INSTALLATION AND USE INSTRUCTIONS Q System QUALIFIERS: PSI-Q & PSI-Qc

Important Safeguards For your protection, please read these instructions completely, and keep for future reference. Carefully observe and comply with all warnings, cautions and instructions placed on the equipment or described in this manual. Stanley Assembly Technologies Applications & Productivity Center, 5800 Enterprise Court, Warren, MI 48092-3476 Tel 586-393-1100 Fax 586-393-1200 Toll Free in the US 1-877-787-7830 www.stanleyworks.com

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THE STANLEY WORKS, ALL RIGHTS RESERVED

Installation and Use

Table of Contents
Safety .............................................................................................................................. 3 Symbols and Terms Warnings Qualified Personnel Specifications ................................................................................................................ 4

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

Installation and Air Supply ........................................................................................... 6

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

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

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

Appendix A:

Stanley Pneumatic Tool Modifications for PSI-Q Qualifiers .......... 10

Appendix B:

Operation Flow Chart PSI-Qc Qualifiers .......................................... 11

Initial Set Up (PSI-Qc) ........................................................................................... 11 Admin Menu (PSI-Qc) ........................................................................................... 13 Appendix C: Operation Flow Chart PSI-Q Qualifiers ............................................ 14

Initial Set Up (PSI-Q) ............................................................................................. 14 Admin Menu (PSI-Q) ............................................................................................. 16

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Safety
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 general hazard. This icon appears as a part of a Danger, Warning, or Caution notice.

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

Qualified Personnel
WARNING
To Avoid Injury: - Read and understand all the safety recommendations and all operating instructions before operating tools and qualifiers. - Save these instructions for future reference. - Train all operators in the safe and proper use of power tools. - Operators should report any unsafe condition to their supervisor. - Follow all safety recommendations in the manual that apply to the tools being used and the nature of the work being performed. - Verify that all warning labels illustrated in this manual are readable. - Replacement labels are available at no additional cost from Stanley Assembly Technologies.

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.

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. 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 information or assistance on Stanley training for assembly Qualifier operation.

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Operation
The PSI-Qc qualifies rundowns for non shut-off pulse tools or impact wrenches. The PSI-Qc can operate either with a signal light for the operator to release the throttle or by actuating a solenoid valve which shuts off the air supply to the tool at cycle complete. The PSI-Q performs POKE YOKE error proofing with air shut-off tools. Torque accuracy depends on the capability of the power tool selected for the application.

The Q System is a process & monitoring system and does not provide torque control. Torque accuracy with shut-off tools is usually good within 20%. This is controlled by the tools internal mechanism. When using stall (non shut-off) pulse tools, accuracy of 10% is easily achieved when adjusted and set-up properly and used with a signal light.

The Qc Qualifier takes a series of mass air flow measurements and turns the data into a rundown signature to detect OK vs. NOK fastening cycles.

Flow Time

Flow

Time

The diagram above shows a typical fastening cycle for a pulse or impact tool. The air consumption of a pulse tool air motor during a run cycle is relative to the work being performed, as well as to the speed of the tool. In Zone 1, the tool is starting and the level of flow will indicate if the fastener is cross-threaded or free spinning. Zone 2 is free speed and is the zone showing the free run-down of the bolt. Zone 3 begins when the fastener has seated and reached snug torque and ends with Zone 4, the final pulse tightening phase. Near the end of zone 4, equilibrium has been attained and the tool can be shut-off with excellent torque accuracy.

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Specifications

Power Source Power Consumption Operating Conditions Temperature Humidity Weight Dimensions

100-240 VAC 50-60 Hz < 1 amp @ 115 VAC

0 to +50 C (32 to 122 F) 0 to 95 % non-condensing 1 kg (2 lbs.) Approximately 15cm (6) wide x 21cm (8.25) high x 4cm (1.5) deep Opto-isolated and relay dry contacts; up to 24 VDC/ 5 amps with screw lug terminals OK/NOK for acceptable cycles vs REHIT/CROSS THREAD, STRIP/SLIP OFF, CYCLE ABORT & BATCH COUNT STATUS RS 232 port; standard RJ45 connector (Pset#/TgTq/COUNT/OK-NOK)

Inputs/Outputs

Error Proofing

Optional Serial Port

Two Line 11mm (0.44) LCD backlit, (16) Characters per line Interface Five-button keypad (Up, Down, Menu, Reset/Reverse & Admin)

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Installation and Air Supply

WARNING
To Avoid Injury: - Always wear eye protection when installing equipment. - Only use equipment and accessories specifically designed to operate with Stanley assembly tools. - Keep the work area clean and uncluttered. - Keep unauthorized personnel out of the work area. - Do not install worn, damaged, or modified equipment that may be unsuitable for safe use. - Train all operators in the safe and proper use of power tools. - Operators should report any unsafe condition. - Install tools in dry, indoor, non-flammable, and non-explosive environments only.

RSM (Remote Sensor Module) 90 PSI

5 4
1. Provide clean dry air @ 90 PSI. Filter and lubricator (recommended) to be installed at this point (3/8 NPT). Adjust pressure regulator to 5-10 PSI lower than the MAX air available. Air hose connects to supply. Use a 3/8 ID hose with full flow fittings with most pulse tools. Use 1/4 hose and fittings with small pulse tools and screwdrivers. MAX hose from RSM to the tool is 30. I/O terminal strip with screw lug terminals. Plug transformer into A/C outlet. Connect the cable to the RSM and to the Q Qualifier as shown, with RJ45 connectors. Standard cable is 15. Optional cables to 200 available. Mount the Q to the wall or to the optional bench mount bracket.

2. 3.

4. 5. 6.

Optional Hose Light Assemblies

21C200605 21C200604 21C200603 24C200000 24C200001 21C200602 8' Hose/light assembly - straight 1/4" 16' Hose/light assembly - straight 1/4" 25' Hose/light assembly - straight 1/4" 8' Hose/light assembly - straight 3/8" 16' Hose/light assembly - straight 3/8" 25' Hose/light assembly - straight 3/8"

7.

WARNING
To Avoid Injury: - Shutoff valve must be in the closed position until the air lines are installed and properly terminated. - Do not connect power to the PSI Qualifier until all air line connections are secured. - Supply air energizes the outlet port when electrical power is supplied to the PSI Qualifier.

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Tool Compatibility

The Q is suitable for use with a wide variety of pneumatic power tools:
Pulse toolsshut-off (PSI-Q) and non shut-off (PSI-Qc) Impact wrenches: 3/8 and 1/2 drive (PSI-Qc) Nutrunnerstorque controlled shut-off (PSI-Q) Screwdriverstorque controlled shut-off (PSI-Q)

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

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Input/Output (I/O)
The Q has onboard I/O that is easily connected using screw lug terminals located at the top of the enclosure. All I/O is optically isolated and rated for 24 VDC. Standard dry contact closure relays are used and can handle up to 5 amps at 24 volts. Wire according to the legend printed on the front label as shown below.

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

Terminals labeled 18 are for use as follows:

1 2 3 4 5 6 7 8

P-SET 1

P-SET 2

NOT USED

CLICK WRENCH

BATCH CLEAR

ENABLE

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Troubleshooting
Set-up and installation of the Q is simple and easy. Just follow the display prompts. Remember to let go of the throttle when the display reads, COMPLETE after any step in the set-up. However, if the unit does not set-up, doesnt recognize the tool or the tool being in cycle, check the following: 1. Did the supply air pressure drop below the initial setting? Remember, set the regulator at least 5 psi below the available supply maximum. If supply drops, re-teach the PSET at the new pressure. 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: Does the tool vent the throttle after shut-off? Some older models did not vent until the throttle is released. Either modify the tool to vent or try a different model. Is the tool a shut-off? If not, use Q39 software instead. Did you adjust the inlet air regulator properly? (see point 1. above)

2.

Is the proper flow screw installed in the bottom of the RSM? The short screw applies to non-shutoff tools using Q39 code on the PSI-Qc . The medium screw applies to most shutoff tools using Q42 code on the PSI-Q. Use the long screw only for small (low air consumption) screwdrivers.

3. 4.

Is the tool shutting off OK? Check the tool for proper operation and re-teach the PSET. The lights dont always come on. Check that the hose size and length is proper for the tool being used. If the air hose is too large of 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. The Q doesnt 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. When using PSI-Qc (Q39 code), the tool is sluggish. Check that the correct flow screw is installed and that the air supply is sufficient so that the pressure drop when the tool is running is not greater than 10 psi from the static pressure. If it is, either the air supply to the RSM is tool low in volume or the RSM is too small for the tool. Change to a 1/2 ported RSM if necessary. This may be required if the tool is larger than 3/8 square drive or draws more than 20 CFM (25 liter/minute). When using PSI-Q (Q42 code), the tool is sluggish and/or cant pull full torque. Check the air pressure/supply. If the tool is 1/2

5.

6.

7.

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Appendix A Stanley Pneumatic Tool Modifications for use with PSI-Q Qualifiers

CT Clutch Shut Off

Remove: A8010 throttle pin Replace with: 20H207500 throttle pin

A40 TA & TP Shut-Off

Remove: A40 throttle valve Replace with: 20H207300 throttle valve

A30 TA Shut-Off

Remove: A30 throttle valve Replace with: 20H207400 throttle valve

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Appendix B Operation Flowchart Initial Setup (PSI-Qc Cont.)

This button is referred to as the ENTER button. Use this button to select an option and to move to the next screen. Q39.XX.XX.XX CLEAR COMPLETE Holding the ENTER & GO BACK buttons will Clear and Set Zero

SETTING ZERO PLEASE WAIT . . . This button is referred to as the GO BACK button. At any screen you may use this to go to the last step. PARAMETER SET 1 NOT SETUP

Press ENTER.

SET TARGET TQ TQ : 18.0

Press UP / DWN arrows to set the TARGET TORQUE. This does NOT adjust tool to actual torque. Press ENTER.

REHIT: Tool running on a fastener that has already been torqued snug.

- REHIT FASTENER RUN TOOL - REHIT FASTENER RUN COMPLETE - SETTING ZERO PLEASE WAIT . . . - REHIT FASTENER RUN TOOL - REHIT FASTENER RUN COMPLETE - SETTING ZERO PLEASE WAIT . . . LEARN JOINT RUN TOOL LEARN JOINT COMPLETE

Engage the tool on a fastener that has already been torqued snug and run until RUN COMPLETE appears.

Run Tool until the socket stops moving.

CONTINUED ON NEXT PAGE

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Appendix B Operation Flowchart Initial Setup (PSI-Qc Cont.)

- RUN FREESPEED RUN TOOL - RUN FREESPEED COMPLETE SET BATCH COUNT COUNT : 3

SET BATCH TIMER TIME : 10

SHUTOFF VALVE? UP/YES DWN/NO

For solenoid valve use, choose YES. You can change the cycle delay in the ADMIN menu, the default is 100.

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

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Appendix B Operation Flowchart Admin Menu (PSI-Qc Cont.)

--- ADMIN MENU --I/O (MOMENTARY) --- ADMIN MENU --BATCH TIMER --- ADMIN MENU --BATCH COUNT

- ADMIN MENU I/O (LATCHED)

SET BATCH TIMER TIME : 05

SET BATCH COUNT COUNT : 2

CONTINUED BELOW

--- ADMIN MENU --CYCLE TIME

--- ADMIN MENU --CYCLE DELAY

--- ADMIN MENU --REHIT (ON)

CYCLE TIME TIME: 000

CYCLE DELAY DELAY: 100

- ADMIN MENU REHIT (OFF)

CONTINUED BELOW

--- ADMIN MENU --PGRM LOCKOUT ON

--- ADMIN MENU --PSET LOCKOUT ON

--- ADMIN MENU --PGRM LOCKOUT OFF

- ADMIN MENU PSET LOCKOUT OFF

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Appendix C Operation Flowchart Initial Setup (PSI-Q Cont.)

This button is referred to as the ENTER button. Use this button to select an option and to move to the next screen. Q42.XX.XX.XX CLEAR COMPLETE Holding the ENTER & GO BACK buttons will Clear and Set Zero

SETTING ZERO PLEASE WAIT This button is referred to as the GO BACK button. At any screen you may use this to go to the last step. PARAMETER SET 1 NOT SETUP

Press ENTER.

The PSET # will define the specific part that you are error proofing. The PSET will be kept in memory.

SELECT PARAMETER PSET # : 1

Press UP / DWN arrows to select parameter set 1 or 2. Press ENTER.

SELECT TARGET TQ TQ: 10.0

GROSS ADJUST SIGNAL - The screw in the middle of the RSM is for adjusting the overall signal. The default setting for this is MEDIUM. If you require to adjust the signal for a particular tool, please use one of the other two screws that are located on the back of the RSM. Longer the screw = higher the signal

ADJUST TOOL TO TARGET : 10.0

At this time, adjust tool to the actual torque by using a transducer and/or torque meter. Press ENTER after the tool has been adjusted.

- RUN FASTENER PLEASE RUN TOOL - RUN FASTENER INCYCLE - RUN COMPLETE KEEP? UP/Y DWN/N

Use tool to run down actual fastener and hold trigger until RUN COMPLETE appears.

If the rundown was unacceptable, press DOWN and perform a new rundown.

CONTINUED ON NEXT PAGE

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Appendix C Operation Flowchart Initial Setup (PSI-Q Cont.)

RUN 5 FASTENERS PLEASE RUN TOOL - RUN FASTENER INCYCLE - RUN COMPLETE KEEP? UP/Y DWN/N SET BATCH COUNT COUNT : 01 Press UP / DWN arrows for the Number of Fasteners ( 01-99). Press ENTER. Use tool to run down actual fastener until RUN COMPLETE appears. Repeat 5 times.

If you do NOT have cycle time requirements or dont require this feature, enter 0.

SET BATCH TIMER TIME : 000

The optional BATCH TIMER screen appears ONLY if you have set the batch count greater than 1. Press UP / DWN arrows for time allowed. Press Enter.

TQ : 010 PS 1 CT : 01 TIMER : 000

This is the RUN MODE / START screen. You are now ready for Error Proofing.

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Appendix C Operation Flowchart Admin Menu (PSI-Q Cont.)

--- ADMIN MENU ---- ADMIN MENU --BATCH TIMER --- ADMIN MENU --BATCH COUNT

- ADMIN MENU OUTPUTS (MOMENT)

SET BATCH TIMER TIME : 05

SET BATCH COUNT COUNT : 2

CONTINUED BELOW

--- ADMIN MENU --FLOW LO LIMIT

--- ADMIN MENU --FLOW HI LIMIT

--- ADMIN MENU --REHIT

- FLOW LO LIMIT 1182 NEW : 22036

- FLOW HI LIMIT 1182 NEW : 4680

ADJUST REHIT 55 NEW : 39

CONTINUED BELOW

--- ADMIN MENU --PGM LOCKOUT OFF

--- ADMIN MENU --PGM LOCKOUT ON

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