Stanley QB Expert Instruction Manual

Instruction Manual

QB Expert Alpha Controller

Software Version 5.2.8

English - Original Document - Revision C

© 2016 STANLEY Black and Decker, Inc. All rights reserved.

Table of Contents

1 Getting Started . . . . . . . . . . . . . . . . . . . . . . . . 2

1.1 What’s Included . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.2 Controller Functions and Connections . . . . . . . . . . . . . . . 4

1.3 CE Directives (Europe) . . . . . . . . . . . . . . . . . . . . . . . 4

1.3.1 Machinery Directive Compliance . . . . . . . . . . . . . . . . . . .4

1.3.2 RoHS Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . .5

1.3.3 WEEE Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . .5

1.4 Regulatory Notices for Radio Transmitter . . . . . . . . . . . . . . . 5

1.4.1 FCC Notice (USA) . . . . . . . . . . . . . . . . . . . . . . . . . . .5

1.4.2 Canadian Compliance Notice . . . . . . . . . . . . . . . . . . . . . . .5

1.4.3 CE Notice (Europe) . . . . . . . . . . . . . . . . . . . . . . . . . . .6

1.5 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.5.1 Warnings and Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . .6

1.5.2 General Power Tool Safety Warnings . . . . . . . . . . . . . . . . . . .8

1.5.3 Safety Instructions for QB Expert Alpha Controllers . . . . . . . . . . 10

1.6 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1.6.1 Physical and Environmental Ratings . . . . . . . . . . . . . . . . . . 11

1.6.2 Electric Service Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1.6.3 E-Stop Precaution . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1.6.4 Tool Speed and Torque Scatter Versus Electric Supply . . . . . . . . . . 11

1.6.5 Tool Temperature Versus Electric Supply . . . . . . . . . . . . . . . . . . 11

1.7 Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . 12

2 QPM QB Expert Alpha Controller . . . . . . . . . . . . 18

2.1 Data Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2.2 Input and Output Functions . . . . . . . . . . . . . . . . . . . 18

2.3 Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2.4 Embedded PLC . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2.5 Networking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2.6 Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

II

QB Expert Alpha Controller

Table of Contents

2.7 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2.7.1 Scroll Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2.7.2 Dropdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2.7.3 Menu Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

2.7.4 Tabs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

2.7.5 Character Scrollbar . . . . . . . . . . . . . . . . . . . . . . . . . . 20

2.7.6 Run Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

2.7.7 Fastening Cycle Log . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2.7.8 Keypad Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

2.7.9 Controller Display Icons . . . . . . . . . . . . . . . . . . . . . . . . . . 24

2.8 Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

2.9 Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

3 Programming . . . . . . . . . . . . . . . . . . . . . . . 30

3.1 SETUP Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

3.1.1 JOBS: Wizard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

3.1.2 JOBS: Manual Programming . . . . . . . . . . . . . . . . . . . . . . 37

3.1.3 COMMUNICATIONS Menu . . . . . . . . . . . . . . . . . . . . . . 52

3.1.4 OTHER Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

3.1.5 RESTORE FACTORY DEFAULTS Menu . . . . . . . . . . . . . . . . . . 74

3.2 SERVICE Area . . . . . . . . . . . . . . . . . . . . . . . . . . 75

3.2.1 Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

3.2.2 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

3.3 ANALYZE Area . . . . . . . . . . . . . . . . . . . . . . . . . . 79

3.3.1 TOOL Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

3.3.2 TRACE Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

3.3.3 STATS Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

3.3.4 LOG Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

3.3.5 I/O Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

4 Alpha Toolbox . . . . . . . . . . . . . . . . . . . . . . . 88

4.1 Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

4.2 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

4.2.1 Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

4.2.2 Navigation Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . 90

4.2.3 Import/ Export Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . 90

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Table of Contents

4.2.4 Manage Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . 90

4.3 Editing Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . 90

4.3.1 Parameter and Data Retrieval . . . . . . . . . . . . . . . . . . . . . . 91

4.4 Trace Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

4.4.1 Analyzing Traces . . . . . . . . . . . . . . . . . . . . . . . . . . 93

4.4.2 Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

4.5 Icons and Security . . . . . . . . . . . . . . . . . . . . . . . . . . 99

5 QPM DC Electric Tools . . . . . . . . . . . . . . . . . 104

5.1 Tool Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 104

5.1.1 Operator Protection . . . . . . . . . . . . . . . . . . . . . . . . . 105

5.1.2 Repetitive Motion . . . . . . . . . . . . . . . . . . . . . . . . . 105

5.1.3 Hearing Protection . . . . . . . . . . . . . . . . . . . . . . . . . 105

5.1.4 Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

5.1.5 Breathing Protection . . . . . . . . . . . . . . . . . . . . . . . . . 106

5.1.6 Tool Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

5.1.7 Sockets and Adapters . . . . . . . . . . . . . . . . . . . . . . . . . 107

5.1.8 Cable Installation . . . . . . . . . . . . . . . . . . . . . . . . . 108

5.2 QPM Tool Controls and Operation . . . . . . . . . . . . . . . . . . 108

5.2.1 Start Trigger Switch . . . . . . . . . . . . . . . . . . . . . . . . . 108

5.2.2 Tool Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

5.2.3 Display and Multiple Function Button . . . . . . . . . . . . . . . . . 109

5.2.4 Tool Status Lights . . . . . . . . . . . . . . . . . . . . . . . . . 110

5.2.5 MFB Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

5.2.6 Worklights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

5.2.7 Program Selection . . . . . . . . . . . . . . . . . . . . . . . . . 111

5.2.8 Directional Control . . . . . . . . . . . . . . . . . . . . . . . . . 111

5.2.9 Tool Temperature . . . . . . . . . . . . . . . . . . . . . . . . . 111

5.2.10 Setting Torque, Angle, and Other Operating Parameter . . . . . . . . . 112

5.2.11 Assembly (Forward) Operation . . . . . . . . . . . . . . . . . . . . . 112

5.2.12 Disassembly (Reverse) Operation . . . . . . . . . . . . . . . . . 112

5.3 Special Application Tools . . . . . . . . . . . . . . . . . . . . . . .112

5.3.1 Exposed Gear Socket Tools . . . . . . . . . . . . . . . . . . . . . 112

5.3.2 Tubenut Nutrunners . . . . . . . . . . . . . . . . . . . . . . . . . 113

6 Alpha Controller Connections . . . . . . . . . . . . . . 118

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QB Expert Alpha Controller

Table of Contents

6.1 Power Cord . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118

6.2 Tool Connector . . . . . . . . . . . . . . . . . . . . . . . . . .118

6.2.1 EA, EB and EC Tools . . . . . . . . . . . . . . . . . . . . . . . . . 118

6.2.2 E Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

6.3 USB Connector . . . . . . . . . . . . . . . . . . . . . . . . . .118

6.4 Serial Connector . . . . . . . . . . . . . . . . . . . . . . . . . .119

6.5 Alpha Toolbox Ethernet Connector . . . . . . . . . . . . . . 120

6.6 Facility/ Spindle Network Ethernet Connectors . . . . . . . . . . . 120

6.7 Ethernet/IP or Profinet Connectors . . . . . . . . . . . . . . .121

6.8 Trailing DeviceNet™ Connector . . . . . . . . . . . . . . . . . . .121

6.9 Profibus Connector . . . . . . . . . . . . . . . . . . . . . . . . . .121

6.10 Leading DeviceNet Connector . . . . . . . . . . . . . . . . . . 122

6.11 Input and Output Connector . . . . . . . . . . . . . . . . . . 122

6.12 Assignable Input and Output Functions . . . . . . . . . . . . . . .126

6.12.1 Input Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . 129

6.12.2 Output Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . 135

6.13 MODBUS TCP . . . . . . . . . . . . . . . . . . . . . . . . . 146

6.13.1 Example Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

7 Embedded PLC . . . . . . . . . . . . . . . . . . . . . . .152

7.1 “Rack” Layout . . . . . . . . . . . . . . . . . . . . . . . . . 152

7.1.1 Addressing Scheme . . . . . . . . . . . . . . . . . . . . . . . . . 152

7.2 Supported Instructions and File Types . . . . . . . . . . . . . . 153

7.3 PLC Editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

7.3.1 Edit Page Controls . . . . . . . . . . . . . . . . . . . . . . . . . 162

7.3.2 Instruction Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

7.3.3 MON and MSG Instructions . . . . . . . . . . . . . . . . . . . . . 164

7.3.4 Applying a Name and Version . . . . . . . . . . . . . . . . . . . . . 164

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Table of Contents

7.4 Converting a RSS File . . . . . . . . . . . . . . . . . . . . . . 164

7.4.1 Invalid Characters . . . . . . . . . . . . . . . . . . . . . . . . . 166

7.4.2 Predefining String or Integer Files . . . . . . . . . . . . . . . . . 166

7.4.3 Applying a Name and Version . . . . . . . . . . . . . . . . . . . . . 166

8 Multi-Spindle . . . . . . . . . . . . . . . . . . . . . . . 170

8.1 Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170

8.2 Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

8.3 Synchronization . . . . . . . . . . . . . . . . . . . . . . . . . 172

8.3.1 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

8.3.2 Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

8.4 Networking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

8.5 Fastening Cycle Data . . . . . . . . . . . . . . . . . . . . . . .174

9 Maintenance . . . . . . . . . . . . . . . . . . . . . . . 178

9.1 Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . 178

9.2 Diagnostics and Troubleshooting . . . . . . . . . . . . . . . . . . 178

9.2.1 Fault Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

9.3 Message Guide . . . . . . . . . . . . . . . . . . . . . . . . . 189

9.4 Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

10 Torsion Compensation . . . . . . . . . . . . . . . . .196

10.1 Torsion Factor . . . . . . . . . . . . . . . . . . . . . . . . . 196

10.2 An gle Validation . . . . . . . . . . . . . . . . . . . . . . . . . 196

VI

11 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . .200

12 Limited Warranty . . . . . . . . . . . . . . . . . . . .204

QB Expert Alpha Controller

Table of Contents

12.1 Mechanical Products Limited Warranty . . . . . . . . . . . . . . 204

12.2 Electronic Products Limited Warranty . . . . . . . . . . . . . . 204

12.3 Software Products Limited Warranty . . . . . . . . . . . . . . 204

12.4 OEM Products Limited Warranty . . . . . . . . . . . . . . . . . . 204

12.5 General Terms . . . . . . . . . . . . . . . . . . . . . . . . . 204

12.6 Specification Changes . . . . . . . . . . . . . . . . . . . . . . 205

12.7 Warranty Claims . . . . . . . . . . . . . . . . . . . . . . . . . 205

12.8 Product Services . . . . . . . . . . . . . . . . . . . . . . . . . 205

12.9 Return Material Authorization (RMA) Procedures . . . . . . . 205

Instruction Manual

VII

QB Expert Alpha Controller

Introduction

1

What’s Included

Controller Functions and Connections

CE Declaration of Conformity

Regional Notices for Transmitter

Safety

Specifications

Installation Instructions

What’s Included

1 Getting Started

This manual is intended to promote proper and safe use and give guidance to owners, employers, supervisors,
and others responsible for training and safe use by operators and maintainers. Please contact your STANLEY Sales
Engineer for further information or assistance on Stanley training or assembly tool operations.

1.1 What’s Included

Included with the QB Expert Alpha controller is a power cord, plinth (for mounting), documentation (in the
envelope) and a mating connector for the I/O port. The mating connector is included so the end user may connect
wires to the controller’s I/O port to their requirements.

5

1

2

, Cleveland, OH 44143 USA

STANLEY ASSEMBLY TECHNOLOGIES

Telephone: [phone] Email: [e-mail] URL: http://StanleyAssembly.com

5335 Avion Park Drive

4

Item Number Description

1 QB Expert Alpha Controller

2 Plinth for mounting controller

3 Power cord

4 24 V DC I/O mating connector

3

5 Envelope with Getting Started Documentation

2

QB Expert Alpha Controller

9

Introduction

1

4

5

2

19

3

8

11

16

POWER

TOOL

13

115/230VAC 50/60HZ

10 AMP 1/N/PE~

WARNING

!

ELECTRIC SHOCK HAZARD

To prevent injury
disconnect power cord
before removing cover

ETHERNET

I/O

AVERTISSMENT

!

RISQUE DE DECHARGE ELECTRIQUE

Pour empecher des dommages
debranches le cordon de secteur
avant d enlever la couverture

USB

SPINDLE

COM PORT

PROTECTED BY ONE OR MORE OF
THE FOLLOWING US PATENTS:
5,315,501
5,637,968
6,516,896

10

12

17

14

15

7

See Description on next page

Instruction Manual

6

FIELDBUS OPTIONS

18

3

Controller Functions and Connections

1.2 Controller Functions and Connections

This table refers to the picture on the previous page.

Item Number Functional Description

1 Red, Green, Yellow LEDs for Limits Evaluation

2 Programmable and Tool Ready LEDs

3 Display

4 Function Keys with Active Label Above

5 Maintenance Due Indicator

6 Cursor Keys with Center Button to Expand Lists

7 Numeric Keypad to Enter Numbers or Select Options

8 Power Switch

9 Alpha Toolbox Connector

10 USB Port for Data Transfer

11 Tool Connector

12 Plant/ Spindle Network Ethernet Connectors

13 Optional Master DeviceNet Connector

14 Serial Connector

15 Optional Profibus or DeviceNet Connector

16 Power Input

17 19-Pin, 24V DC Input/Output Connector

18 Optional Fieldbus Ethernet Connectors

19 Indicates WiFi Enabled (when present)

Information about these items is discussed elsewhere in this manual. Use the Table of Contents to find the page
for the item of interest. If this is an electronic document you are reading click on the item in the Table of Contents
and it will link you directly to the page. Or press CNTRL+F on the keyboard to search the document for the item
of interest.

1.3 CE Directives (Europe)

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

1.3.1 Machinery Directive Compliance

This product complies with the requirements of the European Machinery Directive (2006/42/EC). See the CE
Declaration of Conformity that is delivered with the product.

4

QB Expert Alpha Controller

1.3.2 RoHS Compliance

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

1.3.3 WEEE Compliance

This product and its information meets the requirements of the European Waste of Electrical and Electronic
Equipment (WEEE) Directive (2011/65/EU). This product is marked with a crossed trashcan, see last figure below
in section 1.5.1 Warnings and Cautions.

1.4 Regulatory Notices for Radio Transmitter

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

1.4.1 FCC Notice (USA)

This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) this
device may not cause harmful interference, and (2) this device must accept any interference received, including
interference that may cause undesired operation.

This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to Part
15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference
in a residential installation. This equipment generates, uses and can radiate radio frequency energy and, if not
installed and used in accordance with the instructions, may cause harmful interference to radio communications.
However, there is no guarantee that interference will not occur in a particular installation. If this equipment does
cause harmful interference to radio or television reception, which can be determined by turning the equipment
off and on, the user is encouraged to try to correct the interference by one or more of the following measures:

• reorient or relocate the receiving antenna,

• increase the separation between the equipment and receiver,

• connect the equipment into an outlet on a circuit different from that to which the receiver is connected, or

• consult the dealer or an experienced radio/TV technician for help.
This device contains transmitter module FCC ID: TE7WR702N.

Introduction

• To satisfy FCC RF exposure requirements for mobile transmitting devices, a separation distance of 20 cm
(7.87 in) or more should be maintained between the antenna of this device and persons during operation.
To ensure compliance, operations at closer distances than this are not recommended.

1.4.2 Canadian Compliance Notice

This device complies with Industry Canada license-exempt RSS standard(s). Operation is subject to the following
two conditions:

• This device may not cause interference, and

• This device must accept any interference, including interference that may cause undesired operation of the
device.

Cet appareil est conforme aux norms CNR exemptes de licence d’Industri Canada. Le
fonctionnement est soumis aux deux conditions suivantes:

• cet appareil ne doit pas provoquer d’interférences et

Instruction Manual

CAUTION

5

Safety

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

1.4.2.1 Industry Canada Notice (Canada)

Complies with the Canadian ICES-003 Cleass B specifications.

Cet appareil numérique de la classe B est conforme à la norme NMB-003 du Canada.

This device complies with RSS 210 of Industry Canada. This device meets all the requirements of the Canadian
interference-causing equipment regulations.

Cet appareil numérique de la classe B respecte toutes les exigences du Règlement sur le
matériel brouilleur de Canada.

1.4.3 CE Notice (Europe)

This device has been tested and certified for use in the European Union. This product complies with the
requirements of the European Radio & Telecommunications Terminal Equipment (R&TTE) Directive (1999/5/EC).

The ‘CE’ mark has been placed on the device per the labeling requirements of the Directive.

Given that the operating frequency band is not harmonized by a few European countries, the restriction or
alert sign has been placed alongside the ‘CE’ mark as shown below. As of the date of this document, only
France has a restriction. The restriction is that, if the radio is operated outdoors in the 2450-2483.5 MHz
band, the power must be limited to 10 mW instead of 100 mW. This device is not intended for outdoor use.

1.5 Safety

1.5.1 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:

DANGER

WARNING

CAUTION

Indicates that death or severe personal injury will result if proper precautions are not taken.

Indicates that death or severe personal injury may result if proper precautions are not taken.

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 fire hazard. This icon appears as a part of a DANGER, WARNING, or CAUTION notice.

Indicates a general hazard. This icon appears as a part of a DANGER, WARNING, or CAUTION notice.

Indicates that eye protection should be worn. This icon appears as a part of a DANGER, WARNING, or
CAUTION notice.

6

QB Expert Alpha Controller

Introduction

!

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

Indicates an item of special interest.

Indicates a pinch point hazard. This icon appears as a part of a DANGER, WARNING, or CAUTION
notice.

Indicates an open wrench pinch point hazard. This icon appears as a part of a DANGER, WARNING, or
CAUTION notice.

Indicates an environmental hazard. Do not throw equipment into the normal housekeeping refuse bin.

Instruction Manual

7

Safety

1.5.2 General Power Tool Safety Warnings

These warnings are required by EN 60745.

Read all safety warnings and all instructions. Failure to follow the warnings and instructions may result in
electric shock, fire and/ or serious injury.

Save all warnings and instructions for future reference.

The term “power tool” in the warnings refers to mains-operated (corded) power tool or battery-operated
(cordless) power tool.

1. Work Area Safety

a.) Keep work area clean and well lit. Cluttered or dark areas invite accidents.
b.) Do not operate power tools in explosive atmospheres, such as in the presence of

flammable liquids, gases or dust. Power tools create sparks which may ignite the dust or fumes.

c.) Keep children and bystanders away while operating a power tool. Distractions can cause you

to lose control.

2. Electrical Safety
a.) Power tool plugs must match the outlet. Never modify the plug in any way. do not use

any adapter plugs with the earthed (grounded) power tools. Unmodified plugs and matching

outlets will reduce risk of electric shock.

b.) Aoid body contact with earthed or grounded surfaces, such as pipes, radiators, ranges and

refrigerators. There is an increased risk of electric shock if your body is earthed or grounded.

c.) Do not expose tools to rain or wet conditions. Water entering a power tool will inrease the risk

of electric shock.

d.) Do not abuse the cord. Never use the cord for carrying, pulling or unplugging the power

tool. Keep cord away from heat, oil sharp edges or moving parts. Damaged or entangled

cords increase the risk of electric shock.

e.) When operating a power tool outdoors, use an extension cord suitbable for outdoor use.

Use of a cord suitable for outdoor use reduces the risk of electric shock.

f.) If operating a power tool in a damp location is unavaoidable, use a residual current device

(RCD) proteted supply. Use of an RCD reduces the risk of electric shock. The term “residual

current device(RCD)” may be replaced by the term “ground fault circuit interrupter (GFCI)” or “earth
leakage circuit breaker (ELCB)”.

3. Personal Safety
a.) Stay alert, watch what you are doing and use common sense when operating a power tool.

Do not use a power tool while you are tired or under the influence of drugs, alchohol or
medication. A moment of inattention while operating power tools may result in serious personal

injury.

b.) Use personal protective equipment. Always wear eye protection. Protective equipment such

as dust mask, non-skid safety shoes, hard hat, or hearing protection used for appropriate conditions
will reduce personal injuries.

c.) Prevent unintentional starting. Ensure the switch is in the off-position before connecting

to power source adn/ or battery pack, picking up or carrying the tool. Carrying power tools

with your finger on the switch or energising power tools that have the switch on invites accidents.

d.) Remove any adjusting key or wrench before turning the power tool on. A wrench or key left

attached to a rotating part of the power tool may result in personal injury.

WARNING

8

QB Expert Alpha Controller

Introduction

WARNING

Continued:

e.) Do not overreach. Keep proper footing and balance at all times. This enables better control

fo the power tool in unexpected situations.

f.) Dress properly. Do not wear loose clothing or jewellery. Keep your hair, clothing and

gloves away from moving parts. Loose clothes jewellery or long hair can be caught in moving

parts.

g.) If devices are provided for the connection of dust extraction and collection facilities,

ensure these are connected and properly used. Use of dust collecton can reduce dust-related

hazards.

4. Power Too Use and Care

a.) Do not force the power tool. Use the correct power tool for your application. The correct

power tool will do the job better and safer at the rate for which it was designed.

b.) Do not use the power tool if the switch does not turn it on and off. Any power tool that

cannot be controlled with the switch is dangerous and must be repaired.

c.) Disconnect the plug from the power source and/ or the batatery pack from the power

tool before making any adjustments, changing accessories, or storing power tools. Such

preventive safety measures reduce the risk of starting the power tool accidentally.

d.) Store idle power tools out of the reach of children and do not allow persons unfamiliar

with the power tool or these instructions to operate the power tool. Power tools are

dangerous in the hands of untrained users.

e.) Maintain power tools. Chek for misalignment or binding of moving parts, breakage of

parts and any other condition that may affect the power tool’s operation. If damaged,
have the power tool repaired before use. Many accidents are caused by poorly maintained

power tools.

f.) Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting edges

are less likely to bind and are easier to control.

g.) Use the power tool, accessories and tool bits etc. in accordance with these instructions,

taking into account the working conditions and the work to be performed. Use of the power

tool for operations different from those intended could result in a hazardous situation.

5. Service
a.) Have your power tool serviced by a qualified repair person using only identical

replacement parts. This will ensure that the safety of the power tool is maintained.

Instruction Manual

9

Safety

1.5.3 Safety Instructions for QB Expert Alpha Controllers

WARNING

To Avoid Injury:

• Save these instructions for future reference.

• Read and understand all the safety recommendations and all operating instructions before operating tools
and controllers. Failure to follow all instructions listed below may result in electric shock, fire and/or serious
personal injury.

• Train all operators in the safe and proper use of power tools. Operators should report any unsafe condition
to their supervisor.

• Follow all safety recommendations in the manual that apply to the controllers, tools, battery packs and
chargers being used and the nature of the work being performed.

• Verify that all warning labels illustrated in this manual are readable. Replacement labels are available at no
additional cost from STANLEY Assembly Technologies.

• Only allow suitably qualified personnel to install, program, or maintain this equipment and or system. Follow
all manufacturer installation instructions and applicable regulatory electrical codes and safety codes.

• These persons must be knowledgeable of any potential sources of danger and maintenance measures as set
out in the Installation, Operations, and Maintenance manual.

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

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

• Install tools in dry, indoor, non-flammable, and non-explosive environments only–Humidity: 0 to 95% non­condensing and Temperature: 32 to 122 ºF (0 to +50 ºC).

• Do not install worn, damaged, or modified equipment that may be unsuitable for safe use.

• Controller plugs must match the outlet and must be earth grounded. Never modify a plug in any way or use
any adaptor plugs.

• Avoid body contact with electrically energized surfaces when holding a grounded tool.

• Prior to connecting a power source, always ensure the tool or controller is turned off.

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

• Only use equipment and accessories specifically designed to operate with STANLEY assembly tools and use
them only in the manner for which they are intended.

• Store idle tools and accessories in a safe location accessible only by trained persons.

• Disconnect power source (battery, electricity, etc.) from tool or controller prior to making adjustments,
changing accessories, or storing.

• Prior to operation, always check and test tools and accessories for damage, misalignment, binding or any other
condition that may affect operation. Maintenance and repair should be performed by qualified personnel.

10

• 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.

QB Expert Alpha Controller

1.6 Specifications

1.6.1 Physical and Environmental Ratings

Width: 6.0 inches 152 mm

Dimensions:

Weight: 18 pounds 8.2 kgrams

Operating Conditions:

Ingress Protection Rating: IP54 NEMA 3

1.6.2 Electric Service Ratings

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

Height: 16.0 inches 406 mm
Depth: 10.4 inches 264 mm

Temperature: 32 to 122 ºF (0 to +50 ºC)
Humidity: 0 to 95 % non-condensing

Introduction

Tool Model: E02-E23

EA23
EB02−EB22
EC02−EC22

100 − 126.5V AC 15 A 15 A 20 A * 30 A *

Current for Supply Voltage:

200 − 253V AC 10 A 10 A 10 A 10 A
Standby 0.2 A 0.2 A 0.2 A 0.2 A

Power Consumption:

Continuous 0.3 kVA 0.7 kVA 1.0kVA 2.2 kVA

* 200−240V AC highly recommended

1.6.3 E-Stop Precaution

WARNING

INTEGRATED E-STOP CIRCUIT NOT PRESENT
To Avoid Injury:

• When a QB Expert Alpha controller connects to a tool where a fault can result in personal injury or substantial
damage to property, an E-stop circuit is required. An E-stop circuit must be created in the external electrical
service supply line.

1.6.4 Tool Speed and Torque Scatter Versus Electric Supply

The minimum electric supply voltage required to attain catalog speeds is 104V AC or 208V AC depending which
supply voltage system is used. Supply voltages above these minimums should have NO effect on reducing speed.
Supply voltages BELOW these minimums will reduce maximum free speed proportionally; actual speed should be
the LOWER of the speed command or the maximum attainable speed. Slow Seek and downshift speeds should
not be affected unless they are set close to maximum attainable speed. Similarly torque scatter should NOT be
affected by reduced supply voltages.

E33-E34
EA33−EA34
EB33-EB34
EC33-EC34

E44-E45
EB44-EB45
EC44

E55
EB55

1.6.5 Tool Temperature Versus Electric Supply

Supply voltages that remain within recommended limits during the fastening cycle will provide shortest cycle
times and lowest tool temperatures. Tool temperatures on applications with moderate to high prevailing torque
levels and/or low (i.e. soft) torque rates stand the most chance of being negatively impacted by low or “sagging”

Instruction Manual

11

Installation Instructions

supply voltages. Voltage “sag” is a reduction in voltage which occurs when high current draw causes a voltage
drop in the supply wiring which reduces voltage at the power plug and consequently reduces maximum attainable
tool speed under load. Fuses and breakers are also more likely to blow or trip under these conditions. To minimize
these effects, always connect the system to electric service that meets the recommended supply service ratings.

1.7 Installation Instructions

ELECTRICAL HAZARD
To Avoid Injury:

• This product should be located away from heat sources such as radiators or other devices that produce heat.

• This product should not be subjected to vibration or shock or in close contact with water or other liquids.

• To minimize electrical interference, place the module as far away from possible sources of electrical noise,
such as arc welding equipment.

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

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

• Avoid body contact with electrically energized surfaces when holding a grounded tool.

Please refer to the picutres of a plinth and mounting of the QB Expert Alpha controller on the next two pages.
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 mounting plinths are placed next to each other, the center­to-center distance between the mounting holes in different plinths is 2” (50.8 mm). When mounting plinths are
place one above another, the center-to-center distance between the mounting holes in different plinths is 6”
(152.4 mm).

Install the QB Expert Alpha Controller either directly to the wall or to a plinth (part number 21E204300).
Fasteners through four mounting holes secure plinths to a wall or other surface. Plinths can be connected using

10-32 threaded holes on the bottom and left side and through holes on the top and right side.
Make sure the bolts of the barrel-latches [5] on the plinth are retracted. Place the lower flange of the QB Expert

Alpha controller [1] into the lip [2] on the plinth.
Align the slot [3] in the flange with the lower mounting-pin [4] on the plinth while placing. Rotate the top of the

controller back towards the plinth.
Place the openings on the upper flange of the controller [6] over the upper mounting pins [7] on the plinth.

Release the bolts on the barrel-latches [5] making sure the bolts enter the two barrels [8] on the controller.
Connect the QB Expert Alpha Controller to a power source.
Connect one end of the tool cable to the tool and the other end to the QB Expert Alpha controller and press the

power switch on the controller.
The controller displays a language list at the first boot up. Press the up/down arrows to select a language, then

press either NEXT from the interactive menu button or use the Toggle button to save the selection.
The controller next prompts for regional settings like Time Zone, Time and Date. Follow the prompts until the run

screen appears indicating the controller is ready for programming and operation.

WARNING

12

QB Expert Alpha Controller

6.06

18.00

[457,2]

[154]

4.00

[101,6]

Introduction

13.00

[330,2]

2.50

[63,5]

12.00

[304,8]

n .195 (6-PLACES)

[4,95]

n .375 (6-PLACES)

[9,53]

Instruction Manual

Plinth 21E204300

13

6

1

8

3

1

7

4

2

5

14

8

7

5

Mounting QB Alpha Expert Controller onto Plinth

QB Expert Alpha Controller

Introduction

Instruction Manual

15

QB Expert Alpha Controller

Controller Operation

2

Data Storage

Input and Output Functions

Spoftware

Embedded PLC

Networking

Navigation

Display

Faults

Messages

Data Storage

2 QPM QB Expert Alpha Controller

The QB Expert Alpha controller is a modular, high-end, full-featured controller for QPM DC servo power tools with
torque transducers. It will control any QPM E, EA, EB or EC series servo motor-powered tool. It utilizes closed
loop control of torque, speed and angle so that it can perform various routines for the tool to secure each fastener
with the highest quality results. The high precision torque and angle sensors in the tool provide feedback to the
QB Expert Alpha controller’s digital control circuit. This circuit compares the feedback values to the programmed
values and adjusts the tool’s power and speed values to maintain the programmed speed on the output of the
tool until the fastener has achieved the programmed target torque and/or angle value. Once the programmed
value is sensed the control circuit turns off the tool leaving the fastener with the desired amount of preload or
clamping force.

The QB Expert Alpha controller is certified to IP54 level to withstand the dust, dirt and liquids found in industrial
facilities. Installing into other panels is not necessary.

QB Expert Alpha controllers have an IEEE 802.11b/g/n radio so that the QPM Cordless line of tools may be added
to it as well. Software version 5.2.5 is the first software version to support the QPM cordless tools.

The QB Expert Alpha controller is designed to be a lead controller in a multiple tool system. Multiple systems of
up to 24 spindles can be configured and managed by the QB Expert Alpha controller. Trailing controllers used in
multiple spindle systems can be QB Advanced Alpha or QB Node Alpha or the new QPM Cordless tools.

The QB Expert Alpha controller can be used as a standalone system as it runs its own tool.

2.1 Data Storage

Data associated with 30,000 fastening cycle results and 10,000 traces is stored in the QB Expert Alpha controller.
This data is retrieved with a USB memory stick or Alpha Toolbox. SPC analysis is performed by the QB Expert
Alpha controller on the stored data.

2.2 Input and Output Functions

Bolt Count or Error Proofing functions are an integral part of the QB Expert Alpha controller’s functions. Its eight
inputs and eight outputs on the 24V DC I/O connector support these functions to provide expert plant integration
to external devices such as a PLC.

The inputs and outputs are assignable, and configurable.
The QB Expert Alpha controller supports other bus types such as ModbusTCP, which is standard, plus optional

Ethernet/IP, Profibus, ProfiNet and DeviceNet. DeviceNet can be ordered as either a scanner or device.

2.3 Software

Any computer with a modern web browser connected wirelessly or with an Ethernet cable on the Ethernet
network port, or the ATB port, is used to view the QB Expert Alpha controller’s web-based application called
Alpha Toolbox. Software is not loaded onto a computer to access the data or configure the controller. Alpha
Toolbox updates come with the controller updates.

2.4 Embedded PLC

The QB Expert Alpha controller comes with a software PLC that emulates many commands and features of the
Allen Bradley SLC-500 series controller. Anyone with logic writing skills and the Alpha Toolbox PLC Editor can
program a logic file to add more versatility to the already abundant features of the QB Expert Alpha controller.

2.5 Networking

Ethernet and the Internet Protocol using Transport Control Protocol are a powerful and robust means of moving
data from one computer to another. Many end users rely on it to collect information from plant floor equipment.
The QB Expert Alpha controllers support the XML (2.0, 2.1), PFCS, NPL, TOOLSNET, OPEN and FORD protocols.

18

QB Expert Alpha Controller

For those that haven’t switched to this more robust means of collecting data, the QB Expert Alpha controller
supports the PFCS, OPEN and Toyota PI protocols over a serial connection.

2.6 Navigation

The QB Expert Alpha controller’s four navigation and input areas facilitate menu navigation, selection and data
input:

– Interactive Menu buttons
– Arrows and Toggle button
– Keypad
– Touch screen

5

1

6

4

Controller Operation

Labels for the four interactive menu buttons [1] change with menu selection.
If the label is blank, the button has no function for the current screen.

The up/down arrows [2] navigate menu and character selections; the left/
right arrows enable backspace and space, as well as navigate between tabs.
The Toggle button [3] switches between modes and selects/accepts choices
(synonymous with OK interactive menu button).

The numeric keypad [4] facilitates data input and menu selection (where
applicable) and Job/Task selection when enabled.

The five LEDs [5] specify status of the fastening cycle for spindle 1:

– Red indicates high torque/angle;
– Green indicates an OK fastening cycle;
– Yellow indicates low torque/angle;
– White is programmed by the embedded PLC, and

3

2

– Blue indicates when the tool is enabled to run.

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

2.7 Display

2.7.1 Scroll Bar

A scroll bar appears on the right of the screen when more items are available than the display allows to view at
one time. The black scroll bar indicates which list items are currently displayed. No scroll bar means all items are
currently displayed.

To navigate between menu items, use the up/down arrows or, if available, use the keypad to identify the
corresponding menu item number.

2.7.2 Dropdown

A dropdown arrow appears to the right of menu items with multiple choices. To view choices, highlight the menu
item using the up/down arrows then use the Toggle button to expand the dropdown. Use up/down arrows to
scroll and the toggle or interactive menu button to select/accept.

Instruction Manual

19

Display

2.7.3 Menu Tree

A menu tree appears beside related menu items.

2.7.4 Tabs

Tabs 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.

2.7.5 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 QB Expert Alpha controller’s up/down arrows to scroll through character choices.
The left arrow backspaces. The right arrow moves one position to the right to input the next character. Push
Toggle button or OK interactive menu button to accept entry.

The following screens contain the character scrollbar option: ALL, Job (Name), Task (Name) Step (Name), System
(Name General), System (Users), WIFI (SSID, Password).

2.7.6 Run Display

The Run screen displays normal operating information one spindle at a time. To display a different spindle on a
multiple spindle unit press the right or left arrow key to switch to the next spindle tab.

1

2

8

9

20

10

6

7

4

3

11

QB Expert Alpha Controller

Controller Operation

Icons identify events [1], see list below. Displays last torque and angle readings with units, when a tool is connected
[2]. Up/down arrows next to the torque or angle value indicate the last fastening cycle NOK status whether it
exceeded (up) or did not achieve (down) torque or angle limits.

Identifies the active Job [6] and active Task [7]. Identifies Target batch count [3] and Accumulated bolt count [4]
for the active Job. The side scroll bar indicates events are available in the Event Log. Press the down arrow to
view the events. The number of fastening cycle attempts indicator is below the bolt count box. The run screen
displays unless other programming functions [5] are in use. A Shutoff code is also displayed when applicable [8].
The display also has the current time [10] for the specified region and fastening cycle history in the Fastening cycle
Log [9].

This [11] portion of the screen changes to an orange bar with white background when either Limit Rejects or Job
Timer parameters are used. The orange bar increments in one division of the width equal to the Reject Count value
each time a NOK cycle occurs. This bar also acts as a progress bar for the Job Timer to indicate the progress of
the timer.

The time display [10] will change in the following manner:
When a Part ID is received the time will change to the Part ID for 5 seconds and then return to the clock.
If the Job or Task has been selected the Job Name:Task Name appear on the screen until the batch count (Job) has

been completed and then returns to the clock.
The display background color turns red in the event of a fault; see section “2.8 Faults” on page 25.
The run display changes to indicate the step in which the tool stopped (providing it did not stop during the audit

step).

The Fastening Cycle Log [9] lists the fastening cycles that have occurred in the QB Expert Alpha controller. While
viewing the Run Display press the down arrow to access the Fastening Cycle Log.

Use the up/down arrow keys to scroll through the data listed chronologically (newest at the top, oldest at the
bottom). Each line identifies a fastening cycle. The first column indicates the fastening cycle status or shutoff
code. The second column indicates the achieved torque during the fastening cycle. The third column indicates the
achieved angle during the fastening cycle. The fourth column indicates the working bolt count.

2.7.7 Fastening Cycle Log

Press the interactive MANAGE button after selecting a data line to display the MANAGE dialog box.

Instruction Manual

5

21

Display

Use the up/down arrow keys and the interactive OK button, or the Toggle button, or the number keys, to select
the action required.

Export Rundowns will transfer all fastening cycle data to the USB memory stick after choosing a file name.
Export Trace will transfer fastening cycle trace data to the USB memory stick after choosing a file name. Choose

between the selected trace, the number of traces in the population size or all traces to be exported. When
exporting the SELECTED trace it exports as a comma seperated value file. If POPULATION or ALL are selected the
appropriate number of traces are placed into a zip file before exporting. If selecting All, be aware it will take a
significant amount of time before all traces are put into the zip file and exported.

Delete Rundowns will delete all fastening cycle and trace data from the QB Alpha Expert controller. This action
cannot be undone.

Press the interactive YES button to delete the data. Press the interactive NO button to cancel the delete action.
Use the following sequence to save a Rundown or Trace file.
Insert a USB memory stick into the USB port on the bottom of the QB Expert Alpha controller. Use the down

arrow to select the Name field. Use the Toggle button to enter edit mode. Use the left arrow to delete the name.
Use the up/down arrows or the numeric keypad to write a new file name if required. Press the interactive OK
button or the Toggle button to accept the file name.

Press again to save the file to the USB memory stick.

Press the interactive EXIT button to return to the Run screen.

2.7.7.1 Fastening Cycle Details

Not all items are shown

Press the interactive DETAILS button or the Toggle button after selecting a data line
to display the details.

Details about the event and when it occurred are listed.

Rundown ID: The sequential number of the fastening cycle data

Date: The date the fastening cycle was ran.

Time: The time the fastening cycle completed.

Job: The active Job number in which the fastening cycle ran.

Task: The active Task number in which the fastening cycle ran.

Status: The overal status of the fastening cycle.

22

QB Expert Alpha Controller