Assembly Technologies Alpha Controller User Manual v3.0

Assembly Technologies 

Alpha Controller User Manual v3.0 

Important Safeguards 

For your protection, please read these instructions completely, and keep this manual for future reference. 

Carefully observe and comply with all warnings, cautions and instructions placed on the equipment or 

described in this manual. 

© THE STANLEY WORKS, ALL RIGHTS RESERVED 

www.StanleyAssembly.com 

QA Alpha V 3.0 0308

User Manual 

Contents 

Getting Started ...........................................................................................1 

1.1 Warnings and Cautions ........................................................1 

1.2 User Manual Conventions ....................................................2 

1.3 Specifications, Layout and Display .......................................2 

1.4 Installation Instructions .........................................................4 

1.4.1 Alpha Controller E-Stop Precaution ...................................6 

Programming..............................................................................................7 

2.1 QA Alpha Controller Navigation and Programming...............7 

2.2 Display..................................................................................7 

2.2.1 Scroll Bar ...........................................................................7 

2.2.2 Dropdown...........................................................................8 

2.2.3 Menu Tree..........................................................................8 

2.2.4 Tabs ...................................................................................8 

2.2.5 Character Scrollbar ............................................................8 

2.2.6 Run Display........................................................................8 

2.3 Faults....................................................................................9 

2.4 Log........................................................................................9 

2.5 Alpha Controller Programming............................................10 

2.5.1 Setup Menu: 1. Jobs ........................................................10 

2.5.1.1 Wizard Screens .......................................................11 

2.5.1.2 Setup: Job Tab ........................................................15 

2.5.1.3 Setup: Task Button ..................................................16 

2.5.1.4 Setup: Step Button (Step 1 – Step 12).....................19 

2.5.1.4.1 Strategy TC/AM.................................................19 

2.5.1.4.2 Strategy AC/TM.................................................23 

2.5.1.4.3 Strategy AC/TC .................................................27 

2.5.1.4.4 Strategy BACK (Backoff)...................................31 

2.5.1.4.5 Strategy RATE ..................................................35 

2.5.1.4.6 Strategy YIELD..................................................39 

2.5.1.4.7 Strategy AC/TA .................................................43 

2.5.1.5 Setup: Manage ........................................................47 

2.5.1.6 Setup: Exit ...............................................................47 

2.5.2 Setup Menu: 2. Communications .....................................48 

2.5.3 Setup Menu: 3. Other.......................................................51 

2.5.4 Setup Menu: 4. Full Backup/Restore................................65 

2.5.5 Service .............................................................................66 

2.5.5.1 Tool..........................................................................66 

2.5.5.2 Controller .................................................................68 

2.5.6 Analyze ............................................................................68 

QPM DC Electric Tools ............................................................................71 

3.1 Tool Specifications..............................................................71 

3.2 Operator Protection ............................................................71 

Repetitive Motion .......................................................................71 

3.2.1 Hearing Protection ...........................................................72 

3.2.2 Vibration...........................................................................72 

ii 

Getting Started

Alpha Controller 

3.2.3 Breathing Protection.........................................................72 

3.3 Tool Installation...................................................................72 

3.3.1 Sockets and Adapters ......................................................73 

3.3.2 Suspension Devices.........................................................73 

3.3.3 Cable Installation .............................................................73 

3.4 QPM Tools..........................................................................74 

3.4.1 Display and Multiple Function Button for Hand Held Tools 

74 

3.4.2 MFP Mode .......................................................................74 

3.4.3 Tool Memory ....................................................................75 

3.4.4 Tightening Cycle Counters...............................................75 

3.5 Tool Operation ....................................................................75 

3.5.1 Directional Control............................................................76 

3.5.2 Torque Reaction Devices.................................................76 

3.5.3 Tool Temperature.............................................................76 

3.5.4 Tool Status Lights ............................................................76 

3.5.5 Setting Torque, Angle, and Other Operating Parameters 77 

3.6 Special Application Tools....................................................77 

3.6.1 Exposed Gear Socket Tools ............................................77 

3.6.2 Tubenut Nutrunners .........................................................77 

Controller Connections and Inputs/Outputs .............................................79 

4.1 Alpha Controller Connections .............................................79 

4.1.1 Alpha Controller Power Cord ...........................................79 

4.1.2 Alpha Controller Tool Connector......................................79 

4.1.3 Alpha Controller Serial Connector....................................80 

4.1.4 Alpha Controller Ethernet Connector ...............................80 

4.1.5 Alpha Controller (Model QA1001 _D_) DeviceNet........80 

4.1.6 Alpha Controller (Model QA1001 _P_) Profibus Port .......81 

4.1.7 Alpha Controller (Model QA1001 __V) Input and Output 

Connector ..................................................................................81 

4.2 Assignable Input/Output Functions .....................................82 

Glossary...................................................................................................85 

Software Map ...........................................................................................89 

6.1 Setup ..................................................................................89 

6.1.1 Wizard..............................................................................89 

6.1.2 Job ...................................................................................89 

6.1.2.1 Task.........................................................................89 

6.1.2.2 Step .........................................................................90 

6.1.3 Communications ..............................................................94 

6.1.4 Other ................................................................................94 

6.1.5 Full Backup/Restore.........................................................96 

6.2 Service................................................................................96 

6.2.1 Tool ..................................................................................96 

6.2.2 Controller .........................................................................97 

6.3 Analyze...............................................................................97 

Warranty...................................................................................................99 

Appendix A – Embedded Toolbox..........................................................103 

Contents 

iii


Getting Started 

This manual is intended to promote proper and safe use and give guidance to owners, employers, 

supervisors, and others responsible for training and safe use by operators and maintainers. Please 

contact your Stanley Sales Engineer for further information or assistance on Stanley training or 

assembly tool operations. 

1.1 Warnings and Cautions 

Definitions 

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: 

Warning - Indicates that death or severe personal injury may result if proper 

precautions are not taken. 

Caution - Indicates that property damage may result if proper precautions are not 

taken. 

- Indicates an electrical hazard. This icon appears as a part of a Danger, 

Warning, or Caution notice. 

- Indicates a general hazard. This icon appears as a part of a Danger, 

Warning, or Caution notice. 

- Indicates that eye protection should be worn. This icon appears as a part of 

a Danger, Warning, or Caution notice. 

- Read and understand all the safety recommendations and all operating 

instructions before operating tools and controllers. 

- Indicates an item of special interest. 

WARNING 

To Avoid Injury: 

• Read and understand all the safety recommendations and all operating instructions before 

operating tools and controllers. Save these instructions for future reference. 

• 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 tools 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. 

Getting Started 1


Qualified Personnel 

WARNING 


• Only allow suitably qualified personnel to install, program, or maintain this equipment and or 

system. 

• These persons must be knowledgeable of any potential sources of danger and maintenance 

measures as set out in the Installation, Operations, and Maintenance manual. 

• This product must be transported, stored, and installed as intended, and maintained and 

operated with care to ensure that the product functions correctly and safely. 

• Persons responsible for system planning and design must be familiar with the safety concepts 

of automation equipment. 

1.2 User Manual Conventions 

Underlined text indicates glossary terms. Menu options appear in Arial 10 bold italic. 

1.3 Specifications, Layout and Display 

Dimensions Width: 6.0 in 152 mm 

Height: 14.2 in 361 mm 

Depth: 10.3 in 262 mm 

Weight: 17 lb 7.7kg 

Operating Conditions: Temperature: 32 to 122 ºF (0 to +50 ºC) 

Humidity: 0 to 95 % non-condensing 

Power Source: 

100 – 120 VAC, 50/60 Hz, 15 service or 

220 – 240 VAC, 50/60 Hz, 15 service 

Power Consumption: Stand by: 0.2 A (amperes) 

Continuous: 

1-2.5 kVA 

Tool Motor Power: Service Rating: E02/E_23 E_33/E_34 E44/E45 E55 

Consumption @ 115 VAC: 15A 15A 20A - 

@ 230 VAC: 10A 10A 10A 16A 

Continuous kVA: 0.3 0.7 1 1.7 

2 Getting Started


Item 

Functional Description 

1 Red, Green, Yellow LEDs for Limits Evaluation 

2 Display 

3 Function Keys with Active Label Above 

4 Cursor Keys with Center Button to Expand Lists 

5 Maintenance Due and ATC Active LEDs 

6 Numeric Keypad to Enter Numbers or Select Options 

7 Controller Label and Serial Number 

8 Power Switch 

9 Power Input 

10 USB Port for Data Transfer 

11 Optional 24 VDC Input/Output Connector 

12 Tool Connector 

13 Serial Connectors 

14 Optional Device-Net Connector 

15 Optional Profibus Connector 

16 Ethernet Connector 

Getting Started 3


1.4 Installation Instructions 

WARNING 


• 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. 


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. 

• Install modules in dry, indoor, non-flammable, and non-explosive environments only. 

• Qualified personnel should perform installation and programming. Follow all manufacturer 

installation instructions, applicable regulatory electrical codes, and safety codes. 

• Limit module access to trained and qualified personnel. Lock module cabinets. 

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. 

WARNING 

ELECTRICAL HAZARD 


• Do not use this product near water, for example near a washbowl, wet basement, or the like. 

• 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. 

4 Getting Started


1.4.1 Plinth 

Plinths are used as wall mount brackets for Alpha Controllers. This allows for easy installation, 

quick change out and provides for neat cable management. 

Plinths and Alphas can be mounted individually for single tool operation or grouped for multiple 

applications. 

Plinths connect to each other with four 10-32 machine screws through openings on the top and 

right side to threaded openings on the bottom and left side. When plinths are mounted next to each 

other, the center to center distance between the mounting holes in different plinths is 2" (50.8 

mm). When plinths are mounted one above another, the center to center distance between the 

mounting holes in different plinths is 6" (152.4 mm). 

1. Install the Alpha Controller either directly to the wall or to a plinth. 

2. 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. 

Getting Started 5

1.4.2 Controller 


1. Make sure the bolts of the barrel-latches [5] on the plinth are retracted. Place the lower flange 

of the Alpha controller [1] into the lip [2] on the plinth. 

2. 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. 

3. 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. 

4. Connect the Alpha Controller to a power source. 

5. Connect the tool cable to the Alpha controller and press the power switch on the controller. 

1.4.3 Alpha Controller E-Stop Precaution 

WARNING 

INTEGRATED E-STOP CIRCUIT NOT PRESENT 


When an 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 power supply line. 

6 Getting Started


Programming 

2.1 QA Alpha Controller Navigation and Programming 

The Alpha controller’s three navigation 

and input areas facilitate menu navigation, 

selection and data input: 

• Menu buttons 

• Arrows and Toggle button 

• Keypad 

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 display. 

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 menu button). 

The numeric keypad [4] facilitates data 

input, menu selection (where applicable) 

and job/task selection when enabled. 

2.2 Display 

2.2.1 Scroll Bar 

A scroll bar appears when more items are available than space within the 

display to allow them to be visible. The up arrow [1] and down arrow [3] 

direct scrolling. The black/white scroll bar [2] indicates which list items are 

currently displayed. No scroll bar means all items are currently displayed. 

To navigate between menu items, use the up/down arrows or, if available, use 

the keypad to identify the corresponding menu item number. 

Programming 7


2.2.2 Dropdown 

A dropdown [1] arrow appears to the right of menu items with multiple 

choices. To view these choices, first select the menu item using the 

up/down arrows or, if available, use the keypad to identify the 

corresponding menu item number. Then, use the toggle button to expand 

the dropdown. The up/down arrows scroll through the choices and the 

toggle button selects/accepts the highlighted choice. 

2.2.3 Menu Tree 

A menu tree [1] appears beside related menu items. 

2.2.4 Tabs 

Tabs [1] appear at the top when multiple menu selections exist. 

To navigate between tabs, use the left/right arrows. The active 

tab is white; inactive tabs are grey. 

2.2.5 Character Scrollbar 

This scrollbar enables adding: a-z, A-Z, 0-9, space, _, -, &, *, $, #, @, !, and a 

period (language and/or field determines character availability). The up arrow [1] 

and down arrow [3] direct scrolling with the active character [2] displayed 

between. Use the 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 next character. Push toggle button or OK menu button to accept entry. 

2.2.6 Run Display 

The following screens contain the character scrollbar option: Job (Name), Job 

(Barcode ID), Task (Name), Step (Name), System (General), System (Users), 

System (Date/Time), System (Network), System (Maintain). 

Displays last torque reading and 

units [2] when a tool is connected. 

Icons [1] identify controller events 

(see list below). Specifies current 

job [3]. The run screen displays 

unless other programming 

functions [4] are in use. 

Run Display Codes indicate why a tightening cycle shutoffs prior to completion. 

Run Display 

Description 

Code 

TIME Tightening time exceeds programmed cycle abort time value 

STOP Spindle stopped by either the operator or other device 

125% Spindle stopped due to torque achieving greater than 125% torque limit for the spindle 

FAULT Precedes a fault described in 2.3 

STALL Spindle in stall status 

8 Programming


Alpha Controller Icons 

Icon Status Description 

Locked 

Password required to make changes 

Unlocked 

Changes possible, automatically re-locks in time 

Busy/working 

Wait 

Message waiting 

Check the run screen 

Warning system not operable Check the run screen 

Force on or off 

Identifies an input/output forced on or off 

Stop 

No strategy selected 

2.3 Faults 

The display background color in normal 

operation is white. In the event of a fault, the 

display background becomes red and the fault 

description appears on screen. 

System Faults: 

Overcurrent Fault! 

Logic Voltage Fault! 

Position Feedback Fault! 

Transducer Span Fault! 

Temperature Fault! 

Unrecognized Tool! 

Tool Communications! 

Transducer Current Fault! 

Transducer Zero Fault! 

NO STRATEGY SELECTED! 

Can’t run the wizard! Unknown Tool! 

2.4 Log 

From the main menu (run display), press the 

down arrow to view the log of controller 

events. 

The log lists events by occurrence date and time using the internal clock as set by the user. Events 

included in the log are rundowns and faults. 

The data stored for each rundown includes: 

???? 

The data stored for each fault includes: 

???? 

To access the data, use the up/down cursor keys to scroll. Highlight an event and press the toggle 

key to view the event’s data screen. Use the up/down cursor keys to scroll through the data if there 

is more than will fit on the screen. 

The data cannot be exported from the log screen. This action is performed via the STATS screen 

under Analyze. See 2.5.6. 

Programming 9

2.5 Alpha Controller Programming 


WARNING 

EXCESSIVE TORQUE CONDITION 


• Only trained and qualified personnel should program controllers. 

• Never set control limits above the maximum rating of the tool. 

• Setting control limits above the maximum rating of the tool can cause high reaction torque. 

• Always test for proper tool operation after programming the controller. 

The controller uses three main menus to display information and enable programming: 

• Setup menu 

• Service menu 

• Analyze menu 

Icon Legend Icon Description Navigation 

Menu Buttons 

Press to activate menu option noted above button. 

Left/Right Arrow Keys Navigate tabs as well as backspace and space. 

Up/Down Arrow Keys 

Scroll through menu selection and character selection. 

Toggle Button 

Numeric Keypad 

Selects option for data input, accepts changes. 

Data input and, when applicable, menu selection. Can 

be used for job/task selection when enabled to do so. 

The left column shows the currently defined Alpha Controller settings and menu choices. The 

Options Screen column shows options for each selection. Screen navigation options appear above 

each screen. 

Default Screens 

Options Screen 

2.5.1 Setup Menu: 1. Jobs 

The Setup menu programs the controller to operate a spindle or tool. Settings are saved per Job 

with optional Task and Step assignments. Most controllers will operate with a single Job, Task and 

Step. Tasks control tool operation for tightening a fastener which can have one or more steps. 

Steps are defined by available strategies such as TC/AM (Torque Control, Angle Monitoring). The 

Wizard can be used to setup a Task for simple rundowns. Creating a name for Jobs, Tasks and 

Steps is optional but helpful when multiples Jobs and Tasks exist. 

10 Programming


2.5.1.1 Wizard Screens 

Wizard Screens 


The Wizard assists with programming the controller to assign a Task which operates a single 

spindle. To function, the Wizard requires a tool to be connected. This example shows Torque 

& Angle Strategy. Selecting another Strategy affects subsequent screen options. The wizard 

automatically appears when there are no configured jobs. To access the wizard when jobs exist, 

choose Setup, 1. Jobs, Manage, 1. Add, then choose before or after selected tab. 

Programming 11




12 Programming




Programming 13




14 Programming


2.5.1.2 Setup: Job Tab 

Job Tab Screens 

Tool settings apply to all Tasks. 

Options Screens 

or 

Programming 15


Job Tab Screens 


2.5.1.3 Setup: Task Button 

Task Tab Screens 

A maximum of 99 tasks can be created. 


or 

16 Programming




Programming 17




18 Programming


2.5.1.4 Setup: Step Button (Step 1 – Step 12) 

Step Screens (Step 1 – Step 12) 


Step settings affect only the active Task. Each strategy selection has different configuration 

options. 

2.5.1.4.1 Strategy TC/AM 

Strategy TC/AM Screens 

Step settings affect only the active Task. 


Programming 19




20 Programming




Programming 21




22 Programming




2.5.1.4.2 Strategy AC/TM 

Strategy AC/TM Screens 



Programming 23




24 Programming




Programming 25




26 Programming




2.5.1.4.3 Strategy AC/TC 

Strategy AC/TC Screens 



Programming 27




28 Programming




Programming 29




30 Programming




2.5.1.4.4 Strategy BACK (Backoff) 

Strategy BACK (Backoff) Screens 



Programming 31




32 Programming




Programming 33




34 Programming




2.5.1.4.5 Strategy RATE 

Strategy RATE Screens 


Step settings affect only the active Task. Torque rate strategy (Torque Average and Angle 

Interval) configuration is set in the Task tab. 

Programming 35




36 Programming




Programming 37




38 Programming




2.5.1.4.6 Strategy YIELD 

Strategy YIELD Screens 




Programming 39




40 Programming




Programming 41




42 Programming




2.5.1.4.7 Strategy AC/TA 

Strategy AC/TA Screens 




Programming 43




44 Programming




Programming 45




46 Programming




2.5.1.5 Setup: Manage 

Manage Screens 


Manage enables active tab settings to be added, deleted, and/or copied to the clipboard and 

pasted into another tab. The “Nothing to Paste” error indicates an attempt to paste information 

to the wrong tab type. 

2.5.1.6 Setup: Exit 

Exit Screens 

Programming changes are stored after exiting current menu. 


Programming 47

2.5.2 Setup Menu: 2. Communications 

Communication Screens 




48 Programming




Programming 49




50 Programming




2.5.3 Setup Menu: 3. Other 

Other Screens 



Programming 51


Other Screens 


52 Programming


Other Screens 


Programming 53


Other Screens 


54 Programming


Other Screens 


Programming 55


Other Screens 


56 Programming


Other Screens 


Programming 57


Other Screens 


58 Programming


Other Screens 


Programming 59


Other Screens 


60 Programming


Other Screens 


Programming 61


Other Screens 


62 Programming


Other Screens 


Programming 63


Other Screens 


64 Programming


Other Screens 


2.5.4 Setup Menu: 4. Full Backup/Restore 

Full Backup/Restore Screens 


Programming 65


Full Backup/Restore Screens 


To select a file, use the up and down arrow 

keys to scroll through list. To change 

directories, highlight “Up One Level” and 

then press the center button. 

The default button loads current software 

factory defaults. 

2.5.5 Service 

2.5.5.1 Tool 

Tool Tab Screens 

The odometer increments after every in cycle. 


66 Programming


Tool Tab Screens 


Programming 67

2.5.5.2 Controller 

Controller Tab Screens 



The odometer increments after every in cycle. 

2.5.6 Analyze 

Diag Screens 


Diag displays tool and controller diagnostic information, statistics, traces and I/O status. 

68 Programming


Diag Screens 


When forcing I/O changes during an 

operation, the system provides a warning first. 

Clear = off, Dark = on 

Diag Screens – STATS Button 


Programming 69


Diag Screens – STATS Button 


70 Programming


QPM DC Electric Tools 

This chapter 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. 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. 

3.1 Tool Specifications 

Operating Conditions Temperature 32 to 122 ºF (0 to +50 ºC) 

Humidity 

0 to 95 % non-condensing 

Noise Level: A-weighted emission sound pressure level at the work station < 70dBA (ref 20μPa) 

as determined according to ISO 15744-2002. 

Vibration Level: Weighted root mean square acceleration value at the handle < 2.5 m/s 2 as 

determined according to ISO 8662. 

3.2 Operator Protection 

WARNING 

ROTATING EQUIPMENT 


• 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 

QPM DC Electric Tools 71


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. 

3.2.1 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 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. 

3.2.2 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. 

3.2.3 Breathing Protection 

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

3.3 Tool Installation 

WARNING 


• 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. 


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. 

72 QPM DC Electric Tools


• 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 controllers off when 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. 

3.3.1 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. 

3.3.2 Suspension Devices 

Tool suspension devices or bails help support the weight of the tool during tightening operations. 

Attach these devices securely and periodically inspect them for damage or loosening. 

3.3.3 Cable Installation 

WARNING 

ELECTRICAL HAZARD 


• 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. 


3.4 QPM Tools 

3.4.1 Display and Multiple Function Button for Hand Held Tools 


Handheld QPM tools have a display and a multiple function button. Two sets of lights [3 and 7] 

indicate tool status. Two blue lights indicate tool rotation direction, disassembly [1] or assembly 

[2]. A single multiple function button [5] can change tool direction and or tasks. When the button 

is used to select the task, one of two orange indicators [4 or 6] illuminates to show the active task. 

EA tools have four sets of lights [3 and 7] and an LED [8] that indicates when the tightening cycle 

count exceeds the PM limit. 

Display and MFP Button 

for E02P to E34P (pistol) Models 

Display and MFP Button 

for E23L to E55L (lever) Models 

3.4.2 MFP Mode 

Display for EA23L to EA34L (lever) Models 

The MFP Mode configures the multiple function button for handheld QPM tools. The button can 

be configured to operate in any of the following modes. 

Disable 

The button does nothing. Pressing the button causes the tool 

(default) 

alarm to "beep" once. Only the assembly blue light [2] 

illuminates. 

Reverse (Disassembly) Pressing the button toggles between assembly and disassembly 

and illuminates the appropriate blue light [1] or [2]. All tool 

status lights [3] and [7] flash when the tool is in disassembly 

mode. 

Task Select 

Pressing the button toggles between tasks and illuminates the 

appropriate orange light [6] or [4]. 

Arm 

Pressing the button arms (activates) the start function but does 

not start the tool. The blue assembly light [2] comes on to show 

that the tool is armed. 

Reset Reject 

Pressing the button stops the reject tone. 



3.4.3 Tool Memory 

QPM tools have an onboard tool memory that stores tool identification, calibration factors and 

tightening cycle counters. Memory parameters include: 

• Model Number 

• Serial Number 

• Torque Cal (calibration) factor 

• Angle Cal (calibration) factor 

• Tightening cycle counters 

3.4.4 Tightening Cycle Counters 

QPM tools have onboard counters that record the number of tightening cycles completed by the 

tool. 

• Master Counter. Records the total number of tightening cycle completed. 

• Cycle Counter. Records the number of tightening cycles completed since the last time it was 

reset. 

• PM Counter. Records the number of tightening cycles completed since the last time it was 

reset. 

• PM Threshold. When the PM Counter exceeds the PM Threshold (Limit), the controller 

provides a maintenance alert. 

Each time the controller is turned on, it reads the tightening cycle counters. 

3.5 Tool Operation 

WARNING 

ROTATING SPINDLE 


• Always wear eye and foot protection when operating and when in areas where power tools are 

being used. 

• Keep all body parts and clothing away from the rotating end of the tool. Dress properly. Do not 

wear loose-fitted clothing or jewelry. 

TORQUE REACTION FORCE 


• Be alert and maintain good balance, footing, and posture at all times in anticipation of the tool’s 

torque reaction. Do not over-extend or over-reach. 

• Be prepared for the change in direction and or a higher reaction force when a tool is in reverse. 

• The start lever should be positioned to avoid trapping the operator’s hand between the tool and 

the work piece. 

TOOL MAY NOT SHUT OFF 


• If the tool does not shut off at the end of the tightening cycle, contact the person responsible 

for tool installation or repair. Note: When the tool does not shut off, a stall condition occurs. A 

stall condition can cause a higher than expected torque reaction impulse. 

• Ensure tool is properly installed, adjusted and in good working order. 

• Do not use the power tool if the switch does not turn it on and off. 

• Apply the tool to the joint following all recommendations in this manual. 

• Check to ensure the drive socket is fully seated and locked into position before connecting 

power to the tool. 

Prepare to resist the tool’s torque reaction: 

Start the tool by depressing the start lever or trigger. 

Release start lever after the cycle is complete. 



3.5.1 Directional Control 

WARNING 

UNEXPECTED REACTION FORCES 


• 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. 

3.5.2 Torque Reaction Devices 

WARNING 

PINCH POINT BETWEEN TORQUE REACTION BAR AND WORK PIECE 


• Never place any body part between a reaction bar and the work piece. 

• Before starting the tool, position the reaction bar firmly against a stationary rigid member that is 

opposite to the spindle rotation. 

Torque reaction devices absorb tool torque reaction forces. Always use reaction devices when high 

reaction force could injure an operator. 

Some reaction devices may require modification to fit the application. Follow all appropriate 

installation instructions. 

3.5.3 Tool Temperature 

WARNING 

POTENTIAL BURN HAZARD 

Fixtured tools have higher operating temperatures and do not have additional thermal protection. 


Wear thermal protective gloves when handling fixtured tools. 

Stanley electric tools are thermally protected to prevent overheating. The thermal protection does 

not allow the tool to operate if the tool temperature rises abnormally – the thermal protector 

automatically resets when the tool cools down. 

Controller task settings can have a significant effect on tool operating temperatures. 

3.5.4 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 or control panel. 

Green Tightened to The tightening cycle meets all of the specified parameters. 

specified limits 

Yellow Low torque or angle The tightening cycle was rejected for not reaching either low 

torque or low angle. 

Red High torque or angle The tightening cycle was rejected for exceeding either high 

torque or high angle. 

All lights Reverse The next time the start trigger is engaged the tool will 

release the fastener. 



3.5.5 Setting Torque, Angle, and Other Operating Parameters 

WARNING 

EXCESSIVE TORQUE CONDITION 


• 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 Alpha controller can be setup to change tightening parameters from the tool. 

3.6 Special Application Tools 

3.6.1 Exposed Gear Socket Tools 

WARNING 

PINCH POINT AT THE EXPOSED GEARS OR TEETH 


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. 

3.6.2 Tubenut Nutrunners 

WARNING 

PINCH POINT AT THE EXPOSED GEARS OR TEETH 


• 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. 

Tubenut Sequence of Operation (QPM Tools) 

• Place nutrunner socket on fastener 

• Press the button on the multiple function panel to “arm” the start function (not required in 

modes 0 and 2) 

• Depress start lever 

• The tool stops after reaching torque 

• Release the lever and lift the tool from the fastener, all tool status lights flash to indicate the 

tool will now run in reverse to open the socket 

• Depress the start lever until the socket returns to the open position 

• Release the lever 

• Remove the tool 



Controller Connections and Inputs/Outputs 

Each Alpha Controller can have a different combination of connectors. These connectors serve 

several purposes, such as: 

• Power 

• Tool Connections 

• Discrete inputs and outputs 

CAUTION 

POTENTIAL ELECTROSTATIC DISCHARGE HAZARD AND WATER AND DIRT INGESTION 

To Avoid Damage: 

If not using a connector, keep the connector securely covered with the provided cap. This reduces 

the opportunity for transfer of static electricity and prevents dirt and water from entering the 

controller. 

4.1 Alpha Controller Connections 

4.1.1 Alpha Controller 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 

115 V or 10A/250V for 230 V use of the controller. 

4.1.2 Alpha Controller Tool Connector 

Alpha controllers use a single 30 pin connector to connect two types of QPM DC electric tool 

cables (patent pending). 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 (30-pin Tool 

Connector). QPM EA DC electric tools use a similar connecter except for B clocking. 

30-pin Tool Connector 

Controller Connections and Inputs/Outputs 79


4.1.3 Alpha Controller Serial Connector 

Alpha Controllers have two male DB-9 connectors. One labeled COM PORT 1 connects a laptop 

computer for access to Embedded Toolbox software. The connection between the computer and 

the controller is a simple null-modem cable. 

DB-9 Connector Pins 

Pin Function Pin Function Pin Function 

1 Carrier Detect 4 Data Terminal Ready 7 Request to Send 

2 Receive Data 5 Signal Ground 8 Clear to Send 

3 Transmit Data 6 Data Set Ready 9 Ring Indicator 

A second DB-9 connector COM PORT 2 is setup as 9600,8,N,1 and is not programmable. When 

the box is setup for PFCS protocol over serial the barcode and printout feature is disabled. 

S01, PS01 01/01/1988 00:03:38 0.9A 0A A• 

|| | | | | | | | | || 

|| | | | | | | | | |Carriage Return ‘\r’ 

|| | | | | | | | | Overall Status ‘A’,’R’ 

|| | | | | | | | Angle Status ‘L’,’A’,’H’ 

|| | | | | | | six characters for Angle 

|| | | | | | Torque Status ‘L’,’A’,’H’,’R’ 

|| | | | | six characters for Torque 

|| | | | eight characters for Time 

|| | | ten characters for Date 

|| | thirty two characters for VIN 

|| two digits for Task 

|two digits for Spindle Number 

| 

Always an ‘S’ 

L = low for Torque or Angle 

A = accept for Torque, Angle, or Overall status 

H = high for Torque or Angle 

R = replace for Torque and reject for Overall status 

The barcode input monitors inter character timing. When there is a 500ms gap between characters, 

a complete barcode is assumed. When received, it flashes the new barcode on the display and logs 

it with all rundowns until another barcode is received. If the incoming barcode is longer than 32 

characters then the last 32 characters received is used. 

4.1.4 Alpha Controller Ethernet Connector 

Alpha Controllers have a single RJ-5 Ethernet connection located on the bottom of the module for 

connecting to a plant-wide fastening network. 

4.1.5 Alpha Controller (Model QA1001 _D_) DeviceNet 

Alpha Controllers can have a single Micro DeviceNet port for connecting the Alpha Controller 

to a Sigma Interface or to a master controller from another manufacturer. In addition, error 

proofing is available through this port. 

Pin 

Slave 

1 Shield 

2 V+ 

3 V- 

4 CAN H 

5 CAN L 

Alpha Controllers Micro DeviceNet 

Connector 

80 Controller Connections and Inputs/Outputs


4.1.6 Alpha Controller (Model QA1001 _P_) Profibus Port 

Alpha Controllers can have a single Profibus port for connecting the Alpha Controller to a master 

controller from another manufacturer. 

Figure 4-1 DB-9 Connecter Pins (Profibus Port) 

Pin Function Pin Function Pin Function 

1 Empty 4 Repeater 7 Blank 

2 Empty 5 Data Ref 8 Data Line Inverse 

3 Data Line 6 Power Supply 9 Empty 

4.1.7 Alpha Controller (Model QA1001 __V) Input and Output Connector 

All inputs and outputs are optically isolated 24 VDC 

• Internal 24 VDC supply: Maximum = 1 ampere total 

• External 24 VDC supply: Maximum = 1 ampere per output 

The Alpha controller has a MIL-C-26482 Series II bayonet connector for 24VDC I/O. The 

connector uses a 12-8S insert in the normal position. Connector options are listed below. 

Part No. 19-pin 24V I/O Port Included 

21C104800 Mating Connector - Solder pins Standard 

21C104802 Mating Connector - Crimp pins Optional 

21C104804 Mating Connector - Crimp pins, crimp tool Optional 

21E102202 Breakout Box for plinth mounting Optional 

21C202005 Extension Cable 5M Optional 



When all of the inputs are off (binary 0) the controller looks to the tool for the parameter selection. 

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

controller to provide basic switching control for the tool. 



4.2 Assignable Input/Output Functions 

The following Input/Output functions apply to DeviceNET, Profibus, Modbus/TCP, and 24V. There are 8 

maximum inputs and outputs for 24 VDC. See Appendix A for assignment of inputs and outputs using 

Embedded Tool Box. 

Inputs Description Controller I/O Configuration Options 

IGNORE Input is ignored **Bit width 

START Start the tool N.O./N.C., Latch Y/N, Timer 

SELECT JOB Select a job 

N.O./N.C., Job #, Disable when open 

Y/N 

SELECT TASK Select a task 

N.O./N.C. , Task #, Disable when open 

Y/N 

STOP Stop the tool N.O./N.C. 

RESET JOB Reset a job N.O./N.C. 

TASK SELECT 

BIT 

JOB SELECT BIT 

One bit in a series to select the 

task 

One bit in a series to select the 

job 

N.O./N.C., Bit # 


REVERSE Put the tool in reverse N.O./N.C. 

DISABLE TASK Disable the task N.O./N.C., Task # 

DISABLE JOB Disable the job N.O./N.C., Job # 

TASK VERIFY 

Verify the selected task to the 

inputs 

N.O./N.C., Task # 

JOB VERIFY 

Verify the selected task to the 

inputs 

N.O./N.C., Job # 

TASK VERIFY 

BIT 

JOB VERIFY BIT 

RESET RESULT 

STATUS 

REVERSE START 

Verify the selected task to one 

of the input bits 

Verify the selected job to one 

of the input bits 

Clear the result status 

Put the tool in reverse and start 

the tool 



N.O./N.C. 

N.O./N.C. 

*PART ID Set the part identification Length, Trigger auto/manual 

DISABLE TOOL Disable the tool. N.O./N.C. 

*PART ID 

TRIGGER 

Trigger for part ID/Resets Part 

ID changed output. 

N.O./N.C. 

* Input not available on 24V ** Does not apply to 24V 

82 Controller Connections and Inputs/Outputs


Outputs Description Controller I/O Configuration Options 

OFF Output is turned off **Bit width 

IN CYCLE The tool is in cycle N.O./N.C., Type normal/timed/flash, Time 

JOB SELECTED Indicate job select 

N.O./N.C., Type normal/timed/flash, Time, 

Job # 

DISASSEMBLY 

DETECTED 

Fastener removed 

N.O./N.C., Type normal/timed/flash, Time 

TOOL RUNNING The tool is running N.O./N.C., Type normal/timed/flash, Time 

CYCLE OK Self explanatory N.O./N.C., Type normal/timed/flash, Time 

CYCLE NOK Self explanatory N.O./N.C., Type normal/timed/flash, Time 

TASK SELECTED Indicate task selected 


Task # 

JOB COMPLETE Job complete N.O./N.C., Type normal/timed/flash, Time 

TASK COMPLETE Task complete 


Task # 

TASK SELECTED 

BIT 

Indicate a bit of the selected task N.O./N.C., Bit #, Binary/Binary +1 

JOB SELECTED 

BIT 

Indicate a bit of the selected job N.O./N.C., Bit #, Binary/Binary +1 

TORQUE OK Self explanatory 


Step Audit/Audit -1, Audit -2 

TORQUE HIGH Self explanatory 



TORQUE LOW Self explanatory 



ANGLE OK Self explanatory 



ANGLE HIGH Self explanatory 


ANGLE LOW 

CYCLE 

ABORTED 

Self explanatory 

The rundown was aborted 





STOPPED 

The rundown was stopped by the 

operator 


FAULTED A fault condition is active N.O./N.C., Type normal/timed/flash, Time 

READY The tool is ready to run N.O./N.C., Type normal/timed/flash, Time 

PM The tool requires service N.O./N.C., Type normal/timed/flash, Time 

TORQUE * Torque results 

Format float/int16/int32/fixed, precision, 


ANGLE * 

Angle results 



FAULT CODE * Fault code Format float/int16/int32/fixed, precision 

PARAMETER * Parameter 



START TRIGGER Shows state of start lever or trigger. N.O./N.C., Type normal/timed/flash, Time 

MULTIFUNCTION Shows state of multifunction 

BUTTON 

button. 


SNUG ACHIEVED Snug torque is achieved. N.O./N.C., Type normal/timed/flash, Time 

CYCLE STOPS 

Stop shut off code before cycle 

complete. 


*PART ID 

CHANGED 

When the part ID changes N.O./N.C., Type normal/timed/flash, Time 

STEP BIT Indicates last step of rundown N.O./N.C., Bit #, Binary/Binary +1 

* Outputs not available on 24V ** Does not apply to 24V 



Glossary 

Abort Timer 

Acceleration 

Accept Tone 

AC/TA 

AC/TC 

AC/TM 

Angle Interval 

ATC 

Auto Sequence Tasks 

BACK 

Batch Count 

Downshift Mode 

Downshift Speed 

Downshift Torque 

High Angle 

High Torque 

Jobs 

Low Angle 

Low Torque 

MFP Mode 

The tightening cycle aborts if the tool does not shutoff before this pre-selected 

time. 

How fast the controller changes the speed of the tool from 0 (stopped) to the rated 

speed. 

Controls the tone made from the handle of handheld QPM tools for accepted 

tightening cycles. Allows distinct tones for tools in adjacent workstations. 

Angle Control Torque Averaging. 

Angle Control Torque Control. This strategy controls a tool based on angle and 

Torque. 

Angle Control with Torque Monitor. This strategy controls a tool based on angle 

and monitors the torque limits defined by user. 

(Rate, Yield and AC/TA) Angle interval is used to calculate Torque vs. Angle 

Rate. A larger interval tends to give a smoother rate. 

Allows Adaptive Tightening Control modes to be selected, so that consistent 

torque can be maintained over a wide range of joints. Manual downshift should be 

used when: 

• High Prevailing Torques – Prevailing Torque > 20% of the Torque Set Point 

(TSP). 

• High Starting Torque –Starting Torque > 20% of TSP. 

Enables the tool setup for the next task after the batch count is achieved for the 

prior task in a Job. 

Back-Off. This strategy functions after Angle Control with Torque Monitor 

(AC/TM). It loosens the fastener (turns it the opposite direction from tightening). 

The number of tightening cycles required to be within specified limits to complete 

a batch. The Run display shows the batch count and number of complete tightening 

cycles. Defines the number of rundowns required to be completed for each task. 

Disable: no downshift; Manual: Occurs at specified torque; ATC automatically 

adapts to the joint. 

Once the tool reaches the Downshift Torque point, the controller changes the 

operating speed of the tool from the initial Tool Speed to the Downshift Speed. 

The controller changes the operating speed of the tool from the initial Tool Speed 

to the Downshift Speed at the Downshift Torque level. 

Anytime the peak angle recorded exceeds the High Angle, the tightening cycle is 

recorded as a reject for high angle, the high angle light (red) illuminates and the 

tightening cycle is given an overall status of NOK. 

Anytime the peak torque recorded exceeds the High Torque, the tightening cycle is 

recorded as a reject for high torque, the high torque light (red) illuminates and the 

tightening cycle is given an overall status of NOK. 

Define one or more assembly sequences that can include multiple fasteners 

controlled by one or more tasks. 

Anytime the peak angle recorded during the Angle Audit Step fails to reach the 

Low Angle, the tightening cycle is recorded as a reject for low angle, the low angle 

light (yellow) illuminates and the tightening cycle is given an overall status of 

NOK. 

When the peak torque recorded fails to reach the Low Torque, the tightening cycle 

is recorded as a reject for low torque, the low torque light (yellow) illuminates and 

the tightening cycle is given an overall status of NOK. 

Controls the operation of the multiple-function panel (MFP) on QPM tools. 

Choices includes: MFB Tap (Disabled, Reverse, Task Sel, Arm, Rst Rej, Job Sel, 

Glossary 85


Odometer 

Parameter Set 

PM Counter 

PM Counter 

PM Limit 

RATE 

Reject Tone 

Slow Seek 

Snug Torque 

Soft Stop 

Speed 

Spindle 

Steps 

Strategy 

System Outputs 

Task 

TC/AM 

Thread Direction 

Threshold Torque 

Tool Tones 

Torque Average 

Torque Calibration 

Torque Target 

Trace 

Trip Counter 

Job Rst) and MFB Hold (Disabled, Reverse, Task Sel, Arm, Rst Rej, Job Sel, Job 

Rst). The default value is Disabled. 

The odometer increments after every in cycle to tracks the total tool cycles. It 

cannot be reset. 

Now referenced as a Task. 

Records the number of tightening cycles completed since the last time it was reset 

for Planned Maintenance. 

The PM (preventative maintenance) counter tracks the total tool cycles until 

maintenance is required. 

When the PM Counter exceeds the PM Limit, the controller provides a 

maintenance alert. 

RCAM Torque Rate Control. This strategy uses an increase in Torque Rate 

Control to a specified level to indicate a fastening process event. 

Controls the tone made from the handle of handheld QPM tools for rejected 

tightening cycles. Allows distinct tones for tools in adjacent workstations. 

Slow Seek helps engage the socket or fastener at a pre-selected speed, torque level 

and angular rotation. Once engaged, the tightening cycle completes at a higher 

speed. Slow Seek prevents cross threaded fasteners and previously secured 

fasteners from being counted in a batch. 

The controller begins to monitor the tool for angle at a pre-selected threshold 

torque. Any increase in angle after the snug point results in a corresponding 

increase in the tension or clamp load within the joint. 

Soft stop minimizes the torque impulse to the operator during tool shutoff at the 

end of the tightening cycle. 

The speed at which the tool operates during the initial portion of the tightening 

cycle prior to ATC or downshift. 

A spindle represents a connection to a hand held or fixtured tool connected to a 

controller. 

Instructions to operate a tool defined by available strategies such as TC/AM 

(Torque Control, Angle Monitoring). 

Identifies what variables will be used to control the tool during a tightening cycle. 

(Tool Running, In Cycle, Cycle OK, Cycle NOK, Disassembly Detected, Indicate 

Job) also fixed and pulsed 

Control tool operation for tightening a fastener which can have one or more steps. 

A collection of instructions that define how the tool should perform the tightening 

process. It may be selected from the keypad or 24V device such as a socket tray. 

Formerly referenced as Parameter Set. 

Torque Control with Angle Monitoring. This strategy controls a tool based on 

torque and monitors the angle limits defined by user. 

Sets assembly direction to clockwise (CW) or counter clockwise (CCW). 

Sets the point at which the tool is "In Cycle." When the tool is "In Cycle" the tool 

and controller tightening cycle status lights turn off, the controller displays dashes 

(-) for data, and the "In Cycle" output is turned on. 

Distinctive sounds assigned to tool functions. 

(Rate, Yield and AC/TA) Number of torque samples averaged for rate calculation. 

Torque samples are taken every millisecond. A running average is calculated based 

on these samples. A higher number gives a smoother rate. 

Determines how torque values are assigned to the electrical signals from the torque 

transducer on the tool. This value is unique to each tool and changes over time. 

When the tool is being controlled for torque, the torque target instructs the 

controller when to shutoff the tool. The torque target should be greater than Low 

Torque and less than High Torque, and is required for torque control. 

A display plot of torque versus time (or angle) of a tightening cycle. 

Records the number of total tool tightening cycles completed since the last time it 

was reset. It is usually used as a supplementary count of the PM Counter. 

86 Glossary


Units 

YIELD 

The following torque units and associated labels are used with Stanley controllers 

and tools. 

Abbreviation Common Term = 1 lbfft = 1 Nm 

Nm Newton meter 1.355 818 1 

Ncm Newton centimeter 135.581 8 100 

Ndm Newton decimeter 13.5582 10 

kgm Kilogram meter 0.138 255 2 0.101 971 6 

kgcm Kilogram centimeter 13.825 52 10.197 16 

ftlb Foot pound 1 0.737 562 1 

inlb Inch pound 12 8.850 745 

inoz inch ounce 192 141.611 9 

YCAM Yield Control. This strategy uses Torque vs. Angel Rates as the control 

variable. 

Glossary 87


Software Map 

6.1 Setup 

6.1.1 Wizard 

• Strategy (Torque, Angle, Torque & Angle) 

• Units (NM, FTLB, INLB, INOZ, KGM, NCM, NDM) 

• Thread Direction (CW CCW) 

• High Torque 

• Low Torque 

• Snug Torque 

• High Angle 

• Low Angle 

• Speed 

• Wobble (Angle Target, Speed, Max Torque) 

• Slow Seek (Angle Target, Speed, Max Torque) 

• Start Delay (Delay Time, Max Torque) 

• Conditioner Fastener (Down Target Torque, Delay Time, Max Time, Up Angle Target) 

• Pre-Torque (Torque Target, Delay Between Steps) 

• ATC 

• Backout Fastener (Angle Target, Torque Target, Speed 

• Fastener Release (Speed, Angle Target, Max Torque) 

6.1.2 Job 

• Name 

• Barcode ID 

• Auto Sequence Tasks (Yes, No) 

• Auto Reset Job (Yes, No) 

• Enable Error Proofing 

6.1.2.1 Task 

• Name 

• Batch Count 

• Units (NM, FTLB, INLB, INOZ, KGM, NCM, NDM) 

• Thread Direction (CW, CCW) 

• Threshold Torque 

• Statistical Threshold 

• Disassembly Speed 

• Disassembly Acceleration 

• Cycle Lock-Out 

• Torque Audit Step (Last, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12) 

• Angle Audit Step (Last, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12) 

• Torque Rate 

Software Map 89


• Torque Average 

• Angle Interval 

• Modified 

6.1.2.2 Step 

• Name 

• Strategy TC/AM 

• Torque Target 





• Low Angle 

• Angle Bailout 

• Downshift Mode (Disabled, Manual, ATC) 

• Manual: Downshift Mode 

• Manual: Downshift Speed 

• ATC: Starting Torque % 

• ATC: Ending Torque % 

• ATC: Ending Speed % 

• Soft Stop (Yes, No) 

• Yes: Current Off Time 

• Yes: Current Hold Time 

• Yes: Current Ramp Time 

• Speed 

• Power 

• Acceleration 

• Abort Timer 

• Delay Between Steps 

• Accumulate Angle (Yes, No) 

• Strategy AC/TM 


• Angle Target 


• Low Angle 



• Torque Bailout 

• Downshift Mode (Disabled, Manual) 







90 Software Map


• Speed 

• Power 





• Strategy AC/TC 








• Low Angle 












• Speed 

• Power 





• Strategy BACK 




• Low Angle 








Software Map 91









• Speed 

• Power 





• Strategy RATE 

• Torque Rate Target 






• Low Angle 












• Speed 

• Power 





• Strategy YIELD 

• Yield Target 





92 Software Map



• Low Angle 












• Speed 

• Power 





• Strategy AC/TA 




• Low Angle 




• Max Torque Bailout 

• Mind Torque Bailout 











• Speed 

• Power 




Software Map 93



6.1.3 Communications 

• Obtain IP From Network (No, Yes) 

• IP Address 

• Subnet Mask 

• Gateway 

• DNS 

• Physical 

• Serial 

• Serial Port 1 (Barcode/Printer, Barcode, Printer, ETB) 

• Serial Port 2 (Barcode/Printer, Barcode, Printer, Toyota, PFCS, Open) 

• PFCS 

• Server IP 

• Port 

• Time Out 

• Open 

• Port 

• Cell 

• Buffer while off line 

• Toolsnet 

• Server IP 

• Port 

• Cell 

• Station 

6.1.4 Other 

• General 

• Name 

• Keypad Mode (Disabled, Task Select, Job Select, Part ID) 

• Count Mode (Count Up, Count Down) 

• Stop/Abort within Limits (OK, NOK) 

• Users 

• Add 

• Manage 

• 1. Add 

• 2. Delete 

• 3. Change Password 

• 4. Change Access 

• Outputs 

• C (Off, In Cycle, Job Selected, Disassembly Detected, Tool Running, Cycle OK, Cycle 

NOK, Task Selected, Job Completed, Task Complete, Task Selected Bit, Job Selected 

Bit, Torque OK, Torque Hi, Torque Low, Angle OK, Angle Hi, Angle Low, Cycle 

Aborted, Stopped, Faulted, Ready, PM, Start Trigger, MFB, Snug Achieved, Cycle 

Stopped, Step Bit) 

• D (Off, In Cycle, Job Selected, Disassembly Detected, Tool Running, Cycle OK, Cycle 


94 Software Map





• E (Off, In Cycle, Job Selected, Disassembly Detected, Tool Running, Cycle OK, Cycle 





• F (Off, In Cycle, Job Selected, Disassembly Detected, Tool Running, Cycle OK, Cycle 





• G (Off, In Cycle, Job Selected, Disassembly Detected, Tool Running, Cycle OK, Cycle 





• H (Off, In Cycle, Job Selected, Disassembly Detected, Tool Running, Cycle OK, Cycle 





• J (Off, In Cycle, Job Selected, Disassembly Detected, Tool Running, Cycle OK, Cycle 





• K (Off, In Cycle, Job Selected, Disassembly Detected, Tool Running, Cycle OK, Cycle 





• Inputs 

• L (Ignore, Start, Select Job, Select Task, Stop, Reset Job, Task Select Bit, Job Select bit, 

Reverse, Disable Task, Disable Job, Task Verify, Job Verify, Task Verify Bit, Job Verify 

Bit, Reset Result Status, Reverse Start, Disable Tool) 

• M (Ignore, Start, Select Job, Select Task, Stop, Reset Job, Task Select Bit, Job Select bit, 



• N (Ignore, Start, Select Job, Select Task, Stop, Reset Job, Task Select Bit, Job Select bit, 



• P (Ignore, Start, Select Job, Select Task, Stop, Reset Job, Task Select Bit, Job Select bit, 



• R (Ignore, Start, Select Job, Select Task, Stop, Reset Job, Task Select Bit, Job Select bit, 



• S (Ignore, Start, Select Job, Select Task, Stop, Reset Job, Task Select Bit, Job Select bit, 



Software Map 95


• T (Ignore, Start, Select Job, Select Task, Stop, Reset Job, Task Select Bit, Job Select bit, 



• U (Ignore, Start, Select Job, Select Task, Stop, Reset Job, Task Select Bit, Job Select bit, 



• Triggers 

• Tap Action (Disabled, Reverse, Task Select, Arm, Reset Reject, Job Select, Job Reset) 

• Hold Action (Disabled, Reverse, Task Select, Arm, Reset Reject, Job Select, Job Reset) 

• Start Input (Any, All, Lever, PTS, None) 

• Lights 

• Lights (1,2) (Task, Job) 

• Headlight Timer 

• Tones 

• Accept Tone (None, Beep, Beeeep, Tocatta, Fifth, Turkishmarch, Funeralmarch, Ninth, 

Michigan, Ohio) 

• Reject Tone (None, Beep, Beeeep, Tocatta, Fifth, Turkishmarch, Funeralmarch, Ninth, 

Michigan, Ohio) 

• Tool 

• PM Limit 

• Temperature Limit 

• Torsion Factor 

• Requires Arming (No, Yes) 

• Stats 

• Population 

• Subgroup Size 

• Clock 

• Time 

• Date 

6.1.5 Full Backup/Restore 

• Backup 

• Restore 

• Defaults 

6.2 Service 

6.2.1 Tool 

• About 

• Model 

• Serial 

• Software Version 

• Max Torque 

• Max Speed 

• Counters 

• Odometer 

• PM Counter 

• Trip Counter 

96 Software Map


• Cal 

• Nominal Cal 

• Torque Cal 

• Modified 

6.2.2 Controller 

• About 

• Model 

• Serial 

• Software Version 

• Servo Version 

• Update 

6.3 Analyze 

• Results 

• Cap 

• Perform 

• Cam 

• Export 

o 1. Rundown Data (save) 

o 2. Fault Event Data (save) 

• Job1.1 (Job, Task) 

• 1. Rundown Data 

Software Map 97


Warranty 

Mechanical Products Limited Warranty: 

STANLEY ASSEMBLY TECHNOLOGIES (“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. 

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. 

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 noncompatible 

hardware or accessories. 

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. 

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 

Warranty 99


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. 

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. 

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 

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. 

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. 

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. 

100 Warranty


Contacts 

STANLEY ASSEMBLY TECHNOLOGIES: 5335 Avion Park Drive, Cleveland, Ohio 44143- 

2328 USA Tel: +1 (440) 461-5500 Fax: +1 (440) 461-5592; SATinfo@stanleyworks.com 

STANLEY ASSEMBLY TECHNOLOGIES: 1875 Research Drive, Suite 200 Troy, Michigan 

48092 USA Tel: +1 (248) 824-1100 Fax: (248) 824-1110 Toll Free Service: (877) 787-7830 Toll 

Free Sales: (877) 709-8006 

STANLEY WORKS Ltd. (FRANCE): Outils Portatifs et Systemes d’Assemblage, Zone 

Imoparc bat Loire 4, 78190 Trappes, France Tel: +33 (1) 3050 9100 Fax: +33 (1) 3051 0708 

STANLEY GERMANY, Inc.: Frankfurter Strasse 74, D-64521 Gross-Gerau, Germany Tel: +49 

(0) 6152 8052-0 Fax: +49 (0) 6152 8052-22 SATGER@stanleyworks.com 

STANLEY TOOLS S.r.l. (ITALY): Divisione Assembly Technologies, 47 Via Parco, 20046 

Biassono (MI) Tel: +39 (039) 2389.1 Fax: +39 (039) 2389970 

STANLEY ASSEMBLY TECHNOLOGIES: Gowerton Road, Brackmills, Northhampton NN4 

7BW, England Tel: +44 (1604) 827247 Fax: +44 (1604) 827277 

STANLEY ASSEMBLY TECHNOLOGIES SHANGHAI REPRESENTATIVE OFFICE: 

Room 1908, Shanghaimart Tower, 2299 Yan An Road West, Shanghai 200336, China Tel: 011- 

86-21-3208-4550 Fax: 011-86-21-6236-0191 

www.StanleyAssembly.com 

Warranty 101

Appendix A – Embedded Toolbox 

Features, Navigation and Menu 

1.1 Introduction 

Embedded Toolbox enables communication to an Alpha controller using a networked computer’s 

web browser. To get started, point the browser to the controller’s IP address. 

1.2 Installation 

1.2.1.1 Requirements for Alpha Controllers (Ethernet Connection): 

• Javascript enabled Internet browser with Flash 9 for Windows, Macintosh, or Linux running 

over an Ethernet TCP/IP connection 

• Adobe Flash Player v9 or above (http://www.adobe.com) 

• QA1001 Alpha Controller Version 3.0 or above 

• Q1001 Alpha Controller Version 4.0 or above 

Connect to the controller using the IP address in the browser. Alpha controllers can also connect 

through the Controller Gateway using the serial port as described for the Q0001 Kappa controller. 

1.2.1.2 Requirements for Alpha Controllers Using the Controller Gateway (Serial Connection): 

• Microsoft Windows XP (for serial connection to a controller) 

• QA1001 Alpha Controller Version 3.0 or above 

• Q1001 Alpha Controller Version 4.0 or above 

• Javascript enabled browser and Adobe Flash Player described above 

The Controller Gateway is a Windows based software program that provides a web based interface 

to an Alpha controller connected via a serial link. 

1.2.1.3 Installing the Controller Gateway 

Using the provided installation media, run the setup program and follow the on-screen 

instructions. During installation, TCP/IP ports for the web interface and the live event interface 

can be set. Leave the default values unless you understand their meaning and require a port change 

for your specific environment. 

1.2.1.4 Running the Controller Gateway? 

The installer sets the Controller Gateway to automatically launch each time the computer is 

started. When Controller Gateway is running, a small icon appears on the system tray or Windows 

Task bar (typically at the bottom right corner of the screen). 

Right-clicking on the Controller Gateway icon displays its menu. From the menu, select the Auto- 

Connect option. Note that Auto-Connect is the default option; this means that double-clicking the 

Controller Gateway icon also starts the auto-connection process. 

The auto-connection process launches the default web browser and examines the computers 

available serial ports. The Controller Gateway looks port by port for a compatible Stanley 

controller connection. When one is found, the browser redirects to the controller’s main menu. 

From the menu, setup, maintenance and analysis functions can be performed. 

If a compatible controller is not found, the auto-connect mechanism offers to try again. If you 

choose to not try again, the browser is redirected to an “Offline Mode” menu. In offline mode, 

setups and configuration file exports can be created. These files can be imported to a connected 

controller in the future.


1.3 Navigation 

A lock/unlock icon connects or disconnects the controller. An amplifying signal icon 

shows green when connected and red when disconnected. 

NOTE: 

Use the Show All button – not the browser’s back button – to return to the main menu . 

1.4 Menu Options 

Quick Start gives wizard capability to configure simple tightening cycles 

for a specific job. 

Jobs Management configures tightening cycles with full controller 

capability to manage jobs, tasks and steps. 

Systems Management configures system name, multiple-function 

button (MFB) mode, keypad mode and tones. 

Input / Output configures 24 volt input/output, fieldbus input/output, 

modbus TCP input/output using either a table or graphical view. 

Rundown Analysis enables data import/export/print and analysis 

including traces, statistics, historical data and xbar/range views. 

Tool Diagnostics shows real time tool parameters such as speed and 

temperature. 

I/O Diagnostics enables real time analysis and stimulus for 24 volt 

input/output, fieldbus input/output, modbus TCP input/output. 

Reports shows, saves and prints detail controller reports for: system, 

jobs, tasks and/or combined jobs and tasks. 

Tool Configuration Update upgrades tool configuration information. 

Setup 

• Quick Start 

• Jobs Management 

• System 

Management 

• Input / Output 

Analyze 

• Rundown Analysis 

• Tool Diagnostics 

• I/O Diagnostics 

Report 

• Parameter Sheet 

Service 

• Tool Configuration 

Update 

Appendix A – Embedded Toolbox

QA Alpha Controller 

1.4.1 Setup 

Appendix A – Embedded Toolbox 101


1.4.1.1 Quick Start 

Quick Start provides a graphical user interface (GUI) for wizard programming Alpha controllers. 

1.4.1.1.1 Job Name 

Enter job name on the opening screen. 

Setup 


o Job Name 



1.4.1.1.2 Task Definition 

Identify the number of bolts to be fastened and whether they will be 

fastened using the same parameters. If no, then a bolt control option 

appears at top. 

Setup 


o Job Name 

o Task Definition 



1.4.1.1.3 Task Name 

Enter the task name to identify this set of fastening parameters. 

Setup 


o Job Name 


o Task Name 



1.4.1.1.4 Strategy 

Strategy options include Torque, Angle and Torque & Angle. Use this 

screen to also set units and fastening direction. 

Setup 


o Job Name 


o Task Name 

o Strategy 



1.4.1.1.5 Audit Step 

The Audit Step sets the high and low limits for torque and/or angle 

depending on the strategy selected. Free speed of the tool is also set. For 

angle limits, the snug torque determines the starting point for angle 

measurement. 

Setup 


o Job Name 


o Task Name 

o Strategy 

o Audit Step 



1.4.1.1.6 Controls 

Controls enables setting the variables for: 

• Wobble 

• Slow Seek 

• Start Delay 

• Condition Fastener 

• Pre-Torque 

• ATC 

• Backout Fastener 

• Release Fastener 

The default is Slow Seek selected and ATC enabled. 

Setup 


o Job Name 


o Task Name 

o Strategy 

o Audit Step 

o Controls 



1.4.1.1.7 Wobble 

Set output rotate (degrees), tool speed and maximum torque. 

Setup 


o Job Name 


o Task Name 

o Strategy 

o Audit Step 

o Controls 

- Wobble 



1.4.1.1.8 Slow Seek 

Set output rotate (degrees), tool speed and maximum torque. 

Setup 


o Job Name 


o Task Name 

o Strategy 

o Audit Step 

o Controls 

- Wobble 

- Slow Seek 



1.4.1.1.9 Start Delay 

Set delay time (seconds) and high torque. 

Setup 


o Job Name 


o Task Name 

o Strategy 

o Audit Step 

o Controls 

- Wobble 

- Slow Seek 

- Start Delay 



1.4.1.1.10 Condition Fastener 

Set down torque target (NM), delay between steps (seconds), cycle abort 

time (seconds) and angle target (degrees). 

Setup 


o Job Name 


o Task Name 

o Strategy 

o Audit Step 

o Controls 

- Wobble 

- Slow Seek 

- Start Delay 

- Condition 

Fastener 



1.4.1.1.11 Pre-Torque 

Set target torque (NM) and delay between steps (seconds). 

Setup 


o Job Name 


o Task Name 

o Strategy 

o Audit Step 

o Controls 

- Wobble 

- Slow Seek 

- Start Delay 

- Condition 

Fastener 

- Pre-Torque 



1.4.1.1.12 Backout Fastener 

Set output rotation (degrees), high torque (NM) and tool speed (RPM). 

Setup 


o Job Name 


o Task Name 

o Strategy 

o Audit Step 

o Controls 

- Wobble 

- Slow Seek 

- Start Delay 

- Condition 

Fastener 

- Pre-Torque 

- Backout 

Fastener 



1.4.1.1.13 Release Fastener 

Set tool speed (RPM), output rotation (degrees) and maximum torque 

(NM). 

Setup 


o Job Name 


o Task Name 

o Strategy 

o Audit Step 

o Controls 

- Wobble 

- Slow Seek 

- Start Delay 

- Condition 

Fastener 

- Pre-Torque 

- Backout 

Fastener 

- Release 

Fastener 



1.4.1.1.14 Finished 

Use the save button 

to record the recently defined 

tasks. 

Use the export button 

to make the defined tasks 

available outside of this controller definition. 

Setup 


o Job Name 


o Task Name 

o Strategy 

o Audit Step 

o Controls 

- Wobble 

- Slow Seek 

- Start Delay 

- Condition 

Fastener 

- Pre-Torque 

- Backout 

Fastener 

- Release 

Fastener 

- Finished 



1.4.1.2 Jobs Management 

Jobs Management configures tightening cycles with full controller 

capability to manage jobs, tasks and steps. The number of configurations 

appears directly following the name in parenthesis. The windows 

display the items already setup for the controller. To define a new setup, 

copy and modify an existing setup, step-by-step setup options are 

displayed below the highlighted active window. 

Setups can be imported, exported or saved using the appropriate button 

at the bottom of the screen. 

Setup 



Use the plus button 

Use the minus button 

to add a new job, task or step. 

to delete the selected job, task or step. 

Use the duplicate button 

task or step. 

1.4.1.2.1 Jobs 

to duplicate the selected job, 

Jobs setup includes: job name, auto sequence task, auto reset job, enable 

error proofing and disable reverse on OK options. 

Setup 



o Jobs 



1.4.1.2.2 Tasks 

1.4.1.2.2.1 General 

General setup includes: task name, disassembly speed and disassembly 

acceleration. The date of last modification appears at the bottom of the 

screen. 

Setup 



o Jobs 

o Tasks 

- General 



1.4.1.2.2.2 Units 

Units setup choices include: NM, FTLB, INLB, INOZ, KGM, KGCM, 

NCM and NDM. 

Setup 



o Jobs 

o Tasks 

- General 

- Units 



1.4.1.2.2.3 Fastener Definition 

Fastener Definition options include: batch counting fastenings, number 

of fastening to be batch counted and tool direction. 

Setup 



o Jobs 

o Tasks 

- General 

- Units 

- Fastener 

Definition 



1.4.1.2.2.4 Thresholds 

Threshold setup choices include: beginning torque threshold, angle for 

torque rate measurement and number of torque readings to average. 

Setup 



o Jobs 

o Tasks 

- General 

- Units 

- Fastener 

Definition 

- Threshold 



1.4.1.2.2.5 Audit Definition 

Audit Definition identifies the step for torque and/or angle audit. 

Setup 



o Jobs 

o Tasks 

- General 

- Units 

- Fastener 

Definition 

- Threshold 

- Audit Definition 



1.4.1.2.3 Steps 

1.4.1.2.3.1 General 

General identifies the step name. 

Setup 



o Jobs 

o Tasks 

o Steps 

- General 



1.4.1.2.3.2 Strategy 

Strategy choices include: TC/AM, AC/TM, AC/TC, BACKOFF, RATE, 

YIELD and AC/TA. 

Setup 



o Jobs 

o Tasks 

o Steps 

- General 

- Strategy 



1.4.1.2.3.3 Torque Specification Limits 

Torque Specification Limits choices include: target torque, high and low 

torque limits, bail-out torque limit and minimum, snug torque limit and 

accumulate torque identification. 

Setup 



o Jobs 

o Tasks 

o Steps 

- General 

- Strategy 

- Torque 

Specification 

Limits 



1.4.1.2.3.4 Angle Specification Limits 

Angle Specification Limits choices include: target angle, high and low 

angle limits, bail-out angle limit and a check box to accumulate angle. 

Setup 



o Jobs 

o Tasks 

o Steps 

- General 

- Strategy 

- Torque 

Specification 

Limits 

- Angle 

Specification 

Limits 



1.4.1.2.3.5 Tool Motor Control 

Tool Motor Control option identifies: tool speed, tool acceleration rate to 

speed, downshift torque, downshift speed and shutoff mode (Coast or 

Soft Stop). 

Setup 



o Jobs 

o Tasks 

o Steps 

- General 

- Strategy 

- Torque 

Specification 

Limits 

- Angle 

Specification 

Limits 

- Tool Motor 

Control 



1.4.1.2.3.6 Adaptive Tightening Control (ATC) 

Adaptive Tightening Control option identifies: downshift mode, starting 

and ending torque and ending speed. 

Setup 



o Jobs 

o Tasks 

o Steps 

- General 

- Strategy 

- Torque 

Specification 

Limits 

- Angle 

Specification 

Limits 

- Tool Motor 

Control 

- Adaptive 

Tightening 

Control (ATC) 



1.4.1.2.3.7 Target Controls 

Target Controls choices include yield and TRC targets. 

Setup 



o Jobs 

o Tasks 

o Steps 

- General 

- Strategy 

- Torque 

Specification 

Limits 

- Angle 

Specification 

Limits 

- Tool Motor 

Control 

- Adaptive 

Tightening 

Control (ATC) 

- Target Controls 



1.4.1.2.3.8 Soft Stop 

Soft Stop enables identifying the current off time, hold time and ramp 

time. 

Setup 



o Jobs 

o Tasks 

o Steps 

- General 

- Strategy 

- Torque 

Specification 

Limits 

- Angle 

Specification 

Limits 

- Tool Motor 

Control 

- Adaptive 

Tightening 

Control (ATC) 


- Soft Stop 



1.4.1.2.3.9 Step Timers 

Step Timers sets cycle abort time and elapse time between steps. 

Setup 



o Jobs 

o Tasks 

o Steps 

- General 

- Strategy 

- Torque 

Specification 

Limits 

- Angle 

Specification 

Limits 

- Tool Motor 

Control 

- Adaptive 

Tightening 

Control (ATC) 


- Soft Stop 

- Step Timers 



1.4.1.3 System Management 

System Management enables custom controller configuration for 

triggers and tones. 

Setups can be imported, exported or saved using the appropriate button 

at the bottom of the screen. 

Setup 



• System 

Management 

1.4.1.3.1 General 

General enables naming the controller and specifying keypad mode. 

Setup 



• System 

Management 

o General 



1.4.1.3.2 Triggers 

Triggers controls operation, action and start mode of the multiplefunction 

button (MFB). 

Setup 



• System 

Management 

o General 

o Triggers 



1.4.1.3.3 Lights 

Lights identifies mode and headlight timer value. 

Setup 



• System 

Management 

o General 

o Triggers 

o Lights 



1.4.1.3.4 Tones 

Tones sets sound options for accepted and rejected rundowns. 

Setup 



• System 

Management 

o General 

o Triggers 

o Lights 

o Tones 



1.4.1.4 Input / Output 

Use the graphical button or table button to swap view 

options. Yellow highlight surrounds active button choice. 

Configurations can be added, deleted, saved, imported, exported or 

printed using the appropriate button at the middle of the screen. 

Setup 



• System 

Management 




1.4.1.4.1 Configuration Dropdown 

Use the dropdown to choose a configuration for setup. 

Setup 



• System 

Management 




1.4.1.4.2 Add/Insert/Delete Bit Assignments 

To add a bit assignment at the end of list, click the add button 

. There are eight maximum assignments available for 

the 24 volt options. 

To add a bit assignment before a selected bit assignment, first select 

position with green highlight – click a line once using the left mouse 

Setup 



• System 

Management 


button – then click the insert button 

(the add button 

changes to insert). 

To remove a bit assignment, highlight and click the delete button 

. 



1.4.1.4.3 Function Palette: Bit Function Assignment 

The Function Palette appears after selecting a bit assignment (left click 

once). To assign a function, double click it. Click the red X button in 

the right corner to close window. 

Setup 



• System 

Management 




1.4.1.4.4 Bit Assignment Options 

The options for a selected bit assignment’s function appear at screen 

bottom. Activate field for changes by pointing to and left clicking field 

once using mouse pointer, then adjust. 

Setup 



• System 

Management 




1.4.1.4.5 Screen Examples 

1.4.1.4.5.1 24 Volt Output 

See page 83 for 24 volt assignable Output functions. 

Setup 



• System 

Management 




1.4.1.4.5.2 24 Volt Input 

See page 82 for 24 volt assignable Input functions. 

Setup 



• System 

Management 




1.4.1.4.5.3 Fieldbus Output 

See page 83 for fieldbus assignable Output functions. 

Setup 



• System 

Management 




1.4.1.4.5.4 Fieldbus Input 

See page 82 for fieldbus assignable Input functions. 

Setup 



• System 

Management 




1.4.1.4.5.5 Modbus TCP Output 

See page 83 for Modbus TCP assignable Output functions.. 

Setup 



• System 

Management 




1.4.1.4.5.6 Modbus TCP Input 

See page 82 for Modbus TCP assignable Input functions. 

Setup 



• System 

Management 


1.4.2 Analyze 

1.4.2.1 Rundown Analysis 

Rundown Analysis display options include the controller rundown, traces, summary statistics, 

histogram and x-bar/range. Prior rundown results are shown at screen bottom with results not 

included in the statistics struck out. 

Use the buttons located at the middle right of screen to swap view options (Rundown, Trace, 

Statistics, Histogram and Xbar/range). Yellow highlight surrounds active button choice. 



Use the buttons located at the middle left of screen to import, export and print rundowns. 

1.4.2.1.1 Rundown 

The Rundown view displays details for current rundown. 

Click on the information icon to choose either torque or angle data. 

After making data selections, click the green check to accept or the red x 

to abort. Click the information icon again to close. 

Analyze 


o Rundown 



1.4.2.1.2 Trace 

The Trace view displays a plot of selected tightening variables. 

Click on the information icon to show data point information at the 

location of the vertical cursor. Click again to remove the information. 

The right or left arrow keys move the cursor on the X axis to different 

data points (hold the shift key to increase movement). 

Analyze 


o Rundown 

o Trace 

Use the dropdown to select variables plotted: 



1.4.2.1.2.1 Axis Torque vs. Time Selected 

The Trace displayed reflects the rundown selected below the screen. 

To adjust magnification area, position mouse pointer below the x-axis 

(pointer changes from an arrow to a hand). 

Analyze 


o Rundown 

o Trace 

Next press and hold left mouse button, drag left or right to highlight, 

then release to display. 



1.4.2.1.2.2 Initial Magnification 

Click the back arrow (lower left of trace) to return to the initial 

magnification. 

Analyze 


o Rundown 

o Trace 



1.4.2.1.3 Statistics 

The Statistics view displays statistical overview summary. 




Analyze 


o Rundown 

o Trace 

o Statistics 



1.4.2.1.4 Histogram 

The Histogram view shows the histogram for torque or angle. 




Analyze 


o Rundown 

o Trace 

o Statistics 

o Histogram 



1.4.2.1.5 X-Bar/Range 

The X-Bar/Range view uses the information icon to display a 

dropdown showing either torque or angle data. Click on the information 

icon to choose either torque or angle data. After making data 

selections, click the green check to accept or the red x to abort. Click the 

information icon again to close. 

Analyze 


o Rundown 

o Trace 

o Statistics 

o Histogram 

o X-Bar/Range 



1.4.2.2 Tool Diagnostics 

Tool Diagnostics displays tool torque, current, temperature, angle and 

speed. Setup and pass/fail data for rundowns done while the screen is 

active are listed. Exiting the screen erases the data. 

Analyze 





1.4.2.3 I/O Diagnostics 

I/O Diagnostics displays input and output. 

Use the graphical button or table button to swap view 

options. Yellow highlight surrounds active button choice. 

Analyze 






1.4.2.3.1 Configuration Dropdown 

Use the dropdown to choose a configuration to view. 

Analyze 






1.4.2.3.2 Options 

The options for a selected bit assignment’s function appear at screen 

bottom. 

Analyze 






1.4.3 Report 

Parameter Sheet provides a summary for: System, Jobs, Tasks, and all 

Job and Task combinations. 

Use the buttons that appear directly above report to save, print, scroll 

through pages, and change report views (page and width). 

Reports 

• Parameter Sheet 



1.4.4 Service 

Tool Configuration Update enables upgrading tool configuration 

information for currently attached tool. 

Service 

• Tool Configuration 

Update

Assembly Technologies Alpha Controller User Manual v3.0

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