AcraDyne GEN IV iEC 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 c. Prevent unintentional starting. Ensure WARNING the switch is in the off-position before Read all safety warnings and instructions. connecting to power source and/or battery pack, picking up or carrying Save all warnings and instructions for future the tool.
2 Controller Diagrams 2.1 Front Panel LED Indicator Lights Green LED: Indicates tightening cycle meets specified parameters. Red LED: Indicates tightening cycle rejected for exceeding high torque. Red Flashing LED: Indicates low torque. Tightening cycle was rejected for not achieving low torque. Yellow LED: Indicates High Angle.
2.2 Side View 1. Power Cord Connection 2. Tool Connector: 19 Pin Standard connection point for tool cable 3. Fan Connector: For tools equipped with an on-board cooling fan. Page 6 of 84...
3 Initial Set Up Step 1 Connect tool cable to Tool Connector. Cable consists of a male pin set housed in a molded 19 pin connector with a polarizing notch. Align tool cable notch with tool con nec tor notch on the controller and insert cable.
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.
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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’. Step 8 In Properties window select ‘Internet Protocol Version 4’...
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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). 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.
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Connecting using the Ethernet Port Directly to PC Make a physical connection from the PC to the controller’s Ethernet (1) port using an ethernet • cable. Verify the controller’s Ethernet (1) IP address by using the touchscreen or a system port browser •...
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 Strategy (TC).
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. 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.
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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 Angle Screen Page 15 of 84...
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Run Screen (Job display information) Run Screen displays real-time Job information. PSet View Screen Large Screen Indicators and Audit information (Easy Mode) The large screen indicators are helpful in viewing real-time results of the rundown from a distance. Parameter Set View Curve View Simple View Page 16 of 84...
4.2 PSet Parameter Settings (PSets) control the fastening process. The following describes the different fastening stratagies 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.
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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.
4.2.2 Edit PSet On Home page press: On the PSet screen (left) click on the desired PSet you would like to edit. Click on the Edit button to make changes in the Edit screen (right). If further Stage changes are needed click the Edit button again to enter Edit Stage screen (below).
4.2.3 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: revents 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 In-Cycle Torque is less than the Re-hit Angle Count.
4.2.5 PSet Stages 4.2.5.1 TC-Torque Control Stage Control strategy uses torque as the only control parameter. TC Stage 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.
4.2.5.2 TC_AM Torque Control Angle Monitor Stage Control strategy is convenient for detection of cross threaded or TC AM Stage 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.
4.2.5.3 AC-TM Angle Control Torque Monitor Stage Control strategy in which the tool stops when Angle Target is AC TM Stage 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 Torque...
4.2.5.4 TC_AC Torque Control Angle Control Stage Control strategy in which the tool stops if Target Torque or TC AC Stage 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 Torque the range specified by Angle High Limit and Angle Low Limit...
4.2.5.6 Delay Stage Delay between Stages: Time the tool stops and waits before proceeding to the next stage. Default is 0.2 (sec). Time Delay (sec): Total time in seconds the tool stops and waits before proceeding to the next stage. 4.2.5.7 Ergo Stop Stage Ramps cut-off power when fastening achieves Target Torque or Target Angle value.
4.2.5.9 Unfasten Stage This feature is a specific “backoff” stage used, for example, in a Rundown-Backoff or Rundown-Backoff-Rundown configuration. Unfasten Stage NOTE: In this stage, the tool always runs opposite of the thread direction. Angle (-) Low Limit Angle High: Maximum allowed angle rotation in degrees. High Limit Angle Target: Degrees of rotation the tool will backoff in reverse.
4.2.5.10 AC_TA Angle Control Torque Averaging Stage 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.
4.2.5.11 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.
4.2.5.13 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 its effect to be removed from the final torque applied to the fastener.
Joint Rate parameters have default settings of 5 samples every 20 degrees. This resolution can be adjusted if needed. See previous stage types for Torque, Angle, Speed, and Time detail For more details please go to www.AIMCO-global.com Resources/Manuals/Yield Control Page 30 of 84...
4.2.6 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.
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 ...
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EXAMPLE: Three stage rundown with unfasten on the last stage. (Rundown Back-off) 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.
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: Will stay in current sequence. • Next: will advance 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 Lock on Reject: When enabled, this prevents tool from starting a new rundown if the result of the last...
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Jobs “ Enabled” display and button function: 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. Holding the toggle button will display will display the Job number, while pressing increment or •...
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 Click on an individual run to view/save rundown information.
4.5 Controller The controller menu is where all of the settings for the Gen IV Wcontroller 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. Page 39 of 84...
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. •...
4.5.1.4 Start Input Configuration 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 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.
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.
4.5.1.6 Disassembly 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. Report Disassembly: If enabled, disassembly events will be reported and logged.
4.5.1.7 TubeNut Tubenut Homing Parameters: 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.
4.5.2 I/O 4.5.2.1 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 (below) Element Type: Choose from Byte, Int16 or, Int32.
4.5.2.2 Anybus/Modbus TCP/Ethernet IP 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. •...
4.5.3 Communication Interfaces 4.5.3.1 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.
4.5.3.3 Spindle USB Port This can be used to set up a 2 spindle network through the USB port 4.5.4 Protocols Please see individual white papers at www.aimco-global.com 4.5.5 Front Panel Buttons Enable and disable front panel buttons Page 48 of 84...
4.5.6 Set Time Set time and date. If connected to a PC, use PC Time to set controller time. 4.5.7 Remote Connections Sets number of remote browser connections to controller. Page 49 of 84...
4.5.8 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.
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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’.
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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.
4.6.1 Tool Setup Allows user to make changes to Tool Setup. Model Number: Tool model number of tool connected to controller. Tool ID: Serial Number of current tool connected to controller. Cycle Count: Total number of cycles since last reset. Multiplier: Configures tool to include gearing added to the base model.
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 ‘Tool Button Calibration’ screen calibrates the field between the two. Test throttle and MFB (Multi-Function Button), send values to Tool ID board in this screen.
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.
For more specific instruction contact: AIMCO Technical Service Toll Free 1-800-852-1368 or go to http://www.aimco-global.com/Resources/Manuals//Gen-IV Controller-Smart-arm Configuration-Manual. Page 57 of 84...
4.8 Diagnostics The Diagnostics menu contains all pertinent information regarding unusual behavior of the system. Detailed descriptions are given below. 4.8.1 Controller Overview Model Number: Model Number of the controller. Serial Number: Serial Number of the controller. Type: Type of controller IEC –...
4.8.2 Controller Status 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: • 5 VDC : Represents voltage from 5V power supply powering controller electronics.
Transducer Full Scale (Nm: Full scale torque rating of transducer. 4.8.4 Live Tool Shows a live view of tool transducer in volts. 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.
4.8.6 System Status 4.8.7 I/O Diagnostics The IO 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.
4.8.8 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 4.8.9 Extended Logging Extended Logging can provide more details to the rundown’s curve data.
4.10 Advanced The ‘Advanced’ menu handles complex settings within the controller. Detailed descriptions are given below 4.10.1 Default Login Setup This screen allows the user to select the default Login level upon controller start up: Operator • Technician • Administrator •...
4.10.2 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.
4.10.3 Import Settings This allows the user to download any previously saved settings onto the controller (refer to ‘Export Controller’ for help with saving data). Example of saved Excel file Plug the USB with an export file into any port on the controller. From the Home screen, navigate to Advanced ...
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’...
After the controller restarts, the user should see the messages in Figure 2 Figure 2 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.
4.10.7 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. •...
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.
4. Press to accept the changes. 5. Press to proceed. 6. Press when the calibration is complete, the controller will restart. Custom Calibration: This allows the user to create a custom calibration setting for the touch screen. 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.
5 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.
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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...
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...
7 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 Code Icon Description INVP Stopped or Disabled from PSet outside of Job -...
8 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.
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IEC (AcraDyne DC Tool) Specific Fault Codes Code Fault Type Description Possible Causes FT01 Tool not connected Tool communication Tool not connected • timeout Faulty tool cable • Faulty tool electronics or wiring • FT02 Invalid TID Tool parameter file not •...
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Code Fault Type Description Possible Causes FD15 Drive Vbus high Drives DC bus voltage AC supply power exceeds voltage • exceeds electrical limits ratings of Controller FD16 Drive Vbus low Dives DC bus voltage is Supply power cycled too quickly. Five •...
9 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. •...
12 Troubleshooting Issue: System port IP Address Drivers Solution: NOTE: In the event the RNDIS drivers do not install themselves, the following are the steps to install new drivers in order to get the system port working. RNDIS driver is a part of the Windows 7 operating system, but the OS fails to detect it automatically. The following steps will help the user to install the RNDIS driver: Step 1 After the device is connected to the development PC, OS will automatically search for the...
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Step 4 Browse for driver software on your computer will come up. Select Let me pick from a list of device drivers on my computer. Step 5 A window will come up asking to select the device type. Select Network Adapters as RNDIS emulates a network connection.
LIABILITY WHICH MAY ARISE OUT OF THIRD PARTY has made any attempt to service or modify the tool CLAIMS AGAINST BUYER. THE ESSENTIAL PURPOSE OF or accessory prior to its return to AIMCO under this THIS PROVISION IS TO LIMIT THE POTENTIAL LIABILITY Warranty.
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CORPORATE HEADQUARTERS AIMCO CORPORATION DE MEXICO SA DE CV 10000 SE Pine Street Ave. Cristobal Colon 14529 Portland, Oregon 97216 Chihuahua, Chihuahua. 31125 Phone: (503) 254-6600 Mexico Toll Free: 1-800-852-1368 Phone: (01-614) 380-1010 Fax: (01-614) 380-1019 WWW.AIMCO-GLOBAL.COM LIT-MAN942 Rev. 11/2019...
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