������ 122

6.11 Input and Output Connector ������������������������������������������������������ 122

6.12 Assignable Input and Output Functions ��������������������������������������������126


6.12.1 Input Descriptions ���������������������������������������������������������������������������� 129
6.12.2 Output Descriptions ���������������������������������������������������������������������������� 135
6.13 MODBUS TCP ��������������������������������������������������������������������������� 146
6.13.1 Example Map ����������������������������������������������������������������������������������������� 148

7 Embedded PLC ������������������������������������������������������������������� 152

7.1 “Rack” Layout ��������������������������������������������������������������������������� 152


7.1.1 Addressing Scheme ���������������������������������������������������������������������������� 152
7.2 Supported Instructions and File Types ������������������������������������������� 153

7.3 PLC Editor ��������������������������������������������������������������������������������������� 161


7.3.1 Edit Page Controls ���������������������������������������������������������������������������� 162
7.3.2 Instruction Box ����������������������������������������������������������������������������������������� 163
7.3.3 MON and MSG Instructions ���������������������������������������������������������������� 164
7.3.4 Applying a Name and Version ���������������������������������������������������������������� 164

Instruction Manual V
Table of Contents

7.4 Converting a RSS File ����������������������������������������������������������������� 164


7.4.1 Invalid Characters ���������������������������������������������������������������������������� 166
7.4.2 Predefining String or Integer Files ��������������������������������������������������� 166
7.4.3 Applying a Name and Version ���������������������������������������������������������������� 166

8 Multi-Spindle ������������������������������������������������������������������� 170

8.1 Connection ����������������������������������������������������������������������������������������170

8.2 Disconnect ��������������������������������������������������������������������������������������� 172

8.3 Synchronization ��������������������������������������������������������������������������� 172


8.3.1 Operation ����������������������������������������������������������������������������������������� 173
8.3.2 Recovery ����������������������������������������������������������������������������������������� 173
8.4 Networking ��������������������������������������������������������������������������������������� 173

8.5 Fastening Cycle Data ������������������������������������������������������������������174

9 Maintenance ������������������������������������������������������������������� 178

9.1 Scheduled Maintenance ����������������������������������������������������������������� 178

9.2 Diagnostics and Troubleshooting ������������������������������������������������������ 178


9.2.1 Fault Guide ����������������������������������������������������������������������������������������� 181
9.3 Message Guide ��������������������������������������������������������������������������� 189

9.4 Parts List ��������������������������������������������������������������������������������������� 192

10 Torsion Compensation �������������������������������������������������� 196

10.1 Torsion Factor ��������������������������������������������������������������������������� 196

10.2 Angle Validation ��������������������������������������������������������������������������� 196

11 Glossary ����������������������������������������������������������������������������200

12 Limited Warranty �����������������������������������������������������������204

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12.1 Mechanical Products Limited Warranty ������������������������������������������� 204

12.2 Electronic Products Limited Warranty ������������������������������������������� 204

12.3 Software Products Limited Warranty ������������������������������������������� 204

12.4 OEM Products Limited Warranty ������������������������������������������������������ 204

12.5 General Terms ��������������������������������������������������������������������������� 204

12.6 Specification Changes ����������������������������������������������������������������� 205

12.7 Warranty Claims ��������������������������������������������������������������������������� 205

12.8 Product Services ��������������������������������������������������������������������������� 205

12.9 Return Material Authorization (RMA) Procedures ���������������������� 205

Instruction Manual VII


QB Expert Alpha Controller

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.

1.1 What’s Included


Included with the QB Expert Alpha controller is a power cord, plinth (for mounting), documentation (in the
envelope) and a mating connector for the I/O port. The mating connector is included so the end user may connect
wires to the controller’s I/O port to their requirements.

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

2 QB Expert Alpha Controller


Introduction

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

See Description on next page

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.

1.3 CE Directives (Europe)


STANLEY Engineered Fastening Assembly Technologies declares that the QPM QB Expert Alpha controller
conforms to all the applicable regulations of the Machinery Directive. See the CE Declaration of Conformity that
is delivered with each QB Expert Alpha controller.

1.3.1 Machinery Directive Compliance


This product complies with the requirements of the European Machinery Directive (2006/42/EC). See the CE
Declaration of Conformity that is delivered with the product.

4 QB Expert Alpha Controller


Introduction
1.3.2 RoHS Compliance
This product and its information meets the requirements of the European Restriction of Hazardous Substances
(RoHS) Directive (2011/65/EU).

1.3.3 WEEE Compliance


This product and its information meets the requirements of the European Waste of Electrical and Electronic
Equipment (WEEE) Directive (2011/65/EU). This product is marked with a crossed trashcan, see last figure below
in section 1.5.1 Warnings and Cautions.

1.4 Regulatory Notices for Radio Transmitter


It is mandatory that national, state and local codes and standards be followed.

1.4.1 FCC Notice (USA)


This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) this
device may not cause harmful interference, and (2) this device must accept any interference received, including
interference that may cause undesired operation.
This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to Part
15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference
in a residential installation. This equipment generates, uses and can radiate radio frequency energy and, if not
installed and used in accordance with the instructions, may cause harmful interference to radio communications.
However, there is no guarantee that interference will not occur in a particular installation. If this equipment does
cause harmful interference to radio or television reception, which can be determined by turning the equipment
off and on, the user is encouraged to try to correct the interference by one or more of the following measures:
• reorient or relocate the receiving antenna,
• increase the separation between the equipment and receiver,
• connect the equipment into an outlet on a circuit different from that to which the receiver is connected, or
• consult the dealer or an experienced radio/TV technician for help.
This device contains transmitter module FCC ID: TE7WR702N.

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.

1.4.2 Canadian Compliance Notice


This device complies with Industry Canada license-exempt RSS standard(s). Operation is subject to the following
two conditions:
• This device may not cause interference, and
• This device must accept any interference, including interference that may cause undesired operation of the
device.
Cet appareil est conforme aux norms CNR exemptes de licence d’Industri Canada. Le
fonctionnement est soumis aux deux conditions suivantes:
• cet appareil ne doit pas provoquer d’interférences et

Instruction Manual 5
Safety
• cet appareil doit accepter toute interérence, y compris celles susceptibles de provoquer un fonctionnement non
souhaité de l”appareil.

1.4.2.1 Industry Canada Notice (Canada)


Complies with the Canadian ICES-003 Cleass B specifications.
Cet appareil numérique de la classe B est conforme à la norme NMB-003 du Canada.
This device complies with RSS 210 of Industry Canada. This device meets all the requirements of the Canadian
interference-causing equipment regulations.
Cet appareil numérique de la classe B respecte toutes les exigences du Règlement sur le
matériel brouilleur de Canada.

1.4.3 CE Notice (Europe)


This device has been tested and certified for use in the European Union. This product complies with the
requirements of the European Radio & Telecommunications Terminal Equipment (R&TTE) Directive (1999/5/EC).
The ‘CE’ mark has been placed on the device per the labeling requirements of the Directive.
Given that the operating frequency band is not harmonized by a few European countries, the restriction or
alert sign has been placed alongside the ‘CE’ mark as shown below. As of the date of this document, only
France has a restriction. The restriction is that, if the radio is operated outdoors in the 2450-2483.5 MHz
band, the power must be limited to 10 mW instead of 100 mW. This device is not intended for outdoor use.

1.5 Safety
1.5.1 Warnings and Cautions
The safety notices and warnings for protection against loss of life (the users or service personnel) or for 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.

6 QB Expert Alpha Controller


Introduction

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

! Indicates an item of special interest.

Indicates a pinch point hazard. This icon appears as a part of a DANGER, WARNING, or CAUTION
notice.

Indicates an open wrench pinch point hazard. This icon appears as a part of a DANGER, WARNING, or
CAUTION notice.

Indicates an environmental hazard. Do not throw equipment into the normal housekeeping refuse bin.

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.

8 QB Expert Alpha Controller


Introduction
WARNING
Continued:
e.) Do not overreach. Keep proper footing and balance at all times. This enables better control
fo the power tool in unexpected situations.
f.) Dress properly. Do not wear loose clothing or jewellery. Keep your hair, clothing and
gloves away from moving parts. Loose clothes jewellery or long hair can be caught in moving
parts.
g.) If devices are provided for the connection of dust extraction and collection facilities,
ensure these are connected and properly used. Use of dust collecton can reduce dust-related
hazards.
4. Power Too Use and Care
a.) Do not force the power tool. Use the correct power tool for your application. The correct
power tool will do the job better and safer at the rate for which it was designed.
b.) Do not use the power tool if the switch does not turn it on and off. Any power tool that
cannot be controlled with the switch is dangerous and must be repaired.
c.) Disconnect the plug from the power source and/ or the batatery pack from the power
tool before making any adjustments, changing accessories, or storing power tools. Such
preventive safety measures reduce the risk of starting the power tool accidentally.
d.) Store idle power tools out of the reach of children and do not allow persons unfamiliar
with the power tool or these instructions to operate the power tool. Power tools are
dangerous in the hands of untrained users.
e.) Maintain power tools. Chek for misalignment or binding of moving parts, breakage of
parts and any other condition that may affect the power tool’s operation. If damaged,
have the power tool repaired before use. Many accidents are caused by poorly maintained
power tools.
f.) Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting edges
are less likely to bind and are easier to control.
g.) Use the power tool, accessories and tool bits etc. in accordance with these instructions,
taking into account the working conditions and the work to be performed. Use of the power
tool for operations different from those intended could result in a hazardous situation.
5. Service
a.) Have your power tool serviced by a qualified repair person using only identical
replacement parts. This will ensure that the safety of the power tool is maintained.

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.

10 QB Expert Alpha Controller


Introduction
1.6 Specifications
1.6.1 Physical and Environmental Ratings
Width: 6.0 inches 152 mm
Dimensions: Height: 16.0 inches 406 mm
Depth: 10.4 inches 264 mm
Weight: 18 pounds 8.2 kgrams
Temperature: 32 to 122 ºF (0 to +50 ºC)
Operating Conditions:
Humidity: 0 to 95 % non-condensing
Ingress Protection Rating: IP54 NEMA 3

1.6.2 Electric Service Ratings


These are the minimum electric service ratings for the QB Expert Alpha controller and the tools it can control.
Tool Model: E02-E23 E33-E34 E44-E45 E55
EA23 EA33−EA34 EB44-EB45 EB55
EB02−EB22 EB33-EB34 EC44
EC02−EC22 EC33-EC34
100 − 126.5V AC 15 A 15 A 20 A * 30 A *
Current for Supply Voltage:
200 − 253V AC 10 A 10 A 10 A 10 A
Standby 0.2 A 0.2 A 0.2 A 0.2 A
Power Consumption:
Continuous 0.3 kVA 0.7 kVA 1.0kVA 2.2 kVA
* 200−240V AC highly recommended

1.6.3 E-Stop Precaution


WARNING
INTEGRATED E-STOP CIRCUIT NOT PRESENT
To Avoid Injury:
• When a QB Expert Alpha controller connects to a tool where a fault can result in personal injury or substantial
damage to property, an E-stop circuit is required. An E-stop circuit must be created in the external electrical
service supply line.

1.6.4 Tool Speed and Torque Scatter Versus Electric Supply


The minimum electric supply voltage required to attain catalog speeds is 104V AC or 208V AC depending which
supply voltage system is used. Supply voltages above these minimums should have NO effect on reducing speed.
Supply voltages BELOW these minimums will reduce maximum free speed proportionally; actual speed should be
the LOWER of the speed command or the maximum attainable speed. Slow Seek and downshift speeds should
not be affected unless they are set close to maximum attainable speed. Similarly torque scatter should NOT be
affected by reduced supply voltages.

1.6.5 Tool Temperature Versus Electric Supply


Supply voltages that remain within recommended limits during the fastening cycle will provide shortest cycle
times and lowest tool temperatures. Tool temperatures on applications with moderate to high prevailing torque
levels and/or low (i.e. soft) torque rates stand the most chance of being negatively impacted by low or “sagging”

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.

1.7 Installation Instructions


WARNING
ELECTRICAL HAZARD
To Avoid Injury:
• This product should be located away from heat sources such as radiators or other devices that produce heat.
• This product should not be subjected to vibration or shock or in close contact with water or other liquids.
• To minimize electrical interference, place the module as far away from possible sources of electrical noise,
such as arc welding equipment.
• Install tools and controllers in dry, indoor, non-flammable, and non-explosive environments only.
• Do not use this product near water, for example near a washbowl, wet basement, or the like.
• Avoid body contact with electrically energized surfaces when holding a grounded tool.

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.

12 QB Expert Alpha Controller


Introduction
6.06
[154]

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

Mounting QB Alpha Expert Controller onto Plinth

14 QB Expert Alpha Controller


Introduction

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.

2.1 Data Storage


Data associated with 30,000 fastening cycle results and 10,000 traces is stored in the QB Expert Alpha controller.
This data is retrieved with a USB memory stick or Alpha Toolbox. SPC analysis is performed by the QB Expert
Alpha controller on the stored data.

2.2 Input and Output Functions


Bolt Count or Error Proofing functions are an integral part of the QB Expert Alpha controller’s functions. Its eight
inputs and eight outputs on the 24V DC I/O connector support these functions to provide expert plant integration
to external devices such as a PLC.
The inputs and outputs are assignable, and configurable.
The QB Expert Alpha controller supports other bus types such as ModbusTCP, which is standard, plus optional
Ethernet/IP, Profibus, ProfiNet and DeviceNet. DeviceNet can be ordered as either a scanner or device.

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.

2.4 Embedded PLC


The QB Expert Alpha controller comes with a software PLC that emulates many commands and features of the
Allen Bradley SLC-500 series controller. Anyone with logic writing skills and the Alpha Toolbox PLC Editor can
program a logic file to add more versatility to the already abundant features of the QB Expert Alpha controller.

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.

18 QB Expert Alpha Controller


Controller Operation
For those that haven’t switched to this more robust means of collecting data, the QB Expert Alpha controller
supports the PFCS, OPEN and Toyota PI protocols over a serial connection.

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.

2.7.5 Character Scrollbar


This scrollbar enables adding: a-z, A-Z, 0-9, space, _, -, &, *, $, #, @, !, and a period (language and/or field
determines character availability). The up arrow [1] and down arrow [3] direct scrolling with the active character
[2] displayed between. Use the QB Expert Alpha controller’s up/down arrows to scroll through character choices.
The left arrow backspaces. The right arrow moves one position to the right to input the next character. Push
Toggle button or OK interactive menu button to accept entry.
The following screens contain the character scrollbar option: ALL, Job (Name), Task (Name) Step (Name), System
(Name General), System (Users), WIFI (SSID, Password).

2.7.6 Run Display


The Run screen displays normal operating information one spindle at a time. To display a different spindle on a
multiple spindle unit press the right or left arrow key to switch to the next spindle tab.

1 10 6 7

2 4
8 3
11
9

20 QB Expert Alpha Controller


Controller Operation

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.

2.7.7 Fastening Cycle Log


Press the interactive MANAGE button after selecting a data line to display the MANAGE dialog box.

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.

Press again to save the file to the USB memory stick.

Press the interactive EXIT button to return to the Run screen.

2.7.7.1 Fastening Cycle Details


Press the interactive DETAILS button or the Toggle button after selecting a data line
to display the details.
Details about the event and when it occurred are listed.
Rundown ID: The sequential number of the fastening cycle data
Date: The date the fastening cycle was ran.
Time: The time the fastening cycle completed.
Job: The active Job number in which the fastening cycle ran.
Task: The active Task number in which the fastening cycle ran.
Status: The overal status of the fastening cycle.

Not all items are shown


22 QB Expert Alpha Controller
Controller Operation
SOC: Shutoff Code, see section “2.7.7.2 Shutoff Codes” on page 23
Job Count: The active fastener number for the Job.
Task Count: The active fastener number for the Task.
Tool Model: The model number of the tool used during this fastening cycle.
Tool Serial: The serial number of the tool used during this fastening cycle.
Tool
The temperature of the tool at shutoff.
Temperature:
Part ID: The value in the Part ID buffer when the fastening cycle ran.
Steps: List the steps used during the fastening cycle. The Audit step
values are in Bold.
TC/AM The Strategy or Smart Step used in the current step.
Torque: The Torque value achieved in the current step.
Angle The Angle value achieved in the current step.
Current The Current value achieved in the current step.
Rate The Rate value achieved in the current step (if enabled)
Deviation The Rate Deviation achieved in the current step (if enabled)

Use the up/down arrows to scroll through the Details.


Press the interactive BACK button to return to the Fastening Cycle Log.

2.7.7.2 Shutoff Codes


Shutoff Codes on the display indicate why a fastening cycle terminates prior to completion.
Shutoff Code Description
TIME Fastening cycle time exceeds programmed Cycle Abort time value.
STOP Spindle stopped by either the operator or other device.
>115% Spindle stopped due to torque achieving greater than 115% torque limit for the tool.
FAULT The tool shutoff due to a Fault. See section “2.8 Faults” on page 25.
STALL Spindle stopped due to a stall.
SYNC Spindle failed fastening cycle due to a synchronization error.
T1≠T2 Primary and secondary redundant transducer values are outside comparative limits.
A1≠A2 Primary and secondary redundant angle values are outside comparative limits.
TD Spindle stopped due to torque dropping below Torque Drop Threshold
YIELD Spindle stopped due to bailout on detecting yield during an Angle Control strategy.
[T] A torque/angle window violation for the Torque Monitoring portion of the fastening cycle.
Torque Rate has exceeded the High Limit or not achieved the Low Limit during a Rate
RATE
Monitoring portion of the fastening cycle.
I Current has exceeded the High Current Limit or not achieved the Low Current Limit.

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.

2.7.8 Keypad Mode


When Keypad Mode is set to Job or Task Select (see “3.1.4.1 General Tab” on page 60) at the run screen press
the Toggle button or a number on the keypad. A Job/Task window opens. Use the numbers on the keypad to
type in a Job/Task to be selected to run. Use the toggle or interactive OK button to accept and switch controller
operation to the selected Job/Task number.
When the Keypad Mode is set to PART ID (see “3.1.4.1 General Tab” on page 60) at the run screen press the
Toggle button or a number on the keypad. A PART ID window opens. Use the up/down arrows to write a character,
then the right arrow to move to the next character value to use as the PART ID. The numeric keypad may also be
used to write numbers as PART ID. Press the OK interactive menu button to save it. The limit is 32 characters.

2.7.9 Controller Display Icons


The QB Expert Alpha Controller has Icons in the upper left corner of the screen to indicate the following:
Icon Status Description
Locked A password is required to make edits.
Unlocked Edits are possible, automatically re-locks in time.
Busy/working Wait for icon to clear before continuing.

24 QB Expert Alpha Controller


Controller Operation
Icon Status Description
Fault; system not operable Check the run screen for Fault message.
A user is editing the parameters in the controller
Remote User
remotely, i.e. through Alpha Toolbox.
The controller is connected to an AUDI XML protocol
Audi Command Port Connected
server on the Command port.
The controller is connected to an AUDI XML protocol
Audi Results Port Connected
server on the Results port.
The controller is connected to a PFCS protocol server on
PFCS Solicited Port Connected
the Solicited port.
The controller is connected to a PFCS protocol server on
PFCS Un-Solicited Port Connected
the Un-Solicited port.
OPEN Connected The controller is connected to an OPEN protocol server.
Toolsnet Connected The controller is connected to a Toolsnet protocol server.
ToytotaPI Connected The controller is connected to a ToyotaPI protocol server.

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.

Here is a list of the Faults in the QB Expert Alpha controller:


Total Current – the controller software limits the current applied to any tool
Overcurrent Fault! based on what the tool can handle. This fault is asserted if the total current
applied is greater than allowed.
The Ground Fault Interrupter has exceeded its current trip point. A current
detector monitors the current through the three phases of the motor and asserts
GFI Fault! this fault when the total current applied to the tool does not equal the total
current returned from the tool. All phases are turned off immediately to protect
the controller from shorts at the tool end.
The controller monitors the +5VDC, -5VDC and +12VDC of its onboard Power
Logic Voltage Fault!
Supply. This fault is asserted when those voltages fall outside of nominal range.
The controller is constantly monitoring the resolver zero and span points and
Position Feedback Fault!
asserts this fault if they go outside specification.
This fault is asserted when the transducer zero point has shifted far enough to
Transducer Span Fault!
prevent a full scale reading from the transducer.
This fault is asserted when the transducer zero point has shifted far enough to
Transducer Zero Fault!
prevent drift compensation at the zero point.

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.

26 QB Expert Alpha Controller


Controller Operation
Along with the onscreen indication, the blue light on the controller and tool MFP
extinguishes and the STOPPED output asserts.
Tool Disabled Explanations:
Undefined Task – The selected Task is not programmed to run an audit step;
select another Task or program currently selected Task.
Invalid Job/Task – Appears when a Job or Task number less than one or greater
than 255 is selected.
Network Protocol – The plant control system issued a Stop via a network
protocol. Wait for the protocol to remove the Stop command.
Error Proofing – Error Proofing is turned on and either a Batch count has been
met, or the Job has not been reset. Reset with a Job Reset input.
Tool Disabled Stop Issued – An Input is disabling the tool; remove the Stop input. May also be
caused by Job/ Task Verify inputs not matching selected Job/ Task.
System Initializing – The controller is booting up, please wait.
Cycle Lock-out – The Cycle Lockout timer is active, wait for it to reset.
Reject Count Exceeded – Indicates the Reject Count has been exceeded.
Internal PLC – The internal PLC is commanding the tool to STOP.
Not Armed – There are two things that can cause this event:
1. Tubenuts – By default tubenut tools require arming by tapping the MFB
before the trigger is pressed to run the tool.
2. Reset Reject – The fastening cycle is NOK and the MFB mode is set to Reset
Reject preventing the tool from running until the MFB is pressed to reset the
NOK.

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.

3.1 SETUP Area


This area changes the settings of the Job,s Tasks, Steps, tool strategies, error-proofing, and bolt counting. Users
must have SETUP or ADMINISTRATOR access level to modify values in this area.

3.1.1 JOBS: Wizard


Jobs controls tool operation for tightening a fastener: one to ninety-nine Tasks and one to twelve Steps. Most
controllers operate with a single Job and Task with one or two Steps. Users must have ADMINISTRATOR or SETUP
access in order to modify Job settings. This includes Wizard, Manage and Step parameters.
The Wizard automatically appears after selecting Jobs if a tool is attached and when a Job or Task is added. The
Wizard sets up a Job or Task for simple or complex fastening cycles using the optional strategy controls called
Smart Steps.

30 QB Expert Alpha Controller


Programming

If no tool is attached or if at least one Job exists, the Job tab appears allowing for expert user programming.

3.1.1.1 Wizard Screens


The Wizard presents programming parameters and gives a list of strategy controls (Smart Steps). The first 2
Wizard screens define the Audit step of the Task. The Smart Steps are helper steps inserted either before or after
the Audit step. Smart Steps cannot be audit steps. Only STRATEGY steps can be audit steps. A Task must have
at least one STRATEGY (non-Smart step) step. When complete the Wizard will have created the Job, Task and
appropriate steps based on programming input.

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.

32 QB Expert Alpha Controller


Programming
The minimum allowed angle during this step. The Wizard chooses the value of zero
Low Angle
degrees 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.

34 QB Expert Alpha Controller


Programming
Creates two Smart Steps before the Audit step. The first step is a Torque Control/Angle
Monitoring strategy that rotates the fastener in the same direction as the Audit step is
programmed. This runs a fastener down to an initial torque level. The second is a Back off
strategy which partially removes the fastener.
The purpose of this procedure is to polish the threads and reduce friction variation during
the Audit step. This ensures more consistent results. If selected, this is the first step AFTER
Self Tap and Pre-Torque. Options include:
Down Target The Target Torque for this step prior to the Back off.
Condition Torque
Fastener
The time delay before the controller starts the next sequential step.
Delay Time Triggered when the tool meets the Down Torque Target and entered in
seconds. The Wizard uses 0.05 seconds by default.
The maximum time permissible to have the tool energized during this
Max Time
step. Entered in seconds.
The target angle for the Back off step. The Wizard uses 360˚ by
Angle Target
default.

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.

Accommodates assembly procedures requiring partial removal of the fastener before


additional components can be added to the joint. Creates a Back off strategy Smart Step
after the Audit step. The tool stops after achieving either the angle or torque target. If
selected, this is the first step AFTER the Audit step. Options include:
The number of degrees of rotation the socket turns during this step.
Backout Angle Target
The Wizard uses 1800˚ by default.
Fastener
The Target Torque for this step. The Wizard uses the tool’s rated
Torque Target
torque as 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.

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.

Press the FINISH interactive menu button to close the Wizard.

36 QB Expert Alpha Controller


Programming

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.

3.1.2 JOBS: Manual Programming


Jobs, Tasks and Steps are required to setup a tool strategy. Inputs and Triggers are used to select specific Jobs or
Tasks with different tool strategies, including Error Proofing (bolt counting). Program Job parameters according to
the plant integration scheme desired and then program Task(s) and Step(s) to create the tool strategy.
Job settings apply to all Tasks and Steps within the Job. There can be up to 255 Jobs per Alpha controller.
Select Jobs by pressing the SETUP interactive menu button on the Run screen.

Press 1 or highlight Jobs selection and press the Toggle button.

There can be more than one Job. Use the 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.

38 QB Expert Alpha Controller


Programming
The value of Yes causes the tool to disable after the accumulated fastener count equals
the target fastener count for the job, unless Auto Reset Job is set to Yes. A Trigger or
Input is required to Reset the Job and set the accumulated count to zero. Yes also enables
more parameters that will dynamically appear on the screen, see below. The value of No
keeps the tool enabled even after the Job’s target count is met. The count will not increase
beyond the target value. The value of No will not cause new parameters to appear.
This section identifies whether the tool removes the Disassembly
(Reverse) function on one of the following events:
Yes does not allow the use of Disassembly mode
after each OK fastening cycle. The tool can be used
to back out fasteners after a NOK fastening cycle.
On Cycle OK
No allows the use of Disassembly mode after any
fastening cycle unless the logic of the following two
events is met.
Yes does not allow the use of Disassembly mode
Disable
after the active Job is complete (accumulated
Disassembly On Job
count equals target count). No allows the use of
Complete
Disassembly mode after a Job is complete unless the
Enable Error logic of the other two events is met.
Proofing
Yes does not allow the use of Disassembly
mode after all fasteners have been removed i.e.
On All
accumulated count is back to zero. No allows the use
Fasteners
of Disassembly mode after all fasteners have been
Removed
removed unless the logic of the above two events is
met.

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.

40 QB Expert Alpha Controller


Programming
Writes all Jobs and their parameters to a Job file on the USB memory stick.
Use the following sequence to save a Jobs 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 interactive OK button to acknowledge the save.

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

3.1.2.2 Task Button


Press the TASK interactive menu button to setup the parameters of the Tasks and Step(s) inside the selected Job.
Task settings apply to all Steps inside the Task. The maximum number of Tasks in the Expert Alpha controller is
255. Share these Tasks between the programmed Jobs. There can be up to 99 Tasks per Job.
Select Tasks by pressing the TASK interactive menu button. Use the left/right arrow keys to select the tab/Task
for modifying.

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.

3.1.2.3 Manage Button (Task)


Manage enables Tasks and their settings to be added, deleted, copied to the clipboard and pasted into another

42 QB Expert Alpha Controller


Programming
Task.

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.

3.1.2.4 Step Button


Press the STEP interactive menu button to setup the parameters of the Step(s) inside the selected Task.

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

44 QB Expert Alpha Controller


Programming
TC AM
RC / AM Rate Control with Angle Monitor. The controller shuts off the tool
when the rising
TCtarget
AM rate value is achieved after a selected snug
torque value. The controller also monitors angle. Audit Step torque
and angle readings must fall within their specified limits for the
AC/TA fastening cycle to be acceptable.

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.

46 QB Expert Alpha Controller


Programming
Provides a torque window during the rundown phase of the fastening cycle into which
achieved torque must pass through. This window looks back from the Snug Torque of
the step over the angle interval defined. If achieved torque is outside the window the
fastening cycle is ended with the Shutoff Code of [T]. YES enables this monitor, NO
disables this monitor.

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.

48 QB Expert Alpha Controller


Programming
Selects the type of spindle inertia control toward the end of a fastening cycle.
Disabled Does not reduce the speed of the motor.
Reduces the tool speed to a specific value (Downshift Speed) when
a specific torque value (Downshift Torque) is reached during the
fastening cycle. Speed units are RPM, torque is in torque units.
Manual

Enables the Adaptive Tightening Control algorithm to slow the tool’s


speed as the torque rises. The default values can be modified for
when the algorithm starts (ATC Starting Torque), when it ends (ATC
Ending Torque) and the tool speed after the algorithm ends (ATC
Ending Speed). The torque units are a percent of Target Torque. The
ATC speed values are a percent of Speed.
Downshift
Mode

Enables the Adaptive Tightening Control Plus algorithm to slow the


tool’s speed based on a sampled torque rate. The default values can
be modified for when the algorithm starts monitoring rate (Threshold
Low), when it stops monitoring rate (Threshold High) and the tool
speed after the algorithm ends (Minimum Speed). The torque units
are a percent of Target Torque. The speed values are a percent of
ATC+
maximum speed of the tool.

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

If AUTO is selected the tool is dynamically controlled to a stop.


If Yes is selected the tool’s current will be removed for the time specified in Current Off
Time, then reapplied for the time specified in the Current Hold Time, then current will
ramp to zero over the time specified in Current Ramp Time. Units are in seconds.
Max Torque Determines when to stop the tool based on exceeding a maximum torque value during the
Bailout Angle Control/ Torque Averaging strategy. Units are the selected torque units.
Min Torque Determines when to stop the tool based on dropping below a minimum torque value
Bailout during the Angle Control/ Torque Averaging strategy. Units are the selected torque units.
Torque Yes will use the average torque achieved during an Angle Control/ Torque Averaging
Compensation strategy as the zero torque for the next immediate step only.

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.

3.1.2.5 Manage Button (Step)


Manage enables step settings to be added, deleted, and/or copied to the clipboard and pasted.

50 QB Expert Alpha Controller


Programming

Adds a Step to the selected Task.

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.

3.1.3 COMMUNICATIONS Menu


This area changes the setting of the Ethernet, Serial and fieldbus Communications port(s) located on the bottom
of the Alpha. Users must have COMMUNICATIONS, SETUP or ADMINISTRATOR access level to modify values in
this area.
Select Communications by pressing the SETUP interactive menu button on the Run screen.
Press 2 or highlight selection and press Toggle button.

3.1.3.1 TCP/IP Tab

52 QB Expert Alpha Controller


Programming
This information is required when connecting the Alpha controller to an Ethernet network
using the Ethernet port.
Yes allows the Alpha controller to receive an address from the
network DHCP server. No requires the address parameters to be filled
in manually.

Obtain IP From IP Address The IP Address of the Alpha controller.


Network Network Subnet Mask The Subnet address of the Alpha controller.
Gateway The Gateway address to a connecting network.
DNS The address of the network’s DNS server.

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.

3.1.3.1.1 RENEW Button


Press this button have the controller initiate a GET IP ADDRESS request to the network.
Use the right arrow to move to the next tab or press EXIT to save the changes and return to the Run screen. See
section “3.1.2.6 Exit” on page 52.

3.1.3.2 WIFI Tab


Use these parameters to setup the access point to connect QPM Cordless tools to the Expert Alpha controller. The
access point may also be used to connect computers or other devices with browsers to Alpha Toolbox.

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.

3.1.3.2.1 SHOW Button


Normally the password displays as dots when typed. To see the password press the SHOW interactive menu
button.

3.1.3.2.2 PAIR Button


Press the PAIR interactive menu button to initiate the pairing mode to a QPM Cordless Tool. This will switch the
access point to a pairing SSID while the Expert Alpha controller is in pairing mode.
To pair a QPM Cordless Tool after pressing the PAIR button ensure the QPM Cordless Tool is off by removing the
battery pack and re-installing the battery pack. Wake the QPM Cordless Tool into pairing mode by pressing and
holding the MFB and then tap the start trigger switch. Wait for the tone before releasing the MFB. The QPM
Cordless Tool will find the Expert Alpha controller and request to be added as a trailing spindle by turning on, then
off, the status lights in sequence. Accept the QPM Cordless Tool as a trailing spindle on the Expert. See Section
“8.1 Connection” on page 164 to see how to accept the spindle as a trailing device.
Press the BACK interactive menu button when the pairing operation is complete to return the access point to
normal mode and the user defined SSID.
Use the right arrow to move to the next tab or press EXIT to save the changes and return to the Run screen. See
section “3.1.2.6 Exit” on page 52.

3.1.3.3 Serial Tab


Selects the function for the db-9 COM PORT connector on the bottom of the Alpha controller.

54 QB Expert Alpha Controller


Programming
The port performs both functions at the same time.
Barcode: The port reads input from a barcode scanner and places it into the PART ID
buffer. Data in the PART ID buffer is added to the fastening cycle data when stored and
transmitted via a network protocol or printed.
BARCODE / Print: A pre-defined data string is sent out the port after each fastening cycle that
PRINTER exceeds the Threshold Torque. See section “6.4 Serial Connector” on page 113 for string
definitions.
Baudrate The data transmission rate in bits/second for communication.
Parity Used to determine if data was lost or compromised during transfer.

TOYOTA PI Connects this port to the Toyota PI box.


PFCS Connects this port to the Chrysler network.
OPEN Connects this port to a network using the OPEN protocol with serial messaging.
The internal PLC takes over communications on this port. Baud rate and Parity of the
Serial port may be changed for PLC communications. Set these values according to the
requirements of the end user.
PLC
Baudrate The data transmission rate in bits/second for communication.
Parity Used to determine if data was lost or compromised during transfer.

Use the right arrow to move to the next tab or press EXIT to save the changes and return to the Run screen. See
section “3.1.2.6 Exit” on page 52.

3.1.3.4 PFCS Tab


The plant’s System group must provide these values to allow the Alpha controller to communicate on the PFCS
or NPL network. If using the NPL network there is a setup per spindle, even in a multiple. Be sure to select each
spindle that needs to report to the NPL and setup these parameters.

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.

Server IP Type the IP Address of the PFCS server on the network.


This port is used to send fastening cycle status and data to the PFS system. 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. Starts with 10,000.
Wait to Time period in seconds between a disconnect and an attempt to
Connect reconnect.
Solicited Port 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.

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.

56 QB Expert Alpha Controller


Programming
Use these setting when implementing the NPL protocol communications at Fiat facilities.
This is for batch processing and printer support.
DISABLE: Batch process is disabled.
Batch Mode NO MES: P erform the batch process and printer output without the
MES command
MES: Perform the batch process and printer output with the MES
command.
Operation AUTO: Sends keep alive messages as necessary.
Mode MANUAL: Keep Alive messages are not sent.
Manual YES: Send data to the MES while in Manual Mode.
NPL Settings Messaging NO: Do not send data to the MES while in Manual Mode.
The size in characters to set aside to receive network messages.
Buffer Size
Maximum size is 4096 characters (bytes).
For Smart NPL only.
Mode 1: NOKs are sent when they happen (TR) and in final message
when the Job is complete (ER).
Transfer Mode Mode 2: N OKs are sent when they happen (TR) and sent in the final
message only when the Job failed. OKs are send as ER when
Job is complete and passes.
Mode 3: All results are sent as they happen (TR). Final fastening cycle
in Job is sent as ER.

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.

3.1.3.5 OPEN Tab


The plant’s IT department must provide these values to allow the Alpha controller to communicate on the OPEN
protocol network.

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.

3.1.3.6 TOOLSNET Tab


The plant’s IT department must provide these values to allow the Alpha controller to communicate on the Toolsnet
protocol network. The Expert Alpha controller will communicate only with a Toolsnet server that employs a PIM
server (i.e. World Version 7).

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Server IP Type the IP Address of the Toolsnet server on the network.


The required virtual port on which to communicate this protocol. For the Expert Alpha
Port
controller it is normally 6575.
System Type the cell number where this Alpha controller resides.
System Name Type the system number where this Alpha controller resides.
Station Type the Station number where this Alpha controller resides.
Station Name Type the Station name where this Alpha controller resides.
Selects the types of traces that are sent to the server.
None No traces are sent to the server.

Trace All All traces are sent to the server.


OK Only OK fastening cycle traces are sent to the server.
NOK Only NOK fastening cycle traces are sent to the 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.

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.

3.1.3.8 SCANNER Tab


This tab appears on Alpha controllers only when the leading DeviceNet port option is installed and sets the
communications parameters for the Alpha controller’s DeviceNet network. This allows the Expert Alpha
controller to control devices on its own DeviceNet network.

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.

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3.1.3.8.1 MANAGE Button
Press 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.

ADD Mac Id The Machine Id or Node number of the new device.


The type of connection to the device. The Expert DeviceNet Scanner
Connection
card supports Change of State, Polled, Cyclic and Bit Strobe.
Consumed The number of bytes consumed by the device.
Length
The output address of the device for embedded PLC logic. Controller
Output
generated
Produced The number of bytes produced by the device.
Length
The input address of the device for embedded PLC logic. Controller
Input
generated.

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 FIELDBUS Tab


The Fieldbus tab is a generic term for any of the optional fieldbus types that can be added to the controller and
this tab appears only when one of those options are installed. These fieldbus allow the Expert Alpha controller
to be added to end users’ compatible systems as trailing devices. The types of optional fieldbus are DeviceNet,
EthernetIP, Profibus and Profinet.
The type of fieldbus installed will be identified at the top of the screen.

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.

3.1.3.9.1.1 EDS Button


Press the EDS interactive menu button to create an EDS file equivalent to the DeviceNet I/O map created.
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 type a file name or use the default.
Pressing the OK interactive menu button saves the file to the USB memory stick. Use this controller generated EDS
file in the PLC to which the Alpha controller is connected.
If the DeviceNet I/O map is changed, a new EDS file must be generated.
Use the right/ left arrow to move to the next tab or press EXIT to save the changes and return to the Run screen.
See section “3.1.2.6 Exit” on page 52.

3.1.3.9.2 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.

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This information is required when connecting the Alpha controller to an EthernetIP


network using the Ethernet/IP port.
Yes allows the Ethernet/IP board to receive an address from the
network DHCP server. No requires the address parameters to be filled
in manually.
IP Address The IP Address of the Ethernet/IP port.
Obtain IP From Subnet Mask The Subnet address of the Alpha controller.
Ethernet/IP Network
The Gateway address to a connecting network.
Gateway This value is required. If there is no actual
gateway then type in the controller’s IP Address.
DNS The address of the network’s DNS server.

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.

3.1.3.9.2.1 EDS Button


Press the EDS interactive menu button to create an EDS file equivalent to the Ethernet/IP I/O map created.
Connect a USB memory stick to the USB port on the bottom of the Alpha controller. Use the up/down arrows and/
or the numeric keypad to type a file name or use the default.
Pressing the OK interactive menu button saves the file to the USB memory stick. Use this controller generated EDS
file in the PLC to which the Alpha controller is connected.
If the Ethernet/IP I/O map is changed, a new EDS file must be generated.
Use the right/ left arrow to move to the next tab or press EXIT to save the changes and return to the Run screen.
See section “3.1.2.6 Exit” on page 52.

3.1.3.9.3 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.

3.1.3.9.3.1 GSD Button


Press the EDS interactive menu button to create a GSDML file equivalent to the PROFINET I/O map created.
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 type a file name or use the default.
Pressing the OK interactive menu button saves the file to the USB memory stick. Use this controller generated
GSDML file in the PLC connected to the Alpha controller.
If the PROFINET I/O map is changed, a new GSDML file must be generated.
Use the right/ left arrow to move to the next tab or press EXIT to save the changes and return to the Run screen.
See section “3.1.2.6 Exit” on page 52.

3.1.3.9.4 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.

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Sets the baud rate for the Alpha on the Profibus network. The choices are:

Baudrate

The baud rate is determined automatically and set to the Network


Auto
baud rate as determined by the Leading device.

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.

3.1.3.9.4.1 GSD Button


Press the GSD interactive menu button to create a GSD file equivalent to the Profibus I/O map created.
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 type a file name or use the default.
Pressing the OK interactive menu button saves the file to the USB memory stick. Use this controller generated GSD
file in the PLC connected to the Alpha controller.
If the Profibus I/O map is changed, a new GDS file must be generated.
Use the right/ left arrow to move to the next tab or press EXIT to save the changes and return to the Run screen.
See section “3.1.2.6 Exit” on page 52.

3.1.4 OTHER Menu


This area sets the parameters for all other Alpha features, including: system level, users, passwords, I/O and tool
functions. Each category is represented by its own tab. Use the left/right arrows to select the tabs/category for
modification.
Users must have ADMINISTRATOR or SETUP access level to modify values in this area.

3.1.4.1 General Tab


In Alpha Toolbox only. When YES is selected the Alpha controllers keypad cannot be used
to edit any parameters. It will allow the user to navigate through the system and view
Lock Keypad any parameters. If the keypad is locked and it is desired for it to be unlocked one must
connect to Alpha Toolbox on the controller and set this parameter to No. If set to NO the
keypad on the Alpha controller can be used to edit parameters.
A name distinguishes this controller from other Alpha controllers on the same plant floor.
Use the up/down arrows to type letters. Use the numeric keypad to type numbers. This
Name is also the main Machine ID for PFCS protocol. This value will also be used to label any
files exported via the USB port or Alpha Toolbox. There is a 15 character limit for this
parameter.

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During normal operation the keypad on the face of the controller can be used to select
Jobs (Job Select) or Tasks (Task Select). It can also write a PART ID for storing with
Keypad Mode fastening cycle data or these functions can be disabled. If Job Select, Task Select or PART
ID mode is enabled, simply type a number or letter on the keypad when on the run screen
to select the Job, Task or Part ID, then press the Enter key.
Choose Count Up to indicate the fasteners that have been completed OK. Choose Count
Count Mode Down to indicate the number of fasteners yet to be completed. This affects the count in
the box on the run screen.
Choose OK to mark the fastening cycle as OK, even if the fastening cycle is stopped when
the achieved torque and angle are within limits. Choose NOK to mark the fastening cycle
Stop within
as NOK when the fastening cycle is stopped and the achieved torque and angle values are
Limits
within limits. When event occurs, this option illuminates the red and yellow LEDs on the
tool and controller.
Yes enables the power saving mode for the Expert Alpha controller or the Cordless Tool.
No will turn off the power saving mode.
Time in minutes from last operation when the power saving mode will
Enable Sleep Sleep Timer turn off the controller’s screen or turn off the Cordless Tool. Minimum
Timer value is 1, maximum value is 60, default value is 10.

Running a tool, pressing a button or the touch screen, connecting with Alpha Toolbox,
changing the state of I/O are all operations that will wake up the controller. Press the
Start Trigger Switch on the Cordless Tool to recover from power saving mode.

Use the right arrow to move to the next tab or press EXIT to save the changes and return to the Run screen. See
section “3.1.2.6 Exit” on page 52.

3.1.4.2 Users Tab


A maximum of eight users with unique passwords can be added. Passwords can contain any character, symbol or
number combination written by the keypad (maximum length of 16).
If users are assigned, one must be an Administrator. The first user assigned will be an Administrator by default.
When a user is trying to modify a parameter and the controller is locked, or the user has insufficient privileges,
the log in screen appears.

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.

Press OK to acknowledge and try again or CANCEL the modifying operation.


When a user is logged in the controller is unlocked at that user’s access level. The unlocked icon appears and the
LOGOUT interactive menu button appears on the run screen.

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.

Second, manage the users access by selecting the new user.

Press the MANAGE interactive menu button and select option 4. Change Access.
One user must be an Administrator. Administrator rights give a user full access to the controller. This enables all
privileges including restoring factory defaults, deleting logs and adding users.

To assign the selected user as an Administrator choose Yes, for non-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.

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Users at this level can modify all parameters in the Job area. They may also modify
Setup
parameters in the Other area except in the Users, Tool and Stats tabs.
Users at this level can modify parameters under the Tool tab in the Other area, as well as
Tool set Preventive Maintenance Threshold and reset the PM and Cycle counters in the SERVICE
menu.
Users at this level can force Inputs or Outputs ON or OFF and REMOVE forces in the I/O
Diagnostics
tab of ANALYZE.
Statistics Users at this level can modify parameters under the Stats tab in the Other area.
Communications Users at this level can modify all parameters in the Communications area.

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 I/O Tab


Press the BUS interactive menu button then the up/down arrows to select the I/O bus for editing/ viewing. Then
press OK.
The buses available are dependent on the options installed.

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

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Programming
byte are used then a new byte will be added with the next function addition.
If any byte, word or double word length function is assigned it must be assigned at bit 0 or bit 8. To insert a new
byte to assign these types of functions press the MANAGE button and choose Add.

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.

3.1.4.3.4 Manage Button


Modifies the highlighted function.
Edit To edit a function or its configuration, highlight the function then press the MANAGE
button. Then choose Edit. Choose the same function or a different one then press the
NEXT button. Modify the configuration for the function then press the FINISH button.
Add Adds a new byte, word or double word and function to the selected bus.
Delete Deletes the highlighted byte, word, double word and function from the bus.
Imports an I/O file from a memory stick on the USB port. This will overwrite all I/O
Import
information on all buses.
Export Exports all I/O on all buses to a file on a memory stick on the USB port.

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.

3.1.4.4 Triggers Tab


See section “5.2.5 MFB Mode” on page 104 for an explanation of the options. Options include:

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.

3.1.4.5 Lights Tab


Lights (1, 2) Defines whether the lights indicate a Job or Task.
Headlight Timer Sets the time the tool’s headlights remain on, in seconds, after the trigger is pressed.
Yes enables the timer and the tool’s Red, Green and Yellow status lights will illuminate for
the period of time specified after a fastening cycle and then extinguish.
If No is selected the time is disabled and the tool’s Red, Green and Yellow status lights
Enable Tool Light will remain illuminated after a fastening cycle until the tool is started again. They will
Timer only extinguish while the tool is running.
Tool Light The time in seconds the Red, Green and Yellow status lights will
Timer remain on after a fastening cycle.

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.

3.1.4.6 Tones Tab


The alarm in the tool handle can emit different tones based on the status of the fastening cycle. Choose an Accept
Tone for an OK Fastening cycle and a Reject Tone for a NOK Fastening cycle.

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Programming

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.

3.1.4.7 Tool Tab


Values modified under this tab are saved to the tool not the controller. Users must have TOOL or ADMINISTRATOR
access level to modify these values. The “Update tool” exit window appears anytime changes are made in this
tab.

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.

3.1.4.8 Statistics Tab


Sets values required to calculate the statistics on the stored fastening cycle data.
Display –
Sets the default screen under statistical analysis in the ANALYZE area.
Display

Population Sets the number of fastening cycles included in statistical analysis.


Subgroup Size Sets the size of the subgroups for the population.

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.

3.1.4.9 REGIONAL Tab


Sets the values for the region of the world in which the controller is used.
Language Selects the language for the controller screens and files.
Date Format Selects the Date format for the controller.
24-Hour Time Selects the 12 hour or 24 hour clock.
Time Zone Selects the time zone for the controller referenced to GMT (Greenwich Mean 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.

3.1.4.10 Clock Tab


Local Date and Time can be set here. These will be stored with the events and files.
Daylight Saving Modifies the controller time by the appropriate amount.
Time
Time Sets the controller time.
Date Sets the controller date.

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.

3.1.4.11 PLC Tab


If a PLC logic file is running, the Name, Version and Length parameters are identified. If a PLC file is not running,
the Name, Version and Length are blank.
Press the MANAGE interactive menu button to Import, Export or Delete a PLC file. Connect a USB memory stick
in the USB port for Importing and Exporting.

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.

3.1.5 RESTORE FACTORY DEFAULTS Menu


Use the up/down arrows to select the option desired or press the corresponding number on the keypad.
The BACKUP selection writes the parameter values for the entire Alpha controller to the USB memory stick.
The RESTORE selection reads an Alpha controller backup file on the USB memory stick and overwrites all values
in the Alpha controller.
The DEFAULTS selection restores all values for all parameters to factory default settings. It also deletes all
fastening cycle, trace and error log data. This helps when a controller is in an unknown programmed state.

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Programming
Requires ADMINISTRATOR privileges.

Press EXIT to save the changes and return to the Run screen. See section “3.1.2.6 Exit” on page 52.

3.2 SERVICE Area


In this area the user can view information about the tool and controller, reset tool counters, adjust tool calibration
values and upgrade the firmware in the controller and tool.
Users must have TOOL or ADMINISTRATOR access level to modify parameters.

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.

3.2.1.1 About Tab


This tab displays information about the tool currently attached to the controller. Only the Serial Number value is
editable. If there is no serial number, enter one (can only be entered one time).

3.2.1.1.1 UPDATE Interactive Menu Button


Use this button to change the tool configuration or to update the firmware in the tool.
Change the tool configuration.
Download a configuration INI file from the Internet and transfer it to a USB memory stick. Insert the USB memory
stick into the USB port. Press the UPDATE interactive menu button to open the file browse window.
Use the up and down arrows to find and highlight the desired INI file. Press the OK interactive menu button. The
“Update Tool INI file?” window appears. Press Yes to import and load the new configuration file. Press No to
return to the About screen.
Change the tool firmware.
Download a software BIN file from the Internet and transfer it to a USB memory stick. Insert the USB memory
stick into the USB port. Press the UPDATE interactive menu button to open the file browse window. Use the up
and down arrows to find and highlight the desired BIN file. Press the OK interactive menu button. The “Update
Tool Firmware?” window appears. Press Yes to import and load the new configuration file. Press No to return
to the About screen.

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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.

3.2.1.2 Counters Tab


Each of the three counters increments at the same time after an OK Fastening cycle.

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.

3.2.1.3 CAL Tab


This area is used to set the calibration value(s) for the attached tool.

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Programming

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.

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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.

3.2.2.1 About Tab


This tab displays information about the controller. These values are read only unless blank. The Model and Serial
fields can be written to once.

Press the EXIT interactive menu button when finished.


The About Tab changes to add information about the optional fieldbus card installed such as DeviceNet, Profibus,
ProfiNet or Ethernet/IP.

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Programming

3.2.2.1.1 UPDATE Button


This button is used to update the firmware in the Alpha controller.
Download a software BIN file from the Internet and transfer it to a USB memory stick. Insert the USB memory
stick into the USB port on the bottom of the Alpha controller. Scroll to the binary file provided and then press the
OK interactive menu button.
The “Update Controller Firmware” screen appears to confirm the action. Press YES to continue with the update.
Press NO to cancel the update.
A progress bar on the bottom of the screen indicates the file transfer status from the USB memory stick to the
Alpha controller memory.
When the file transfer is complete, the “Cycle power to complete the update” window appears indicating it is time
to reboot the controller to complete the upgrade. Turn off the controller, remove the USB memory stick, wait 20
seconds, then turn on the controller.
After the controller starts, it checks that the file is complete and written to permanent memory. The controller
auto-reboots. When the run screen appears, the controller is updated and ready.
During the file transfer process, a file error can cause the transfer to abort and the error message appears. Contact
your STANLEY representative if this happens.
The “Invalid File” screen appears if the update file is for a different controller. Contact your STANLEY representative
if this happens.
Trailing controllers and QPM Cordless Tools that are connected to the Expert may also be updated this way by
simply choosing the spindle before selecting SERVICE > CONTROLLER. It is advised to update trailing controllers
and QPM Cordless Tools before updating the lead controller (Expert).
Press EXIT when finished.

3.3 ANALYZE Area


Analyze displays tool and controller diagnostic information, traces and I/O status.
Press the ANALYZE button to perform diagnostics on the controller, tool or I/O, look at fastening cycle traces,
perform Statistical Process Control analysis, or to download error log data.

3.3.1 TOOL Tab


This tab shows live status. It updates every millisecond. Use this tab to perform controller or tool diagnostics

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.

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Programming

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.

3.3.2 TRACE Tab


Press the right arrow to enter the Trace area of the controller.

This tab plots a torque verses time curve after every fastening 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.

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ANALYZE Area

Torque – Displays Torque vs. Time.


Angle – Displays Angle vs. Time.
Torque/Angle – Displays Torque vs. Angle.
Speed – Displays Speed vs. Time.
Torque Rate – Displays the Torque Rate vs. 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.

3.3.3 STATS Tab


Press the right arrow to enter the Statistics area of the controller.

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.

Values are recalculated each time a tab is selected.


Results
This section shows a summary of the fastening cycle data results stored in the controller.
n – Shows the number of rundowns included in the population size.

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Programming
n OK – Identifies the number of OK rundowns.
n NOK – Identifies the number of NOK rundowns.
n – Displays the number of fastening cycles that exceeded the high limit.
n – Displays the number of fastening cycles that did not achieve the low limit.
n Abr – Displays the number of fastening cycles that were aborted.
n Stp – Shows the number of fastening cycles that were stopped.
R – Shows the subgroup range (highest minus lowest value).
– Identifies the highest value of all the fastening cycles in the population
– Identifies the lowest value of all the fastening cycles in the population
The Display parameter under Setup/Other/STATS tab determines which of the following sections are displayed
after the Results.
Capability
This section shows the capability statistics for the selected Job and Task.
Cp – Displays the capability index for a stable process.
Cpk – Displays the capability index for a stable process, typically defined as the minimum of CPU or CPL.
CR – Displays the capability ratio for a stable process and is simply the reciprocal of Cp.
CPL – Shows the lower capability index.
CPU – Shows the upper capability index.
R bar – Identifies the average range of a constant size subgroup series.
3 sigma – Displays the sample estimated Standard Deviation times three.
X bar – Displays the value’s average (mean).
Performance
This section shows the performance statistics for the selected Job and Task.
Pp – Shows a performance index of a stable process.
Ppk – Shows a performance index of a stable process typically defined by a minimum of two calculations.
PR – Identifies the performance ratio for a stable process.
3 sigma – Identifies the sample estimated Standard Deviation times three.
X bar – Displays the value’s average (mean).
Coefficient D’aptitude Moyen
This section shows the CAM statistics for the selected Job and Task.
CAM – Coefficient d’Aptitude Moyen (Mean Aptitude Coefficient) shows a capability index for a stable process
used in Europe.
R bar – Identifies the average range of a constant size subgroup series.
3 sigma– Identifies the sample estimated Standard Deviation times three.
X bar – Displays the value’s average (mean).
Use the right arrow to move to the next tab or press EXIT to save the changes and return to the Run screen. See
section “3.1.2.6 Exit” on page 52.

3.3.4 LOG Tab


The Expert Alpha controller stores up to 1000 Events in the log.
Use the up/down arrows to select an event the press the Toggle key to get more details.

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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.

Press YES to clear the data, NO to return to the LOG screen.


Use the right arrow to move to the next tab or press EXIT to save the changes and return to the Run screen. See
section “3.1.2.6 Exit” on page 52.

3.3.5 I/O Tab


This tab indicates the real time status of the 24V DC Inputs and Outputs. Forcing the I/O on or off is also performed
here. Users must have DIAGNOSTICS or ADMINISTRATOR access level to force I/O.

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.

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Programming
A clear Input or Output pin icon identifies it as OFF; a green Input or Output pin icon identifies it as ON.
There is a square cursor around the active pin; Use the Left/Right and Up/Down arrow keys to move the cursor.
The text at the screen’s bottom left corner indicates the active pin’s assigned function.
Manually control the I/O by forcing pins either ON or OFF. Applying force means the pin will always be in that
forced state and does not toggle to the opposite state (even if the system requires it to toggle). This is useful for
troubleshooting signals that integrate with other equipment.

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.

If a force is active when the EXIT button is pressed a prompt appears.

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.

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The controller display windows are dynamic, rather than static, and indicate the status of the fastening cycle. They
will turn green for an OK fastening cycle and red for a NOK fastening cycle for one second then return to normal.
A red box will cover the display if there is a fault until the fault is cleared.

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.

4.2.2 Navigation Buttons


Use the navigation buttons and menus provided instead of the browser’s Back and Forward buttons to navigate
through the Alpha Toolbox’s screens.

The Home button brings up the Alpha Toolbox run screen. Any others such as ,
and will send the user back one screen.

4.2.3 Import/ Export Buttons


The Print button will use a printer attached to the computer to print a parameters report for the
selected area. If in the Trace area it will print a picture of the trace.
The Import button w ill display the computer’s browse window. Browse to the file required and
press open to import a previously saved (Exported) JSON file. When the file has finished importing the “Imported
complete” window displays and the parameters are immediately overwritten. Click the OK button to close.

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.

4.2.4 Manage Buttons


The Manage buttons perform the same function as the interactive menu MANAGE buttons on the controller. See
section “3 Programming” on page 26 for descriptions on these buttons and how to use them.

4.3 Editing Parameters


Drill down through the menus to get to the parameter of interest. While viewing parameters the font is black in color and
the background for the value box is light grey.

When the parameter is clicked once the screen is selected for editing and the background for the value box turns white.

Type the required value into the box.

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.

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4.3.1 Parameter and Data Retrieval
It is a good idea to capture the stored parameters and data on a regular basis to analyze and understand the
application.

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.

4.3.1.1.2 Fastening Cycle Data


The Expert Alpha controller stores resultant audit data for 30,000 fastening cycles on a first in/ first out basis.
Click on the Full Backup / Restore menu from the Home screen in Alpha.

Click on the Rundowns menu. The rundowns.csv file is immediately transferred to the computer. Be sure to
understand 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.

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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.

4.4 Trace Data


The Expert Alpha controller stores resultant audit data for 10,000 fastening cycles on a first in/ first out basis.
Click on the Analyze>Trace menu from the Home screen in Alpha Toolbox.

Select the Rundowns button to display the rundowns.

A list of rundowns appears on the left. Click on the 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

92 QB Expert Alpha Controller



number to distinguish it from the rest and so it can be correlated with the record in the rundowns.csv file.

4.4.1 Analyzing Traces


The Trace menu screen in Alpha Toolbox makes it easy to view, print, analyze, export for sharing, and import
saved trace files.

4.4.1.1 Screen Controls


The left side of the screen has three types of content. The Rundown button lists the fastening cycles stored in the
controller. The Information button shows detailed step by step information about the selected fastening cycle. The
Point Details button displays details about a point on the trace graph where the mouse is hovering.

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.

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Trace Data

Rundown – Indicates the unique number for the fastening cycle.


Date – The date the fastening cycle occurred.
Time – The time the fastening cycle occurred.
Job – The Job in which the fastening cycle occurred.
Task – The Task in which the fastening cycle occurred.
Status – Overall status of the fastening cycle.
Job Count – The working bolt of the Job during this fastening cycle.
Task Count - The working bolt of the Task during this fastening cycle.
Tool Model – The model number of the tool performing the fastening cycle.
Tool Serial – The serial number of the tool performing the fastening cycle.
Tool Temperature – The temperature of the tool at the tool shutoff.
Steps – The steps performed during the fastening cycle. The step’s strategy type, peak Torque, Current, Angle,
Torque Rate and Deviation achieved during the step is displayed. The audit step is indicated by blue font. Smart
Steps are indicated by name rather than by strategy type.
Click on the step name and the graph on the right will highlight that individual step.

94 QB Expert Alpha Controller



4.4.1.1.3 Point Details
Click on the Points Detail button to display information about the selected fastening cycle. Use the mouse to
hover over the drawn trace graph on the right in the Trace screen. The values in the Points Detail window change
with the mouse hover.

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.

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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

96 QB Expert Alpha Controller




Y1 Axis Selector Y2 Axis Selector

Preset Selector

Event

Torque Window Graph

Event

Angle Window

X Axis Selector Master Detail Icon

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.

Click the icon to open the Master Detail window.

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.

4.4.1.2.1 Points on Graph


Crosshairs and a point information box appear at the point where the mouse hovers over the graph. The X and Y
axes information is presented in the point information box. Move the mouse alonteh the X and Y axes and the
values change in the point information box.

4.4.2 Events
The dots on the graphs indicate events that occurred during the fastening cycle. Events are things such as

98 QB Expert Alpha Controller



Threshold Exceeded, ATC Active and Control Point (target achieved). The point information box changes color
and the event is indicated when the mouse hovers over the event point on the graph.

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.

4.5 Icons and Security


The Alpha controller will allow only one user to edit parameters at any one time. However, it will allow multiple

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

Other User Editing

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.

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Instruction Manual 101


QB Expert Alpha Controller

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.

5.1 Tool Specifications


Temperature 32 to 122 ºF (0 to +50 ºC)
Operating Conditions
Humidity 0 to 95 % non-condensing

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.

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Tool Operation
5.1.1 Operator Protection
WARNING
ROTATING EQUIPMENT
To Avoid Injury:
• Always wear eye and foot protection when operating, installing, or maintaining power tools, and when in
areas where power tools are being used, maintained, or installed. Some applications may require the use
of safety glasses and face shields. Use eye protection that conforms to ANSI Z87.1.[3] and ANSI Z41-PT99M
I/75 C/75.
• Always stay alert when operating tools and/or their accessories. Do no operate tools and/or their
accessories while tired, under the influence of drugs, alcohol or any other mind-altering substance.
• Repetitive work motions or vibration may be harmful to your hands, arms, shoulders or back.
• Use suitable protective equipment and work methods whenever an application presents a hazard.

5.1.2 Repetitive Motion


The use of power tools may involve highly repetitive motions of the fingers, hands, wrists, and shoulders. These
repetitive motions can lead to cumulative trauma disorders (CTD). Many personal and workplace factors can
contribute to these disorders.
Currently available data have identified the following risk factors. These risk factors are not necessarily causation
factors of CTDs. The mere presence of a risk factor does not necessarily mean there is excessive risk of injury.
Generally, the greater the exposure to a single risk factor or combination of factors the greater the risk for CTDs.
• Forceful exertions and motions
• Extreme postures and motions
• Repetitive exertions and motions
• Intended duration of exertion, postures, motions, vibration, and cold
• Insufficient rest or pauses
• Work organization risk factors
• Environmental risk factors
These risk factors span job design and content, operator training, work method, work pace, work environment,
proper tool selection and other work place factors beyond the control of the tool manufacturer. Tool owners and
employers should analyze jobs for all of the risk factors identified above and take appropriate action.
Some measures which may reduce the risk of CTDs:
• Use minimum hand grip force consistent with proper control and safe operation.
• Keep wrists as straight as possible.
• Avoid repetitive movements of the hands and wrists.
• If wrist pain, hand tingling, numbness, or other disorders of the shoulders, arm, wrist or finger occur; notify
supervisor, discontinue task, reassign user to a different job; if relief is not found contact experts skilled in
treating such disorders.
Wrist supports, torque reaction devices, and balancers should be used if it can be determined that such devices
can reduce the risk of repetitive motion disorders.

5.1.3 Hearing Protection


Power tool operators and adjacent personnel may be exposed to excessive sound levels. The tool in use is
generally only one of many sources of noise that an operator experiences. Other tools and machines in the area,
joint assembly noise, work processes, and other ambient noise sources all contribute to the sound level operators

Instruction Manual 105


Tool Specifications
are exposed to.
The actual sound level an individual is exposed to and the individual’s exposure time over the work day are
important factors in determining hearing protection requirements. Worker sound level exposure can only be
determined at the job site and is the responsibility of tool owners and employers.
Measure worker sound level exposure and identify high-risk noise areas where hearing protection is required.
Follow federal (OSHA), state or local sound level statues, ordinances and or regulations.

5.1.4 Vibration
Power tools can vibrate during use. To minimize the possible effects of vibration:
• Keep hands and body dry.
• Avoid anything that inhibits blood circulation such as tobacco, cold temperatures and certain drugs.
• Operators should notify their employer when experiencing prolonged symptoms of pain, tingling, 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.

5.1.5 Breathing Protection


Respirators shall be used where contaminants in the work area present a hazard.

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Tool Operation
5.1.6 Tool Installation
WARNING
To Avoid Injury:
• Always wear eye and foot protection when installing equipment.
• Only use equipment and accessories specifically designed to operate with STANLEY assembly tools and use
them only in the manner for which they are intended.
• Do not install worn, damaged, or modified equipment that may be unsuitable for safe use.
• Train all operators in the safe and proper use of power tools. Operators should report any unsafe condition.
• Store idle tools and accessories in a safe location accessible only by trained persons.
• Disconnect power source (air, electricity, etc.) from tool prior to making adjustments, changing accessories,
or storing.
• Prior to operation, always check and test tools and accessories for damage, misalignment, binding or
any other condition that may affect operation. Maintenance and repair should be performed by qualified
personnel.
• Do not operate tools in or near explosive environments or in the presence of flammable liquids, gases,
dust, rain or other wet conditions.
• Keep the work area clean, well lit and uncluttered.
• Keep unauthorized personnel out of the work area.
DC Electric Tools & Controllers:
• Install tools in dry, indoor, non-flammable, and non-explosive environments only – Humidity: 0 to 95%
non-condensing and Temperature: 32 to 122 ºF (0 to +50 ºC).
• Installation, maintenance and programming should be performed by qualified personnel. Follow all
manufacturer installation instructions and applicable regulatory electrical codes and safety codes.
• Tool and controller plugs must match the outlet. This equipment must be earth grounded. Never modify a
plug in any way or use any adaptor plugs.
• Avoid body contact with electrically energized surfaces when holding a grounded tool.
• Prior to connecting a power source, always ensure the tool or controller is turned off.
• Limit controller access to trained and qualified personnel. Lock controller cabinets.

Turn the controllers off when removing or attaching tools.


STANLEY electric tools must be connected to a controller to operate. To ensure superior performance and
safe operation, use a STANLEY controller specifically designed for each tool. These instructions are specific to
STANLEY electric tools when used with STANLEY electric tool controllers and accessories. Some features may
not be applicable, performance may be degraded and some safety systems may not be available when tools are
connected to non-STANLEY controllers and accessories.

5.1.7 Sockets and Adapters


Use only industrial grade sockets and adapters (power bit and power or impact socket type).
Replace worn or damaged sockets that are unsuitable for safe operation immediately.
Always ensure drive socket is fully seated and locked into position before connecting power to tool.

5.1.7.1 Quick Change Chuck


NOTE: The chuck accepts 1/4” (6.35 mm) hex accessories and bit tips only.
Remove power or air before changing accessories and bits.

Instruction Manual 107


QPM Tool Controls and Operation
To install an accessory or bit , fully insert the accessory. The accessory is locked into place.
To remove an accessory, pull the chuck collar away from the front of the tool. Remove the accessory.

5.1.7.2 Square Drive


WARNING
To Avoid Injury:
• Use only industrial or grade impact accessories. Other grade accessories may break and cause a hazardous
condition. Inspect accessories prior to use to ensure that it con­tains no cracks.

CAUTION
• Inspect square drives and detent pins prior to use. Missing or damaged items should be replaced before use.

Remove power or air before changing accessories.


To install an accessory on the square drive, align the hole in the side of the accessory with the detent pin on the
anvil square drive. Press the accessory on until the detent pin engages in the hole. Depression of detent pin may
be necessary to aid installation of the accessory.
To remove an accessory, depress the detent pin through the hole and pull the accessory off.

5.1.7.3 Suspension Devices


Tool suspension devices or bails help support the weight of the tool during tightening operations. If needed,
attach these devices securely and periodically inspect them for damage or loosening.

5.1.8 Cable Installation


WARNING
ELECTRICAL HAZARD
To Avoid Injury:
• Never use a tool with a damaged cable.
• Never abuse a cable, carry a tool by its cable, hang a tool by its cable, or pull on a cable to disconnect it
from the tool or the controller.

To ensure superior performance and safe operation, use the STANLEY cables 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.

5.2 QPM Tool Controls and Operation


5.2.1 Start Trigger Switch
The trigger switch is used to start the tool in either direction. The speed of the tool is programmable in the
controller, not the trigger switch. It is not a variable speed trigger. The trigger switch function is on or off. Press
the start trigger switch to start the tool. Release the start trigger switch to allow the tool to stop.

5.2.2 Tool Memory


QPM tools have an on board tool memory that stores tool identification, calibration factors and fastening cycle
counters. Memory parameters include:

108 QB Expert Alpha Controller


Tool Operation
• Model Number
• Serial Number
• Torque Cal (calibration) factor
• Gear Ratio
• Fastening cycle counters
• Jobs parameters
• Fastening cycle data
• Trace data

5.2.2.1 Fastening Cycle Counters


QPM tools have on board counters that record the number of fastening cycles completed by the tool.

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.

5.2.3 Display and Multiple Function Button


Handheld QPM tools have a display and a multiple function button (MFB). Two sets of lights [3 and 7] indicate
Fastening cycle status. Two blue lights indicate whether the tool is armed (on) or not armed (off) and tool rotation
direction, disassembly [1] or assembly [2]. A single multiple function button [5] can change tool direction and or
parameter sets. When the button is used to select the Job, one of two orange indicators [4 or 6] illuminates to
show the active Job. EA tools have four sets of lights [3 and 7] and an LED [8] indicates when the fastening cycle
count exceeds the PM limit.

Instruction Manual 109


QPM Tool Controls and Operation
1 4 2

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.

5.2.5 MFB Mode


The MFB Mode configures the multiple function button for handheld QPM tools. The button can be configured to
operate in any of the following modes.
Disable The button does nothing.
Pressing the button toggles between assembly and disassembly and illuminates the
Reverse
appropriate blue light [1] or [2]. All tool status lights [3] and [7] flash when the tool is in
(Disassembly)
disassembly mode.
Pressing the button toggles between Job/Task 1 and Job/Task 2 and illuminates the
Job/Task Select
appropriate orange light [6] or [4].
Pressing the button arms (activates) the trigger but does not start the tool. The blue
Arm
assembly light [2] comes on to show that the tool is armed for three seconds.
This function, when selected, will cause the tool to disable after a NOK Fastening cycle.
Reset Reject The Reject Tone, when enabled, will sound. Pressing the button re-enables the tool
indicating the operator acknowledges the rejected Fastening cycle and wishes to repair it.

110 QB Expert Alpha Controller


Tool Operation
Pressing the button causes the selected Job to be reset. This means that the fastener
Job Reset
count is reset and the tool, if disabled due to Error Proofing requirements, re-enables.
This function, when selected, causes the tool to disable after a NOK Fastening cycle. The
Reject Tone, when enabled, will sound. Pressing the button re-enables the tool in the
Reset and
Reverse direction and indicates that the operator acknowledges the rejected Fastening
Reverse
cycle and wishes to repair it. The tool switches to the forward direction after the controller
detects a fastener has been removed.

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.

5.2.7 Program Selection


The QPM Expert Alpha controller has various means of changing the selected Job/Task such as inputs or barcode
scans of product. See Section “6.12 Assignable Input and Output Functions” on page 120 to understand how
to select a Job/Task.

5.2.8 Directional Control


WARNING
UNEXPECTED REACTION FORCES
To Avoid Injury:
• Be prepared – when a tool operates in reverse, the tool’s torque reaction is opposite to the reaction
produced when the tool operates in forward direction.
• The tool can have a higher initial reaction force when loosening a fastener.
• Always stop the tool before changing direction of spindle rotation.

Clockwise is the normal direction for securing a fastener, however a fastener can have left hand threads which
requires the tool’s output to 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.

5.2.9 Tool Temperature


STANLEY tools are thermally protected to prevent overheating. Temperature is sensed inside the tool and the value
is reported to the controller. The thermal protection does not allow the tool to operate if the tool temperature
rises abnormally – the thermal protector resets automatically when the tool cools down. The maximum tool
temperature before damage occurs is 150°C.
EN60745-1 Hand-Held Motor-Operated Electric Tools - Safety is the most applicable standard to the tools. It

Instruction Manual 111


Special Application Tools
defines +60°C as the limit for thermal rise over ambient of a contactable surface (e.g. if the ambient is 25°C, the
surface limit is 85°C.) Since the default limit is 85°C inside the tool regardless of ambient, no external surface can
exceed this value no matter what the ambient temperature.
STANLEY allows the temperature limit adjustment to provide flexibility to the professional user. Once a customer
changes the setting from the factory default, it is their responsibility to ensure the safety of the user.
Controller parameter settings can have a significant effect on tool operating temperatures.

5.2.10 Setting Torque, Angle, and Other Operating Parameter


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 via the controller.

CAUTION
• Ensure fastener and/or system will withstand the level of torque generated by the tool. Excessive torque may
cause breakage and possible personal injury.

The Alpha controller can be setup to change tightening Jobs or Tasks from the tool’s MFB.

5.2.11 Assembly (Forward) Operation


Prepare to resist the tool’s torque reaction.
Keep the tool pointed straight at (perpendicular to) the fastener. Start the tool by depressing the start trigger
switch. The tool stops after reaching torque.
Release start trigger switch after the cycle is complete.

5.2.12 Disassembly (Reverse) Operation


Prepare to resist the tool’s torque reaction which will be the opposite of the assembly reaction.
Start the tool by depressing the start lever or trigger. The tool is not running inside of a strategy so it will not
stop on its own.
Release start lever after sufficient time or rotation to stop the tool.

5.3 Special Application Tools


5.3.1 Exposed Gear Socket Tools

112 QB Expert Alpha Controller


Tool Operation
WARNING
PINCH POINT AT THE EXPOSED GEARS OR TEETH
To Avoid Injury:
• Keep body parts and clothing away from the exposed gear sockets. Dress properly. Do not wear loose-fitted
clothing or jewelry.

Exposed gear socket tools are designed to fit into tight spaces where other tools do not fit. These tools have
exposed gears or ratchet teeth. It is recommended to use the MFB ARMING feature for these types of tools.

5.3.2 Tubenut Nutrunners


WARNING
PINCH POINT AT THE EXPOSED GEARS OR TEETH
To Avoid Injury:
• Never place body parts or clothing, near the socket opening. Dress properly. Do not wear loose-fitted
clothing or jewelry.
• Follow the Tubenut Nutrunner Sequence of Operation

Tubenut nutrunners are used for installing tube fittings.

5.3.2.1 General Sequence of Operation


Place nutrunner socket around the tube and onto the nut.
Press the MFB to ARM the start function if this is programmed.
Depress start trigger to start the tool’s tightening strategy.
The tool stops after reaching torque.
Release the start trigger and lift the tool from the nut. All tool status lights flash to indicate the tool will now run
in reverse to open the socket.
Depress the start trigger until the socket returns to the open position.
Release the start trigger.
Remove the tool from the tube.

5.3.2.2 ARM Mode


All tubenut tools are programmed with ARM required for personal safety. End users are free to reprogram the
tool so that ARM is not required. The tubenut operation will behave differently between ARM required and not
required. This table explains the operations of the tubenut tool with and without ARM required.

Instruction Manual 113


Special Application Tools
Normal Operator Does Not Press
Arming Tool is Disabled
Operation MFB to Arm Tool
Assembly Mode: Assembly Mode: Assembly Mode:
After the operator starts the tool Tool will run in Normal The tool will not run when
and when the trigger switch is Assembly mode when operator pulls the trigger. The
released the tool switches to operator presses the start controller display will indicate
Homing mode. Tool does not trigger switch. “Error Proofing”.
have to reach target. When operator releases start When operator releases start
trigger switch the tool will trigger switch the tool will
switch to Homing mode. switch to Homing mode.
Homing Mode: Homing Mode: Homing Mode:
Not Tool will run in Homing mode Tool will run in Normal Tool will run in Normal Homing
Required when operator presses the start Homing mode when operator mode when operator presses
trigger switch. presses the start trigger the start trigger switch.
Tool will remain in Homing switch.
mode until one of the following
conditions is met:
1. Dog Torque is achieved.
2. T otal Homing angle is <360°
when operator releases the
start trigger switch.
3. ARM Timeout has elapsed.
Assembly Mode: Assembly Mode: Assembly Mode:
Operator must ARM the tool by The tool will not run. The The tool will not run when
pressing the MFB once quickly. controller display will indicate operator presses the start
Operator must start the tool “Arming Required”. trigger switch. The controller
before ARM times out. When the display will indicate “Error
start trigger switch is released Proofing”.
the tool switches to Homing When operator releases start
mode. Tool does not have to trigger switch the tool will
reach target. switch to Homing mode.
Required
Homing Mode: Homing Mode: Homing Mode:
Tool will remain in Homing The tool cannot enter Homing Tool will run in Normal Homing
mode until one of the following mode unless the tool has mode when operator presses
conditions is met: been armed in the assembly the start trigger switch.
1. Dog Torque is achieved. mode at least once.
2. T otal Homing angle is <360°
when operator releases the
start trigger switch.
3. ARM Timeout has elapsed.

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Instruction Manual 115


QB Expert Alpha Controller

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

6.1 Power Cord


Alpha Controllers use an IEC 60320 style connector. The power source connector for the power cord is based on
customer requirements. The power cord should be rated at either 15A/125V for 115V AC or 10A/250V for 230V
AC power connections.

6.2 Tool Connector


6.2.1 EA, EB and EC 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 B
position.

30-pin Tool Connector

6.2.2 E Tools
Alpha controllers use a single 30 pin connector to connect one QPM EA DC electric tool cable. QPM EA DC electric
tool cables use a MIL-C-38999 Series III connector. The connector is a 17-30S with the insert clocked in the normal
position.

30-pin Tool Connector

6.3 USB Connector


The USB connector is used for data transfer between a USB memory stick and the controller, controller upgrades
and for receiving PART ID ASCII data from a USB barcode scanner. No mounting or unmounting of the memory
stick is required. Simply insert a USB memory stick when requested and remove after the operation is complete.
Do not energize the controller with a USB memory stick installed.

118 QB Expert Alpha Controller


Controller Connections


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.

6.4 Serial Connector


Alpha controllers have one male DB-9 connector. The setup is 9600-baud rate, 8 data bits, No Parity and 1 Stop
bit, and is not programmable except with the PLC. The connection between a device such as a computer and the
controller is a null-modem cable.
Communication functions can be selected for the serial port. See section “3.1.3.3 Serial Tab” on page 50.

DB-9 Connector Pins

Pin Function Pin Function Pin Function

1 Carrier Detect 4 Data Terminal Ready 7 Request to Send


2 Receive Data 5 Signal Ground 8 Clear to Send

3 Transmit Data 6 Data Set Ready 9 Ring Indicator

The controller uses only pins 2, 3, and 5.


Fastening Cycle String:
S01,JB01,  4.1,A,126.2,A,A,06/09/2008 10:20:19,                                ,
  |    |     | |     | | |  |  |    |  |  |  |                       |
  |    |     | |     | | |  |  |    |  |  |   |                       barcode (32 characters)
  |    |     | |     | | |  |  |    |  |  |  second
  |    |     | |     | | |  |  |    |  |  minute
  |    |     | |     | | |  |  |    |  hour
  |    |     | |     | | |  |  |    year
  |    |     | |     | | |  |  day
  |    |     | |     | | |  month
  |    |     | |     | | overall status (A=OK, R=NOK)
  |    |     | |     | angle status (A=OK, H=HIGH, L=LOW)
  |    |     | |     angle result (last step ran or audit step whichever is smaller, fixed decimals)
  |    |     | torque status (A=OK, H=HIGH, L=LOW)
  |    |     torque result (last step ran or audit step whichever is smaller, decimals are tool/units dependant)
  |    job number
  spindle number (1=LEADING, 2=TRAILING)

Instruction Manual 119


Alpha Toolbox Ethernet Connector
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.

6.5 Alpha Toolbox Ethernet Connector


Expert Alpha controllers have one RJ-45 Ethernet connection located on the bottom of the controller for
connecting to a computer for setup, diagnostics, upgrades and configurations with Alpha Toolbox. The Alpha
Toolbox Ethernet Connector is connected to internal DHCP and DNS servers. When a computer is connected via
an Ethernet cable to the Alpha Toolbox connector the Alpha will give the computer an IP and other addresses
to create its own network. The computer must be setup to recieve its IP Address from the Network. Once the
computer has received and set the IP Address open a browser and type http://ATB.QPM into the URL line. The
controller will serve the Alpha Toolbox web pages to the computer’s browser.

6.6 Facility/ Spindle Network Ethernet Connectors


Expert Alpha controllers have two RJ-45 Ethernet connections located on the bottom of the controller for
connecting to a facility network or spindle network. The facility network can consist of the controller and a PC
or a plant-wide fastening network. The second Ethernet connector is available to provide connections to another
Alpha to create a spindle network. The single IP Address entered in the TCP/IP tab under Communications is for
the facility network ETHERNET port. It is not required for users to know the static IP Address of the SPINDLE port
as it is a separate network and controlled by the Expert.

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

120 QB Expert Alpha Controller


Controller Connections
The Alpha controller listens on the ports specified but transmits on any available port to the port specified of the
target computer.
The ETHERNET port uses 10/100 MBaud auto-select.

6.7 Ethernet/IP or Profinet Connectors


Expert Alpha controllers have two RJ-45 Ethernet connections located on the bottom of the controller for
connecting to an Ethernet/IP or Profinet network when the option is ordered. The two ports are connected
internally and have the same IP Address. Two ports are provided so that controllers may be daisy-chained together
to create the fieldbus network rather than sending a cable from each controller back to a switch.

Ethernet/IP or Profinet Controller Network

6.8 Trailing DeviceNet™ Connector


Alpha controllers can have a single Mini DeviceNet™ port for connecting the Alpha Controller to a Leading
controller such as a PLC.
Pin Trailing

1 Drain
2 V+

3 V-
4 CAN H

5 CAN L
Alpha Controllers Mini DeviceNet™
Connector

6.9 Profibus Connector


Alpha Controllers can have a single Profibus port for connecting the Alpha Controller to a Leading Profibus
controller from another manufacturer.

Instruction Manual 121


Leading DeviceNet Connector

Figure 5‑1 DB-9 Connecter Pins (Profibus Connector)


Pin Function Pin Function Pin Function

1 Empty 4 Repeater 7 Blank


2 Empty 5 Data Ref 8 Data Line Inverse

3 Data Line 6 Power Supply 9 Empty

6.10 Leading DeviceNet Connector


Alpha controllers can have a single Micro DeviceNet™ port for connecting peripheral devices to the Alpha
Controller as a Leading controller. The assignable I/O and the embedded PLC can be programmed to run the
peripheral devices.
Pin Leading

1 Drain
2 V+

3 V-

4 CAN H

5 CAN L
Alpha Controllers Micro DeviceNet™
Connector

6.11 Input and Output Connector


All eight inputs and eight outputs are isolated 24V DC relays and contacts. The Alpha has an internal 24V DC
power supply that can be used to provide the I/O signals; an external 24V DC power supply may be used instead.
The following are amperage ratings:
Internal 24V DC supply: Maximum = 1 ampere total
External 24V DC supply: Maximum = 1 ampere per output
The Alpha controller’s Input circuits conform to the IEC 61131-2 standard for PLCs.
LIMITS per IEC 61131-2
Type Type 2 limits
Rated
Of State 0 Transition State 1
Voltage
Limit V low (v) I low (ma) V trans (v) I trans (ma) V high (v) I high (ma)

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.

122 QB Expert Alpha Controller


Controller Connections
Part No. 19-pin 24V I/O Port Included
21C104800 Mating Connector - Solder pins Standard

21C104802 Mating Connector - Crimp pins Optional

21C104804 Mating Connector - Crimp pins, crimp tool Optional

21E102202 Breakout Box for plinth mounting Optional

21C202005 I/O Cable 5M Optional

21C202010 I/O Cable 10M Optional

21C202020 I/O Cable 20M Optional

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

C Output O:0.0/0 L Input I:0.0/0

D Output O:0.0/1 M Input I:0.0/1

E Output O:0.0/2 N Input I:0.0/2

F Output O:0.0/3 P Input I:0.0/3

G Output O:0.0/4 R Input I:0.0/4

H Output O:0.0/5 S Input I:0.0/5

J Output O:0.0/6 T Input I:0.0/6

K Output O:0.0/7 U Input I:0.0/7

A 24 VDC N/A V 24 VDC Return N/A

B Output Supply N/A

Schematics of the Inputs, Outputs and other pins, with cabling, are shown below:

Instruction Manual 123


Input and Output Connector
Inputs
(example)

124 QB Expert Alpha Controller


Controller Connections
Outputs: Sourcing
(example)

Instruction Manual 125


Assignable Input and Output Functions
Outputs: Sinking
(example)

6.12 Assignable Input and Output Functions


The following Input/ Output (I/O) functions apply to the 24V DC I/O connector. There is a maximum of eight
inputs and eight outputs for the 24V DC I/O connector. There is a maximum of 512 bytes of input and 512 bytes
of output on each type of Fieldbus used with the controller (except DeviceNet with a limit of 256 bytes for both
inputs and outputs). Ninety-nine is the maximum number of I/O functions that can be assigned to each Fieldbus
input or output. Each I/O function can have a length of 1 to 32 bits. You must keep track of the lengths for each
I/O function you assign to stay within the maximum length of the Fieldbus you are using.
More than one Fieldbus connection can be used at the same time. For instance, the Alpha controller can use the
24V DC I/O connector AND ModbusTCP on Ethernet AND DeviceNet all at the same time. If more than one type
of Input uses a particular function, the controller responds to an input when a function is asserted on any one of
those inputs.
It is important to understand how the Alpha controller, and the internal PLC, responds to the rising and falling
edges of input functions as they are asserted or removed, not while the levels are high or low. The STOP bit is an
exception; it is a true OR function rather than working off the transition. One type of Input does not have priority
over the other. The controller responds to the first change in status of an input function, no matter which Fieldbus
connection makes the change.
If more than one Fieldbus shares a particular output function, that function is asserted on all shared fieldbuses.
The table below lists the available input and output functions, gives a brief description and indicates the
configuration options for each. The configuration options are an important aspect of the I/O functions, as they
add powerful, multiple dimensions to each function in the controller. These new dimensions allow integration of
the controller in unique ways, providing increased flexibility.

126 QB Expert Alpha Controller


Controller Connections
Please see the full description of each function in the section following this table.
Inputs Description Configuration Options

DISABLE JOB Disable the job Contact Type, Job, Spindle

DISABLE TASK Disable the task Contact Type, Task, Spindle

DISABLE TOOL Disable tool (will complete running if it is in cycle) Contact Type , Spindle

IGNORED Input is not used Input is not assigned

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

PART ID Sets the part identification Length, Trigger, Spindle

RESET JOB Reset a job Contact Type , Spindle

RESET RESULT STATUS Clear the result status Contact Type , Spindle

REVERSE Put the tool in reverse Contact Type , Spindle


Contact Type, Job, Disable when open,
SELECT JOB Select a job
Spindle
SELECT JOB (BIT) One bit in a series to select the job Contact Type, Bit, Mode, Spindle
Contact Type, Task, Disable When Open,
SELECT TASK Select a task
Spindle
SELECT TASK (BIT) One bit in a series to select the task Contact Type, Bit, Mode, Spindle

SET ZERO POSITION Used to set Zero Position for Position Control Strategy Contact Type, Spindle

START Start the tool Contact Type, Latch, Time, Spindle

START REVERSE Put the tool in reverse and start the tool Contact Type , Spindle

STOP Stop the tool Contact Type , Spindle

TASK VERIFY Verify the selected task to the inputs 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

Outputs Description Configuration Options


*ANGLE Angle result value Data Type, Step, Spindle

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

*BOLT Active Accumulated Bolt Count Data Type, Spindle

*CONSTANT User defined value Data Type, Constant

CYCLE ABORTED The fastening cycle was aborted/stopped Contact Type, Type, Time, Spindle

CYCLE NOK Fastening cycle was NOK Contact Type, Type, Time, Spindle

Instruction Manual 127


Assignable Input and Output Functions
Outputs Description Configuration Options

CYCLE OK Fastening cycle was OK 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

*FAULT CODE Fault code value Data Type, Spindle

FAULTED A fault condition is active Contact Type, Type, Time, Spindle

IN CYCLE The tool is in cycle 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

*PARAMETER Parameter number Data Type, Param, Step, Spindle

*PART ID Active PART ID Data Type, Spindle

PM The tool requires service Contact Type, Type, Time, Spindle

READY The tool is ready to run Contact Type, Type, Time, Spindle

*RUNDOWN BOLT Accumulated Bolt Count of last fastening cycle Data Type, Spindle

*RUNDOWN DAY Day of last fastening cycle Data Type, Spindle

*RUNDOWN HOUR Hour of last fastening cycle Data Type, Spindle

*RUNDOWN JOB Job of last fastening cycle Data Type, Spindle

*RUNDOWN MINUTE Minute of last fastening cycle Data Type, Spindle

*RUNDOWN MONTH Month of last fastening cycle Data Type, Spindle

*RUNDOWN PART ID Last fastening cycle PART ID Data Type, Spindle


*RUNDOWN SECOND Second of last fastening cycle Data Type, Spindle

*RUNDOWN STATUS Overall status of last fastening cycle Data Type, OK, NOK, Spindle

*RUNDOWN TASK Task of last fastening cycle Data Type, Spindle

*RUNDOWN UNITS Torque Units of last fastening cycle Data Type, Spindle

*RUNDOWN YEAR Year 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

STOPPED A STOP input is asserted Contact Type, Type, Time, 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

128 QB Expert Alpha Controller


Controller Connections
Outputs Description Configuration Options

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 Torque result value Data Type, Step, 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

* Outputs not available on 24 VDC

6.12.1 Input Descriptions


Each of the single bit input functions has a Configuration setting of Contact Type. The Contact Type can be
Normally Open (N.O.) or Normally Closed (N.C.). If an input’s contact type is normally open, the input is asserted
when 24V DC is applied to the 24V DC connector input pin, or when the fieldbus bit transitions from low to high.
If an input’s contact type is normally closed, the input is asserted when 24V DC is removed from the 24V DC
connector input pin, or when the fieldbus bit transitions from high to low.
The Input functions assert on the transition only.
Job or Task selection can come from multiple inputs at once, including the MFB. There is no priority, each one
is equal. The Alpha controller switches its active Job or Task with each input change. The last one to change
becomes the active Job or Task.
Spindle – Indicates to which spindle in the multi-spindle system this function applies.
Inputs Description
When asserted on any input bus, the controller disables the tool while this specific job is selected. This acts like a
STOP to stop the tool during use. Use the JOB parameter under Configuration to select the job to be disabled while
this input is asserted.
When removed the tool will be allowed to run while this specific job is selected.
Size: 1 bit
DISABLE JOB
Configuration:
Contact Type: Normally Open (N.O.), Normally Closed (N.C.)
Job: Type the job number to select when this input is asserted.
Spindle: Type the spindle number in which the Job is to be disabled.
When asserted on any input bus, the tool is disabled while this specific task is selected. This acts like a STOP to stop
the tool during use. Use the Task parameter under Configuration to select the disabled task.
When removed, the tool will be allowed to run while this specific task is selected.
Size: 1 bit
DISABLE TASK Configuration:
Contact Type: Normally Open (N.O.), Normally Closed (N.C.)
Task: Type the task number to disable when this input is asserted.
Spindle: Type the spindle number in which the Task is to be disabled.

Instruction Manual 129


Assignable Input and Output Functions
Inputs Description
When asserted on any input bus, the controller prevents the tool from running. It does NOT stop the tool if the tool
is running, but prevents it from running when the next START signal is applied. The START input can come from any
bus or the tool trigger.
When removed the tool is allowed to run after the next START input.
DISABLE TOOL Size: 1 bit
Configuration:
Contact Type: Normally Open (N.O.), Normally Closed (N.C.)
Spindle: Type the spindle number for which the tool is to be disabled.
The input is not used. This is a placeholder. For fieldbus, the length of this input function may be set to any size that
IGNORE meets the need.
When asserted on any input bus, the controller verifies the selected job number is equal to this input’s job number.
Use the JOB parameter under Configuration to select the job number to verify. If the wrong job is selected the tool
is disabled.
When removed, verification will not happen.
Size: 1 bit
JOB VERIFY
Configuration:
Contact Type: Normally Open (N.O.), Normally Closed (N.C.)
Job: Type the job number to verify when this input is asserted.
Spindle: Type the spindle number for which the job is to be verified.
When asserted on any input bus, the controller verifies the selected and active job is equal to this input’s job. Use
the BIT parameter under Configuration to select the job number to verify. If there is a mismatch between the active
job number and this input’s job number the tool is disabled. This is one bit of a binary number created by many of
these bits. See SELECT TASK BIT to understand how to use bits to create binary numbers.
When removed verification will not happen.
Size: 1 bit, except on fieldbus where it can be any size to fit the need.
Configuration:
JOB VERIFY BIT
Contact Type: Normally Open (N.O.), Normally Closed (N.C.)
Bit: Type the number this bit to be in the binary number scheme to verify a job.
Mode: All JOB VERIFY 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) plus 1.
Spindle: Type the spindle number for which the job is to be verified.
When asserted on any fieldbus input, the controller reads the new PART ID input and places the data into the Part
ID buffer. This is added to the fastening cycle data and stored in the controller. This input function is NOT available
on the 24V DC input bus.
Size: Can be any size from 1 to 32 bytes.
*PART ID When removed nothing happens.
Configuration:
Length: Type the length of the expected data string in bits.
Spindle: Type the spindle number to receive the PART ID data.

130 QB Expert Alpha Controller


Controller Connections
Inputs Description
When asserted, on any input, the controller resets the accumulated bolt count to zero for the active job and
acts as a part entry to re-enable the tool if disabled. The tool could be disabled due to “Error Proofing” and the
accumulated bolt count equal to target bolt count.
When removed nothing happens.
RESET JOB Size: 1 bit
Configuration:
Contact Type: Normally Open (N.O.), Normally Closed (N.C.)
Spindle: Type the spindle number in which the job is to be reset.
When asserted on any input bus, the controller resets to 0 (zero) any fastening cycle results status output bit on the
same bus. Meaning, if asserted on DeviceNet, only the DeviceNet output status bits are reset. Output status bits on
other buses will remain in their original state.
The list of status bits that will reset are:

CYCLE OK CYCLE NOK

TORQUE OK TORQUE HIGH

TORQUE LOW ANGLE OK

ANGLE HIGH ANGLE LOW


RESET RESULT
STATUS CYCLE ABORTED CYCLE STOP

CURRENT OK CURRENT HIGH

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.

Instruction Manual 131


Assignable Input and Output Functions
Inputs Description
When asserted or removed on any input type, the controller selects a job. This is one bit, in a series of bits, to create
a binary number.
See SELECT TASK (BIT) function description for explanation of this bit (note that this references Jobs not Tasks).
Size: 1 bit, except on fieldbus where it can be any size to fit the need.
Configuration:
SELECT JOB Contact Type: Normally Open (N.O.), Normally Closed (N.C.)
(BIT) Bit: Type the number of this bit, in the binary number scheme, to select jobs.
Mode: All JOB SELECT BITs must be the same mode, modes cannot be mixed.
Binary – Creates a decimal number equivalent to the weighted value of this binary bit(s).
Binary + 1 – Creates a number equivalent to the weighted value of this binary bit(s) and adds the value of one
(1) to that number.
Spindle: Spindle: Type the spindle number in which the job is to be selected.
When asserted, on any input type, the controller makes this input’s Task the active Task.
When removed either nothing happens or if “Disable when open” is selected as yes, then the tool becomes
disabled.
Size: 1 bit
Configuration:
SELECT TASK Contact Type: Normally Open (N.O.), Normally Closed (N.C.)
Task: Type the Task 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 task is to be selected.

132 QB Expert Alpha Controller


Controller Connections
Inputs Description
When asserted or removed, on any input bus, the controller selects a Task. This is one bit, in a series of bits, to
create a binary number.
The number created by this and other SELECT TASK BITs determines the active task for the tool. More than one
input assigned as a TASK SELECT BIT creates a number greater than one. The maximum number of tasks required
determines the maximum number of these inputs.
In binary numbers, the digit furthest to the right is the ones digit. The next digit to the left is the twos digit, next
is the fours digit, then the eights digit, and so on. The integer equivalent to a binary number can be found by
summing all the weighted values of the selected digits. For example, the binary number 10101 is equivalent to
the integer 21. The math is 1 + 4 + 16 = 21: the high digits (one) are added together and the low digits (zero) are
ignored.

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.

Instruction Manual 133


Assignable Input and Output Functions
Inputs Description
When asserted, on any input type, the tool starts and runs the currently selected job/task. This input is overridden
by the STOP input. If STOP is used and a tool restart is required, remove the STOP, remove the START, then re-assert
the START. If the tool is required to operate in Disassembly mode, remove the START, assert the REVERSE input, and
then re-assert the START.
When removed, from any bus of Input, the tool stops. Even if a second START input is active, the tool stops when
any START is removed.
Size: 1 bit
Configuration:
START Contact Type: Normally Open (N.O.), Normally Closed (N.C.)
Latch: This is applicable to external inputs only. This is not applicable to the trigger on the tool handle.
Yes – Causes the START input to latch internally after a time period has elapsed. The physical START input can
be removed without stopping the tool. The tool runs until all steps in the active task are complete or time out.
A TIME parameter is available to set how long the START input must be applied, in seconds, before the Latch
becomes active.
No – The Latch function is off.
Spindle: Type the spindle number for tool to be started.
When asserted on any input bus, the tool mode is switched to Reverse (Disassembly) AND the tool is started. This is
different from the REVERSE input function in that REVERSE puts the tool into Reverse mode only.
When removed the tool stops and switches back to Forward mode.
START Size: 1 bit
REVERSE
Configuration:
Contact Type: Normally Open (N.O.), Normally Closed (N.C.)
Spindle: Type the spindle number for tool to be reversed.
When asserted, on any input type, the controller stops the tool. It also prevents the tool from running while it is
applied.
When removed nothing happens other than the tool runs.
STOP Size: 1 bit
Configuration:
Contact Type: Normally Open (N.O.), Normally Closed (N.C.)
Spindle: Type the spindle number for tool to be stopped.
When asserted on any input bus, the controller verifies the selected and active task is equal to this input’s task. Use
the TASK parameter under Configuration to select the task number to verify. If the wrong task is selected the tool is
disabled.
When removed, verification will not happen.
Size: 1 bit
TASK VERIFY
Configuration:
Contact Type: Normally Open (N.O.), Normally Closed (N.C.)
Task: Type the task number to verify when this input is asserted.
Spindle: Type the spindle number for which the task is to be verified.

134 QB Expert Alpha Controller


Controller Connections
Inputs Description
When asserted on any input bus, the controller verifies the selected task number is equal to this input’s task
number. Use the BIT parameter under Configuration to select the task number to verify. If there is a mismatch
between the active task and the selected task the tool is disabled. This is one bit of a binary number created by
many of these bits. See SELECT TASK BIT to understand how to use bits to create binary numbers.
When removed verification will not happen.
Size: 1 bit, except on fieldbus where it can be size any size to fit the need.
Configuration:
TASK VERIFY
BIT Contact Type: Normally Open (N.O.), Normally Closed (N.C.)
Bit: Type the number this bit will be in the binary number scheme to verify a task.
Mode: All TASK VERIFY BITs must be the same mode, no mixing of modes allowed.
Binary – Creates a decimal number equivalent to the weighted value of this binary bit(s).
Binary + 1 – Creates a number equivalent to the weighted value of this binary bit(s) and add the value of one
(1) to that number.
Spindle: Type the spindle number for which the task is to be verified.

* Outputs not available on 24 VDC

6.12.2 Output Descriptions


Each of the output functions has Configuration settings: Contact types, Output types and others. It is recommended
to configure them immediately once the output functions are assigned to a pin.
Contact Type
The Contact Type can be Normally Open (N.O.) or Normally Closed (N.C.).
Sourcing Outputs (PNP type)
If an output’s contact type is normally open and the output is asserted, the output pin transitions from 0V DC to
24V DC. If an output’s contact type is normally closed and the output is asserted, the output pin transitions from
24V DC to 0V DC.
Sinking Outputs (NPN type)
If an output’s contact type is normally open and the output is asserted, the output pin transitions from 24V DC to
0V DC. If an output’s contact type is normally closed and the output is asserted, the output pin transitions from
0V DC to 24V DC.
Output Type
The Output Type defines the behavior of the output signal.
Normal – The output asserts and stays asserted until a reset condition occurs.
Minimum On Time – Keeps the output asserted for this minimum time in seconds, even though a reset condition
occurs. After the timer is finished, the output resets if a reset condition has occurred, otherwise it remains asserted
until a reset condition occurs.
Timed – The output asserts for this period of time, then resets on its own without waiting for the reset condition
to occur.
Time – Units are in seconds.
Flash – The output flashes for as long as it is asserted.
Period – Sets the flashing on and off times, which are equal. Units are in seconds
Spindle – Indicates from which spindle in the multi-spindle system this function comes.

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Assignable Input and Output Functions
Outputs Description
This output is the peak achieved angle value during the fastening cycle from the Audit step. It asserts when
the fastening cycle is complete (before the IN CYCLE bit resets). The value resets to zero (0) when the tool is
commanded to run again.
Size: Can be any size from 0 to 32 bytes depending on Data Type
*ANGLE
Data Type: Float, Int8, Int16, Int32, Fixed Point, String
Step: Audit, Audit-1, Audit-2
Spindle: Type the spindle number from which the angle value comes.
Asserts at the end of a fastening cycle when the achieved angle value is above the High Angle limit for the Audit
step. Resets when the tool is commanded to start again. Can also be reset with the RESET RESULTS STATUS
input.
Size: 1 bit
Configuration:
ANGLE HIGH Contact Type: Normally Open (N.O.), Normally Closed (N.C.)
Step: Audit, Audit-1, Audut-2
Output Type: Normal, Timed, Flash
Minimum ON Time, Time, Period
Spindle: Type the spindle number from which the angle status comes.
Asserts at the end of a fastening cycle when the achieved angle value is below the Low Angle limits for the
Audit step. Resets when the tool is commanded to start again. Can also be reset with the RESET RESULTS
STATUS input.
Size: 1 bit
Configuration:
ANGLE LOW Contact Type: Normally Open (N.O.), Normally Closed (N.C.)
Step: Audit, Audit-1, Audut-2
Output Type: Normal, Timed, Flash
Minimum ON Time, Time, Period
Spindle: Type the spindle number from which the angle status comes.
Asserts at the end of a fastening cycle when the achieved angle value is within limits for the Audit step. Resets
when the tool is commanded to start again. Can also be reset with the RESET RESULTS STATUS input.
Size: 1 bit
Configuration:
ANGLE OK Contact Type: Normally Open (N.O.), Normally Closed (N.C.)
Step: Audit, Audit-1, Audut-2
Output Type: Normal, Timed, Flash
Minimum ON Time, Time, Period
Spindle: Type the spindle number from which the angle status comes.

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Outputs Description
This output will be one of three selections. The selections are the User Defined Value for the associated angle
status of the last fastening cycle. For example: if the last fastening cycle’s angle status was Low, and the User
Defined Value for Low is -, then this output value is-.
The OK User Defined Value is selected when the achieved angle for the defined Step are within specified limits.
The Low User Defined Value is selected when the achieved angle for the defined Step is below the Low Angle
limit.
The High User Defined Value is selected when the achieved angle, for the defined Step, is above the High Angle
limit.
It asserts when the fastening cycle is complete (before the IN CYCLE bit resets). The value resets to zero (0)
*ANGLE STATUS when the tool is commanded to run again.
Size: Can be any size from 0 to 32 bytes depending on Data Type
Configuration:
Data Type: Float, Int8, Int16, Int32, Fixed Point, String
Step: Audit, Audit-1, Audit-2
OK: User Defined Value
Low: User Defined Value
High: User Defined Value
Spindle: Type the spindle number from which the angle status comes.
This output is the value of the active accumulated bolt count. As the bolt count changes so does this output.
Size: Can be any size from 0 to 32 bytes depending on Data Type
*BOLT Configuration:
Data Type: Float, Int8, Int16, Int32, Fixed Point, String
Spindle: Type the spindle number from which the bolt status comes.
This value is defined by the end user in the Constant parameter. It asserts when the fastening cycle is complete
(after the IN CYCLE bit resets). The value resets to zero (0) when the tool is commanded to run again.
Size: Can be any size from 0 to 32 bytes depending on Data Type
*CONSTANT
Configuration:
Data Type: Float, Int8, Int16, Int32, Fixed Point, String
Constant: Type the value of the constant required
Asserts when the controller shuts the tool off due to a fault or if the Stop/Abort within Limits parameter is used
and the fastening cycle has a shutoff code of ABORT. Resets when the tool is commanded to run again. Can also
be reset with the RESET RESULTS STATUS input.
Size: 1 bit
Configuration:
CYCLE ABORTED
Contact Type: Normally Open (N.O.), Normally Closed (N.C.)
Output Type: Normal, Timed, Flash
Minimum ON Time, Time, Period
Spindle: Type the spindle number from which the abort status comes.

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Assignable Input and Output Functions
Outputs Description
Asserts at the end of a fastening cycle when the achieved torque and/or angle for the Audit step are NOT within
specified limits. Also asserts when the Stop/Abort within Limits parameter is set to Yes and the tool is stopped
or aborted within limits. Resets when the tool is commanded to run again. Can also be reset with the RESET
RESULTS STATUS input.
Size: 1 bit
CYCLE NOK Configuration:
Contact Type: Normally Open (N.O.), Normally Closed (N.C.)
Output Type: Normal, Timed, Flash
Minimum ON Time, Time, Period
Spindle: Type the spindle number from which the cycle status comes.
Asserts at the end of a fastening cycle when the achieved torque and angle for the Audit step are within
specified limits. Will not assert if the Stop/Abort within Limits parameter is set to Yes and the tool is stopped
or aborted within limits. Resets when the tool is commanded to run again. Can also be reset with the RESET
RESULTS STATUS input.
Size: 1 bit
CYCLE OK Configuration:
Contact Type: Normally Open (N.O.), Normally Closed (N.C.)
Output Type: Normal, Timed, Flash
Minimum ON Time, Time, Period
Spindle: Type the spindle number from which the cycle status comes.
Asserts when the tool shuts off due to a loss of Start signal or the operator released the trigger before the target
was achieved. Resets when the tool is commanded to run again. Can also be reset with the RESET RESULTS
STATUS input.
Size: 1 bit
Configuration:
CYCLE STOPPED
Contact Type: Normally Open (N.O.), Normally Closed (N.C.)
Output Type: Normal, Timed, Flash
Minimum ON Time, Time, Period
Spindle: Type the spindle number from which the cycle status comes.
Asserts when the tool is running in Reverse and the achieved torque value exceeds the Threshold Torque value
through some rotation. Resets when the tool is stopped.
Size: 1 bit
Configuration:
DISASSEMBLY
DETECTED Contact Type: Normally Open (N.O.), Normally Closed (N.C.)
Output Type: Normal, Timed, Flash
Minimum ON Time, Time, Period
Spindle: Type the spindle number from which the disassembly status comes.

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Outputs Description
This output is the number value of the fault code present in the controller. It asserts when a fault is active and
resets when the fault clears. The values are as follows:
1 – Overcurrent Fault! 2 – Logic Voltage Fault!

3 – Position Feedback Fault! 4 – Transducer Span Fault!

5 – Temperature Fault! 6 – Unrecognized Tool!

7 – Tool Communications! 8 – Transducer Current Fault!

9 – Transducer Zero Fault! 10 – Unused


*FAULT CODE
11 – Unused 12 – Unused

13 – Unsupported Tool! 14 – GFI Fault!

15 – Servo Connection Fault!


Size: Can be any size from 0 to 32 bytes depending on Data Type
Configuration:
Data Type: Float, Int8, Int16, Int32, Fixed Point, String
Spindle: Type the spindle number from which the fault code comes.
Asserts when there is a fault on the controller. Resets when the fault clears.
Size: 1 bit
Configuration:
FAULTED Contact Type: Normally Open (N.O.), Normally Closed (N.C.)
Output Type: Normal, Timed, Flash
Minimum ON Time, Time, Period
Spindle: Type the spindle number from which the fault comes.
Asserts during the fastening cycle when the achieved torque value exceeds the Threshold Torque value. Resets
when the fastening cycle has ended.
Size: 1 bit
Configuration:
IN CYCLE
Contact Type: Normally Open (N.O.), Normally Closed (N.C.)
Output Type: Normal, Timed, Flash
Minimum ON Time, Time, Period
Spindle: Type the spindle number from which the signal comes.
Asserts when the tool’s operation is set to Reverse. Resets when the tool’s operation is set to Forward.
Size: 1 bit
Configuration:
IN REVERSE Contact Type: Normally Open (N.O.), Normally Closed (N.C.)
Output Type: Normal, Timed, Flash
Minimum ON Time, Time, Period
Spindle: Type the spindle number from which the signal comes.

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Assignable Input and Output Functions
Outputs Description
Asserts when a job is completed (accumulated bolt count equals target bolt count). Resets when a different job
is selected or when the input RESET JOB is asserted.
Size: 1 bit
Configuration:
JOB COMPLETE
Contact Type: Normally Open (N.O.), Normally Closed (N.C.)
Output Type: Normal, Timed, Flash
Minimum ON Time, Time, Period
Spindle: Type the spindle number from which the signal comes.
Asserts when a job is selected by any means. Resets when the active job is complete.
Size: 1 bit
Configuration:
Contact Type: Normally Open (N.O.), Normally Closed (N.C.)
JOB SELECTED
Job: Type the job number that, when selected, asserts this output.
Output Type: Normal, Timed, Flash
Minimum ON Time, Time, Period
Spindle: Type the spindle number from which the signal comes.
Asserts when required to indicate the active job. This is one bit in a series of bits to create a binary number. As
jobs change so will the binary number created from these bits.
Size: 1 bit
Configuration:
Contact Type: Normally Open (N.O.), Normally Closed (N.C.)
JOB SELECTED BIT Bit: Type the number this bit to be in the binary number scheme for selected jobs.
Mode: All JOB SELECTED BITs must be the same mode, modes cannot be mixed.
Binary – Creates a decimal number equivalent to the weighted value of this binary bit(s).
Binary + 1 – Creates a number equivalent to the weighted value of this binary bit(s) and adda the value
of one (1) to that number.
Spindle: Type the spindle number from which the signal comes.
Asserts when the tool’s Multi-function Button is pressed. Resets when the Multi-function Button is released.
Size: 1 bit
Configuration:
MULTI-FUNCTION
Contact Type: Normally Open (N.O.), Normally Closed (N.C.)
BUTTON
Output Type: Normal, Timed, Flash
Minimum ON Time, Time, Period
Spindle: Type the spindle number from which the signal comes.
The output is not used. This is essentially a placeholder.
NOT USED
For fieldbus, the length of this input function may be set to any size that meets the need.

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Outputs Description
This output is the value of the selected Parameter. It changes when the parameter changes.
Size: Can be any size from 0 to 32 bytes depending on Data Type
Configuration:
Data Type: Float, Int8, Int16, Int32, Fixed Point, String
*PARAMETER Parameter: Strategy, Torque Target, High Torque, Low Torque, Angle Target, High Angle, Low Angle, Snug
Torque, Speed, Step Name, Torque Cal, Tool Serial Number, Torque Bailout, Angle Bailout, Downshift Torque,
Downshift Speed, Tool Model Number, Task Name, Job Name, Task Bolt Count.
Step: Audit, Audit-1, Audit-2
Spindle: Type the spindle number from which the signal comes.
This value is equal to and changes as the PART ID input changes.
Size: Can be any size from 0 to 32 bytes depending on Data Type
*PART ID Configuration:
Data Type: Float, Int8, Int16, Int32, Fixed Point, String
Spindle: Type the spindle number from which the signal comes.
Asserts when the Preventive Maintenance Count in the tool’s memory has exceeded the Preventive Maintenance
Threshold. Resets when the Preventive Maintenance Count is reset to zero.
Size: 1 bit
Configuration:
PM
Contact Type: Normally Open (N.O.), Normally Closed (N.C.)
Output Type: Normal, Timed, Flash
Minimum ON Time, Time, Period
Spindle: Type the spindle number from which the signal comes.
Asserts when there is no fault on the controller and the tool is ready to run. This output resets when the tool is
disabled. The blue light on the controller and tool will illuminate when this output is on.
Size: 1 bit
Configuration:
READY Contact Type: Normally Open (N.O.), Normally Closed (N.C.)
Output Type: Normal, Timed, Flash
Minimum ON Time, Time, Period
Spindle: Type the spindle number from which the signal comes.
This is the accumulated bolt count value of the last fastening cycle. It asserts when the fastening cycle is
complete (after the IN CYCLE bit resets). The value resets to zero (0) when the tool is commanded to run again.
Size: Can be any size from 0 to 32 bytes depending on Data Type
*RUNDOWN BOLT
Configuration:
Data Type: Float, Int8, Int16, Int32, Fixed Point, String
Spindle: Type the spindle number from which the signal comes.
This is the day value of the last fastening cycle date. It asserts when the fastening cycle is complete (before the
IN CYCLE bit resets). The value resets to zero (0) when the tool is commanded to run again.
Size: Can be any size from 0 to 32 bytes depending on Data Type
*RUNDOWN DAY
Configuration:
Data Type: Float, Int8, Int16, Int32, Fixed Point, String
Spindle: Type the spindle number from which the signal comes.

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Assignable Input and Output Functions
Outputs Description
This is the hour value of the last fastening cycle time. It asserts when the fastening cycle is complete (before the
IN CYCLE bit resets). The value resets to zero (0) when the tool is commanded to run again.
Size: Can be any size from 0 to 32 bytes depending on Data Type
*RUNDOWN
HOUR Configuration:
Data Type: Float, Int8, Int16, Int32, Fixed Point, String
Spindle: Type the spindle number from which the signal comes.
This value indicates the job in which the last fastening cycle was performed. It asserts when the fastening cycle
is complete (before the IN CYCLE bit resets). The value resets to zero (0) when the tool is commanded to run
again.
Size: Can be any size from 0 to 32 bytes depending on Data Type
*RUNDOWN JOB
Configuration:
Data Type: Float, Int8, Int16, Int32, Fixed Point, String
Spindle: Type the spindle number from which the signal comes.
This is the minute value of the last fastening cycle time. It asserts when the fastening cycle is complete (before
the IN CYCLE bit resets). The value resets to zero (0) when the tool is commanded to run again.
Size: Can be any size from 0 to 32 bytes depending on Data Type
*RUNDOWN
MINUTE Configuration:
Data Type: Float, Int8, Int16, Int32, Fixed Point, String
Spindle: Type the spindle number from which the signal comes.
This is the month value of the last fastening cycle date. It asserts when the fastening cycle is complete (before
the IN CYCLE bit resets). The value resets to zero (0) when the tool is commanded to run again.
Size: Can be any size from 0 to 32 bytes depending on Data Type
*RUNDOWN
MONTH Configuration:
Data Type: Float, Int8, Int16, Int32, Fixed Point, String
Spindle: Type the spindle number from which the signal comes.
This is the PART ID value of the last fastening cycle date. It asserts when the fastening cycle is complete (before
the IN CYCLE bit resets). The value resets to zero (0) when the tool is commanded to run again.
Size: Can be any size from 0 to 32 bytes depending on Data Type
*RUNDOWN
PART ID Configuration:
Data Type: Float, Int8, Int16, Int32, Fixed Point, String
Spindle: Type the spindle number from which the signal comes.
This is the second value of the last fastening cycle time. It asserts when the fastening cycle is complete (before
the IN CYCLE bit resets). The value resets to zero (0) when the tool is commanded to run again.
Size: Can be any size from 0 to 32 bytes depending on Data Type
*RUNDOWN
SECOND Configuration:
Data Type: Float, Int8, Int16, Int32, Fixed Point, String
Spindle: Type the spindle number from which the signal comes.

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Outputs Description
This output will be one of two selections. The selections are the User Defined Value for the associated status of
the last fastening cycle. For example: if the last fastening cycle status was OK, and the User Defined Value for OK
is Good, then this output value is Good.
The OK User Defined Value asserts at the end of a fastening cycle when the achieved torque and angle for the
Audit step are within specified limits.
The NOK User Defined Value asserts at the end of a fastening cycle when the achieved torque and angle for the
Audit step are NOT within specified limits.
*RUNDOWN The value resets to zero (0) when the tool is commanded to run again.
STATUS
Size: Can be any size from 0 to 32 bytes depending on Data Type
Configuration:
Data Type: Float, Int8, Int16, Int32, Fixed Point, String
OK: User Defined Value
NOK: User Define Value
Spindle: Type the spindle number from which the signal comes.
This value indicates the task in which the last fastening cycle was performed. It asserts when the fastening
cycle is complete (after the IN CYCLE bit resets). The value resets to zero (0) when the tool is commanded to run
again.
Size: Can be any size from 0 to 32 bytes depending on Data Type
*RUNDOWN TASK
Configuration:
Data Type: Float, Int8, Int16, Int32, Fixed Point, String
Spindle: Type the spindle number from which the signal comes.
This is the numeric equivalent value of the torque units of the last fastening cycle. It asserts when the fastening
cycle is complete (after the IN CYCLE bit resets). The value resets to zero (0) when the tool is commanded to run
again.
The numeric equivalent values are:
0 – NM
1 – FTLB
2 – INLB
3 – INOZ
*RUNDOWN
4 – KGM
UNITS
5 - KGCM
6 – NCM
7 – NDM
Size: Can be any size from 0 to 32 bytes depending on Data Type
Configuration:
Data Type: Float, Int8, Int16, Int32, Fixed Point, String
Spindle: Type the spindle number from which the signal comes.
This is the year value of the last fastening cycle date. It asserts when the fastening cycle is complete (before the
IN CYCLE bit resets). The value resets to zero (0) when the tool is commanded to run again.
Size: Can be any size from 0 to 32 bytes depending on Data Type
*RUNDOWN
YEAR Configuration:
Data Type: Float, Int8, Int16, Int32, Fixed Point, String
Spindle: Type the spindle number from which the signal comes.

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Assignable Input and Output Functions
Outputs Description
Asserts at the end of a fastening cycle if the achieved torque value exceeds the Snug Torque value during the
fastening cycle. Resets when the tool is commanded to run again. Can also be reset with the RESET RESULTS
STATUS input.
Size: 1 bit
Configuration:
SNUG ACHIEVED Contact Type: Normally Open (N.O.), Normally Closed (N.C.)
Step: Audit, Audit-1, Audut-2
Output Type: Normal, Timed, Flash
Minimum ON Time, Time, Period
Spindle: Type the spindle number from which the signal comes.
Asserts when the tool’s trigger is pressed. Resets when the tool trigger is released.
Size: 1 bit
Configuration:
START TRIGGER Contact Type: Normally Open (N.O.), Normally Closed (N.C.)
Output Type: Normal, Timed, Flash
Minimum ON Time, Time, Period
Spindle: Type the spindle number from which the signal comes.
Asserts at the end of the fastening cycle to indicate the last step ran. This is one bit, in a series of bits, to create
a binary number.
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.)
STEP (BIT) Bit: Type the number this bit will be in the binary number scheme for steps.
Mode: All STEP BITs must be the same mode, no mixing of modes allowed.
Binary – Creates a decimal number equivalent to the weighted value of this binary bit(s).
Binary + 1 – Creates a number equivalent to the weighted value of this binary bit(s) and add the value
of one (1) to that number.
Spindle: Type the spindle number from which the signal comes.
Asserts when the STOP input is received, or anytime the tool is stopped. Resets when the STOP input or the Stop
Tool Operation is reset. The icon is on when this output is on.
Size: 1 bit
Configuration:
STOPPED
Contact Type: Normally Open (N.O.), Normally Closed (N.C.)
Output Type: Normal, Timed, Flash
Minimum ON Time, Time, Period
Spindle: Type the spindle number from which the signal comes.
Asserts when a task is complete (all bolts assigned to task are OK). Resets when a task is selected.
Size: 1 bit
Configuration:
Contact Type: Normally Open (N.O.), Normally Closed (N.C.)
TASK COMPLETE
Task: Type the task number that, when completed, asserts this output.
Output Type: Normal, Timed, Flash
Minimum ON Time, Time, Period
Spindle: Type the spindle number from which the signal comes.

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Outputs Description
Asserts when a task is selected by any means. Resets when the active task is complete.
Size: 1 bit
Configuration:
Contact Type: Normally Open (N.O.), Normally Closed (N.C.)
TASK SELECTED
Task: Type the task number that, when selected, asserts this output.
Output Type: Normal, Timed, Flash
Minimum ON Time, Time, Period
Spindle: Type the spindle number from which the signal comes.
Asserts when required to indicate the active task. This is one bit in a series of bits to create a binary number. As
tasks change so will the binary number created from these bits.
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.)
TASK SELECTED
Bit: Type the number this bit will be in the binary number scheme for selected tasks.
BIT
Mode: All TASK SELECTED BITs must be the same mode, no mixing of modes allowed.
Binary – Creates a decimal number equivalent to the weighted value of this binary bit(s).
Binary + 1 – Creates a number equivalent to the weighted value of this binary bit(s) and add the value
of one (1) to that number.
Spindle: Type the spindle number from which the signal comes.
Asserts anytime the tool is energized. Resets when the tool is commanded to stop.
Size: 1 bit
Configuration:
TOOL RUNNING Contact Type: Normally Open (N.O.), Normally Closed (N.C.)
Output Type: Normal, Timed, Flash
Minimum ON Time, Time, Period
Spindle: Type the spindle number from which the signal comes.
This output is the peak achieved torque value during the fastening cycle from the Audit step. It asserts when
the fastening cycle is complete (before the IN CYCLE bit resets). The value resets to zero (0) when the tool is
commanded to run again.
Size: Can be any size from 0 to 32 bytes depending on Data Type
*TORQUE Configuration:
Data Type: Float, Int8, Int16, Int32, Fixed Point, String
Step: Audit, Audit-1, Audit-2
Spindle: Type the spindle number from which the signal comes.
Asserts at the end of a fastening cycle when the achieved torque value is above the High Torque limit for the
Audit step. Resets when the tool is commanded to start again. Can also be reset with the RESET RESULTS
STATUS input.
Size: 1 bit
Configuration:
TORQUE HIGH Contact Type: Normally Open (N.O.), Normally Closed (N.C.)
Step: Audit, Audit-1, Audut-2
Output Type: Normal, Timed, Flash
Minimum ON Time, Time, Period
Spindle: Type the spindle number from which the signal comes.

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MODBUS TCP
Outputs Description
Asserts at the end of a fastening cycle when the achieved torque value is below the Low Torque limits Audit
step. Resets when the tool is commanded to start again. Can also be reset with the RESET RESULTS STATUS
input.
Size: 1 bit
Configuration:
TORQUE LOW Contact Type: Normally Open (N.O.), Normally Closed (N.C.)
Step: Audit, Audit-1, Audut-2
Output Type: Normal, Timed, Flash
Minimum ON Time, Time, Period
Spindle: Type the spindle number from which the signal comes.
Asserts at the end of a fastening cycle when the achieved torque value is within limits for the Audit step. Resets
when the tool is commanded to start again. Can also be reset with the RESET RESULTS STATUS input.
Size: 1 bit
Configuration:
TORQUE OK Contact Type: Normally Open (N.O.), Normally Closed (N.C.)
Step: Audit, Audit-1, Audut-2
Output Type: Normal, Timed, Flash
Minimum ON Time, Time, Period
Spindle: Type the spindle number from which the signal comes.
This output will be one of three selections. The selections are the User Defined Value for the associated torque
status of the last fastening cycle. For example: if the last fastening cycle’s torque status was High, and the User
Defined Value for High is +, then this output value is +.
The OK User Defined Value is selected when the achieved torque for the defined step are within specified limits.
The Low User Defined Value is selected cycle when the achieved torque for the defined Step is below the Low
Torque limit.
The High User Defined Value is selected when the achieved torque for the defined step is above the High Torque
limit.
It asserts when the fastening cycle is complete (before the IN CYCLE bit resets). The value resets to zero (0)
* TORQUE STATUS when the tool is commanded to run again.
Size: Can be any size from 0 to 32 bytes depending on Data Type
Configuration:
Data Type: Float, Int8, Int16, Int32, Fixed Point, String
OK: User Defined Value
Low: User Defined Value
High: User Defined Value
Step: Audit, Audit-1, Audit-2
Spindle: Type the spindle number from which the signal comes.

* Outputs not available on 24 VDC

6.13 MODBUS TCP


The fieldbus Modbus TCP comes as a standard feature on the Ethernet port in the Expert controller. This is a
Modbus variant used for communications over TCP/IP networks, connecting over virtual port 502. By default the
Modbus TCP fieldbus does not have any I/O assigned. See section “3.3.5 I/O Tab” on page 78 to learn how to
edit the I/O. See section “6.12 Assignable Input and Output Functions” on page 126 to learn about the values
to edit. There is no configuration or programming specifically for the Modbus protocol itself. The Alpha’s CPU

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takes care of all the protocol’s overhead and handshaking requirements.
The Expert Alpha controller supports the following public Modbus function codes:
01 (0x01) Read Coils
02 (0x02) Read Discsreet Inputs
03 (0x03) Read Holding Registers
04 (0x04) Read Input Registers
05 (0x05) Write Single Coil
06 (0x06) Write Single Register
15 (0x0F) Write Multiple Coils
16 (0x10) Write Multiple Registers
Please visit http://Modbus.org for more information about the Modbus fieldbus.
Use the following table to correlate the external PLC addressing to the controller’s inputs and outputs.
Controller I/O External PLC Data External PLC
Memory Type
Type Address Type Read/ Write
“1” Coil Input 10001 - 20256 Bit Read/ Write
“2” Input Output 20001 - 20256 Bit(s) Read
"3" Holding Register Input 30001 - 30256 Mixed Read/ Write
"4" Input Register Output 40001 - 40256 Mixed Read
“5” Force Single Coil Input 50001 - 50256 Bit Read/ Write
"6" Single Register Input 60001 - 60256 Mixed Read/ Write
“15” Force Multiple Coils Input 0F0001 - 0F0256 Bit(s) Read/ Write
"16" Multiple Register Input 100001 - 100256 Mixed Read/ Write
For Mixed Data Type the type of data depends on the user assigned input and output functions.
It is important to understand that the coils and registers use the same memory.

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MODBUS TCP
6.13.1 Example Map
Here is an example of mapping addresses between an external PLC and the Alpha controller after the I/O functions
have been assigned in the Alpha controller.
Controller Inputs
External PLC Alpha Controller
Address# Modbus Input* Assigned Function Length (Bits)
30001:0 0/0 Start 1
30001:1 0/1 Stop 1
30001:2 0/2 Reverse 1
30001:3 0/3 Job Select (Bit) 0 1
30001:4 0/4 Job Select (Bit) 1 1
30001:5 0/5 Job Select (Bit) 2 1
30001:6, 7 0/6 Ignored 2
30001:8 - 15 1/0 Ignored 8
30002 2/0 Part ID (ASCII) 80
#
Register:Bit *Byte/Bit
Integer, Float and ASCII data must start on a zero (first) bit of a byte and not in the middle of a byte. Function
code 03 (0x03) can only transmit a 16-bit register, not the individual bits within a register. The PLC will need to
send the 16-bit register and the Alpha controller will parse the individual bits after receipt.
Controller Outputs
External PLC Alpha Controller
Address#
Modbus Output* Assigned Function Length (Bits)
40001:0 0/0 Fault 1
40001:1 0/1 Ready 1
40001:2 0/2 Tool Running 1
40001:3 0/3 In Cycle 1
40001:4 0/4 Cycle OK 1
40001:5 0/5 Cycle NOK 1
40001:6, 7 0/6 Not Used 2
40001:8 -15 1/0 Not Used 8
40002 2/0 Torque (Float) 32
40004 6/0 Angle (Float) 32
#
Register:Bit *Byte/Bit
Integer, Float and ASCII data must start on a zero (first) bit of a byte and not in the middle of a byte. Function
code 04 (0x04) can only transmit a 16-bit register, not the individual bits within a register. The PLC will need to
capture the 16-bit register and then parse the individual bits after receipt.

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Instruction Manual 149


MODBUS TCP

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QB Expert Alpha Controller

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.

7.1 “Rack” Layout


The Alpha controller’s PLC has a 4-slot virtual rack layout. There are some differences between a SLC-504 rack
and the Alpha rack. The CPU card does not have its own slot, rather it is taken into account since it is embedded
and cannot be changed. The discreet 24 VDC I/O uses the same slot rather than separate input or output “cards”.
The virtual rack is filled as follows:

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.

7.1.1 Addressing Scheme


Use the following syntax when programming to reference any input or output: Type: Slot#.Word/Bit         Type can
be Input I or Output O.
For example, if a switch was wired to Pin L, a light was wired to Pin C and logic was required to turn on the light
when the switch was activated, the logic and addressing would look like this:

As ASCII it would be: SOR XIC I:0.0/0 OTE 0.0/0 EOR


See section “6.11 Input and Output Connector” on page 116 for PLC addressing of the 24V DC connector.

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7.2 Supported Instructions and File Types
See Tabel 1 and Table 2 for a listing of supported instructions and file types.
NOTE: The Alpha controller supports only one ladder in the program file. Jump commands are not supported so
all logic must be performed in one ladder.
Table 1: Supported Instructions
Instruction Descriptions Instruction Descriptions Instruction Descriptions
ABS Absolute CTU Count Up NOT Not
ACI String to Integer DIV Divide NXB Next Branch
ACL ASCII Clear Buffer END Program End OR OR
ACN String Concatenate EOR End of Rung OSR One-Shot Rising
ADD Add EQU Equal OTE Output Energize
Greater Than or
AEX String Extract GEQ OTL Output Latch
Equal
AIC Integer to String GRT Greater Than OUT Output Unlatch
AND And LEQ Less Than or Equal RES Reset
ASCII Read
ARD LES Less Than RTO Retentive Timer
Characters
ASC String search LIM Limit Test SOR Start of Rung
Masked
ASCII String
ASR MEQ Comparison for SUB Subtract
Compare
Equal
AWT ASCII Write MOV Move TOF Timer Off-Delay
BND Branch End MUL Multiply TON Timer On-Delay
BST Branch Start MVM Masked Move XIC Examine if Closed
CLR Clear NEG Negate XIO Examine if Open
CTD Count Down NEQ Not Equal XOR Exclusive OR
Table 2 Supported Files

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.

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Supported Instructions and File Types
Instructions Description
String to Integer
ACI Use the ACI instruction to convert a numeric ASCII string to an integer value between -32,768
and 32,767.
ASCII Clear Buffer
ACL
Clears the send and/or the receive buffers.
String Concatenate
ACN Combines two strings using ASCII strings as operands. The second string is appended to the
first and the result stored in the destination.
Use the ADD instruction to add one value (source A) to another value (source B) and place the
ADD
result in the destination.
String Extract
Use the AEX instruction to create a new string by taking a portion of an existing string and
moving it to the new string.
Enter the following parameters when programming this instruction.
• Source is the existing string. The source value is not affected by this instruction.
AEX • Index is the starting position (from 1 to 82) of the string to extract (an index of 1
indicates the left-most character of the string).
• Number is the number of characters (from 1 to 82) to extract (startis at the indexed
position). If the index plus the number is greater than the total characters in the source string,
the destination string will be the characters from the index to the end of the source string.
• Destination is the string function (ST14:X) where the extracted string is stored.
Integer to String
AIC
Converts an integer value, between -32,768 and 32,767, to an ASCII string.
Performs a bit-by-bit logical AND. The operation is performed using the value at source A and
AND
the value at source B. The result is stored in the destination.
ASCII read characters
Performs a read from a source channel and moves the value into a destination string. Provides
a Result integer for the status of the read.
Channel 0 = Serial port
Channel 2 = Ethernet port
The internal PLC supports reading from and writing to the Network Ethernet port on the Expert
ARD controllers. Here are the rules:
If Channel ID is set to 2 then the virtual port 8786 will be used.
If a Channel ID >1024 is used then that number is the virtual port used.
 nly one virtual port can be used and the first rung in the logic with an ARD or ARW command
O
with a Channel ID >1024 determines which virtual port will be used.
The Channel ID cannot be set to an address, it must be an integer.

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Instructions Description
String Search
Use the ASC instruction to search an existing string for an occurrence of the source string.
Enter the following parameters when programming this instruction:
• Source is the string you want to find when examining the search string.
ASC • Index is the starting position (from 1 to 82) of the source string. (An index of 1
indicates the left-most character of the string.)
• Search is the string you want to examine.
• Result is an integer where the processor stores the position of the search string where
the source string begins. If no match is found, result is set equal to zero.
ASCII String Compare
ASR Use the ASR instruction to compare two ASCII strings. The system looks for a match in length
and upper/lower case characters. If two strings are identical, the rung is true; if there are any
differences, the rung is false.
ASCII Write
Writes a source string to the designated channel. Provides a Result integer for the status of the
write.
Channel 0 = Serial port
Channel 1 = Display
Channel 2 = Ethernet
AWT The internal PLC supports reading from and writing to the Network Ethernet port on the Expert
controllers. Here are the rules:
If Channel ID is set to 2 then the virtual port 8786 will be used.
If a Channel ID >1024 is used then that number is the virtual port used.
 nly one virtual port can be used and the first rung in the logic with an ARD or ARW command
O
with a Channel ID >1024 determines which virtual port will be used.
The Channel ID cannot be set to an address, it must be an integer.
Branch End
BND
Marks the end of a branch.
Branch Start
BST
Marks the beginning of a new branch on a rung.
Clear
CLR
Sets the value of a destination word to zero.

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Supported Instructions and File Types
Instructions Description
Count Down
Counts false-to-true transitions.
When rung conditions for a CTD instruction have made a false-to-true transition, the
accumulated value is decremented by one count, provided that the rung containing the CTD
instruction is evaluated between these transitions.
The accumulated counts are retained when the rung conditions again becomes false. The
accumulated count is retained until cleared by a reset (RES) instruction that has the same
address as the counter reset.
This Bit Is Set When And Remains Set Until One of
the Following
CTD
A RES instruction having the same
Count Down address as the CTD instruction
Accumulated value wraps
Underflow Bit is executed OR the count is
around to +32,768 from -32,767
OV (Bit 11) incremented greater than or equal
to +32,767 with a CTU instruction
Done Bit DN (Bit Accumulated value is equal to or The accumulated value becomes
13) greater than the preset value less than the preset value
Count Down Rung conditions go false or a RES
Enable Bit CU rung conditions are true instruction having the same address
(Bit 14) as the CTD instruction is enabled
Count Up
Counts false-to-true rung transitions.
When rung conditions for a CTU instruction have made a false-to-true transition, the
accumulated value is incremented by one count, provided that the rung containing the CTU
instruction is evaluated between these transitions.
The accumulated value is retained when the rung conditions again become false. The
accumulated count is retained until cleared by a reset (RES) instruction that has the same
address as the counter reset.
The count value must remain in the range of -32768 to 32767. If the count value goes above
32767 the overflow (OV) bit is set. If the count value goes below -32768, the counter status
underflow (UN) bit is set. A counter can be reset to zero using the reset (RES) instruction.
CTU And Remains Set Until One of
This Bit Is Set When
the Following
A RES instruction having the same
Count Up Accumulated value wraps address as the CTU instruction
Overflow Bit OV around to -32,768 from is executed OR the count is
(Bit 12) +32,767 decremented less than or equal to
+32,767 with a CTD instruction
Done Bit DN (Bit Accumulated value is equal to The accumulated value becomes
13) or greater than the preset value less than the preset value
Rung conditions go false or a RES
Count Up Enable
Rung conditions are true instruction having the same address
Bit CU (Bit 15)
as the CTU instruction is enabled

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Instructions Description
Divide
Use the DIV instruction to divide one value (source A) by another (source B). The rounded
DIV quotient is then placed in the destination. If the remainder is 0.5 or greater, round up occurs
in the destination. The unrounded quotient is stored in the most significant word of the math
register. The remainder is placed in the least significant word of the math register.
Program End
END
Marks the end of the program.
End of Rung
EOR
Marks the end of a rung.
Equal
EQU Use the EQU instruction to test whether two values are equal. If source A and source B are
equal, the instruction is logically true. If these values are not equal, the instruction is logically
false.
Greater than or Equal
Use the GEQ instruction to test whether one value (source A) is greater than or equal to
GEQ another (source B). If the value at source A is greater than or equal to the value at source B,
the instruction is logically true. If the value at source A is less than the value at source B, the
instruction is logically false.
Greater Than
Use the GRT instruction to test whether one value (source A) is greater than another (source B).
GRT If the value at source A is greater than the value at source B, the instruction is logically true. If
the value at source A is less than or equal to the value at source B, the instruction is logically
false.
Less Than or Equal
Use the LEQ instruction to test whether one value (source A) is less than or equal to another
LEQ (source B). If the value at source A is less than or equal to the value at source B, the instruction
is logically true. If the value at source A is greater than the value at source B, the instruction is
logically false.
Less Than
LES Use the LES instruction to test whether one value (source A) is less than another (source B). If
source A is less than the value at source B, the instruction is logically true. If the value at source
A is greater than or equal to the value at source B, the instruction is logically false.
Limit Test
Use the LIM instruction to test for values within or outside a specified range, depending on
how limits are set.
LIM
If the Low Limit has a value equal to or less than the High Limit, the instruction is true when
the Test value is between the limits or is equal to either limit. If the Test value is outside the
limits, the instruction is false.

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Supported Instructions and File Types
Instructions Description
Masked Comparison for Equal
Use the MEQ instruction to compare data at a source address with data at a compare address.
Use of this instruction allows portions of the data to be masked by a separate word.
MEQ The source is the address of the value to compare. The mask is the address of the mask through
which the instruction moves data. The mask can also be a hexadecimal value (constant). The
compare is an integer value or the address of the reference.
If the 16 bits of data at the source address are equal to the 16 bits of data at the compare
address (less masked bits), the instruction is true.
Message
Use MSG to send an instruction directly to the CPU. Can be used to send messages to trailing
Alpha controllers. Proper syntax is required.
MSG Text editor syntax: MSG # XXXXH HW LW: where # is spindle number, XXXXH is the command,
HW is High Word and LW is Low Word. High Words and Low Words contain information
provided by the instruction.
The user must be trained by a STANLEY trainer to use this instruction.
Monitor
Use MON to monitor for a CPU event and use as a trigger. Can be used to send messages to
trailing Alpha controllers. Proper syntax is required.
MON Text editor syntax: MSG # XXXXH HW LW: where # is spindle number, XXXXH is the command,
HW is High Word and LW is Low Word. High Words and Low Words contain information
provided by the instruction.
The user must be trained by a STANLEY trainer to use this instruction.
Move
MOV This output instruction moves the source value to the destination location. As long as the rung
remains true, the instruction moves the data each scan.
Multiply
MUL Use the MUL instruction to multiply one value (source A) by another (source B) and place the
result in the destination.
Masked Move
MVM The MVM instruction is a word instruction that moves data from a source location to a
destination, and allows portions of the destination data to be masked by a separate word. As
long as the rung remains true, the instruction moves the data each scan.
Negate
NEG Use the NEG instruction to change the sign of the source and then place it in the destination.
The destination contains the two’s complement of the source.
Not Equal
NEQ Use the NEQ instruction to test whether two values are not equal. If source A and source B are
not equal, the instruction is logically true. If the two values are equal, the instruction is logically
false.
This instruction performs a bit-by-bit logical NOT. The operation is performed using the value at
NOT
source A. The result (one’s complement of A) is stored in the destination.

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Instructions Description
Next Branch
NXB
Marks the beginning of another branch.
This instruction performs a bit-by-bit logical OR. The operation is performed using the value at
OR
source A and the value at source B. The result is stored in the destination.
One Shot Rising
The OSR instruction is a retentive input instruction that triggers an event to occur one time. Use
the OSR instruction when an event must start based on the change of state of the rung from
false-to-true.
When the rung conditions preceding the OSR instruction go from false-to-true, the OSR
OSR instruction will be true for one scan. After one scan is complete, the OSR instruction becomes
false, even if the rung conditions preceding it remain true. The OSR instruction will only become
true again if the rung conditions preceding it transition from false-to-true.
The address assigned to the OSR instruction is not the one-shot address referenced by the
program, nor does it indicate the state of the OSR instruction. This address allows the OSR
instruction to remember its previous rung state.
Output Energize
OTE Use the OTE instruction in the ladder program to turn on a bit when rung conditions are
evaluated as true.
Output Latch
OTL is a retentive output instruction. OTL can only turn on a bit (while OTU can only turn off a
bit). This instruction is usually used in pair with the OTU instruction. The program can examine
a bit controlled by OTL instructions as often as necessary.
OTL When rung conditions become false (after being true), the bit remains set and the
corresponding output remains energized.
When enabled, the latch instruction tells the controller to turn on the addressed bit. Thereafter,
the bit remains on, regardless of the rung condition, until the bit is turned off (typically by an
OTU instruction in another rung).
Output Unlatch
OTU is a retentive output instruction. OTU can only turn off a bit (while OTL can only turn on a
bit). This instruction is usually used in pairs with the OTL instruction. The program can examine
OTU a bit controlled by the OTU instruction as often as necessary.
The unlatch instruction tells the controller to turn off the addressed bit. Thereafter, the
bit remains off, regardless of the rung condition, until it is turned on (typically by an OTL
instruction in another rung).
Reset
RES Use a RES instruction to reset a timer or counter. When the RES instruction is enabled, it
resets the Timer On Delay (TON), Retentive Timer (RTO), Count Up (CTU) or Count Down (CTD)
instruction having the same address as the RES instruction.

Instruction Manual 159


Supported Instructions and File Types
Instructions Description
Retentive Timer
Use the RTO instruction to turn an output on or off after its timer has been on for a preset time
interval. The RTO instruction is a retentive instruction that begins to count millisecond intervals
when rung conditions become true. The RTO instruction retains its accumulated value when the
rung conditions become false. The Time Base must be 10 msec. The timer will not work in any
other Time Base.
And Remains Set Until One of
This Bit Is Set When
the Following
RTO
Timer Done Bit DN accumulated value is equal to or the appropriate RES instruction is
(Bit 13) greater than the preset value enabled
rung conditions are true and the
Timer Timing Bit Rung conditions go false or when
accumulated value is less than the
TT (Bit 14) the done bit is set
preset value
rung conditions go false or if
Timer Enable Bit
rung conditions are true the timer is reset with the RES
EN (Bit 15)
instruction
Start of Rung
SOR
Marks the beginning of a new rung.
Subtract
SUB Use the SUB instruction to subtract one value (source B) from another (source A) and place the
result in the destination.
Timer Off Delay
Use the TOF instruction to turn an output on or off after its rung has been off for a preset
time interval. The TOF instruction begins to count millisecond intervals when the rung makes
a true-to-false transition. As long as rung conditions remain false, the timer increments
its accumulated value (ACC) each millisecond until it reaches the preset value (PRE). The
accumulated value is reset when rung conditions go true regardless of whether the timer has
timed out. The Time Base must be 10 msec. The timer will not work in any other Time Base.
And Remains Set Until One of
This Bit Is Set When
TOF the Following
rung conditions go false and the
Timer Done Bit DN
accumulated value is greater than rung conditions are true
(Bit 13)
or equal to the preset value
rung conditions are false and the
Timer Timing Bit rung conditions go true or when
accumulated value is less than the
TT (Bit 14) the done bit is set
preset value
Timer Enable Bit
rung conditions are false rung conditions go true
EN (Bit 15)

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Instructions Description
Timer On Delay
Use the TON instruction to turn an output on or off after the timer has been on for a preset
time interval. The TON instruction begins to count millisecond intervals when rung conditions
become true. As long as rung conditions remain true, the timer adjusts its accumulated value
(ACC) each evaluation until it reaches the preset value (PRE). The accumulated value is reset
when rung conditions go false, regardless of whether the timer has timed out. The Time Base
must be 10 msec. The timer will not work in any other Time Base.
And Remains Set Until One
TON This Bit Is Set When
of the Following
Timer Done Bit DN accumulated value is equal to or
rung conditions go false
(bit 13) greater than the preset value
rung conditions are true and the
Timer Timing Bit TT rung conditions go false or
accumulated value is less than the
(bit 14) when the done bit is set
preset value
Timer Enable Bit EN
rung conditions are true rung conditions go false
(bit 15)
Examine If Closed
XIC Use the XIC instruction in the ladder program to determine if a bit is on. When the instruction
is executed, if the bit addressed is on (1), then the instruction is evaluated as true. When the
instruction is executed, if the bit addressed is off (0), then the instruction is evaluated as false.
Examine If Open
XIO Use the XIO instruction in the ladder program to determine if a bit is off. When the instruction
is executed, if the bit addressed is off (0), then the instruction is evaluated as true. When the
instruction is executed, if the bit addressed is on (1), then the instruction is evaluated as false.
Exclusive Or
XOR Performs a bit-by-bit logical Exclusive Or. The operation is performed using the value at source
A and the value at source B. The result is stored in the destination.

7.3 PLC Editor


Use the PLC editor provided in Alpha Toolbox to create and edit ladder logic files for the Expert. See section “4.1
Connection” on page 82 on how to connect to Alpha Toolbox with a computer.
To get to the PLC Editor in Alpha Toolbox navigate to the Setup/Other/PLC page and click on the Edit button.

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PLC Editor

7.3.1 Edit Page Controls

Menu of Instructions Zoom Out Zoom In


Undo Redo Add Rung
Add Branch
Instruction

Delete Move Rung


Comments Selected Rung

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.

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Redo revert the effects of the undo action. Multiple Redo’s are allowed through all stored Undo states.
Add Initialization Files button will insert predefined strings and integers that are initialized when the PLC starts.

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.

7.3.2 Instruction Box


Each instruction has a box to contain its parameters and their values. Each box contains a Name field and a

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Converting a RSS File
description of the instruction. The Name field may be selected and modified to create a different instruction box.
Use the mouse to hover over the items in the box. A red outline will appear to indicate which field values can be
modified.

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.

Continue adding/ editing rungs/ instructions to complete the ladder logic.

7.3.3 MON and MSG Instructions


There are two special case instructions that are exclusive to the Alpha controller. One is MON, or Monitor, the
other is MSG, or Message. MON monitors for events in the Alpha’s CPU and can be used as a trigger to activate
a rung. MSG is an output and inserts commands directly into the Alpha’s CPU. When used in a multiple tool
application on the leading Alpha, MON and MSG can interact with the trailing Alpha’s CPUs.
These instructions require a specific syntax and have unique fields. See the instruction description in section .

7.3.4 Applying a Name and Version


After saving the ladder logic Alpha Toolbox will display the PLC tab. Type a Name and Version number to be
applied to the ladder logic. The Length field is automatically generated by the Alpha.

7.4 Converting a RSS File


After creating/editing a ladder logic program using RSLogix500, the information must then be converted to a
format recognized by the Alpha. First highlight all the rungs from top to bottom, then select Copy from the Edit
menu.

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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.

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Converting a RSS File
Once the file is saved it can be put into the Alpha controller. See section “3.1.4.11 PLC Tab” on page 68.

7.4.1 Invalid Characters


When the logic refers to a specific word in a string file it uses DATA[X], where X is the referenced word. The Alpha
controller does not support the DATA[X] syntax. This must be converted to a number. For example, if the word
referred to is ST14:3.DATA[5] then this must be converted to ST14:3.6 in the file. DATA[5] refers to word six in the
string. The Alpha controller must be given the word number not the DATA[X] number. The X value in DATA[X] is
always one less than the word number referenced in the string.
RSLogix can also substitute one address for a value. When this happens it puts a pound sign (#) in front of the
address. The Alpha controller does not support this pound sign. Find another way to program without using
substitutions.

7.4.2 Predefining String or Integer Files


To use predefined strings or integers, type the string or integer file address and its value before the logic in the
file. There must be a space between the address and the value. For Strings, the value must be encapsulated
within backslash and double quotes. There must be a space after the string or integer value before the first SOR
command or next string or integer.

7.4.3 Applying a Name and Version


To provide a name, put another JSON parameter tag after the logic tag and before the ending brackets. The new
tag is ”701”: “NAME”. There is a 15 character limit to this parameter. If another tag, such as the version number
will be added the name tag must have a comma after it but before the carriage return and line feed (CRLF).

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.

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QB Expert Alpha Controller

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.

170 QB Expert Alpha Controller


Multiple Spindle

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.

Instruction Manual 171


Disconnect

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.

172 QB Expert Alpha Controller


Multiple Spindle
To synchronize the Alpha controllers simply assign a START input on the lead controller and configure the Spindle
number as ALL.

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.

Instruction Manual 173


Fastening Cycle Data

If required setup parameters for embedded protocols under Setup>Communications.

8.5 Fastening Cycle Data


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

174 QB Expert Alpha Controller


Multiple Spindle

Instruction Manual 175




176 QB Expert Alpha Controller


QB Expert Alpha 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.

Store idle tools and controllers in a dry secure area.


For maximum tool life, only use lubricants specified in the service instructions.
Keep maintenance and repair records on all tools and controllers. Frequency of repair and nature of the repairs
can reveal unsafe applications.

9.1 Scheduled Maintenance


The modules require routine maintenance to insure optimal performance. On a monthly basis:
• Visually inspect and tighten external connections.
• Visually inspect all external cables for excessive wear, frayed wire, or breaks. Replace as needed.

9.2 Diagnostics and Troubleshooting


Use the following diagnostics and troubleshooting guide to identify, isolate, and diagnose both mechanical and
controller software related problems.

178 QB Expert Alpha Controller


Maintenance
Major Consideration To Clear/Reset from
Fault Possible Cause Probable Solution
That Led to Solution Fault Condition
Physical inspection:
worn, frayed, or
Tool cable Replace Replace tool cable
broken connections
or wires
Swap with known,
Tool Replace/Repair Replace/Repair tool
good operating tool
Verify and or adjust
tool calibration
factor(s) to
Calibration Factors Verify/Adjust Zero or Span Fault match calibration
factor(s) for tool.
May require tool
recertification.
No bolt count on
the Run screen for Create new
the selected Job/ strategy
Task
Cycle Abort set to Set higher amount
zero (0) on Cycle Abort
Torque Target
Tool does not run set to zero (0) on Set higher amount
torque control on Torque Target
Strategy Verify/Adjust strategy
Angle Target set
Set higher amount
to zero (0) on angle
on Angle Target
control strategy
Tool Speed set to Set higher amount
zero (0) on Tool Speed
Power set to zero Set higher amount
(0) on Power
Acceleration set Set higher amount
to zero (0) on Acceleration
See Fault Guide
Fault displayed on (Section “9.2.1
Fault Various errors
screen Fault Guide” on
page 181)
See Message Guide
Press and hold
STOP condition or Remove STOP (Section “9.3
trigger and view
input condition Message Guide” on
message on display
page 189)

Instruction Manual 179


Diagnostics and Troubleshooting
Major Consideration To Clear/Reset from
Fault Possible Cause Probable Solution
That Led to Solution Fault Condition
Physical inspection: Repair/replace/
incorrect wiring, reprogram external
termination, input and output
External input Repair/replace/
connections, connections and
connections reprogram
Tool does not run devices or wiring as necessary
remotely programming of I/O based on I/O
assignments drawings
Lost + 24 V DC No or low voltage
Power Return for repair (<11V) between Return for repair
Supply Pins A and V
Power off Turn Alpha on
Power on Plug unit in
No power Restore power
No lights, no Check power at
Plugged in
display source
Unit is on, plugged
AMP board Failure Return for repair in, and there is Return for repair
power at the source
Set Torque Audit
Completed Torque Audit
Step and or Angle
Rundown - Zero for Step and or Angle
Incorrect Audit Step Verify/Adjust Audit Step on the
Torque and Angle Audit Step set on
actual desired audit
Readings undefined step
step
Completed Tool ran strategy Set Threshold
Rundown - No Threshold Torque but no fastening Torque to zero (0)
Verify/Adjust
Torque and Angle set too high cycle values appear or a value lower
Readings on display than final torque
Low-torque reject.
Incomplete Snug Torque has Set higher amount
Long bolt Verify/Adjust been set to zero
rundown (AC/TM) on Snug Torque
(0)
Parts changed. Low Insert a Self Tap
Incomplete
Prevailing Torque Verify/Adjust angle reject. Parts step prior to audit
rundown (TC/AM)
not snug step
Consistent high Snug Torque has
Set higher amount
angle reject (TC/ Long bolt Verify/Adjust been left at default
on Snug Torque
AM) value

180 QB Expert Alpha Controller


Maintenance
Major Consideration To Clear/Reset from
Fault Possible Cause Probable Solution
That Led to Solution Fault Condition
Torque Target
Increase High
is close to High
Torque
Consistent high Torque
torque reject (TC/ Hard joint Verify/Adjust Add a within step
AM) downshift or turn
No downshift
on ATC or ATC+ to
the audit step

9.2.1 Fault Guide


Use the following Error Code guides to identify, isolate, and diagnose both mechanical and software issues.
Major Consideration To Clear/Reset from
Fault Possible Cause Probable Solution
That Led to Solution Fault Condition
Replace defective
tool, cable, or
controller.
If the controller
Exchanging is found to be
known good defective, return to
Replace defective
Defective tool, tools controllers STANLEY Assembly
tool, cable, or
cable, or controller and cables can Technologies for
controller
determine which repair.
caused a failure If the tool is found
to be defective,
repair it by
replacing the motor
Overcurrent Fault! or gearing or head.
Increase speed
of tool, increase
downshift speed, or A larger tool
remove downshift is used with a
altogether. long rundown or
Downshift Speed Fault condition
Create a Pre-torque set very low. resets when DC bus
Low DC bus voltage step with a Delay
Fluctuating voltage is within
Between Steps
incoming AC limits.
of at least 0.05
seconds. voltage as seen
on the ANALYZE
Change input screen.
voltage to 230 V
AC

Instruction Manual 181


Diagnostics and Troubleshooting
Major Consideration To Clear/Reset from
Fault Possible Cause Probable Solution
That Led to Solution Fault Condition
Replace defective
tool, cable, or
controller.
If the controller
Exchanging is found to be
known good defective, return to
Replace defective
Defective tool, tools controllers STANLEY Assembly
tool, cable, or
cable, or controller and cables can Technologies for
controller
determine which repair.
caused a failure If the tool is
found to be
GFI Fault! defective, repair
it by replacing the
motor.
Use an ohmmeter
or the motor tester
to check:
Phase-to-phase
Replace defective Replace defective
Defective Tool values; they should
tool tool
be equal.
Phase-to-ground;
they should be >2
Megohms.
Use a voltmeter
to test for proper
voltage WHILE the
Insufficient AC Repair incoming tool is running. Repair incoming
input power power system power system
Check for proper
Logic Voltage Fault! grounding at the
receptacle.
Defective triple
power supply or Return controller Logic Voltage Fault!
Return for repair
logic board inside for repair appears on display
controller

182 QB Expert Alpha Controller


Maintenance
Major Consideration To Clear/Reset from
Fault Possible Cause Probable Solution
That Led to Solution Fault Condition
Exchanging known
Replace defective good tool can Replace defective
tool verify the tool is the tool
cause of failure
Defective tool
Visual/mechanical
Re-engage and lock Re-engage and lock
inspection of pins
pins in connector in pins in connector in
in tool handle
Position Feedback handle handle
connector
Fault!
Whip was removed
from extension
Reduce total cable cable and Fault condition
Tool cable longer
length to < 60 connected directly resets when cable
than 60 meters
meters to the controller, length is reduced.
which then cleared
the error
Torque Cal. set Read the Nominal
to a non-standard Set Torque Cal. to Torque Cal. value
value (i.e. greater the specific torque from the tool and May require tool
than 20% variance calibration value for compare it to the recertification
from Nominal the tool specific Torque
Cal.) Cal.
Transducer Span Wrong values
Wrong tool
Fault! Download correct indicated under Download correct
parameters in tool
tool INI file to tool SERVICE>TOOL tool INI file to tool
memory board
screen
Visual/mechanical
Re-engage and lock Re-engage and lock
inspection of pins
Defective tool pins in connector in pins in connector in
in tool handle
handle handle
connector

Instruction Manual 183


Diagnostics and Troubleshooting
Major Consideration To Clear/Reset from
Fault Possible Cause Probable Solution
That Led to Solution Fault Condition
Torque Cal. set Read the Nominal
to a non-standard Set Torque Cal. to Torque Cal. value
value (i.e. greater the specific torque from the tool and May require tool
than 20% variance calibration value for compare it to the recertification
from Nominal the tool specific Torque
Cal.) Cal.
Remove the object
wrapped around Remove the object
Transducer Zero gear case. ANALYZE screen wrapped around
Fault! Tool gear case Open gear case and shows a zero offset gear case.
binding inspect for wrong on the transducer Reassemble gear
components or health meter case with proper
components are in components.
backward
Visual/mechanical
Re-engage and lock Re-engage and lock
inspection of pins
Defective tool pins in connector in pins in connector in
in tool handle
handle handle
connector

184 QB Expert Alpha Controller


Maintenance
Major Consideration To Clear/Reset from
Fault Possible Cause Probable Solution
That Led to Solution Fault Condition
Modify
Viewed Temperature
Temperature value parameter value.
Wrong value Modify under SETUP-> The maximum for
in Temperature Temperature OTHER-> TOOL tab handheld tools
parameter parameter value and compared with is 85˚C. The
Temperature value maximum for
on ANALYZE screen fixtured tools is
125˚C.
This error
automatically resets
when temperature
Tool is hot to touch drops and stays
and shuts down: below trip point for
QPM tools 8 minutes on QPM
shutdown when tools.
Use a larger tool for tool internal It can also be reset
Excessive duty cycle
the job temperature by cycling power,
reaches and stays however, if the
Temperature Fault! above programmed tool has not cooled
set point for 8 down this error
minutes will reappear in 8
minutes.
For fixtured tools
turn off Soft Stop.
To prevent an
over temperature,
Tool is hot to touch modify the
and shuts down: strategy by raising
QPM tools downshift speed
Contact STANLEY or eliminating the
Assembly shutdown when
Inefficient tool internal downshift; Also
Technologies for try a multi-step
Rundown Strategy temperature
help on modifying strategy with a
strategy reaches and stays
above programmed Delay Between
set point for 8 Steps of at least
minutes 0.5 seconds.
For fixtured tools
turn off Soft Stop.

Instruction Manual 185


Diagnostics and Troubleshooting
Major Consideration To Clear/Reset from
Fault Possible Cause Probable Solution
That Led to Solution Fault Condition
Tool has
operated without
overheating for a
Perform
significant period of
Open and inspect maintenance on
time but suddenly
tool head and tool; open and
Output / gearing overheats; operator
gearing; replace inspect tool head
failure notices change of
any worn or broken and gearing;
tool operation (i.e.,
parts replace any worn or
noise, vibration,
broken parts
and speed are
Temperature Fault! different than
normal)
Continued
The type of joint
(hard or soft)
can cause (see When tested with
Excessive Duty Switch from 115
a voltmeter, or as
Cycle cause above); V AC to 230 V AC
Reduced incoming observed on the
switch from 115 or correct reduced
voltage ANALYZE screen,
incoming voltage
V AC to 230 V AC incoming voltage is
problem
or correct reduced <90% of nominal
incoming voltage
problem
Wrong values
Wrong tool
Download correct indicated under Download correct
Unrecognized Tool! parameters in tool
tool INI file to tool SERVICE-> TOOL tool INI file to tool
memory board
screen

186 QB Expert Alpha Controller


Maintenance
Major Consideration To Clear/Reset from
Fault Possible Cause Probable Solution
That Led to Solution Fault Condition
Replace defective
tool, cable, or
controller.
If the controller
Exchanging is found to be
known good defective, return to
Replace defective
Defective tool, tools controllers STANLEY Assembly
tool, cable, or
cable, or controller and cables can Technologies for
controller
determine which repair.
caused a failure If the tool is found
to be defective,
see the next row
for troubleshooting
Tool and repair.
Communications! Replace and
reprogram the Tool
Tool Memory Board Replace the Tool Tool found to be
Memory Board in
failure Memory Board defective
the handle of the
tool
Visual/mechanical
Re-engage and lock Re-engage and lock
inspection of pins
Defective tool pins in connector in pins in connector in
in tool handle
handle handle
connector
Check tool whip/
No values
Tool not electrically extension cable
indicated under Connect tool to
connected to connections and
SERVICE>TOOL controller
controller ensure they are
screen
tight

Instruction Manual 187


Diagnostics and Troubleshooting
Major Consideration To Clear/Reset from
Fault Possible Cause Probable Solution
That Led to Solution Fault Condition
Replace defective
tool, cable, or
controller.
If the controller
Exchanging is found to be
known good defective, return to
Replace defective
Defective tool, tools controllers STANLEY Assembly
tool, cable, or
cable, or controller and cables can Technologies for
controller
determine which repair.
caused a failure If the tool is found
to be defective,
see the next row
for troubleshooting
and repair.
Open tool handle
and check
transducer cable
connections to
Transducer Current ensure tightness
Fault! and the wiring is
not damaged.
Remove motor
View transducer
housing sleeve
health, current
and check blue
and torque
transducer wire for
output meters on
Transducer / Replace transducer damage.
ANALYZE screen
transducer cable / transducer cable Remove the gear
and determine
within tool failure in tool pack from the
if values are in
normal range. motor on the
Tool found to be tool and replace
defective the torque
transducer; testing
with a known
good transducer
connected to
the tool before
replacement helps
determine which
parts are faulty.
Change tool to a
The wrong tool type the controller
Change tool to a
type has been Unsupported Tool! can run. Look
Unsupported Tool! type the controller
connected to the fault on display under SERVICE->
can run.
controller. Controller for list of
supported tools.

188 QB Expert Alpha Controller


Maintenance
Major Consideration To Clear/Reset from
Fault Possible Cause Probable Solution
That Led to Solution Fault Condition
Reboot controller; Reboot controller;
Controller Firmware
Servo Connection keep controller Servo Connection keep controller
has just been
Fault! off for at least 20 Fault! on display off for at least 20
updated
seconds seconds
Spindle
Lead or trailing Turn lead or trailing Turn lead or trailing
Communications on
controller is off controller on controller on
display
Controller is setup
Default the Controller is a Default the
as a lead or trailing
controller single spindle controller
controller
Spindle
Communications Reconnect Ethernet
Visual/Mechanical cable between
Reconnect Ethernet Lead and trailing
inspection to
Ethernet cable cable between controllers.
ensure cable
disconnected Lead and trailing
connections are If using external
controllers
tight switches ensure
they are energized.

9.3 Message Guide


Major Consideration To Clear/Reset from
Message Possible Cause Probable Solution
That Led to Solution Message Condition
Cable has
Communication
disconnected from Reconnect cable Visual inspection Reconnect cable
Fault
controller or PI box
Actual bolt count
Operator backed Re-fasten loosened Re-fasten loosened
Count Fault on display is less
out a fastener fastener fastener
than required
Operator performed
Reset Job or loosen
a double hit or Actual bolt count
a secured fastener Reset Job or loosen
Program Fault fastened more on display is more
to return to the a fastened fastener
fasteners than was than required
proper bolt count
expected
Download a new Tool Update Failed Download a new
Tool INI file is
file and try to load error message file and try to load
corrupt
it again appears. it again

Tool Update Failed See Tool See Tool


Loss of
Communications! in Tool Communications! in
communication
section “9.2.1 Fault Communications! section “9.2.1 Fault
between tool and
Guide” on page fault on display Guide” on page
controller
181 181
The PLC is PLC Message
PLC Message providing the None is displayed on Press OK
message controller

Instruction Manual 189


Message Guide
Major Consideration To Clear/Reset from
Message Possible Cause Probable Solution
That Led to Solution Message Condition
Press OK.
Bad command or Read the entire file Delete the PLC file.
Invalid PLC File
Invalid PLC File syntax used in the and fix the syntax Read the entire file
appears on display
PLC.json file issue and fix the syntax
issue.
Red, Greed,
Yellow Status
lights are blinking
Trailing spindle is in sequence on Press OK.
Choose a number
wanting to connect trailing controller Choose a number
and add the spindle
to lead controller and tool with ‘Add and add the spindle
Identifying Spindle Spindle’ dialog box
on display of lead
controller
Operator pressed Display on lead
the Identify button Press OK controller is on Press OK
under ANALYZE ANALYZE screen
Tool Disabled:
Program the
Undefined Task
An unprogrammed selected Task or
Select a different message on display
Task has been select another Task
Task when the operator
selected that is already
pressed the tool’s
programmed
start trigger
Tool Disabled:
Invalid Job/Task
A non-valid Job/ Select a different
Select a different message on display
Task has been Job/Task from 1
Job/Task when the operator
selected to 99
pressed the tool’s
start trigger
Tool Disabled
Tool Disabled: Have a valid part
Network needs to
Network Protocol enter the station.
know that a valid
Have a valid part message on display
unprocessed part Disconnect the
enter the station when the operator
has entered the Ethernet cable from
pressed the tool’s
station the controller.
start trigger
Tool Disabled:
Select a new Job/ Error Proofing Select a new Job/
Accumulated bolt
Task. message on display Task.
count is equal to
when the operator
Job/Task bolt count Reset the Job. Reset the Job.
pressed the tool’s
start trigger

190 QB Expert Alpha Controller


Maintenance
Major Consideration To Clear/Reset from
Message Possible Cause Probable Solution
That Led to Solution Message Condition
Tool Disabled: Stop
Remove the active Issued message on Remove the active
A input is applied
input. display when the input.
that is assigned as
operator pressed
STOP Reassign input. Reassign input.
the tool’s start
trigger

Select a different Tool Disabled: Stop Select a different


Job/Task. Issued message on Job/Task.
Job/ Task Verify
display when the
inputs not matching Select a different Select a different
operator pressed
selected Job/ Task. socket for socket for
the tool’s start
verification. trigger verification.

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.

Instruction Manual 191


Parts List
Major Consideration To Clear/Reset from
Message Possible Cause Probable Solution
That Led to Solution Message Condition
Tool Disabled: Not
Armed message Press the MFB to
appears on display arm the tool.
Press the MFB to
Tool is not armed whenever the Change the tool’s
arm the tool
operator presses parameter to not
the tool’s start require arming.
trigger
Tool Disabled Tool Disabled: Not
Press the MFB to
Continued Armed message
acknowledge and
appears on display
Press the MFB to reset the NOK
whenever the
A Reset Reject is acknowledge and fastening cycle.
operator presses
active reset the NOK the tool’s start Change the MFB
fastening cycle trigger. parameter to not
require Reset
Reset Reject is
Reject.
programmed.

9.4 Parts List


WARNING
To Avoid Injury:
• Only use approved replacement parts when repairing controllers. Using unapproved parts could cause injury
to personnel and or damage to equipment.

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

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194 QB Expert Alpha Controller


QB Expert Alpha Controller

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.

10.2 Angle Validation


Now that the angle can be indicated with great precision, the other challenge is to validate these results against
an external torque/angle transducer with monitor. This is not as simple as setting both the controller and the
monitor to the same snug torque and comparing the resulting angle.
It has been found that a tool’s torque trace will never track exactly the same as the external. The calibration is only
the average of a number of readings, generally at a high torque near the maximum capacity of the tool. When
any individual torque reading from the tool’s controller is compared to a torque reading from the external torque
monitor, it can easily have a difference of several percent higher or lower. This means that the tool’s controller will
start counting angle at a different point than the external torque/angle monitor starts counting. This could be five

196 QB Expert Alpha Controller


Appendix A
to 10 degrees different depending of the hardness of the joint.
The only way to get consistent results when validating an angle reading against an external monitor is to pre-
torque the joint slightly higher than the snug torque. Run the tool on this already-tightened joint, with the snug
torque set to the same value in both the controller and the monitor, even if the tool’s transducer and the external
transducer do not exactly agree near the snug torque, they will both start counting angle just before the fastener
starts to rotate, so their zero angle will be synchronized exactly.
For example, if a brake line fitting requires six NM plus 40 degrees, pre-torque the joint to seven NM first. Then
change to an Angle Control strategy, with six NM snug torque, plus 40 degrees angle target, and reset the
external torque/angle monitor. Then as the tool is run in this angle control mode, the tool will start counting angle
as soon as it has six NM (which might have been five or seven NM according to the external transducer), which is
before the joint actually starts to rotate. And the external monitor will start counting angle as soon as it has six
NM which is also before the joint starts to rotate. This way, both meters are reading angle from the same point,
even though the torque readings may differ slightly because of the allowable tolerances in the torque calibration.

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QB Expert Alpha Controller

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.

200 QB Expert Alpha Controller


Glossary
The speed at which the tool operates during the initial portion of the Fastening cycle
Speed prior to ATC or downshift.
A spindle represents a connection to a hand held or fixtured tool connected to a
Spindle controller.
Strategy Identifies what variables will be used to control the tool during a 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

Abbreviation Common Term = 1 lbfft = 1 Nm

Nm Newton meter 1.355 818 1

Ncm Newton centimeter 135.581 8 100


Units
kgm Kilogram meter 0.138 255 2 0.101 971 6

kgcm Kilogram centimeter 13.825 52 10.197 16

ft lb Foot pound 1 0.737 562 1

in lb Inch pound 12 8.850 745

in oz inch ounce 192 141.611 9

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QB Expert Alpha Controller

12 Limited Warranty

Mechanical Products Limited Warranty


Electronic Products Limited Warranty
Software Products Limited Warranty
OEM Products Limited Warranty
General Terms
Specification Changes
Warranty Claims
Product Services
Return Material Authorization (RMA) Procedures
Mechanical Products Limited Warranty
12 Limited Warranty
12.1 Mechanical Products Limited Warranty
Stanley Black&Decker, Inc. (“STANLEY”) warrants its Assembly Technologies mechanical products to the original
purchaser to be free from deficiencies in material or workmanship for the useful life of the product.
Under this lifetime limited warranty STANLEY will, at its discretion, repair or replace any product which, upon
inspection, is acknowledged by STANLEY to be defective.
This limited lifetime warranty shall apply to products which have been used under normal operating conditions for
their intended use and shall not apply to products which have been subjected to: abnormal wear and tear, abuse,
misuse, improper maintenance, negligence, continued use after partial failure, accident, alterations or repairs with
non-genuine STANLEY replacement parts.

12.2 Electronic Products Limited Warranty


STANLEY warrants its Assembly Technologies electronic products to the original purchaser to be free from
deficiencies in material or workmanship for a period of one year after the date of shipment.
Under this limited warranty STANLEY will, at its discretion, repair or replace any product which, upon inspection,
is acknowledged by STANLEY to be defective.
This warranty shall apply to products which have been used under normal operating conditions for their intended
use and shall not apply to products which have been subjected to: abnormal wear and tear, neglect, component
degradation, improper handling, overload, abuse, misuse, improper maintenance, use with improper accessories,
or where alterations have been made.

12.3 Software Products Limited Warranty


STANLEY warrants its Assembly Technologies software products to the original purchaser to be free from
deficiencies in material or workmanship for a period of one year after the date of shipment.
Under this limited warranty STANLEY will, at its discretion, make available replacement software or an upgrade
for any product which, upon inspection, is acknowledged by STANLEY to be defective. Installation of the software
shall be the responsibility of the requestor.
This warranty shall apply to products which have been used with specified, compatible hardware under normal
operating conditions for their intended use and shall not apply to products which have been: modified, misused,
improperly handled, improperly maintained, or used with non-compatible hardware or accessories.

12.4 OEM Products Limited Warranty


Some STANLEY Assembly Technologies custom engineered systems include components manufactured by others.
The limited warranties of each individual manufacturer shall apply to these components and STANLEY makes no
representation or warranty of any kind, expressed or implied, with respect to such components.

12.5 General Terms


This limited warranty gives you specific legal rights and is in lieu of all other warranties, expressed or implied,
including the implied warranties of merchantability and fitness for a particular purpose. Some states and countries
do not allow limitations on implied warranties, so the above may not apply to you. You may also have other rights
which vary by state or country.
STANLEY shall not be responsible for incidental or consequential damages or the inability to use its products for
any purpose whatsoever. STANLEY’s maximum liability shall not in any case exceed the contract price for the
products claimed to be defective. Some states and countries do not allow the exclusion or limitation of incidental
or consequential damages, so this specific limitation or exclusion may not apply to you.

204 QB Expert Alpha Controller


Limited Warranty
12.6 Specification Changes
STANLEY retains the right to discontinue and/or change specifications of any Assembly Technologies products
without responsibility for incorporating changes in products already sold.

12.7 Warranty Claims


To apply for warranty consideration, the original purchaser should take the following action:
a. Contact the STANLEY Assembly Technologies customer service department to obtain a “Return Authorization
Number” and “Warranty Claim Report Form.”
b. Package the product including proof of purchase and the completed warranty claim form.
c. Note the Return Authorization Number on the exterior of the package and return freight to:
STANLEY Assembly Technologies
Central Repair Facility
5335 Avion Park Drive
Cleveland, Ohio 44143-2328
In the event that a product is repaired or replaced under the terms of the warranty, the warranty period of the
repaired or replacement product shall be limited to the remaining portion of the original warranty period.

12.8 Product Services


STANLEY provides full services for design, modification, service, repair, and training on STANLEY products.
Contact STANLEY Assembly Technologies or their agents for information on training courses to aid users in
becoming familiar with operations, maintenance, or programming of the STANLEY DC electric tools and controllers.
No modification of STANLEY tools and controllers can be made without the express permission of STANLEY
Assembly Technologies. Refer all service to STANLEY Assembly Technologies, or their representatives.

12.9 Return Material Authorization (RMA) Procedures


A Return Material Authorization or RMA is required before returning any material for warranty or repair service.
• Contact STANLEY Assembly Technologies or their agents.
• Request Customer Service or Repair Services.

! NOTE: An RMA can be given without a purchase order. However, non-warranty repairs cannot be performed until
a written purchase order or credit card authorization is received.
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.

Instruction Manual 205


GLOBAL
LOCATIONS
World Headquarters Germany
STANLEY Assembly Technologies STANLEY Engineered Fastening Germany
5335 Avion Park Drive Max-Eyth-Str. 1, 35394 Giessen, Germany
Cleveland, Ohio 44143-2328, USA Tel: +49 (0) 641 405 - 728 Fax: +49 (0) 641 405 - 383
Tel: +1.440.461.5500 Fax: +1.440.461.5592 Email: Vahid.Amirzadeh@sbdinc.com
Email: SATinfo@sbdinc.com India
Sales and Support STANLEY Engineered Fastening India
Americas/Asia-Pacific 6th Floor, Apex Towers, No 54, 2nd Main Road, R A Puram
STANLEY Assembly Technologies CHENNAI – 600 028, India
2380 Meijer Drive Tel: +91 44 4343 7100 Fax: +91 44 4306 0768
Troy, MI 48084, USA Email: Rajesh.Patil@sbdinc.com
Tel: +1.248.677.9709 Italy
Sales: 877.709.8006 Service: 877.787.7830 STANLEY Engineered Fastening Italy
Email: SATinfo@sbdinc.com c/o Energipark – Building 03/Sud
China Via Energy Park, 6 – 20871 Vimercate (MB) Italy
STANLEY Engineered Fastening China Tel: +39 (039) 9590.200 Fax: +39 (039) 9590.318
BUILDING NO. 9, 615 FENGDENG ROAD Email: Gianantonio.Meneghetti@sbdinc.com
MALU TOWN, JIADING DISTRICT Japan
Shanghai 201801, China STANLEY Engineered Fastening Japan
Tel: +86 21.3915.5588-5511 Fax: +86 21.3915.5555 Hosoda, Noyori-cho, Toyohashi-shi
Email: Mengshen.Gu@sbdinc.com Aiti (Aichi) 441-8540, Japan
France Tel: +81 0532.25.1126 Fax: +81 0532.25.1120
STANLEY Engineered Fastening France Email: Haruhiko.Suzuki@sbdinc.com
Outils Portatifs et Systemes d’Assemblage Spain
Zone Imoparc bat Loire 4, 78190 Trappes, France STANLEY Engineered Fastening Spain
Tel: +33 (1) 3050 9100 Fax: +33 (1) 3051 0708 Avenida de Madrid, 35
Email: Vahid.Amirzadeh@sbdinc.com 28802 Alcalá de Henares (Madrid), Spain
Tel: +34 (91) 877-0380
Email: Felix.Barba@sbdinc.com
www.StanleyEngineeredFastening.com