QB Alpha Controller Setup Guide

Table of Contents

Introduction 5

1.1

Whats Included ...............................................................................................................6

1.2

1.3

1.4

1.5

1.6

1.7

Controller Functions and Connections

CE Directives (Europe)

Regulatory Notices for Radio Transmitter

Safety

Specifications

Installation Instructions

Controller Operation

2.1

Data Storage

2.2

2.3

2.4

2.5

2.6

2.7

2.8

2.9

Input and Output Functions .........................................................................................26

Software .......................................................................................................................26

Embedded PLC ..............................................................................................................26

Networking ...................................................................................................................26

Navigation ....................................................................................................................26

Display ..........................................................................................................................27

Faults ............................................................................................................................34

Messages ......................................................................................................................35

Programming 37

3.1

SETUP Area

3.2

3.3

SERVICE Area ................................................................................................................84

ANALYZE Area ..............................................................................................................89

Alpha Toolbox 95

Connection

Connection ....................................................................................................................96

4.2

4.3

4.4

4.5

Controls

Editing Parameters

Trace Data

Icons and Security

2 QB Controllers

Table of Contents

Tool Operation

Tool Specifications

Controller Connections

Power Cord

Embedded PLC 155

7.1 'Rack' Layout

Multiple Spindle 171

8.1

Connection .................................................................................................................. 172

8.3

8.3

8.4

Disconnect .................................................................................................................. 175

Synchronization ........................................................................................................... 175

Networking ................................................................................................................. 176

3 Instruction Manual

Table of Contents

QB Controllers

QB Controller Manual

Introduction

What's Included Controller Functions and Connections CE Declaration of Conformity Regional Notices for Transmitter Safety Specifications

Installation Instructions

Introduction

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. The controller software version is constantly being updated with items from minor cosmetic changes to addition of major product features, please note that there may be slight differences seen in this manual versus on your controller. If there are items missing from this controller manual, please ensure that this is the latest revision controller manual and that the controller is updated with the latest software version.

1.1 Whats Included

Included with the QB Alpha controller is a power cord, plinth (for mounting), documentation (in the envelope) and a mating connector for the I/O port (Only included with controllers that contain 24V DC I/O capability). The mating connector is included so the end user may connect wires to the controller's I/O port to their requirements.

QB Controllers

Getting Started

FIELDBUS OPTIONS

Instruction Manual

QB Alpha Specialist Controller

Introduction

QB Controllers

QB Alpha Advanced Controller

Getting Started

Instruction Manual

QB Alpha Standard + Controller

Introduction

QB Controllers

QB Alpha Network Node Controller

Getting Started

Instruction Manual

QB Alpha Node Controller

Introduction

QB Controllers

Getting Started

Controller Functions and Connections

This table refers to the picture on the previous page.

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 press CNTRL+F on the keyboard to search the document for the item of interest.

CE Directives (Europe)

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

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.

RoHS Compliance

Instruction Manual

Introduction

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

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.

Regulatory Notices for Radio Transmitter

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

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.

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
• cet appareil doit accepter toute interérence, y compris celles susceptibles de provoquer un fonctionnement non souhaité de l'appareil.

QB Controllers

Getting Started

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.

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.

Safety

Warnings and Cautions

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

Indicates 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.

Instruction Manual

Introduction

Read and understand all the safety recommendations 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.

QB Controllers

Getting Started

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.

• 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.
• 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)'.
• Personal Safety
• a.) Stay alert, watch what you are doing and use common sense when operating a power tool. Do not use a power tool while you are tired or under the influence of drugs, alchohol or medication. A moment of inattention while operating power tools may result in serious personal injury.
• b.) Use personal protective equipment. Always wear eye protection. Protective equipment such as dust mask, non-skid safety shoes, hard hat, or hearing protection used for appropriate conditions will reduce personal injuries.
• c.) Prevent unintentional starting. Ensure the switch is in the off-position before connecting to power source adn/ or battery pack, picking up or carrying the tool. Carrying power tools with your finger on the switch or energising power tools that have the switch on invites accidents.
• d.) Remove any adjusting key or wrench before turning the power tool on. A wrench or key left attached to a rotating part of the power tool may result in personal injury.

Instruction Manual

Introduction

Continued:

• e.) Do not overreach. Keep proper footing and balance at all times. This enables better control for the power tool in unexpected situations.
• f.) Dress properly. Do not wear loose clothing or jewelry. Keep your hair, clothing and gloves away from moving parts. Loose clothes jewelry 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 Tool 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. Check 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.

WARNING

QB Controllers

Getting Started

Safety Instructions for QB Alpha Controllers

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% noncondensing and Temperature: 32 to 122 ºF (0 to +50 ºC).
• Do not install worn, damaged, or modified equipment that may be unsuitable for safe use.
• Controller plugs must match 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 manner 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.

WARNING

Instruction Manual

Introduction

Specifications

Physical and Environmental Ratings

Electric Service Ratings

These are the minimum electric service ratings for the QB Alpha controller and the tools it can control.

E-Stop Precaution

INTEGRATED E-STOP CIRCUIT NOT PRESENT

To Avoid Injury:

• When a QB 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.

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.

Tool Temperature Versus Electric Supply

WARNING

QB Controllers

Getting Started

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' s upply 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.

Installation Instructions

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.

Plinth Mounting Dimensions

Install the QB 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 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 Alpha Controller to a power source.

Connect one end of the tool cable to the tool and the other end to the QBAlpha 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.

WARNING

Instruction Manual

Introduction

1.7.1 Plinth Mounting Dimensions

18.00

[457,2]

QB Controllers

Getting Started

Instruction Manual

QB Controller Manual

Controller Operation

Data Storage

Input and Output Functions

Spoftware

Embedded PLC

Networking

Navigation

Display

Faults

Messages

QB Alpha Controllers

2 QB Alpha Controllers

The QB Alpha controllers are a modular, high-end, full-featured controller for QPM DC servo power tools with torque transducers.

They will control any QPM E, EA, EB, EC or B series servo motor-powered tool (QB Alpha Specialist and Network Node controllers do not have connections for a corded E, EA, EB, or EC 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 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 Alpha controllers are certified to IP54 level to withstand the dust, dirt and liquids found in industrial facilities. Installing into other panels is not necessary.

QB Expert, Specialist, and Network Node 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 QPM Cordless tools. The QB Expert Alpha controller can be used as a standalone system as it runs its own corded tool.

The QB Specialist 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 Specialist Alpha controller. Trailing controllers used in multiple spindle systems can be QB Advanced Alpha or QB Node Alpha or QPM Cordless tools. The QB Specialist Alpha controller can be used as a standalone system with up to 15 QPM cordless tools only.

The QB Advanced Alpha controller is designed to be a lead controller in a multiple tool system. Multiple systems of up to 2 spindles can be configured and managed by the QB Advanced Alpha controller. Trailing controllers used in multiple spindle systems can be QB Advanced Alpha or QB Node Alpha controllers. The QB Advanced Alpha controller can be used as a standalone system as it runs its own corded tool.

The QB Standard+ Alpha controller is designed to be a standalone system. Multiple spindles cannot be configured or managed by the QB Standard+ Alpha controller. The QB Standard+ Alpha controller can only be used as a standalone system as it can only run its own corded tool.

The QB Network Node Alpha controller is designed to be a facility network interface for a single or a multiple tool system. Multiple systems of up to 6 cordless spindles can be configured and managed by the QB Network Node Alpha controller. Trailing spindles used in multiple spindle systems can be QPM cordless tools only.

The QB Node Alpha controller is designed to be a trailing spindle in a multiple tool system. Trailing controllers used in multiple spindle systems can be managed by an Alpha Expert, Alpha Specialist, or Alpha Advanced. The QB Node Alpha controller can be used as a standalone system as it runs its own corded tool.

Data Storage

Data associated with 30,000 fastening cycle results and 30,000 traces are stored in the the QB Expert, Advanced, Standard+, and Node Alpha controllers. This data is retrieved with a USB memory stick or Alpha Toolbox.

The QB Network Node, and Specialist Alpha controller does not store fastening cycles or trace data for the attached QPM Cordless tools.

Instruction Manual

Controller Operation

Input and Output Functions

Bolt Count or Error Proofing functions are an integral part of the QB Alpha controllers.

The QB Expert, Specialist, Advanced, Standard+ and Network Node Alpha controller's contain eight inputs and eight outputs on the 24V DC I/O connector. The inputs and outputs support functions to provide expert plant integration to external devices such as a PLC. The inputs and outputs are assignable, and configurable.

The QB Expert, Specialist, Advanced, and Network Node Alpha controllers support ModbusTCP, which is standard with these controllers.

The QB Expert, Specialist, and Advanced Alpha controllers support the other optional bus types Ethernet/ IP, Profibus, ProfiNet and DeviceNet. DeviceNet can be ordered as either a scanner or device.

The QB Node Alpha does not have any 24V DC or fieldbus Inputs or Outputs.

The QB Standard+, Node, and Network Node Alpha controllers do not have Ethernet/IP, Profibus, ProfiNet and DeviceNet bus options.

Software

Any computer with a modern web browser connected with an Ethernet cable on the Ethernet network port, or the ATB port, is used to view the QB 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.

The QB Expert, Specialist, and Network Nodes Alpha Toolbox can be accessed wirelessly by connecting to the controllers WIFI direclty.

Embedded PLC

The QB Expert, Specialist, Advanced, Standard+ and Network Node Alpha controller's 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 Alpha controllers.

The QB Node Alpha does not have an embedded PLC.

Networking

The QB Expert, Specialist, Advanced, and Network Node Alpha controller's support the XML (2.0, 2.1), PFCS, NPL, TOOLSNET, OPEN and FORD protocols. 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. For those that haven't switched to this more robust means of collecting data, these controllers support PFCS, OPEN and Toyota PI protocols over a serial connection.

The QB Standard+ Alpha controller does not connect to a plant network, nor does it have the industry standard Ethernet protocols.

The QB Node Alpha controller does not have the industry standard Ethernet protocols.

Navigation

The QB Expert, and Specialist controllers have 4 methods of navigation on the front of the controller used to facilitate menu navigation, make selections, and input data; touchscreen, arrows and toggle button, keypad, and interavtive menu buttons.

The QB Advanced, and Standard+ controllers have 3 methods of navigation on the front of the controller used to facilitate menu navigation, make selections, and input data; arrows and toggle button, keypad, and

QB Controllers

QB Alpha Controllers

interavtive menu buttons.

The QB Node, and Network Node Alpha controllers do not have any way to navigate or input data from the controllers front panel. These controllers are programmed using the embedded software called Alpha Toolbox. See section '4 Alpha Toolbox' on page 95 to learn how to connect and use this software.

Labels for the four interactive menu buttons [1] change with menu selection. 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;
• Green indicates an OK fastening cycle;
• Yellow indicates low torque/angle;
• White is programmed by the embedded PLC ( Lead controllers embedded PLC for QB Node Controllers), and
• Blue indicates when the tool is enabled to run.

The Orange Wrench icon [6] indicates preventive maintenance is due on the tool of spindle 1.

Display

The QB Expert, Specialist, Advanced, and Standard+ Alpha controllers have a display and keypad that can be used to view, operate, and program. A computer, smart phone, or tablet can also be connected to view, operate, and program using the controllers embedded Alpha Toolbox.

The QB Node, and Network Node Alpha controllers does not have a display or keypad like the other controllers in the family. A computer, smart phone, or tablet is required to connect in order to view, operate, and program. The display on the Advanced or Expert controller can also be used to view/ edit information on the Node controller

Instruction Manual

Controller Operation

when connected as a multiple spindle system.

Scroll Bar

On the controller screen, if available, and Alpha Toolbox, the 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 on a QB Expert, Specialist, Advanced, or Standard+ Alpha controllers, use the up/down arrows or, if available, use the keypad to identify the corresponding menu item number.

Dropdown

On a QB Expert, Specialist, Advanced, or Standard+ Alpha controllers screen, 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.

Menu Tree

On a QB Expert, Specialist, Advanced, or Standard+ Alpha controllers screen, a menu tree appears beside related menu items.

Tabs

On a QB Expert, Specialist, Advanced, or Standard+ Alpha controllers, tabs appear at the top when multiple menu selections exist. To navigate between tabs, use the left/right arrows.

Character Scrollbar

On a QB Expert, Specialist, Advanced, or Standard+ Alpha controllers, 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 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 are examples that contain the character scrollbar option: ALL, Job (Name), Task (Name) Step (Name), System (Name General), System (Users), WIFI (SSID, Password), and other releated fields that require custom inputs.

2.7.6 Run Display

On a QB Expert, Specialist, Advanced, or Standard+ Alpha controllers, 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.

Icons identify events [1], see list below. [2] The last torque and angle readings with units, when a tool is connected. 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. A Shutoff code is also displayed when applicable [8]. The display

QB Controllers

QB Alpha Controllers

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 Run screen displays unless other programming functions [5] are in use.

The display background color turns red in the event of a fault; see section '1.5 Safety' on page 15.

The run display changes to indicate the step in which the tool stopped (providing it did not stop during the audit step).

The Fastening Cycle Log [9] lists the fastening cycles that have occurred in the QB Alpha controllers. 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.

Fastening Cycle Log

On a QB Expert, Specialist, Advanced, or Standard+ Alpha controllers, make sure the the Run screen is displayed, next press the down arrow and then press the interactive MANAGE button after selecting a data line to display the MANAGE dialog box.

Instruction Manual

Controller Operation

Controller Operation

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 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 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.

QB Controllers

QB Controllers

QB Alpha Controllers

Fastening Cycle Details

Not all items are shown

On a QB Expert, Specialist, Advanced, or Standard+ Alpha controllers, make sure the the Run screen is displayed, next press the down arrow and then press the interactive DETAILS button after selecting a data line to display the DETAILS dialog box.

Details about the event and when it occurred are listed.

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

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

Instruction Manual

Controller Operation

Shutoff Codes

Shutoff Codes on the display indicate why a fastening cycle terminates prior to completion.

Fastening Cycle Trace

On a QB Expert, Specialist, Advanced, or Standard+ Alpha controllers, make sure the the Run screen is displayed, next press the down arrow and then press the interactive TRACE button after selecting a data line to display the TRACE dialog box. 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.

• Torque - Torque vs. time
• Angle - Angle vs. time
• Torque/Angle - Torque vs. Angle
• Speed - Tool Speed vs. time.

Press the interactive BACK or EXIT buttons to leave the trace screen.

QB Controllers

QB Alpha Controllers

Keypad Mode

On a QB Expert, Specialist, Advanced, or Standard+ Alpha controllers, when Keypad Mode is set to Job or Task Select 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 75) 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.

Controller Display Icons

On a QB Expert, Specialist, Advanced, or Standard+ Alpha controller screens, there are Icons that indicate the status of the controller. They are located in the upper left corner of the controllers screen and on Alpha toolbox they are located on the bottom left hand side of the web browser window.

Instruction Manual

Controller Operation

Faults

On a QB Expert, Specialist, Advanced, or Standard+ Alpha controllers, the Run screen 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 Alpha controllers:

QB Controllers

QB Alpha Controllers

Messages

On a QB Expert, Specialist, Advanced, or Standard+ Alpha controllers, messages appear on the screen when certain non-critical conditions exist. They may appear on any screen at any time.

Instruction Manual

Controller Operation

QB Controllers

Programming

Programming

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 following provides a guide for programming the QB Expert, Specialist, Advanced, or Standard+ Alpha controllers.

The QB Network Node, and Node Alpha controller is programmed using the embedded software called Alpha Toolbox. See section '4 Alpha Toolbox' on page 95 to learn how to connect and use this software.

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.

• Jobs - use to perform tool strategy programming such as torque and speed parameters.
• Communications - use to program Ethernet, serial port, fieldbus and network protocol options.
• Other - use to set parameters for all other features, including system level, users, passwords, I/O and tool functions.
• Full Backup / Restore - 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.

WARNING

QB Controllers

Programming

3.1 SETUP Area

This area changes the settings of the Jobs, 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.

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.

Instruction Manual

Programming

Strategy

Batch Count

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 52 for an explanation of the strategies.

• 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 proofing scheme and remote input and output device. Acceptable values are between 1 and 99. The default value is 1.

Thread Direction Use CW (clockwise) for tightening right hand fasteners. Use CCW (counter-clockwise) for tightening left hand fasteners.

To modify a parameter, select the parameter using the up/down arrow keys then press the Toggle button, otherwise use Alpha Toolbox to modify a parameter. Enter the appropriate value then press the Toggle button or Enter if using Alpha Toolbox. 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

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Programming

AC/TM 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 and the downshift mode, ATC+(Adaptive tightening control plus) if checke, or no downshift if not selected. The downshift mode can be changed later if ATC (Adaptive Tightening Control), or a manual downshift setting is desired, see 'Downshift Mode' on page 57 for a full explanation of each downshift type.

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.

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.

Instruction Manual

Programming

Not Selected

Selected

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:

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:

QB Controllers

Programming

Instruction Manual

Programming

QB Controllers

Programming

Press the FINISH interactive menu button to close the Wizard.

The Job tab screen appears. This allows manual editing of parameters prior to saving Wizard programming.

To save, press the EXIT interactive menu button on the controller, then press the YES interactive menu button to save changes. This saves the parameters and opens the Run screen.

If using Alpha toolbox, ensure that you 'Save Changes' as described in section '4 Alpha Toolbox' on page 95.

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.

The maximum number of Jobs in the Expert, Advanced, Standard Plus controllers is 255.

Specialist Controllers do not store Jobs on the controller. The number of Jobs a wirelessly paired B-Series tool is based on the B-Series Cordless tool memory. B-Series Cordless tools contain their own memory of Jobs/ Tasks/ Steps.

Select Jobs by pressing the SETUP interactive menu button on the Run screen.

If using Alpha toolbox, this menu is already expanded and does not require selection of the SETUP Menu.

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

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Programming

If using Alpha toolbox, select Jobs from the run screen.

There can be more than one Job.

Use the left/right arrow keys to select the tab/Job for modifying.

If using alpha toolbox, simply select the desired job to edit in the expanded list of Jobs along the left edge of the browser.

QB Controllers

Programming

Instruction Manual

Programming

Manage Button (Jobs)

Press the MANAGE interactive menu button to Add, Delete, Copy or Paste Jobs.

If using Alpha Toolbox, the Manage Button is already expanded accross the top of the browser.

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.

QB Controllers

Programming

Export

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

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 '1.3 CE Directives (Europe)' on page 13.

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, Advanced, Standard Plus controllers is 99. Share these Tasks between the programmed Jobs. There can be up to 99 Tasks per Job.

Specialist Controllers do not store Tasks on the controller. The number of Tasks a wirelessly paired B-Series tool is based on the B-Series Cordless tool memory. B-Series Cordless tools contain their own memory of Jobs/ Tasks/ Steps.

Select Tasks by pressing the TASK interactive menu button. Use the left/right arrow keys to select the tab/Task for modifying.

If using Alpha Toolbox, simply select the desired task to edit in the expanded list of tasks along the left edge of the browser.

Instruction Manual

Programming

QB Controllers

Programming

Manage Button (Task)

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

If using Alpha Toolbox, the Manage Button is already expanded accross the top of the browser.

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

Press the EXIT interactive menu button to save changes and return to the Run screen. See section '1.3 CE Directives (Europe)' on page 13.

Press the CANCEL interactive menu button to return to the Job level.

If using Alpha toolbox, ensure that you 'Save Changes' as described in section '4 Alpha Toolbox' on page 95.

Instruction Manual

Programming

C/TA

Step Button

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

If using Alpha Toolbox, simply select the desired Step to edit in the expanded list of tasks along the left edge of the browser.

Step settings only affect the selected Job and Task. There can be only one Audit step per Task. Each Step is 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 bar on the display to view more parameters. AC TM AC TC

TC AM

AC/TA

QB Controllers

Programming

TA

AC TM

Strategy (Advanced)

AC/TA

AC/TA

Strategy (Advanced)

AC / TC

AC TC

TC AM

AC TM

AC / TA AC/TA

AC TM

RC / AM

YC / AM

BACK OFF

AC/TA

Angle Control and Torque Control. This strategy enables precision control for both torque and angle on critical joints. The controller shuts off the tool when both a target torque value and a target angle value are achieved after a selected snug torque value occurs. Audit 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 cannot be reached (i.e. Bailout limits have been achieved). AC TM AC TC TC AM

Angle Control or Torque Control. The controller shuts off the tool when either a target torque value or a target angle value is achieved after a selected snug torque value occurs. Bailouts are set to the targets. Audit Step final torque and angle results must fall within their specification limits for the fastening cycle to be judged acceptable. AC TC

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. AC TC

TC AM

Rate Control with Angle Monitor. The controller shuts off the tool when the rising target 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 fastening cycle to be acceptable. TC AM

Yield Control with Angle Monitor. The controller shuts off the tool when the falling target 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 fastening cycle to be acceptable. For implementation description see '10.4 Fastener Yield Control Implementation' on page 198

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. Which means the tool 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. TC AM AC TM AC TC

Position Control with Torque 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 TM AC TC TC AM

Instruction Manual

Programming

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.

QB Controllers

Programming

Bailout on High Angle

Monitor Torque Window

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.

The angle value at which the tool will shutoff during an Torque Control strategy if the tool has not reached target torque.

Angle Bailout

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. For implementation description see '10.5 Monitor Torque Window' on page 200.

Instruction Manual

Programming

Monitor Torque Rate

Bailout on Torque Drop

Speed

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.

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.

Torque Drop

The value, as a percentage of running peak torque, the torque must drop before the controller shuts off the tool.

Torque

Threshold

Filter

The amount of angle the tool's output must rotate where the torque drop must be maintained before the fastening cycle is ended with a shutoff code of TD.

The velocity of the output of the tool before any Downshift Mode activates (required for any step). Units are RPM. Must be greater than 0. Default is 9999.

The torque at which this monitoring begins.

QB Controllers

Programming

Acceleration

Downshift Mode

The rate the tool ramps up to Speed in RPM/s (revolutions per minute per second). Should be greater than 1,000 RPM/s. The default is 3,000 RPM/s.

Selects the type of spindle inertia control toward the end of a fastening cycle.

Disabled

Manual

ATC

ATC+

Does not reduce the speed of the motor.

Reduces the tool speed to a specific value (Downshift Speed) at a specific rate (Deceleration) when a specific torque value (Downshift Torque) is reached during the fastening cycle. Speed units are RPM, deceleration units are RPM/sec, torque is in torque units.

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 speed values are a percent of Speed.

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 maximum speed of the tool.

Instruction Manual

Programming

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.

QB Controllers

Programming

Manage Button (Step)

Manage enables step settings to be added, deleted, and/or copied to the clipboard and pasted. If using Alpha Toolbox, the Manage Button is already expanded accross the top of the browser.

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.

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 39 for a description of these Smart Steps.

Add

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Programming

Exit

Press the EXIT interactive menu button to save changes and return to the Run screen, See section '1.3 CE Directives (Europe)' on page 13.

Press the CANCEL interactive menu button to return to the Task level.

If using Alpha toolbox, ensure that you 'Save Changes' as described in section '4 Alpha Toolbox' on page 95.

Programming changes are stored after exiting current menu. Alert Operator(s) to any changes in tool behavior before saving.

If using Alpha toolbox, ensure that you 'Save Changes' as described in section '4 Alpha Toolbox' on page 95.

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.

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, otherwise use Alpha Toolbox.

If using Alpha toolbox, this menu is already expanded and does not require selection of the COMMUNICATION Menu.

Press 2 or highlight selection and press Toggle button.

QB Controllers

Programming

TCP/IP Tab

RENEW Button

Press this button to 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 60.

If using Alpha Toolbox, simply select the desired Tab to edit in the expanded list along the left edge of the browser and ensure that you 'Save Changes' as described in section '4 Alpha Toolbox' on page 95.

Instruction Manual

Programming

WIRELESS Tab

Use these parameters to setup the access point to connect QPM Cordless tools to the Expert, Specialist, or Network Node Alpha controllers. 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, Specialist, or Network Node Alpha controllers, type in an SSID value, type in a PASSWORD and choose the applicable REGION.

Radio

Name

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. 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.

This parameter sets the Service Set Identifier (SSID) for the access point in the QPM 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 Alpha controller is QBserialnumber, where serialnumber is the serial number of the controller; i.e. QB-032014007.

QB Controllers

Programming

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, available on Expert, Specialist, and Network Node Controllers, to initiate the pairing mode to a QPM Cordless Tool. If there are unsaved changes, the changes must be saved before you can put the controller in pair mode. If you select 'PAIR' with unsaved changes a popup message will display 'CHANGES PENDING!'. The 'PAIR' button will switch the access point to a pairing SSID while the 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 wireless capable 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 wireless capable Alpha Controllers. See Section '8.1 Connection' on page 174 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, otherwise use Alpha Toolbox.

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 60.

If using Alpha Toolbox, simply select the desired Tab to edit in the expanded list along the left edge of the browser and ensure that you 'Save Changes' as described in section '4 Alpha Toolbox' on page 95.

3.1.3.3 Serial Tab

The Serial Tab selects the function for the db-9 COM PORT connector on the bottom of the Alpha controller.

Instruction Manual

Programming

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 60.

If using Alpha Toolbox, simply select the desired Tab to edit in the expanded list along the left edge of the browser and ensure that you 'Save Changes' as described in section '4 Alpha Toolbox' on page 95.

PFCS Tab

For Controllers with PFCS, 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.

QB Controllers

Programming

Instruction Manual

Programming

QB Controllers

Programming

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 60.

If using Alpha Toolbox, simply select the desired Tab to edit in the expanded list along the left edge of the browser and ensure that you 'Save Changes' as described in section '4 Alpha Toolbox' on page 95.

OPEN Tab

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

Use the right arrow to move to the next tab or press EXIT to save the changes and return to the Run screen, otherwise use ALpha Toolbox. See section '3.1.2.6 Exit' on page 60.

If using Alpha Toolbox, simply select the desired Tab to edit in the expanded list along the left edge of the browser and ensure that you 'Save Changes' as described in section '4 Alpha Toolbox' on page 95.

Instruction Manual

Programming

TOOLSNET Tab

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

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 60.

If using Alpha Toolbox, simply select the desired Tab to edit in the expanded list along the left edge of the browser and ensure that you 'Save Changes' as described in section '4 Alpha Toolbox' on page 95.

QB Controllers

Programming

XML Tab

For controller with XML, The plant's IT department must provide these values to allow the Alpha controller to communicate on the XML protocol network.

Use the right arrow to move to the next tab or press EXIT to save the changes and return to the Run screen, otherwise use Alpha Toolbox. See section '3.1.2.6 Exit' on page 60.

If using Alpha Toolbox, simply select the desired Tab to edit in the expanded list along the left edge of the browser and ensure that you 'Save Changes' as described in section '4 Alpha Toolbox' on page 95.

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 Alpha controllers 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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MANAGE Button

Press the MANAGE interactive menu button.

If using Alpha Toolbox, the Manage Button is already expanded accross the top of the browser.

EDIT

This edits the selected device that has already been added to the controller.

This adds a device for the to control. Set the options for the devices added in the Scanner dialog box.

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 60.

If using Alpha Toolbox, simply select the desired Tab to edit in the expanded list along the left edge of the browser and ensure that you 'Save Changes' as described in section '4 Alpha Toolbox' on page 95.

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FIELDBUS Tab

The Fieldbus tab is a generic term for any of the optional fieldbus types that can be added to the Expert, Specialist, or Advanced controllers and this tab appears only when one of those options are installed. These fieldbus allow the configurable 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.

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.

The Fieldbus Configurable Alpha controllers 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 '2.8 Faults' on page 34 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, otherwise use Alpha Toolbox. 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 60.

If using Alpha Toolbox, simply select the desired Tab to edit in the expanded list along the left edge of the browser and ensure that you 'Save Changes' as described in section '4 Alpha Toolbox' on page 95.

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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.

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 '2.8 Faults' on page 34 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.

If using Alpha Toolbox, simply select the desired Tab to edit in the expanded list along the left edge of the browser and ensure that you 'Save Changes' as described in section '4 Alpha Toolbox' on page 95.

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Profinet

This tab appears on the Alpha controllers only when the PROFINET option is installed.

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 (-).

• 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 Ethernet board inside and cannot be changed.

Name

Physical

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'2.8 Faults' on page 34 to assign and configure the PROFINET I/O.

If using Alpha Toolbox, simply select the desired Tab to edit in the expanded list along the left edge of the browser and ensure that you 'Save Changes' as described in section '4 Alpha Toolbox' on page 95.

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, otherwise use Alpha Toolbox. 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 60.

If using Alpha Toolbox, simply select the desired Tab to edit in the expanded list along the left edge of the browser and ensure that you 'Save Changes' as described in section '4 Alpha Toolbox' on page 95.

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3.1.3.9.4 Profibus

This tab appears on Alpha controllers only when the Profibus port option is installed.

This tab sets the communications parameters for the Alpha controller on a Profibus network.

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

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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 '2.8 Faults' on page 34 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 60.

If using Alpha Toolbox, simply select the desired Tab to edit in the expanded list along the left edge of the browser and ensure that you 'Save Changes' as described in section '4 Alpha Toolbox' on page 95.

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

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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 60.

If using Alpha Toolbox, simply select the desired Tab to edit in the expanded list along the left edge of the browser and ensure that you 'Save Changes' as described in section '4 Alpha Toolbox' on page 95.

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.

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Options include:

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.

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There is no overlap between areas. Select more than one area for access if required.

Press OK to save.

To delete a user press the MANAGE button and select option 2. Delete. Confirm deletion by pressing OK. This action requires the Administrator password; once entered, user is deleted.

Import - Users can be entered from a backup file. Connect a USB memory stick to the USB port, scroll to desired file and press IMPORT. The new users display on the User list.

Export - To backup Users, connect a USB memory stick to the USB port, name the file, then press SAVE.

Press OK to save.

Use the right arrow to move to the next tab or press EXIT to save the changes and return to the Run screen. See section '3.1.2.6 Exit' on page 60.

If using Alpha Toolbox, simply select the desired Tab to edit in the expanded list along the left edge of the browser and ensure that you 'Save Changes' as described in section '4 Alpha Toolbox' on page 95.

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.

If using Alpha Toolbox, simply select the desired Tab to edit in the expanded list along the left edge of the browser. The buses available are dependent on the options installed.

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 130 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 138

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for configuration options and descriptions. After modifying press FINISH.

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 130 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 132 for configuration options and descriptions. After modifying press FINISH.

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 132 or '6.12.2 Output Descriptions' on page 138 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.

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Manage Button

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 byte are used then a new byte will be added with the next function addition.

Assign at bit 0 or bit 8

Add After Selection

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.

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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 117 for an explanation of the options. Options include:

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

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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.

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.

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.

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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.

Statistics Tab

Sets values required to calculate the statistics on the stored fastening cycle data.

-

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.

REGIONAL Tab

Sets the values for the region of the world in which the controller is used.

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.

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.

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3.2.1 Tool

Ladder logic for the embedded PLC can be created or edited using Alpha Toolbox. See section 'PLC Editor' on page 157.

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. 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.

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.

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.

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).

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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.

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 60.

If using Alpha Toolbox, simply select the desired Tab to edit in the expanded list along the left edge of the browser and ensure that you 'Save Changes' as described in section '4 Alpha Toolbox' on page 95.

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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 60.

If using Alpha Toolbox, simply select the desired Tab to edit in the expanded list along the left edge of the browser and ensure that you 'Save Changes' as described in section '4 Alpha Toolbox' on page 95.

CAL Tab

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

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Press EXIT to save the changes and return to the Run screen. See section '3.1.2.6 Exit' on page 60. If using Alpha Toolbox, simply select the desired Tab to edit in the expanded list along the left edge of the browser and ensure that you 'Save Changes' as described in section '4 Alpha Toolbox' on page 95.

3.2.2 Controller

This tab displays the controller information. Updating the controller's firmware is managed here.

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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.

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 'Reboot Required' 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

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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 Alpha Controller may also be updated this way by simply choosing the spindle before selecting SERVICE > CONTROLLER. It is advised to update trailing controllers and B-Series QPM Cordless Tools before updating the lead controller.

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 during troubleshooting operations.

If using Alpha Toolbox, the display will not show the live tool view.

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 34 for limits.

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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 20 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 82.

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 60.

If using Alpha Toolbox, simply select the desired Tab to edit in the expanded list along the left edge of the browser and ensure that you 'Save Changes' as described in section '4 Alpha Toolbox' on page 95.

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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.

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 60.

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

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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.

3.3.4 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.

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.

3.3.5 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.

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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 60.

3.3.6 LOG Tab

The QB Alpha controller stores up to 1000 Events in the log.

The B-Series Cordless tools store up to 100 Events in the log.

Use the up/down arrows to select an event the press the Toggle key to get more details.

The details provide the Date and Time the event occurred.

Source - Shows where the user changed the values. Controller indicates 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 60.

Instruction Manual

Programming

Date

The date at which the event occurs in the format selected in the Region tab. The date can be changed by navigating to Setup->Other->Clock. The date format can be changed by navigating to Setup->Other->Region.

Time

The time at which the event occurs in the format HH: MM: SS AM/PM. The time and time zone can be changed by navigating to Setup->Other->Clock.

Event

• Overcurrent Fault- See 'Fault Guide' section 9.2.1 for explanation of fault.
• Logic Voltage Fault- See 'Fault Guide' section 9.2.1 for explanation of fault.
• Position Feedback Fault- See 'Fault Guide' section 9.2.1 for explanation of fault.
• Transducer Span Fault- See 'Fault Guide' section 9.2.1 for explanation of fault.
• Temperature Fault- See 'Fault Guide' section 9.2.1 for explanation of fault.
• Unrecognized Tool- See 'Fault Guide' section 9.2.1 for explanation of fault.
• Tool Communications- See 'Fault Guide' section 9.2.1 for explanation of fault.
• Transducer Current Fault- See 'Fault Guide' section 9.2.1 for explanation of fault.
• Transducer Zero Fault- See 'Fault Guide' section 9.2.1 for explanation of fault.
• Unsupported Tool- See 'Fault Guide' section 9.2.1 for explanation of fault.
• Tool Configuration Fault- See 'Fault Guide' section 9.2.1 for explanation of fault.
• Servo Connection Fault- See 'Fault Guide' section 9.2.1 for explanation of fault.
• Spindle Communications- See 'Fault Guide' section 9.2.1 for explanation of fault.
• GFI Fault- See 'Fault Guide' section 9.2.1 for explanation of fault.
• Battery Pack Fault- See 'Fault Guide' section 9.2.1 for explanation of fault.
• Low Battery- See 'Fault Guide' section 9.2.1 for explanation of fault.
• Heatsink Temperature Fault- See 'Fault Guide' section 9.2.1 for explanation of fault.
• Overvoltage Fault- See 'Fault Guide' section 9.2.1 for explanation of fault.
• Tool Jammed- See 'Fault Guide' section 9.2.1 for explanation of fault.
• Parameter Changed- A parameter within the spindle was modified and saved.
• Spindle Connected- The spindle was connected and communicating successfully.
• Spindle Disconnected- The spindle was disconnected or communication error.
• Firmware Update- The firmware on the spindle was updated successfully.
• Powered On- The spindle was powered on from an off state.
• Log Cleared- The event log was cleared.
• Network Status Change- The spindles network protocol status has changed state.
• Cpks Limit- The capability index fell below the programmable minimum Cpk limit.
• Ppks Limit- The statistical capability index fell below the programmable minimum Ppk limit.
• CAMs Limit- The statistical capability index fell below the programmable minimum CAM limit.
• X Bar Trend- The audit value's average statistical trend is drifting up or down.
• Log File Error- Please contact a STANLEY service team member.

QB Controllers

Programming

• Internal Fault- Please contact a STANLEY service team member.
• Time Changed- The internal spindle clock time or date was modified and saved.
• PM Counter Reset- The preventative maintenance counter was rest to zero.
• Trip Counter Reset- The trip counter was reset to zero.
• Unknown- The event error was not recognized, most likely due to mismatched software between Alpha Toolbox, lead spindle, and trailing spindles.

Source

The source that detects the event or fault. If a user profile is created, this field is populated with the user that makes the parameter change instead of the source the change was made. The possible items that could be populated in this field are listed below.

• Controller- The controller was the source that made a parameter change.
• Lead- The lead controller was the source that issued the event about a trailing spindle.
• Alpha Toolbox- Alpha Toolbox was the source that made a parameter change.
• Servo- The controller was the source that issued the event/ fault.
• Tool- The tool was the source that issued the event/ fault.
• Username- The user logged in at the time of a parameter change.

3.3.6.5 Details:

Details explaining the event or fault. Depending on the event or fault, this could also be the parameter or the spindle that changes were made to. The possible items that could be populated in this filed are listed below.

• SP#- The spindle number the event occurred.
• Asserted- The event or fault became active.
• Cleared- The event or fault was cleared.
• Spindle Network- Spindle network or list of spindles are modified
• Ethernet Cable Connected- Ethernet port communication started

Instruction Manual

Programming

3.3.7 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 126 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 78 to assign functions to the pins.

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 60.

QB Controllers

QB Controller Manual

Alpha Toolbox

Connection Controls Editing Parameters Trace Data Icons and Security

Alpha Toolbox

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.

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, 6, 6a, etc. Ethernet cable terminated with RJ45 connectors. 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 38 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 27 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

QB Controllers

Alpha Toolbox

run screen with a scroll bar, if necessary, to view them all.

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.

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 38 for descriptions on these menu items and parameters and how to

Instruction Manual

Alpha Toolbox

use them.

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.

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.

Manage Buttons

4.2.4 Manage Buttons

Editing Parameters

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.

When finished entering the value press the computer's Enter or Tab keys to set the value. The 'Save Changes' dialog box opens. Click Apply to save the changes to the controller. Click Cancel to discard the changes.

4.3.1 Parameter and Data Retrieval

QB Controllers

Alpha Toolbox

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

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.

Fastening Cycle Data

The 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.

SOC is short for Shutoff Code. This column will contain numbers representing the reason the tool shutoff. Here

Instruction Manual

Alpha Toolbox

are the values for the numbers, see section '2.7.7.2 Shutoff Codes' on page 32 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 Alpha controllers stores resultant audit data for 30,000 fastening cycles on a first in/ first out basis. Click on the Analyze>Trace menu from the Home screen in Alpha Toolbox.

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 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.

QB Controllers

Alpha Toolbox

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.

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 27 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.

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.

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.

Instruction Manual

Alpha Toolbox

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.

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.

QB Controllers

Alpha Toolbox

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.

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.

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.

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

Instruction Manual

Alpha Toolbox

cycles are received. When the user navigates away from the Trace screen the imported files are removed from the list.

Graph

The selected fastening cycle graph (plot) is drawn in the window on the right in the Trace screen. There are two Y axes and one X axis. The values for the axes can be selected. By default the Y1 axis is Torque while the Y2 Axis is None and the X axis is Angle. The graph for each Y axes value has its own color. The value selected on one Y axis is not available to the other. The Angle value is not available if the X axis has Angle selected.

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

QB Controllers

Alpha Toolbox

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.

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.

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

Instruction Manual

Alpha Toolbox

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 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.

QB Controllers

Alpha Toolbox

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 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.

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.

The zero point of the X axis of Time for each graph in overlay view is the programmed Threshold Torque. Change the X axis from Time to Angle and the zero point changes to the programmed Snug Torque.

Selected and locked fastening cycles will move down the list as new ones come into the list. Use the scroll bar to view or unlock older traces.

Instruction Manual

QB Controller Manual

Tool Operation 5 Display Multiple Function Button Start Trigger Switch Tool Memory Worklights Tool Operation Special Application Tools

QPM DC Electric Tools

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.

Tool Specifications

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.

Instruction Manual

Tool Operation

Operator Protection

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.

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

WARNING

QB Controllers

QPM DC Electric Tools

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.

Instruction Manual

Tool Operation

5.1.6 Tool Installation

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.

WARNING

QB Controllers

QPM DC Electric Tools

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.

Square Drive

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 con tains no cracks.

CAUTION

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

Remove power 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.

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.

Cable Installation

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.

QPM Tool Controls and Operation

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. QPM Cordless tools trigger will be disabled during pairing mode.

WARNING

WARNING

Instruction Manual

Tool Operation

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:

• 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.

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.

QB Controllers

QPM DC Electric Tools

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.

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.

Instruction Manual

Tool Operation

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.

Program Selection

The QPM Alpha controllers have 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 130 to understand how to select a Job/Task.

Directional Control

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.

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 defines +60°C as the limit for thermal rise over ambient of a contactable surface (e.g. if the ambient is 25°C, the

WARNING

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QPM DC Electric Tools

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.

Setting Torque, Angle, and Other Operating Parameter

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 controllers can be setup to change tightening Jobs or Tasks from the tool's MFB.

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.

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.

Special Application Tools

Exposed Gear Socket Tools

WARNING

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

Instruction Manual

Tool Operation

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.

QB Controllers

QB Controller Manual

Controller 6 Connections

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

Controller Connections

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 EB DC electric tool cable. QPM EB 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.

6.2.2 E Tools

Alpha controllers use a single 30 pin connector to connect one QPM E DC electric tool cable. QPM E 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.

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.

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Alpha 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 63.

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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

All 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 and Specialist 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.

Advanced and Node Alpha controllers have two RJ-45 Ethernet connections located on the bottom of the controller forconnecting to a data collection or spindle network. The data collection network can consist of the controller anda 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 Communicationsis for the network ETHERNET port and the SPINDLE port.

Standard + and Network Node Alpha controllers do not connect to a plant network, nor does it have the

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Alpha Controller Connections

industry standard Ethernet protocols or RJ-45 Ethernet connections besides the one used for Alpha Toolbox.

The following virtual ports are used for the various protocols of the controller:

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, Specialist, and Advanced Ethernet/IP or Profinet Ports are present on Alpha controllers only when the option is installed. Ethernet/IP or Profinet configured 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.

6.8 Trailing DeviceNet™ Connector

Instruction Manual

Controller Connections

Expert, Specialist, and Advanced Alpha controllers can have a single Mini DeviceNet™ port, if this option is configured, for connecting the Alpha Controller to a Leading controller such as a PLC.

6.9 Profibus Connector

Expert, Specialist, and Advanced Alpha Controllers can have a single Profibus port, if this option is configured, for connecting the Alpha Controller to a Leading Profibus controller from another manufacturer.

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

6.10 Leading DeviceNet Connector

Expert, Specialist, and Advanced Alpha controllers can have a single Micro DeviceNet™ port , if this option is configured, 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.

6.11 Input and Output Connector

Connector

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Alpha Controller Connections

Expert, Specialist, Advanced, Network Node, and Standard + Alpha controllers contain a 24V DC 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.

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.

When the Alpha controller is used with fixtured tools, it must use a Remote Start/Stop/Reverse pendent to the

Instruction Manual

Controller Connections

controller to provide basic switching control for the tool. Pin descriptions are shown in the following table:

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

Inputs (Example)

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Alpha Controller Connections

Outputs: Sinking

(example)

Instruction Manual

Controller Connections

6.12 Assignable Input and Output Functions

Expert, Specialist, Advanced, Network Node, and Standard + Alpha controllers contain a 24V DC Input and Output Connector. 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.

Please see the full description of each function in the section following this table.

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Alpha Controller Connections

Instruction Manual

Controller Connections

6.12.1 Input Descriptions

Expert, Specialist, Advanced, Network Node, and Standard + Alpha controllers contain a 24V DC Input and Output Connector. Each of the single bit input functions has a Configuration setting of Contact Type. The Contact

QB Controllers

Alpha Controller Connections

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.

Instruction Manual

Controller Connections

QB Controllers

Alpha Controller Connections

Instruction Manual

Controller Connections

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Alpha Controller Connections

Instruction Manual

Controller Connections

6.12.2 Output Descriptions

Expert, Specialist, Advanced, Network Node, and Standard + Alpha controllers contain a 24V DC Input and Output Connector. 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.

QB Controllers

Alpha Controller Connections

Instruction Manual

Controller Connections

Outputs

ANGLE OK

Description

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:

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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Alpha Controller Connections

Instruction Manual

Controller Connections

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Alpha Controller Connections

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Alpha Controller Connections

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Alpha Controller Connections

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Alpha Controller Connections

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Alpha Controller Connections

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Alpha Controller Connections

6.13 MODBUS TCP

The fieldbus Modbus TCP comes as a standard feature on the Ethernet port in Expert, Specialist, and Advanced Alpha controllers. 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 '3.3.7 I/O Tab' on page 96 to learn how to edit the I/O. See section '6.12 Assignable Input and Output Functions' on page 130 to learn about the values to edit. There is no configuration or programming specifically for the Modbus protocol itself. The Alpha's CPU takes care of all the protocol's overhead and handshaking requirements.

The QB Alpha controllers 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.

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.

Instruction Manual

Controller Connections

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

# 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

# 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.

QB Controllers

QB Controller Manual

Embedded PLC 7

Rack Layout Supported Instructions and File Types PLC Editor Converting a RSS File

Embedded PLC

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.

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, Specialist, and Advanced 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.

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 126 for PLC addressing of the 24V DC connector.

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Embedded PLC

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.

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Embedded PLC

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Embedded PLC

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Embedded PLC

7.3 PLC Editor

Use the PLC editor provided in Alpha Toolbox to create and edit ladder logic files. See section '4.1 Connection' on page 98 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.

Instruction Manual

Embedded PLC

7.3.1 Edit Page Controls

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.

QB Controllers

Embedded PLC

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.

Instruction Manual

Embedded PLC

Instruction Box

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

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 .

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.

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.

QB Controllers

Embedded PLC

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 '3.1.1.1 Wizard Screens' on page 39.

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.

Once the file is saved it can be put into the Alpha controller. See section '3.1.4.11 PLC Tab' on page 83.

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Embedded PLC

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.

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.

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.

QB Controllers

QB Controller Manual

Multiple Spindle 8

Connection Disconnect Synchronization Networking

Multiple Spindle

8 Multi-Spindle

Expert and Specialist Alpha controllers can be managers (leaders) to twenty-three other Advanced or Node Alpha controllers or QPM Cordless tools (if the Expert or Specialist is a wireless version). An Ethernet cable connection between them creates a multiple spindle system. The lead Alpha controller manage all I/O connections and ladder logic for the multiple spindle system.

Advanced Alpha controllers can be managers (leaders) to one other Advanced or Node Alpha controller. The lead Alpha controller manage all I/O connections and ladder logic for the multiple spindle system.

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. For QPM Cordess Tools follow the pairing instructions in the QPM Cordless Tool manual otherwise to connect an Advanced and Node controllers to the lead controller connect the Ethernet cable as follows:

Expert and Specialist Alpha controllers, when used as a lead controller, do not require any setting to be changed to recognize a trailing spindle. Using the keypad or Alpha Toolbox on the trailing controller set the Obtain IP Address From Network parameter to YES, this is set to YES by default. Exit and save the setting. Next connect the lead controller to the trailing controller, at that point the lead Expert or Specialist will then provide the IP Addresses to the trailing controller.

Advanced controllers, when used as a lead spindle require manual pairing of the lead and trailing spindle, connect the Ethernet cable as shown.

Using the keypad, or Alpha Toolbox, on the leading (Advanced) and trailing (Advanced or Node) controller set the Obtain IP Address From Network parameter to NO. Then enter an IP Address and Subnet Mask values for both controllers. Remember to keep the IP Addresses similar but not exactly the same while keeping the Subnet Mask values the same. Type the IP Address of the lead controller into the LEAD IP ADDRESS parameter of the trailing controller. Exit and save the setting.

QB Controllers

Multi-Spindle

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.

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 38.

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.

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See Section '4.3 Editing Parameters' on page 100 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 (forgotten) and a different controller is attached the different controller must then be acknowledged before it is added to the system. If a trailing controller is offline or disconnected the spindle's tab on the lead controller's display will turn red. The lost spindle's display on Alpha Toolbox will turn red as well. When the spindle comes back online the red will turn to the normal color.

Use the right arrow to select the tab with the disconnected spindle. The color change to red and shows a 'Spindle Communication' Fault to 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.

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Multi-Spindle

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 177.

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. Expert, Specialist, Advanced, and Node Alpha controllers 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. QPM Cordless B-Series tools cannot be synchronized with other tools. 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.

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.

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Multiple Spindle

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.

Networking

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 60. 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, Specialist, or Advanced 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 controller.

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.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.

WARNING

QB Controllers

Multi-Spindle

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.

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QB Controller Manual

Maintenance

Scheduled Maintenance Diagnostics and Troubleshooting Fault Guide Message Guide Parts List

Maintenance

9 Maintenance

There are no user serviceable components within the QB 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.

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Maintenance

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Maintenance

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Maintenance

9.2.1 Fault Guide

Use the following Error Code guides to identify, isolate, and diagnose both mechanical and software issues.

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Maintenance

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Maintenance

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Message Guide

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Parts List

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.

WARNING

Instruction Manual

Appendix A:

10 Appendix A:

Supplementary documentation to better understand the STANLEY QB Alpha Controllers, QPM EB, EA, EC, ESeries corded tools, and QPM B-Series cordless tools.

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

Instruction Manual

Appendix A

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 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 pretorque 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.

10.3 Torque Recovery Implementation

After a torque control cycle, typically with multi-spindle applications or on a soft joint, one or more fasteners may be found to have low residual torque (indicating a loss of clamp load).

This phenomenon can be caused by material flow, component embedment or relaxation within the individual joints, or by cross-talk. Cross-talk occurs when one fastener arrives at the target torque first, and as the surrounding fasteners are tightened, they can distort parts of the assembly such that the first fastener can lose some of its clamp load.

The purpose of this fastening strategy is to re-torque all the fasteners in order to recover any clamp load that may have been lost during (or immediately after) the previous torque control step. This should then result in acceptable residual torque values for all fasteners in an assembly as well as consistent values across many assemblies.

A simple solution is to wait a short time to allow for any relaxation to occur, and then run another torque control step. To not impact the fasteners, the torque should be increased at a controlled rate. This is done by ramping up the current limit to the level necessary to deliver the target torque. This re-torque step ends when the target torque is reached.

The fastener may or may not rotate, depending on if it did, or did not, experience relaxation. Any fastener that did relax will have its lost torque recovered during this torque recovery step.

In order to report the peak dynamic torque from this multi-step fastening cycle, the controller monitors if the fastener actually advances during the torque recovery step.

If the fastener does rotate, then the peak torque from the torque recovery step should be reported as the peak dynamic torque for that cycle.

If the fastener does not rotate during the torque recovery step, then the peak torque from the previous step should be reported as the peak dynamic torque for that cycle.

To report the final tightening angle beyond the snug torque, we need to report the total angle for both the torque control step and the torque recovery step.

10.4 Fastener Yield Control Implementation

The process of tightening a fastener involves stretching, or preloading, the bolt to allow it to store enough force to hold the assembled parts together. Preloading the bolt to a higher load will hold the assembled parts together with more clamp force. Preloading a fastener to the yield point of the bolt material will provide the maximum clamp force possible from each fastener.

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Appendix A:

Preloading a fastener to its yield point can also assure a static loading condition for the fastener when the service loads may exceed the preload available with other fastening methods, thereby reducing the risk of fatigue failures.

A bolt acts like an extension spring. Within its elastic region, any increase in deflection will produce a proportional increase in load. But once the bolt is stretched beyond its elastic limit and into the plastic region, the same incremental amount of deflection will produce a proportionally smaller increase in load. As long as the bolt is preloaded within its elastic limit, no permanent deformation of the bolt will occur. When unloaded, it will return to its original length.

But once the bolt is deflected beyond its elastic limit and into the plastic region, permanent elongation will occur. The yield point of a material is traditionally defined as the point at which 0.2% permanent elongation occurs.

When tightening a fastener, the applied Torque is directly proportional to Load, and the Angle of rotation is directly related to the Deflection through the thread pitch. By monitoring the dynamic Torque and the Angle of rotation during a fastening cycle (beyond the initial free run-down and pull-up phases of a fastening cycle), the rate of change of Torque vs. Angle is directly related to the rate of change of Load vs. Deflection of the bolt material, thereby providing a convenient method for monitoring the onset of the elastic limit of the bolt material.

The QPM Controller software can now detect this fastener yield point and stop the fastening process when this occurs.

Limitations & Recommendations for Yield Control

The type of fasteners used and the make-up of the assembled components can have a significant effect on the success of implementing a fastener Yield Control strategy. If the fastened components can yield throughout the assembly process, this can be interpreted as fastener yield. Since the cross-sectional area of the threaded portion of a bolt is less than the area of the shank portion, all the yield will occur in the threaded area. Bolts with reduced areas in the shank portion will distribute the yield over a greater length. The Yield Control strategy tends to work better on joints with longer bolt grip lengths which allow greater total bolt elongation.

Since the angle of rotation is a key element in this strategy, it is recommended this fastening strategy not be used with hand-held assembly tools. Understand that the nature of some applications will require a back-up wrench to be hand-held on the opposite end of the assembly. Tests showed no adverse effect when handholding the backup wrench.

Since this fastening strategy will tighten any fastener to its yield point, a different grade fastener will yield at a different Load value. Take caution to assure that other grade fasteners are not mixed with the fasteners intended for this application. The QPM Alpha controller Yield & Torque Rate Control consistency of fastener material properties within a given Grade is also critical for good Clamp Load control.

This fastening strategy is not a substitute for good fastener quality control. Slight variations in frictional properties of fastener components will not affect the Clamp Load control. But certain applications will exhibit the occasional 'stick-slip' condition which can affect the ability to sense the onset of fastener yield.

A fastener yield strategy can be difficult to verify in a production environment. During laboratory tests, measure each fastener before and after each assembly to verify that yield has occurred. Disassembling product parts is not practical, but recommend an offline test fixture to allow the production tooling to be run on production fasteners and fastener elongation measured on a statistical sampling basis. Occasionally observing the Torque vs. Angle trace in production is recommended and can provide a quick indication that fastener Yield is indeed occurring.

Any embedment or joint relaxation which occurs after the fastening process can affect the final clamp load. A complete laboratory analysis of the joint is important to understand any characteristics that may affect the final clamp load before implementing this fastening strategy.

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Appendix A

Monitor Torque Window

This strategy is mainly used as prevailing torque monitoring. Monitor torque window monitors torque during an angle window somewhere within the rundown phase with reference to Snug Torque.

Once the fastening cycle achieves snug torque of the step with Monitor torque window enabled, the QB Alpha controller then 'looks back' to see if the torque at any time violated the Monitor torque window defined by Upper and Lower Torque and Angle limits.

The achieved torque must enter the window between the Upper and Lower Torque values at the Upper Angle and must leave the window between the Upper and Lower Torque values at the Lower Angle. If the torque rose above the Upper Torque limit, or fell below the Lower Torque limit at any time in the monitoring window step, the fastening cycle is stopped at Snug Torque, the final torque is not achieved on the fastener and it is marked as a NOK fastening cycle. If the torque did not violate the Upper or Lower Torque limits the fastening cycle then continues

Upper Angle = the distance, in degrees of rotation, previous to Snug Torque that BEGINS the Prevailing Torque Monitor window.

Lower Angle = the distance, in degrees of rotation, previous to Snug Torque that ENDS the Prevailing Torque Monitor window.

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Glossary

Glossary

11 Glossary

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Limited Warranty 12

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

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.

Instruction Manual

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:

• Contact the STANLEY Assembly Technologies customer service department to obtain a 'Return Authorization Number' and 'Warranty Claim Report Form.'
• Package the product including proof of purchase and the completed warranty claim form.
• 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.

QB Controllers

GLOBAL LOCATIONS

World Headquarters

Sales and Support Americas/Asia-Pacific

STANLEY Assembly Technologies

2380 Meijer Drive

Troy, MI 48084, USA

China

STANLEY Engineered Fastening China BUILDING NO. 9, 615 FENGDENG ROAD MALU TOWN, JIADING DISTRICT Shanghai 201801, China

Tel: +86 180.186.93206

France

STANLEY Engineered Fastening France Emhart Fastening and Assembly S.N.C. Batiment Le Monet Paris Nord 2, 9 allee des Impressionnistes CS 59328 Villepinte, 95941 Roissy CDG Cedex, France Tel: +33 (1) 3050 9100 Fax: +33 (1) 3051 0708 Email: Vahid.Amirzadeh@sbdinc.com

Germany

India

India

Italy

Italy

Japan

Japan

Spain

STANLEY Engineered Fastening Spain Avenida de Madrid, 35 28802 Alcalá de Henares (Madrid), Spain Tel: +34 (91) 877-0380 Email: Felix.Barba@sbdinc.com