AcraDyne Gen IV iEC Controller

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Product Information

Specifications

• Model: Gen IV iEC Controller
• Brand: AcraDyne
• Supported MIDs: Yes
• 24 Volt I/O: Yes
• Assignable I/O: Yes

Product Usage Instructions

Initial Setup

1. Connect the controller to a power source and ensure it is
properly grounded.

2. Refer to the Controller Diagram in the manual to understand
the different components.

Connecting to the Controller

1. Use the provided cables to establish a connection between the
controller and your device.

2. Follow the step-by-step instructions on how to establish a
secure connection.

Quick Set Up (Default PSets from Tool)

1. Access the Quick Set Up menu on the controller.

2. Select the default PSets from the tool for quick
configuration.

Home Page (Main Menu)

1. The Home Page displays options like Run, PSet, Job, Barcode
Reader Details, etc.

2. Navigate through the menu using the console LED display and
buttons.

Frequently Asked Questions (FAQ)

Q: How do I calibrate the torque on the controller?

A: To calibrate torque, navigate to the Torque Calibration
option in the Tool Setup menu and follow the on-screen
instructions.

Q: Can I set up a multi-spindle network with this

controller?

A: Yes, you can set up a multi-spindle network by following the
instructions provided in section 4.5.10.1 of the manual.

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Gen IV iEC Controller Operation Manual
10000 SE Pine St., Portland, OR 97216 · 800-852-1368 · 503-254-6600 · Fax 800-582-9015 www.aimco-global.com

AcraDyne Gen IV iEC Controller Manual

Table of Contents

1. Safety Information . . . . . . . . . . 3

4.5.10 Master Spindle Setup . . . . . . . 48

2. Controller Diagram . . . . . . . . . . 4 2.1 Bottom Panel . . . . . . . . . . . 4 2.2 Front Console LED Display . . . . . . . 4
3. Initial Setup. . . . . . . . . . . . . 5

4.5.10.1 Setting up Multi-Spindle Network . . . . 48
4.5.11 Languages . . . . . . . . . . 48 4.6 Tool . . . . . . . . . . . . . . 50
4.6.1 Tool Setup . . . . . . . . . . . 50 4.6.2 Service Log . . . . . . . . . . 50

3.1 Connecting to the Controller . . . . . . 5

4.6.3 Button Calibration . . . . . . . . 50

3.2 Quick Set Up (Default PSets from Tool) . . . 7

4.6.4 Torque Calibration . . . . . . . . 51

4. Home Page (Main Menu) . . . . . . . . 8 4.1 Run . . . . . . . . . . . . . . 8 4.2 PSet . . . . . . . . . . . . . . 10 4.2.1 Add New PSet . . . . . . . . . 10
4.2.1.1 Add New Stage . . . . . . . . . 10 4.2.1.2 AcraDrive Discontinuous Drive Mode Settings11 4.2.2 PSet Stages . . . . . . . . . . 14 4.2.2.1 TC Torque Control Stage . . . . . . 14 4.2.2.2 TC_AM Torque Control Angle Monitor Stage 15 4.2.2.3 AC_TM Angle Control Torque Monitor Stage 16 4.2.2.4 TC_AC Torque Control Angle Control Stage 17 4.2.2.5 Yield Control Stage . . . . . . . . 18 4.2.2.6 Delay Stage . . . . . . . . . . . 19 4.2.2.7 Unfasten Stage . . . . . . . . . . 19 4.2.2.8 Ergo Stop Stage . . . . . . . . . 20 4.2.2.9 Brake Stop Stage . . . . . . . . . 20 4.2.2.10 AC_TA Angle Control Torque Averaging
Stage . . . . . . . . . . . . . 21 4.2.2.11 AC_TCOMP Angle Control Torque
Compensation Stage . . . . . . . 22 4.2.2.12 AC_TCOMP Display of Torque
Compensation Value . . . . . . . 22 4.2.2.13 Sync Stage . . . . . . . . . . . 23 4.2.2.14 Thread Forming Stage . . . . . . . 23 4.2.2.15 Homing Stage . . . . . . . . . . 24 4.2.2.16 AC_TM Anti-Necking Stage . . . . . 25 4.2.2.17 Rate_Control Stage . . . . . . . . 26 4.2.3 Edit PSet . . . . . . . . . . . 27 4.2.4 Advanced Options. . . . . . . . 27 4.2.5 Default Psets . . . . . . . . . . 28 4.2.6 Manage PSets . . . . . . . . . 28 4.2.7 Multistage Rundown Evaluation and
Reporting . . . . . . . . . . . 29

4.6.5 Torque Calibration Routine . . . . . 51 4.6.6 TID Parameters . . . . . . . . . 51 4.6.7 TID Memory . . . . . . . . . . 52 4.7 Accessories . . . . . . . . . . . 52 4.8 Diagnostics . . . . . . . . . . . . 53 4.8.1 Controller Overview . . . . . . . 53 4.8.2 Controller Status. . . . . . . . . 53 4.8.3 Tool Overview . . . . . . . . . 54 4.8.4 Live Tool . . . . . . . . . . . 54 4.8.5 Indicators . . . . . . . . . . . 54 4.8.6 Identify Controller . . . . . . . . 55 4.8.7 Record Logs . . . . . . . . . . 55
4.8.7.1 Change Log . . . . . . . . . . 55
4.8.7.2 Information Log . . . . . . . . . 55
4.8.7.3 Error Log . . . . . . . . . . . . 55
4.8.7.4 All . . . . . . . . . . . . . . 55 4.8.8 System Status. . . . . . . . . . 55 4.8.9 I/O Diagnostics . . . . . . . . . 55 4.8.10 Network Diagnostics . . . . . . . 55 4.8.11 Extended Logging . . . . . . . . 56 4.8.12 Statistics . . . . . . . . . . . 56 4.9 Login . . . . . . . . . . . . . . 56 4.10 Advanced . . . . . . . . . . . . 56 4.10.1 Login Setup . . . . . . . . . . 56 4.10.2 Results Archive . . . . . . . . . 57 4.10.3 Import Settings . . . . . . . . . 57 4.10.4 Export Controller . . . . . . . . 58 4.10.5 Update Controller . . . . . . . . 58 4.10.6 Backup Restore . . . . . . . . . 58 4.10.7 Restore Factory Defaults . . . . . . 59 4.10.8 Previous Software . . . . . . . . 59 4.10.9 Calibrate Touch Screen . . . . . . 59 4.10.10 Soft Reboot . . . . . . . . . . 60

4.2.8 Multiple Stage Rundown Examples . . 30 4.3 Job . . . . . . . . . . . . . . 31
4.3.1 Add New Job . . . . . . . . . 31

5. Barcode Reader Details . . . . . . . . 61 6. Glossary of Terms. . . . . . . . . . . 63

4.3.1.1 Advanced Options . . . . . . . . 31

7. Icons Defined . . . . . . . . . . . . 64

4.3.2 Jobs “Enabled” Display and Button Function . . . . . . . . . . . 32
4.4 Results . . . . . . . . . . . . . 33

8. Stop Codes. . . . . . . . . . . . . 65 9. Error Codes. . . . . . . . . . . . . 66

4.4.1 Saving Rundown(s) . . . . . . . 33

10. Dual-Lever Tools Requiring Two-Handed

4.5 Controller . . . . . . . . . . . . 35

Operation . . . . . . . . . . . . . 68

4.5.1 Tool Setup . . . . . . . . . . . 35 4.5.1.1 Lock Tool On Reject . . . . . . . . 35

11. 24 Volt I/O . . . . . . . . . . . . . 69

4.5.1.2 Buzzer . . . . . . . . . . . . . 36

12. Assignable I/O . . . . . . . . . . . 71

4.5.1.3 Lights . . . . . . . . . . . . . 36 4.5.1.4 Start Input. . . . . . . . . . . . 36 4.5.1.5 MFB (Multi-Function Button) . . . . . 37

13. Controller Supported MIDs. . . . . . . . 83 14. Dimensions . . . . . . . . . . . . . 84

4.5.1.6 Disassembly . . . . . . . . . . . 38

15. Specifications . . . . . . . . . . . . 84

4.5.1.7 Tubenut . . . . . . . . . . . . 39 4.5.1.8 Past Due Service Calibration . . . . . 39 4.5.2 IO . . . . . . . . . . . . . 40 4.5.2.1 Physical IO . . . . . . . . . . . 40 4.5.2.2 Physical IO Monitor . . . . . . . . 40 4.5.2.3 Anybus/Modbus TCP/Ethernet IP Inputs . 41 4.5.2.4 Anybus/Modbus TCP/Ethernet IP Outputs. 42 4.5.3 Communication Interfaces . . . . . 43 4.5.3.1 Ethernet/Second Ethernet . . . . . . 43 4.5.3.2 System Port . . . . . . . . . . . 43 4.5.3.3 Serial Port . . . . . . . . . . . . 43 4.5.3.4 Anybus . . . . . . . . . . . . 44 4.5.3.5 Spindle USB Port . . . . . . . . . 44 4.5.3.6 Serial USB . . . . . . . . . . . . 46 4.5.4 Protocols . . . . . . . . . . . 46 4.5.5 Front Panel Buttons. . . . . . . . 46 4.5.6 Power Up . . . . . . . . . . . 46

16. Tubenut Tool Setup Details. . . . . . . . 85 16.1 Overview . . . . . . . . . . . . 85 16.2 Tubenut Homing . . . . . . . . . . 85 16.2.1 Tubenut Home TID parameters . . . . 85 16.3 Setting the Tool’s Tubenut Home TID Parameters . . . . . . . . . . . . 85 16.4 Controller Parameters Affecting Tubenut Homing . . . . . . . . . . . . . 85 16.5 Tubenut Resistance Detection . . . . . 86 16.5.1 Obstruction Detection TID Parameters . 86 16.5.2 Setting the Tool’s Tubenut Obstruction Detection . . . . . . . . . . . 86 16.5.3 Controller Parameters Affecting Tubenut Resistance Detection . . . . 86 16.5.4 Tubenut Homing Start Input Logic Selection . . . . . . . . . . . 86

4.5.7 Bar Code Setup . . . . . . . . 47

17. Troubleshooting . . . . . . . . . . . 87

4.5.8 Set Time . . . . . . . . . . . 48 4.5.9 Remote Connections . . . . . . . 48

18. AIMCO Warranty . . . . . . . . . . . 88

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AcraDyne Gen IV iEC Controller Manual

1. Safety Information General Power Tool Safety Warnings

WARNING Read all safety warnings, instructions, illustrations, and specifications provided with this power tool. Failure to follow all instructions listed below may result in electric shock, fire, and/or serious injury. Save all warnings and instructions for future reference.
1. Work area safety a. Keep work area clean and well lit. b. Do not operate power tools in explosive atmospheres, such as in the presence of flammable liquids, gases, or dust. c. Keep children and bystanders away while operating a power tool.
2. Electrical safety a. Power tool plugs must match the outlet. Never modify the plug in any way. Do not use any adapter plugs with earthed (grounded) power tools. b. Avoid body contact with earthed or grounded surfaces, such as pipes, radiators, ranges, and refrigerators. c. Do not expose power tools to rain or wet conditions. d. Do not abuse the cord. Never use the cord for carrying, pulling, or unplugging the power tool. Keep cord away from heat, oil, sharp edges, or moving parts. e. When operating a power tool outdoors, use an extension cord suitable for outdoor use. f. If operating a power tool in a damp location is unavoidable, use a residual current device (RCD) protected supply.
3. Personal safety a. Stay alert, watch what you are doing, and use common sense when operating a power tool. Do not use a power tool while you are tired or under the influence of drugs, alcohol, or medication. b. Use personal protective equipment. Always wear eye protection. c. Prevent unintentional starting. Ensure the switch is in the off-position before connecting to power source and/or battery pack, picking up or carrying the tool. d. Remove any adjusting key or wrench before turning the power tool on. e. Do not overreach. Keep proper footing and balance at all times.

4. Power tool use and care
a. Do not force the power tool. Use the correct power tool for your application.
b. Do not use the power tool if the switch does not turn it on and off.
c. Disconnect the plug from the power source and/ or remove the battery pack, if detachable, from the power tool before making any adjustments, changing accessories, or storing power tools. Such preventive safety measures reduce the risk of starting the power tool accidentally.
d. Store idle power tools out of the reach of children and do not allow persons unfamiliar with the power tool or these instructions to operate the power tool. Power tools are dangerous in the hands of untrained users.
e. Maintain power tools and accessories. Check for misalignment or binding of moving parts, breakage of parts, and any other condition that may affect the power tool’s operation. If damaged, have the power tool repaired before use. Many accidents are caused by poorly maintained power tools.
f. Use the power tool, accessories, and tool bits, etc., in accordance with these instructions, taking into account the working conditions and the work to be performed. Use of the power tool for operations different from those intended could result in a hazardous situation.
g. Keep handles and grasping surfaces dry, clean, and free from oil and grease. Slippery handles and grasping surfaces do not allow for safe handling and control of the tool in unexpected situations.
5. Service
a. Have your power tool serviced by a qualified repair person using only identical replacement parts. This will ensure that the safety of the power tool is maintained.
6. Equipment Installation, Operation, and Maintenance
a. Safety of any system incorporating the equipment is the responsibility of the system assembler
b. Position the equipment so that it is easy to access the disconnecting device
c. Do not replace main power cord with an inadequately rated cord.
d. Only allow your power tool to be repaired by a qualified technician using only original spare parts, available from AIMCO. This ensures that the safety of your device is maintained.

f. Dress properly. Do not wear loose clothing or jewelry. Keep your hair, clothing, and gloves away from moving parts.

g. Do not let familiarity gained from frequent use of tools allow you to become complacent and ignore tool safety principles. A careless action can cause severe injury within a fraction of a second.

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AcraDyne Gen IV iEC Controller Manual

2. Controller Diagram
2.1 Bottom Panel

1 Tool Connector (19 pin) – Standard connection point for tool cable

2 USB Port – for import/export of data

1

6 3 Power Disconnect Switch – Turns controller on

and off

4 Power Cord Connection

2

7

5 Anybus – To connect customer’s fieldbus

network (ex. Profibus)

6 System Port – USB connection used to connect

3

8

external computer to configure/monitor the

controller

9

7 Ethernet Port RJ45 – Connection used to

connect external computer to configure/

4

monitor the controller

8 Serial Port (DB-9 Pin M) – Serial data output for

5

communication with peripherals such as bar code readers

9 24 Volt I/O Connector (DB-25 Pin M) – Input and output of signals for process control

2.2 Front Console LED Display

Indicator Lights

Green Red
Red Flashing Yellow
Yellow Flashing Blue

Indicates fastening cycle meets specified parameters.
Indicates fastening cycle rejected for exceeding high torque.
Indicates low torque. Fastening cycle was rejected for not achieving low torque.
Indicates High Angle. Fastening cycle was rejected for exceeding high angle.
Indicates Low Angle. Fastening cycle was rejected for not achieving low angle.
Tool is In-cycle, above threshold.

Toggle Button
Toggles what is shown in the secondary display

Parameter Settings (PSet)/Job Display

Increment/Decrement Buttons
Change PSet

Torque Display
Always displays torque value
Secondary Display
Toggle button switches secondary display between
· Units of measure · Ethernet IP address · USB (System Port) IP address · COMP: Torque Compensation
Tare Value (See details in AC_TCOMP Stage) · Angle report NOTE: If Jobs are enabled refer to “4.3 Job” on page 31 for Toggle Button function.

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AcraDyne Gen IV iEC Controller Manual

3. Initial Setup
Step 1: Connect tool cable to Tool Connector. AcraDyne recommends not exceeding 20m length of cable. Cable consists of a male pin set housed in a molded 19 pin connector with a polarizing notch. Align tool cable notch with tool connector notch on the controller and insert cable. Securely thread connector coupler to controller body.
Step 2: Repeat above process to connect tool cable to AcraDyne tool being used with the controller.
Step 3: Plug female end of power cable into Power Cable Connector.
Step 4: Plug male end of power cable into appropriate power source.
*It is recommended that 5000, 6000, 7000 and 8000 series tools be supplied by 200-240VAC.
Due to a variety of 230Vac power outlets, the standard power cable plug-end provided with the controller may need to be modified in order to connect to local 230Vac power outlets. AcraDyne has a wide variety of country-specific power cord options available. Check with your authorized AcraDyne representative to see if your specific configuration is available. In any case, connection to local power should be made in consultation with a qualified electrician.
Step 5: The Redundant Eath Ground (required) must be connected to ground using the #14 AWG conductor, a green wire with a yellow stripe. Attach using a

10-14AWG ring terminal and #10 star washer (Figure 1).

NOTE: Warning will appear if the controller is power cycled too quickly. If fault appears, Power Down controller, wait a minimum of 10 seconds between controller Power Down and Power Up to clear error and restart controller.
3.1 Connecting to the Controller
There are three ways to program/communicate with the controller:
· Controller touch-screen console · System Port: (USB connection) Direct connection
to controller. · Ethernet Port: Via direct connection or LAN.
Touchscreen Console
Controller functions and programming can be accessed directly through the touch-screen.
1. Power on controller. 2. Run screen will appear 3. Controller is ready for use.
Connecting via the System Port Directly to PC

Figure 1 — Redundant Earth Ground Attachment
Step 6: Turn controller on by pushing the Power Disconnect Switch to the POWER ON position, a light indicates power on.

The following is an example using Window 7. Your screen may look different depending on the operating system.
Windows USB Setup Step 1: Power on PC and controller, allow enough time for them to become fully operational.
Step 2: Attach controller to PC using a USB 2.0 A-B cable. If this is the first time connecting the devices, wait for Windows to install the RNDIS driver. This should happen automatically.

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AcraDyne Gen IV iEC Controller Manual

Step 3: After the driver is installed, go to `Control Panel’.

Step 6: Go to `Change adapter settings’.

Step 4: Go to `Network and Internet’.

Step 7: Find the Local Area Connection that is using the USB Ethernet/RNDIS Gadget’ network. Right click this network and go toProperties’.
Step 8: In Properties window select Internet Protocol Version 4′ and click Properties’.

Step 5: Go to `Network and Sharing Center’.

Step 9: In `Properties’, set the IP address to a static address.

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AcraDyne Gen IV iEC Controller Manual

Type an IP address of 192.168.1.5 (Any address on the same subnet as the controller will work). Set subnet mask to 255.255.255.0
Step 10: To connect to the controller, open a browser such as Chrome or Firefox. Enter 192.168.1.4, the default system port IP address.

255.255.255.0. (For instructions, see the example in “Step 9” earlier in this section.)
To connect to the controller. In the Computer/Laptop open a browser such as Chrome or Firefox. Enter 10.10.30.99, the default Ethernet port IP address.

You will see the controller software on your computer screen.

You will see on your computer screen the controller software

Connecting using the Ethernet Port Directly or via LAN to PC

NOTE: Controller does not have a DHCP client, it will not automatically configure itself with a usable IP address. Consult your Network Administrator for configuring a correct IP address for your network. The PC, Laptop or Tablet IP address will need to be configured to communicate with the controller.
3.2 Quick Set Up (Default PSets from Tool)
On the Home Page press the following to accept default PSet Parameters:

Turn on the computer and make a physical connection by using a straight through Ethernet cable.
Turn on controller. Verify the controller IP address in `Communication Interfaces’ or press toggle button to verify the IP address. If defaulted 0.0.0.0 set desired IP address.

This will generate three generic PSets for the tool connected to the controller. It will automatically use the 40%, 60%, and 80% of the rated maximum torque of the tool in a two-stage Torque Control Strategy (TC). A prompt will display rated Max Torque and Max RPM of the connected tool for reference. These Psets can be modified to meet application requirements.

Set a static IP address of the Computer/Laptop
to 10.10.30.98 (example) and subnet mask to 7

AcraDyne Gen IV iEC Controller Manual

4. Home Page (Main Menu)

Click on (or remote sessions can hover over) the rundown status icon or stop icons for a text description.

4.1 Run
The Run Screen is essentially the dashboard of the Gen IV controller and provides a look at real-time information regarding rundowns.

Graph displays curves representing Torque (black trace) and Angle (blue trace). The blue left arrow at the origin of the graph will change the X-axis of the rundown curve from Time (In-Cycle) to Time (Overall) and Angle.
Below the graph is a historical table that will give information and status of the most recent rundowns, including current PSet, accepted/failed rundown status,torque and angle.
Arrows allow user to scroll through screens that show real time Job information such as Run Screen or rundown indicators.

Home tab will return user to the Home Page

On the Run Screen, click

for curve detail.

Time (In-Cycle) Screen
Indicates the current JOB. Indicates the current PSet in which you are operating. Indicates accepted rundown.
Indicates failed rundown.
Displays Torque and Angle for current rundown.

Click on blue arrow to change curve X axis.
Choose Time In-cycle, Time Overall, Angle, or Angle In-Cycle screen.
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AcraDyne Gen IV iEC Controller Manual
Large Screen Indicators and Audit information The large screen indicators are helpful in viewing real time results of the rundown from a distance.
Example of Accepted Job
Example of Failed Job
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AcraDyne Gen IV iEC Controller Manual

4.2 PSet Parameter Settings (PSets) control the fastening process. The following describes the different fastening strategies and how to setup the basic PSet parameters necessary to perform a fastening. Up to 256 PSets are available.
For AcraDrive capable tools see “4.2.1.2 AcraDrive Discontinuous Drive Mode Settings” on page 11.
4.2.1 Add New PSet

On Home Page press the

tab.

On PSets screen press to add a new Pset.

Time Limit(s): Maximum allowable time (in seconds) tool is allowed to run.
Advanced Options: see “4.2.4 Advanced Options” on page 27
Audit Options: A PSet can be assigned 20 stages, and a tightening or loosening event can be performed in any of them. The Audit Options button allows the user to select the one stage that is of most importance and make the OK/NOK judgment of the event based on what transpires in that Stage. Default performs the Audit function after the last Stage completes.

Add a PSet Edit a PSet Copy a PSet Delete a PSet

Once PSet values are entered press Add New Stage screen.

to enter

4.2.1.1 Add New Stage A single stage or multiple stages build a PSet. Up to 20 stages can be assigned per PSet.

Default PSets: See “3.2 Quick Set Up” on page 7. Manage: See “4.2.6 Manage PSets” on page 28.
On Add New PSet screen (below) enter appropriate values.
PSet Number: Current PSet to be added.
Torque Units: Unit of measure.
In Cycle Torque: Threshold value at which tool is “In Cycle” and results from the Rundown will be reported.
Cycle Complete Torque: Torque level that determines completion of a fastening cycle.
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AcraDyne Gen IV iEC Controller Manual

The following stage options are available:

Discontinuous Mode Parameters

Once the desired stage(s) are selected and

configured, press to save stage and again to save the PSet and return to initial PSet menu.

Next Press to go to the RUN screen or

to

return to the Home page. The tool should now be

operational and you are ready to run a configured

PSet.

4.2.1.2 AcraDrive Discontinuous Drive Mode Settings The iEC Discontinuous Mode pulses the tool output to reduce torque reaction forces on the operator. To accomplish this, the tool relies on motor and gear inertia to transmit torque to the fastener instead of only the torque capability of the motor. Discontinuous Mode is only available for tools designed for discontinuous mode operation.

Detection Torque: 1.0 ­ 10 Nm, 0.1 ­ 1.0 kgm, 0.75 ­ 7.5 ft-lb, 9.0 ­ 90 in-lb · The Torque Value at which the forward-moving
state transitions to the backward-moving state. Higher values for Detection Torque mean that in order to determine a pulse, the impact torque is greater than the Detection Torque.
Current Limit: 1 ­ 50 A · Maximum current allowed throughout the
duration of the rundown. Higher values allow more aggressive fastening, but lower values can improve accuracy.
Time Between Pulses: 0 ­ 10 ms · How long to wait before the next pulse.
Forward Speed: 100 ­ 2000 RPM · How fast to rotate in the fastening direction.
Backdrive Speed: 100 ­ 1000 RPM · How fast to rotate in the un-fastening direction.

Discontinuous Mode Stages The following stages can be used in Discontinuous Mode: · TC (Torque Control) · TC_AM (Torque Control, Angle Monitor) · AC_TM (Angle Control, Torque Monitor) · TC_AC (Torque Control, Angle Control)
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AcraDyne Gen IV iEC Controller Manual

Discontinuous Mode Disassembly Parameters

If another pulse is detected while running the slower speed. The Pulse Time Out timer will reset, allowing the speed to return to the pulse Forward Speed setting.
Discontinuous Mode Sequence of Operation:

Enable Discontinuous Disassembly: · Determines whether to utilize Discontinuous Mode
in disassembly. Only tools with Discontinuous Mode enabled can use this mode.
Detection Torque: 1.0 ­ 10 Nm, 0.1 ­ 1.0 kgm, 0.75 ­ 7.5 ft-lb, 9.0 ­ 90 in-lb · The Torque Value at which the forward-moving
state transitions to the backward-moving state. Higher values for Detection Torque mean that in order to determine a pulse, the impact torque is greater than the Detection Torque.
Current Limit: 10 ­ 50 A · Maximum current allowed. Higher values allow
more aggressive fastening, but lower values can improve accuracy.
Time Between Pulses: 0 ­ 10 ms · How long to wait before the next pulse.
Forward Speed: 100 ­ 2000 RPM · How fast to rotate in the fastening direction.
Backdrive Speed: 100 ­ 1000 RPM · How fast to rotate in the un-fastening direction.
Pulse Timeout: 0.1 ­ 10 seconds · Amount of time not detecting a pulse required to
transition into normal continuous disassembly. When running in disassembly, the Pulse Time Out timer will start counting down and reset each time a pulse is detected If a pulse is not detected before the timer times out, the tool will slow down to the continuous speed setting. This can help prevent the fastener from completely backing off the threads when disassembling.

The following steps occur in sequence until either the target torque has been reached, a fault occurs, or a limit is reached:
1. The motor is commanded forward at Forward Speed until the measured torque exceeds Detection Torque.
2. The motor is commanded backward at Backdrive Speed until either the measured torque becomes negative, or an internal safety timer has expired.
3. The motor is commanded to brake until Time Between Pulses has elapsed.

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AcraDyne Gen IV iEC Controller Manual
Optimization and Troubleshooting
The following are examples of potential issues and how they can potentially be solved with minor tweaks to the Pulse Settings mentioned previously in this section.
· The tool stalls and struggles to reach the Target Torque:
Increase Current Limit if it isn’t already at the maximum allowed value.
Increase Backdrive Speed to prevent the tool from vibrating in place (the flat spot on the angle graph above shows an example of this).
· The tool exceeds the High Torque limit: Decrease Current Limit to create softer pulses. Decrease Forward Speed to reduce torque overshoot. If neither of the above fix the problem, try the following:
Change the PSet to have two
Discontinuous Mode stages instead of one:
The first should be more aggressive, with maximum Current Limit and/or Forward Speed.
The second should be less aggressive, with decreased Current Limit and/or Forward Speed.
Ensure the PSet has a Brake Stop stage
at the end. Increasing Detection Torque can also
sometimes increase torque accuracy.
· The tool is not driving the fastener forward: Decrease Backdrive Speed to ensure the tool doesn’t back off too much after a pulse.
· The reaction force on the operator is too much: Decrease Detection Torque. Decrease Current Limit. Decrease Forward Speed.
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AcraDyne Gen IV iEC Controller Manual

4.2.2 PSet Stages 4.2.2.1 TC Torque Control Stage
Control strategy uses torque as the only control parameter. The tool stops when Torque Target is reached. Rundown is considered to be successful (Accept) if the stage peak torque value falls within the range specified by the Torque High Limit and the Torque Low Limit parameters.

Stage Type: · Continuous Drive · Discontinuous Drive
Torque High: The upper control limit of the rundown.
Torque Target: Final desired torque.
Torque Low: The lower control limit of the rundown.
Speed (RPM): Tool Output speed target.
Acceleration (kRPM/s): The length of time it will take for tool to change speed. The lower the value the slower the acceleration (see “Glossary” on page 63 for detailed description).
Stage Timeout (s): Maximum allowable time (in seconds) in this stage. If time is exceeded, the tool will stop and Rundown will be terminated.

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AcraDyne Gen IV iEC Controller Manual

4.2.2.2

TC_AM Torque Control Angle Monitor Stage
Stage Type: · Continuous Drive · Discontinuous Drive

Torque High: Upper control limit of the rundown.

Torque Target: Final desired torque.

Torque Low: The lower control limit of the rundown.

Control strategy is convenient for detection of cross threaded or stripped fasteners. Rundown is considered to be successful (Accept) if the stage peak torque value falls within range specified by Torque High Limit and Torque Low Limit and final angle value falls within the range specified by Angle High Limit and Angle Low Limit parameters.

Angle Bailout: Determines when to stop the tool on angle during any Torque Control strategy. Should be set equal to or above High Angle. Units are degrees of rotation.
Angle High: Maximum acceptable angle rotation in degrees.
Angle Low: Minimum acceptable angle rotation in degrees.
Angle Reference: (drop down menu) · Overall Angle: Angle is measured starting from lever/trigger pull. · In-cycle Angle: Angle is measured from In-Cycle torque value (determined in PSet screen). · Stage Angle: Angle is measured from Reference Torque. If Stage Angle is selected, this will be the start point (in Torque) at which angle is monitored. NOTE: Set Reference Torque to zero to measure Stage Angle from the beginning of the stage.

Reference Torque: If Stage Angle is selected in the Reference menu, this will be the Torque start point at which angle is monitored.

Speed (RPM): Tool Output speed target.

Acceleration(kRPM/s): How quickly the tool will change speed. The lower the value the slower the acceleration (see “Glossary” on page 63 for detailed description).

Stage Timeout (s): Maximum allowable time (in seconds) in this stage. If time is exceeded, the tool will stop and the Rundown will be terminated.

Torque Monitor Window: Enabling the Torque Monitor Window adds a window on the runscreen that shows start/end angle thresholds as well as lower and upper torque limits. When the Angle Reference is between the Start/End Angle Limits, the Torque must remain between the Lower and Upper Torque limits. If the Torque goes outside these limits, the rundown will be aborted and flagged as a reject.

Runscreen with Torque Monitor Window

· Start Angle: Lower angle reference threshold to audit torque. · End Angle: Upper angle reference threshold to audit torque. · Lower Torque Limit: Minimum torque value within angle window. · Lower Torque Limit: Maximum torque value within angle window.

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AcraDyne Gen IV iEC Controller Manual

4.2.2.3 AC_TM Angle Control Torque Monitor Stage
Stage Type: · Continuous Drive · Discontinuous Drive

Angle High: Maximum allowed angle rotation in degrees.

Angle Target: Angle target desired.

Angle Low: Minimum allowed angle rotation in degrees.

Control strategy in which the tool stops when Angle Target is reached or Torque High Limit is exceeded. Rundown is considered to be successful (Accept) if the stage peak torque value falls within range specified by torque upper and lower limits and final angle value falls within the range specified by Angle High Limit and Angle Low Limit parameters.

Angle Reference: (drop down menu)
· Overall Angle: Angle is measured starting from lever/trigger pull.
· In-cycle Angle: Angle is measured from In-Cycle torque value (Determined in PSet screen).
· Stage Angle: Angle is measured from Reference Torque.

Reference Torque: If Stage Angle is selected in the reference menu, this will be the start point (in Torque) at which angle is monitored.

NOTE: Set Reference Torque to zero if you want Stage Angle measured from the beginning of the stage.

Torque Bailout: Determines when to stop the tool based on torque value during any Angle Torque Bailout value should be equal or greater than High Torque.

Torque High: Upper control limit of the rundown.

Torque Low: Lower control limit of the rundown.

Speed (RPM): Tool Output speed target.

Acceleration (kRPM/s): How quickly the tool will change speed. The lower the value, the slower the acceleration (see “Glossary” on page 63 for detailed description).

Stage Timeout (s): Maximum allowable time (in seconds) in this stage. If time is exceeded, the tool will stop and the Rundown will be terminated.

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AcraDyne Gen IV iEC Controller Manual

4.2.2.4 TC_AC Torque Control Angle Control Stage

Stage Type: · Continuous Drive · Discontinuous Drive

Torque High: Upper control limit of the rundown.

Torque Target: Final desired torque.

Torque Low: Lower control limit of the rundown.

Angle High: Maximum allowed angle rotation in degrees.

Control strategy in which the tool stops if Target Torque or Target Angle is reached, whichever happens first.
Rundown is considered to be successful (Accept) if the stage peak torque value falls within range specified by Torque High Limit and Torque Low Limit, and final angle value falls within the range specified by Angle High Limit and Angle Low Limit parameters.

Angle Target: Angle target desired.
Angle Low: Minimum allowed angle rotation in degrees.
Angle Reference: (drop down menu)
· Overall Angle: Angle is measured starting from lever/ trigger pull.
· In-cycle Angle: Angle is measured from In-cycle value (determined in PSet screen.)
· Stage Angle: Angle is measured from Reference Torque.

Reference Torque: If Stage Angle is selected in the Reference Menu, this will be the start point (in Torque) at which angle is monitored.
NOTE: Set Reference Torque to zero if you want Stage Angle measured from the beginning of the stage.
Speed (RPM): Tool Output speed target.
Acceleration (kRPM/s): How quickly the tool will change speed. The lower the value, the slower the acceleration (see “Glossary” on page 63 for detailed description).
Stage Timeout (s): Maximum allowable time (in seconds) in this stage. If time is exceeded, the tool will stop and the Rundown will be terminated.

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AcraDyne Gen IV iEC Controller Manual

4.2.2.5 Yield Control Stage
This strategy detects the yield of the fastener and reports the torque and angle that resulted from the fastening event. Controlling by detecting Yield is very beneficial on joints where clamp load varies greatly relative to final torque. This strategy can be used alone or combined with other strategies as steps in a parameter set. As an example, a common fastening strategy could be three steps: · Torque Stage ­ To set a minimum
threshold · Yield Stage ­ To control clamp load · Angle Stage ­ To attain a specific
bolt stretch above Yield

Yield Target %: Programmable with a default setting of 50%.
The lower this value, the more sensitive the strategy will be. Too low could cause early and false detection.
The higher this value, the less sensitive the strategy will be. A more pronounced change in slope is required for the yield to be determined.
The measurement is joint specific and 0% when parallel to the slope determined to be the elastic range and 100% is when the slope is horizontal.
Joint Rate parameters have default settings of 5 samples every 20 degrees. This resolution can be adjusted if needed.
See “AC_TM Angle Control Torque Monitor Stage” on page 16 for Torque, Angle, Speed, and Time parameter details).
Torque Bailout: Determines when to stop the tool based on torque value during any Angle Torque Bailout value should be equal or greater than High Torque.
Torque High: Upper control limit of the rundown.
Torque Low: Lower control limit of the rundown.
Angle Bailout: Determines when to stop the tool on angle during any Torque Control strategy. Should be set equal to or above High Angle. Units are degrees of rotation.
Angle High: Maximum acceptable angle rotation in degrees.
Angle Low: Minimum acceptable angle rotation in degrees.
Angle Reference: (drop down menu) · Overall Angle: Angle is measured starting from lever/trigger pull. · In-cycle Angle: Angle is measured from In-Cycle torque value (determined in PSet screen). · Stage Angle: Angle is measured from Reference Torque. If Stage Angle is selected, this will be the start point (in Torque) at which angle is monitored. NOTE: Set Reference Torque to zero to measure Stage Angle from the beginning of the stage.
Reference Torque: If Stage Angle is selected in the Reference menu, this will be the Torque start point at which angle is monitored.
Speed (RPM): Tool Output speed target.
Acceleration(kRPM/s): How quickly the tool will change speed. The lower the value the slower the acceleration (see “Glossary” on page 63 for detailed description).
Stage Timeout (s): Maximum allowable time (in seconds) in this stage. If time is exceeded, the tool will stop and the Rundown will be terminated.
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AcraDyne Gen IV iEC Controller Manual

4.2.2.6 Delay Stage

This stage determines the time delay between stages.
Time Delay (s): Total time (in seconds) the tool stops and waits before proceeding to the next stage. Default is 0.2 (sec).

4.2.2.7 Unfasten Stage
This feature is a specific “backoff” stage used, for example, in a Rundown- Backoff or RundownBackoff-Rundown configuration. NOTE: In this stage, the tool always runs opposite of the thread direction.

Angle High: Maximum allowed angle rotation in degrees.
Angle Target: Degrees of rotation the tool will backoff in reverse.
Angle Low: Minimum allowed angle rotation in degrees.
Torque Bailout: Determines when to stop the tool based on torque value during any Angle Control strategy; should be equal or greater than High Torque.
Torque High: Upper control limit of the rundown.
Torque Low: Lower control limit of the rundown.
Speed (RPM): Tool Output speed target (in the unfastening direction).

Acceleration (kRPM/s): How quickly tool will change speed. The lower the value, the slower the acceleration (see “Glossary” on page 63 for detailed description).
Audit Enable: False: When set to False the stage will not be evaluated for pass or fail. True: When set to True the stage will be evaluated for pass or fail using high and low limits.
Stage Timeout (s): Maximum allowable time (in seconds) in this stage. If time is exceeded, the tool will stop and the Rundown will be terminated.

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AcraDyne Gen IV iEC Controller Manual

4.2.2.8 Ergo Stop Stage

Ramps cut-off power when fastening achieves Target Torque or Target Angle value. This feature reduces torque reaction to the operator in a hand-held tool as final torque or angle is achieved.
Ramp Down Time (s): Total time (in seconds) to ramp down to zero current/torque.
Torque Current Reduction %: Amount (in percent) to reduce the current to the motor.

4.2.2.9 Brake Stop Stage

The Brake Stop Stage is used for electronic braking of the tool. It can be helpful in applications where a high RPM is used for the rundown, helping to reduce torque and angle target overshoot.
The Brake Stop stage is also required after a high torque target stage, to prevent the tool motor from springing backwards too fast as the tool gearing relaxes. This motor back drive can cause a voltage spike on the drive DC bus. This spike in voltage can result in drive or other faults to occur. As a guideline, rundowns exceeding 1,000Nm should have a brake stop as the final stage.
Max Brake Hold Time (s): Amount of time (in seconds) that brake is applied.
Duty Cycle %: Manual control the strength of the brake force ­ a higher value is stronger
Auto-Release: Automatically controls the strength of the brake force and releases when cycle complete torque is reached. It is recommended to enable this when using the brake stop to relax the joint after a high torque rundown, to prevent voltage spikes.

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AcraDyne Gen IV iEC Controller Manual

4.2.2.10 AC_TA Angle Control Torque Averaging Stage Angle Target: Angle target desired.

Angle Low: Minimum allowed angle rotation in degrees.

Angle Reference: (drop down menu) · Overall Angle: Angle is measured starting from lever/trigger pull. · In-cycle Angle: Angle is measured from In-Cycle torque value determined in PSet screen). · Stage Angle: Angle is measured from Reference Torque.

Reference Torque: If Stage Angle is selected in the Reference menu, this will be the Torque start point at which angle is monitored.

Torque Bailout: Determines when to stop the tool based on torque value during any Angle. Torque Bailout value should be equal or greater than High Torque.

Torque High: Upper control limit of the rundown.

Average High: The average high torque of the rundown.

Average Low: The average low torque of the rundown.

Control Strategy that is helpful in applications where the rotational resistance measured can produce a pass or fail reading. This will help in gauging rolling resistance of a given part and aid in detecting latent failures in rotating assemblies.

Speed (RPM): Tool Output speed target.
Acceleration (kRPM/s): How quickly the tool will change speed. The lower the value the slower the acceleration (see “Glossary” on page 63 for detailed description).
Stage Timeout (s): Maximum allowable time (in seconds) in this stage. If time is exceeded, the tool will stop and the Rundown will be terminated.

Pass

Fail

Average Torque falls within Avg. Torque limits.
Reported torque is the average of the torque measured during the AC_TA Stage.
Notice that final torque is greater than the Avg. Torque High limit.

Average Torque greater than Avg. Torque High limit.
Reported torque is the average of the torque measured during the AcTa Stage.

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AcraDyne Gen IV iEC Controller Manual
4.2.2.11 AC_TCOMP Angle Control Torque Compensation Stage The Angle Control Torque Compensation Strategy is used to compensate for the prevailing torque of the fastener. The prevailing torque can be averaged over a set angle and the torque will be adjusted by the average torque measured, allowing it’s effect to be removed from the final torque applied to the fastener.
Setup: See “AC_TA Angle Control Torque Averaging Stage” on page 21.
This strategy will behave the same as Angle Control Torque Averaging (AC_TA) with the additional re-taring of the torque transducer; it has all the same parameters.
The Problem In the two following fastening cycles, the final torque is 4Nm. The first fastening has about 1Nm of prevailing torque during the free run and the second has about 2Nm. In the first fastening, about 3Nm of torque goes into the final clamping load of the joint. The second fastening only gets about 2Nm of torque to clamp the part, 33% less than the first.
Removing the Prevailing Torque The strategy will measure the average prevailing torque over a given angle. At the completion of the stage the torque transducer will have its tare value adjusted by the average torque. Removing the prevailing torque readings for the remainder of the fastening cycle.
In the fastening shown, the first stage is an Angle Control Torque Compensation strategy followed by a torque control strategy to 4Nm. This will allow a consistent 4Nm to be applied to the clamp load of the part.
4.2.2.12 AC_TCOMP Display of Torque Compensation Value LED Display: The bottom LED display field can be configured to display the Torque Compensation Tare Value by using the toggle button to select `COMP’ from the available options.
Run Screen: In addition to the Final Audit Torque, the Final Torque Total and the Torque Compensation Value will be displayed if an AC_TComp stage was completed during the rundown.
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AcraDyne Gen IV iEC Controller Manual

4.2.2.13 Sync Stage

Set synchronization point between stages for spindle networks. All spindles will wait on this stage until all controllers are ready to proceed to the next stage.
Stage Timeout (s): Total time in seconds the controller will wait in this stage before timing out and aborting the rundown.

4.2.2.14 Thread Forming Stage

The `Thread Forming PSet Strategy’ can be used in fastening applications where the initial thread forming torque is greater than the final torque target to be left on the fastener. This strategy is intended to be used as the first stage of a multistage PSet, prior to the final audit stage.
The Thread Forming Strategy is a variant of the Angle Control Torque Monitoring (AC_TM) Stage, which in addition, includes a reset of the overall peak torque value when the stage completes. This provides a way to reset the peak torque value after thread forming so that only the peak torque from the fastening portion of the rundown is used for the overall evaluation of the rundown and reported.
Sequence of Operation: The stage will run until the angle target is reached, or is terminated early. If the stage completes successfully the overall peak torque is reset to the current torque value, then the next stage in the sequence will begin. If the stage is terminated early, or fails on the torque and angle limits, the overall peak torque is not reset and the rundown will be terminated.
Setup: See “AC_TM Angle Control Torque Monitor Stage” on page 16 for Torque, Angle, Speed, and Time parameter details)

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AcraDyne Gen IV iEC Controller Manual

4.2.2.15 Homing Stage
Control strategy in which the tool’s output returns to a home position in the direction set in the parent PSet. The home position is defined by the position of the output when the controller is powered on. The stage is considered successful (Accept) if the output travels and stops within the home region, defined by the angle high and low limits. If the output is already in the home region when the stage begins, the tool will perform a revolution first. When the output crosses the lower limit, the tool will brake to a stop. After completing the stage, the position of the output, referenced from the home position, will be reported.

Angle High: Upper limit of the Tool Output position defining the home region. (Units: Degrees from the Home position in the direction of rotation defined in the PSet)
Angle Low: Lower limit of the Tool Output position defining the home region. (Units: Degrees from the Home position in the opposite direction of rotation defined in the PSet).
Torque Bailout: The tool will stop if this torque is exceeded. The Torque Bailout value should be equal or greater than High Torque.
Torque High: Upper control limit of the rundown.
Torque Low: Lower control limit of the rundown.
Speed (RPM): Tool Output speed target.
Acceleration (kRPM/s): How quickly the tool will change speed. The lower the value the slower the acceleration (see “Glossary” on page 63 for detailed description).
Stage Timeout (s): Maximum allowable time (in seconds) in this stage. If time is exceeded, the tool will stop and the Rundown will be terminated.
Note: To maintain the tool’s home position without drifting, some tools will require a more refined value for the tool parameter PPRO. Please contact an AIMCO representative for instructions on how to load this value into the tool if it is needed.

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AcraDyne Gen IV iEC Controller Manual

4.2.2.16 AC_TM Anti-Necking Stage
Control strategy in which the tool stops when Angle Target is reached, or Torque High Limit is exceeded. Rundown is considered to be successful (Accept) if the stage peak torque value falls within the range specified by torque upper and lower limits and final angle value falls within the range specified by Angle High Limit and Angle Low Limit parameters. If the final torque of the rundown is not within the parameter specified by Percent Peak Torque Drop, the rundown is considered be unsuccessful and a low torque will be reported.

Angle High: Maximum allowed angle rotation in degrees.
Angle Target: Angle target desired.
Angle Low: Minimum allowed angle rotation in degrees.
Angle Reference: (drop down menu) · Overall Angle: Angle is measured starting from lever/trigger pull. · In-cycle Angle: Angle is measured from In-Cycle torque value (determined in PSet screen). · Stage Angle: Angle is measured from Reference Torque.
Reference Torque: If Stage Angle is selected in the Reference menu, this will be the start point (in Torque) at which angle is monitored.
NOTE: Set Reference Torque to zero if you want Stage Angle measured from the beginning of the stage.
Torque Bailout: Determines when to stop the tool based on torque value during any Angle Torque Bailout value should be equal or greater than High Torque.
Torque High: Upper control limit of the rundown.
Torque Low: Lower control limit of the rundown.
Percent Peak Torque Drop: The maximum allowed percentage torque drop from peak torque during a rundown. If the final torque is too low, a low torque will be reported.
Speed (RPM): Tool Output speed target.
Acceleration (kRPM/s): How quickly the tool will change speed. The lower the value the slower the acceleration (see “Glossary” on page 63 for detailed description).
Stage Timeout (s): Maximum allowable time (in seconds) in this stage. If time is exceeded, the tool will stop and the Rundown will be terminated.

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AcraDyne Gen IV iEC Controller Manual

4.2.2.17 Rate_Control Stage

The joint rate is monitored and the stage is complete when it exceeds Rate Target (Nm/deg or another torque unit if selected in the PSet). This strategy can be used to detect when the parts are initially clamped (large change in the joint rate). A typical usage would add an AC_TM stage after it to get a more consistent clamp load on the part.

Rate Target: The target joint rate for the tool to shutoff or switch to the next stage. The units depend on the torque units selected for the parameter set (default Nm/deg).
The controller Torque/ Angle graph can be used to help determine the value for the Rate Target. While connected to the controller with an external browser (not the controller touch screen), Reference lines can be drawn on the graph (run screen and saved results) and the joint rate for the line will be calculated. Clicking on the graph will remove any reference line.
Torque Bailout: Determines when to stop the tool based on torque value during any Angle Torque Bailout value should be equal or greater than High Torque.
Torque High: Upper control limit of the rundown.
Torque Low: Lower control limit of the rundown.
Angle Bailout: Determines when to stop the tool on angle during any Torque Control strategy. Should be set equal to or above High Angle. Units are degrees of roataion.
Angle High: Angle target desired.
Angle Low: Minimum allowed angle rotation in degrees.
Angle Reference: (drop down menu) · Overall Angle: Angle is measured starting from lever/trigger pull. · In-cycle Angle: Angle is measured from In-Cycle torque value (determined in PSet screen). · Stage Angle: Angle is measured from Reference Torque.
Reference Torque: If Stage Angle is selected in the Reference menu, this will be the start point (in Torque) at which angle is monitored.
NOTE: Set Reference Torque to zero if you want Stage Angle measured from the beginning of the stage.
Speed (RPM): Tool Output speed target.
Acceleration (kRPM/s): How quickly the tool will change speed. The lower the value the slower the acceleration (see “Glossary” on page 63 for detailed description).
Stage Timeout (s): Maximum allowable time (in seconds) in this stage. If time is exceeded, the tool will stop and the Rundown will be terminated.

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4.2.3 Edit PSet On Home page press

AcraDyne Gen IV iEC Controller Manual

On the PSet screen click on the desired PSet you would like to edit.

If further Stage changes are needed click the Edit button again to enter Edit Stage screen (below).

Once desired changes are made click save changes.

twice to

Click on the Edit button Edit screen (below).

to make changes in the

4.2.4 Advanced Options
PSet Name: Add PSet name if desired (up to 10 characters).
Thread Direction: Defines fastening direction (default is right hand).
Re-hit/Reject Parameters: Prevents the fastening of an already tightened fastener. If enabled, tool will stop and the rundown will be aborted, if the angle of rotation between the Re-Hit Reference Torque and the InCycle Torque is less than the Re-Hit Angle Count.
NOTE: If the attempted rundown is a Re-Hit, it will not be reported or recorded.

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AcraDyne Gen IV iEC Controller Manual

Re-hit Reject Enable: Enables the feature.
Re-Hit Reference Torque: This torque value is the start of the angle count that determines a Re-Hit. (This value should be lower than the In Cycle Torque specified in the PSet.)
Re-Hit Angle Count: If the angle count between the Re-Hit Reference Torque and the In Cycle Torque is less than this value, the rundown is determined to be a Re-Hit.
Joint Compensation Ratio: Adjusts the target torque of the tool to compensate for joint characteristics. This value has an inverse relationship with the target torque (Output torque = Target Torque / Ratio). Ratio values above 1.0 result in a lower output torque where values below 1.0 result in higher output torques.
Joint Rate Parameters: Joint rate parameters have default settings of 5 samples every 20 degrees. This resolution can be adjusted if needed.
Report Trigger Loss as NOK: If enabled and a rundown is terminated early before completion:
· The overall result of the rundown will be reported as a reject.
· The torque and angle status will be reported as evaluated with the following exception: If torque and angle are both within limits, the torque and angle status will both be reported as low. This is done to further indicate that the rundown was terminated before completion.
4.2.5 Default Psets
See “3.2 Quick Set Up” on page 7.

4.2.6 Manage PSets
Save PSets to Browser Allows the PSet information to be saved to the local PC connected to controller. PSet information is saved as a .txt file and can be opened using any text editor such as WordPad. It can also be opened with Excel. The format of the .txt file is tab separated values. Export PSets to Browser Save the PSets as a database file to the PC connected to controller. These PSets can later be imported to another controller. Import PSets from Browser Import previously exported PSets to controller. Delete PSets Enables deletion of selected PSets.

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AcraDyne Gen IV iEC Controller Manual

4.2.7 Multistage Rundown Evaluation and Reporting
If a rundown cycle completes, or is terminated early while in or after the final audit stage of the PSet: · The overall evaluation of the rundown will be
determined using the torque and angle limits set in the final audit stage. · The peak torque and angle achieved during the rundown, are used for the evaluation and reported. · The torque and angle status, and overall result reported, will reflect this evaluation.
Note: The fastening torque must achieve the In-Cycle torque value set in the PSet for the rundown to be evaluated or reported.
If a rundown is terminated early before reaching the final audit stage: · The overall result of the rundown will be reported
as a reject. · The torque and angle evaluation will be
determined using the limits set in the stage that was running when the rundown was terminated. · The torque and angle at the point in time when the rundown was terminated, is used for the stage evaluation. · The torque and angle status reported will reflect this stage evaluation with the following exception:
If torque and angle are both within limits of the stage that was running, or if the stage was a non-audit stage, the torque and angle status will both be reported as low. This is done to further indicate that the rundown terminated before reaching the final audit stage.
· The peak torque and angle achieved during the rundown will be reported.
Note: The fastening torque must achieve the In-Cycle torque value set in the PSet for the rundown to be evaluated or reported.
Unfastening Stage special considerations: · Rundown Back-Off multi stage PSet (Unfastening
as the last stage) If the unfasten stage is set to Non Audit’: The peak torque and angle reported from the fastening portion of the rundown will be used for the evaluation and reported. If the unfasten stage is set toAudit’:
The final torque and angle in the
unfastening direction, at the point in time when the run cycle completes or is terminated, will be used for the evaluation and reported.
The final torque and angle will be reported
as negative in the unfastening direction.
If the rundown cycle is terminated before
reaching the final unfastening audit

stage, the final torque and angle values will be reported as zero and the torque and angle status will be reported as low. · Rundown Back-Off Rundown multi stage PSet (Unfastening as a middle stage) The value for peak torque in the forward direction, will be reset to zero when tool begins an unfastening portion of the rundown. If the rundown is terminated during the unfastening stage, the final torque and angle values will be reported as zero and the torque and angle status will be reported as low.
Torque Averaging Stages (AC_TA and AC_TCOMP) reporting exception: · If a torque averaging stage fails to complete, or
is the final audit stage, and the peak torque is less than the high torque limit, the final torque reported will be the torque average during that stage.
Torque and angle measurement details: · Peak Torque is used for the overall evaluation
and reported: The peak torque achieved, from the start of the rundown to the when the torque falls below the cycle complete value set in the PSet
· Torque is used for the stage evaluation: The torque at the point in time when the stage was terminated or completed
· Peak Angle is used for the overall evaluation and reported: The peak angle achieved, measured from the angle reference set in the final audit stage, to the when the torque falls below the cycle complete value set in the PSet Note: If an angle reference is not defined in the final audit stage, the angle is measured from when the torque first crosses the InCycle torque set in the PSet.
· Angle is used for the stage evaluation: The angle at the point in time when stage was terminated or completed, measured from the angle reference set in the stage. Note: `Audit Stages’ are stages that have torque and angle limits defined. These stages include:
TC Stage TC_AM Stage TC_AC Stage AC_TM Stage AC_TA Stage AC_TCOMP Stage Unfastening Stage (If Audit is selected)
Note: If the evaluation of any stage during the rundown fails, or a bail out limit is exceeded, the fastening cycle will be terminated early and any subsequent stages will not run.

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AcraDyne Gen IV iEC Controller Manual
4.2.8 Multiple Stage Rundown Examples EXAMPLE: Two-stage rundown with downshift This example shows a typical two stage rundown with a higher first stage free speed and slower down shift speed to minimize overshooting of the target torque.
EXAMPLE: Three stage rundown with unfasten on the last stage. (Rundown Backoff) This example shows a typical three stage rundown with a back-off stage at the end of the rundown. NOTE: The unfasten stage’s audit parameter is set to false, therefore, the torque and angle reported are from the fastening portion of the rundown.
EXAMPLE: Four stage rundown with an unfasten stage in the middle. (Rundown back off Rundown) NOTE: The peak torque was reset at the start of the fastening stage. The torque reported was from the final stage.
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AcraDyne Gen IV iEC Controller Manual

4.3 Job
A Job is a collection of PSets which can be run when performing multiple fastening operations on a single application.
Jobs provide: · Error proofing · Logical grouping
of PSets · Fastening order · Job status

accessed in the Results screen (see “4.4 Results” on page 33).
After appropriate values are entered, press to Add New Job Sequence screen.

to go

Click to Enable/Disable Job function.

PSet: Choose any current PSet already configured in controller
Action: · None: Will stay in current sequence. · Next: will advance to next sequence set up after
count is reached.

4.3.1 Add New Job

To add a new Job press

on the Home Page.

Press on Jobs screen (above) to enter Add New Job screen (below)

Job Number: Up to 99 Jobs can be configured.

Job Name: Enter Job Name

Job Action: · Disable Tool: Disable tool after job is finished. Job complete Icon will appear.

Tool will not operate until job is reset.
· Reset Job: Will reset after Job is finished. Once Reset Job is finished, the following icon appears:

This means that results from the last successful rundown of a job are cleared. Information from last successful rundown can still be

Count: Fastener number required to complete sequence.

Once values are entered press return to Job screen

two times to

4.3.1.1 Advanced Options Enter Advanced Options

if needed.

Lock on Reject Parameters: · Enable: When
enabled, this prevents tool from starting a new rundown if the result of the last rundown was a reject. Tool remains locked until one of the four Unlock Mode conditions are satisfied.

Unlock Mode: · Reverse:
Running tool in disassembly mode. · Reverse and Throttle: Running tool in disassembly mode. · Reverse and Unlock Torque: Exceeding “Unlock Torque” while tool is in the disassembly direction (backing off a rejected fastener).
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AcraDyne Gen IV iEC Controller Manual

· Any MFB Press: Pressing MFB button on tool (regardless of MFB configuration).
· External I/O: Assignment of “Remove Lock on Reject” will allow for an external Input signal to release the lock condition.
Unlock Torque: If Unlock Mode is set to “Reverse and Unlock Torque”, this torque value must be exceeded when the tool is in the disassembly direction in order to unlock the tool.
Limit Reject Parameters: · Enable: Enable or Disable · Maximum Rejects: Number of rejected fasteners
allowed
Additional Options: · Report Missing Fasteners: Add an option to
each JOB that would allow us to report any missing fasteners. When it is set, the controller will report an NOK rundown for each fastener that is defined in the JOB but has not been run. These NOK results will be reported whenever a new job is started AND the prior JOB is incomplete.
These generated NOK results are treated like any other fastening. They are displayed on the run screen, stored in the results and transmitted on all protocols.

· Holding the toggle button will display will display the Job number, while pressing increment or decrement buttons will change it. The two numbers on the PSet/Job display will be separated by decimals.
· Pressing the toggle button will change secondary display between:
Units of measure Ethernet 1 IP address Ethernet 2 IP address System port IP address Angle report Bolt count Job sequence
NOTE: Job sequence shows which PSet you are currently on in the job (this is not the pset number). The first pset in the job is always job sequence 1, and the next is 2, etc.
Bolt count is shown as current bolt count out of total number of bolts. Example: If you have 3 total bolts. When you start the job you will see 0.3. After one rundown you will see 1.3 and then 2.3 on the next run and so on until the job is completed.

4.3.2 Jobs “Enabled” Display and Button Function

Torque Display
Always displays torque value
Secondary Display
Parameter Setting (PSet)/ Job Display

Toggle Button PSet Job Functions

Increment/ Decrement Buttons

· Increment and Decrement buttons change the job sequence. The PSet number will change and job sequence number on secondary display will change if jobs are enabled.
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4.4 Results

AcraDyne Gen IV iEC Controller Manual

This screen provides a history of rundowns performed. Information such as ID Number, Time Stamp, Parameter Set#, Accept / Reject status, and Torque and Angle are recorded for each rundown.

Example: Rejected Rundown Information.

Click on Individual Runs for Rundown information.

Filter Button gives filter options in Rundown screen.
Save Button saves rundowns as .Txt File.
Deletes individual rundowns by clicking on them
Select Columns Button lets you customize the columns shown on the Results Screen

4.4.1 Saving Rundown(s)

Saving All Rundowns

Click on

in main rundown screen to view/save

total rundowns. A dialog box will open that allows

you to choose the download format, either a CSV

file or a TW4 file. The CSV file includes rundown data

in tab separated variables and can be viewed using

Excel or opened it text editor such as Notepad. The

raw data can be imported to Excel to build graphs,

charts etc. Contact AIMCO Technical Service for

pre-made Torque and Angle Templates.

The TW4 file can be opened using the ACE Platform G4 Utility located on the software page of the
AIMCO website.

Home Button returns to main display menu.
Play Button sends you directly to Run Screen. Refresh Button refreshes screen to include latest rundowns.

The dialog box also shows options for including stage results or log entries in the downloaded file. If downloading a TW4 file, all information will be automatically selected.
Click and your browser will download the file.

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AcraDyne Gen IV iEC Controller Manual

Saving Individual Rundowns

rundown from the Results screen.

To save an individual rundown, select a

This opens the Rundown Information View. Click on

in save the rundown. The file will automatically download as a CSV file.

Rundown Information View

Sample of Individual Rundown Information

The format can also be changed with the optional “version” parameter. An http request to the controller for file “fastening.csv” with the optional parameter “version” set to 1 (http://ipaddress/ fastening.csv?version=1) will return a CSV file in the “QualityWorX File” format.
The “id” and “version” options can be used in any combination as needed.

HTTP Method for Retrieving and Saving Rundown Results
An http request to the controller for file “fastening. csv” (http://ipaddress/fastening.csv) will return the most recent rundown in the full rundown CSV format. This is in the same format as “Home->Results” selecting a results then selecting save.
Optionally, a specific ID can be selected. An http request to the controller for file “fastening.csv” with the optional parameter “id” set to the desired id number (http://ipaddress/fastening.csv?id=47) will return rundown id the full rundown CSV format.
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4.5 Controller

AcraDyne Gen IV iEC Controller Manual

The controller menu is where all of the settings for the Gen
IV controller are configured. All of the different configuration capabilities are explained below.

4.5.1 Tool Setup

In this screen user can enable/disable various tool functions.

4.5.1.1 Lock Tool On Reject When enabled, this prevents tool from starting a new rundown if the result of the last rundown was a reject. Tool remains locked until one of the four Unlock Mode conditions above are satisfied. Unlock Mode: The action that re-enables the tool for use.
· Reverse: Running tool in disassembly mode. · Reverse and Throttle: Running tool in disassembly mode. · Reverse and Unlock Torque: Exceeding “Unlock Torque” while tool is
in the disassembly direction (backing off a rejected fastener). · Any MFB Press: Pressing MFB button on tool (regardless of MFB
configuration). · External I/O: Assignment of “Remove Lock on Reject” will allow for an
external Input signal to release the lock condition Unlock Torque: If Unlock Mode is set to “Reverse and Unlock Torque”, this torque value must be exceeded when tool is in the disassembly direction in order to unlock tool.
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AcraDyne Gen IV iEC Controller Manual
4.5.1.2 Buzzer Set the way the buzzer behaves in OK/NOK situations. Menu options are · Silent · Constant · Beep
If a rundown is rejected, the beeping can be stopped by making a successful rundown or by using the MFB.
4.5.1.3 Lights Headlight Enable: Enables or Disables the Headlight (pistol style tools only).
Turn off After Delay: Enabling will set the tool indicator lights to turn off automatically after a rundown is completed and the configured time has passed.
Delay: How long after a rundown is completed to turn off the tool indicator lights
4.5.1.4 Start Input
Start from IO: Start tool through I/O from external source.
Start From Tool Buttons: Normal operating condition: Tool lever and MFB control tool operation.
Start From Master Tool: Used when one tool’s start lever in the multispindle machine will be used as the start command for the entire system
Start From Remote Start: Used when the system start command would come over the Eth port connection
Tool Throttle Configuration: Four options are available:
· Lever or PTS (Push to Start): This the default configuration. Pressing either the Lever or PTS will start the tool.
· Lever and PTS (Push to Start): Both the Lever and the PTS need to be pressed in order to start the tool.
· Lever: Only the Lever will start the tool. · PTS: Only the PTS will start the tool.
Latching Options: · Not Latched: Start Input is not latched. · Latched on Time: Start Input latches if lever is pressed for a set time. · Latched on MFB: Latches on the following sequence: Press and hold lever. Press MFB while lever is still being held down. Release the lever. Release the MFB.
Latch Hold Time (s): Amount of time (in seconds) the lever needs to be depressed to latch throttle (if Latched on Time is selected above).
NOTE: Throttle will unlatch automatically at the end of the rundown or when the lever is repressed. If the tool is installed with dual levers requiring two-handed operation, the above Start Input Configuration settings will be ignored (see Dual Lever Two Handed Tools section).
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AcraDyne Gen IV iEC Controller Manual

4.5.1.5 MFB (Multi-Function Button)

The MFB Mode configures the multiple function button for handheld AcraDyne tools. The button can be configured to operate in any of the following modes:

Tap Mode: Actions will commence if MFB is held less than hold time.

· Disabled: MFB button will not work.

· Disassembly Toggle: Depress the MFB each time to switch between

forward and reverse.

· Disassembly One Shot: Tool will automatically return to forward

after fastening. The MFB will NOT have to be depressed for forward

operation.

· Change PSET: Tapping MFB button toggles between PSet A

and PSet B. Status lights flash once indicating PSET A is selected

or

twice indicating PSET B is selected.

· Change Job: Tapping MFB button changes jobs.

· Arming: Tapping MFB button arms (activates) the Start function but

does not start the tool. Blue status light illuminates indicating tool is

Armed. Arming resets in three seconds if tool Start is not initiated.

· Stop Reject Tone: Tapping MFB silences the audible reject tone.

· Increment PSET Number: Tapping MFB will switch upward to next

PSet.

· Increment Job Number: Tapping MFB switches upward to next Job.

· Increment Job Sequence: Tapping MFB switches to next PSet in the

current Job.

Tap A Parameter: Assign a specific PSet (Job) to the “A” parameter, toggle back and forth between “A and “B” parameters using MFB.

Tap B Parameter: Assign a specific PSet (or Job) to the “B” parameter.

Hold Time (s): Amount of time (in seconds) required to hold the MFB until Hold Action is triggered.

Hold Mode: Actions will commence after Hold timer preset time has elapsed (Adjustable in Hold Time window). Default value is one second.

NOTE: The same options are available in Hold mode as in Tap mode.

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AcraDyne Gen IV iEC Controller Manual
4.5.1.6 Disassembly

Discontinuous Settings: For a description of these options, see “Discontinuous Mode Parameters” on page 11

Overall Timeout (s): Total amount of time, in seconds, after throttle is depressed that tool will operate.
Speed (RPM): Maximum speed of the Output spindle.
Acceleration (kRPM/s): Rate at which tool is set to ramp up to maximum RPM.
Enable on Reject Only: If enabled, this option will only allow the tool to be placed in disassembly after a rejected fastening.
Report Disassembly: If enabled, disassembly events will be reported and logged.
Threshold Torque: Disassembly will be reported only if this torque value is reached. This is entered as a positive value.
Torque Units: Units for the Disassembly Threshold Torque
Decrement Fastener Count: If Disassembly is detected the fastener count in JOBS
· Never: Decrement count will be ignored · Always: Decrement will always be active · Only after NOK: Decrement only occurs after a
tightening has been judged to be NOK (Reject)

When a disassembly event is reported: The disassembly will be displayed on the run screens and logged in the rundown record, containing the following:
· Overall evaluation will be marked as `Disassembled’ Peak torque during the disassembly (torque shown as negative).
· Peak overall angle during the disassembly (angle shown as negative).
· Curve data from the disassembly · Parameters from the current PSet selected · Fastening events from the disassembly.
All of the controller’s status LEDs will be turned OFF. The LED display will show peak torque and angle as negative
I/O Considerations: When disassembling, all assignable IO outputs that report rundown status will remain in the state from the last fastening cycle. This includes:
· Ok and Nok signals · Torque/Angle high or low signals · Torque and Angle Values
All assignable I/O outputs reporting a fasting events will not change state during the disassembly. This includes:
· Fastening Complete · In Cycle · Fastening Stopped · Fastening Aborted
NOTE: When the tool is placed into disassembly mode, all of the tool’s LEDs flash and the Horn beeps. This will continue until the tool is placed back into fastening mode.

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AcraDyne Gen IV iEC Controller Manual
4.5.1.7 Tubenut Trigger Action: Two options are available
· Release and Repress: Socket will return Home on release and repress of main lever. NOTE: If the main lever is released while homing in this configuration the tool will stop and will continue to Home once the lever is repressed.
· Release: Socket will return Home upon release of main lever. Speed (RPM): The speed in RPMs which a tubenut tool will return to the open position (default 50 RPM). Acceleration (kRPM/s): Rate at which tool is set to ramp up to maximum homing RPM. Reverse Dwell Time (s): Amount of time (in seconds) before Output attempts to return Home, after Home command is initiated (default 500ms). Hold at Home Dwell Time (s): Amount of time (in seconds) Output is held at Home position (default 500ms). Retry Home when Disabled: This will allow a retry of the tube-nut homing sequence (by releasing then repressing the lever) even if the controller has been disabled or the stop input is on. NOTE: Output is held at Home for the Home Dwell Time to prevent socket from bouncing back to partially closed position.
4.5.1.8 Past Due Service Calibration Service Past Due: Four options are available:
· No Action: No Action will be taken. · Log Error: Errors will be saved on Service Log. · Display Error: Calibration/Service message will appear on screen
between each rundown. Tool remains functional. · Disable Tool: Disable tool in preset Service period. Exceeded (date/
time) LED warning appears on the controller. Calibration Past Due: Same options as above
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4.5.2 IO

AcraDyne Gen IV iEC Controller Manual

Input Configuration

Output Configuration

See “12. Assignable I/O” on page 71 for more details on available assignment functions and how to configure.
See “11. 24 Volt I/O” on page 69 for the pinout of the 24Volt Logic IO port, and wiring examples.

NOTE: See “12. Assignable I/O” on page 71 for details.

4.5.2.1 Physical IO

Assign functionality to 24V Input and Output pins. Shows the “live state” of each Input and Output.
Functions shown in screen shot are default settings.
To change these assignments, click on any I/O state to enter Output/Input Configuration screen (following).

4.5.2.2 Physical IO Monitor
Provides monitoring of Physical 24 Volt I/O. Force on/off the individual I/O pins for testing of field wiring.
Each indicator shows the state of the associated pin.
Green = On Red = Off
· Force: When Buttons from I/O are selected, this field selects which Inputs and Outputs can be forced through the Monitor I/O screen.
· Off/On: If Force is enabled this button will toggle the state of pin selected.

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AcraDyne Gen IV iEC Controller Manual

4.5.2.3 Anybus/Modbus TCP/Ethernet IP Inputs These types of communication are useful for data communication between controller and PLCs. It is an effective, quick way for the data transfer of short data packages.

Press to enter Input Configuration Screen
Example of the Anybus Input screen with five Inputs set up. Click on to change an individual Element or return to Input Configuration screen. Will delete individual Elements.

Element Type: Choose from Byte, Int16, Int32, or ASCII.
Element: Shows element # being configured
Bit (not shown): Enter Bit #.
Bits: # of bits the assignment will read.
Start at: Starting bit location.
Polarity (not shown): Select Normally Open (N.O.) or Normally Closed Outputs (N.C.).
Length (not shown, available in ASCII ID function): Number of characters desired to send.
Torque (not shown, available in Click Wrench function): Torque value to be reported when using Click Wrench input. Value input is what will be sent from controller when Input Signal is received from a Click Wrench. Value is NOT calculated by the controller rather it is solely what the Click Wrench is calibrated to by outside means.
Torque Units (not shown, available with Click Wrench function): Choose from Nm, Kgm, Kgcm, Ftlb, and Inlb.
Function: See “12. Assignable I/O” on page 71 for details. Select desired Input Function(s).
Click on after appropriate selections are made.

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AcraDyne Gen IV iEC Controller Manual

4.5.2.4 Anybus/Modbus TCP/Ethernet IP Outputs
Press to enter Output Configuration Screen Example of the Anybus Output screen with five Outputs set up.
Click on to change an individual Element or return to Input Configuration screen.
Will delete individual Elements.

Element Type: Choose from Byte, Int16, Int32, or ASCII.
Element: Shows element # being configured
Bit: Enter Bit #.
Bits (not shown): # of bits the assignment will read.
Start at: Starting bit location.
Polarity: Select Normally Open or Normally Closed Outputs.
Mode: · Normal: Output signal
sent. · Timed Signal Sent: Time
entered in seconds · Flash Signal Sent: Time
entered in seconds
Function: See “12. Assignable I/O” on page 71 for more details on assignable functions.
Click on after appropriate selections are made.

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AcraDyne Gen IV iEC Controller Manual

4.5.3 Communication Interfaces

4.5.3.2 System Port

IP Address: The IP address of controller’s System Port (Default is 192.168.1.4)
Subnet Mask: The Subnet Mask of controller’s System Port.

4.5.3.1 Ethernet/Second Ethernet
IP Address: IP address of controller’s Ethernet port.
Subnet Mask: Subnet mask of the controller.
Gateway: Gateway is the IP address of the gateway computer that provides access beyond the local network.

NOTE: It is not recommended to change this setting. 4.5.3.3 Serial Port

NOTE: Consult your local System Administrator to connect the controller to your Network and assign IP addresses.

Port Mode: The following modes are available: · Serial Output: A serial data string will be Output in the following format after each rundown: # P 1 BB TTT.T AAAA 0000 0000 J (Notice the decimal point next to the least significant T)

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AcraDyne Gen IV iEC Controller Manual

P: Parameter set (“1” ­ “9”) for PSets 1-9, (“A” ­ “W”) for PSets 10-32.
B: Job count T: Torque result A: Angle result J: Judgment
@=overall pass, H=low torque, I (eye)=high torque, J=low angle, K=high angle, G=fault during fastening · Barcode Reader: See “5. Barcode Reader Details” on page 61 for Barcode setup. · Serial Output and Barcode Reader: Select from dropdown and configure per hardware requirements · Open Protocol: Select from dropdown and configure per hardware requirements · PFCS: Select from dropdown and configure per hardware requirements · PI Line Control: This is customer specific. Please reference PI Line Control Document on AIMCO Website/Manuals. · Tohnichi Wrench: Supports connecting a Tohnichi wrench/R-CM receiver to the controller. See Gen IV Serial Instructions on AIMCO Website/Manuals.

4.5.3.4 Anybus

Baud: Serial ports can be configured for different baud rates available.
· 75, 110, 300, 1200, 2400, 4800, 9600, 19200, 38400, 57600, 115200

4.5.3.5 Spindle USB Port

Data Bits / Stop Bits / Parity: Configure per hardware requirements

Serial Output Formats: See “Serial Output Format Options” on page 45 for details. · Standard · Standard with PSet · UEC Serial Modified · Profibus · UEC Serial · CVS String

Output Followed by Null Control Character: Adds a one-byte NULL character to the end of the serial string. Needed by systems that use the NULL character to signify the end of the string. See following section for more information.

Send PSet Change · Sends a serial string any time the PSet is changed. String is in the form `%%CAN8X%%%%CAN4YNAC%%’ where X is the previous pset and Y is the new pset. See following section for more information.

Send Job Completed:

· Sends a serial string containing “Job

Completed” whenever a job has been

completed.

44

Displays when the controller is AnyBusenabled by hardware
This can be used to set up a 2 spindle network through the USB port.

AcraDyne Gen IV iEC Controller Manual

Serial Output Format Options

Standard Output Format:
· O P HHHHH LLLLL TTTTT P HHHHH LLLLL AAAAA CR CR NULL* O: Overall Pass/Fail
P’ = Pass,F’ = Fail
P: Torque Pass/Fail

• P’ = Pass,F’ = Fail
  HHHHH: Torque High Limit
  Units selected in the PSet X10
  LLLLL: Torque Low Limit
• Units selected in the PSet X10
  TTTTT: Torque Result
  Units selected in the PSet X10
  P: Angle Pass/Fail
  P’ = Pass,F’ = Fail
  HHHHH: Angle High Limit
  Degrees
  LLLLL: Angle Low Limit
  Degrees
  AAAAA: Angle Result
  Degrees
  CR: Carriage return control character CR: Carriage return control character NULL: Null control character (if option is selected)

O: Overall Pass/Fail

• P’ = Pass,F’ = Fail

P: Torque Pass/Fail

• P’ = Pass,F’ = Fail

HHHHH: Torque High Limit

• Units selected in the PSet X10

LLLLL: Torque Low Limit

• Units selected in the PSet X10

TTTTT: Torque Result

• Units selected in the PSet X10

P: Angle Pass/Fail

P’ = Pass,F’ = Fail

HHHHH: Angle High Limit

Degrees

LLLLL: Angle Low Limit

Degrees

AAAAA: Angle Result

Degrees NAC%: Message End

CR: Carriage return control character

LF: Line feed control character

NULL: Null control character (if option is selected)

UEC Serial Format (matches UEC 4800 and Gen3):

Standard Output with Carriage Return, Line Feed and PSet Format: · O P HHHHH LLLLL TTTTT P HHHHH LLLLL AAAAA 1 CR LF NULL
O: Overall Pass/Fail
P’ = Pass,F’ = Fail
P: Torque Pass/Fail
P’ = Pass,F’ = Fail
HHHHH: Torque High Limit
Units selected in the PSet X10
LLLLL: Torque Low Limit
Units selected in the PSet X10
TTTTT: Torque Result
Units selected in the PSet X10
P: Angle Pass/Fail
P’ = Pass,F’ = Fail
HHHHH: Angle High Limit
Degrees
LLLLL: Angle Low Limit
Degrees
AAAAA: Angle Result
Degrees
1: PSet
PSet(1′ ­9′) for PSets 1-9, (A’ ­Z’) for PSets 10-35
CR: Carriage return control character LF: Line feed control character NULL: Null control character (if option is selected)
UEC Serial Modified Format (matches some Gen4 earlier versions): · # P 1 BB TTT.T AAAA PPPP 0000 J CR NULL

: Message Start P: PSet

PSet(1′ ­9′) for PSets 1-9, (A’ ­Z’) for PSets 10-35
1: Spindle Number (Always 1) BB: Job Bolt Count
Total number of accepts during the Job
TTT.T: Torque Result
Units selected in the PSet
AAAA: Angle Result
Degrees
PPPP: Pulse Count 0000 J: Judgment
@’ = Overall Pass,H’ = Low Torque, I’ = High Torque,J’ = Low Angle, K = High Angle,G’ = Fault During Fastening CR: Carriage return control character NULL: Null control character (if option is selected)

· # 1 P BB TTT.T AAAA PPPP 0000 J CR NULL* #: Message Start 1: Spindle Number (Always 1) P: PSet

• PSet(1′ ­9′) for PSets 1-9, (A’ ­Z’) for PSets 10-35
  BB: Job Bolt Count
• Total number of accepts during the Job
  TTT.T: Torque Result
• Units selected in the PSet
  AAAA: Angle Result
• Degrees
  PPPP: Pulse Count
  L = Low Pulse Count, M = High Pulse Count
  0000 J: Judgment
• @’ = Overall Pass,H’ = Low Torque, I’ = High Torque,J’ = Low Angle, K = High Angle,G’ = Fault During Fastening, ‘’ = None of these conditions apply CR: Carriage return control character NULL: Null control character (*if option is selected)
  CSV String’ · S01,JB01, TTT.T, S, AAA.A, S, O, MM/DD/YYYY HH:MM:SS, VVV<CR><LF> S01: Spindle number JB01: Job number TTT.T: Torque S: Torque Status (A = OK, H = High, L = Low) AAA.A: Angle S: Angle Status (A = OK, H = High, L = Low) O: Overall Status (A = OK, R = NOK) MM: Month DD: Day YYYY: Year HH: Hour MM: Minute SS: Second VVV: 32 character barcode ID <CR>: Carriage Return <LF>: Line Feed Output Followed by NULL Character’. · The NULL characters can be seen by using PUTTY and
  connecting to the controller in `Raw’ mode. Then set logging to log all output and check the log to see the NULL

Profibus Output Format: · %CAN 1 O P HHHHH LLLLL TTTTT P HHHHH LLLLL AAAAA NAC%
CR LF NULL* %CAN: Message Start 1: PSet

• PSet(1′ ­9′) for PSets 1-9, (A’ ­Z’) for PSets 10-35

characters.
Send PSet Change’. · PSets up to 9 match the number, 10-35 are A-Z, greater than 35 is*’: %%CAN8X%%%%CAN4YNAC%% X: Last PSet Y: New PSet

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4.5.3.6 Serial USB 4.5.4 Protocols

AcraDyne Gen IV iEC Controller Manual

4.5.5 Front Panel Buttons

See “4.5.3.3 Serial Port” on page 43 for reference

Enable/ Disable front panel buttons on controller console.

For information about these settings, see individual protocol instructions on AIMCO’s website at www. aimco-global. com/manuals.

4.5.6 Power Up
Allows user several “Job” choices upon controller Power Up:
Power Up Job Number: Controller will power up on the job # selected. · Last Job: When
“Last job” is selected, controller will power up on last job selected prior to being Powered Down.
Power Up Job Action · Reset Job: Job
will be reset when controller is Powered Up. · Wait for Job Reset: Controller will wait for an External Job reset command upon Power Up and will retain job information existing prior to power down. · Resume Last Job: Upon Power Up, tightening sequence will resume at the next fastening from the point in the job when power was shut down.

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AcraDyne Gen IV iEC Controller Manual

4.5.7 Bar Code Setup
Required Identifiers for Tool Enable: Selects which four Identifiers (ID#1-4) are required to enable tool.
Reset identifiers for Job Complete: Selects which four Identifiers (ID#1-4) to reset on a job complete. Select Identifiers by clicking on them.
Block New Identifiers While Job is Running: Check to enable feature that ignores any barcode scanning while a JOB is in progress

Identifier Type: Identifies which identifier (ID#1-4) received barcode will be stored into.
Identifier Description: Text field can be used to give a description to each identifier type. (Example: Vehicle).
Action: Action executed by controller when barcode with a matching identifier mask is scanned. The actions are:
· Do Nothing · Select Job (This will require a Job to be
configured on the JOB page when using this option) · Select PSet
Action #: When Select Job or Select PSet is selected, this is the number of the Job or PSet that will be selected.
Reset Identifiers: Can reset other identifiers (ID#1-4) when barcode is received. Click on identifiers to reset.
Step 3: Press to save and re-enter completed barcode configuration screen.

Click anywhere in body if additional identifiers are required.

Step 2: Enter appropriate information on Barcode ID Configuration Screen.

Press to save barcode configuration.

Identifier Mask: The Mask is a string used to compare the received barcode against. The received barcode must be at least as long in length as the Mask. The Mask can also contain “don’t care” characters of a decimal point or period in the string. These characters are counted in the length, however, the actual received character in that position doesn’t matter.
Example:
VIN#123456

See “5. Barcode Reader Details” on page 61 for more information)
To configure Serial Port for Barcode Reader: On Home page click Controller Communication Interfaces Serial

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AcraDyne Gen IV iEC Controller Manual

Select Barcode Reader and the correct Baud rate.

need to be set up on the master controller. Spindle rundown results are also viewable from the master.
Click “Master Enable” to enter Master Spindle Configuration screen.

Press to save changes.
4.5.8 Set Time
Set time and date. If connected to a PC, use PC Time to set controller time.
4.5.9 Remote Connections
Sets number of remote browser connections to controller. Displays the IP addresses of remote browser connections to the controller.

Master Enabled: Enable or disable the spindle network.
Stop on Error: All spindles will stop if any problem is reported (bad rundown, a stop condition, or a cable disconnection has occurred on any spindle). If this option is not checked, spindles will finish the current rundown even if an error has occurred on one spindle.
Spindles: Use Dropdown to select number of Spindles to be connected in a Multispindle configuration
Trigger Source: Select whether the start input for running the spindle network comes from the master spindle’s tool trigger, IO, or Remote Start.
*All spindles need to have their start input set to respond to the master tool in order to have them all run from a single trigger or IO start signal. This is configured under Controller Tool Setup Start Input and set the input source to `Start from Master Tool’.
Latching Options: Select latching throttle option. If Latch on Time is selected, the spindle network will continue to run after the throttle has been held down for the selected amount of time.
4.5.10.1 Setting up Multi-Spindle Network See following page

4.5.10 Master Spindle Setup
Several Gen IV controllers can be linked together via an Ethernet connection to create a multi-spindle network. Operations requiring multiple fasteners to be inserted simultaneously or in a synchronized fashion is possible with this setup. Up to 10 tools can be operated from one master controller. The spindle network can be controlled via physical IO or across supported protocols. PSets will be synchronized across the spindle network so PSets and Jobs will only

4.5.11 Languages
Select from: · English · Chinese · Japanese · Korean · Spanish · Portuguese
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AcraDyne Gen IV iEC Controller Manual

4.5.10.1 Setting up Multi-Spindle Network
Hardware Connect the master controller and spindles together via an Ethernet switch. Ensure that all controllers have the appropriate tools connected and apply power.
Software Steps to enable the multi-spindle network: 1. Configure the IP address of each spindle: Ensure that they are
all on the same subnet. 2. Set each controller to be controlled from the master controller:
Go to Controller Tool Setup Start Input and set the input source to Start from Master Tool’. 3. Enable the master controller: The configuration screen for setting up the master spindle controller is found under Controller Master Spindle Setup. To begin setup, enable the master spindle by clicking on the red X underMaster Enabled’. This will unroll several new options. Now set the number of spindles and add their IP addresses to the list. Click OK to add the spindles to the master controller. Clicking OK will synchronize PSets and time across the controllers. 4. Add a PSet: Once the PSet is saved then it is ready to be run. 5. View the results: Spindle network results can be found under the “Spindle Results” tab now appearing on the main menu. Clicking on a spindle result will show the results of each individual spindle.
Spindle IP Addresses: The number of spindles listed depends on the number of spindles enabled. Add the IP addresses of the spindles to add them to the spindle network.
PSets: Synchronizing Stages When setting up a PSet, the Sync stage is available to synchronize spindle rundowns. Sync stages allows each spindle to pause between stages and wait for other spindles to reach the same stage before proceeding.
For example, a PSet set up to perform TC, Sync, Unfasten, Sync, TC will ensure that all spindles reach the target torque before going to the unfasten stage. At that time, all spindles will unfasten to the desired angle and will not proceed until each spindle has completed that stage before running down to the final torque. The rundown curve for this type of PSet is shown with four spindles.
PSet with Sync Example

Clicking on a spindle result item will display results of each spindle used in the operation

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4.6 Tool 4.6.1 Tool Setup

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Obstruction Torque (in-lbf): First 90° of rotation in the fastening direction. Cycle will be aborted if this torque is exceeded. If the tool rotates 90° and stops without any obstruction, the value is too low.
Hold At Home Torque (in-lbf): After reaching the open position, this is the torque preventing socket from bouncing to a partially closed position. This torque should be set to a value slightly less than the tubenut Home torque.
Home Detection Torque (in-lbf): In the reverse direction, reaching this torque indicates to controller that socket is in open position. If socket does not attempt to return to open position, this value is too low. AcraDyne recommends starting at approximately 12 in-lbs.

Allows user to make changes to Tool Setup.
Model Number: Tool model number of tool connected to controller.
Serial Number: Serial Number of current tool connected to controller.
Cycle Count: Total number of cycles since last reset.

4.6.2 Service Log

Service Parameters are stored in memory of tool and can be viewed in this screen. `Next Service’ or ‘Next Cal’ will turn red if value entered is exceeded.

External Multiplier: Configures tool to include gearing added to the base model. Units: Gear Ratio * 100 (Example: Adding a multiplier with a gear ratio of 5:1, Multiplier setting = 5).
Gear Inversion: 1 = tool Output rotates same direction as motor ­1= tool Output rotates in opposite direction as motor.
High Resolution Pulses Per Revolution: Determines resolution of the tool motor hall sensors

4.6.3 Button Calibration
After a tool has been worked on, it is possible the relationship between hall sensors and magnet have changed. Using the `Button Calibration’ screen calibrates the field between the two.
Select “Button Calibration” from the Tool Menu.
Tool disable confirmation screen will appear.

Tube Nut Parameters: See “16. Tubenut Tool Setup
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4.6.4 Torque Calibration

Test throttle and MFB (MultiFunction Button), send values to Tool ID board in this screen. Follow the on-screen instructions for button calibration.
Manually calibrate and reset tool to Factory Calibration.

4.6.5 Torque Calibration Routine
Used to calibrate tool using a Master Transducer. The following are steps to calibrate tool.
1. Press the “Start Calibration” button.
2. Run Tool to Final Torque.
3. Enter external transducer (Master) value in Measured Torque box.
4. Press “Send New Cal Values to Tool” button.
5. `New Cal’ value is calculated automatically and assigned to tool ID Board.
4.6.6 TID Parameters
Used by factory to load Tool ID parameters into tool.

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4.6.7 TID Memory

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Allows a Qualified Service Technician to view or edit tool.

Press the scan button to search for AcraDyne accessories on the network or enter the IP address of the accessory manually

4.7 Accessories

This screen shows accessories configured in the controller. New accessories can be added, edited, and deleted using the buttons at the bottom of the table.
To add a new accessory,
press or to navigate to the Accessory Scanning and Setup page.

The Smart Arm Accessory allows an articulated arm with encoders to be used with the Gen IV controller. Fastener locations can be programmed into the controller so that the controller will perform specific actions when the tool is located on a specific fastener.
For more specific instruction contact: AIMCO Technical Service, Toll Free 1-800-852-1368 or go to http://www .aimco-global.com/manuals and download the Gen-IV Controller Smart Arm Configuration Manual.

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4.8 Diagnostics

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The Diagnostics menu contains all pertinent information regarding unusual behavior of the system. Detailed descriptions are given in the following sections.

4.8.2 Controller Status

Shows “Live” status of controller, voltages, active faults, and temperature.

4.8.1 Controller Overview
Model Number: Model Number of the controller.
Serial Number: Serial Number of the controller.
Type: Type of controller: · IEC: Intelligent
Electric Controller · IEC4W: Intelligent Electric Controller 4 Mobile
SYSREL: System Release # shown
Application: Current Application software version.
Firmware: Current Firmware software version.
Servo: Current Servo Drive
Available Hardware: Available hardware on the controller.

Bus Voltages: Alarm icon will appear on controller console and under “Active Faults” (see below) if any of these values are out of range:
· Servo Power: Live monitoring of power demand from tool to controller
· 24 Vdc: Represents voltage from 24V power supply. Value is reported as on or off (.0-24.0 volts) and is for external use via 24V I/O port.
· 9 Vdc: Represents voltage from 9V power supply powering Tool electronics.
· 5 Vdc: Represents voltage from 5V power supply powering controller electronics.
· 3.3 Vdc: Represents controller electronics internal 3.3V Bus voltage.
· SOM 1.8 Vdc: Represents controller electronics internal 1.8V Bus voltage
· Torque Vdc: Status indication of tool transducer voltage
CPU Temperature (° C): Represents temperature of CPU measured in Celsius.
Mainboard Temperature (° C): Represents temperature inside controller measures in Celsius.
Active Faults: Any tool/ controller faults will be shown in this area.
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4.8.3 Tool Overview
This “read only” screen gives an overview of the tool connected to the controller. The information is stored in the memory on the Tool ID board (TID).
· Model Number: Model number of tool connected to controller.
· Serial Number: Serial number of tool connected to controller.
· Cycle Count: Number of fastening cycles tool has performed since counter was reset.
· Speed Range (RPM): Free speed of tool output. · Maximum Torque (Nm): Maximum torque output
of tool.
The following information is used internally by AcraDyne Technicians and not generally relevant to the end user: · Gear Ratio After Transducer: Any gearing
between transducer and tool output. · Gear Inversion:
1= Tool Output rotates same direction as motor. -1= Tool Output rotates in opposite direction as motor. (Example: Tube nut tools typically show -1 for gear inversion) · External Multiplier: Gear ratio of external “after market” multiplier. · Pulses Per Revolution Output: Number of motor hall pulses that occur per one revolution of motor Output. · Transducer Full Scale (Nm): Full scale torque rating of transducer. · Discontinuous Mode Allowed: Yes or No

4.8.4 Live Tool
Torque: Shows a live view of tool transducer in volts and Nm. Voltage will be approximately 2.0 volts (± 0.005 Vdc) when tool is at rest and torque is zero (verify the voltage is within the green zone in the graph).
During a rundown, tool transducer voltage increases as torque increases.
Motor Hall sensors A, B, C will be monitored along with tool throttle, Multi- Function Button, and RPM. The Hall Signals chart displays the live angle value. This value is set to zero when navigating to/out of the live tool screen. The “Reset Angle” button resets the live tool angle counter.

4.8.5 Indicators

Allows user to test tool LEDs, headlight, and buzzer.

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4.8.6 Identify Controller
`Identify Controller’ will cause lights on controller and tool to flash making the system easy to locate. This is especially helpful when programming is being done and multiple controllers are being used in close proximity to each other.
4.8.7 Record Logs
Logs information describing usage of controller and tools that have been used with that controller.
4.8.7.1 Change Log Log displays changes made to tool or controller.
4.8.7.2 Information Log Log displays all information entries.
4.8.7.3 Error Log Log displays ONLY Error Entries.
4.8.7.4 All Displays all Changes, Information and Error entries.
4.8.8 System Status

4.8.9 I/O Diagnostics
The I/O Diagnostics screen shows a log of all IO state changes from any assignable input or output. This can aid in verifying the correct functionality for IO configuration.
The refresh button will update the screen with the most recent IO changes. The save button will generate a log file that can be viewed on a PC. This file can be downloaded when viewing from a PC or saved to a USB drive when using the controller touch screen. This saved CSV file contains much more detailed information (timing, IO settings, etc) than can be displayed on the controller screen.
4.8.10 Network Diagnostics
Network Diagnostics can be useful in troubleshooting Ethernet communication issues
Ethernet: Shows if the Ethernet port is physically connected and if the hardware is operational.
Test Connection: Provides a way to check the ethernet connection to other devices on the same network.
Capture: Captures and saves the ethernet traffic for evaluation

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4.8.11 Extended Logging
Extended Logging can provide more details to the rundown’s curve data.
If Extended Logging is enabled, extra fastening events are logged in the curve data.
NOTE: Care should be taken when using this feature, as it will require more memory to store the curves and make the saved rundown records larger.
4.8.12 Statistics
Enter the desired number of samples and PSET to observe calculated statistics. Number of samples must be equal to or less than the existing recent results stored within the controller. Statistics are presented as a courtesy to users who wish to review them in quick fashion on the controller screen.
The Lower Spec Limit (LSL) and Upper Spec Limit (USL) are the lowest and highest torque or angle values that should occur in the audit torque or angle stage. By default, the audit torque or angle stage is the last auditable stage. This can be changed in PSet Edit Stage Audit Options.

4.9 Login
When a password is required it can be entered in this screen.
Three levels of access to the controller are available:
· Operator: Run/Login/View PSet screens available.
· Technician: Run/PSet/Job/Diagnostics and Login screens available.
· Administrator: All screens available.
4.10 Advanced
The `Advanced’ menu handles complex settings within the controller. Detailed descriptions are given in the following sections.
4.10.1 Login Setup
This screen allows the user to select the default Login level upon controller start up.
· Operator · Technician · Administrator
The Remote Login Level sets the default login level for remote sessions, allowing administrators to avoid logging in when accessing the controller over the network.

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4.10.2 Results Archive
Example of Saved Excel File

Select a file and
press

Approximately one million rundowns can be stored. Twenty files with approximately 50,000 rundowns are maintained at a time. The user can, at any time, save the runs to either a USB stick or to the Web as a CSV file imported directly into an Excel spreadsheet.
Using the touchscreen console, you can select multiple files to save.
Using the web option, you can select one of these files at a time to save (web option is default).
Select either USB or Web Archive location.

4.10.3 Import Settings
This allows the user to download any previously saved settings onto the controller (refer to `Export Controller’ for help with saving data).
1. Plug the USB with an export file into any port on the controller.
2. From the Home screen, navigate to Advanced Import Settings.
3. Select the settings to be checking the
corresponding box
Operations: This includes PSets and Jobs.
I/O: This includes I/O settings for the local I/O, Anybus, Modbus, and EtherNet/IP.
Configuration: This includes all settings of the controller except I/O, Master Spindle, Rundowns, PSets or Jobs.

Spindle: This includes any Master Spindle setup (i.e. number of spindles, IP addresses, etc).
4. Press to accept the changes.
5. Press to proceed.
6. Press when the import is complete and the controller will restart.
Import settings that were exported from another controller via a USB flash drive. Use this to quickly apply the same settings across several controllers. For example, it is common to have multiple controllers with the same I/O configuration. Set up one controller with the correct I/O configuration and export the controller from Advanced Export Controller. Now the I/O settings can be imported using this screen.
NOTE: Setting can only be imported from controllers running the same version of software.

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4.10.4 Export Controller
This allows the user to save Configuration, Operations, I/O, and Spindle settings onto a USB flash drive.
1. Plug a USB into any port on the controller.
2. From the Home screen, navigate to Advanced Export Controller.
3. Press to continue, and the controller will begin the export process.
4. Press to complete the export.
4.10.5 Update Controller
NOTE: Updated firmware versions will typically be sent via email zip file. Always save PSet and IP address information before upgrading controller.
Upgrading the AIMCO Gen IV Controller Using the TouchScreen or a System Port browser session, navigate to the Advanced’ menu. ClickUpdate Controller.’
If a USB stick containing the zip file has been plugged in to the controller, the file will show in the Available Updates list. Select the latest release and
click when ready.
If updating through a system port browser session, a dialog box will appear. Click the Choose File button and navigate to the folder where the zip file is located on the computer. Select the latest release and click
when ready.

After the controller restarts, the user should see following messages
Controller Upgrade Notification
When the controller has finished, navigate to Diagnostics Controller Overview to view any changes to the `Software Versions’. Any system settings (Ethernet IP address, PSets, Jobs, etc.) will remain unchanged.
4.10.6 Backup Restore
The Backup function allows the user to create an image of the controller software/firmware including all Configurations, Operations, I/O, and Spindle settings. This is used to create a point in which the controller can restore to if the need arises. In that case, the Restore function would be used.
1. From the Home screen, navigate to Advanced Backup Restore.
2. Press Backup to initialize the backup process.
3. Press to replace previous backup with current system, the backup process will begin.
4. Press Restore to initialize the restore process.
5. Press to restore all settings and firmware to last backup, the restore process will begin.
6. The controller will restart when finished.

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4.10.7 Restore Factory Defaults
This allows the user to reset the controller’s parameters to factory settings
1. From the Home screen, navigate to Advanced Restore Factory Defaults.
2. Select the settings to be changed and accept
· Operations: This includes PSets and Jobs.
· I/O: This includes I/O settings for the local I/O, Anybus, Modbus, and EtherNet/IP.
· Configuration: This includes all settings of the controller except I/O, Master Spindle, Rundowns, PSets or Jobs.
· Results: This includes all rundown data /information
· Log: This includes the Change, Information, Error, and Combined logs.
3. Press to accept the changes.
4. Press to proceed.
5. Press when the calibration is complete, the controller will restart.

4.10.8 Previous Software
The `Previous Software’ page enables users to change the software to an alternate version. When the controller is updated, the previous version will be retained to easily revert versions. Settings are not affected. Any changes to settings are retained when changing to an alternate version. The screen shows the current version along with the version information of the alternate version.
This feature is only available for versions 3R19 going forward. It is not possible to revert to a release earlier than 3R19.
4.10.9 Calibrate Touch Screen
Custom and Factory default calibration are available on the controller console.
1. From the Home screen, navigate to Advanced Calibrate Touch Screen.
2. Press to disable the tool.
3. Select the desired calibration
Custom Calibration: This allows the user to create a custom calibration setting for the touch screen.
Factory Default Calibration: This calibrates the touchscreen to the factory defaults.
4. Press to accept the selection.
5. Press to proceed.

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AcraDyne Gen IV iEC Controller Manual
In the case of custom calibration, a screen will appear with instructions on how to increase precision.
6. Press when the calibration is complete, the controller will restart.
NOTE: The controller may need to be reset before the custom calibration is possible. 4.10.10 Soft Reboot Restart the controller without turning the power off. 1. From the Home screen, navigate to Advanced
Soft Reboot. 2. Press to
proceed, the controller will restart.
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5. Barcode Reader Details
The Gen IV controller supports the following barcode reader functionality:
· Support up to four identifiers. · Each rundown result can be associated with up
to four identifiers. · Identifier(s) can be used to select a parameter
set or a job. · Display identifier(s) on controller. · Ability to lock-out tool until correct identifier(s) is
entered. · Ability to block barcode reads while a job is in
progress. · Barcode reads (identifiers) can come from any or
all the following sources: Serial barcode reader Open protocol Fieldbus network Telnet port
Solution Regardless of the source (serial barcode reader, telnet, fieldbus, or protocol) each new string is passed through the same process:
· All four identifiers are reset to an empty string on power-up.
· Each received barcode is processed through a Barcode Match Table to look for a match, if one is found the barcode is accepted.
· Each fastening will then be associated with the received barcode(s) until a new one is received or they are reset.
Parameters The parameters that pertain to the processing of barcode strings:
· The Barcode Match Table is used to identify the newly received barcode string.
· Which of the four Identifiers (ID#1-4) are required to enable the tool?
· Which of the four Identifiers (ID#1-4) to reset on a job complete?
· Parameter to disable all barcode reads while a job is in progress. If set, barcode reads will be disabled after the first fastener is ran until job is complete.
Barcode Match Table The Barcode Match Table is used to identify which barcode has been received. The controller can have up to 99 entries (rows) in the table. Each entry has actions that will be performed when a matching barcode is received. The table is searched from

top to bottom in an attempt to find a matching barcode. If none are found, the barcode is ignored.

Mask The Mask is a string used to compare against the received barcode. The received barcode must be at least as long in length as the Mask. The Mask can also contain “don’t care” characters of a decimal point or period in the string. These “don’t care” characters are counted in the length but the actual received character in that position doesn’t matter.

Identifier Type The “Identifier Type” field identifies which identifier (ID#1-4) the received barcode will be stored in.

Action Action can be one of the following: · None · Select PS#1-256 · Select Job#1-20

Reset ID
The “Reset ID” has the ability to reset other identifiers (ID#1-4) when barcode is received.

Examples:

Operator Scans When a vehicle enters the station, the operator scans the VIN. The controller selects the correct job number and enables the tool. Each fastener will be identified with this VIN stored locally, and/or sent to a server for storage. The job settings will disable the tool when the job is complete.

Setup In this example, there are three possible vehicle types each with its own job. The barcode scan will select the correct job (enabling the tool) and the scan will be stored into ID#1.

Mask “VIN…..7…”
“VIN…..8…”
“VIN…..9…”

ID type Action
ID#1 Select 1 Job#
ID#2 Select 2 Job#
ID#3 Select 3 Job#

Reset ID ID#1 ID#2 ID#3 ID#4 No No No No
No No No No
No No No No

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The tool enable/disable will be controlled by the job settings; the correct job will be selected by the barcode scan. The “ID Required to Enable the Tool” feature does not need to be utilized.

Required Identifiers for Tool Enable

ID#1

ID#2

ID#3

ID#4

No

No

No

No

These settings are irrelevant since the only way to enable the tool is with a new job and the only way to select a new job is to scan a new barcode.

ID#1 Yes

Reset Identifiers on Job Complete

ID#2

ID#3

No

No

ID#4 No

Examples This is what the `Operator Scans’ example looks like once set up in the Barcode Configuration Screen (see “4.5.7 Bar Code Setup” on page 47).

Airbag Install The customer wants to track the serial number of each airbag being installed, as well as the operator installing it. When the operator reports to the station, they will scan their employee ID. When the vehicle comes into the station, the operator scans the VIN of the vehicle and the serial number of the airbag. Once all three scans are received, the tool is enabled. Once the correct number of fasteners are installed, the tool is disabled by the job settings. From that point, the operator only needs to scan the vehicle and the airbag to enable the tool.

Setup We will assign the employee ID to ID#1, the vehicle VIN to ID#2, and the airbag serial number to ID#3. Scanning a new employee ID will reset the other IDs and force a scan of the vehicle VIN and airbag serial number. The scan of the vehicle VIN will also select the correct job number.

Mask “EMP….” “VIN……..”
“SN…….”

ID type Action ID#1 None
ID#2 Select 1 Job#
ID#3 None

Reset ID ID#1 ID#2 ID#3 ID#4 No Yes Yes No No No No No
No No No No

Once all three scans are received, the tool will be enabled.

ID#1 Yes

Required Identifiers for Tool Enable

ID#2

ID#3

Yes

Yes

ID#4 No

When job is complete, the vehicle VIN will be reset and the airbag serial number, but not the employee ID; this way subsequent vehicles will only require a VIN and S/N to enable tool.

ID#1 No

Reset Identifiers on Job Complete

ID#2

ID#3

Yes

Yes

ID#4 No

This is what the Airbag Install example looks like set up in “4.5.7 Bar Code Setup” on page 47.

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6. Glossary of Terms

Acceleration This setting controls how quickly the tool comes to programmed RPM. The value is stated in thousand(k) revolutions per minute (RPM) per second(s).

Default setting is 10 which means that at the start of the rundown or stage, the tool will reach 10,000 RPMs in a one second period of time.

Given the speed ratings of the tools in the AcraDyne range, this means that the programmed RPM will instantly be running at the throttle press, or start, of the stage.

To increase the time in which the tool comes up to speed (aka Soft Starting) the value should be reduced to the level desired.

Controller Firmware will limit the programmed value to effect the tool down to 10% of its rated speed. This means that a 1,000 RPM tool can be set to accelerate at 100 RPM/Second. Should an entry be made that is lower than this value, the Firmware of the controller will run the step/stage at no less than 100 RPM/Second

For a theoretical example: A setting of 1 will result in the tool accelerating (reaching the programmed RPM setting) in a 1,000 RPM step over a time period of 1 second. If the programmed speed was 2,000 RPM it would take 2 seconds to reach that 2,000 RPM setting during that step or stage of the rundown.

A setting of .5 will result in the tool accelerating (reaching the programmed RPM setting) in a 500 RPM step over a time period of 1 second. Using the 2,000 RPM example, it would take the tool 4 seconds to reach 2,000 RPM.

Summary: Lower values equal slower ramp up to programmed speed.

Accept Tone Controls tone made from handle of handheld tools for accepted fastening cycles.

Angle

Degree fastener rotates from snug, or threshold level, to peak torque.

Cycle Complete

Torque level that determines completion of a fastening cycle.

High Angle

When peak angle recorded exceeds High Angle, the fastening cycle is recorded as a reject for High Angle, the High Angle light (flashing yellow) illuminates, and fastening cycle is given an overall status of NOK.

High Torque

When peak torque recorded exceeds the High Torque, the fastening cycle is recorded as a reject for High Torque, the High Torque light (flashing red) illuminates, and fastening cycle is given an overall status of NOK.

Job

A Job is a collection of Psets or Multi-

stages, which are useful when performing

several multiple fastening operations,

each with different requirements. This is

convenient since the operator does not

have to select a new Pset or Multistage for

every fastening.

Low Angle

When the peak angle recorded during the Angle Audit Step fails to reach the Low Angle, fastening cycle is recorded as a reject for Low Angle, the low angle light (flashing yellow) illuminates, and fastening cycle is given an overall status of NOK.

Low Torque

When the peak torque recorded fails to reach the Low Torque, fastening cycle is recorded as a reject for Low Torque, the Low Torque light (flashing red) illuminates, and fastening cycle is given an overall status of NOK.

MFB

Multi-Function Button

Multi-stage

In some instances, it is necessary to perform a fastening in several stages. This requires specific fastening strategies. Multi-stage allows user to create linear sequences up to 256 Psets to perform a fastening divided into stages.

Parameter Set

A Parameter Set is a collection of instructions that define how the tool should perform the fastening process. It may be selected from the console or device such as a socket tray or PC.

Snug Torque

Controller begins to monitor tool for angle at a preselected threshold torque. Any increase in angle, after the snug point, results in a corresponding increase in tension or clamp load within the joint.

Speed

Speed at which tool operates during the initial portion of the fastening cycle prior to downshift.

Spindle

A spindle represents a connection to a
handheld, or fixtured, tool connected to a controller.

Strategy

Identifies the variables being used to control tool during a fastening cycle.

Thread Direction

Sets assembly direction to clockwise (CW) or counter clockwise (CCW).

Threshold Torque

Sets point at which tool is “In Cycle”.

Torque Calibration

Determines how torque values are assigned to the electrical signals for torque transducer on tool. Value is unique to each tool and changes over time.

Torque Target When the tool is being controlled for torque, the torque target instructs controller when to shutoff tool. Torque target should be greater than Low Torque and less than High Torque, this is required for torque control.

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7. Icons Defined

Icon

Description Home Navigation Button Run Navigation Button Run Screen Select Buttons
Go Back Button
Accept Changes Button
Cancel Changes Button
Add New Button
Edit Button

Function
Navigate to the main menu (“HOME”) screen. Navigate to the Run Screen.
Switch between the different run screen pages. Navigate to one menu level back.
Accept the changes made and return to the parent screen. Reject the changes made and return to the parent screen. Add a new item (Pset, Stage, Job, and other). Edit selected Item.

Where Used All screens except for edit screens. All screens except for edit screens. Run Screen
All screens except for edit screens. Edit screens
Edit screens
PSet and Job edit screens.
PSet and Job edit screens.

Move Up and Down Buttons

Move selected item up or down in the sequence order.

PSet and Job edit screens.

Copy Button Delete Button Filter Button

Copy selected Items
Remove or unassign selected items. Filter Items in a list or table.

PSet, Job, and other edit screens. Edit and list view screens.
List view screens

Save Button
Select Columns Button
Fault Indicator
Invalid PSet Indicator

Save selected item to file.
Allows customization of columns shown on the Results Screen. Fault exists that is preventing the tool from running (can be pressed for more Info). Selected Pset does not exist or is not valid.

List view screens Results Screen
Run Screen
Run Screen

Icon

Description
Barcode Scan Required Indicator Job Complete Indicator Lock on Reject (LOR)

Function
A barcode is required to enable the tool.

Where Used Run Screen

Job is complete. Run Screen

Lock tool on

Run Screen

rejected fastener.

Disassembly Job Reset Complete
Scan

A disassembly event has been detected. Reset Job has finished. Results from last successful rundown of a job are cleared. Search for accessories on the network

Run Screen
Add New Job Screen
Add Accessories Screen

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8. Stop Codes
If a Stop condition is detected that prevents the tool from running, a code will appear on the LED display. Any active stop conditions are also displayed on the RUN screen.

Code IO

Icon

Description
Stopped or Disabled from Physical 24 volt IO input

Code BRCD

Icon

Description
Bar Code ID scan required to enable tool

ABUS MODB EIP RTU OP OP REV ARM JOB JOB JOB LOR

Stopped or Disabled from ANYBUS
Stopped or Disabled from Modbus
Stopped or Disabled from Ethernet IP
Stopped or Disabled from Modbus RTU
Stopped or Disabled from Open Protocol Lost Open Protocol Connection
Disassembly Disabled
Tool Requires Arming ­ MFB button configured to enable the tool to run. Job Sequence Complete
Job Complete
XML Count Complete
Locked on Reject

SRVC INVP
INVP
INVJ
PSET SPND NET XML NOK FLT

Tool Disabled For Service – Tool service or calibration interval has expired
Invalid PSet – Parameter set number for a non-existent Pset has been selected to run. Most likely via one of the following methods:
Job MFB I/O PSet outside of Job – Parameter set number outside of the job has been selected. Most likely via one of the following methods: MFB I/O Invalid Job – Job number for a non-existent Job has been selected to run. Most likely via one of the following methods: MFB I/O PSet Mismatch
Spindle Not Configured ­ Spindle selected to run from a Multi-Spindle Job has not been configured XML Disconnected
Stop from XML
XML Max Rejects Exceeded
Controller Fault – Error has been detected. See fault code list for details

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9. Error Codes
If an error condition is detected that prevents the tool from running, a fault code will appear on the LED display. Any active faults are also displayed on GUI RUN screen. Fault history can be viewed in the Controller Error Log.

Gen4 Common Hardware Fault Codes

Code FH17 FH18 FH19 FH20 FH21
FH22 FH23 FH24
FH25
FH32

Fault Type

Description

Possible Causes

1.8vdc MB out of tolerance

Main board 1.8 bus voltage exceeds electrical limits

· Faulty Controller main board or other Controller electronics

1.8vdc SOM out of System on Module 1.8 bus

· Faulty Controller main board or other Controller

tolerance

voltage exceeds electrical limits

electronics

3.3vdc out of tolerance

Main board 3.3 bus voltage exceeds electrical limits

· Faulty Controller main board or other Controller electronics

5vdc out of tolerance

5 Volt bus voltage out of range

· Faulty power supply or wiring · Faulty Controller main board or other Controller
electronics

9vdc out of tolerance

9 Volt bus voltage out of range

· Faulty power supply or wiring · Faulty Controller main board or other Controller
electronics · Faulty tool cable · Faulty tool electronics or wiring

24 volt level low

24 Volt I/O power not detected

· Faulty power supply or wiring · Short or other problem with external connections to
the 24Volt I/O port.

Controller temp high Controller’s internal temperature · Ambient air temperature exceeds rating of

exceeds limit

Controller

+15vdc out of tolerance

+15 Volt bus voltage out of range · Faulty power supply or wiring · Faulty Controller main board or other Controller electronics · Faulty tool cable · Faulty tool electronics or wiring

­15vdc out of tolerance

­15 Volt bus voltage out of range · Faulty power supply or wiring · Faulty Controller main board or other Controller electronics · Faulty tool cable · Faulty tool electronics or wiring

Processor Fault

RTOS processor not communicating with the Application processor

· Faulty mainboard electronics
· RTOS processor firmware corrupted or not loaded · Faulty SOM board or connector

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AcraDyne Gen IV iEC Controller Manual

IEC (AcraDyne DC Tool) Specific Fault Codes

CODE FT01 FT02 FT04
FT05
FT06 FT07
FT08 FD12 FD13
FD14
FD15 FD16 FS26 FS27
FS28 FS29 FS31

Fault Type Description

Possible Causes

Tool not

Tool communication timeout

· Tool not connected

connected

· Faulty tool cable

· Faulty tool electronics or wiring

Invalid TID Tool parameter file not compatible · Corrupt tool ID memory location

parameters with Controller

· TID file not loaded in tool

Torque signal Tool torque signal voltage is

· Tool not connected

out of Range beyond electrical limits

· Faulty tool cable

· Faulty transducer

· Transducer electronics not calibrated

· Faulty tool/controller electronics or wiring

Torque tare Tool torque signal no load voltage · Transducer electronics significantly out of calibration

value out of is out of range

· Faulty transducer

range

· Faulty tool cable

· Tool gear binding

· Faulty controller electronics or wiring

Motor hall Hall signals states are all high or all · Tool not connected

states invalid low

· Faulty tool cable

· Faulty tool electronics or wiring

· Faulty motor halls or wiring

Motor halls Hall signal sequence incorrect

· Faulty tool cable

skipping

· Faulty tool electronics or wiring

states

· Faulty motor hall or wiring

· Hall signal leads are connected incorrectly

· Too many tool extension cables

Tool

Tool ground conductors not

· Tool not connected

ground not connected

· Faulty tool cable

connected

· Faulty tool ground wires

· Faulty tool electronics or wiring

Drive not

Drive CAN communication time · Faulty Controller main board electronics

connected out

· Faulty drive electronics or connection

Drive Fault Drive reporting fault via CAN

· Tool not connected

SW

communication

· Faulty tool cable

· Faulty tool motor

· Application exceeds capability of drive

· Faulty drive

Drive Fault Drive reporting fault via IO signal · Tool not connected

HW

· Faulty tool cable

· Faulty tool motor

· Application exceeds capability of drive

· Faulty drive

Drive Vbus Drives DC bus voltage exceeds · AC supply power exceeds voltage ratings of Controller

high

electrical limits

Drive Vbus Drives DC bus voltage is too low to · Supply power cycled too quickly. Five second delay required

low

run tool

after switching off the Controller before turning back on.

Power on Run command on power up

· Tool laying on lever on power up

throttle

· Tool buttons out of calibration

· Run command from logic I/O on power up.

Locked rotor Motor has stalled for more than · Poor parameter settings for application.

100 milliseconds

· Torque signal out of calibration

· Faulty tool gearing or motor

· Corrupted TID parameters

· Faulty Controller or tool electronics

Target out of Parameter set torque target out of · Target torque exceeds tool capability

range of tool range of rated tool capability

· Joint Compensation Ratio set too low.

· Corrupted TID parameters

Invalid tool Tool configuration not compatible · Tubenut tool commanded to run a parameter set with left

with parameter set

hand thread direction or with an unfastening stage

· Tubenut tool commanded to go in the disassembly direction

Lost Master Lost Connection to Master Spindle · Faulty Ethernet Connection

Start Signal

· RTOS processor firmware corrupted or not loaded

· Faulty SOM board or connector

· Controller export performed during rundown

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AcraDyne Gen IV iEC Controller Manual
10. Dual-Lever Tools Requiring Two-Handed Operation
Two Handed Functionality
· Tool will not run unless both switches are pressed within one second of each other.
· If the one second timer times out, both switches must be released to reset the timer.
· If either trigger is released the tool stops. · To restart the tool, both switches must be
released and pressed within one second of each other. NOTE: All settings in Controller Start Input Configuration will be ignored.
I/O cannot be used to start a two-handed tool.
Latching throttle is disabled for a twohanded tool.
· Exceptions exist for Tubenut tool homing.
Tubenut Tool Homing Exceptions for Two Handed Functionality
· If controller’s tubenut homing configuration is set to RELEASE: Releasing either, or both, of the levers will initiate the homing sequence. Homing will continue until sequence is complete.
· If controller’s tubenut homing configuration is set to RELEASE AND REPRESS: Releasing either of the levers, then pressing both levers will initiate the homing sequence. Homing will continue while both of the levers are being pressed. If either lever is released, before homing is complete, tool will stop and homing will pause until both levers are pressed. To restart tool, after homing is complete, both switches must be released and pressed within one second of each other.
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AcraDyne Gen IV iEC Controller Manual

11. 24 Volt I/O
Port Pinout and Diagrams An I/O wiring adapter kit is available (Part #27348) from AIMCO to make connection to I/O port on the controller easier. Contact your AIMCO Sales Representative for ordering information. Toll Free: 1-800-852-1368.

Pin # 1 2 3 4 5
6 7 8 9 10 11 12 13 14 15 16 17 18
19 20 21 22 23 24 25

Function Output 1 Output 2 Output 3 Output 4 Outputs 1-4 common Input 1 Input 2 Input 3 Input 4 Input 5 Input 6 Input 7 Input 8 Output 5 Output 6 Output 7 Output 8 Outputs 5-8 common N/C N/C 24 V Return 24 V Return +24 Vdc +24 Vdc +24 Vdc

Default Assignment Accept Reject In Cycle Torque High
Run Forward Run Reverse Disable Tool PSet Bit 1 PSet Bit 2 PSet Bit 3 Reset Job
Torque Low Angle High Angle Low Job Complete

NOTE: The Default Assignments in Table above are factory defaults and can be changed. See “12. Assignable I/O” on page 71.

24 Volt I/O Connections
Turn off system before connecting to the LOGIC I/O port. There may be risk of damaging the controller.
· 24Vdc Supply: The internal 24Vdc power can supply up to 1 amp.
· Inputs: Inputs are a sinking configuration with the common connected to the ground pins. 24Vdc is logic ON and 0Vdc is logic OFF.
· Outputs: Outputs are normally open relay contacts. The relays are rated for 24Vdc, 1 amp.
NOTE: If Outputs are driving an inductive load, such as a solenoid or large relay, it is recommended to add a diode in parallel with the load to prevent voltage surges.

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AcraDyne Gen IV iEC Controller Manual

Importing I/O on an iEC4 These instructions detail how to import I/O into an iEC4 controller via the

References

• Aimco-Global | Tough tools Made in the USA.

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