Stanley Theta Controller User manual

Assembly Technologies
Theta Controller User Manual
Software Version QC1-3. .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.
© 2009 THE STANLEY WORKS, ALL RIGHTS RESERVED
www.StanleyAssembly.com
Theta
User0
0
0
9

User Manual
ii
Contents
Getting Started...........................................................................................1
1.1 EC Directives........................................................................1
1.2 Warnings and Cautions ........................................................1
1.3 Specifications, Layout and Display.......................................2
1.4 Installation Instructions.........................................................4
1.4.1 Theta Controller E-Stop Precaution...............................6
Programming..............................................................................................7
2.1 Theory of Operation..............................................................7
2.1.1 Data Storage .................................................................7
2.1.2 Input and Output Elements............................................7
2.2 Software ...............................................................................7
2.3 Networking............................................................................7
2.4 QA Theta Controller Navigation and Programming...............8
2.5 Display..................................................................................8
2.5.1 Scroll Bar.......................................................................8
2.5.2 Dropdown......................................................................8
2.5.3 Menu Tree.....................................................................9
2.5.4 Tabs...............................................................................9
2.5.5 Character Scrollbar........................................................9
2.5.6 Run Display...................................................................9
2.6 Faults..................................................................................10
2.7 Messages ...........................................................................11
2.8 Theta Controller Programming............................................12
2.8.1 Setup Menu: 1. Jobs....................................................13
2.8.1.1 Wizard Screens .......................................................13
2.8.1.2 Setup: Job Tab ........................................................17
2.8.1.3 Setup: Manage Button (Job)....................................19
2.8.1.4 Setup: Task Button ..................................................19
2.8.1.5 Setup: Step Button...................................................21
2.8.1.6 Setup: Manage Button (Step) ..................................23
2.8.1.7 Setup: Exit ...............................................................23
2.8.2 Setup Menu: 2. Communications.................................24
2.8.3 Setup Menu: 3. Other..................................................25
2.8.3.1 General Tab.............................................................25
2.8.3.2 Users Tab................................................................26
2.8.3.3 I/O Tab.....................................................................28
2.8.3.3.1 Output Bus........................................................28
2.8.3.3.2 Input Bus...........................................................29
2.8.3.4 Triggers Tab ............................................................29
2.8.3.5 Lights Tab................................................................30
2.8.3.6 Tones Tab................................................................30
2.8.3.7 Tool Tab...................................................................31
2.8.3.8 Regional Tab ...........................................................32
2.8.3.9 Clock Tab.................................................................32
2.8.4 Setup Menu: 4. Restore Factory Defaults....................32

Theta Controller
Contents iii
2.8.5 Service.........................................................................33
2.8.5.1 Tool..........................................................................33
2.8.5.1.1 About Tab..........................................................33
2.8.5.1.2 Counters Tab ....................................................33
2.8.5.1.3 CAL Tab............................................................34
2.8.5.2 Controller.................................................................34
2.8.5.3 Controller.................................................................34
2.8.5.3.1 About Tab..........................................................35
2.8.6 Analyze........................................................................35
2.8.6.1 TOOL tab.................................................................35
2.8.6.2 TRACE tab...............................................................36
2.8.6.3 I/O tab......................................................................36
QPM DC Electric Tools ............................................................................38
3.1 Tool Specifications..............................................................38
3.2 Operator Protection ............................................................39
3.2.1 Repetitive Motion.........................................................39
3.2.2 Hearing Protection.......................................................39
3.2.3 Vibration ......................................................................40
3.2.4 Breathing Protection....................................................40
3.3 Tool Installation...................................................................40
3.3.1 Sockets and Adapters..................................................40
3.3.2 Suspension Devices....................................................41
3.3.3 Cable Installation.........................................................41
3.4 QPM Tools..........................................................................41
3.4.1 Display and Multiple Function Button for Hand Held
Tools 41
3.4.2 MFB Mode...................................................................41
3.4.3 Tool Memory................................................................42
3.4.4 Tightening Cycle Counters ..........................................42
3.5 Tool Operation....................................................................43
3.5.1 Directional Control.......................................................43
3.5.2 Torque Reaction Devices ............................................43
3.5.3 Tool Temperature........................................................44
3.5.4 Tool Status Lights........................................................44
3.5.5 Tool Audible Device.....................................................44
3.5.6 Setting Torque, Angle and Other Operating
Parameters................................................................................44
3.6 Special Application Tools....................................................44
3.6.1 Exposed Gear Socket Tools........................................44
3.6.2 Tubenut Nutrunners.....................................................45
Theta Controller Connections...................................................................46
4.1 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
4.2 Assignable Input/Output Functions.....................................50
4.2.1 Input Descriptions........................................................51

User Manual
iv
4.2.2 Output Descriptions.....................................................53
Glossary...................................................................................................55
Appendix A – Controller Gateway............................................................57
Appendix B – Torsion Compensation.......................................................58
Warranty...................................................................................................60

Theta Controller
Getting Started 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 EC Directives
The QPM tightening systems are designed and built, in whole or in part, using the following
standards and or directives.
2006/42/EC Machinery Directive
Standard Title / Description
EN292-1,2 Safety of Machinery - Basic Concepts
EN14121-1 Safety of Machinery - Principles of Risk Assessment
EN501 8 Electronic Equipment for Use in Power Installations
EN60204-1 Safety of Machinery Part 1 - Electrical Equipment of Machines
EN60 45-1 Hand-Held Motor-Operated Electric Tools - Safety
89/336/EEC Electromagnetic Compatibility Directive
Standard Title / Description
EN55011 Conducted and Radiated Emissions
EN61000-3-2 Current Harmonics
EN61000-3-3 Voltage Fluctuation and Flicker
EN61000-4-3 Radiated Immunity
EN61000-4-4 Fast Burst Transients
EN61000-4-5 Surge
EN61000-4-6 Conducted Immunity
EN61000-4-8 Magnetic Immunity
EN61000-4-11 Voltage dips/interruptions
EN61000-4-2 Electrostatic Discharge Immunity
Level 4: Contact Discharge 8 KV Air Discharge 15 KV
1.2 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
Indicates that death or severe
personal injury will result if
proper precautions are not taken.
Indicates a general hazard. This
icon appears as a part of a
Danger, Warning, or Caution
notice.
Warning
Indicates that death or severe
personal injury may result if
proper precautions are not taken.
Indicates that eye protection
should be worn. This icon
appears as a part of a Danger,
Warning, or Caution notice.
Caution
Indicates that property damage
may result if proper precautions
are not taken.
Read and understand all the
safety recommendations and all
operating instructions before
operating tools and controllers.

User Manual
2
Indicates an electrical hazard.
This icon appears as a part of a
Danger, Warning, or Caution
notice.
Indicates an item of special
interest.
W A R N I N G
To Avoid Injury:
•Read and understand all the safety recommendations and all operating instructions before
operating tools and controllers. Save these instructions for future reference.
•Train all operators in the safe and proper use of power tools. 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.
Qualified Personnel
W A R N I N G
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.
1.3 Specifications, Layout and Display
Dimensions Width: 6.0 in 152 mm
Height: 14.2 in 361 mm
Depth: 8.2 in 208 mm
Weight: 15 lb 7.0kg
Operating Conditions: Temperature: 32 to 122 ºF (0 to +50 ºC)
Humidity: 0 to 95 % non-condensing
Power Source: 100 – 126 VAC, 50/60 Hz, 15 – 20A service or
207 – 253 VAC, 50/60 Hz, 10 – 16A service
Power Consumption: Stand by: 0.2 A (amperes)
Continuous: 1-2.5 kVA
Tool Motor Power: Service Rating: EC02/EC22 EC33/EC34 EC44/E45 EC55
Consumption @ 115 VAC: 15A 15A 20A* 30A*
@ 230 VAC: 10A 10A 10A 16A
Continuous kVA: 0.3 0.7 1 1.7
* 200- 240 VAC recommended, heavy duty power cord required with 100- 120 VAC

Theta Controller
Getting Started 3
1
2
3
4
5
6
8
9
10
11
12
13
7
14
Item Functional Description
1 Red, Green, Yellow LED's for Limits Evaluation
2 Display
3 Function Keys with Active Label Above
4 Cursor Keys with Center Button to Expand Lists
5 Maintenance Due and ATC Active LED's
6 Numeric Keypad to Enter Numbers or Select Options
Controller Label and Serial Number
8 Power Switch
9 Power Input
10 24 VDC Input/Output Connector
11 20A Fuse MDA-20 (P/N 21R20100 )
12 Serial Connector for Laptop
13 Tool Connector
14 Serial Connector for Network Protocols

User Manual
4
1.4 Installation Instructions
W A R N I N G
To Avoid Injury:
•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.
•Train all operators in the safe and proper use of power tools. Operators should report any
unsafe condition.
•Store idle tools and accessories in a safe location accessible only by trained persons.
•Disconnect power source (air, electricity, etc.) from tool 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.
•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.
DC Electric Tools & Controllers:
•Install tools in dry, indoor, non-flammable, and non-explosive environments only – Humidity: 0
to 95% non-condensing and Temperature: 32 to 122 ºF (0 to +50 ºC).
•Installation, maintenance and programming should be performed by qualified personnel.
Follow all manufacturer installation instructions and applicable regulatory electrical codes and
safety codes.
•Tool and controller plugs must match the outlet. This equipment 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.
W A R N I N G
To Avoid Injury:
•Install modules in dry, indoor, non-flammable, and non-explosive environments only.
•Qualified personnel should perform installation and programming. Follow all manufacturer
installation instructions, applicable regulatory electrical codes, and safety codes.
•Limit module access to trained and qualified personnel. Lock module cabinets.
W A R N I N G
ELECTRICAL HAZARD
To Avoid Injury:
•Install modules 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.
•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.

Theta Controller
Getting Started
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"
(50.8 mm). When mounting plinths are place one above another the center to center distance
between the mounting holds in different plinths is 6" (152.4 mm).

User Manual
6
1. Install the Theta Controller either directly to the wall or to an optional mounting plinth.
2. Fasteners through four mounting holes secure plinths to a wall or 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.
3. Make sure the bolts of the barrel-latches [5] on the plinth are retracted. Place the lower flange
of the Theta controller [1] into the lip [2] on the plinth.
4. 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.
5. 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.
6. Connect the Theta Controller to a power source.
7. Connect the tool cable to the Theta controller and press the power switch on the controller.
8. The controller displays a language list at the first factory boot up. Press
the up/down arrows to select a language, then press either OK from the
interactive menu button or use the toggle button to save the selection. The
controller next displays the run screen and is ready for programming and
operation.
1.4.1 Theta Controller E-Stop Precaution
W A R N I N G
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
power supply line.

Theta Controller
Programming 7
Programming
2.1 Theory of Operation
The Theta controller is designed as a medium-feature transducerized DC tool controller. It will
control any 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.
2.1.2 Input and Output Elements
Bolt Count and Error Proofing functions are an integral part of the Theta controller’s functions. Its
four inputs and four outputs, on the 24 VDC connector, support these functions to provide
advanced plant integration by external devices such as a PLC.
The inputs and outputs are assignable and configurable.
2.2 Software
The Controller Gateway connects to the Theta’s COM 1 via a serial connection and performs all
the functions of the Embedded Toolbox. This software is required to reside on the end user’s
computer.
2.3 Networking
The Theta controller supports the OPEN protocol, Toyota PI protocol and PRINT mode through
its second serial port. Each protocol requires a unique Theta controller firmware.

User Manual
8
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. If
the label is blank, the button has no
function for the current display.
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 menu button).
The numeric keypad [4] facilitates data
input and menu selection (where
applicable) and job/step selection when
enabled.
2. Display
2. .1 Scroll Bar
A scroll bar appears when more items are available than space within the
display allows. The up arrow [1] and down arrow [3] direct scrolling. The
black/white scroll bar [2] 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. .2 Dropdown
A dropdown [1] 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.

Theta Controller
Programming 9
2. .3 Menu Tree
A menu tree [1] appears beside related menu items.
2. .4 Tabs
Tabs [1] 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. . 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 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. Push toggle button or OK menu button to accept entry.
The following screens contain the character scrollbar option: Job (Name), Step
(Name), System Name (General), and System (Users).
2. .6 Run Display
Icons identify events [1] (see list below).
When a tool is connected, the last torque
and angle readings (and units) display [2].
Up/down arrows next to the torque or
angle value indicate the last fastening
cycle NOK status (exceeded ▲or did not
achieve ▼torque or angle limits).
Identifies the active Job [6] and active Task [7]. Identifies Target bolt 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 run display changes to indicate the
step in which the tool stopped (providing it
did not stop during the audit step).
The display background color in normal operation is white. After an OK fastening cycle, the
display background color changes to green for two seconds, then reverts back to white for the next
cycle. After a NOK fastening cycle, the display background color changes to red for two seconds,
then reverts back to white for the next cycle. The display background color turns red in the event
of a fault; see section 2.6 Faults.
Shutoff Codes on the display indicate why a tightening cycle terminated prior to completion.
Shutoff Code
Description
TIME Tightening time exceeds programmed Cycle Abort time value
STOP Spindle stopped by either the operator or other device
125% Spindle stopped due to torque achieving greater than 125% torque limit for the spindle
FAULT Precedes a fault described in section 2.6 Faults
STALL Spindle in stall status

User Manual
10
CAN 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 Check the run screen for Fault message
Force on or off Identifies an input/output forced on or off
User Entered Password This icon appears next to the user, in the User list, that has entered
their password and unlocked the controller.
Stop Tool Operation (press
trigger for cause) Along with the onscreen indication, the blue light on the tool MFP
extinguishes and the STOPPED output asserts.
Stop Tool Explanations
Undefined Job – The selected Job/Task is not programmed to run a
tool. Select another Job/Task or program the currently selected
Job/Task.
Network Protocol – The plant control system is issuing a Stop via a
network protocol. Wait for the protocol to remove the Stop
command.
Error Proofing – Bolt count has been met. Reset with a Job Reset
input.
Stop Issued – An Input is disabling the tool. Remove the Stop input.
Invalid Job – The selected Job is wrong based on the validation
inputs.
System Initializing – The controller is booting up; please wait.
Cycle Lock-out – The Cycle Lockout timer is active; wait for it to
reset.
Not Armed – There are two things that can cause this event:
a) Tubenuts – By default tubenuts require arming by tapping
the MFB before the trigger is pressed to run the tool.
b) Reset Reject – The fastening cycle is NOK and the MFB
mode is set to Reset Reject preventing the tool from
running until the MFB is pressed to reset the NOK.
2.6 Faults
The display background color in normal operation
is white. In the event of a fault, the display
background becomes red and the fault description
appears on screen. The background color reverts
to white only when the fault is cleared.

Theta Controller
Programming 11
Overcurrent Fault! There are two things that can cause this hardware fault:
a) GFI – the Ground Fault Interrupter has exceeded its
current trip point. A current detector monitors the current
through the three phases of the motor and asserts this fault
when the total current applied to the tool does not equal the
total current returned from the tool. All phases are turned
off immediately to protect the controller from shorts at the
tool end.
b) Total Current – the controller software limits the current
applied to any tool based on what the tool can handle. This
fault is asserted if there is a short at the tool end and the
total current applied is greater than allowed.
Logic Voltage Fault! The controller monitors the +5VDC, -5VDC and +12VDC of its
onboard Power Supply. This fault is asserted when those voltages
fall outside of nominal range.
Position Feedback Fault! The controller is constantly monitoring the resolver zero and span
points and asserts this fault if they go outside specification.
Transducer Span Fault! This fault is asserted when the transducer zero point has shifted far
enough to prevent a full scale reading from the transducer.
Temperature Fault! This fault is asserted when the tool temperature detector has
reached the temperature limit set by the Temperature Limit
parameter. It resets after detected temperature has dropped by 5°C.
Unrecognized Tool! The controller is communicating to the tool but does not recognize
the model number written in the tool memory board.
Tool Communications! The controller is not communicating to a tool.
Transducer Current Fault Transducer current has fallen outside nominal values. For E series
tools that is 15.74 mA +/- 75% (4.5 – 26mA). For EA series tools
that is 4.16 mA +/- 75% (1 to 7mA).
Transducer Zero Fault! The transducer zero point has shifted too far for the controller to
compensate. These points are visible on the controller diagnostics
screen under 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.
They may appear on any screen at any time.
Communication Fault Used for Toyota Protocol only. Controller has lost
communications to the PI box.
Count Fault Used for Toyota Protocol only. Controller and PI box have a bolt
count mismatch.
Program Fault Used for Toyota Protocol only. More tightening cycles were
performed than the PI box expected.
Tool Update Failed Controller failed to update the tool configuration.
Nothing to Configure! The parameter selected has nothing to configure.

User Manual
12
2.8 Theta Controller Programming
W A R N I N G
EXCESSIVE TORQUE CONDITION
To Avoid Injury:
•Only trained and qualified personnel should program controllers.
•Never set control limits above the maximum rating of the tool.
•Setting control limits above the maximum rating of the tool can cause high reaction torque.
•Always test for proper tool operation after programming the controller.
The controller uses three main menus to display information and enable programming:
•Setup menu
•Service menu
•Analyze menu
To begin programming a tool strategy, press the Setup menu button.
1. Jobs – use to perform tool strategy programming such as torque and speed parameters.
2. Communications – use to program serial port options.
3. Other – use to set parameters for all other features, including system level, users, passwords, I/O
and tool functions.
4. Restore Factory Defaults – use to backup/restore/delete programming and return controller to
factory defaults.
To access, press the corresponding menu number on the keypad, or use the up/down arrow keys to
highlight, then press the Toggle button.
Icon Legend Icon Description Navigation
Menu Buttons Press to activate menu option noted above button.
Left/Right Arrow Keys Navigate tabs as well as backspace and space.
Up/Down Arrow Keys Scroll through menu selection and character selection.
Toggle Button Selects option for data input, accepts changes.
Numeric Keypad 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.
Default Screens Options Screen

Theta Controller
Programming 13
NOTE:
Programming changes are stored after exiting current menu and returning to run screen.
2.8.1 Setup Menu: 1. Jobs
Jobs controls tool operation for tightening a fastener: one to 16 and one TC/AM (Torque Control,
Angle Monitoring) Step with up to three optional Smart Steps. Most controllers operate with a
single Job and Task with one or two Steps. Users must have ADMINISTRATOR or SETUP
access in order to modify Job settings. This includes Wizard, Manage and Step parameters.
The Wizard automatically appears after selecting Jobs if a tool is attached and a Job or Task is
added. The Wizard sets a Job or Task for simple or complex fastening cycles using the optional
Smart Steps.
If no tool is attached, or if at least one Job exists, the Job tab appears allowing for advanced user
programming.
2.8.1.1 Wizard Screens
Wizard Screens Options Screen
The Wizard assists with programming the controller to assign a Job, which consists of one
Audit Step with optional Smart Steps. To function, the Wizard requires a tool to be connected.
It automatically appears when there are no configured jobs or when adding a new job. The
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. The controller
also monitors angle which can indicate changes in joint rate. Audit torque and
angle results must fall within their specified limits for the fastening cycle to be
acceptable.
Units – operating units:
NM, Newton Meters
FTLB, Foot Pounds
INLB, Inch Pounds
INOZ, Inch Ounces
KGM, Kilogram Meters
KGCM, Kilogram Centimeters
NCM, Newton Centimeters
Thread Direction – for tightening a right hand fastener use CW, clockwise. Use CCW, counter-
clockwise for left hand fasteners.

User Manual
14
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.
Press the CANCEL interactive menu button at any time to stop Wizard operation.
Use the keypad to enter the desired values for
High Torque, Low Torque and Speed.
High Torque – The Wizard uses the
maximum torque for the connected tool.
Low Torque – The Wizard uses zero as the
low torque limit of the strategy.
Speed – The Wizard uses the maximum
speed of the connected tool.
The final TC/AM step is now defined. The Wizard uses the median value between the High
and Low Torque parameters as the Target Torque. It also calculates and programs other
parameters automatically, including: Snug Torque, Threshold Torque, Statistical Torque and
High Angle Bailout. Change these values after saving Wizard programming if desired.
Press the PREV interactive menu button to move back to previously programmed screens
within the Wizard.
Next, select the controls specific to your application. Option screens appear for each specific
control chosen. The Wizard makes assumptions and calculates specific values, modify these
values if necessary.
Use the Toggle button to select or deselect the
controls specific to your application. Press the
NEXT interactive menu button to view the
option screens for each specific control
chosen. The Wizard makes assumptions,
calculates and presents specific values.
Modify these values if necessary.
Not Selected
Selected
Wobble, Slow Seek, Self Tap, and Pre-Torque
are Smart Steps that can be added to the
beginning of the tool strategy. Backout
Fastener is a Smart Step that can be added
after the audit step. These controls only exist
when an audit step exists; they cannot be
programmed as steps unto themselves.
ATC (Adaptive Tightening Control) controls
tool inertia toward the end of the tightening
cycle for more consistent fastening.

Theta Controller
Programming 1
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). If selected,
this will be the first step in the tool strategy.
Wobble Options include:
Angle Target – The number of degrees of
rotation the socket turns during this step.
Speed – The speed of the tool during this step.
Max Torque – The maximum allowed torque
during this step. A low value is calculated by
the Wizard to detect cross-threads.
Slow Seek is an Angle Control / Torque
Monitoring strategy in the same direction for
which the final tool strategy is programmed.
This allows the flats of the socket to align
with the flats on the fastener before a standard
forward rotation and high speed are applied.
Using Slow Seek as a first step also allows for
cross-thread detection. If selected, this is the
first step after Wobble. If Wobble is not
selected, this is the first step in the tool
strategy. Slow Seek options include:
Angle Target – The number of degrees of
rotation the socket turns during this step.
Speed – The speed of the tool during this step.
Max Torque – The maximum allowed torque
during this step. A low value is calculated by
the Wizard to detect cross-threads.
Self Tap is an Angle Control / Torque
Monitoring strategy in the same direction for
which the final tool strategy is programmed.
This Smart Step allows the tool to compensate
for a high prevailing torque application. If
selected, this step follows the Slow Seek step
and just prior to the audit step. Self Tap
options include:

User Manual
16
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 – The maximum allowed torque
during this step.
Pre-Torque is a Torque Control /Angle
Monitoring strategy in the same direction for
which the final tool strategy is programmed.
The tool runs the fastener to a preliminary
torque level and suspends the fastening cycle
for a period of time. After a time delay, the
Audit step begins. If selected, this is the first
step AFTER Start Delay. Options include:
Torque Target – The Target Torque for this
step.
Delay Between Steps – The time period to
suspend the tool strategy before continuing.
If SYNCHRONIZE is used, the tool waits
here until all synchronized tools have
completed this step before continuing.
ATC (Adaptive Tightening Control) is not a
strategy or a step. It is an algorithm that
modifies the tool’s speed as the torque rises.
Select this, instead of a downshift, as an
option to increase tool capability.
There are no options with this selection. The
values are calculated automatically.
Backout Fastener – Accomodates assembly
procedures requiring partial removal of the
fastener before additional components can be
added to the joint. Creates a Backoff strategy
step after the Audit step. The tool stops after
achieving either the angle or torque target. If
selected, this is the first step after the Audit
step. Options include:
Angle Target – The number of degrees of
rotation the socket turns during this step.
Torque Target – The Target Torque for this
step.
Speed – The socket speed during this step.