ABC-4000-3 Intelli-Control Manual
Contents
1. AIMCO AIMCO Intelli Control Tool System Manual Model ABC 4000 3 PO Box 16460 Portland OR 97292 0460 800 852 1368 Fax 800 582 9015 www aimco global com Contents Installation System Requirements Connections Figure 1 Left Side of Control Box Figure 2 Right Side of Control Box Figure 3 Bottom View of Box Tool Controllers Operation Control Box Features Figure 5 Control Box Features Using the Intelli Control Tool System Process Details Figure 6 Bar Code Controller Figure 7 Smart Relay Smart Relay Features Figure 8 Smart Relay Display and Buttons Smart Relay Screens Figure 9 Main Screen Figure 10 Edit Task Air Pressure Screen Figure 11 Task Air Pressure Screen Default Air Pressure Settings Using the AUX AIR Figure 12 AUX AIR Bar Code Label Maintenance SMC IP Air Regulator Additional Information Troubleshooting Guide Recommended Spare Parts 1 all vanl MO CLG AAP AP Aw WW a W W o O NNN Installation The system control box is supplied with 4 mounting holes in the rear of the box These holes are 1 2 in diameter and are 14 5 between centers Use these holes to mount the control box in the desired location System Requirements The following outlines the system requirements Electrical 120VAC 4 AMPS Air 120 SCFM O 80 PSI AIR SUPPLY CONNECTION va NPT Connections Power is connected by inserting the power cord Figure 1 Le2. For more information please refer to a dom TI a EL EE ag i A dl I 0 amp J am ar Manus the Bar Code Wand Manual Using the Intelli Control Tool System Once all of the connections are made and the tool controllers have been programmed the sys tem is ready for use Simply scan a part bar code and the system will adjust the tool torque and air pressure for that task Process Details 1 When a task is selected the bar code data controller will select the task from the pre pro grammed task list 2 This information is sent to the smart relay and the work select for that task is selected 3 The tool for the selected task is activated and the other tools will be disabled 4 Displays The display on the bar code control ler display the task description tool controller and work select The display on the smart relay will display the task air pressure and the task descrip tion MEYENCE ana aF LE ia EA ERA A ze m AIN a oO oy ee JE Me OIDO 7 Figure 6 Bar Code Controller 3 DO am ar Manus Smart Relay Screens The following is a list ofthe screens available on the smart relay and their functions Te i F Moe ter amp Figure 7 Smart Relay Smart Relay Features The air pressure for each task and the AUX AIR can be individually set The is done using the smart relay The following outlines the relay and Figur
3. K button on the top of the regulator until UNL flashes on the regulator display and then press the SET button 2 SET the max air pressure Use the Down arrow key to step through the menu until F2 is displayed and press SET The number on the display is the current max air pressure set ting Use the UP and DOWN arrow buttons to adjust the number to the desired value and press the SET button 3 LOCK the regulator This is done by holding down the LOCK button until LOC flashes on the display and then press the SET button NOTE Refer to the air regulator manual for more information 6 all Wanus 0 DO am ar Manus Additional Information Troubleshooting Guide The following is a basic list of problems Bar Code Data Controller The Data Controller does not Check the label to make sure Displays 999 when label is recognize the label Either the that it is not damaged If the scanned label is damaged or is not a number needs to be added programmed number to the program contact your AIMCO Rep No air to tool Tool is disabled based on the Check the Bar Code Data task scanned Controller display for the correct tool removed air supply No power to system System has been unplugged or Check that the power is plugged circut breaker has been tripped in If the circuit breaker has been tripped or the fuse is blown contact your AIMCO Rep Recom
4. e 9 Main Screen how to adjust the air pressure for each task The MAIN screen displays the current air pres sure setting and the current task Pressing the ESC button on any screen returns to this screen DISPLAY UP BUTTON _ ALT BUTTON a th q Moe ter a RIGHT BUTTON EDIT TASK AIR PRESSURE ASTERISK BUTTON DOWN BUTTON Figure 8 Smart Relay Display and Buttons Display This displays the information for the operator UP DOWN LEFT RIGHT BUTTONS These buttons are used to navigate between the screens and change PSI values Figure 10 Edit Task Air Pressure Screen ALT ASTERISK BUTTONS Used to increase and decrease the PSI values Pressing the Down Button on the Main screen ESC BUTTON Pressing the ESC key from any displays the Edit Task Air Pressure screen This screen returns to the MAIN screen screen allows the operator to adjust the air pres OK BUTTON Used to acknowledge an error sure for each task from the tool controllers Pressing the RIGHT or LEFT button from this screen toggles thru the TASK screens 4 TASK 1 AIR 65 PSI Figure 11 Task Air Pressure Screen The TASK AIR PRESSURE screen displays the individual air pressures Pressing the UP or DOWN button increases or decreases the pressure by 1 PSI Pressing the ALT or button increases or de creases the pressure by 5 PSI Once the desired pressure is displayed press the RIGHT or LEFT button to go to the
5. ft Side of Control Box into a standard 120VAC outlet TOOL AIR CONNECTIONS a NPT Air is supplied to the control box by connecting air to the supply connection on the left side of the control box An air line filter should be installed prior to the control box to remove any moisture in the air customer supplied Tool air connections can be located on the right side of the control box These connections are 1 2 NPT as well The tool connections are labeled A B and C from top to bottom Make sure to check all fitting bulkneads when making the connections to ensure that none of NET them have loosened during shipping BC Figure 2 Right Side of Control Box NOTE lf any tool lubrication is to be used it must be installed down stream of the control box Refer to the following figures for connection loca tions 1 DO am ar Manus TOOL CONTROLLER CABLES AIR REGULATOR EXHAUST BAR CODE WAND CONNECTION OUTLET POWER CONNECTION OUTLET Figure 3 Bottom View of Box Once all of the air and power connections have been made the cables for the tool controls must be connected to the corresponding tool control boxes Please refer to the wiring schematic for these connections Tool Controllers Once all of the tool controller cables have been connected to the tool controllers they may need to be programmed for the specific work selects and torques Please refer to the tool controller manual
6. mended Spare Parts The following parts should be kept in stock SMC ITV3050 31N4L4 IP Regulator 120 PSI 0 10VDC 1 2 NPT 1 Keyence BL 80RKE Bar Code Reader Handheld DV90SET Bar Code Controller Software 456443X Valve 1 2 NPT 24VDC Normally Closed La EasySoftPro6 10 Easy Relay software MN Moeller EASY800 PC CAB Easy Relay Programming Cable Ooi o Standard USB Cable for programming Bar Code Data Controller 7 1204 E Maple Rd Troy MI 48083 800 852 1368 FAX 800 582 9015 AIMCO CORPORATE HEADQUARTERS 10000 S E Pine St Portland OR 97216 800 852 1368 FAX 800 582 9015 Ave Morones Prieto 2110 Pte Col Loma Larga Monterrey NL CP 64710 Mexico 52 81 1001 1600 FAX 52 81 1001 1630 LIT MAN690 Rev 12 06 Printed in USA 2006 AIMCO
7. next task or press the ESC button to return to the MAIN screen The new pressure setting will be used the next time that the task is scanned Default Air Pressure Settings The smart relay is preset with the following air settings Using the AUX AIR The controller is equipped with an auxiliary air AUX AIR connection This can be used for an additional non controlled tool To activate the AUX AIR simply scan the bar code label found on the front of the control box located under the smart relay aux alr Figure 12 AUX AIR Bar Code Label This will set the controller air pressure to the air pressure set for AUX AIR in the smart relay and will disable all of the tools NOTE The AUX AIR connection is always active and Is set to the current air pressure Maintenance The Intelli Control Tool System is designed with minimal maintenence The following items should be performed regularly to ensure the life of the control box Empty the air filter daily Check all fitting bulkneads weekly to make sure that none of them have loosened SMC IP Air Requlator The air regulator is set for a maximum air pres sure of 101 PSI This not only limits the air pres sure to the tools but changes the linear scale of the regulator If the air pressure needs to be changed or the air regulator needs to be re placed perform the following 1 UNLOCK the regulator This is done by hold ing down the UNLOC
8. s included with this system UEC 4500 Tool Controller When using the UEC 4500 Tool Controller the following programming changes must be made in order to communicate properly with the Intelli Control box NOTE Please refer to the UEC 4500 manual for instructions on changing these modes Mode 71 Value 7 Mode 72 Value 8 Mode 73 Value 3 Mode 74 Value 3 Mode 75 Value 4 Mode 76 Value 8 2 all Wanus Operation This section outlines the features and operation of the Intelli Control Tool System Control Box Features ACCEPTIREJECT LIGHTS BAR CODE DATA CONTROLLER SMART RELAY DISPLAY Figure 5 Control Box Features Bar Code Data Controller The bar code data controller and the bar code wand not shown read in the bar codes of the pre programmed tasks and send this information to the smart relay For more information please refer to the Bar Code Data Controller Manual Smart Relay Display The smart relay is used to display information to the operator It is also used to program the air pressure for each task Accept Reject Lights These lights display the result of each run down A signal is received from the tool controller and the accept light green is lit if the torque is within range or the reject light red is lit if there is an error Bar Code Wand not shown The bar code wand is used by the operator to scan the bar code label on each part prior to tightening
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