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3.1 Connecting to the Controller

There are three ways to program/communicate with the controller:

•

Controller touch-screen console

•

System Port: (USB connection) Direct connection to controller.

•

Ethernet Port: Via direct connection or LAN.

Touchscreen Console

Controller functions and programming can be accessed directly through the touch-screen.
1. Power on controller.
2. Run screen will appear.
3. Controller is ready for use.

Содержание Gen IV

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

Страница 2: ...Quick 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...

Страница 3: ...t 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...

Страница 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 Detail...

Страница 5: ...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...

Страница 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...

Страница 7: ...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 haza...

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

Страница 9: ...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 fo...

Страница 10: ...Vac 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...

Страница 11: ...troller 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 acces...

Страница 12: ...s 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 d...

Страница 13: ...tep 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...

Страница 14: ...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...

Страница 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...

Страница 16: ...c 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 rate...

Страница 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...

Страница 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...

Страница 19: ...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 fro...

Страница 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 t...

Страница 21: ...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 multipl...

Страница 22: ...t 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...

Страница 23: ...ld 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 dete...

Страница 24: ...mit 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 kRP...

Страница 25: ...grees 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 startin...

Страница 26: ...d 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 T...

Страница 27: ...lowed 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...

Страница 28: ...ue 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...

Страница 29: ...e 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 kRP...

Страница 30: ...s 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 Tor...

Страница 31: ...d 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 t...

Страница 32: ...etup 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 s...

Страница 33: ...elow 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...

Страница 34: ...lt 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 t...

Страница 35: ...d 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...

Страница 36: ...rted 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 no...

Страница 37: ...wer 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...

Страница 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 fina...

Страница 39: ...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...

Страница 40: ...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 Tor...

Страница 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...

Страница 42: ...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...

Страница 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 Techni...

Страница 44: ...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 satisfi...

Страница 45: ...e 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...

Страница 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 initi...

Страница 47: ...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 f...

Страница 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 t...

Страница 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 R...

Страница 50: ...ent 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 Sele...

Страница 51: ...s 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...

Страница 52: ...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...

Страница 53: ...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 b...

Страница 54: ...l 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 optio...

Страница 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 Degr...

Страница 56: ...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...

Страница 57: ...C 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 opt...

Страница 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...

Страница 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 Set...

Страница 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...

Страница 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...

Страница 62: ...sconnection 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 inpu...

Страница 63: ...d 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 a...

Страница 64: ...le 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 t...

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

Страница 66: ...e 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 pos...

Страница 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...

Страница 68: ...librate 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...

Страница 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...

Страница 70: ...he 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 inst...

Страница 71: ...pear 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 volt...

Страница 72: ...l _____________________________________________________________________________________________ The following information is used internally by AcraDyne Technicians and not generally relevant to the e...

Страница 73: ...fy 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...

Страница 74: ...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 scree...

Страница 75: ...anced 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 u...

Страница 76: ...sole 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 locat...

Страница 77: ...ler 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 control...

Страница 78: ...te 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 t...

Страница 79: ...estore 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 repla...

Страница 80: ...ns 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 Rund...

Страница 81: ...es 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...

Страница 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...

Страница 83: ...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...

Страница 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 s...

Страница 85: ...n 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...

Страница 86: ...ti 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...

Страница 87: ...nges 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 an...

Страница 88: ...o 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 servic...

Страница 89: ...19 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...

Страница 90: ...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 F...

Страница 91: ...ansducer 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 Fau...

Страница 92: ...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 Fa...

Страница 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 t...

Страница 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 ar...

Страница 95: ...rt 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 A...

Страница 96: ...bus 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 se...

Страница 97: ...e 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...

Страница 98: ...ffset 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 t...

Страница 99: ...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...

Страница 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 o...

Страница 101: ...ill 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...

Страница 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 valu...

Страница 103: ...h 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 Indicat...

Страница 104: ...l 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...

Страница 105: ...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...

Страница 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...

Страница 107: ...e 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...

Страница 108: ...ctive 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 Su...

Страница 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 e...

Страница 110: ...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 B...

Страница 111: ...t 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...

Страница 112: ...e 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 assignm...

Страница 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 Fa...

Страница 114: ...t 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...

Страница 115: ...he 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 Co...

Страница 116: ...scribe 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 8...

Страница 117: ...vice 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 999...

Страница 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 F 0 to50 C Humidity Non condensing Ingress Protection IP20 Elect...

Страница 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...

Страница 120: ...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...

Страница 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...

Страница 122: ...ort 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...

Страница 123: ...oftware 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 emu...

Страница 124: ...MCO 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 defectiv...

Страница 125: ...NTIES 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 STR...

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