AcraDyne iPC Controller Manual Important Safeguards For your protection, please read these instructions completely. Keep this manual for future reference. Carefully observe and comply with all warnings, cautions and instructions placed on the equipment or described in this manual. Contents 1.) Safety Information ...................................
1.) Safety Information General Power Tool Safety Warnings WARNING Read all safety warnings and instructions. Failure to follow the warnings and instructions may result in electric shock, fire, and/or serious injury. Save all warnings and instructions for future reference. The term “power tool” in the warnings refers to your mains-operated (corded) power tool or battery-operated (cordless) power tool.
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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. A moment of inattention while operating power tools may result in serious personal injury.
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of the power tool for operations different from those intended could result in a hazardous situation. 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. Page 7 of 92 MAN177 rev_08_21_2018...
2.) Controller Diagram 2.1 Bottom Panel 1. Tool Connection 2. USB port-for import/export of data including firmware updates 3. Power Cord Connection 4. Power Disconnect Switch-Turns controller on and off 5. System Port- USB connection used to connect external computer to configure/monitor the controller 6.
3.) Initial Set Up Step 1: Connect Sensor Cable to CN-1 Connector of IPC Controller and connect Amphenol Connector to the tool. Step 2: Plug female end of power cable into Power Cable Connector. Step 3: Plug male end of power cable into appropriate power source. Connection to local power should be made in consultation with a qualified electrician.
3.1 Connecting to the Controller There are three ways to program/communicate with the controller: 1. Controller touch-screen console 2. System Port: (USB A to B connection) Direct connection to controller 3. Ethernet Port: Via direct connection or LAN Touchscreen Console Controller functions and programming can be accessed directly through the touch-screen.
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Connecting via The System Port directly to PC 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.
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Step 5: Go to ‘Network and Sharing Center’. Step 6: Go to ‘Change adapter settings’. Step 7: Find the Local Area Connection that is using the ‘USB Ethernet/RNDIS Gadget’ network. Right click this network and go to ‘Properties’. Page 13 of 92...
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Step 8: In Properties window select ‘Internet Protocol Version 4’ and click ‘Properties’ Step 9: In ‘Properties’, set the IP address to a static address. Type an IP address of 192.168.1.5 (Any address on the same subnet as the controller will work).
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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. You will see the controller software on your computer sceen. Page 15 of 92...
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Connecting using the Ethernet Port Directly or via LAN to PC 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’. Set a static IP address of the Computer/Laptop to 10.10.30.98 and subnet mask to 255.255.255.0.
3.2 Quick Set Up: (Default PSets from Tool) On the Home Page press: to accept default PSet Parameters. 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 Pulse Monitor Strategy (TC_PM).
4.1 Run Features The Run Screen is essentially the dashboard of the Gen IV controller and provides a look at real time information regarding rundowns. Indicates the current JOB Indicates the current PSet you are operating in Indicates accepted rundown Indicates failed rundown Displays Torque and Angle for current rundown...
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Time Overall Screen Click for curve detail. Click on arrow to change curve X axis. Choose Time in-cycle, Time Overall or Angle screen Page 19 of 92...
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Run Screen (Job display information) Run Screen displays real time Job information. Large Screen Indicators and Audit information The large screen indicators are helpful in viewing real time results of the rundown from a distance. Accepted Failed Page 20 of 92...
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. 4.2.1 Add New PSet n Home Page press the tab.
4.2.3 TC-PM Torque Control Pulse Monitor 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. Enter approriate values in Edit stage Screen Torque High: Upper control limit of the rundown Torque Target: Final desired torque (CUT Level)
4.2.4 Advanced Options PSet Name: Add PSet name if desired (up to 10 characters). Judgement Delay: Tool provides judgment after tool stops producing pulses and this delay expires. Initial Current (%) Percentage of maximum current delivered to the motor before in-cycle torque threshold. Reduce this value to reduce the amplitude of torque pulses.
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 Click to Enable/Disable Job function. 4.3.1 Add New Job To add a new Job, press on the Home Page.
PSet Number: Choose any current PSet already configured in controller Action: • None: Stays in current sequence • Next: Advances to next sequence set up after count is reached • Count: Fastener number required to complete sequence Once values are entered press two times to return to Job screen 4.3.2 Advanced Options Limit Reject Parameters...
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Jobs “Enabled” display and button function: Indicator Light Torque Display (Always displays torque value) Secondary Display Parameter Setting (PSet)/Job display and Increment/Decrement buttons Toggle button: PSet/Job functions • 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.
4.4 Results 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. Deletes individual rundowns by clicking on them separately and deleting them in the next screen or deleting all rundowns by clicking on the icon at the bottom of Results page.
Rundown file is tab separated variables and can be viewed using Excel. The raw data can now be imported to Excel to build graphs, charts etc. Contact AIMCO Technical Service for pre- made Torque and Angle Templates. INDIVIDUAL RUNDOWNS...
4.5 Controller The controller menu is where all the settings for the iPC controller are configured. All the different configuration capabilities are explained below: 4.5.1 Tool Setup 4.5.1.2 Tool Parameters In this screen the user can set-up various tool functions. For proper operation of the tool, this information must be entered each time a new tool is connected to the controller.
4.5.1.3 Disassembly Report Disassembly: When enabled this will show disassembly and angle torque values Threshold Torque: Value at which the tool is in cycle disassembly value will be reported Torque Units: Choose unit of measure Decrement Fastener Count: If Disassembly is detected the the fastener count in JOBS Never: Decrement count will be ignored Always: Decrement will always be active...
4.5.3 I/O 4.5.3.1 Physical I/O Outputs check inputs and outputs 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 (below).
4.5.3.3 Anybus/ Modbus TCP/Ethernet IP Inputs These types of communication are useful for data communication between controller and PLC’s. It is an effective, quick way for the data transfer of short data packages. Press to enter Input Configuration Screen (below) Element Type: Choose from Byte, Int16 or Int32 Element: Shows element # being...
4.5.3.4 Anybus/Modbus TCP/Ethernet IP Outputs check inputs and outputs Press to enter Output Configuration Screen (below) Element Type: Choose from Byte, Int16 or Int32. Element: Shows Element # being configured. Bit: Enter Bit # Polarity: Select Normally Open or Normally Closed Outputs. Mode: Normal - Output signal sent.
4.5.4 Communication Interfaces 4.5.4.1 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: Consult your local System Administrator to connect the controller to your Network and assign IP addresses 4.5.4.2 System Port...
(see below for format) Barcode Reader: (See Section 5.0 for Barcode ▪ setup) Serial Output and Barcode Reader. ▪ (Contact AIMCO Technical Service for detailed information on the following) Open Protocol ▪ PFCS ▪ Modbus RTU ▪...
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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 ▪...
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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 ▪...
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• 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 ▪...
4.5.5 Front Panel Buttons Enable/ Disable front panel buttons on controller console 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. When “Last job” is selected, controller will power up on last job selected prior to being Powered Down •...
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 Step 1 : Click anywhere in body to enter the Barcode ID configuration Screen or add additional Identifiers...
• 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...
4.5.9 Remote Connections Sets number of remote browser connections to controller. 4.5.10 Languages Select from: English Chinese Japanese Korean Spanish Portugese - Brasil Page 43 of 92...
4.6 Diagnostics The Diagnostics menu contains all pertinent information regarding unusual behavior of the system. Detailed descriptions are given below. 4.6.1 Controller Overview • Model Number: Model Number of the controller. • Serial Number: Serial Number of the controller. • Type: Type of controller- IPC –...
4.6.2 Controller Status check voltages Shows “Live” status of controller, voltages, active faults and temperature. Power Supplies: Alarm icon will appear on controller console and under “Active Faults” (see below) if any of these values are out of range: • 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 •...
4.6.4 Tool Communications update image Access this screen to view the communications between the tool and controller. Data should be continually streaming if the system is working normally. This can be used to identify issues with tool communication. If no data is being sent between the tool and controller then there may be a hardware problem.
4.6.7 System Status 4.6.8 I/O Diagnostics This screen shows a record of the last changes in state of all the assigned I/O that are active. Record can be saved to disgnose I/O functionality Page 47 of 92...
4.7 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 screens available • Technician Run/PSet/Job/Diagnostics and Login screens available • Administrator All screens available 4.8 Advanced The ‘Advanced’...
4.9.1 Login Setup This screen allows the user to select the default Login level upon controller start up • Operator • Technician • Administrator 4.9.2 Results Archive 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 USV file imported directly into an Excel spreadsheet.
4.9.3 Import Settings This allows the user to download any previously saved settings onto the controller (refer to ‘Export Controller’ for help with saving data). XAMPLE OF SAVED XCEL FILE Plug the USB with an export file into any port on the controller. From the Home screen, navigate to Advanced→Import Settings.
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. Click ‘Update Controller’...
4.9.6 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.
• 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 •...
NOTE: The controller may need to be reset before the custom calibration is possible Factory Default Calibration: This calibrates the touchscreen to the factory defaults 4.9.9 Soft Reboot Restart the controller without turning the power off 1. From the Home screen, navigate to Advanced Soft Reboot →...
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 •...
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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.
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Examples This is what the ‘Operator Scans’ example looks like once set up in 4.5.8 Barcode Configuration Screen. 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.
6.) Icons Defined ICON DESCRIPTION FUNCTION WHERE USED Home Navigation Navigate to the main menu All screens except Button (“HOME”) screen for edit screens Run Navigation Navigate to the Run Screen All screens except Button for edit screens Run Screen Select Switch between the Run Screen Buttons...
6.1 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 ICON Description Stopped or Disabled from Physical 24 volt IO input ABUS Stopped or Disabled from ANYBUS MODB...
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XML Disconnected Stop from XML XML Max Rejects Exceeded Controller Fault - Error has been detected. See fault code list for details Page 60 of 92...
7.) 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. Gen IV Common Hardware Fault Codes CODE Fault Type...
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IPC (URYU Electric Pulse Tool) Specific Fault Codes CODE Fault Type Description Possible Causes FP01 Torque signal out of Tool torque signal voltage • Tool not connected Range is beyond electrical limits • Faulty tool cable • Faulty transducer • Transducer electronics not calibrated •...
8.) 24 Volt I/O Port Pinout and Diagrams A 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.
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Importing I/O on an iPC4 check images These instructions detail how to import IO into an iPC4 controller via the system port to modify the Anybus outputs. 1. Power on the controller 2. Insert the USB stick into a USB port 3.
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9. Verify the Anybus outputs. a. Navigate to Controller->IO- >Anybus Outputs b. Click on the first row of element #1 and verify it is set as ‘Running Job Number’, Bit 0, Bits 8, Start at 0. c. Click on element #4 and verify it is set as “Torque (x100)”, Bit 0, Bits 16...
9.) Assignable I/O Introduction The Gen IV controller supports assignable I/O. Buses The controller is divided up into buses. Each bus has a set of inputs and a set of outputs. Currently the controller supports the following buses. Bus Number Physical I/O Fieldbus (Anybus module) I/O Modbus TCP...
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Element Polarity 0-31 N.O./N.C. Width Offset √ √ √ √ The “Stop” assignment will stop the tool if it is running and prevent it from being started. Disable Supported Feature Element Polarity 0-31 N.O./N.C. Width Offset √ √ √ √ The “Disable”...
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The “Select Job Sequence” input will select the job sequence number according to the input value. Uses the width parameter limit the width of the input bits read. The minimum width is 1 and the maximum is 8. After the input is read the offset parameter will be added to the value do get the actual job sequence number.
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the input value changes and it is non-zero the date and time of the controller will be set to the new value. Set Date/Time (word swap) Supported Feature Element Polarity 0-31 N.O./N.C. Width Offset √ √ √ √ The “Set Date/Time (word swap)” assignment is the same as the “Set Date/Time” assignment except the high and low words (16bit) are swapped prior to evaluation.
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Increment Batch Supported Feature Element Polarity 0-31 N.O./N.C. Width Offset √ √ √ √ The “Increment Batch” assignment will insert a manual rundown into the current sequence of the current JOB. This will cause the JOB count to increment by one. Click Wrench Supported Feature Element...
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Outputs All output assignments have a Bus, Element, and Bit configuration to define its location in the system. Along with the basic configuration many also have other configuration(s) that allow its behavior to be modified to suit the application. Supported Feature Controller Element Polarity...
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Normal Mode In the “Normal” mode the output will track the state of the assignment (while still observing the polarity setting). If the polarity is set N.O. and the assignment has an active output the output will be on and stay on till the assignment goes to inactive. Assignments active state Output state Figure 1.
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Flash Mode In the “flash” mode the output will flash at the time rate while the assignments state is active (while still observing the polarity setting). Assignments active state Output state Time Figure 3. Flash Mode Width and Offset For multiple bit outputs (for example “Running PSet Number”) the width variable defines the number of bits the assignment will output.
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Assignments Supported Feature Element Polarity Mode Time Width Offset Input Input Input 0-32 N.O., Normal, Element N.C. Timed, Flash √ √ √ √ √ The “Ok” output assignment will go active at the completion of an acceptable fastening. It will go inactive when the next fastening is started (the torque exceeds the threshold value) or a Job reset.
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Low Torque Supported Feature Element Polarity Mode Time Width Offset Input Input Input 0-32 N.O., Normal, Element N.C. Timed, Flash √ √ √ √ √ The “Low Torque” output assignment will go active at the completion of a fastening that has a low torque results.
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Low Angle Supported Feature Element Polarity Mode Time Width Offset Input Input Input 0-32 N.O., Normal, Element N.C. Timed, Flash √ √ √ √ √ The “Low Angle” output assignment will go active at the completion of a fastening that has a low angle results.
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Fastening Aborted Supported Feature Element Polarity Mode Time Width Offset Input Input Input 0-32 N.O., Normal, Element N.C. Timed, Flash √ √ √ √ √ The “Fastening Aborted” output assignment will go active at the completion of a fastening that was aborted by the system.
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Error Supported Feature Element Polarity Mode Time Width Offset Input Input Input 0-32 N.O., Normal, Element N.C. Timed, Flash √ √ √ √ √ The “Error” output assignment will be active while the controller has an error. Tool Enabled Supported Feature Element Polarity Mode...
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PFCS Connected Supported Feature Element Polarity Mode Time Width Offset Input Input Input 0-32 N.O., Normal, Element N.C. Timed, Flash √ √ √ √ √ The “PFCS Connected” output assignment will be active if the controller has an active PFCS connection.
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Torque (continued) The “Torque” output assignment will output the final torque value of the most recent rundown. The value will be cleared to 0 at the start of a new fastening cycle or a Job reset. At the end of the fastening cycle the final torque will be truncated to an integer and output.
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Fastener Removed Supported Feature Element Polarity Mode Time Width Offset Input Input Input 0-32 N.O., Normal, Element N.C. Timed, Flash √ √ √ √ √ The “Fastener Removed” output assignment will go active when a fastener is removed by the operator.
Pulses High Supported Feature Element Polarity Mode Time Width Offset Input Input Input 0-32 N.O., Normal, Element N.C. Timed, Flash √ √ √ √ √ The “Pulses High” output assignment will go active at the completion of a fastening that has an pulse count that exceeds the high limit.
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36 Job info acknowledge 37 Job info unsubscribe 38 Select Job 39 Job restart 40 Tool data upload request 41 Tool data upload reply 42 Disable tool 43 Enable tool 50 Vehicle ID number download request 51 Vehicle ID number subscribe 52 Vehicle ID number 53 Vehicle ID number acknowledge 54 Vehicle ID number unsubscribe...
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150 Identifier download request 157 Reset all Identifiers 200 Set external controlled relays Only supports 0 (off) and 1 (on) 210 Status external monitored inputs subscribe 211 Status external monitored inputs 212 Status external monitored inputs acknowledge 213 Status external monitored inputs unsubscribe 214 IO device status request 215 IO device status reply 216 Relay function subscribe...
12.) Specifications Mechanical: Dimensions: Width: 6.25 in 159 mm Height: 15.75 in 400 mm Depth: 12.5 in 316 mm Weight: 15.65 lbs 7.1 kg Operating Conditions: Temperature: 32 to 122 ᵒF (0 to50 ᵒC) Humidity: Non-condensing Ingress IP20 Protection: Electrical: AC Power Source: 120 VAC, 1Φ/2 Φ, 50/60 Hz.
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Step 1: After the device is connected to the development PC, OS will automatically search for the RNDIS driver. After it fails to find the driver, the following message will be shown: Step 2: Right click on Computer and select Manage. From System Tools, select Device Manager.
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Step 6: In the Select Network Adapter window, select Microsoft Corporation from the Manufacturer list. Under the list of Network Adapter, select Remote NDIS Compatible Device. Step 7: The RNDIS Kit device is now installed and ready for use. ----------------------------------------------------------------------------------------------------------------------------- --------------- Issue: DC Bus High Voltage Warning when using an HT tool Solution: Adding a Brake Stop of 0.5 to 1.0 Second stage to the end of the rundown should eliminate this issue.
The warranty provision with respect to each such product may be amended by AIMCO from time to time in its sole discretion. The liability of AIMCO hereunder shall be limited to replacing or repairing, at its option, any defective products which are returned freight pre-paid to AIMCO or, at AIMCO's option, refunding the purchase price of such products.
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THIS EXCLUSION ALSO INCLUDES ANY LIABILITY WHICH MAY ARISE OUT OF THIRD PARTY CLAIMS AGAINST BUYER. THE ESSENTIAL PURPOSE OF THIS PROVISION IS TO LIMIT THE POTENTIAL LIABILITY OF AIMCO ARISING OUT OF THIS AGREEMENT AND/OR SALE. NOTE: The AIMCO Warranty confers specific legal rights, however some states or jurisdictions may not allow certain exclusions or limitations within this warranty.
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