SAT_Q-Qc_Manual.pub

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Carefully observe and comply with all warnings, cautions and instructions placed on the equipment or described in this manual.

1 INSTALLATION AND USE INSTRUCTIONS Q System QUALIFIERS: PSIQ & PSIQc Important Safeguards For your protection, please read these instructions completely, and keep for future reference. Carefully observe and comply with all warnings, cautions and instructions placed on the equipment or described in this manual. QOPMAN0306 Stanley Assembly Technologies Applications & Productivity Center, 5800 Enterprise Court, Warren, MI Tel Fax Toll Free in the US THE STANLEY WORKS, ALL RIGHTS RESERVED

2 Installation and Use Table of Contents Safety... 3 Symbols and Terms Warnings Qualified Personnel Specifications... 4 Operation... 5 Installation and Air Supply... 6 Tool Compatibility... 7 Inputs / Outputs (I/O)... 8 Troubleshooting... 9 Appendix A: Stanley Pneumatic Tool Modifications for PSIQ Qualifiers Appendix B: Operation Flow Chart PSIQc Qualifiers Initial Set Up (PSIQc) Admin Menu (PSIQc) Appendix C: Operation Flow Chart PSIQ Qualifiers Initial Set Up (PSIQ) Admin Menu (PSIQ) QOPMAN0306

3 Safety....,..,. Tool controller. Qualified Personnel (Tool controller.. tool.. Tool.. Stanley Assembly Technologies..,,.,,,.. PSI Qualifier,,. Stanley Assembly Technologies threaded.. Stanley Stanley Sales Engineer. QOPMAN0305 3

4 Operation PSIQc The PSIQc nonqualifies shutoffrundowns pulse impact for non shutoff wrenches pulse tools. or impact wrenches. PSIQc throttle The PSIQc can operate either with solenoid a signal valve light for the operator to release the throttle or by actuating a solenoid valve which shuts off the air supply to the tool at cycle complete. PSIQ The PSIQ air performs shutoff POKE POKE YOKE YOKE error proofing with air shutoff tools. Torque accuracy depends on the capability of the power tool selected for the application. PSIQ The Q System is a process & monitoring system and does not provide torque control. shutoff ±20%.. non shutoff Torque accuracy with shutoff tools is usually good within ±20%. This is controlled by the tool s internal mechanism. When using stall ±10% (non shutoff) pulse tools, accuracy of ±10% signal is easily light achieved when adjusted and setup properly and used with a signal light. PSIQc OK NOK fastening rundown data. The Qc Qualifier takes a series of mass air flow measurements and turns the data into a rundown signature to detect OK vs. NOK fastening cycles Flow Flow Time Time The diagram above shows a typical fastening cycle for a pulse or impact tool. The air Run consumption of pulse a pulse tool air motor during a run cycle tool is relative to the work being. performed, Zone as 1 well tool as the speed of the tool., In Zone 1, the fastener tool is starting crossthreaded and the level (of flow, will indicate if ) the fastener freeis spinning crossthreaded (, or free spinning. ) flow() Zone 2 is free speed. and is the Zone zone 2 showing free speed the free rundown free of the bolt. Zone 3 begins Zone when. the fastener Zone 3 has fastener seated and reached (, snug ) torque and ends Zone with 4 Zone, 4, the final pulse tightening phase. Near the end of zone 4, equilibrium has been attained and the tool can be shutoff with excellent torque accuracy.. Flow() Zone 4 tool shutoff. 4 QOPMAN0306

Specifications Power Source 100240 VAC 5060 Hz Power Consumption Operating Conditions Temperature Humidity Weight < 1 amp @ 115 VAC 0 to +50 ºC (32 to 122 ºF) 0 to 95 % noncondensing 1 kg (2 lbs.

5 Specifications Power Source VAC 5060 Hz Power Consumption Operating Conditions Temperature Humidity Weight < VAC 0 to +50 ºC (32 to 122 ºF) 0 to 95 % noncondensing 1 kg (2 lbs.) Approximately Dimensions Inputs/Outputs Error Proofing 15cm (6 ) wide x 21cm (8.25 ) high x 4cm (1.5 ) deep Optoisolated and relay dry contacts; up to 24 VDC/ 5 amps with screw lug terminals OK/NOK for acceptable cycles vs REHIT/CROSS THREAD, STRIP/SLIP OFF, CYCLE ABORT & BATCH COUNT STATUS Optional Serial Port RS 232 port; standard RJ45 connector (Pset#/TgTq/COUNT/OKNOK) Interface Two Line 11mm (0.44 ) LCD backlit, (16) Characters per line per line Fivebutton Fivebutton keypad keypad (Up, Down, Menu, Reset/Reverse & Admin) (Up, Down, Menu, Reset/Reverse & Admin) QOPMAN0305 5

To Avoid Injury: Always wear eye protection when installing equipment. Stanley Only use assembly equipment tools and accessories specifically designed to operate with Stanley assembly. tools. Keep the work area clean and uncluttered.

. Train tool all operators in the safe and proper use of power tools.. Operators should report any unsafe condition.

Filter and lubricator (recommended) to be installed at this point (3/8 NPT). Adjust pressure regulator to 510 PSI lower than the MAX air available. 2. Air hose connects to supply. 3.

6 To Avoid Injury: Always wear eye protection when installing equipment. Stanley Only use assembly equipment tools and accessories specifically designed to operate with Stanley assembly. tools. Keep the work area clean and uncluttered.. Keep unauthorized personnel out of the. work area. Do not install worn, damaged, or modified equipment that may be unsuitable for safe use.. Train tool all operators in the safe and proper use of power tools.. Operators should report any unsafe condition.. Tool Install tools in dry, indoor, nonflammable, and nonexplosive environments only.. RSM (Remote Sensor Module) 90 PSI Provide clean dry 90 PSI. Filter and lubricator (recommended) to be installed at this point (3/8 NPT). Adjust pressure regulator to 510 PSI lower than the MAX air available. 2. Air hose connects to supply. 3. Use a 3/8 ID hose with full flow fittings with most pulse tools. Use 1/4 hose and fittings with small pulse tools and screwdrivers. MAX hose from RSM to the tool is I/O terminal strip with screw lug terminals. 5. Plug transformer into A/C outlet. 6. Connect the cable to the RSM and to the Q Qualifier as shown, with RJ45 connectors. Standard cable is 15. Optional cables to 200 available. 7. Mount the Q to the wall or to the optional bench mount bracket. 4 Optional Hose Light Assemblies 21C ' Hose/light assembly straight 1/4" 21C ' Hose/light assembly straight 1/4" 21C ' Hose/light assembly straight 1/4" 24C ' Hose/light assembly straight 3/8" 24C ' Hose/light assembly straight 3/8" 21C ' Hose/light assembly straight 3/8" 3 To Avoid Injury: Shutoff valve must be in the closed position until the air lines are installed and properly terminated..) Do not connect power to the PSI Qualifier PSI until Qualifier all air line connections are secured.. Supply air PSI energizes Qualifier the outlet port when electrical outlet power port is supplied to. the PSI Qualifier. 6 QOPMAN0306

Tool Compatibility PSIQ The Q is suitable pneumatic for use with power a wide tools variety of pneumatic.

drive drive (PSIQc) (PSIQc) Nutrunners Nutrunners torque torque controlled controlled shutoff shutoff (PSIQ) (PSIQ) Screwdrivers Screwdrivers torque torque cont

7 Tool Compatibility PSIQ The Q is suitable pneumatic for use with power a wide tools variety of pneumatic. power tools: Pulse tools Pulse shutoff tools shutoff (PSIQ) (PSIQ) and and non non shutoff (PSIQc) Impact wrenches: Impact wrenches: 3/8 and 3/8 1/2 and 1/2 drive drive (PSIQc) (PSIQc) Nutrunners Nutrunners torque torque controlled controlled shutoff shutoff (PSIQ) (PSIQ) Screwdrivers Screwdrivers torque torque cont controlled shutoff shutoff (PSIQ) (PSIQ) All torque controlled shutoff shutoff tools use tool a venting throttle throttle valve design to provide for venting throttle throttle valve reset.. When using these tools, the Q, learns PSIQ the flow signal that includes, Q the venting signal throttle from vent this throttle flow signal reset vent. Once the venting tool shuts signal off, the. signal is seen and the Q responds. See Appendix, A for components PSIQ to make Stanley. pneumatic tools A compatible. Stanley pneumatic tools. QOPMAN0305 7

Input/Output (I/O) PSIQ enclosure screw lug terminals I/O.. I/O 24VDC The Q has onboard I/O that is easily connected using screw lug terminals located at the top of the enclosure.

8 Input/Output (I/O) PSIQ enclosure screw lug terminals I/O.. I/O 24VDC The Q has onboard I/O that is easily connected using screw lug terminals located at the top of the enclosure. All I/O is optically isolated and. 24volts 5amps. Wire rated for 24 VDC. Standard dry contact closure relays are used and can handle up to 5 amps at 24 volts. Wire according to the legend printed on the front label label as shown below. An input signal pin is 1 defined 24VDC, as a signal that (common) is applied between desired input pin1, (common). and the desired input. Either polarity will be. accepted. pin 7 Closing 8the connection between PSIQ pins 7 and 8 enables. the Q. A limit, switch, relay or any contact closure that is isolated can accomplish this.. An Internal internal jumper Enable jumper is also. supplied. This factory installed jumper must be removed if external jumper control is desired. Do. not apply 2 any other pin volt age to these two pins. The outputs for Cycle and Batch are plainly marked.. Cycle Batch outputs Terminals labeled 1 8 are for use as follows: PSET 1 PSET 2 NOT USED CLICK WRENCH BATCH CLEAR ENABLE 8 QOPMAN0306

9 Troubleshooting PSIQ Setup and installation. of the Q is simple and easy. Just follow. the display prompts. COMPLETE Remember to let go of the throttle when the display. reads, COMPLETE after any step in the setup. However, if the. unit does not setup, doesn t. recognize the tool or the tool being in cycle, check the following: 1.? 1. Did the supply air pressure drop below the initial setting? Remember, set the regulator at least 5 psi below the available supply maximum. If supply drops, reteach the PSET at the new pressure. Regulator 5 psi.,. 2. After repeated attempts as prompted on the display, CHANGE ORIFICE shows on the screen. This means that the venting signal is 2. weak. Check the following: Does the tool vent the throttle after shutoff? Some older models did not vent until the throttle is released. Either modify the tool " ORIFICE" to vent or try a different. model. venting ( ). Is the tool a shutoff? If not, use Q39 software instead. Did you adjust the inlet air? regulator properly? (see point 1. above).. shutoff? Is the proper flow screw installed in the bottom of the RSM? The short screw applies to nonshutoff tools using Q39 code on the PSIQc Q39. software The medium. screw applies to most shutoff tools using Q42 code on the PSIQ. Use the long screw only for small (low air inlet air regulator consumption) screwdrivers.? RSM 3. Is the tool shutting off OK? Check the? tool for proper operation and reteach the PSET. PSIQc Q39 code nonshutoff. 4. The lights don t always come on. Check that the hose size and length is proper for the tool being used. If the air hose is too large of an AIR TANK, the venting PSIQ signal Q42 may code not be getting through by the shutoff time the operator. releases the throttle. (low airchange consumption) to a shorter or smaller screwdrivers air hose.. 5. The Q doesn t respond to the keypad. Check that the LOCKOUT feature is not enabled. Reenable if it is. If nothing (no key responds), 3. the ribbon? cable inside the unit is probably off. Open the case and reinstall properly. 6. When using PSIQc (Q39 code), the tool is sluggish. Check that the correct flow screw is installed and that the air supply is sufficient so that the pressure drop when the tool is running is not greater than 10 psi from the static pressure. If it is, either the air supply to the RSM 4. is tool low in. volume or the RSM is too small for the tool. Change to a 1/2 ported RSM if necessary. This may be required if the tool is larger than 3/8 square drive or draws more than. 20 CFM (25 liter/minute)., throttle venting signal. 7. When using PSIQ (Q42 code),. the tool is sluggish and/or can t pull full torque. Check the air pressure/supply. If the tool is 1/2 5. PSIQ. LOCKOUT.. (no key responds), ribbon cable.. 6. PSIQc (Q39 code). Flow screw pressure drop 10psi (static pressure). 10psi RSM RSM 3/8" square drive 20CFM (25liter/minute) 1/2" ported RSM. 7. PSIQ (Q42code),. 1/2". QOPMAN0305 9

10 Appendix A Stanley Pneumatic Tool Modifications for use with PSIQ Qualifiers CT Clutch Shut Off Remove: A8010 throttle pin Replace with: 20H throttle pin A40 TA & TP ShutOff Remove: A40 throttle valve Replace with: 20H throttle valve A30 TA ShutOff Remove: A30 throttle valve Replace with: 20H throttle valve 10 QOPMAN0306

11 Appendix B Operation Flowchart Initial Setup (PSIQc Cont.) This button is referred to as the ENTER button. Use this button to select an option and to move to the next screen. This button is referred to as the GO BACK button. At any screen you may use this to go to the last step. Q39.XX.XX.XX SETTING ZERO PLEASE WAIT... PARAMETER SET 1 NOT SETUP CLEAR COMPLETE Holding the ENTER & GO BACK buttons will Clear and Set Zero Press ENTER. SET TARGET TQ TQ : 18.0 Press UP / DWN arrows to set the TARGET TORQUE. This does NOT adjust tool to actual torque. Press ENTER. REHIT: Tool running on a fastener that has already been torqued snug. REHIT FASTENER RUN TOOL REHIT FASTENER RUN COMPLETE Engage the tool on a fastener that has already been torqued snug and run until RUN COMPLETE appears. SETTING ZERO PLEASE WAIT... REHIT FASTENER RUN TOOL REHIT FASTENER RUN COMPLETE SETTING ZERO PLEASE WAIT... LEARN JOINT RUN TOOL Run Tool until the socket stops moving. LEARN JOINT COMPLETE CONTINUED ON NEXT PAGE QOPMAN

12 I Appendix B Operation Flowchart Initial Setup (PSIQc Cont.) RUN FREESPEED RUN TOOL RUN FREESPEED COMPLETE SET BATCH COUNT COUNT : 3 SET BATCH TIMER TIME : 10 SHUTOFF VALVE? UP/YES DWN/NO For solenoid valve use, choose YES. You can change the cycle delay in the ADMIN menu, the default is 100. TQ : 18.0 PS : 1 CT : 03 TIMER : QOPMAN0306

05 SET BATCH COUNT COUNT : 2 CONTINUED BELOW ADMIN MENU CYCLE TIME ADMIN MENU CYCLE DELAY ADMIN MENU REHIT (ON) CYCLE TIME

13 Appendix B Operation Flowchart Admin Menu (PSIQc Cont.) ADMIN MENU I/O (MOMENTARY) ADMIN MENU BATCH TIMER ADMIN MENU BATCH COUNT ADMIN MENU I/O (LATCHED) SET BATCH TIMER TIME : 05 SET BATCH COUNT COUNT : 2 CONTINUED BELOW ADMIN MENU CYCLE TIME ADMIN MENU CYCLE DELAY ADMIN MENU REHIT (ON) CYCLE TIME TIME: 000 CYCLE DELAY DELAY: 100 ADMIN MENU REHIT (OFF) CONTINUED BELOW ADMIN MENU PGRM LOCKOUT ON ADMIN MENU PSET LOCKOUT ON ADMIN MENU PGRM LOCKOUT OFF ADMIN MENU PSET LOCKOUT OFF QOPMAN

Appendix C Operation Flowchart Initial Setup (PSIQ Cont.) This button is referred to as the ENTER button. Use this button to select an option and to move to the next screen.

14 Appendix C Operation Flowchart Initial Setup (PSIQ Cont.) This button is referred to as the ENTER button. Use this button to select an option and to move to the next screen. This button is referred to as the GO BACK button. At any screen you may use this to go to the last step. Q42.XX.XX.XX SETTING ZERO PLEASE WAIT PARAMETER SET 1 NOT SETUP Holding the ENTER & GO BACK buttons will Clear and Set Zero Press ENTER. CLEAR COMPLETE The PSET # will define the specific part that you are error proofing. The PSET will be kept in memory. SELECT PARAMETER PSET # : 1 Press UP / DWN arrows to select parameter set 1 or 2. Press ENTER. SELECT TARGET TQ TQ: 10.0 GROSS ADJUST SIGNAL The screw in the middle of the RSM is for adjusting the overall signal. The default setting for this is ME DIUM. If you require to adjust the signal for a particular tool, please use one of the other two screws that are located on the back of the RSM. Longer the screw = higher the signal ADJUST TOOL TO TARGET : 10.0 RUN FASTENER PLEASE RUN TOOL RUN FASTENER INCYCLE At this time, adjust tool to the actual torque by using a transducer and/or torque meter. Press ENTER after the tool has been adjusted. Use tool to run down actual fastener and hold trigger until RUN COMPLETE appears. RUN COMPLETE KEEP? UP/Y DWN/N CONTINUED ON NEXT PAGE If the rundown was unacceptable, press DOWN and perform a new rundown. 14 QOPMAN0306

15 Appendix C Operation Flowchart Initial Setup (PSIQ Cont.) RUN 5 FASTENERS PLEASE RUN TOOL RUN FASTENER INCYCLE Use tool to run down actual fastener until RUN COMPLETE appears. Repeat 5 times. RUN COMPLETE KEEP? UP/Y DWN/N SET BATCH COUNT COUNT : 01 Press UP / DWN arrows for the Number of Fasteners ( 0199). Press ENTER. If you do NOT have cycle time requirements or don t require this feature, enter 0. SET BATCH TIMER TIME : 000 The optional BATCH TIMER screen appears ONLY if you have set the batch count greater than 1. Press UP / DWN arrows for time allowed. Press Enter. TQ : 010 PS 1 CT : 01 TIMER : 000 This is the RUN MODE / START screen. You are now ready for Error Proofing. QOPMAN

16 Appendix C Operation Flowchart Admin Menu (PSIQ Cont.) ADMIN MENU ADMIN MENU BATCH TIMER ADMIN MENU BATCH COUNT ADMIN MENU OUTPUTS (MOMENT) SET BATCH TIMER TIME : 05 SET BATCH COUNT COUNT : 2 CONTINUED BELOW ADMIN MENU FLOW LO LIMIT ADMIN MENU FLOW HI LIMIT ADMIN MENU REHIT FLOW LO LIMIT 1182 NEW : FLOW HI LIMIT 1182 NEW : 4680 ADJUST REHIT 55 NEW : 39 CONTINUED BELOW ADMIN MENU PGM LOCKOUT OFF ADMIN MENU PGM LOCKOUT ON 16 QOPMAN0306

(Table of Contents) 2 (Specifications) 3 ~ 10 (Introduction) 11 (Storage Bins) 11 (Legs) 11 (Important Operating Requirements) 11 (Location Selection)

SERVICE MANUAL (Table of Contents) 2 (Specifications) 3 ~ 10 (Introduction) 11 (Storage Bins) 11 (Legs) 11 (Important Operating Requirements) 11 (Location Selection) 12 (Storage Bins) 12 (Ice Machine)