Stanley Theta Controller User Manual
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Stanley Theta Controller User Manual

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Theta Controller User Manual
Software Version QC1-3.5.0
Important Safeguards
For your protection, please read these instructions completely, and keep this manual for future
reference. Carefully observe and comply with all warnings, cautions and instructions placed on the
equipment or described in this manual.
Assembly Technologies
© 2009 THE STANLEY WORKS, ALL RIGHTS RESERVED
www.StanleyAssembly.com
ThetaUser070709

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Summary of Contents for Stanley Theta Controller

  • Page 1 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. © 2009 THE STANLEY WORKS, ALL RIGHTS RESERVED www.StanleyAssembly.com ThetaUser070709...

  • Page 2: Table Of Contents

    Theta Controller E-Stop Precaution.......6 Programming....................7 Theory of Operation..............7 2.1.1 Data Storage ..............7 2.1.2 Input and Output Elements ..........7 Software ................7 Networking................7 QA Theta Controller Navigation and Programming....8 Display ..................8 2.5.1 Scroll Bar ...............8 2.5.2 Dropdown ..............8 2.5.3 Menu Tree ..............9 2.5.4 Tabs................9...
  • Page 3 Theta Controller Connections..............46 Theta Controller Connections ..........46 4.1.1 Theta Controller Power Cord ........46 4.1.2 Theta Controller Tool Connector .........46 4.1.3 Theta Controller Serial Connector .......47 4.1.4 Theta Controller Input and Output Connector....47 Assignable Input/Output Functions ........50 4.2.1 Input Descriptions............51 Contents...
  • Page 4 User Manual 4.2.2 Output Descriptions .............53 Glossary ....................55 Appendix A – Controller Gateway ............57 Appendix B – Torsion Compensation............58 Warranty....................60...

  • Page 5: 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.

  • Page 6: Specifications, Layout And Display

    • Verify that all warning labels illustrated in this manual are readable. Replacement labels are available at no additional cost from STANLEY ASSEMBLY TECHNOLOGIES. Qualified Personnel W A R N I N G To Avoid Injury: •...
  • Page 7 Theta Controller Item Functional Description Red, Green, Yellow LED's for Limits Evaluation Display Function Keys with Active Label Above Cursor Keys with Center Button to Expand Lists Maintenance Due and ATC Active LED's Numeric Keypad to Enter Numbers or Select Options...

  • Page 8: Installation Instructions

    • Always wear eye and foot protection when installing equipment. • Only use equipment and accessories specifically designed to operate with Stanley assembly tools and use them only in the manner for which they are intended. • Do not install worn, damaged, or modified equipment that may be unsuitable for safe use.
  • Page 9 Theta Controller 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 center to center distance between the mounting holes in different plinths is 2"...

  • Page 10: Theta Controller E-Stop Precaution

    INTEGRATED E-STOP CIRCUIT NOT PRESENT To Avoid Injury: When a Theta 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...

  • Page 11: Programming

    QPM EC model series tool. It will not control E or EA model series tools. 2.1.1 Data Storage Data associated with 25 fastening cycles is stored in the Theta controller. This data can be retrieved with the Controller Gateway software, one of the selected Serial network protocols or sent to a printer.

  • Page 12: Qa Theta Controller Navigation And Programming

    User Manual 2.4 QA Theta Controller Navigation and Programming The Theta controller’s three navigation and input areas facilitate menu navigation, selection and data input: • Menu buttons • Arrows and Toggle button • Keypad Labels for the four interactive menu buttons [1] change with menu selection.

  • Page 13: Menu Tree

    (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 Theta Controller’s up/down arrows to scroll through character choices. The left arrow backspaces. The right arrow moves one position to the right to input next character.

  • Page 14: Faults

    User Manual Can occur during a tightening cycle when a spindle firmware update is in progress Theta Controller Icons Icon Status Description Locked Password required to make changes Unlocked Changes possible, automatically re-locks in time Busy/working Wait Fault, system not operable...

  • Page 15: Messages

    Analyze. Unsupported Tool! The wrong tool type has been connected to the controller. The Theta controller cannot run the tool that is connected. 2.7 Messages Messages appear on the screen when certain non-critical conditions exist that asserts the warning.

  • Page 16: Theta Controller Programming

    Data input and, when applicable, menu selection. Can be used for job selection when enabled to do so. The left column shows the currently defined Theta Controller settings and menu choices. The Options Screen column shows options for each selection. Screen navigation options appear above each screen.

  • Page 17: Setup Menu: 1. Jobs

    Wizard presents programming parameters and gives a list of strategy controls. These controls are explained further in this section. Strategy – TORQUE (TC/AM) is the only strategy the Theta controller supports. There are no other options for this parameter. TORQUE (TC/AM): Torque Control with Angle Monitor. The controller shuts off the tool when the tool reaches the target torque value.
  • Page 18 User Manual Wizard Screens Options Screen To modify, select using the up/down arrow keys then press the Toggle button. After all parameters/selections/options are finished, press the NEXT interactive menu button to advance through the Wizard. Repeat for subsequent windows. Press the PREV interactive menu button to move back to previously programmed screens within the Wizard.
  • Page 19 Theta Controller Wizard Screens Options Screen Wobble is an Angle Control / Torque Monitoring strategy in the opposite direction for which the final tool strategy is programmed. This allows the fastener threads to align with the locking device threads before a standard forward rotation and high speed are applied (prevents cross-threads).
  • Page 20 User Manual Wizard Screens Options Screen Angle Target – The number of degrees of rotation the socket turns during this step. Snug Torque – Angle measurement, for the target angle, starts at this torque. Speed – The speed of the tool during this step. Max Torque –...

  • Page 21: Setup: Job Tab

    Theta Controller Wizard Screens Options Screen Press the FINISH interactive menu button to close the Wizard. The Job Tab screen appears. This allows parameter changes to be made prior to saving Wizard programming. To save, press the EXIT interactive menu button.
  • Page 22 User Manual Job Tab Screens Options Screens input to select the Task to run within a Job. Auto Reset Job – Yes resets the Job automatically after the Batch Count has been met. The tool will not disable with Error Proofing enabled. No requires an Input or Trigger to Reset the Job. The tool disables with Error Proofing enabled.

  • Page 23: Setup: Manage Button (Job)

    Theta Controller 2.8.1.3 Setup: Manage Button (Job) Manage Button (Job) Screens Options Screen Manage enables active job settings to be added, deleted, and/or copied to the clipboard and pasted. Add – Adds a Job to the controller. If a tool is attached, the Wizard begins for easy setup of Job parameters.
  • Page 24 User Manual Task Tab Screens Options Screens Name – Name the Task to define the operation performed (15 character maximum). Use the up/down arrows for letters or use the numeric keypad. Batch Count – This is the number of fasteners the Job is required to count.

  • Page 25: Setup: Step Button

    Theta Controller 2.8.1.5 Setup: Step Button Step Button Screens Options Screens Step settings only affect the selected Job/Task. There can be only one audit step per Task. In the Theta, that audit step is a Torque Control / Angle Monitor (TC / AM) strategy. The audit step can have Smart Steps associated with it.
  • Page 26 User Manual Step Button Screens Options Screens Disabled – Does not reduce the speed of the motor. Manual – Reduces the tool speed to a specific value (Downshift Speed) when a specific torque value (Downshift Torque) is achieved during the tightening cycle. Speed units are RPM, Torque is in torque units.

  • Page 27: Setup: Manage Button (Step)

    Theta Controller 2.8.1.6 Setup: Manage Button (Step) Manage Button (Step) Screens Options Screen Manage enables step settings to be added, deleted and/or copied to the clipboard then pasted. Add – Allows the addition of Smart Steps. The Smart Step choices are Wobble, Slow Seek and Self Tap.

  • Page 28: Setup Menu: 2. Communications

    OPEN – An error proofing / data collection protocol used in tool applications at Ford, Honda and other facilities. This protocol can be used by others as it does not take special equipment like the Toyota protocol. The Theta controller supports the following MID’s (Rev 1 only) on the OPEN protocol. Description MID_COMMUNICATIONS_START...

  • Page 29: Setup Menu: 3. Other

    Printer – A pre-defined data string is sent to the port after each tightening cycle that exceeds the Threshold Torque. See section 4.1.3 Theta Controller Serial Connector for string definitions. Toyota – Connects this port to the Toyota PI box.

  • Page 30: Users Tab

    User Manual Other Screens Options Screen Count Mode – Choose Count Up to indicate the fasteners that have been completed OK. Choose Count Down to indicate the number of fasteners yet to be completed. Stop/Abort within Limits – Choose OK to mark the fastening cycle as OK, even if the fastening cycle is stopped or aborted while the achieved torque and angle are within limits.
  • Page 31 Theta Controller Other Screens Options Screen One user must be an Administrator. Administrator rights give a user full access to the controller. This enables all privileges including restoring factory defaults and adding users. The Administrator must login to change user’s access. The unlocked icon appears in the upper left corner of screen after Administrator login.

  • Page 32: I/O Tab

    User Manual Other Screens Options Screen Use the right arrow to move to the next tab or press EXIT to save the changes and return to the Run screen. See section 2.8.1.7 Setup: Exit for further information. 2.8.3.3 I/O Tab This is the place to assign elements to the controller’s Inputs and Outputs.

  • Page 33: Input Bus

    Theta Controller Other Screens Options Screen 2.8.3.3.2 Input Bus The 24 VDC connector has pins 3 through 6 designated as Inputs to the controller. The pin assignments are selectable on this tab. Use the up/down arrows to select the pin you wish to assign, then press the Toggle button or the EDIT interactive menu button.

  • Page 34: Lights Tab

    User Manual Other Screens Options Screen Any – Either the tool trigger or tool push- to-start switch starts the tool. All – Requires that both the tool trigger and the tool push-to-start switch must be activated to start the tool. Lever –...

  • Page 35: Tool Tab

    Theta Controller Other Screens Options Screen 2.8.3.7 Tool Tab Values modified under this tab are saved to the tool not the controller. Users must have TOOL or ADMINISTRATOR access level to modify values here. PM Limit – When the PM Counter in the tool...

  • Page 36: Regional Tab

    User Manual Other Screens Options Screen Use the right arrow to move to the next tab or press EXIT to save the changes and return to the Run screen. See section 2.8.1.7 Setup: Exit for further information. 2.8.3.8 Regional Tab Select language.

  • Page 37: Service

    Theta Controller Restore Factory Defaults Screens Options Screen After pressing the button the screen returns to run mode. 2.8.5 Service Tool Tab Screens Options Screen The Service area presents information about the tool and controller. Users must have TOOL or ADMINISTRATOR access level to modify any parameters here.

  • Page 38: Cal Tab

    User Manual Tool Tab Screens Options Screen either the PM Counter or the Trip Counter. Use the right arrow to move to the next tab or press EXIT to save the changes and return to the Run screen. See section 2.8.1.7 Setup: Exit for further information. 2.8.5.1.3 CAL Tab Nominal Cal –...

  • Page 39: About Tab

    Theta Controller Controller Tab Screens Options Screen 2.8.5.3.1 About Tab This tab displays information about the controller. These values are read only unless blank. The Model and Serial fields can be written to once. 2.8.6 Analyze Analyze Screens Options Screen Analyze displays tool and controller diagnostic information, traces and I/O status.

  • Page 40: Trace Tab

    Pin 1 is the 24VDC Return to complete the current loop. Pin 16 is the bus for the Outputs. Pin 2 is the bus for the Inputs. See section 4.1.4 Theta Controller Input and Output Connector for a schematic. Pins 3 through 6 are for Inputs. Pins 7 through 14 are for Outputs.
  • Page 41 Theta Controller Analyze Screens Options Screen Choose Yes to remove the force(s) and return to the run screen. Choosing No does NOT remove the force(s), it returns to the run screen. The system runs with forces applied until they are removed or until the controller’s next power cycle.

  • Page 42: Qpm Dc Electric Tools

    STANLEY ASSEMBLY TECHNOLOGIES are intended for use in industrial threaded fastening or precision position and or adjustment applications only. Some instructions may not apply to all tools. Please contact your Stanley Sales Engineer for information or assistance on Stanley training for assembly tool operation.

  • Page 43: Operator Protection

    Theta Controller 3.2 Operator Protection W A R N I N G ROTATING EQUIPMENT To Avoid Injury: • Always wear eye and foot protection when operating, installing, or maintaining power tools, and when in areas where power tools are being used, maintained, or installed. Some applications may require the use of safety glasses and face shields.

  • Page 44: Vibration

    Limit controller access to trained and qualified personnel. Lock controller cabinets. Turn controllers off when attaching tools. Stanley electric tools must be connected to a controller to operate. To ensure superior performance and safe operation, use a Stanley controller specifically designed for each tool. These instructions are specific to Stanley Electric Tools when used with Stanley Electric Tool Controllers and accessories.

  • Page 45: Suspension Devices

    Never abuse a cable, carry a tool by its cable, hang a tool by its cable, or pull on a cable to disconnect it from the tool or the controller. To ensure superior performance and safe operation, use the Stanley cables specifically designed to operate these tools.

  • Page 46: Tool Memory

    User Manual Pressing the button arms (activates) the trigger but does not start the tool. The blue assembly light [2] comes on to show that the tool is armed. Reset Reject This function, when selected, causes the tool to disable after a NOK tightening cycle.

  • Page 47: Tool Operation

    Theta Controller 3.5 Tool Operation W A R N I N G ROTATING SPINDLE To Avoid Injury: • Always wear eye and foot protection when operating and when in areas where power tools are being used. • Keep all body parts and clothing away from the rotating end of the tool. Dress properly. Do not wear loose-fitted clothing or jewelry.

  • Page 48: Tool Temperature

    3.5.5 Tool Audible Device The tool also has an audible device designed to be operator aid. The Theta controller pulses the audible device when the tool is in the Reverse direction. There is no audible indication of OK or NOK tightening cycles.

  • Page 49: Tubenut Nutrunners

    Theta Controller 3.6.2 Tubenut Nutrunners W A R N I N G PINCH POINT AT THE EXPOSED GEARS OR TEETH To Avoid Injury: • Never place body parts or clothing, near the socket opening. Dress properly. Do not wear loose-fitted clothing or jewelry.

  • Page 50: Theta Controller Connections

    User Manual Theta Controller Connections Each controller or Theta Controller has a different combination of connectors. These connectors serve several purposes, such as: • Power • Tool Connections • Discrete inputs and outputs • Communications C A U T I O N...

  • Page 51: Theta Controller Serial Connector

    V trans (v) I trans (ma) V high (v) I high (ma) 24 volt The Theta controller has a terminal block connector for error proofing. Error proofing in the Theta controller is based on simple bolt counting with Poke-Yoke. Theta Controller Connections...
  • Page 52 NOTE: One I/O mating connector (P/N 21C104800) is included with each Theta controller When the Theta controller is used with fixtured tools, it must use a Remote Start/Stop/Reverse pendent to the controller to provide basic switching control for the tool.
  • Page 53 Theta Controller Inputs: Sinking (example) Outputs: Sourcing (example) Theta Controller Connections...

  • Page 54: Assignable Input/Output Functions

    The configuration options are an important aspect of the I/O functions, as they add powerful, multiple dimensions to each function not previously seen in Stanley tool controllers. These new dimensions allow integration of these controllers in unique ways, providing an amazing amount of flexibility.

  • Page 55: Input Descriptions

    The tool will run until the currently active Job is complete or times out. A TIME parameter becomes available to set how long the START input must be applied, in seconds, before the Latch becomes active. No – when selected turns the Latch function off. Theta Controller Connections...
  • Page 56 User Manual Inputs Description STOP When asserted, the controller stops the tool. It also keeps the tool from running while it is applied. When removed nothing happens other than the tool will be allowed to run. The size of this input function is 1 bit. Configuration: Contact Type SELECT...

  • Page 57: Output Descriptions

    NOT within the limits of the audit step. Resets when the tool exceeds Threshold Torque on the next tightening cycle. The size of this output function is 1 bit. Configuration: Contact Type Output Type Theta Controller Connections...
  • Page 58 User Manual Outputs Description Asserts when a job is completed (accumulated bolt count equals target bolt COMPLETE count). Resets when a different job is selected. Size: 1 bit Configuration: Contact Type Output Type FAULTED Asserts when there is a fault on the controller. Resets when the fault clears. Size: 1 bit Configuration: Contact Type...

  • Page 59: Glossary

    Theta Controller Glossary Abort Timer The tightening cycle aborts if the tool does not shutoff on target before this pre- selected time. Acceleration The rate at which the controller increases tool speed from 0 (stopped) to the Speed value. Accept Tone Controls the tone made from the handle of handheld QPM tools for accepted tightening cycles.
  • Page 60 It is usually used as a supplementary count of the PM Counter. Units The following torque units and associated labels are used with Stanley controllers and tools. The labels are derived from SP811, SI Unit rules and style conventions from the National Institute of Standards and Technology...

  • Page 61: Appendix A - Controller Gateway

    The auto-connection process launches the default web browser and examines the computers available serial ports. The Controller Gateway seeks each port for a compatible Stanley controller connection. When one is found, the browser displays the main menu. From the main menu, setup, maintenance and analysis functions can be performed.

  • Page 62: Appendix B - Torsion Compensation

    The resolver indicated more angle than the tool output actually rotated. To correct for this slight error in angle data, the Theta controller has a Stanley-exclusive solution. The Torsion Factor allows the operator to input a value that compensates for the torsional spring rate of any part of the fastening system (the gears of the tool, the joint components or the tool mounting device);...
  • Page 63 Theta Controller maximum capacity of the tool). When any individual torque reading from the tool's controller is compared to a torque reading from the external torque monitor, there can easily be a several percent difference higher or lower. This means that the tool's controller starts counting angle at a different point than the external torque/angle monitor starts counting.

  • Page 64: Warranty

    Under this lifetime limited warranty Stanley will, at its discretion, repair or replace any product which, upon inspection, is acknowledged by Stanley to be defective.
  • Page 65 Theta Controller Stanley shall not be responsible for incidental or consequential damages or the inability to use its products for any purpose whatsoever. Stanley's maximum liability shall not in any case exceed the contract price for the products claimed to be defective. Some states and countries do not allow the exclusion or limitation of incidental or consequential damages, so this specific limitation or exclusion may not apply to you.
  • Page 66 User Manual 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;...

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