PSI_Qualifier_Installation & Instruction_Manual.pdf

8/14/2019 PSI_Qualifier_Installation & Instruction_Manual.pdf

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INSTALLATION AND USE INSTRUCTIONS

Q System QUALIFIERS: PSI-Q & PSI-Qc

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.

Stanley Assembly TechnologiesApplications & Productivity Center, 5800 Enterprise Court,

Warren, MI 48092-3476 Tel 586-393-1100 Fax 586-393-1200Toll Free in the US 1-877-787-7830 www.stanleyworks.com

Q-OPMAN-0306 THE STANLEY WORKS, ALL RIGHTS RESERVED


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Installation and Use

Table of Contents

Safety.............................................................................................................................. 3

Symbols and Terms

WarningsQualified Personnel

Specifications................................................................................................................ 4

Operation ........................................................................................................................ 5

Installation and Ai r Supply........................................................................................... 6

Tool Compatibility......................................................................................................... 7

Inputs / Outputs (I/O)..................................................................................................... 8

Troubleshooting............................................................................................................ 9

Appendix A: Stanley Pneumat ic Tool Modificat ions for PSI-Q Qualif iers .......... 10

Appendix B: Operation Flow Chart PSI-Qc Qual if iers.......................................... 11

Initial Set Up (PSI-Qc) ...........................................................................................11

Admin Menu (PSI-Qc) ...........................................................................................13

Appendix C: Operation Flow Chart PSI-Q Qualif iers............................................ 14

Initial Set Up (PSI-Q) ............................................................................................. 14

Admin Menu (PSI-Q) .............................................................................................16


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Danger -Indicates that death or severe personal injury willresult if proper precautions are not taken.Warning -Indicates that death or severe personal injury mayresult 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.

-Read and understand all the safety recommendations and all operating instructions before operating tools and qualifiers.

Qualified Personnel

Safe UseThis manual is intended to promote proper and safe use and give guidance to owners, employers, supervisors and others respon-

sible for training and safe use by operators. Qualifiers from Stanley Assembly Technologies are intended for use in industrialthreaded fastening or precision position and or adjustment applications only. Some instructions may not apply to all applications.Please contact your Stanley Sales Engineer for information or assistance on Stanley training for assembly Qualifier operation.

W A R N I N G

To Avoid Injury:- Read and understand all the safety recommendations and all operating instructions before operating tools and qualifiers.- 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 A ssembly Technologies.

W A R N I N G

To Avoid Injury:- 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 InstallationOperations, and Maintenance manual.

- This product must be transported, stored, and installed as intended, and maintained and operated with care to ensure that the productfunctions correctly and safely.

- Persons responsible for system planning and design must be familiar with the safety concepts of automation equipment.

SafetyThe safety notices and warnings for protection against loss of life (the users or service personnel) or for the protection against damage to propertyare 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:


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Operation

The PSI-Qc qualifies rundowns for non shut-off pulse tools or impact wrenches. The PSI-Qc can operate either with a signal 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.

The PSI-Q performs POKE YOKE error proofing with air shut-off tools. Torque accuracy depends on the capability of the powertool selected for the application.

The Q System is a process & monitoring system and does not provide torque control.

Torque accuracy with shut-off tools is usually good within 20%. This is controlled by the tools internal mechanism. When usingstall (non shut-off) pulse tools, accuracy of 10% is easily achieved when adjusted and set-up properly and used with a signal light.

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.

The diagram above shows a typical fastening cycle for a pulse or impact tool. The air consumption of a pulse tool air motor during arun cycle is relative to the work being performed, as well as to the speed of the tool. In Zone 1, the tool is starting and the level of

flow will indicate if the fastener is cross-threaded or free spinning. Zone 2 is free speed and is the zone showing the free run-down

of the bolt. Zone 3 begins when the fastener has seated and reached snug torque and ends with Zone 4, the final pulse tighteningphase. Near the end of zone 4, equilibrium has been attained and the tool can be shut-off with excellent torque accuracy.

Time

1 2 3 4

Flow

Time

Flow


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Power Source 100-240 VAC 50-60 Hz

Power Consumption < 1 amp @ 115 VAC

Operating ConditionsTemperature

Humidity

0 to +50 C (32 to 122 F)

0 to 95 % non-condensing

Weight 1 kg (2 lbs.) Approximately

Dimensions 15cm (6) wide x 21cm (8.25) high x 4cm (1.5) deep

Inputs/OutputsOpto-isolated and relay dry contacts; up to 24 VDC/

5 amps with screw lug terminals

Error Proofing

OK/NOK for acceptable cycles vs REHIT/CROSSTHREAD, STRIP/SLIP OFF, CYCLE ABORT &

BATCH COUNT STATUS

Optional Serial PortRS 232 port; standard RJ45 connector

(Pset#/TgTq/COUNT/OK-NOK)

Interface

Two Line 11mm (0.44) LCD backlit, (16) Characters

per line

Five-button keypad

(Up, Down, Menu, Reset/Reverse & Admin)

Specifications


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W A R N I N G

To Avoid Injury:- Always wear eye protection when installing equipment.

- Only use equipment 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 all operators in the safe and proper use of power tools.- Operators should report any unsafe condition.- Install tools in dry, indoor, non-flammable, and non-explosive environments only.

W A R N I N G

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 until all air line connections are secured.- Supply air energizes the outlet port when electrical power is supplied to the PSI Qualifier.

Installation and Air Supply

Optional Hose Light Assemblies21C200605 8' Hose/light assembly - straight 1/4"21C200604 16' Hose/light assembly - straight 1/4"21C200603 25' Hose/light assembly - straight 1/4"

24C200000 8' Hose/light assembly - straight 3/8"24C200001 16' Hose/light assembly - straight 3/8"21C200602 25' Hose/light assembly - straight 3/8"

1. Provide clean dry air @ 90 PSI. Filter and lubricator

(recommended) to be installed at this point (3/8 NPT).Adjust pressure regulator to 5-10 PSI lower than theMAX air available.

2. Air hose connects to supply.

3. Use a 3/8 ID hose with full flow fittings with most pulsetools. Use 1/4 hose and fittings with small pulse tools

and screwdrivers. MAX hose from RSM to the tool is 30.

4. 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 asshown, with RJ45 connectors. Standard cable is 15.

Optional cables to 200 available.

7. Mount the Q to the wall or to the optional bench mountbracket.

RSM (Remote Sensor Module)

90 PSI

12

3

4

5


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Tool Compatibi lity

The Q is suitable for use with a wide variety of pneumatic power tools:

Pulse toolsshut-off (PSI-Q) andnon shut-off (PSI-Qc)

Impact wrenches: 3/8 and 1/2 drive (PSI-Qc)

Nutrunnerstorque controlled shut-off (PSI-Q)

Screwdriverstorque controlled shut-off (PSI-Q)

All torque controlled shut-off tools use a venting throttle design to provide for throttle valve reset. When using these tools, the Q learns theflow signal that includes the venting signal from this throttle reset vent. Once the tool shuts off, the signal is seen and the Q responds. SeeAppendix A for components to make Stanley pneumatic tools compatible.


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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 andrated 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 onthe front label as shown below.

An input signal is defined as a 24VDC signal that is applied between pin-1, (common) and the desired input. Either polarity will be accepted.Closing the connection between pins 7 and 8 enables the Q. A limit switch, relay or any contact closure that is isolated can accomplish this. Aninternal Enable jumper is also supplied. This factory installed jumper must be removed if external control is desired. Do not apply any other volt-

age to these two pins. The outputs for Cycle and Batch are plainly marked.

Input/Output (I/O)

P-SET 1 P-SET 2 NOT

USED

CLICK

WRENCH

BATCH

CLEAR

ENABLE

1 2 3 4 5 6 7 8

Terminals labeled 18 are for use as follows:


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Set-up and installation of the Q is simple and easy. Just follow the display prompts. Remember to let go of the throttle when the display reads,

COMPLETE after any step in the set-up. However, if the unit does not set-up, doesnt recognize the tool or the tool being in cycle, check thefollowing:

1. Did the supply air pressure drop below the initial setting? Remember, set the regulator at least 5 psi below the available supply maxi-mum. If supply drops, re-teach the PSET at the new pressure.

2. After repeated attempts as prompted on the display, CHANGE ORIFICE shows on the screen. This means that the venting signal isweak. Check the following:

Does the tool vent the throttle after shut-off? Some older models did not vent until the throttle is released. Either modify the tool

to vent or try a different model.

Is the tool a shut-off? If not, use Q39 software instead.

Did you adjust the inlet air regulator properly? (see point 1. above)

Is the proper flow screw installed in the bottom of the RSM? The short screw applies to non-shutoff tools using Q39 code on the

PSI-Qc . The medium screw applies to most shutoff tools using Q42 code on the PSI-Q. Use the long screw only for small (low airconsumption) screwdrivers.

3. Is the tool shutting off OK? Check the tool for proper operation and re-teach the PSET.

4. The lights dont 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 anAIR TANK, the venting signal may not be getting through by the time the operator releases the throttle. Change to a shorter or smallerair hose.

5. The Q doesnt respond to the keypad. Check that the LOCKOUT feature is not enabled. Re-enable if it is. If nothing (no key re-sponds), the ribbon cable inside the unit is probably off. Open the case and reinstall properly.

6. When using PSI-Qc (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 RSMis 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 islarger than 3/8 square drive or draws more than 20 CFM (25 liter/minute).

7. When using PSI-Q (Q42 code), the tool is sluggish and/or cant pull full torque. Check the air pressure/supply. If the tool is 1/2

Troubleshooting


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Appendix A

Stanley Pneumatic Tool Modifications for use with PSI-Q Qualifiers

CT Clutch Shut Off

A40 TA & TP Shut-Off

A30 TA Shut -Off

Remove: A8010 throttle pin

Replace with: 20H207500 throttle pin

Remove: A40 throttle valveReplace with: 20H207300 throttle valve

Remove: A30 throttle valveReplace with: 20H207400 throttle valve


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CONTINUED ON NEXT PAGE

Appendix BOperation Flowchart Initial Setup (PSI-Qc Cont.)

Q39.XX.XX.XX

PARAMETER SET 1NOT SETUP

SETTING ZERO PLEASE WAIT . . .

CLEAR COMPLETE

Holding the ENTER &

GO BACK buttons will

Clear and Set Zero

This button is referred to as the

GO BACK button. At any screenyou may use this to go to the last

step.


ENTER button. Use this buttonto select an option and to move

to the next screen.

Press ENTER.

- REHIT FASTENER -RUN TOOL

SET TARGET TQTQ : 18.0

Press UP / DWN arrows to set the

TARGET TORQUE. This doesNOT adjust tool to actual torque.

Press ENTER.

- REHIT FASTENER -RUN COMPLETE

Engage the tool on a fastener that has

already been torqued snug and rununtil RUN COMPLETE appears.

REHIT: Tool running on a fastener

that has already been torqued snug.

- SETTING ZERO -PLEASE WAIT . . .

- REHIT FASTENER -RUN TOOL

- REHIT FASTENER -RUN COMPLETE

- SETTING ZERO -PLEASE WAIT . . .

LEARN JOINTRUN TOOL

LEARN JOINTCOMPLETE

Run Tool until the socket

stops moving.


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Appendix BOperation Flowchart Initial Setup (PSI-Qc Cont.)

- RUN FREESPEED -RUN TOOL

- RUN FREESPEED -COMPLETE

SET BATCH COUNTCOUNT : 3

SET BATCH TIMERTIME : 10

TQ : 18.0 PS : 1CT : 03 TIMER : 010

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.


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--- ADMIN MENU ---BATCH COUNT

--- ADMIN MENU ---BATCH TIMER

Appendix BOperation Flowchart Admin Menu (PSI-Qc Cont.)

--- ADMIN MENU ---I/O (MOMENTARY)


- ADMIN MENU -I/O (LATCHED)

- ADMIN MENU -REHIT (OFF)

--- ADMIN MENU ---REHIT (ON)

--- ADMIN MENU ---CYCLE DELAY

--- ADMIN MENU ---CYCLE TIME

CYCLE DELAYDELAY: 100

CYCLE TIMETIME: 000

--- ADMIN MENU ---PGRM LOCKOUT ON

--- ADMIN MENU ---PGRM LOCKOUT OFF

--- ADMIN MENU ---PSET LOCKOUT ON

- ADMIN MENU -PSET LOCKOUT OFF

CONTINUED BELOW

CONTINUED BELOW


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CONTINUED ON NEXT PAGE

Appendix COperation Flowchart Initial Setup (PSI-Q Cont.)

Q42.XX.XX.XX

PARAMETER SET 1NOT SETUP

SETTING ZERO PLEASE WAIT

Press UP / DWN arrows to

select parameter set 1 or 2.

Press ENTER.

CLEAR COMPLETE

Holding the ENTER &

GO BACK buttons will

Clear and Set Zero

SELECT PARAMETERPSET # : 1

ADJUST TOOL TOTARGET : 10.0


GO BACK button. At any screen

you may use this to go to the last

step.


ENTER button. Use this button

to select an option and to move

to the next screen.

Press ENTER.

At this time, adjust tool to the

actual torque by using a trans-

ducer and/or torque meter.Press ENTER after the tool

has been adjusted.

The PSET # will define the specific

part that you are error proofing. The

PSET will be kept in memory.

SELECT TARGET TQTQ: 10.0

- RUN FASTENER -PLEASE RUN TOOL

- RUN FASTENER -INCYCLE

Use tool to run down actual fastener and

hold trigger until RUN COMPLETE

appears.

- RUN COMPLETE -KEEP? UP/Y DWN/N

If the rundown was unacceptable,

press DOWN and perform a newrundown.

GROSS ADJUST SIGNAL - The screw

in the middle of the RSM is for adjust-

ing 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 arelocated on the back of the RSM.

Longer the screw = higher the signal


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Appendix COperation Flowchart Initial Setup (PSI-Q Cont.)

TQ : 010 PS 1CT : 01 TIMER : 000

This is the RUN MODE / START

screen. You are now ready for Error

Proofing.

RUN 5 FASTENERSPLEASE RUN TOOL

Use tool to run down actual fastener

until RUN COMPLETE appears.

Repeat 5 times.



The optional BATCH TIMER screen appears

ONLY if you have set the batch count greaterthan 1.

Press UP / DWN arrows for time allowed.

Press Enter.

Press UP / DWN arrows for the

Number of Fasteners ( 01-99).

Press ENTER.

If you do NOT have cycle time

requirements or dont require this

feature, enter 0.

- RUN FASTENER -INCYCLE

- RUN COMPLETE -KEEP? UP/Y DWN/N


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CONTINUED BELOW

CONTINUED BELOW

- FLOW LO LIMIT -1182 NEW : 22036

--- ADMIN MENU ---

- ADMIN MENU -OUTPUTS (MOMENT)

--- ADMIN MENU ---FLOW LO LIMIT

--- ADMIN MENU ---PGM LOCKOUT OFF

Appendix COperation Flowchart Admin Menu (PSI-Q Cont.)


--- ADMIN MENU ---BATCH COUNT

--- ADMIN MENU ---BATCH TIMER


ADJUST REHIT 55 NEW : 39

--- ADMIN MENU ---REHIT

--- ADMIN MENU ---FLOW HI LIMIT

- FLOW HI LIMIT -1182 NEW : 4680

--- ADMIN MENU ---PGM LOCKOUT ON

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PSI_Qualifier_Installation & Instruction_Manual.pdf