Aimco AcraDyne Gen IV Operator'S Manual Download Page 43

Page: 43 / 125

Page

125

4.4.1 Saving Rundown(s)

TOTAL RUNDOWNS

Click on

in main rundown screen to view/save total

rundowns.

Then click on

the PC to save

or open the file using a text editor such as Notepad. The format of

the 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.

AMPLE OF INDIVIDUAL

RUNDOWN INFORMATION

Summary of Contents for AcraDyne Gen IV

Page 1: ...Page 1 of 125 MAN177 rev_01 10 19 Gen IV Controller Operator Manual ...

Page 2: ...uick Set Up Default PSets from Tool 16 4 Home Page Main Menu 16 4 1 Run 17 4 2 PSet 20 4 2 1 Add New PSet 20 4 2 2 Edit PSet 22 4 2 3 Advanced Options 23 4 2 4 Manage PSets 23 4 2 5 PSet Stages 24 TC Torque Control Stage 24 TC_AM Torque Control Angle Monitor Stage 25 AC TM Angle Control Torque Monitor Stage 26 TC_AC Torque Control Angle Control Stage 27 Delay Stage 28 Ergo Stop Stage 28 Brake Stop...

Page 3: ...et IP Inputs 50 4 5 2 4 Anybus Modbus TCP Ethernet IP Outputs 51 4 5 3 Communication Interfaces 52 4 5 3 1 Ethernet Second Ethernet 52 4 5 3 2 System Port 52 4 5 3 3 Serial 53 4 5 3 4 Anybus 57 4 5 3 5 Spindle USB Port 58 4 5 4 Front Panel Buttons 58 4 5 5 Power Up 59 4 5 6 Bar Code Setup 59 4 5 7 Set Time 61 4 5 8 Remote Connections 61 4 5 9 Master Spindle Setup 62 4 5 10 Languages 65 4 6 Tool 65...

Page 4: ... Dual Lever Tools Requiring Two Handed Operation 93 10 24 Volt I O 94 11 Assignable IO Details 97 11 1 Controller supported MIDs 115 12 Dimensions 118 13 Specifications 118 14 Tubenut Tool Setup Details 119 14 1 Overview 119 14 2 Tubenut Homing 119 14 2 1 Tubenut Home TID parameters 119 14 3 Setting the Tool s Tubenut Home TID Parameters 119 14 4 Controller Parameters Affecting Tubenut Homing 120 ...

Page 5: ...t 5000 6000 7000 and 8000 series tools be supplied by 200 240VAC 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 Unmodified plugs and matching outlets will reduce risk of electric shock b Avoid body contact with earthed or grounded surfaces such as pipes radiators ranges and refrigerators There is an increased...

Page 6: ... on A wrench or a key left attached to a rotating part of the power tool may result in personal injury e Do not overreach Keep proper footing and balance at all times This enables better control of the power tool in unexpected situations f Dress properly Do not wear loose clothing or jewelry Keep your hair clothing and gloves away from moving parts Loose clothes jewelry or long hair can be caught ...

Page 7: ...c 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 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 8: ...Page 8 of 125 2 Controller Diagram 2 1 Bottom Panel ...

Page 9: ...e was rejected for not achieving low torque Yellow LED Indicates High Angle Fastening cycle was rejected for exceeding high angle Yellow Flashing LED Indicates Low Angle Fastening cycle was rejected for not achieving low angle Blue LED Tool is In cycle above threshold Increment and Decrement buttons change pset Toggle button switches secondary display between o Units of measure o Ethernet IP addre...

Page 10: ...0Vac power outlets AcraDyne has a wide variety of country specific power cord options available Check with your authorized AcraDyne representatives 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 Secondary Protective Earth Attachment it is required must be connected to ground using the 1...

Page 11: ...ntroller 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 ...

Page 12: ...ws 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 Step 3 After the driver is installed go to Control Panel Step 4 Go to Network and Internet ...

Page 13: ...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 and click Properties ...

Page 14: ...f 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 You will see the controller software on your computer sceen ...

Page 15: ... example and subnet mask to 255 255 255 0 For instructions see the example 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 on your computer sceen the controller software NOTE Controller does not have a DHCP client it will not automatically configure itself with a...

Page 16: ...ic 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 4 Home Page Main Menu ...

Page 17: ... 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 ...

Page 18: ...Page 18 of 125 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 19: ...b 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 Failed Accepted ...

Page 20: ... 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 On Home Page press the tab On PSets screen right press to add a new Pset Stage Torque and RPM at Glance ...

Page 21: ...o run Advanced Options see 4 2 3 Default PSets See 3 2 Quick Setup Manage see 4 2 4 Manage PSets Once PSet values are entered press to enter Add New Stage screen Add New Stage A single stage or multiple stages build a PSet Up to 20 stages can be assigned per PSet The following stage options are available Once the desired stage s are selected and configured press to save stage and again to save the...

Page 22: ...ft 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 Once desired changes are made click twice to save changes ...

Page 23: ...uld 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 4 2 4 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 opene...

Page 24: ...imit parameters Torque High The upper control limit of the rundown Torque Target Final desired torque Torque Low The lower control limit of the rundown Max 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 accleration see Glossary for detailed description Stage Timeout Maximum allowable time in this stage If...

Page 25: ...egrees of rotation Angle High Maximum acceptable angle rotation in degrees Angle Low Minimum acceptable angle rotation in degrees Reference Torque 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 ...

Page 26: ...ed in PSet screen Stage Angle Angle is measured from Reference Torque 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 if you want Stage Angle measured from the begining of the stage Torque Bailout Determines when to stop the tool based on torque value during any Angle Torque Bailout value should be equ...

Page 27: ...llowed angle rotation in degrees 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 this will be the start point in Torque at which angle is monitored NOTE Set Reference Torque to zero i...

Page 28: ...que or Target Angle value This feature reduces torque reaction to the operator in a hand held tool as final torque or angle is achieved Torque Current Reduction Amount in percent to reduce the current to the motor Ramp Down Time Total time to ramp down to zero current torque Brake Stop Stage Used for active braking of tool It is helpful in applications where a high RPM tool is used and possible ov...

Page 29: ...be equal or greater than High Torque High Torque Upper control limit of the rundown Low Lower control limit of the rundown Max 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 accleration see glossary of terms for in depth description Audit Enable False When set to False the stage will not be evaluat...

Page 30: ...is measured starting from 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 this will be the Torque start point at which angle is monitored Max RPM Tool Output speed target Acceleration kRPM s How quickly the tool will change speed The lower th...

Page 31: ...ad Forming Strategy is a variant of the Angle Control Torque Monitoring 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 T...

Page 32: ...Setup See AC_TA for Torque Angle Speed Time set up if needed This strategy will behave the same as Angle Control Torque Averaging 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...

Page 33: ...below 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 AC_TCOMP Display of Torque Compensation ValueLED 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 availa...

Page 34: ...olt stretch above Yield Yield Target is 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 deter...

Page 35: ...ed as low This is done to further indicate that the rundown terminated before reaching the final audit stage o 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 o Rundown Back Off multi stage PSet Unfastening as t...

Page 36: ...orted 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 In Cycle torque set in the PSet o Angle is used for the stage evaluation The angle at the point in time...

Page 37: ...ower down shift speed to minimize overshooting of the target torque 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 ...

Page 38: ... of 125 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 ...

Page 39: ...o Enable Disable Job function 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 Enter Advan...

Page 40: ...e Reverse and Unlock Torque Exceeding Unlock Torque while tool is in the disassembly direction Backing off a rejected fastener MFB Pressing MFB button on tool Regardless of MFB configuration 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 Disa...

Page 41: ... the PSet Job display will be separated by decimals Pressing the toggle button will change secondary display between o Units of measure o Ethernet 1 IP address o Ethernet 2 IP address o System port IP address o Angle report o Bolt count o 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 an...

Page 42: ...d deleting them in the next screen or deleting all rundowns by clicking on the icon at the bottom of Results page A Confirmation screen will appear Save Button saves rundowns as Txt File Filter Button gives filter options in Rundown screen Home Button returns to main display menu Play Button sends you directly to Run Screen Refresh Button refreshes screen to include latest rundowns Click on Indivi...

Page 43: ... editor such as Notepad The format of the 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 SAMPLE OF INDIVIDUAL RUNDOWN INFORMATION ...

Page 44: ...k 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 To...

Page 45: ...re 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 Latch on Time Start Input latches if leve...

Page 46: ... 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 INCRE...

Page 47: ...g 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 IO Considerations When disassembling all assignable IO outputs t...

Page 48: ... return Home after Home command is initiated default 500ms Hold at Home Dwell Time Amount of time 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 f...

Page 49: ... 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 Enable Disable When Buttons from I O are selected this field selects which Inputs and Outputs can be forced through the Monitor I O screen Force Off On If Force is enabled this button wi...

Page 50: ...ment Shows element being configured Bit Enter Bit Bits of bits the assigmnet will read Start at Starting bit location Polarity Normaly Open or Normaly Closed Inputs used in certain Input functions Select desired Input Function s Click on after appropriate selections are made Below is an example of the Anybus Input screen with five Inputs set up Click on to change an individual Element or return to...

Page 51: ...ts Mode Normal Output signal sent Timed signal sent Time entered in seconds Flash signal sent Time entered in Seconds Select desired Output Function s from list above Click on after appropriate changes are made Below is an example of the Anybus Output screen with five Outputs set up Click on to make changes on an individual Element or return to the Output Configuration screen Will delete element N...

Page 52: ...e 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 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 NOTE It is not recommended to change this setting ...

Page 53: ...e I eye hi torque J low angle K hi angle Barcode Reader See Section 5 0 for Barcode setup Serial Output and Barcode Reader Open Protocol See 4 5 4 1 for details on Open Protocol Baud Serial ports can be configured for different baud rates available 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 ...

Page 54: ...il 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 Standard Output with Carriage Return Line Feed and PSet Format o 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 Fai...

Page 55: ... 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 opti...

Page 56: ...e feed control character NULL Null control character if option is selected UEC Serial Format matches UEC 4800 and Gen3 o 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 0000...

Page 57: ...AC NULL CAN Message Start 8 A Previous PSet PSet 1 9 for PSets 1 9 A Z for PSets 10 35 NAC CAN 4 B New PSet PSet 1 9 for PSets 1 9 A Z for PSets 10 35 NAC Message End NULL Null control character if option is selected 4 5 3 4 Anybus Node Address Configures the Anybus node address for controller ...

Page 58: ...Page 58 of 125 4 5 3 5 Spindle USB Port This can be used to set up a 2 spindle network through the USB port 4 5 4 Front Panel Buttons Enable Disable front panel buttons on controller console ...

Page 59: ... 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 ormation existing prior to power down 4 5 6 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 co...

Page 60: ... Vehicle Action Action executed by controller when barcode with a matching identifier mask is scanned The actions are Select Job This will require a Job to be configured on the JOB page when using this option Do Nothing 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 ...

Page 61: ...Page 61 of 125 4 5 7 Set Time Set time and date If connected to a PC use PC Time to set controller time 4 5 8 Remote Connections Sets number of remote browser connections to controller ...

Page 62: ...isconnection 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 Trigger Source Select whether the start input for running the spindle network comes from the master spindle s tool trigger or the start input from IO All spindles need to have their start input set to respond to the master tool in order to hav...

Page 63: ...nd under Controller Master Spindle Setup To begin setup enable the master spindle by clicking on the red X under Master 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 slave spindles to the master controller Clicking OK will synchronize PSets and time across the controllers 4 Add a PSet Once the PSet is saved th...

Page 64: ...dle 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 th...

Page 65: ...Page 65 of 125 4 5 10 Languages Select from English Chinese Japanese Korean Spanish 4 6 Tool ...

Page 66: ...he fastening direction Cycle will be aborted if this torque is exceeded If the tool rotates 90 degrees and stops without any obstruction the value is too low Open Loop in Lb After reaching the open position this is the hold at Home torque preventing socket from bouncing to a partially closed position This torque should be set to a value slightly less than the tube nut Home torque Home in Lb In the...

Page 67: ... 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 Follow the on screen instructions for button calibration Tool disable confirmation screen will appear 4 6 4 Torque Calibration Manually calibrate and reset tool to Factory Calibration ...

Page 68: ...alibrate 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 Ca l value is calculated automatically and assigned to tool ID Board 4 6 6 Indicators Allows user to test tool LEDs headlight and buzzer ...

Page 69: ...Page 69 of 125 4 6 7 TID Parameters Used by factory to load Tool ID parameters into tool 4 6 8 TID Memory Allows a Qualified Service Technician to view or edit Tool ...

Page 70: ...the GenIV 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 Data Sites 1 manuals gen iv controller smart arm manual pdf 4 8 Diagnostics The Diagnostics menu co...

Page 71: ...ppear 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 9 VDC Represents voltage from 9V power supply powering Tool electronics 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 1 8 VDC Represe...

Page 72: ...ol _____________________________________________________________________________________________ The following information is used internally by AcraDyne Technicians and not generally relevant to the end user Gear Ratio After Tranducer 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 Exa...

Page 73: ...ify 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 6 Record Logs Logs information describing usage of controller and tools that have been used with that controller 4 8 6 1 Change Log Log displays ch...

Page 74: ...n 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 Admimistrator All screens available ...

Page 75: ...vanced menu handles complex settings within the controller Detailed descriptions are given below 4 10 1 Login Setup This screen allows the user to select the default Login level upon controller start up Operator Technician Administrator ...

Page 76: ...nsole 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 a file and press 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 i...

Page 77: ...ller 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 IO configuration Set up one controller with the correct IO configuration and export the controller from Advanced Export Controller Now the IO settings can be imported using this screen NOTE Setting can only be imported from controller...

Page 78: ...ate to the Advanced menu Click Update Controller and select the latest release See Figure 1 as an example FIGURE 1 AVAILABLE UPDATES Click the green checkmark when ready 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 V...

Page 79: ...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 ...

Page 80: ...ons 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 th...

Page 81: ...ges 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 4 10 9 Soft Reboot Restart the controller...

Page 82: ... 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 j...

Page 83: ...e 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 ID type Action Reset ID ID 1 ID 2 ID 3 ID 4 VIN 7 ID 1 Select Job 1 No No No No VIN 8 ID 1 Select Job 2 No No No No VIN 9 ID 1 Select Job 3 No No No No The tool enable disable will be controlled by the job settings the correct job will be selected by the barcode s...

Page 84: ... 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 Store to Action Reset ID ID 1 ID 2 ID 3 ID 4 EMP ID 1 None No Yes Yes No VIN ID 2 Select Job 1 No No No No SN ID ...

Page 85: ...un 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...

Page 86: ...lti 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 ...

Page 87: ...anges Button Reject the changes made and return to the parent screen Edit screens Add New Button Add a new item Pset Stage Job and other PSet and Job edit screens Edit Button Edit selected Item 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 Copy selected Items PSet Job and other edit screens Delete Button...

Page 88: ...to enable the tool to run JOB Job Sequence Complete JOB Job Complete JOB XML Count Complete LOR Locked on Reject BRCD Bar Code ID scan required to enable tool SRVC Tool Disabled For Service Tool service or calibration interval has expired INVP Invalid PSet Parameter set number for a non existent Pset has been selected to run Most likely via one of the following methods o Job o MFB o IO INVP PSet o...

Page 89: ...H19 3 3vdc out of tolerance Main board 3 3 bus voltage exceeds electrical limits Faulty Controller main board or other Controller electronics FH20 5vdc out of tolerance 5 Volt bus voltage out of range Faulty power supply or wiring Faulty Controller main board or other Controller electronics FH21 9vdc out of tolerance 9 Volt bus voltage out of range Faulty power supply or wiring Faulty Controller m...

Page 90: ...g Faulty Controller main board or other Controller electronics Faulty tool cable Faulty tool electronics or wiring FH32 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 ...

Page 91: ...ransducer Faulty tool cable Tool gear binding Faulty controller electronics or wiring FT06 Motor hall states invalid Hall signals states are all high or all low Tool not connected Faulty tool cable Faulty tool electronics or wiring Faulty motor halls or wiring FT07 Motor halls skipping states Hall signal sequence incorrect Faulty tool cable Faulty tool electronics or wiring Faulty motor hall or wi...

Page 92: ...r up FS27 Locked rotor Motor has stalled for more than 100 millisaeonds Poor parameter settings for application Torque signal out of calibration Faulty tool gearing or motor Corrupted TID parameters Faulty Controller or tool electronics FS28 Target out of range of tool Parameter set torque target out of range of rated tool capability Target torque exceeds tool capability Joint Compensation Ratio s...

Page 93: ... 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 o Releasing either or both of the levers will initiate the homing sequence o Homing will continue until sequence is complete If controller s tubenut homing configuration is set to RELEASE AND REPRESS o Releasing either of the leve...

Page 94: ... 24 V Return 9 Input 4 PSet Bit 1 22 24 V Return 10 Input 5 PSet Bit 2 23 24 Vdc 11 Input 6 PSet Bit 3 24 24 Vdc 12 Input 7 Reset Job 25 24 Vdc 13 Input 8 NOTE The Default Assignments in Table above are factory defaults and can be changed See Assignable I O section 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...

Page 95: ...ort to modify the Anybus outputs 1 Power on the controller 2 Insert the USB stick into a USB port 3 Connect to the controller via system port and web browser default address 192 168 1 4 4 Navigate to Advanced Import Settings 5 Select ONLY IO 6 Click OK 7 Click OK in the Confirmation dialog box 8 The controller will restart ...

Page 96: ...ybus 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 ...

Page 97: ...he bus The first element on the bus is 0 and goes up the last legal element for the given bus The bits in each element is referenced from 0 LSB to 31 MSB Inputs All input 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 Supp...

Page 98: ...offset variable allows a fixed value to be added to the read value For example to use bits 4 5 of the physical inputs to select parameter sets 1 4 the assignment would look like Select PSet Bus 1 For the physical bus Element 0 For the first element on the bus Bit 4 For the starting bit location Width 2 To span the two bits 4 5 Offset 1 Adding 1 to the read input value so we get Binary 00 1 Binary ...

Page 99: ...N C Width Offset The Select PSET input will select the parameter set 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 parameter set number Selecting an invalid parameter set number will disable the tool Select Job Supporte...

Page 100: ... set from 1 to 32 bits The input value will read as an integer value and an ASCII string with leading zeroes will be produced and passed to the ID recognition system The length of the string is based on the width of the assignment The string will always be sized to accommodate the maximum value of the input For example a width setting of 16 can have an integer value of 0 65535 so the produced ID w...

Page 101: ...will compare the current parameter set 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 parameter set number If the parameter set input value does not match the current parameter of the controller the tool will be disabled Clear Res...

Page 102: ... 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 If the Job sequence input value does not match the current Job sequence of the controller the tool will be disabled ASCII ID Supported Feature Bus Element Bit 0 31 Polarity N O N C Width Offset The ASCII ID assignment will set th...

Page 103: ...gh Angle Fastening Complete In Cycle Fastening Aborted Fastening Stopped Batch Complete Job Complete Error Tool Start Switch Tool Push to Start Switch Tool MFB Tool Enabled Tool Running Service Indicator ToolsNet Connected Open Protocol Connected PFCS Connected Running PSet Number Running Job Number ...

Page 104: ...ll be high when it is active 24vdc for physical outputs and logic 1 for all network type buses When the polarity is set to N C the output will be low for active 0vdc for physical inputs and logic 0 for all network type buses Mode Normal 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 a...

Page 105: ...e while still observing the polarity setting FIGURE 2 TIMED MODE FIGURE 3 TIMED MODE ASSIGNMENT DEACTIVATES BEFORE TIME EXPIRES Flash In the flash mode the output will flash at the time rate while the assignments state is active while still observing the polarity setting FIGURE 4 FLASH MODE Assignments active Output state Assignments active Output state Time Time Assignments active Output state ...

Page 106: ... 32 Polarity N O N C Mode Normal Timed Flash Time Width Offset Input Bus Input Element Input Bit 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 Nok Supported Feature Bus Element Bit 0 32 Polarity N O N C Mode Normal Timed Flash Time Width Offset Input B...

Page 107: ...he threshold value or a Job reset High Torque Supported Feature Bus Element Bit 0 32 Polarity N O N C Mode Normal Timed Flash Time Width Offset Input Bus Input Element Input Bit The High Torque output assignment will go active at the completion of a fastening that has a high torque results It will go inactive when the next fastening is started the torque exceeds the threshold value or a Job reset ...

Page 108: ...active at the completion of a fastening that has a higha angle results It will go inactive when the next fastening is started the torque exceeds the threshold value or a Job reset Fastening Complete Supported Feature Bus Element Bit 0 32 Polarity N O N C Mode Normal Timed Flash Time Width Offset Input Bus Input Element Input Bit The Fastening Complete output assignment will go active at the comple...

Page 109: ... The Batch Complete output assignment will go active at the completion of a fastening that satisfies the bolt count of a Job sequence It will go inactive when the next fastening is started the torque exceeds the threshold value or the job is reset Job Complete Supported Feature Bus Element Bit 0 32 Polarity N O N C Mode Normal Timed Flash Time Width Offset Input Bus Input Element Input Bit The Job...

Page 110: ...t will reflect the state of the tools multifunction button Tool Enabled Supported Feature Bus Element Bit 0 32 Polarity N O N C Mode Normal Timed Flash Time Width Offset Input Bus Input Element Input Bit The Tool Enabled output assignment will be active if the tool is enabled Tool Running Supported Feature Bus Element Bit 0 32 Polarity N O N C Mode Normal Timed Flash Time Width Offset Input Bus In...

Page 111: ...it 0 32 Polarity N O N C Mode Normal Timed Flash Time Width Offset Input Bus Input Element Input Bit The PFCS Connected output assignment will be active if the controller has an active PFCS connection Running PSet Number Supported Feature Bus Element Bit 0 32 Polarity N O N C Mode Normal Timed Flash Time Width Offset Input Bus Input Element Input Bit The Running PSet Number output assignment will ...

Page 112: ...he tool is put into disassembly mode Torque Supported Feature Bus Element Bit 0 32 Polarity N O N C Mode Normal Timed Flash Time Width Offset Input Bus Input Element Input Bit 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 torqu...

Page 113: ... Mode Normal Timed Flash Time Width Offset Input Bus Input Element Input Bit The Rundown Saved to FTP Server output assignment will output the ID of the last rundown that was saved to the FTP server Fastener Removed Supported Feature Bus Element Bit 0 32 Polarity N O N C Mode Normal Timed Flash Time Width Offset Input Bus Input Element Input Bit The Fastener Removed output assignment will go activ...

Page 114: ...it 0 32 Polarity N O N C Mode Normal Timed Flash Time Width Offset Input Bus Input Element Input Bit The Pulses output assignment will output the pulse count 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 Pulses Ok Supported Feature Bus Element Bit 0 32 Polarity N O N C Mode Normal Timed Flash Time Width Offset Input Bus Input E...

Page 115: ...the completion of a fastening that has an pulse count that falls below the low limit It will go inactive when the next fastening is started the torque exceeds the threshold value or a Job reset 11 1 Controller supported MIDs Supported MID MID Description Revisions Note 1 Communication start 1 2 3 2 Communication start acknowledge 1 2 3 3 Communication stop 4 Command error 5 Command accepted 10 Par...

Page 116: ...bscribe 64 Old tightening result upload request 65 Old tightening result upload reply 70 Alarm subscribe 71 Alarm 72 Alarm acknowledge 73 Alarm unsubscribe 76 Alarm status 77 Alarm status acknowledge 80 Read time upload request 81 Read time upload reply 82 Set time 90 Multi spindle status subscribe 91 Multi spindle status 92 Multi spindle status acknowledge 91 Multi spindle status unsubscribe 100 ...

Page 117: ...evice status request 1 2 215 IO device status reply 216 Relay function subscribe See supported relay functions below 217 Relay function 218 Relay function acknowledge 219 Relay function unsubscribe 9999 Keep alive open protocol communication Supported Relay Functions Number Function 1 OK 2 NOK 5 Low Torque 6 High Torque 7 Low angle 8 High angle 9 Cycle complete 10 Alarm 11 Batch NxOK 12 Job OK 19 ...

Page 118: ...ons 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 Protection IP20 Electrical AC Power Source 120 VAC 1Φ 50 60 Hz 15 20A dedicated service ...

Page 119: ... Torque Home in Lb o When tool is homing reaching this torque indicates to controller that the tool output socket has reached the Home stop and is in the open position o If tool output does not attempt to return or does not completely reach the Home position this value is too low NOTE Setting this value too high can potentially damage the tool o Units lbf in o TID memory location 53 Hold at Home T...

Page 120: ...s to the homing speed o Units kRPM second o Default value 0 5 seconds o Range 0 1 to 10 seconds Tubenut Homing Reverse Dwell Time o Amount of time before the output is allowed to Home after rundown is complete and tool lever is released o Units Seconds o Default value 0 5 seconds o Range 0 to 2 Seconds Tubenut Home Dwell Time o Amount of time tool holds at Home to prevent bounce back o Too short o...

Page 121: ... obstruction is detected inside this zone the tool will stop and the fastening cycle will be aborted o Units Degrees of rotation of the output from Home to where the output is closed o Default value 90 Degrees o Range 0 to 180 Degrees Obstruction Check Speed Limit o Maximum speed output will run during the check for obstructions o Decreasing this can reduce the impact force when hitting an obstruc...

Page 122: ...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 de...

Page 123: ...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 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 ...

Page 124: ...IMCO agrees without charge to repair or replace at its option and Ex Works EXW its authorized service centers any product or accessory warranted hereunder proving to AIMCO s satisfaction to be defective as a result of defective workmanship or material In order to qualify for this warranty written notice to AIMCO must be given immediately upon discovery of such defect at which time AIMCO will issue...

Page 125: ...ANTIES EXPRESSED OR IMPLIED AND AIMCO EXPRESSLY DISCLAIMS ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE THIS WARRANTY SETS FORTH THE SOLE AND EXCLUSIVE REMEDY IN CONTRACT TORT STRICT LIABILITY OR OTHERWISE THIS WARRANTY IS THE ONLY WARRANTY MADE BY AIMCO WITH RESPECT TO THE GOODS DELIVERED HEREUNDER AND MAY BE MODIFIED OR AMENDED ONLY BY A WRITTEN INSTRUMENT SIGNED BY A DULY ...

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