Atlas Copco RE Qualifier II User manual

RE Qualifier System Manual i
TABLE OF CONTENTS
Quick Start Guide ............................................................................1
Introduction .....................................................................................3
Main Screen ....................................................................................3
Passwords ........................................................................................5
AutoCal™ .......................................................................................6
Viewing A Run ................................................................................8
Resetting the Batch .......................................................................10
More Options ................................................................................11
Editing Parameter Sets ..................................................................12
Selecting a New Parameter ...........................................................15
Globalizing a Parameter ...............................................................16
Editing I/O Options .......................................................................17
Editing the Time and Date ............................................................19
Resetting the Total and/or Batch ..................................................20
Viewing Past Statuses ...................................................................21
Choosing a New Password ...........................................................22
Adjusting the Display ...................................................................23
I/O Structure .................................................................................24
RS-232 Connector
I/O Connector
Remote Transducer Connector
Dip-Switch Settings ......................................................................26
Dip-Switch
Test Modes
Part Numbers ................................................................................27

1 RE Qualifier System Manual
Step 1:
Power up the unit and wait for the
MAIN screen to appear. Once it
is in view, press the AUTO CAL
soft-key.
Step2:
Enter the password to access pro-
gramming functions. All units
ship from the factory with a
default password of 0 1 0 4.
Step 3:
Be sure the transducer is plugged
into the RE Qualifier and that the
tool is connected to the transducer.
Then press the NEXT soft-key.
Step 4:
Run the tool on the target fastener
and then press the NEXT soft-key.
Be certain to run the fastener from
beginning to end, allowing the
tool to clutch out.
Step 5:
Check the screen and be sure the
calibration was successful. If not,
return to step 1. If the calibration
succeeded, proceed to step 6.
Press any key to continue.
Step 6:
If the batch count needs pro-
grammed, press the MORE soft-
key.
Quick Start Guide

RE Qualifier System Manual 2
Step 7:
Once the MORE OPTIONS screen
is in view, press ‘1’ on the keypad
in order to EDIT THE PARAME-
TER.
Step 8:
Select the current parameter by
pressing the number on the key-
pad adjacent to the desired param-
eter.
Step 9:
Press the ‘8’ key in order to edit
the number of fasteners in a batch.
Step 10:
Enter the desired number for the
batch setting. When complete hit
ENT.
Step 11:
When the EDIT PARAMETER
screen re-appears, press the
LOCK AND RETURN soft-key.
Step 12:
The unit will return to the MAIN
screen and be locked. Run several
fasteners to ensure that the unit is
working properly.

Introduction
This document is an operations guide for the Atlas Copco RE
Qualifier II. The RE Qualifier monitors a pneumatic signal from
inside any Atlas Copco tool equipped with an RE port. By ana-
lyzing the pneumatic signal, the RE Qualifier can aid in the manu-
facturing process by determining if a fastener has been installed
properly and also by counting the number of fasteners that have
been installed.
Main Screen
To the left is an example of what the main screen looks like.
During normal operations, when the unit is monitoring fastening
processes, this is the screen that will be in use.
Along the right hand side of
the screen, four boxes appear
vertically and are labeled
PSET, STATUS, TOTAL, and
PRESSURE.
The box labeled PSET will
contain a letter corresponding
to the parameter set that is
currently in use. The RE
Qualifier has eight different parameter sets (A - H).
The STATUS box will be empty when the tool is in cycle. After
the completion of a cycle, this box will hold the status from the
last fastening process. Cycle OK, Batch OK, Rej Tmin, Rej
Tmax, and No Clutch are all statuses that may appear in this
area. Cycle OK indicates that the last fastener was installed prop-
erly. Batch OK means that the last group of fasteners that make
up the previous assembly have been installed properly. Rej Tmin
informs the operator that the minimum run timer was violated and
that the last fastener was not installed properly. Rej Tmax indi-
3 RE Qualifier System Manual

cates that the maximum run timer was violated. The status No
Clutch informs the user that the tool’s clutch did not complete the
fastening process.
The box labeled TOTAL displays the number of batches that have
been completed since the last reset. This number will start at 0
and count up to 65,535 before rolling back over to zero. This
value can be reset through the use of the keypad.
A live pressure indication will appear in the final box labeled
PRESSURE. This pressure value is given in PSI and it represents
the pressure inside the tool’s port.
In the center of the screen, a batch count and the number of fas-
teners in the batch appears. This information is represented as
COUNT of BATCH. The count is the number of fasteners that
have been completed towards the programmed batch setting. The
batch is a number that is programmed into the current parameter.
The batch should represent the number of fasteners in the assem-
bly under construction.
Along the bottom of the screen are several “soft” key indications.
Below each of these soft key indicators is a button. The function
of the button will change as different screens are accessed. The
text in the soft key indicators will also change to inform the user
of the current function of the button below it.
Above the left most soft key on the main screen is an icon that
resembles a padlock. The padlock will be in one of two states,
either open or closed. If the padlock is closed, the unit is locked
and a password will have to be entered in order to access pro-
gramming features. If the padlock is open, programming features
are readily available through the selections on the soft-keys.
RE Qualifier System Manual 4

Passwords
Users will be prompted to enter a password any time the unit is
locked and a programming function is accessed. All units are
shipped with the initial pass-
word set to 0 1 0 4.
Once prompted to enter a
password, use the keypad to
enter the four digit code. If
any mistakes are made during
the entry process, the CLR
button can be used to remove
one digit at a time.
As each digit is entered, an asterisk (*) will appear indicating that
a number has been entered. Once all four numbers have been
entered in the proper sequence, the user can press either the
Accept Password soft-key or the ENT button.
If the user wishes to return to the main screen without entering
the password, either the Cancel soft-key or the ESC button may
be pressed.
If the password is entered properly, the user will be taken to the
function that was requested prior to the Enter Password screen
appearing. The password can be changed to any four digit code.
5 RE Qualifier System Manual

AutoCal™
The RE Qualifier has been programmed to automatically recog-
nize the pneumatic signature from several different types of tools.
In order to calibrate the RE Qualifier using this feature, press the
AutoCal™ soft-key while the unit is showing the main screen.
If the unit is locked, enter the password when prompted for it.
The first screen in the
AutoCal™ process will say,
“AUTOCAL .. Be certain that
the tool is OFF. Then press
NEXT.”. At this point be
sure the pressure transducer is
connected to both the tool
and to the RE Qualifier and
push the soft-key labeled
NEXT.
After pressing NEXT, the screen will state, “AUTOCAL .. Run a
typical fastener and upon completion press NEXT.”. Tighten a
target fastener using the tool that the RE Qualifier is monitoring.
During this process, run the
fastener completely allowing
the tool’s clutch mechanism
to turn off the tool. If you
make a mistake during this
part of the process, run anoth-
er fastener. The RE Qualifier
will use the very last fasten-
ing process it sees as the
basis for the calibration.
RE Qualifier System Manual 6

At the end of the fastening sequence, release the tool and press
the NEXT soft-key. The RE-
Qualifier will try to set-up it’s
calibration parameters using
the pneumatic signature from
the last run.
Once the calibration attempt
is complete, the RE Qualifier
will inform the user if the cal-
ibration was successful or
not. In either case, pressing
any key on the key-pad will return the user to the main screen.
7 RE Qualifier System Manual

Viewing A Run
Each time a fastening process occurs, the RE Qualifier captures
the analog information associated with the pneumatic signal. The
RE Qualifier can hold up to
ten seconds worth of analog
information.
This analog signature can be
viewed with the current
parameter set overlaid on top
of it. In order to view the
run, press the VIEW RUN
soft-key while the unit is
showing the main screen.
The screen will say “Loading” while the information to generate
the graph is collected. Once the data for the graph is gathered, a
screen similar to the one above will appear.
The horizontal axis on this screen represents time. The vertical
axis represents pressure. In the upper right hand corner of the
screen is a legend that tells the user what the time and pressure
scale are for this particular graph.
Horizontal lines will appear on top of the graph. These lines will
represent the Cycle Start (CS), Run Start (RS) and Clutch Level
(CL). The cycle start level is a parameter setting that tells the unit
when to start and stop collecting data. If the pressure is above the
cycle start level, data is gathered for viewing and auto-calibration
purposes.
Once the pressure rises above the run start level, some kind of sta-
tus will be generated at the end of the run (ie. Cycle OK, Batch
OK, or a reject of some type).
RE Qualifier System Manual 8

Once the pressure rises above the clutch level, the RE Qualifier
assumes that the clutch has turned the tool off.
The vertical lines on top of the graph represent timers. The line
labeled Ts represents the point at which minimum run timer and
the maximum run timer start. This line will always be located at
the point which the pressure signature crosses the run start level.
T- indicates the point at which the minimum run timer was satis-
fied. T+ indicates the point at which the maximum run timer
would be violated. CL1 and CL2 are the beginning and end of
the clutch timer. The clutch timer will always begin at the point
where the pneumatic signature crosses the clutch level.
Using the ZOOM IN and ZOOM OUT soft-keys, the user can
compress and expand the graph along the time scale. This feature
may be useful in seeing items that may have occurred after the
pneumatic level dropped back below the cycle start level. The
maximum run timer is often off screen for the initial plotting of
the pneumatic curve.
Pressing the RETURN soft-key will return the software to the
main screen without locking the unit. Pressing the LOCK AND
RETURN will lock the unit and return the software to the main
screen.
9 RE Qualifier System Manual

Resetting the Batch
In order to reset the count to zero from the main screen, press the
RESET BATCH soft-key. A
second screen will appear
which reads, “Press ‘ENT’ to
RESET BATCH. Press
‘ESC’ to cancel and return”.
If the user presses the
ENTER (labeled ENT) button
at this point, the batch count
will be set to zero. Also, any
output status signals that per-
tain to the previous cycle will be dropped.
If the ESCAPE button (labeled ESC) is pressed, the software will
return to the main screen without resetting any values. A batch
reset can be performed if the unit is locked or un-locked.
RE Qualifier System Manual 10

More Options
In order to access the rest of the functions, press the MORE soft-
key while the main screen is visible.
A list of nine additional func-
tions will appear similar to
the picture on the left. In
order to access any of the
functions on the list, press
the number on the keypad
that is associated with the
desired function from the list.
Pressing ‘1’ will allow the user to edit any given parameter.
Pressing ‘2’ will allow the user to select a new parameter.
Parameters can be selected from the menu or electrically through
the I/O port on the side of the unit. A dip-switch setting governs
which selection method is in use (front panel selection/electrical
I/O selection).
Pressing ‘3’ will allow the user to globalize a parameter set.
During globalization, the data from one parameter is selected and
copied into all of the other parameter sets.
Pressing ‘4’ allows access to the I/O options.
Pressing ‘5’ allows access to the time and date functions.
Pressing ‘6’ allows the user to reset the total, the batch, or both
the total and the batch.
Pressing ‘7’ allows the user to view past statuses.
Pressing ‘8’ will allow a user to program a new password into the
unit.
11 RE Qualifier System Manual

Pressing ‘9’ allows the user to adjust the LCD’s brightness and
contrast.
Users may also return to the main screen by pressing either the
RETURN or LOCK AND RETURN soft-keys.
Editing Parameter Sets
Choosing ‘1. Edit Parameter’
from the MORE OPTIONS
menu allows access to timers,
pressure levels, totals, and
batch settings for any given
parameter. In order to edit a
parameter, press the ‘MORE’
soft-key while at the main
screen.
If the unit is locked, the pass-
word will have to be entered
to proceed. Once the ‘MORE
OPTIONS’ screen appears,
select ‘EDIT PARAMETER’
by pressing ‘1’ on the key-
pad.
After choosing to edit a
parameter a list of the eight
possible parameters will
appear. Pressing a numeric
key 1 through 8 will allow
the user to access one of the
RE Qualifier System Manual 12

parameter sets A through H. Pressing ‘ESC’ at the SELECT
PARAMETER screen will return the program to the MORE
OPTIONS screen.
Once one of the eight parameters is selected by pressing one of
the associated numeric keys, that parameter will appear. Each
listing in the parameter set
will have a number associated
with it, a title, and then a
value. For instance the mini-
mum run timer in the exam-
ple to the left is listed as:
1. Timer Min = 0.121
Pressing the ‘1’ key will
allow the user to adjust Timer
Min’s value. Pressing any of the other number keys will allow
the user to adjust the value associated with that setting.
After an item from the parameter list is selected, another screen
will appear showing that items original value. On the screen will
also be a new value. A user can edit the new value by typing the
desired value on the keypad.
Once the new value is entered and is displayed on the screen,
pressing the ENT button will store that value into memory.
Conversely, the ESC button can be pressed to abort the editing
process.
When editing a parameter set it helps to know how each value
effects the operation of the RE Qualifier.
Timer Min defines the amount of time that the pneumatic signal
must be above the Run Start level but below the Clutch Level.
Timer Min is the minimum run-down time for a fastener.
13 RE Qualifier System Manual

Timer Max is the maximum time the pressure level can be above
the Run Start level prior to the signal rising above the Clutch
Level. Timer Max is the maximum time for the fastening process.
Time Clutch is the minimum time that the pressure level must be
above the Clutch Level setting at the end of a fastening.
Timer Bump is an ignore timer. In most cases, Timer Bump can
and should be set to zero.
Cycle Start is the pressure level at which the RE Qualifier will
store data.
Run Start is the pressure level which starts Timer Min and Timer
Max. While the pneumatic signal is above Run Start but below
the Clutch Level, the RE Qualifier assumes that the fastener is
fastening.
The Clutch Level is the pressure at which the pneumatic signal is
considered to be clutched out. Both Timer Min and Timer Max
stop running when the pressure reaches this level. Timer Clutch
is activated when the pressure rises above the Clutch Level.
The Batch setting represents the number of fastenings that must
be completed before a Batch OK signal is asserted.
The Total is the number of batches that have been completed.
RE Qualifier System Manual 14

Selecting a New Parameter
Selecting ‘2’ SELECT PARAMETER from the MORE OPTIONS
menu allows the user to choose a new parameter. This only
works if the dip-switch is set so that parameter selection is done
through the keypad.
After ‘2’ is pressed and
released, the SELECT PARA-
METER screen appears.
Pressing the number on the
screen that is associated with
the desired parameter tells the
RE Qualifier to load a the
new parameter set and use it
when monitoring fastening
processes and batch counting.
If ESC is pressed instead of
one of the number keys, no
new parameter is selected and
the screen will return to the
MORE OPTIONS page.
Users may wish to use more
than one parameter in order
to accommodate different tools. Utilizing multiple parameters will
also help if different assemblies are being produced with a vary-
ing number of fasteners.
15 RE Qualifier System Manual

Globalizing a Parameter
Selecting ‘3’ GLOBALIZE PARAMETER from the MORE
OPTIONS menu allows the user to choose the parameter that will
be copied into all of the other
parameters.
After ‘3’ is pressed and
released, the SELECT PARA-
METER screen appears.
Pressing the number on the
screen that is associated with
the desired parameter tells the
RE Qualifier to copy the
selected parameter into all of
the other parameter sets.
If ESC is pressed instead of
one of the number keys, no
parameters are copied and the
screen will return to the
MORE OPTIONS page.
This feature may be useful
when setting up several parameter sets where only one variable
(like batch) changes between each parameter.
RE Qualifier System Manual 16

Editing I/O Options
Selecting ‘4’ EDIT I/O OPTIONS from the MORE OPTIONS
menu allows the user to program features that relate to the input
and output structure.
After ‘4’ is pressed and
released, the EDIT I/O
OPTIONS screen appears.
Six setting are listed on this
screen. Pressing the number
next to a desired setting will
select that setting. Each set-
ting that is active will have an
asterisk (*) in front of the
number.
Numbers 1 and 2 both relate
to how the relays work. If 1
is selected, the relays will be
momentary and will come on
for 200 milli-seconds each
time they are activated by a
change in status. If the relays
are set to latching (2) the relay will remain on until the beginning
of the next cycle.
Numbers 3 and 4 control whether or nor a double beep will be
generated when a batch is completed. If 3 is selected, the double-
beep feature will be turned off and the buzzer will only sound if a
reject occurs. If 4 is selected, each batch completion will be
announced with a short double-beeping of the buzzer.
17 RE Qualifier System Manual