PSI Qualifier User Manual - Stanley Engineered Fastening
Contents
1. 2 24R500011 Pan Head Screw 24 1 24X500140_ I O Connector STD 10 24X500041 Cover RSM 25 1 24X500134 I O Connector AUX ll 2 24R500215 Flat Head Screw 26 1 24X500139 Valve Solenoid 12 24R500214 Flat Head Screw 27 1 24X500138 Muffler 13 24R500213 Flat Head Screw 28 1 24B500285_ Board Valve Interface RSM 22 PSI Qualifier 2 7 2 Qualifier Hi Flow Assembly PSI Q and PSI Qc High Flow Assembly OE SR 4A500421 VA NAL KIT HI FLOW RJ 45 Communications Port 2 4A300421 VALVE SIGNAL KIT TURN THE Q HI FLOW INTO THE QC HI FLOW CONTROLLER FOR NON SHUT OFF PULSE TOOLS mii a a ai m a gg 24E500038 Enclosure Keypad Interface 24R500207 O Ring 2 24B500077_ Main Board 16 1 24X500448 Regulator 2 3 24X500040 Rear Cover 18 2 24P500002 Hex Nipple 1 2 4 24B500032_ PFCS Network Card Optional 19 2 24X500420 2 to 3 8 NPT Reducer 5 4 24R500215 Flat Head Screw 20 1 24R501391 Label Sticker RSM Flow 6 24X500519 Overlay 21 1 24X500092 Power Supply 7 24E500515_ Enclosure RSM High Flow 22 1 24C503808 Network Cable Yellow 8 24B500136 Board Assembly RSM Flow Sensor 23 1 24C501208 Network Cable Black 9 2 24R500011 Pan Head Screw 24 1 24X500140 I O Connector STD 10 24X500041 Cover RSM 25 1 24X500134 I O Connector AUX II 2 24R500215 Flat Head Scr2. Italy Tel 39 039 238 9950 Fax 39 039 238 9970 SATinfo stanleyworks com STANLEY ASSEMBLY TECHNOLOGIES Gowerton Road Brackmills Industrial Estate Northampton NN4 7BW UK Tel 44 1604 827003 Fax 44 1604 661654 SATinfo stanleyworks com STANLEY ASSEMBLY TECHNOLOGIES Rm 202 Building 12 No 899 Zuchongzhi Road Zhangjiang High Tech Park Shanghai China Tel 86 21 6162 1858 ext 2151 Fax 86 21 5080 5101 Mobile 86 137 0174 6593 mting stanleyworks com STANLEY ASSEMBLY TECHNOLOGIES Stanley Works India Pvt Ltd A B House 4 24A Asaf Ali road New Delhi 110002 India Tel 91 11 4356 9000 ext 102 Fax 91 11 4356 9069 sagarwal stanleyworks com www stanleyAssembly com Contacts 25
3. LEARN JOINT RUN TOOL on a new production part Run the tool until the socket stops turning If the job is a soft joint or a long rundown let go of the throttle just before the socket stops turning This sets the pulse time of the process Check the torque If the rundown was not acceptable or normal then press the RETURN key and LEARN JOINT again If reversing the tool and running return to REHIT FASTENER step four 7 RUN FREESPEED RUN TOOL in free air remove any attached socket or transducer Watch the screen Run the tool until the screen reads RUN COMPLETE 8 SET BATCH COUNT Scroll UP to select the number of fasteners to be counted per assembly 9 SET BATCH TIMER If BATCH COUNT is greater than one then select a TIME seconds to give the operator to complete all of the fasteners in the assembly If all fasteners are not finished as OK within this allotted time the batch is rejected as NOT OK and the BATCH COUNT is reset to zero for the next part The timer starts after the first fastener in the part is completed as OK Select 0 to turn off this feature Scroll UP to set Press ENTER to select 10 SHUT OFF VALVE Tool can be shut off with the PSI Qc system valve upon completion of each cycle or choose to signal the operator with the CYCLE OK output or green light that the cycle finished so operator should release the trigger Press UP for YES or DOWN for NO The set up is now complete Test error proofing and torque Please procee
4. OK Cycle NOK BatchOK Batch NOK Return Getting Started 5 User Manual Diagram 3 1 8 RJ 45 Communications Port When using this port you will need a RJ 45 to DB 9 convertor It is an option that can be ordered from Stanley or a customer supplied device that will need to be wired as shown in the following table Internal Wiring for RJ45 to DB9F Adapters RJ45 Pin DB9 Pin Data Collection RJ45 Serial Adapter to DB9F gt gt Part 24K500496 3 3 Network Serial Protocol PFCS RJ45 5 5 Adaptor to DROE 6 2 Part 24K500497 3 3 Table 3 1 8 1 Networking The Q Systems can communicate to a Serial network via the PFCS Serial protocol or using a standard protocol These are options added and configured when the system is ordered The PFCS protocol setup is automatic When the Q System is turned on it sends data to the PFCS network server which then replies with the specific setup information The Q System will then configure itself using the received information The information sent is OK after each OK fastening cycle Data for NOK fastening cycles will not be sent The standard protocol will send OK out the serial port after each OK rundown To communicate with the Q System using this protocol setup the receiver for a baud rate of 9600 8 data bits no parity and 1 stop bit The exact string is OKCR where CR is Carriage Return o gt PSI Qualifier Installati
5. Q systems take a series of mass air flow measurements and turn the data into a fastening cycle signature to detect OK vs NOK fastening cycles Diagram below shows a typical fastening cycle for a pulse impact or geared tool The air consumption of a tool air motor during a fastening cycle is relative to the work being performed and tool speed Zone 1 Tool starts The level of flow indicates if the fastener is cross threaded or free spinning Zone 2 Shows free speed and shows the free run down of the bolt Zone 3 Begins when the fastener has seated and reached Snug Torque Zone 4 Final shut off phase Equilibrium has been achieved and the tool can be shut off and is vented throttle reset When Q system senses this it begins the pulse time counting When the programmed time is achieved the cycle completes and the fastener is documented as OK If any Zone is not sensed by the Q system then the fastening cycle is NOT OK PSI Qualifier Diagram 1 Q System Flow Signature 1 5 Electrical Safety Operator safety is of maximum importance from the perspective of both ergonomic comfort as well as electrical safety This is why the Q Systems power supplies are CE approved and UL listed It consists of a wall mount VAC transformer with a 16VAC 50 Hz 1 Amp power output The specific power supply is ordered for the region in which the Q System is to be used See Table 1 below fo
6. Sensor Module d S RSM Provides venturi for air flow detection Solenoid Valve PSI Qc only OUTPUTS INPUTS Fast acting 1 2 valve connects to RSM Lite Hose Connector RJ 45 Communications Port Power Connector Two Line Display CYCLE OK NOK Lights ENTER key ADMIN key UP DOWN keys BATCH OK NOK Lights Green OK Red NOK RETURN key Table 2 PSI Q Qc Hardware Specifications 1 7 Inputs Outputs PSI Qualifier 1 7 1 Inputs e Externally powered inputs PSET 1 PSET 2 and BATCH CLEAR e Power requirement 12VDC 2 5MA to 24VDC 5 0MA e An input is activated when a 12 to 24VDC signal that is applied between pin 1 common and the desired externally powered input Either polarity will be accepted e Self powered inputs DISABLE and ACCEPT CLICK e Closing the connection between pins 7 and 8 disables the Q System A limit switch relay or any contact closure that is isolated can accomplish this e The ACCEPT input is used to advance the fastener counter by one count every time pins 5 and 8 are momentarily tied together by isolated contacts This is useful after a repair or during Q System verifications using a click wrench with integral switch e Do not apply any external voltages to pins 5 7 or 8 e Terminals labeled 1 8 are for use as follows 1 2 3 4 5 6 7 8 ACCEPT DISABLE CLICK Y O Diagram 2 1 7 2 Outputs 1 2 3 4 5 6 G oO O Return Cycle
7. a time seconds to allow the operator to comfortably complete all of the fasteners in the part or assembly The total number of fasteners is the BATCH e Choose 0 to turn this feature off Press ENTER to set e Ifthe operator does not finish the assembly within this set time the Q rejects the BATCH or part fires the BATCH NOK output and BATCH NOK light and resets the BATCH timer and BATCH count to zero for the next part PSI_Q ADJUST GAIN Press ENTER This allows for the increase in the error proofing sensitivity This helps if the setup procedure for REHIT is difficult Increase the number shown by one or two only if necessary PSLQ PSI Qc OIL CHANGE CT allows a maintenance schedule to be entered based on cycle counting e Press DOWN to SET Scroll UP to choose the total number of cycles before MAINTENANCE DUE PSI Q PSI Qc TARGET TORQUE is a value set to remind the operator of the torque level to which the tool is set Scroll UP or DOWN to change the TARGET TQ if the job specification changes PSI Qc CYCLE TIME displays the CYCLE TIME learned in the pulse phase of the tightening cycle from the LEARN JOINT portion of the Set Up Menu The units displayed are Q time not any standard units Press ENTER to view Scroll UP or DOWN to change set the pulse time Press ENTER to accept PSI Qc CYCLE DELAY allows the adjustment of the time between cycles when the air is OFF If the Q39 is programmed to
8. above e If feasible lower the pulse unit torque manually until the torque achieved is no longer acceptable and note the FLOW number Set a MAINT number that is 5 10 below the noted FLOW numbers during this testing e Press ENTER to set chosen number If the pulsing flow reaches over the set MAINT number MAINT ALARM appears in place of the normal run screen but only after the ALARM TRIP is reached e To clear alarm enter the ADMIN MENU and CLEAR MAINT appears Press ENTER to clear Press the RETURN key to exit PSI Qc PRESSURE ALARM monitors the PRESSURE during the pulse phase and will ALARM if this PRESSURE drops below a programmed PRESSURE number The units are Q units not any standard units This feature is OFF by default PRESSURE 0 This feature must be set up by running good cycles while viewing this screen e Press ENTER to view Run a few good cycles and note the FLOW number e Scroll UP to change the PRESSURE number to 20 60 counts below the lowest FLOW number noted above e If feasible lower the pressure manually until the torque achieved is no longer acceptable and note the FLOW number Set a PRESSURE number that is 5 10 above the noted FLOW numbers during this testing e Press ENTER to set chosen number If the pulsing pressure falls below the set PRESSURE number LOW PSI ALARM appears in place of the normal run screen but only after the ALARM TRIP is reached e To clear alarm enter the ADMIN MENU and
9. not let go of the throttle until the display reads RUN COMPLETE KEEP This is critical in this step and all steps If the rundown was acceptable or normal then press the UP key to accept or KEEP REPEAT this step as shown on the display with new fasteners if possible until the next step appears If you slip abort the cycle or reverse a fastener make sure to press the DOWN key to discard the rundown 14 PSI Qualifier 5 If CHANGE ORIFICE appears change the FLOW SCREW see section 2 4 3 6 RUN 3 FASTENERS RUN TOOL on an actual production part Hold the throttle and do not let go until the display reads RUN COMPLETE KEEP If the rundown was acceptable or normal then press the UP key to accept or KEEP REPEAT this step as shown on the display REPEAT with new fasteners if possible until the next step appears If you must reverse press the DOWN key to discard the rundown 7 RUN FREESPEED RUN TOOL in free air remove any attached socket or transducer The screen will read IN CYCLE while running Let go at this point and the screen will read RUN COMPLETE KEEP Press the UP key to accept or KEEP Repeat this step until next step appears 8 SET BATCH COUNT Scroll UP to select the number of fasteners to be counted per assembly One is the minimum 9 SET BATCH TIMER If BATCH COUNT is greater than one then select a TIME seconds to give the operator to complete the assembly If all fasteners are not finished as OK within the allott
10. 2 9 Service and Maintenance un 24 PSI Qualifier Getting Started 1 1 Warnings and Cautions The safety notices and warnings for protection against loss of life the users or service personnel or for the protection against damage to property are highlighted in this document by the terms and pictograms defined here The terms used in this document and marked on the equipment itself have the following significance Indicates that death or severe Indicates a general hazard This Danger personal injury will result if icon appears as a part of a proper precautions are not taken Danger Warning or Caution notice Indicates that death or severe Indicates that eye protection Warning personal injury may result if CS should be worn This icon proper precautions are not taken E appears as a part of a Danger Warning or Caution notice Indicates that property damage Read and understand all the Caution May result if proper precautions safety recommendations and all are not taken operating instructions before operating tools and controllers Indicates an electrical hazard This icon appears as a part of a Danger Warning or Caution notice 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 Ope
11. CLEAR LOW PSI appears Press ENTER to clear Press the RETURN key to exit PSI Qc ALARM TRIP sets the number of cycles before the PRESSURE out of specific ALARM TRIPS e Press ENTER to view Scroll UP or DOWN to change Press ENTER to accept The error proofing set up is now complete 2 6 Operation Flowchart Admin Menu This is an example of how to navigate the Admin menu it does not go into all sections of the Admin menu Installation and Use 19 PSI Qualifier a Loes Ces Ces CES Ces Ces Continued Installation and Use 21 User Manual 2 7 Drawing BOM 2 7 1 Qualifier Assembly PSI Q and PSI Qc Assembly 6 kd 24A500190 VALVE SIGNAL KIT TURNS THE Q INTO THE QC CONTROLLER FOR NON SHUT OFF PULSE TOOLS mii aa a W er 24E500038 Enclosure Keypad Interface 24R500212 Flat Head Screw 2 24B500077_ Main Board 15 3 24R500207 O Ring 3 24X500040_ Rear Cover 16 1 24X500047 Regulator 4 24B500032_ PFCS Network Card Optional 18 1 24P500002 Hex Nipple 3 8 NPT 5 4 24R500215__ Flat Head Screw 20 1 24R501391 Label Sticker RSM Flow 6 24X500519 Overlay 21 1 24X500092 Power Supply 7 24500083 Enclosure RSM 22 1 24C503808 Network Cable Yellow 8 24B500136_ Board Assembly RSM Flow Sensor 23 1 24C501208 Network Cable Black 9
12. GALA Assembly Technologies PSI Qualifier User Manual Installation and Programming 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 www StanleyAssembly com 2009 December THE STANLEY WORKS ALL RIGHTS RESERVED User Manual Contents SEENEN 1 1 1 Warnings and Cautions 0 0 0 0 ccc cccececeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeneees 1 1 2 Qualified Personnel EE 1 Aos oale EE 2 E Wee e de 2 E E 3 1 6 SPSCWICANOMS EE 3 17 e elt abner eine i Rear 4 1 7 1 el 5 T72 e e EE 5 1 8 RJ 45 Communications Port eccessescecccceeeeeeeeeeeseeeees 6 1 8 1 NGEIWOIKING tee ee E EE 6 Installation and BEE 7 E ME Mee 31 N A E ewe ei ech ee ce eae cacene eee 7 2 2 Hardware Software Tool CGompatbultv 8 2 2 1 POG EE 9 22A Eet 9 2 3 Initial Setup Operation Flowchart 10 2 3 1 e EE 11 E Ol iene erea AE AA AE S 13 2 4 Initial Set Up Mem ee 14 2 4 1 PSO EE 14 NR e 15 2 4 3 Change alte 16 2 5 Administration Menu wrceceicareccty dancer stares ricernntatitecaticermecteints 16 2 6 Operation Flowchart Admin Men 19 2 7 Drawing EE sb Machetes egene et 22 2 7 1 Qualifier ASSO ly vise s ssc tect eccn cei Geheatan eet 22 2 7 2 Qualifier Hi Flow Aesembhy 23 2 8 Troubleshooting and Adjustment ccecceeeeseeeeeeeeees 23
13. and to the PSI Q interface as shown JED cable only required with optional Lite Hose assembly Standard cable lengths are 15feet Optional cable lengths are available Mount the PSI Q interface appropriately Installation and Use 7 User Manual Solenoid Valve for PSI Qc only Diagram 4 Optional JED Lite Hose Assemblies 24C500102 8 Hose light assembly straight 1 4 24C500105 16 Hose light assembly straight 1 4 24C500108 25 Hose light assembly straight 1 4 24C500202 8 Hose light assembly straight 3 8 24C500205 16 Hose light assembly straight 3 8 24C500208 25 Hose light assembly straight 3 8 Table 4 WARNING To Avoid Injury e Shutoff valve must be in the closed position until the air lines are installed and properly terminated e Do not connect power to the Q system until all air line connections are secured e _ Supply air energizes the outlet port when electrical power is supplied to the Q system 2 2 Hardware Software Tool Compatibility The Q System has the ability to error proof many types of tools due to its ability to monitor air flow signature Some tools need the shutoff solenoid of the PSI Qc while other tools have their own shutoff mechanism and can simply use the PSI Q Each tool described in the table below requires a unique software version in the specified hardware in order to run and be error proofed properly Be
14. d to ADMIN MENU to adjust setup Installation and Use 15 User Manual 2 4 3 Change Orifice Q NOTE g Disconnect the AIR SUPPLY before proceeding The FLOW SCREW is located on the bottom and in the middle of the Remote Sensor Module RSM see Picture 3 below There are two spare screws at the end of the RSM Each screw is a different length For a small tool replace the original medium length screw with the long screw For a large tool change to the shortest screw Make sure the o ring is with the screw and seals the air supply RESET or CLEAR the memory as stated above and begin the set up procedure from the beginning Picture 3 2 5 Administration Menu To enter the Administration Menu press the small square in the middle of the display lights on the Q System interface All ADMIN functions are listed below for both hardware versions of the Q System Check the Hardware column to determine if it is applicable to your Q ADMIN Function PSI_Q LAST FAIL displays the reason for the last rejected fastener This is for analysis PSI Q FLOW LOW LIMIT displays the LOW LIMIT number of the venting throttle signal that the PSI Q learned and programmed from the tool during the set up procedure This venting throttle signal is the air flow after the tool clutch has fired and the tool has shut off e Press ENTER to view The LOW LIMIT number is shown on the left and can be changed by scrolling UP or DOWN This is n
15. e and easy Just watch the screen and follow the display prompts First it is very important to set the Q System regulator 5 10 psi below the available maximum supply When beginning it is always a good idea to CLEAR the memory to factory settings Within one second after plugging in the power hold the ENTER and RETURN buttons down until CLEAR COMPLETE appears This clears and sets zero Please note the software version appears after CLEAR COMPLETE 2 4 1 PSI Q Make sure the software version shows Q42 1 PARAMETER 1 NOT SET UP There are two parameter sets available Both can be utilized if two separate part assemblies are running with a different number of fasteners to be counted Since the tool shut off mechanism controls the actual torque both parts must have the same torque requirement Scroll UP or DOWN to choose PARAMETER SETS Press ENTER to select and move on to next step 2 SELECT TARGET TQ Scroll UP until the TARGET or mean TORQUE for the application is reached This is a label for the application and does not represent any change to the tool s torque output Press ENTER to select and move on to the next step 3 ADJUST TOOL TO TARGET Run the tool and test the torque output as your facility requires using an acceptable torque monitoring device Adjust the clutch shut off mechanism in the tool until satisfied 4 RUN FASTENER RUN TOOL on an actual production part Hold the throttle while watching the PSI Q Do
16. ed time the batch is rejected as NOT OK and the BATCH COUNT is reset to zero for the next part The timer starts after the first fastener in the part is completed as OK Select 0 to turn off this feature Scroll UP to set Press ENTER to select The set up is now complete Please proceed to ADMIN MENU to complete error proofing setup 2 4 2 PSI Qc Make sure the software version shows Q39 1 Select Tool that can easily reach 10 20 over the High Limit of the application specification 2 Adjust Tool Run the tool and test the torque output using an acceptable torque monitoring device Adjust the pulse mechanism in the tool until its maximum output is set to reach the High Limit of the application 3 PARAMETER 1 NOT SET UP There are two parameter sets available Both can be utilized if two separate part assemblies are running with a different number of fasteners to be counted Since the air pressure is not regulated both parts must have close to the same torque requirement Scroll UP or DOWN to choose PARAMETER SET Press ENTER to select and move on to next step 4 REHIT FASTENER RUN TOOL on an actual a fastener that has already been torqued to specification Watch the screen and run the tool Do not let go of the throttle until the display reads CYCLE COMPLETE This is critical SETTING ZERO may appear on the display Repeat REHIT until the next step appears 5 If CHANGE ORIFICE appears change the FLOW SCREW see section 2 4 3 6
17. ew 26 1 24X500063_ Valve Solenoid L 12 24R500214 Flat Head Screw 27 1 24X500447 Muffler 12 13 24R500213 Flat Head Screw 28 1 24B500449 Board Valve Interface RSM 14 24R500212 Flat Head Screw 2 8 Troubleshooting and Adjustments Set up and installation of the Q System is simple and easy Just follow the display prompts Remember to hold the throttle until the display reads COMPLETE after any step in the set up Installation and Use User Manual However if the unit does not set up does not recognize the tool or the tool being in cycle check the following 1 Did the supply air pressure drop below the initial setting Remember to set the regulator at least 5 psi below the available supply maximum 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 is weak Check the following e 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 e Is the tool a shut off If not use Q39 software instead e Did you adjust the inlet air regulator properly see point 1 above e Is the proper flow screw installed in the bottom of the RSM The short screw applies to non shutoff tools using Q39 code The medium screw applies to most shutoff tools using Q42 c
18. ged for any reason the system may need to be set up from the beginning with the new tool to ensure proper function The Q System is designed to operate a tool with an 8 35 long 3 8 diameter air hose With a longer hose the system may require a longer dwell time between fasteners See CYCLE DELAY under section 2 5 2 9 Service and Maintenance The PSI Q and PSI Qc require no scheduled adjustments or maintenance Should service be required contact your local distributor or Stanley Assembly Technologies 24 PSI Qualifier 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 48083 USA Tel 1 248 824 1100 Fax 1 248 824 1110 Toll Free Service 877 787 7830 Toll Free Sales 877 709 8006 SATinfo stanleyworks com STANLEY ASSEMBLY TECHNOLOGIES Outils Portatifs et Systemes d Assemblage Zone Immoparc Route De Chartres B timent Loire 4 78190 Trappes Cedex France Tel 33 130 50 91 00 Fax 33 130 51 07 08 SATinfo stanleyworks com STANLEY DEUTSCHLAND GmbH Division Assembly Technologies Frankfurter Stra e 74 D 64521 Gro Gerau Germany Tel 49 6152 8052 0 Fax 49 6152 8052 22 SATGER stanleyworks com STANLEY ASSEMBLY TECHNOLOGIES Divisione SWK UTENSILERIE s r l Via Parco 47 20046 Biassono MI
19. information or assistance on Stanley training or Qualifier operations 1 4 Introduction The PSI Q performs Poka Yoke error proofing for shut off air tools Torque accuracy with shut off type tools is usually good within 15 20 depending on the consistency of the joint s This is controlled by the tool s internal shut off mechanism The PSI Qc performs Poka Yoke error proofing for non shutoff or stall type air tools or impact wrenches Torque accuracy with non shut off pulse tools is usually good within 5 15 depending on the consistency of the joint s and the dependability of the operator Better torque accuracy can be achieved if the tool is allowed to run until the socket or fastener has nearly stopped turning 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 All tools should be tested for torque accuracy periodically during the applications lifetime to determine whether maintenance is required and also to determine a maintenance schedule The PSI Q and PSI Qc share many of the same components The difference between the two is the software and the PSI Qc has the solenoid valve kit part 24A500190 Both of these systems will be referred to as the Q systems in this manual when the descriptions are equivalent They are a process monitoring system and do not provide torque control or values The
20. le time requirements or don t require this feature enter zero The optional BATCH TIMER screen appears only if fastener batch count is set to greater than one Press UP DWN arrows for time allowed Press Enter This is the RUN MODE START screen System is ready for Error Proofing LI 12 PSI Qualifier 2 3 2 PSI Qc 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 RETURN button At any screen use this to go to the last step REHIT Run tool on a fastener that has already been torqued to snug Press ENTER Installation and Use ieee oo eg Holding the ENTER and RETURN buttons at the same time Clears and Sets Zero Press ENTER Press UP DWN arrows to set the TARGET TORQUE This does NOT adjust tool This is a label Press ENTER Engage the tool on a fastener that has already been torqued to snug and run until CYCLE COMPLETE appears below Run Fastener and tool shuts off at default Cycle Time If Cycle Time is not acceptable adjust Cycle Time UP or DOWN Continued on Next Page 13 User Manual Time allowed to complete each part Set to 0 to turn off When valve is installed choose YES Change cycle delay in the ADMIN menu the default is 50 Run Screen A 2 4 Initial Set Up Menu Set up and installation of the Q System is simpl
21. next cycle e Press ENTER to choose LATCH or MOMENT Press the UP or DOWN arrow to move to the next option PSI Q PGM LOCKOUT OFF ON allows the LOCKOUT of the programming PSI Qc ENTER key e Press ENTER to set LOCKOUT ON or OFF Press UP or DOWN to move on e LOCKOUT ON locks the ENTER key when the Q is in the RUN screen PSI Q PSET LOCKOUT OFF ON allows the LOCKOUT of the parameter set PSI Qc change feature e Press ENTER to set the LOCKOUT ON or OFF Press UP or DOWN to move on e LOCKOUT ON locks the UP and DOWN parameter change keys when the Q is in the RUN screen PSI Q ADMIN LOCK OFF ON allows an entry code to be entered for access to PSI Qc the ADMIN MENU Installation and Use e Press ENTER Use the programming keys to enter a four place code This will be the ADMIN password e Press ENTER to set Scroll UP or DOWN to move Press ENTER 17 18 User Manual again for OFF e LOCKOUT ON locks the ADMIN MENU unless the code is keyed in then press ENTER PSI Q PSI Qc BATCH COUNT allows the setup of the fastener COUNT feature per part or assembly e Press ENTER to choose Scroll UP or DOWN to select the number of fasteners Press ENTER to set e Once all the fasteners are completed correctly the BATCH OK output and BATCH green light fires PSI Q PSI Qc BATCH TIMER allows the setup of a timer to help the operator finish each assembly within a reasonable time e Scroll UP or DOWN to set
22. non shut off tools can be utilized When using these tools the PSI Qc learns the flow signals from the tool system installation Once the tool runs the process for which it was set up the flow signals are seen and the PSI Qc responds Some tool models may require an adjustment to open a governor or speed control on the tool to allow greater air flow during free speed verses the air flow during pulsing In other words the PSI Qc must sense a drop in air flow during pulsing verses the air flow during free speed Installation and Use 9 User Manual Picture 2 Example of Compatible PSI Qc tools 2 3 Initial Setup Operation Flowchart Here are operational flow charts on how to perform an initial setup of the Q Systems Section 2 3 1 is for the PSI Q while section 2 3 2 is for the PSI Qc Choose the appropriate section for you hardware If you would like full descriptions of how to perform an initial setup of the Q Systems see section 2 4 1 for the PSI Q and section 2 4 2 for the PSI Qe 10 PSI Qualifier 231 PSI Q 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 RETURN button At any screen use this to go back to the last step GROSS SIGNAL ADJUST If rundown is not accepted change the RSM s middle screw to adjust the overall signal see section 2 4 3 Default setting is the MEDIUM length screw U
23. nt a pre assembled position While still viewing this screen run the fastener down with the tool Note the number on the left This is the rundown time Run a few more fasteners each time hand start them well past the point at which they would normally be started You may even hand start the fastener all of the way down but not tight Note the number each time the tool is run e Now put the tool on the fastener that is rundown tight and pull the throttle This represents a REHIT fastener time Note the number on the PSI Q as before Repeat this procedure a few times noting the REHIT time for each This number will be less than the previous OK rundowns from above e Use the UP key to scroll to adjust the REHIT or minimum rundown time number e This REHIT number minimum runtime should be between the OK rundown number and the REHIT rundown numbers A good rule for setting a starting point is to set the REHIT number to 10 counts above the highest number generated when running the REHIT fasteners e Rundown several more OK normal and REHIT fasteners Note the runtime number each time All normal OK rundowns should display a number greater than the number programmed All REHIT fasteners should display a number that is less than the number programmed e Press ENTER to set and UP or DOWN to move on PSI Q OUTPUTS LATCH MOMENT allow the outputs to time out or turn off PSI Qc after two seconds or stay latched until the
24. ode Use the long screw only for small low air consumption screwdrivers 3 Is the tool shutting off OK Check the tool for proper operation and re teach the PSET 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 it acts like an AIR TANK the venting signal may not be getting through by the time the operator releases the throttle Change to a shorter or smaller air hose 5 The system doesn t respond to the keypad Check that the LOCKOUT feature is not enabled Re enable if it is If nothing no key responds the ribbon cable inside the unit is probably off Open the case and reinstall properly 6 When using PSI Q Q42 code the tool is sluggish and or can t pull full torque Check the air pressure supply If the tool has an 1 2 square drive or larger change to an 1 2 RSM assembly Pay attention to the installation and to the air hose and fittings as described earlier 7 The system does not shut off Change the PASS SHUTOFF OFF to ON in the ADMIN MENU 8 The system does not shut off the tool fast enough Adjust the CYCLE TIME in the ADMIN MENU Make sure to check torque on the softest joint s of the application Also check to see that the socket has stopped turning when the PSI Qc shuts off the tool 9 The system stops functioning properly Any change to the hoses or connectors affects the system after set up If the tool is chan
25. on and Use WARNING To Avoid Injury e Always wear eye and foot protection when installing equipment Only use equipment and accessories specifically designed to operate with Stanley assembly tools Keep the work area clean well lit 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 2 1 Air Supply Connect the Remote Sensor Module RSM to the PSI Q Qc and the tool as shown in Diagram 4 1 Provide clean dry air with a minimum of 90 psi 6 bar and a maximum of 125 psi 8 6 bar Mandatory filter regulator and lubricator to be installed before the RSM 3 8 NPT Adjust pressure regulator to 5 10 psi 0 3 0 6 bar lower than the maximum air pressure available 2 Connect customer supplied air hose or Lite Hose to RSM solenoid valve if a PSI Qc load side Connect Lite Hose electrical connection inside RSM 3 Use a 3 8 ID hose with full flow fittings for most tools Use 1 4 hose and fittings for small tools and screwdrivers Maximum hose length from RSM to the tool is 30 feet 9 meters T O terminal strip with screw lug terminals Plug transformer into A C outlet Connect the RJ45 cables between the RSM
26. ot recommended e Press ENTER to set and scroll UP or DOWN to move on PSI Q FLOW HIGH LIMIT displays the HIGH LIMIT number of the venting throttle signal that the PSI Q learned and programmed from the tool during the set up procedure This venting throttle signal is the air flow after the tool clutch has fired and the tool has shut off e Press ENTER to view The HIGH LIMIT number is shown on the left and can be changed by scrolling UP or DOWN This is not recommended e Press ENTER to set and UP or DOWN to move on PSI Q REHIT must be set up in order to error proof for REHIT fasteners REHIT displays two numbers The number on the left designates the total time of the last fastening cycle This number can represent either an OK cycle or a REHIT fastener depending on the last rundown The units displayed do not represent seconds it is a PSI Q generated unit An OK fastener must run for a designated minimum time before it will be counted as a CYCLE OK If the fastener does not run for this minimum amount of time than the Q designates it as a REHIT fastener and fires the CYCLE NOK and it will not be counted The REHIT number on the right designated as NEW is set to 0 by default This 16 PSI Qualifier means all fasteners REHIT and OK will be accepted as CYCLE OK until this feature is set up correctly e Press ENTER to view the ADJUST REHIT screen Hand start a fastener down to the furthest point that will still represe
27. r the appropriate power supply for your country Part to Order Japan 100 VAC 1 Amp 24X500143 Australia 240 VAC 1 Amp 24X500144 United Kingdom 240 VAC 1 Amp 24X500145 Europe 220 VAC 1 Amp 24X500146 U S A 110 VAC 1 Amp 24X500092 Table 1 International Power Supplies WARNING ELECTRICAL HAZARD To Avoid Injury e Plug power cord into a grounded outlet that conforms to National Electric Code standards e Do not defeat the grounding pin on plug or substitute a cable that does not conform to the power and safety requirements of system 1 6 Specifications Specification Description External Wall Mount Transformer to 16VAC 50 Hz 1 AMP Getting Started 3 User Manual Specification Description Gs Temperature 0 to 50 C 32 to 122 F Operating Condens Humidity 0 95 non condensing 15cm 6 wide x 21cm 8 25 high x 4cm 1 5 deep 12VDC 10 or 24VDC 10 Inputs 2 5 milliamps Optically isolated Optically isolated dry relay contacts Outputs 5 to 48 VDC 5 Amps Error Proofin OK for acceptable cycles NOK for REHIT CROSS THREAD STRIP SLIP 8 OFF CYCLE ABORT amp BATCH COUNT STATUS Serial Port Optional RS 232 port with RJ45 connector PFCS protocol or just OK output Two Line Display 11mm 0 44 LCD backlit 16 Characters per line Interface Five button keypad Up Down Menu Reset Return and Admin LED Indicators Red or Green for fastening cycle or batch Remote
28. rators 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 1 2 Qualified Personnel WARNING 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 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 Getting Started 1 User Manual 1 3 Safe Use 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 Qualifiers 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 applications Please contact your Stanley Sales Engineer for further
29. se one of two replacement screws located on the back of the RSM Longer screw higher signal for smaller tools Shorter screw lower signal for larger tools Wii Holding the ENTER and RETURN buttons Clears and Sets Zero Press UP DWN arrows to select parameter set PSET 1 or 2 Press ENTER The PSET defines the part being error proofed The PSET stays in memory At this time adjust tool to apply actual torque using a transducer and or torque meter Press ENTER after tool has been adjusted Use tool to run down actual fastener and hold trigger until RUN COMPLETE appears and the tool shuts off If the rundown was unacceptable not normal press DOWN and perform a new rundown Continued on Next Page Installation and Use 11 User Manual Use tool to run down actual fastener until RUN COMPLETE appears If CHANGE ORIFICE appears the rundown is not accepted change the RSM s middle screw to adjust the overall signal see section 2 4 3 Default setting is the MEDIUM length screw Use one of two replacement screws located on the back of the RSM Longer screw higher signal for smaller tools Repeat until the next step appears T Run the tool in mid air for 2 3 seconds Repeat three times Shorter screw lower signal for larger tools Press UP DWN arrows for the Numter of Fasteners 01 99 Press Enter If you do not have cyc
30. shut off the valve after each cycle is complete the off time can be adjusted Press ENTER to view Scroll UP or DOWN to change Press ENTER to select PSI Qc PASS SHUTOFF ON OFF allows the selection ON to SHUT OFF the tool when an OK cycle is achieved or OFF allows the tool to run until the operator lets go of the throttle The operator gets signaled by the CYCLE OK green light that the cycle has been completed OK e Press ENTER to choose Press UP or DOWN to move on PSI Qc REHIT ON OFF allows the selection ON to detect a REHIT fastener for error proofing or OFF to accept a REHIT fastener as an OK cycle e Press ENTER to choose Press UP or DOWN to move on PSI Qualifier PSI Qc REHIT SHUTOFF ON OFF allows the selection to SHUT OFF the tool when a REHIT occurs or turns the valve OFF and allows the tool to run until the operator lets go of the throttle when a REHIT occurs e Press ENTER to choose Press UP or DOWN to move on PSI Qc MAINTENANCE ALARM monitors the air flow during the pulse phase and ALARMS if this air flow reaches over a programmed MAINTENANCE number The units are Q units not any standard units This feature is OFF by default MAINT 5000 This feature must be set up by running good cycles while viewing this screen e Press ENTER to view Run a few good cycles and note the FLOW number e Scroll UP to change the MAINT number to 20 60 counts above the highest FLOW number noted
31. sure you have the correct hardware and software for your tool Tool Type Setup Section Oetiker Hose Clamp PSI Q 2 3 1 PSI Q Non shutoff pulse tool PSI Qc 2 3 2 PSI Qc Direct Drive Stall tool PSI Qc Q41 2 3 2 PSI Qc PSI Qualifier Shutoff Pulse Tool PSI Q Q42 2 3 1 PSI Q Air Hammer Pin Press PSI Q Q60 2 3 1 PSI Q Rivet Tool PSI Q Q62 2 3 1 PSI Q Table 5 2 2 1 PSI Q The PSI Q is typically used with a wide variety of shut off pneumatic tools e Pulse tools shut off type e Nutrunners torque controlled shut off e Screwdrivers torque controlled shut off e Compatible Push to Start shut off screwdrivers only available from Stanley All torque controlled shut off tools which use a venting throttle design to provide throttle valve reset can be utilized When using these tools the PSI Q learns the flow signals from the tool system installation which includes this venting signal from the throttle reset feature Once the tool shuts off the signal is seen and the PSI Q responds Some shut off tool models may require a modification to allow a greater vent signal Contact your Stanley salesman or the factory for more information em mr Ces Picture 1 Example of Compatible PSI Q tools 2 2 2 PSI Qc The PSI Qc is typically used with virtually all non shut off pneumatic pulse tools e Pulse tools non shut off stall type e Impact wrenches 3 8 and 1 2 drive All
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