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iEC DC Tool Controller Users Guide - aimco

1. 1 2 3 4 5 6 7 8 9 1 Figure 2 8 Rundown Log example 2 9 Log Info Log info describes the usage of the Controller and the tools that have been used with that controller POR Counts Number of times the controller power has been cycled Controller Cycles Number of rundown the controller has completed Tool Log Displays history of tools that have been previously connected to the controller Monthly Usage Displays history of the number of rundowns the controller has preformed divided in to months and years Note Serial Model number entries in usage log are abbreviated for functionality will legacy tools 40 ToolWare iEC Series Torque Units NM Log Counters 1 19 2009 2 5 2009 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Current Monthly Usage for 2009 is 50 Figure 2 9 Tool controller Log Info example 2 10 Statistics The statistics page takes a collection of final torque samples from a rundown file then calculates and displays statistical information about the collection In addition a histogram is plotted and the final torque for each rundown is displayed graphically The maximum number of rundowns that can be evaluated is 2048 If more data is stored in the file then data for only first 2048 rundowns are used Torque values are displayed in the units shown on the Main Window toolbar Rundown Files are saved using Toolwa
2. 33 a Coro NON chars E ah ae ae CEDE Pon ENDE S pn 34 2 E 34 212 5 34 2 4 9 ab vasti dei eda odit ie erc dita bakes 20s 7708 29 tussi die edo a 2 ISION se E 1 Getting Started with ToolWare 1 1 Terminology and Abbreviations Terminology and abbreviations used in this manual are described in the table below Table 1 1 Terminology and Abbreviations Term Abbreviation Explanation Tool AcraDyne Nut runners including Pistol Straight and Tubenut wrench Controller AcraDyne iEC Controller CIM Controller Interface Module is an adapter between the Controller CAN bus and PC USB port Rundown A complete tightening cycle SCC Spindle Control Card CNC Communications Network Card Gen 1 Tool with Light Ring Gen 3 4 Tool with Multi Function Button MFB 1 2 Introduction to ToolWare 1 2 1 About this document This document is a manual for using ToolWare software It consists of three parts Chapter 1 Getting Started with ToolWare introduces the software and gives step by step instructions on using it to run AcraDyne tools Chapter 2 Working with ToolWare gives d
3. 4 Diagram Figure 2 4 Diagram Figure 3 4 Main Display Panel Diagram Figure 4 sasusunusunuusuxnsassuusuyusasuusuauuauususausuunusun 5 Dimensions 5 Initial Setup 6 Main Display Functions Changing Parameter Sets 2 1 1 3 9 8 Programming the Display Options Steps 1 3 8 Display Optional Values for Individual Rundowns Steps 1 2 10 Using the Optional Keypad Display Module KDM KDM Diagram 1 Parameter Set Terms sasssunsssansaunussunsaunussuusuaunusauussunsauussensssuunusuuuusuns 11 Turning the KDM On Off 12 Main Menu 1 Parameter Setup Setting Up Parameter Sets 12 Accessing Quick Start P
4. 4 4 4 4 e gt e og rar 4 e b A 5 4 4 gt gt ccc 4 Reset To Factory Defaults gt Tq 4 5 Tq Downshift Tq Threshold lt C Convert Units in Controller and Toolvare gt lt 4 4 Cycle Complete 4 Current Units Angle High Limit Angle Target Angle Low Limit Rpm Freespeed Rpm Downshift gt gt 4 cc gt ecc gt lt gt Ergo Mode Soft Start Link Pset Link Delay ms Batch Settings Count Preset Action Next PSet A I 5 lt gt lt gt gt A 5 lt e e 2 2 5 E 5 Current Parameter Set Changed 28 Figure 2 2 Parameter Sets View Edit Window 13 2 2 1 Parameter Entry Fields Strategy Select one of four fastening strategy options Tc Torque Control strategy uses torque as the only control parameter The Tool stops when Target is reached Rundown is considered to be successful Accept if the final torque value falls within the range specified by Tq High Limit and Tq Low Limit parameters
5. Torque Control Angle Monitoring strategy is convenient for detection of cross threaded or stripped fasteners Rundown is considered to be successful Accept if the final torque value falls within the range specified by Tq High Limit and Tq Low Limit and final angle value falls within the range specified by Angle High Limit and Angle Low Limit parameters Torque Monitoring Angle Control strategy The tool stops when Angle Target is reached or High Limit is exceeded Rundown is considered to be successful Accept if the final torque value falls within the range specified by torque upper and lower limits Torque Control Angle Control strategy The tool stops if target torque or target angle is reached whichever happens first Rundown is considered to be successful Accept if both the final torque value and final angle value fall within their respective high and low limits Direction defines fastening direction It should be clock wise CW for right threaded fasteners and counter clock wise CCW for left threaded fasteners Tq High Limit used for Accept Reject decision Rundown does not pass if the measured torque exceeds this limit Tq Target the target torque value Tq Low Limit used for Accept Reject decision Rundown does not pass if the torque measured at the end of rundown is below this limit high and low torque limits are automatically and symmetrically set aro
6. EXT FLT 4096 This message will clear when an allowable parameter set is selected or when the out of range parameter set is reprogrammed to be within the capabilities of the tool Main Display Functions Changing Parameter Sets To change the parameter set that is active press the CHANGE PSET button Fig 4 until the desired parameter set number is displayed With each separate press of the button the parameter set numeral will advance upwards through the highest parameter set that is programmed and then cycle back to parameter set 1 A maximum of 8 parameter sets can be programmed into the iEC controller The display for each type of strategy will vary The main control parameter Torque Angle or both will be displayed when the Parameter Set is selected The different strategies will display as follows Example PSET 2 Torque Control Example PSET 3 Angle Control Strategy 25 ft lb Target Strategy 270 Degree Target Example PSET 4 Torque Control Angle Control Strategy 25 ft lb Target 270 Degree Target Note SCC Firmware Version 3 00 extends the number of parameter sets that can be programmed to 32 The extended parameter sets can be programmed via Toolware 3 0 or greater For parameter sets 10 32 the numeric Pset LED will flash the first digit then the second followed by a pause If any of the parameter sets are Linked the CHANGE PSET button will automatically skip to the first Pset of the Linked
7. If the user changes the password and then loses or forgets the new password the Factory Default password will still allow the user to access all menus and functions Please call your AIMCO sales representative for assistance in entering the Factory Default Password To access the ADMIN SECURITY function From the MAIN MENU press 3 for ADMIN Press 2 for SECURITY The following text will be displayed on the KDM display screen If the password function is already enabled the text will read 1 DISABLE PWORD To activate the password function press 1 ENABLE PWORD To enter a new password press 2 CHANGE PWORD The following text will be displayed on the KDM display screen Enter a 4 digit password Once the four digits are entered the user will automatically be prompted to confirm the password When the correct password is confirmed the following text will briefly be displayed on the KDM display screen Using the Optional Keypad Display Module Tool Information This section of the ADMIN menu provides the user with useful information regarding the tool that is currently connected to the iEC controller This information may be needed for reference when setting up parameter sets or calibrating the tool The items that can be viewed in TOOL INFO are ID The serial number for the tool Tq The maximum torque rating of the tool in the units that are selected in PSET DEFAULTS Speed The maximum output spindle speed o
8. command through logic I O is turned on You can verify this by monitoring the tool buttons in toolware Make sure that the throttle is completely returning home completely after being released Button Timeout The button signals from the tool are not being received by the controller in a certain amount of time Try connecting another tool to the system Button State An illegal light ring state has occurred Two or more direction halls are enabled You can verify this by monitoring buttons using ToolWare Try recalibrating the buttons using ToolWare CW Center and CCWorTrigger and MFB button Undefined Voltage Either the controller voltage configuration or the tool voltage parameter are undefined Try the tool on another system Incompatible Voltage The controller is not compatible with the tool Illegal tool A tubenut tool is connected to a system setup for multiples Free Run Timeout The tool has run for a period of time before seeing the threshold torque The throttle must be released and pressed again before the tool will run again This time is adjustable using ToolWare The default value is 5 seconds Load Run Timeout The tool has run for a period of time after seeing the threshold torque The throttle must be released and pressed again before the tool will run again This time is adjustable using ToolWare The default value is 15 seconds Hall Error The motor hall sensors for commutation have achieved an illegal state a specifi
9. eight parameters sets will be configured at 10 Nm 20Nm 30 Nm 40 Nm 50 Nm 60 Nm 70 Nm and 80 Nm Change units changes the torque units in the ToolWare Select SEND to change units in the Controller also Convert Units in Controller and ToolWare if checked automatically converts units in controller and ToolWare to new units when new unit of measurement is selected If Rundown Backoff Rundown or Low Speed Control are active in controller User will be notified on this screen 17 2 3 CurveWare In ToolWare select lt Main Functions CurveWare gt from the top menu select lt CurveWare gt directly from the lower menu to open lt CurveWare gt window shown in the Figure 2 3 Only rundown information after most recent Power On of the controller can be graphed ToolWare iEC Series File Help Torque Units NM iEC Connected USB Torque 22 30 Degrees 0 No Of Data Points 500 40 35 50 Graph Torque Nm vs Time m ec Plot Name Plot Curzer Mode Show 2009 205 1 4152 TergAnglees Time v Al Plot Figure 2 3 CurveWare example Max Torque is the upper torque limit of the rundown Max Angle is the upper angle limit of the rundown No of Data Points is the number of data points that should be used in the plot Maximal number of acquired data points is 4000 Current Plot the rundown that has been recorded is highlighted in the graph Receive d
10. in seconds the tool is allowed to run free without the load before reaching cycle threshold This is a safety feature in case the tool is placed down on the throttle The default setting is 5 seconds Load Timeout The amount of time the tool is allowed to run after crossing cycle threshold The default setting is 15 seconds Cycle Complete The amount of time in ms the torque must remain below cycle complete before the event is counted as a cycle and the final torque is displayed default 200 ms Locked Rotor Safety feature which shuts off the tool when it has reached a stalled condition The amount of time which the tool can remain in a stalled condition is programmed in milliseconds The default setting is 100 ms Gen 1 Tool Button Configuration This feature allows the user to program the functionality of the light ring The default setting for this section is e CW Forward e Center Reverse e CCW Auxiliary Control Source allows user to choose the source that controls the tool operation Buttons from Tool IO Determines the source of the Trigger Forward Reverse and Aux Commands 25 Gen3 4 Tool Button Configuration Multi Function Button MFB Tap action triggered if button held less than hold time Hold action triggered if button held to hold time or longer Hold Time Amount of time required to hold the MFB until Hold Action is triggered Arming Timeout Amount of time after the tool is arme
11. map Eie Msg Status Pause Yellow Green Blue White Flashing Flashing Flashing Flashing Flashing Byte Bit Name Function Tool Enable enabled state of the tool enabled state of the tool state of the tool On if the tool is ready to run Will be off if tool is disabled or there is a fault Tool Ready the controller 7 status on for an accept This bit is timed and be on for Status OK second iti 1 i 1 Status NOK status on for a reject This bit is timed and will be on for 2 Mso Received On to indicate a message has been received from the MKS module and the 9 inputs have changed This bit is timed and will be on for 72 second Batch Complete Indicates the batch is complete Will go off when batch is reset or when the p tool is turned off PE Light Tower Status Bitwise status of the Light Tower lights 4 Light Tower Status Bitwise status of the Light Tower lights 67 Notused Pt Byte Controller Inputs PLC White Baise Tool Byte Enable Flash Enable Sequence Number EM 31 Serial Number 29 Networking Function Tool Enable If PLC Enable is 0 this input is ignored If PLC Enable is 1 this bit can be used to enable or the tool Pause enna Pause to 1 cause the light stack to strobe Setting it to 0 put the light stack back into its normal operation Setti
12. 4 3 Table 1 4 3 Status Bar Contents Status Item Display Options N m Lbs ft Torque Units Lbs in KgCm KgM Offline Connection USB Ethernet 1 5 Connecting IEC Controller with ToolWare supports 2 options of connecting Controller to PC depending on the interface and the model of AcraDyne Controller e USB port through the CIM adapter P N AEC CIM e Ethernet port through the Ethernet crossover cable or standard cable Figure 1 5 1 and Figure 1 5 2 show the Communication Connection interface panels of iEC Controller y Use Future Use Tool Cable Ethernet Port2 Ethernet 1 Bar Code Scanner RJ45 CAT 5E Regular Cable Straight through pin out Figure 1 5 2 iEC controller electrical interface top panel Some connections available on iEC3 and iEC4 models only 1 5 4 Connecting to USB port IEC Controller AEC CIM PC P N 23112 Includes P N 23217 22940 CAN port Cable PN 23217 Cable PN 22940 1 5 2 Connecting to Ethernet Port RJ45 cable PC Controller cross over Ethernet port Ethernet port 1 5 3 Connecting to the network Cable Network Controller PN 20403 Router Ethernet port Ethernet port RJ45 CATSE 2 Working with ToolWare 2 1 Connecting PC with the Controller 2 1 1 Setting up USB Connection Follow the steps below to set up USB connection Turn on the computer e Plug the USB cable P
13. Green LED indicates OK rundown B TORQUE Steady red indicates flashing red indicates LO C ANGLE Steady yellow indicates flashing yellow indicates LO D CYCLE Blue LED indicates tool is in rundown cycle Q 2 Primary Display Field Displays Parameter Set Target or Rundown torque 3 Secondary Display Field Selectable Display Choices Angle etc 4 Programmable Display Selection Buttons A Optional Display Access Accesses the Programmable Options menu B NEXT Scrolls through the different display options for the Secondary Display C SET Sets the selected display option the Secondary Display 5 CHANGE PSET Scrolls upwards through programmed Parameter Sets 6 PSET Indicator displays PSET that is currently operating 7 IR PORT ENABLED Future function not currently enabled 101 50 fF 40240 1 lt abo Y 7 152 40 Pd 4 59 A 116 68 Y 3 41 88 52 Ay 0 i 1 e 45 gt 0 4 1 N 5 Inches Millimeters e INITIAL SETUP Step 1 Connect the tool cable to the Tool Connection Figure 3 pg 4 The cable consists of a male pinset housed in a molded connection with a notch or a 26 Pin male connector with two opposing locating pins Align the notch of the tool cable with the notch of the connector or the male and female lo
14. Log out of the user level the user is in 2 5 8 Exit Exits ToolWare 21 2 6 Controller 2 6 1 View Firmware Rev Displays the current DSP revision and Servo Rev 2 6 2 Edit Configuration Parameters The user can Edit the controller configuration from this screen The screen is shown in Figure 2 6 2 ToolWare iEC Series n t3 Torque Units NM iEC Connected USB Adaptive Control Angle Count On Trigger Batch Hold Reset In Cycle Configuration Joint Rate Threshhold Lock on Reject Low Speed Control Rehit Reject Rundown Back off Rundown Serial Output Format Soft Start Start Delay Statistics Time Controls Gen 3 4 Buzzer and Headlight 1 Tubenut Gen 4 Tubenut Multi Function Button Push To Start Operation Tap Action Operation Logic Disassembly Toggle x Either PTS OR Trigger for Run x Hold Action Hold Disabled Control Source Hold Time Arming Timeout Sec Buttons From Tool 3 5 3 5 Buttons From 1 0 Save DSP Parameters To File DSP Parameters To File Reset To Factory Defaults Open DSP Parameters File DSP Parameters File Figure 2 6 2 Edit Controller Parameter screen Adaptive Control Enable Adaptive control is a useful option when a high CPK Process Capability is chosen as the most important variable This is done by adjusting the control to ensure the average applied torque is centered between the upper an
15. Option is selected press the SET button Fig 4 to lock this option as the visible display Once the SET button is pressed the display screens will clear Upon completing a rundown cycle the value for the selected Display Option will be shown in the Secondary Display Field Fig 4 The selected Display Option will be displayed for a Parameter Sets Display Optional Values for Individual Rundowns By scrolling through the Display Options after a rundown cycle the value for each option can be quickly viewed Step 1 Immediately after a rundown cycle the selected Display Option will be shown in the Secondary Display Field To view a different Display Option value press the NEXT button before conducting another rundown Step 2 Continue to press the NEXT button to scroll though the available options As each option is selected the corresponding value will be displayed in the Secondary Display Field The Display Option that is last shown before another rundown is conducted will be set as the programmed display option To stop viewing the Display Option for the most recent rundown simply conduct another rundown or press CHANGE PSET to select a different parameter set Using the Optional Keypad Display Module 1 KDM Display Screen 2 KDM Power On Off Button 3 Shift Button used to access alternate functions on highlighted buttons 4 SEND Button Used to send new or edited parameter sets to the tool and
16. Pset group For information on Linked parameter sets see the Setting Parameters section in the ToolWare portion of the user manual Programming the Display Options The Programmable Display Options feature in the iEC allows the user to select the information that will be displayed in the Secondary Display Field Step 1 Press the DISPLAY OPTIONS button Fig 4 to access the Display Options Menu Immediately a message will appear in the Primary Display Field Fig 4 that will indicate which display option is currently selected If no rundowns have been conducted since the most recent Power On of the controller the Secondary Display Field will display the default information relating to the current display option If rundowns have been conducted since the controller was last Powered On then the Secondary Display Field will display the value for that option pertaining to the most recent rundown in the current parameter set Main Display Functions Step 2 To scroll through the available display options press and release the NEXT button Repeated presses will cycle the display options as follows DFLT gt ANGL gt BCNT gt TOT gt OK gt NOK gt CP gt CPK gt JTRT tL The definition of each Display Option is as follows DFLT Default Field is blank if a Torque Control Strategy is programmed For all other strategies the field will display the angle of rotation from Threshold to Final Torque ANGL Angle If selecte
17. Resetting defaults is easily done using Toolware as well Refer to the Toolware users guide for details Q WHAT IS ADAPTIVE CONTROL Upon reaching target torque the controller signals the tool to shut off and the tool stops Depending on the speed of the tool and the joint rate the final torque output may be higher than the target torque This difference in torque is called overshoot Adaptive Control averages and centers the final torque readings around the target torque value It averages the overshoot torque on 10 consecutive rundowns After that it pre targets the tool to shut off before reaching the target so that the final reading is closer to your target torque setting For example if the target torque is 10 Nm and the average of 10 readings is 10 2 Nm using adaptive control will calculate the average overshoot torque of 0 2 Nm 10 2 10 0 and the tool will shut off at 9 8 Nm so that the final torque reading is 10 0 Nm Because of the way Cpk is measured having more readings above the target torque decreases the Cpk value Using Adaptive Control will result in a higher Cpk value since the range of the final torque readings is more centered on your target torque setting Q WHAT IS THE CAL VALUE The cal value of an AcraDyne tool is based on a scale of 0 256 points By adjusting this value the torque values generated by the tool s transducer can be correlated with a torque value as determined by a master calibration transd
18. and keep alive messages Cell ID Optional variable that is passed through the Open protocol connection Channel ID Optional variable that is passed through the Open protocol connection Controller Name Optional variable that is passed through the Open protocol connec tion To set up a serial port for Open protocol set the function on the desired COM port to Open Protocol and cycle the power on the controller 24 Networking The Controller supports the following MIDs See the latest Open protocol specification for details on each MID MID Description Note 0040 Rev 1 and 2 supported 0060 Last tightening result data subscribe Rev 1 2 and 999 supported 0063 Last tightening result data unsubscribe eee 0070 Alarm subscribe 0082 Set Time in the Torque Controller 216 219 Relay function subscription Relays 1 2 5 8 11 19 22 24 only 220 223 Digital In function subscription Input 1 3 8 9 16 18 53 only 25 Networking Chrysler PFCS The controller has the ability to connect to the Chrysler PFCS network Once the controller is on the local network there are several parameters that must be set to work correctly 1 Server IP Address This is the IP address of the Chrysler server If the server is on another subnet you will also have to verify the gateway in the Ethernet settings 2 Server Port Number This is the TCP port the server is listening on for a new connection 3 Ack Tim
19. controller 5 Numerical Alternate Function keypad Parameter Set Terms ANGLE CONTROL TORQUE MONITOR Control strategy in which angle is the control parameter but torque is monitored ANGLE TARGET Desired value for angle rotation measured from threshold torque value AUTO SET Feature that allows manual entry of control parameters but all others are determined by system defaults CYCLE Torque level that determines the completion of a fastening cycle THRESHOLD The torque value above which the system is in cycle and data points are stored DOWNSHIFT TORQUE Torque level at which the spindle changes from free speed to downshift speed ERGO MODE Ramps the cut off of power after reaching target torque providing an ergonomic shutoff during a hand held tightening operation Can negatively effect cpk calculations HI LIMIT The upper control limit for torque and or angle LO LIMIT The lower control limit for torque and or angle Must be set lower than target parameter Any torque angle lower than this value will be indicated by a yellow light and with a Lo Torque and or Low Angle error on KDM RPM FREE Spindle output speed at the beginning of a tightening cycle entered as a percentage of maximum tool speed RPM DOWN Spindle output speed after exceeding downshift torque entered as a percentage of maximum tool speed SSTART Soft Start Speed of output spindle ramps up at a programmable rat
20. for a new connection This parameter is not used for a serial connection to PFCS 3 Ack Time Out sec The amount of time the controller will wait for an acknowledge from the PFCS server 4 No Retries The number of times the controller will retry a message if it is not answered by the PFCS server 5 Reconnect Time Out sec The amount of time the controller will wait before attempting to re connect to the PFCS server 6 Connection Inactivity Time sec The amount of time the controller will wait before send a keep alive message 7 Auto Machine Id If set to a 1 the controller will request a machine ID from PFCS If it is a 0 it will use the programmed one from each parameter set 23 Networking Open Protocol The controller has the ability to accept an Open protocol connection This connection is available over Ethernet and or the standard serial ports Through this connection you can enable disable the tool set the active parameter set collect rundown data and much more 1 2 OV Port Number The TCP port number the controller listens on to accept an Open protocol connection via Ethernet The default port is 4545 but can be changed if required Cable Loss Detection Only used for a serial Open protocol connection If set to 1 the controller will close the connection on a time out If it is set to 0 the controller will not close the connection See the latest Open protocol specification for details on time outs
21. on the Parameter Set screen whenever it is in use Low Speed Control is a feature that applies across all PSETs globally Selection of Low Speed Control ON or OFF requires a Power Cycling of the IEC control for the change to become effective Prompts will indicate to the user this requirement and the LED on the IEC controller will change to OFF indicating that a Power Cycle is required While Low Speed Control has many benefits and is not inherently negative to tool performance when left in use it does apply slightly higher power levels to the tool motor and in high duty cycle applications where it is not necessary this feature should be turned off Specific Information Related to Low Speed Control range of tools when used with Low Speed Control activated is 4 100 of the tool s normal speed rating e TubeNut tools may not home accurately in Low Speed Control Mode Ergo Mode is not usable when using Low Speed Control Low Speed Control is effective on all 1000 Series 2000 Series and 3000 Series tools up to 90NM larger tools are unable to use this feature Disable Tool when SVC CAL Due Option to select Default Disable tool in preset Service or Calibration period exceeded date or time LED warning appears on IEC Tool re enabling accomplished by to be determined Option de selected Tool remains enabled LED warning appears on IEC Angle Count Configuration e This option determines when the angle count is started Star
22. parameter set is not active press CHANGE PSET to cycle through the available parameter sets until the appropriate set is displayed The tool is now ready to be run to the appropriate target torque value The AUTO SET function is under development for future versions of the iEC controller If the user exits the CONFIGURE mode before pressing all edits and modifications that have been entered will be lost and the entries will revert back to the previous value Main Menu 2 Calibration The Auto Cal is non functional for the user Using the Optional Keypad Display Module KDM Main Menu 3 Administration Functions Parameter Set Defaults Parameter set defaults are the values used to calculate control parameters when using either Quick Start or Auto Set This is also the area where units of measurement for all parameters is set To access the Parameter Set Default function From the MAIN MENU press 3 for ADMIN Press 1 for SETUP PSET The following text will be displayed on the KDM display screen Navigation and value entry is the same as described in the section Setting Up Parameter Sets on pages 12 16 All programmable default values are described below TQTARGET The default torque target shown when entering quick programming The value entered is a percentage of the maximum torque of the tool For example if the value entered is 80 and the maximum torque of the tool is 30 Nm the default target torque when enterin
23. the current rundown information in an easy to read screen If there is a failure in the tightening the Torque Angle is displayed in red Use Record Rundowns to save the Rundown information straight to the Computer memory You can use View saved rundowns to see the saved rundowns Series Help Torque Units iEC Connected USB AcraVision Record Rundowns View Saved Rundowns Current Settings Torque NM Current Parameter Set 1 Total Parameter Sets 4 Torque Target 8 Torque High 9 3 2 Torque Low 6 8 Angle High 0 Angle Low 0 Angle Deg Status Torque Hi RA craDyne 8 A Division of AIMCO Figure 2 11 AcraVision Screen example 45 2 12 System 2 12 1 Serial Test Hyper terminal like screen that can be used to monitor the serial output messages from the iEC controller 3 Addendum 3 1 Fault codes Fault codes are displayed to inform the operator about what is happening in the Controller and why something doesn t behave as expected ToolWare iEC Series Fault Codes faulty tool id board or tool cable 32 Too GND ground circuit problem between controller and too faulty tool cable faulty tool connector faulty ground connection within tool 64 Power Throttle run command onpowerup 1 on throttle lever on power up tool buttons out of calibration faulty tool id board 255 Button State illegal button state exa
24. will stop if the angle of rotation between cycle complete and threshold torque is less than a specified number of degrees Rehit Reject On Off If Enabled will abort the attempt to fasten a pre tightened fastener The default setting for this option is off Rehit Reject Angle Used to determine if a fastener is already tightened If the angles of rotation between cycles complete torque and cycle threshold torque is less than the programmed angle then the fastener is assumed tightened and no pass reject will be reported Note Rehit Reject and In Cycle Configuration At Throttle are mutually exclusive selections 23 Rundown Backoff Rundown This feature includes three modes that engage reverse rotation of the tool Enable activates the feature There are four options available when the feature is enabled e Rundown Backoff SP Tool will rundown to selected PSet torque reverse the fastener a set number of degrees defined by Back Off Degrees Reports the Torque and Angle from the rundown e Rundown Backoff Rundown Rundown to the 1 Rundown torque specified below then reverse the fastener a set number of degrees and re tighten the fastener to the target torque established in the parameter set Reports the Torque and Angle at end of cycle Rundown Backoff Tool will rundown to 1st Rundown Torque reverse the fastener a set number of degrees Reports the Torque and Angle at end of cycle Off Switches Run
25. 0 is selected for the PSet all rundowns in the file will be used in the collection 42 Stats e POP Population The total number of observations used to calculate the statistical data Mean Sum of All Readings Number of Readings Overall capability which is the ratio of 6 sigma to the tolerance The equation for CP is Torque High Limit Torque Low Limit 6 Sigma CPK Process capability which takes both sigma and mean into account The equation for is the smaller of Torque High Limit 3 Sigma or Mean Torque Low Limit 3 Sigma e Sigma The standard deviation multiplied by 6 A total range of 6 sigma will include 99 7 of all data The equation for six sigma is as follows 6 e Range The difference between the maximum and minimum reading e Min Tq The maximum torque reading e Max Tq The minimum torque reading 43 Histogram of Final Torque Samples The histogram shows the frequency count of the number of times that a specified interval or bin occurs in the collection of final torque samples The range of the histogram is equally divided in to a specified number bins using the following equations e The width e of the frequency bin is i max min o Where mis the selected Number of Bins max is the upper ceiling for the torque range to be evaluated Range Ceiling min is the lower floor for the torque range to be evaluat
26. 6 142 Eower 0 7 85 7 159 lt GConnecing IEC Controller with PO se et tectam e c bas deed da 8 1 5 1 Connecting to USB port ss oe un e ERI e i a Rh Re Mos 10 1 5 2 Connecting to Ethernet POLL 10 1 5 3 Connecting to the 10 2 Working with uchiha na ae dt 10 2 1 Connecting PC 10 2 1 1 Setting Up USB 10 2 1 2 Setting up Ethernet 11 2 2 Paramoelels GIAN e rds Need 13 221 Parameter Entry 05 ed 14 222 Paramele Oels te a 17 18 27 Monitoring mim Re ud 19 2 0 He Gate DRM uic ies 20 CONNEC Nis REP 20 252 i eod epu 21 200235 T ee 21 29 4 dote 21 21 2 56 Language 0 A 21 2 0 UE 21 ee sai even ac io tae note 21 us cx de bec p 22 2 61 Miew Firmware ROW sins ic tnde ia ince asthe 22 2 6 2 Edit Configuration Pararneters 22 2 6 3 Angle Offset ap dan obe ic etta etai vitta 33 264 MiewiEdit Date
27. AcraDyne DC Tool Controllers AIMCO PO Box 16460 Portland OR 97292 0460 800 852 1368 Fax 800 582 9015 www aimco global com Introduction Thank you for your purchase of an AcraDyne iEC DC Tool Controller from AIMCO The iEC represents the most advanced controller for AcraDyne series electric controlled assembly tools and is capable interfacing with all series of AcraDyne tools This manual is designed to provide the user of the AcraDyne iEC Controller with a guide to understanding the features and functions of the controller Programming this controller using AcraDyne s ToolWare software package provides a broad range of operating choices to tackle the most difficult assembly projects with ease Statistical analysis communication and system diagnostic features are also built in For more detailed programming data analysis and system monitoring information please refer to the AcraDyne ToolWare Operations section at the back of this manual For additional service and support please contact your AIMCO distributor or contact AIMCO at 1 800 852 1368 between the hours of 7 00 4 00 PM Pacific Time Table of Contents Safety Information 3 Front Panel Diagram Figure 1
28. DC Electric assembly tools for intermittent assembly processes Front Panel Figure 1 1 Display Panel Annunciation and Display programming see Page 5 for detail 2 Power Disconnect Switch Turns controller on and off 3 Keypad Display Module KDM Onboard Interface for setup and programming Optional Bottom Panel Figure 2 1 CAN Connectors For connection of AEC CIM communication module and peripheral devices 2 System Connector DB 15 Pin For upgrading changing controller firmware 3 External transducer Connector DB 25 Pin Non active future feature 4 External I O Connector DB 25 Pin Input and output of signals for process control 5 Power Cord Connection IPC 29 Connector 6 Ethernet Connection Access Light Tower Board Connection Bottom Exit Tool Connection Optional 7 RS232 Connection DB 9 Pin Serial data output for communication with peripherals such as bar code readers Top Panel Figure 3 1 Tool Connector 26 Pin Standard connection point for tool cable 2 Serial data connection for peripherals 3 Ethernet connection port 2nd connection optional with advanced communication packages 4 Serial data connection for peripherals Main Display Panel Figure 4 8 5 ACCEPT torque IR PORT Wine ENABLED CHANGE INTELLIGENT EC B 1 Rundown Feedback Indicators A ACCEPT
29. N 22940 into your computer s USB Port or USB Hub and the other end to the CIM Module PN 23112 e Plug the 23217 cable into the connector on the CIM and the other end of the cable to either of the CAN ports in the controller e Launch ToolWare and configure it for USB connection by selecting File Connection USB 2 1 2 Setting up Ethernet Connection Make physical connection Connection options e Use Ethernet crossover or standard cable to connect Controller to PC directly e Use Ethernet crossover or standard cable to connect Controller to network router Specify the IP Address of controller in the PC e Open Control Panel by clicking lt Start Settings Control Panel gt Select lt Network Connections gt for configuration Double click lt Local Area Connection gt to open its Status Window Click on lt Properties gt button to open Properties Window Scroll the list of connections to find lt nternet Protocol TCP IP gt and double click it to open Internet Protocol Properties window e Click on Use the following IP address gt and enter the IP address of 10 10 30 155 e Set the subnet mask to 255 255 255 0 e Click on lt OK gt button to exit lt nternet Protocol Properties gt window e Click on lt OK gt button to exit lt Local Area Connection Area Properties gt window e Click on lt OK gt button to exit lt Local Area Connection Area Status gt window e Exit lt Control Panel gt window Configure ToolWare
30. P The controller will accept a connection from a Modbus TCP master Controller Outputs The Controller s outputs are located at address 0 and contain one status word Controller Outputs 5 122 njof o 5 ol 0 Handshake Job Compete Healthy Running Process number Bit Function s Running 1 s hean ates the controler has nous 6 qwe LLL Ds qwe LLL Controller Inputs The Controller inputs are located at address 1024 and 1036 Address 1024 contains one control word and 1036 con tains the 20 character VIN Controller Inputs Bits 5 1 5 4 3 mem _ Bit name Function Process number input The enable must be off to change the Process Number On 0 7 Process Number a change to the Process Number the batch is also reset Handshake Will be echoed to the Handshake output 28 Networking Profibus DeviceNET The controller can have an optional Profibus or DeviceNET interface These interfaces are accom plished through the use of a serial bridge The serial bridge is provided by MKS Instruments See the latest MKS documentation for details on sending and receiving messages Logical I O The controller has five status bytes of outputs Controller Outputs ZARAR Tool Tool _
31. PM Down RPM Down RPM Down Ergo Mode Ergo Mode Ergo Mode Ergo Mode Soft Start Soft Start Soft Start Soft Start ANG Target ANG HI Limit ANG LO Limit 35 APPENDIX Menu Structures Administration Menu ACRADYNE KDM 2007 FIRMWARE REV X X iEC CONNECTED MAIN MENU 3 ADMIN SECURITY RESET DEFAULTS TO TARGET ENABLE 4 TOOL CAL VALUE T0414 DEBE 2 LOGIC IO TQ THOLDA 3 PARAMETER SETS DSHIFT CALIBRATION VALUE NEW PASSWORD CONFIRM PASSWORD 36 APPENDIX C I O Diagram amp Definitions iEC2 iEC3 and iEC4 series controllers have a range of Input Output I O capabilities By referencing the diagram below the user can access the controllers functions for a variety of line control and error proofing functions A connector kit is available PT 23490 from AIMCO to make connection to the I O port on the iEC controller easier contact your AIMCO sales representative for ordering information C CO 9 9 2 9 9 2 9 9 5 69 49 69 69 2 2 29 69 G9 25 Definition Pin Definition Output Accept 14 Output Torque Low Output Reject 15 Output Angle High Output In Cycle 16 Output Angle Low Output Torque High 17 Output Batch Complete Output 1 4 Common 18 Output 5 8 Common Input Run Forward 19 Input Analog 1 Input Run Reverse 20 Input Analog 2 Input D
32. a group of sequential Parameter Sets actuated by a single trigger pull To define the last Parameter Set in the group unselect Link PSet by placing a 0 in the field Link Delay used to add a delay time between the linked steps Running a Linked PSet rundown e Toruna Linked PSet group select the first PSet in the group as the Current PSet Via the CHANGE PSET button on the controller or using Logic IO or using the Current PSet selection in Toolware e Link the PSets by selecting the next PSet in the Current PSet s Link PSet Drop down If you want to have a delay between the rundowns enter that in the Link Delay Drop Down box If you want to link more PSets then repeat this step e Run the tool as usual by pressing and holding the throttle e The tool will sequence thru each PSet in the Linked PSet group Atthe completion of last the PSet of the group the controller will signify the Linked PSet rundown is complete by lighting the cycle accept or reject led and turning off the blue In cycle led The current PSet will automatically reset to the first PSet in the group to ready for the next rundown e A release and repress of the trigger is necessary to start the next Linked PSet rundown Linked PSet Results Reporting The angle count is reset to 0 at the end of each linked step of a Linked PSet rundown RBR Combined with a Linked PSet Rundown Note The RBR RB and RBsp options are only preformed at the en
33. ables the user to specify how ToolWare will connect with and communicate to the Controller The options are as follows 20 USB is used if the computer is connected with the controller using the USB connection in the computer Ethernet can be selected to set the IP address the connection should use Offline mode gives the user the opportunity to edit parameter files and configuration files to save without being connected to the controller 2 5 2 Open Enables the user to select the file to open 2 5 3 Save Saves the file to the PC in the specified directory 2 5 4 Print Print the Screen or the Data 2 5 5 Login Login is not required for general access though advanced features are not available in this mode On occasion when advanced features need to be accessed a password will be given and can be entered here An AcraDyne technician or an AIMCO salesperson can create a temporary password to give to a customer This password will be valid for the day it is given This can be used when a customer needs to access technical areas on a temporary basis It is based on the calendar date and will be valid until midnight of that date Contact your AIMCO sales representative to get more information on passwords for use with ToolWare 2 5 6 Language User can change language and locale either for the particular session or set it as default for the system The application switches to the language the User selects 2 5 7 Logoff
34. al point next to the least significant T P parameter set 1 9 for PSets 1 9 W for PSets 10 32 B batch count T torque result A angle result J judgment overall pass H low torque eye hi torque J low angle K hi angle 30 Statistics Minimum Stats Number of rundowns that need to be preformed before the statistics will be calculated and displayed on the controller Stat Samples Maximum number of rundowns used for calculating and displaying statistical data on the iEC controller Statistical Outliers The statistical outliers parameter is a code that is used to determine if the data from a rundown will be excluded from the data set being used in the static calculations that are displayed on the iEC controller The exclusions are based on the results of the rundowns The following are the codes for each exclusion type 2 Final Torque Result Above High Limit 4 Final Torque Result Below Low Limit 8 Final Angle Result Above High Limit 16 Final Angle Result Below High Limit 128 Re Hit To exclude any combination of the above list add up the code values Example To exclude rundowns where the final torque was above the high limit 2 or the angle was below the low limit 16 Set the value for statistical outliers to 2 16 8 Lock on Reject When enabled this prevents the tool from starting a new rundown if the result of the last rundown was a reject The tool remain
35. ame and password Since the controller only contains one password one user the User name can be left blank Once the password is entered it is returned to the controller were it will be checked and if it is correct the parameters are saved If it is incorrect the controller will request it from the browser again After a password has been entered most browsers will cache it and return on subsequent request with out prompting the user So as long as the browser is not closed it would not be necessary to enter the password on every change to the parameters To remove a password from the controller it just needs to be set to a zero length string and saved via the submit button Of course this action requires the existing password If the password is lost or un known contact your AIMCO representative for a method of retrieval FTP The controller has the ability to provide an FTP server to allow the transfer of stored rundown data For security reason it is turned off by default Changing the setting to from off to on or on to off will not take effect till power is cycled on the controller Once enabled the FTP server will allow anonymous log ins The only files available are the rundown results in CSV and TXT format These can be transferred to the client and deleted No other FTP server features are supported Toolsnet The controller has the ability to send rundown data to a ToolsNet server Once the controller is on the local netw
36. arameter 5 13 Editing Quick Start Parameter Sets 13 Configuring New Quick Start Parameter Sets eese 14 Configuring a Complete Parameter Set esee Entering Editing Values in the 15 Main Menu 2 Calibration sausssuusanuauuusumsauuussuuauauuuauuusanssaussausuausasn 16 Main Menu 3 Administration Functions Parameter Set Defaults 17 Security 18 Information 19 Reset Factory Defaults 19 5 7 20 Filter Frequency 20 Adaptive Control 21 Networking 22 Proofing sssssunsassanusu
37. c number of times If the tool does not run at all or the square drive has to be rotated before the tool will run the motor is probably damaged Run this tool on a different controller to determine where the problem lies Tool Offset Based on the offset value of the transducer during re zero and the tool cal value the tool cannot mathematically reach the target torque This problem can occur if the cal value has been drastically changed and the target torque in near the max torque of the tool Try resetting the cal value to defaults and calibrating the tool using an approved rotary transducer 47 Tool Level The tool transducer output voltage has exceeded the maximum minimum allowable value Try the tool on another system Locked rotor The controller has not sensed hall transitions from the motor for a period of time This is possible if the tool is trying to achieve a high torque at a low speed Increase the rundown speeds and make sure the tool is calibrated properly It is also possible that the controller is faulty If the tool does not run at all try connecting it to a different controller Drive Fault The servo drive is not trying to run the tool Try the tool on another controller PSet Value An illegal rundown parameter set has been sent to the controller Try resetting the parameter sets back to factory defaults TID Parameter Value The tool sent an illegal parameter to the controller Try cycling power to the system Als
38. cating pins and insert the cable Next securely thread the connector cover to the controller body Step 2 Repeat the above process to connect the cable to the AcraDyne tool that will be used with the controller AcraDyne pistol style tools manufactured prior to January 2011 are hard wired on the tool side and re quire no additional connection Step 3 Plug the female end of the power cable into the Power Cable connection Figure 2 pg 4 Step 4 Plug the male end of the power cable into the appropriate power source Due to the variety of 220V power outlets worldwide the standard power cable plug end provided with the controller may need to be modified to connect to local 220V power outlets The iEC Controller is designed to work with either a 110V or 220V input supply When operating a 3000 series tool 120V the maximum speed of the tool is of its catalog speed Since speed parameters are set as a percentage of maximum the actual speeds of these tools run on 110V will be 2 of the speed run on 220V Step 5 Turn the controller on by rotating the Power Disconnect Switch Figure 1 pg 4 to the POWER ON position represented by the symbol When an iEC with SCC code 2 0 and higher is powered on three messages will be shown on the dis play SYS INIT indicates the system is initializing IEC indicates the firmware version that is operating in the controller SERVO FIRMWARE A or indicates the firm
39. d field will display angle of rotation for the previous rundown regardless of strategy for the parameter set BCNT Batch Count Field will display the batch count information for the selected parameter set Displayed values are current count cc and batch total bt with the information displayed as cc bt TOT Total Count Value shows the total number of rundowns for all parameter sets from midnight to midnight OK OK Count Value shows the total number of acceptable rundowns for all parameter sets from midnight to midnight NOK NOT OK Count Value shows the total number of unacceptable rundowns for all parameter sets from midnight to midnight CP Cp Value Statistical value is Cp for selected parameter set based on collection of programmed minimum number of rundowns This value is reset upon controller initialization or new Parameter Set Download or Tool Change CPK Cpk Value Statistical value is Cpk for selected parameter set based on collection of programmed minimum number of rundowns This value is reset upon controller initialization or new Parameter Set Download or Tool Change JTRT Joint Rate Displays joint rate of selected Parameter Set based on previous rundown The value is displayed in degrees of rotation from the Joint Rate Threshold not Parameter Set Threshold to final torque By default the Joint Rate Threshold is 10 of target torque Main Display Functions Step 3 When the desired Display
40. d that the tool will automatically disarm Tap MFB Function Options Actions will commence upon release of the MFB button on the tool as programmed Arming TubeNut Tool Default Tapping MFB button arms activates the start function but does not start the tool Blue status light illuminates to indicate tool is Armed Arming will reset in 3 seconds if tool start is not initiated Change PSET Tapping MFB button toggles between PSET A and PSET B Status lights flash indicating PSET A is selected or twice if PSET B is selected Reset Reject Tone Tapping MFB button silences reject tone Tap Disabled Tapping MFB button has no effect on tool Hold MFB Function Options Actions will commence after Hold timer preset time has elapsed Adjustable in Hold Time window Default value is 1 second Arming TubeNut Tool Default Holding MFB button arms activates the start function but does not start the tool Blue status light illuminates to indicate tool is Armed Arming will reset in 3 seconds if tool start is not initiated Change PSET Holding MFB button toggles between PSET A and PSET B Status lights flash indicating PSET A is selected or twice if PSET B is selected Reset Reject Tone Holding MFB button silences reject tone Hold Disabled Default Holding MFB button has no effect on tool Push to Start Operation Choices are Both Push to Start PTS and Trigger must be depressed for tool start Either PTS or Trigger may be pressed for tool star
41. d lower control limit This feature has three options which are explained below 22 Off Turns adaptive control off The tool will produce torque until the target torque is achieved Therefore all results will be equal to or greater than the target This will cause the average torque to be greater than the target torque thus making it extremely difficult to produce a high CPK First Ten Takes an average of the first ten readings in a new parameter set and adjusts the control to make the average torque correspond with the target torque Therefore there will be readings both above and below the target torque thus maximizing CPK All Similar to above but continually adjusts the control based on the average of the previous ten readings in an attempt to maximize CPK Pct Adjustment Adjustment Determines how much of a correction adaptive control will try to make The higher the number the greater the correction adaptive control will make In Cycle Configuration At Threshold the tool status is switched to In Cycle when torque reaches torque threshold set point At Throttle the tool status is switched to In Cycle immediately when rundown is triggered Note In Cycle Configuration At Throttle and Rehit Reject are mutually exclusive selections Rehit Reject This feature prevents operator from attempting to tighten the fastener that has already been tightened If this feature is enabled the rundown
42. d of the last step of a Linked PSet rundown Results Reporting The results of the last PSet Step in the group are used to report If the trigger is released before the rundown sequence is complete the results from the step that the controller was currently running before being interrupted are reported The controller reports curve data from the last rundown step and any linked previous steps if not separated by a delay time Batch Processing ToolWare allows the user to specify PSets for the sequence of rundowns During the batch process the controller monitors each rundown and switches PSets automatically We can control the actions of the controller as each step in the batch is completed When PSets are linked only the last PSet has batch settings Count Preset defines the number of accepted ACCEPT rundowns that must be completed for the associated parameter set Action At Preset Count Complete The choice of options for end of batch events is Reset count and output batch complete Act2 Hold count and output batch complete Disable tool Hold count and output batch complete Act4 Go to next PSet amp do not output batch complete Go to next PSet and output batch complete Next PSet determines the parameter set that is automatically activated when the count for the associated PSet is reached 2 2 2 Parameter Sets Parameter Enable check boxes allow the user to generate up to 32 di
43. diting a parameter set the Control Strategy definitions on page 11 of the PSET will be identified by an asterisk Press the button on the KDM corresponding to the desired Control Strategy The following text will briefly be displayed on the KDM display screen followed by the following text The PS text in the bottom right corner of the display is for the users reference and identifies the PSET that is being configured or edited Entering Editing Values in the KDM The flashing cursor highlights which field can be changed Two possibilities exist for entering values into a field depending on which function is being programmed For numeric values press the appropriate key on the KDM For YES or NO entries press b or When an lt and or gt symbol appears in the upper right corner of the KDM display this notifies the user that additional functions may be accessed by scrolling to the previous or next page of text To scroll to one of these pages press 1 15 Using the Optional Keypad Display Module To move to and modify the next or previous function press A or The cursor will then highlight the field that can be modified 0 To clear mistakenly entered value press When all functions have been modified appropriately press c Verify that the correct parameter set is active by observing the PSET Indicator on the Main Display Panel If the desired
44. down Backoff or Rundown Backoff Rundown to off mode 1 Rundown in Ibs The initial rundown torque measured in in Ibs Dwell Time before Back Off Dwell time ms between first rundown and the start of back off Back Off Degree The amount of rotational degrees the fastener is backed off after reaching 1st rundown torque Back Off Torque Limit This is the backoff torque limit measured in in Ibs Dwell Time before Second Rundown Dwell time ms between back off and the start of second rundown Soft Start This feature allows the user to set the speed and timing of how quickly the tool ramps up to Freespeed RPM Dwell ms the amount of time that the tool will rotate at slow speed before progressing to the Freespeed RPM default 500 ms Dwell RPM the RPM at which the tool will run during soft start period default 90 24 Ramp ms the amount of time from the end of the soft start period until the tool reaches the Freespeed RPM default 600 ms Start Delay Start Delay On Off When enabled the tool will ignore programmed torque parameters until the timer runs out This is often used in jobs with prevailing torque that exceeds target torque The default setting is disabled Start Delay ms The amount of time at the beginning of the fastening cycle measured in milliseconds which the tool will ignore programmed torque parameters default 500 ms Time Controls Free Run Timeout The amount of time
45. e Out This is the amount of time the controller will wait for an acknowledge message from the server The default is 3 seconds 4 No Retries The number of retries the controller will attempt before disconnecting The default value is 3 5 Reconnect Time Out The amount of time the controller will wait before attempting to re connect to the server The default value is 20 seconds 6 Connection Inactivity Time The amount of time the controller will wait between connection at tempts The default value is 120 seconds 7 Auto Machine ld If set to Yes default the machine ID will be provided by the Chrysler PFCS server upon connection If set to No the machine ID is entered per parameter set on the Advanced tab on the web interface This will result in each parameter set having its own ID 26 Networking AIMCO Database The controller has the ability to send rundown data to an AIMCO data collection server Once the con troller is on the local network there are two parameters that must be set to store data correctly on the server 1 Server IP Address This is the IP address of the AIMCO data collection server If the server is on another subnet you will also have to verify the gateway in the Ethernet settings 2 Server Port Number This is the TCP port the server is listening on for a new connection See your local AIMCO data collection server administrator for the correct port number 27 Networking Modbus TC
46. e to RPM free speed allows the operator or system to engage the socket onto the fastener in a more controlled fashion TARGET level which when achieved causes the power to the drive motor to be cut off TORQUE CONTROL Control strategy in which torque is the only control parameter TORQUE CONTROL ANGLE MONITOR Control strategy in which torque is the control parameter but rotational angle is monitored A valuable strategy for controlling torque while also checking for cross threaded or stripped fasteners 11 Using the Optional Keypad Display Module KDM The Optional KDM allows for quick access to the IEC Control programming features Not all features are accessible by use of the KDM For access to higher level features i e Batch Programming Button Options Linked PSet please use a PC connected to the controller and the ToolWare software interface program Turning the KDM On After turning on the iEC Controller described in Initial Set up Pg 6 press the POWER button on the KDM The following text will be shown on the KDM Display Screen Turning the KDM Off 1 Turning off the iEC Controller detailed in Initial Set up Pg 6 2 Pressing the POWER button on the KDM for 2 seconds Note The KDM does not support Psets above 8 Linked Psets or Batch Control These features are available via Toolware 3 0 or greater Main Menu 1 Parameter Setup Starting from the Main Menu a variety of f
47. ease MFB e Press and Hold Option 1 Hold trigger down for x seconds to latch throttle e No Latch Option Default Serial Output Format This function allows the user to select the format of the information in the ASCII character string packet that is sent out of the controller via the RS232 Port a Standard Output Format HHHHH LLLLL TTTTT P HHHHH LLLLL AAAAA CR CR O Overall Pass Fail P Tq Pass Fail HHHHH Tq High Limit LLLLL Tq Low Limit TTTTT Tq Result P Angle Pass Fail HHHHH Angle High Limit LLLLL Angle Low Limit AAAAA Angle Result CR CR b Profibus Output Format 1 P HHHHH LLLLL TTTTT P HHHHH LLLLL AAAAA 7o CAN Msg Start 1 PSet 1 9 for PSets 1 9 W for PSets 10 32 O Overall Pass Fail P Tq Pass Fail HHHHH Tq High Limit LLLLL TqLow Limit TTTTT Tq Result P Angle Pass Fail 29 Angle High Limit LLLLL Angle Low Limit AAAAA Angle Result NAC Msg End CR LF c Standard Output with CR LF Format O P HHHHH LLLLL TTTTT P HHHHH LLLLL AAAAA 1 CR LF O Overall Pass Fail P Tq Pass Fail HHHHH Tq High Limit LLLLL Tq Low Limit TTTTT Tq Result P Angle Pass Fail HHHHH Angle High Limit LLLLL Angle Low Limit AAAAA Angle Result 1 PSet 1 9 for PSets 1 9 A W for PSets 10 32 CR LF d UEC Serial Format 4 P 1 BB AAAA 0000 0000 J Notice that there is a decim
48. ed HOW SHOULD ADJUST THE SETTINGS FOR SOFT JOINTS A softer joint requires more tightening time You can afford to increase the speed during the rundown and still maintain acceptable repeatability Increase the DWNSHIFT downshift torque setting a little at a time to decrease cycle time while still meeting the torque limit requirements Q THE TOOL DOESN T OPERATE WHEN I PRESS THE LEVER One common cause of this is choosing the improper tool for the parameter set if the target torque value is above the tool s maximum rating then the tool will not run and FLT EXT1 4096 wil be displayed on the Display Panel Another common reason for this problem is that the control ring on the tool is in a position that is programmed as NEUTRAL the MFB button has been programmed for a non running scenario or the tool is running off Refer to the ToolWare Users Guide to correct this situation Q HOW DO I CHANGE THE UNITS OF MEASURE The units of measure for torque is a universal setting for all parameter sets To change the units go to the Admin menu on the KDM and choose Pset Defaults Keep in mind that the con troller does not convert values for you If you have a parameter setting of 10 Nm and you change the units to ft lbs the new setting is 10 ft lbs Changing the units of measure using Toolware allow for calculation of values Refer to the Toolware users guide for more details Lastly being a universal setting all parameter sets
49. ed Range Floor e The center points of each bin are set according to the following equation center For reference the Parameter Set values for Torque Hi Torque Low and Torque Target are taken from the first rundown in the collection and plotted as horizontal lines Histogram adjustment The width center point and number of bins can be adjusted by selecting different values for Range Ceiling Range Floor and the Number of Bins e Number of Bins Selection The histogram initially uses the number of rundowns in the collection for the number of bins If there are more than 200 rundowns then the number of bins is set to 200 The number of bins can be adjusted from 2 to the number of rundowns 1 e Range Ceiling Adjustment This value is initially set to the maximum torque sample rounded up to the next higher integer This can be adjusted in increments of 0 1 e Range Floor Adjustment This value is initially set to the minimum torque sample rounded down to the next lower integer This can be adjusted in increments of 0 1 Bin width and center points will be updated on a change to these values 44 Final Torque Sample Graph The Final Torque Sample graph shows the final torque of each rundown in the collection For reference the Parameter Set values for Torque Hi Torque Low and Torque Target are taken from the first rundown in the collection and plotted as vertical lines 2 11 AcraVision AcraVision displays
50. ed in the memory of the Tool and they can be viewed in this screen The Next Service cycle or Next Service date in this screen will turn red if they exceed the value the service is due 37 ToolWare iEC Series Eile Help Tool Service And Calibration Log Receive From Tool Send To Tool Tool Info Tool Model Number 2010 Tool ID Parameter Rev 255 Cycle Count 5019 Service Log Calibration Log Month Day Month Year 4 Year Last Service Date 7 2008 Use Today s Date LastCalDate 4 2 2008 Use Today s Date Last Cal Cycles Use Current Count Next Service Date 11 8 2008 Next Service Cycles 5017 Service Interval Months Cal Interval Months Service Interval Cycles X 1000 x Cal Interval Cycles X 1000 2 8 Rundowns Data for rundowns in all or selected Parameter Sets can be displayed in a tabular format This information can then be saved as a Ms csv File e You can print the rundown results by using File gt Print in the menu e Rundowns must be saved to file before the statistics function can be used to evaluate the data e Controller memory can be cleared by clicking the Clear iEC Rundown Memory button 2 8 1 Download Data If rundown data is to be analyzed with the Statistics function select All Data If no statistical analysis is to be applied select Results Only This will significantly decrease the time taken to download
51. es such a s pipes radiators ranges and refrigerators There is an increased risk of electric shock if your body is earthed or grounded Do not expose power tools to rain or wet conditions Water entering a power tool will increase the risk of electric shock Do not abuse the cord Never use the cord for carrying pulling or unplugging the power tool Keep cord away from heat oil sharp edges or moving parts Damaged or entangled cords increase the risk of electric shock When operating a power tool outdoors use an extension cord suitable for outdoor use Use of a cord suitable for outdoor use reduces the risk of electric shock WIRING SAFETY Power Cord Connector DANGER Ground the system There may an electric shock or fire T B risk L3 DANGER Turn off the system before wiring Ground There may be an electric shock or fire risk 120 240 VAC 10 50 60 Hz 16 Amps NOTE Verify that the rated voltage of the system matches with the connected AC power There may be risk of electric shock fire risk or damage to the tool and controller PERSONAL SAFETY a b c 9 9 9 Stay alert watch what you are doing and use common sense when operating a power tool Do not use a power tool while you are tired or under the influence of drugs alcohol or medication A moment of inattention while operating power tools may result in serious personal injury Use safety equipment Always wear eye protection Safety e
52. ess amp Verify that the correct parameter set is active by observing the PSET Indicator on the Main Display Panel If the desired parameter set is not active press CHANGE PSET to cycle through the available parameter sets until the appropriate set is displayed The tool is now ready to be run to the appropriate target torque value When exiting from Quick Start mode all torque values are cleared from the KDM Upon re entering Quick Start mode target torque values for all parameters will be set to the value determined by applying the default percentage to the tool that is connected to the controller Configuring a Complete Parameter Set For a detailed explanation of each of the programmable functions within a parameter set see the list of key terms in Parameter Set Terms on page 11 From the MAIN MENU press 1 for SETUP PSET Press 2 for CONFIGURE The following text will be displayed on the KDM display screen Using the Optional Keypad Display Module Depending on the number of Parameter Sets that have previously been programmed into the iEC Controller the user will have the option of choosing from 1 to 8 parameter sets to edit If the user chooses to configure a new parameter the next set will be assigned the next available PSet value up to 8 Press the button on the KDM corresponding to the PSET that will be edited or configured The following text will be displayed on the KDM display screen If e
53. etailed explanation of the software features and functions Chapter 3 Addendum provides reference information needed for troubleshooting and general knowledge 1 2 2 ToolWare Overview ToolWare is a software program designed for configuring AcraDyne electric tools and controllers directly from PC for threaded assembly applications The ToolWare version in use must be compatible with the firmware of the Controller which consists of DSP firmware and CNC Communication Network Card firmware ToolWare compatibility with Torque Tool Controller Firmware Compatible Firmware Release DSP CNC card ToolWare Version Note If you wish to update your controller software please contact your AIMCO sales representative 1 3 ToolWare Installation 1 3 1 PC Requirements ToolWare requires a PC with 1GB or higher RAM and Windows XP or later version OS 1 3 2 Installing ToolWare To install ToolWare e Insert the installation CD and installation will start automatically You can also manually start it by double clicking on Setup exe e Follow instructions on screen to complete installation e User should have Administrative Privileges to install ToolWare It is recommended to have your ToolWare CD files or Download files stored on your Hard Drive 1 4 Introduction to ToolWare User Interface When ToolWare is initially opened the selection box shown in Figure 1 4 1 will appear if n
54. f the tool in revolutions per minute RPM CAL The scaled value that correlates the voltage signal of the transducer to a torque value To access the ADMIN SECURITY function From the MAIN MENU press 3 for ADMIN Press 3 for TOOL INFO Reset Factory Defaults The RESET DEFAULTS menu allows the user to quickly reset the iEC Controller setting to the original factory default values The values that can be reset are 1 TOOL CAL VALUE 2 LOGIC I O 3 PARAMETER SETS To access the RESET DEFAULTS MENU From the MAIN MENU press 3 for ADMIN Press 4 for RESET DEFAULTS this choice can also be viewed by scrolling to the next text page to view the additional ADMIN MENU options The following text will be displayed on the KDM display screen The user can then select the values to reset by pressing the corresponding number on the keypad 19 Using the Optional Keypad Display Module The user will be prompted to confirm the desire to reset values with the following text To select Y and confirm the desire to reset the values press YES To cancel the reset process press 3 NO Error Codes By default the iEC Controller only displays Error Codes in the Primary and Secondary Display Fields of the Main Display Panel Figures 1 amp 4 These errors will display automatically when recorded Error codes are listed in Appendix A in this users guide For additional information on Error Codes contact AcraDyne Technical Su
55. fferent sets of parameters Each set can be used individually or sets can be arranged into batch sequence If the box is unchecked and the parameters are sent to the controller it deletes the parameter set Copy button allows the user to copy one set of parameters into another The user must specify the destination parameter set number Delete removes parameter from overall set Receive downloads parameters from the iEC Controller to PC Downloaded parameters are displayed but not saved in the PC Send uploads the current parameters from ToolWare to the controller The controller will automatically switch to Parameter Set 1 after all parameter sets have been loaded New allows the user to create a new of parameters regardless of what set is selected as currently active in the Controller or in the ToolWare Open opens a saved Parameter file stored in the computer and displays it in the ToolWare Screen Parameter set must be SENT to the controller to be used Save saves the parameter sets displayed on the ToolWare screen as a file to a designated location on the computer Reset to Factory Defaults resets the controller s parameters to the factory settings e f Reset To Factory Defaults is selected while tool is connected to controller three parameter sets will be configured at 30 40 and 60 of the tool s maximum rated torque e f Reset To Factory Defaults is selected while tool is disconnected from controller
56. for connection with PC e Launch ToolWare program e Click on lt File Connection TCP IP gt to open lt TCP IP Connection Setup gt window e Specify IP address of controller 10 10 30 150 by default e Click on lt Connect gt button to establish connection e Verify communication by reading DSP firmware version Select lt DSP View Revision gt Verify the DSP firmware version returned successfully Successful Connection A successful Ethernet connection will be indicated by the following text on the main screen of the ToolWare program ToolWare iEC Series Eel File Controller Tool Rundowns Statistics Acravision System Main Functions Fault Codes Help Parameter Sets CurveWare Monitor Torque Units NM iEC Connected E Net 12 2 2 Setting Parameters In ToolWare select lt Main Functions Parameter Sets gt from the top menu or select lt Parameter Sets gt directly from the lower menu to open lt Parameter Sets View Edit gt window shown in the Figure 2 2 ToolWare can send and receive up to 32 Parameter sets to the controller Help Torque Units NM Parameter 56655 25 26 27 a Select Select Select Current Select Select Select Select Receive Send Strategy New Direction s es Tq High Limit Tq Target Tq Low Limit Save 21 5
57. g ToolWare Output 8 Batch Done DB25 pin 17 The relay closes after completing the batch count The output is programmable for latched or timed opera tion using ToolWare The batch count is also set using ToolWare Output 1 4 Common DB25 pin 5 Connects to the common pins of output relays 1 4 Output 5 8 Common DB25 pin 18 Connects to the common pins of output relays 5 8 Analog In 1 DB25 pin 19 Analog input 1 for future use 39 APPENDIX C I O Diagram amp Definitions Analog In 2 DB25 pin 20 Analog input 2 for future use Input 1 Run Forward DB25 pin 6 Runs tool forward Buttons from I O must be selected using ToolWare Input 2 Run Reverse DB25 pin 7 Runs tool reverse Buttons from I O must be selected using ToolWare Input 3 Disable Tool DB25 pin 8 Prevents the tool from running Input 4 Pset Bit 1 DB25 pin 9 Binary bit one for selecting parameter sets See chart below Input 5 Pset Bit 2 DB25 pin 10 Binary bit two for selecting parameter sets See chart below Input 6 Pset Bit 3 DB25 pin 11 Binary bit three for selecting parameter sets See chart below Input 7 Reset Batch DB25 pin 12 Sets the batch count to zero Input 8 Decrement Batch DB25 pin 13 Decreases the batch count by one GND DB25 pins 21 and 22 OVDC 24VDC DB25 pins 23 25 24VDC Parameter selection chart Pset Pset Pset Pset Pset Pset Pset 4 5 6 7 8 40 APPENDIX D Light Assignment for Light To
58. g quick programming will be 27 0 Nm TQ The default percentage used for high and low torque limit The value entered is a percentage of target torque TQTHOLD The default torque threshold The value entered is a percentage of target torque TQDSHIFT The default setting for torque downshift point The value entered is a percentage of target torque The default setting for cycle complete torque The value entered is a percentage of target torque RPMFREE The default setting for RPM free speed The value entered is a percentage of maximum output speed in revolutions per minute RPM 3000 series AcraDyne tools operating at 120V will run at 1 2 of the programmed speed RPMDOWN The default setting for spindle speed after crossing the downshift torque level The value entered is a percentage of maximum output spindle speed in revolutions per minute RPM UNITS The default engineering units for operation The KDM is only capable of using one engineering unit for all parameter sets Changing the units in this section will affect all parameters sets 17 a Using the Optional Keypad Display Module KDM Security The security function allows the user to set up a password in order to prevent unauthorized persons from altering the programming of the iEC controller Once the password function is activated the user will be prompted to enter the correct password whenever attempting to navigate past the Main Menu
59. he example below barcode of Abc123 selects PSET 1 abc567 selects PSET 2 def selects PSET 4 ABc selects PSET 5 and does nothing Pse cis VIN Match Machine ID 1 2 2 abc TMO2 3 DEF 4 4 def 4 5 6 7 33 APPENDIX Error Codes amp Descriptions Error Code Fault AUT1 1 32 64 128 256 512 2048 4096 EXT2 AN gt TID Timeout Tool GND Power On Throttle Button Timeout Button State Undefined Voltage Tool Update Req d Illegal Tool Free Run Timeout Load Run Timeout Hall Error Tool Offset Tool Level Locked Rotor Drive Fault PSet Value TID Param Value TID Param Timeout Target Value Fault TID EE Write Drive Comm Vbus Drive Update Req Description Tool ID board communication timeout Ground circuit problem between controller and tool RUN command on during power up Button run fwd rev communication timeout button state example fwd and rev Tool voltage parameter undefined Tool parameter file is not compatible with controller version Tool type is not compatible with controller Tool has run below threshold level with no load for 5 seconds Tool has run above threshold level for 15 seconds Motor communication signal error Tool cannot reach target torque due to transducer error Tool transducer output beyond electrical limits Motor has stalled for 100 millisec
60. isable Tool Input PSET Bit 1 21 GND Input PSET Bit 2 22 GND Input PSET Bit 3 23 24VDC Input Reset Batch 24 24VDC Input Decrement Batch 25 24VDC 37 APPENDIX C I O Diagram amp Definitions LOGIC CONNECTIONS NOTE Turn off the system before connecting to the LOGIC I O port There may be risk of damaging the controller 24Vdc Supply The internal 24Vdc power can supply up to 2 amps Inputs The inputs are a sinking configuration with the common connected to the ground pins 24Vdc is logic ON and OVdc is logic OFF LOGIC I O INPUT CONNECTION EXAMPLE iEC Controller Circuit User Wiring 24 Internal 24 Vdc P Suppl 6 Remote Run Switch Run Forward Input GND LOGIC I O CONNECTIONS Outputs The outputs are normally open relay contacts The relays are rated for 24Vdc 1 amp Note If the outputs are driving an inductive load such as a solenoid or large relay it is recommended to add a diode in parallel with the load to prevent voltage surges LOGIC OUTPUT CONNECTION EXAMPLE iEC Controller Circuit User Wiring p 8 FT 24 Vdc 24 Vdc 1 4 Common 5 4 2 Accept Output 2 Reject Output 3 In Cycle Output Remote Light Relay PLC input or Other Torque High Output GND 21 221 For Inductive loads Add a diode in parallel with load 38 APPENDIX C I O Diagram amp Definitions Definitions O
61. k communication configuration This version of ToolWare is designed to be fully compatible with all iEC series AcraDyne Tool Controllers and the iControl AcraDyne Tool Systems In addition this software compliments and enhances features and benefits of AcraDyne 1000 2000 3000 and 8000 HT series tools that are connected to and used with AcraDyne controllers While past versions of AcraDyne s ToolWare software have been completely backwards compatible version 2 1 0 0 marks the first version that is no longer compatible with the discontinued Evolution series controllers Should you require software to run the older Evolution or iControl controllers please visit www aimco global com and look to the Downloads tab There you will find older versions of ToolWare that will function with the Evolution or iControl controllers and are downloadable free of charge Contents COMEMOS e 1 1 Getting Started with 3 11 Terminology and Abbreviations iecore eie aie ecco detects a 3 1 2 _Jntroduction IO 3 12 COC US IVES dos seta Bhan ofer te in qa 3 1 2 2 ToolWare Overview caeco teen 3 1 3 ToolWare InstallaliOm a es ead 4 EIT bas MR dea dero 4 1 3 2 a 4 1 4 Introduction to ToolWare User Interface 5 141 ToolWare Menu 0
62. l Multiplier 0 00 Current Torque Cal Torque Calibration Routine Current Cal Value 128 Test Started Click to Cancel Factory Cal Value 128 Final Torque 10 6 LS SAEI LISTS Enter External Transducer Torque Below Then press SEND to finish tool calibration Measured Torque 106 Send To Tool Figure 2 7 3 Tool calibration screen 36 Buttons and LED s Calibrate Buttons 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 Trigger Ccw Center and Cw positions and send the values to the Tool LED States Turns the tool lights on off or flashes Used for testing of the Tool ToolWare iEC Series File Help Torque Units NM iEC Connected USB Tool Buttons and Leds Button States Tool Info Tool Model Number AES 12020 Trigger Off Tool Id 28025 Counter Clockwise Off Button Cal Trigger Cal Value 699 693 Ccw Cal Value 395 392 Clockwise On Center Cal Value 434 430 Cw Cal Value 466 462 Calibrate Buttons Release Trigger Then Press Run Test Button Center LED Check Red Led Off Flash Yellow Led Off Flash Blue Led Flash Green Led Flash Figure 2 7 4 LED programming and button calibration Service and Calibration Log The Service Parameters are stor
63. ly in specific situations Please contact AcraDyne Technical Support or your AIMCO representative for information on using and adjusting ADAPTIVE CONTROL 21 Networking The controller has several networking options available including Ethernet and hardwired field bus All parameters pertaining to networking are configured in the web interface via its Ethernet Ethernet Each Ethernet connection can be configured to communicate with most popular plant equipment includ ing data collection servers laptop software and PLCs Ethernet ports by default are set to an IP address of 10 10 30 150 and need to be changed before being put into service To gain initial access to the controller e Configure a computer s Ethernet port to an IP address of 10 10 30 xxx Do not set it to 10 10 30 150 that address is assigned to the controller 10 10 30 99 works in most cases e Connect an Ethernet crossover cable from the computer to the controller e Launch the computers web browser Type the controller IP address 10 10 30 150 into its ad dress bar Navigate to the communications page Set the desired IP Address IP Mask and Gateway Cycle power on the controller and connect it to the network Web Interface The controller s web interface is available from any computer on that has access on the local network To access the web interface launch a browser and type the controller IP address into its address bar From the interface you will ha
64. mber of cycles run by tool Tool Motor Temp View motor temp from tool e Edit Tool Setup Set up tool parameters Torque Calibrate the tool to a master transducer Calibrate Suttons anc LERS Program and test buttons and LED s rege anc va Drauon Get alerts for tool service and calibration Rundowns Display rundown data in a tabular format Log Info Usage View tool and controller usage information as Performs statistical analysis of a previously saved Statistics rundown data file AcraVision Displays real time rundown information in full screen view Serial Test Used for testing of serial data string information System Fault Codes oe a list of fault codes for the controller and Parameter Sets Opens the parameter set programming window Main CurveWare Displays rundown graphs for analysis Functions er Performs statistical analysis of a previously saved Statistics rundown data file Monitor I O Displays the status of I O signals Fault Codes a a list of fault codes of the controller and Hel About ToolWare Displays the latest version of the ToolWare ToolWare Help Opens a PDF Help file 1 4 2 Lower Menu Bar Lower Menu Bar is a shortcut to the frequently used Upper Menu items located under lt Main Functions gt submenu These frequently used functions include e Parameter Sets e CurveWare e Monitor I O 1 4 3 Status Bar Status Bar is combined with the Lower Menu Bar Information displayed on the status bar is listed in the Table 1
65. mple fwd and rew buttons out of calibration 512 Undefined Voltage tool or controller voltage parameter is undefined corrupt communication message from drive corrupt tool id memory location 2048 Tool Update Req _ tool parameter file is not compatible with controller corrupt tool id memory location outdated tool id parameters 4096 Too tooltype is not compatible with controller controller does not recognize tool type Tool type not compatable with low speed control ooo 1 Free Run Timeout tool has run no load too long tool has run w o crossing threshold for 5 seconds has after crossing threshold for 15 seconds Error motor commutation signal error faulty tool cable faulty tool motor obsolete tool cable used probably with extension P Te Rr rst commutation signet em Jes significantly out of calibration tool exposed to magnetic parts faulty transducer Hed exposed to magnetic parts faulty transducer faulty tool cable poor parameter settings for the application motor drive shut down or not responding tool stall detected by drive faulty controller components 1 Pset Vale illegal parameter set value communication problem B TID Param Value illegal tool parameter value tool id memory location tool id communication problem 32 TID Param Timeout communication timeout when reading tool paramete
66. ng White Flash to 1 cause the light stack to flash the white light Setting it to 0 put the light stack back into its normal operation Tool pu e function Sequence Number NEHMEN character Sequence Number Serial Number 20 character Serial Number Ethernet IP The controller will accept a connection from an Ethernet IP master The controller has two connection assemblies One for the controllers output image Assembly Instance 100 The default size of this is 34 bytes If fastening results are not included then the size is 2 bytes And one for the controller s input image Assembly Instance 112 with a size of 32 bytes Logic I O The controller has two status bytes of outputs Assembly instance 100 Controller Outputs Bit a 7 Enable Bypass Status Status E Complete NOK OK 30 Networking Optionally the controller can include the fastening results in the output image Including the fastening results increases the output size to thirty four bytes of data Controller Outputs Tool Tool Ready Enable Status Status NOK OK plete Final Torque Real Torque Low Limit Real Torque Target Real Torque High Limit Real Final Angle Real Angle Low Limit Real Angle Target Real Angle High Limit Real Each value will be sent as a real IEEE 754 float and can be configured as little or big endian to match the receiving equipment NEIG Func
67. o try the tool on another system TID Parameter Timeout The tool did not respond to a requested parameter for a period of time Try cycling power to the system Also try the tool on another system Target Value Fault The target torque is set higher than the capacity of the tool No Direction Hall The tool was told to start running either from the throttle or through logic I O but it wasn t told what direction to go Use ToolWare to monitor the buttons Make sure the wiring to the I O is correct if running the tool remotely Xdcr Level The tool transducer output voltage has exceeded the maximum minimum allowable level 48 Notes AIMCO Corporate Headquarters 10000 SE Pine Street Portland OR 97216 800 852 1368 FAX 800 582 9015 www aimco global com Ave Crist bal Colon 14529 Chihuahua Chihuahua 31125 Mexico 011 52 614 380 1010 FAX 011 52 614 380 1019 LIT MAN921 Rev 10 2012 Printed in USA 2012 AIMCO
68. ocket trays audible signals and PLC modules The part number is 23490 Contact your AIMCO representative for this item This screen allows the user to activate and display the operation of the input and output signals to the controller Off Delays of outputs in this screen and send it to the controller or receive the same from the controller For testing and setting purposes the physical outputs and logical inputs can be forced ON OFF temporally This screen also shows the state of the physical I O We can temporally change the control source between Tool buttons and Logic I O port Selection of PSets through IO is limited to PSets 1 8 Selection of entire 32 PSets library requires network connectivity ToolWare iEC Series Monitor 1 0 iEC Connected E Net Outputs Function State Input Forme Output Enable Enable ows o o oc o D ns o o U U HEN oc 3 Connector Physical Input and Output States Out Out2 003 4 4 int 2 4 5 n h7 8 e 3 gt s uttons PD 5 amp Out Out Dgd 2v 2 45 3 Figure 2 4 Monitor screen Off Delay specifies how long the output signal will be ON before turning OFF Each of the 8 in
69. of the Parameter Set that is to be edited The following text will be displayed on the KDM display screen To change the target torque value in 1 unit increments press A N or To change the target torque value in 1 0 unit increments press A or 7 After the target torque is entered correctly press Verify that the correct parameter set is active by observing the PSET Indicator on the Main Display Panel If the desired parameter set is not active press CHANGE PSET to cycle through the available parameter sets until the appropriate set is displayed The tool is now ready to be run to the appropriate target torque value Using the Optional Keypad Display Module KDM Configuring New Quick Start Parameter Sets Depending on the number of Parameter Sets that have previously been programmed into the iEC Controller the new parameter set will automatically be assigned a value from 2 through 8 Press the number on the KDM that corresponds to the number for the next parameter set to be configured For example if the following text were to be displayed in the Quick Start screen the user would press 4 on the keypad to configure a new Quick Start Pset The following text will be displayed on the KDM display screen To change the target torque value in 0 1 unit increments press 2N or 8 4 To change the target torque value in 1 0 unit increments press or E 387 After the target torque is entered correctly pr
70. onds Motor drive shut down or not responding Illegal parameter set value Tool ID board communication error Tool ID board communication error Torque target out of range of tool capabilities Communication timeout while writing to tool memory Communication timeout reading writing to motor drive Measured controller voltage is not within required limits Drive firmware not compatible with low speed control NOTE Multiple Error Codes will be displayed as the sum of each error code number indicated in the table above for example AUT1 129 represents AUT1 128 and AUT1 1 which would be a tool ID board timeout and a button timeout 34 Appendix B KDM Menu Structures Main Menu Structure ACRADYNE KDM 2007 FIRMWARE REV X X iEC CONNECTED 1 SETUP PSET 2 CALIBRATION Parameter Set up Menu ACRADYNE KDM 2007 FIRMWARE REV X X iEC CONNECTED MAIN MENU SETUP PSET QUICK START CONFIGURE CONFIG NEXT EDIT PSET EDIT PSET Torque Torque Units xx xx Units xx xx TQCON ANGCON TQ Target HI Limit LO Limit TQ CONTROL TQCONT ANGMON TQMON ANGCONT TQ Target TQ Target TQ Target HI Limit HI Limit HI Limit LO Limit LO Limit LO Limit l l l Thold Dwn Shift Cyc Comp Auto Set Thold Thold Thold Dwn Shift Dwn Shift Dwn Shift Cyc Comp Cyc Comp Cyc Comp Auto Set Auto Set Auto Set RPM Free RPM Free RPM Free RPM Free RPM Down R
71. one of the levers and pressing it again is required to return the socket to home Both levers must be pressed and held to return to home e If either lever is released before the homing is complete the tool will stop Homing will continue when both levers are again pressed Once the homing is complete releasing both levers and pressing them again within 1 second of each other is required to start the next rundown cycle e Arming Note If the arming timer times out the tool must be re armed before homing can continue Tubenut Homing Option Auto Home on Release of Trigger e If Single Trigger Lever Once the cycle is complete releasing the lever is required to return the socket to home e Homing will continue until complete regardless of lever position Once the homing is complete releasing the lever and pressing it again is required to start the next rundown cycle e If Dual Trigger Levers are Installed Once the cycle is complete releasing either lever is required to return the socket to home e Homing will continue until complete regardless of either lever posi tion Once the homing is complete releasing both levers and pressing them again within 1 second of each other is required to start the next rundown cycle Tubenut Homing Option Do Not Home Once the cycle is complete the tool will not home and the tool is ready for the next cycle Releasing the lever and pressing it again is required to star
72. ork there are five parameters that must be set to store data correctly on the server 1 Server IP Address This is the IP address of the Toolsnet server If the server is on another subnet you will also have to verify the gateway in the Ethernet settings 2 Server Port Number This is the TCP port the server is listening on for a new connection The default for this is 6547 but it should be verified with the local Toolsnet server administrator 3 Station Id This is used to identify the data in the Toolsnet database Work with your local Tools net server administrator to set this correctly 4 System Number This is used to identify the data in the Toolsnet database Work with your local Toolsnet server administrator to set this correctly 5 Station Number This is used to identify the data in the Toolsnet database Work with your local Toolsnet server administrator to set this correctly PFCS The controller has the ability to communicate over the Chrysler PFCS protocol over Ethernet or one of the serial ports Once the controller is connect to the desired network there are several parameters used to configure it s behavior on the PFCS network 1 Server IP Address This is the IP address of the PFCS server If the server is on another sub net you will also have to verify the gateway in the Ethernet settings This parameter is not used for a serial connection to PFCS 2 Server Port Number This is the TCP port the server is listening on
73. ot connected to the controller Tool are 15 in Offline Mode Figure 1 4 1 Dialog box for selection of controller platform being used The ToolWare interface is similar to the workspace of most MS Windows applications Figure 1 4 2 shows the main screen and structure consisting of two menu bars ToolWare iEC Series Eile Controller Tool Rundowns LogInfo Statistics Acravision System Main Functions Fault Codes Help Parameter Sets Curve Ware Monitor Torque Units NM iEC Connected USB Figure 1 4 2 Main Screen of ToolWare 1 4 1 ToolWare Menu Structure Menu Level Supported Functionality Connection Establish Connection with the Controller Open Open a file Save Save a file Print Prints screen graphic or data file File Login oun to the program to access appropriate menu LANGUAGE Switch Language Locale LogOff Program remains open some menu items not accessible Exit Close the program View Firmware Rev Returns controllers Servo amp firmware version Controller Edit Configuration Parameters Modify controller configuration View Edit Date Time Set the date amp time in the Controller Reset Controller to Defaults Restore factory values of controller parameters Tool Parameters View tool parameters Torque Cal Value View the tool calibration value View RPM s View tool output drive rotations minute Cycle Count View nu
74. ownloads last rundown data from the Controller 18 Save saves data points of all curves in the plot in ASCII file Remove removes the currently selected plot from the graph Receive View Receive View allows the user to choose the display features of the graph Torque downloads and displays torque data points Angle downloads and displays angle data points PSet displays markers indicating parameter set values View Controls Pan reposition the view in the drawing area Pan Zoom change magnification View return to the original dimensions Show Plots displays all the plots Cursor mode restricts cursor locations to curve data points Plot Axis allows user to choose between Torque Angle Vs Time and Torque Vs Angle The axes of the graph will change accordingly Plot Name allows the user to rename the plot By default the plot name is formed by using the date and time at which the plot was created CurveWare allows for 10 sequential curves to be overlaid upon each other for analysis purposes 2 4 Monitoring I O In ToolWare select Main Functions Monitor gt from the top menu or select Monitor directly from the lower menu to open Monitor window shown in the Figure 2 4 The I O function is only available in iEC2 iEC3 and iEC4 models A connector kit is available from AIMCO that allows the user to connect and route wiring to a variety of devices including light towers s
75. pport or your AIMCO representative Filter Frequency The Filter Frequency is non functional for the user 20 Using the Optional Keypad Display Module Adaptive Control ADAPTIVE CONTROL provides the user with a function to allow the iEC Controller to adapt to the joint dynamics of a particular application and to adjust the target torque accordingly in order to provide accurate and repeatable performance ADAPTIVE CONTROL works only in Torque Control or Torque Control Angle Monitor Strategies The user may access the ADAPTIVE CONTROL function by following these steps From the MAIN MENU press 3 for ADMIN Press 7 for ADAPTIVE CONTROL The following text will be displayed on the KDM display screen The currently active choice is noted by an asterisk to the right of the option The Factory Default setting for ADAPTIVE CONTROL is 1 OFF To enable or disable ADAPTIVE CONTROL press the number on the keypad corresponding to the desired choice There are two modes of operation for ADAPTIVE CONTROL Adapt To 10 Rundowns The Control Target Torque is adjusted by the difference between the mean of the first 10 rundowns and the hi lo limit mean Adapt To All Rundowns The Control Target Torque is adjusted by a percentage of the difference between the mean of each consecutive 10 rundowns and the high low limit mean This percentage is programmable through advanced user access ADAPTIVE CONTROL should be used on
76. put fields corresponds to the output field Example If 200 is the value in the first field that the output signal for Accept will be ON for duration of 200 mSec If the value is 0 then the corresponding output will remain ON indefinitely or until the next rundown starts Control Source allows user to choose the source that controls the tool operation Buttons From Tool Normal operating condition tool lever and control ring control tool operation Buttons From I O For testing purposes allows the tool lever and control ring to be over ridden by buttons the Monitor I O screen Force Enable When Buttons From 1 0 is selected this field selects which inputs and outputs can be forced through the Monitor I O screen Function State When Buttons From I O is selected and the operation is selected by checking Force Enable clicking on this field will force the respective operation to take place regardless of tool button positions This field will be red when the operation is off and will turn green when the operation is on Connector Physical States this diagram is a real time display of the I O connector Each position corresponds to the indicated terminal on the 25 pin I O connector on the bottom of the controller 2 5 File Menu In ToolWare select lt File gt from the top menu File Menu enables us to select the Connection type with which we want the ToolWare to connect to the Controller 2 5 1 Connection This en
77. quipment such as dust mask non skid safety shoes hard hat or hearing protection used for appropriate conditions will reduce personal injuries Avoid accidental starting Ensure the switch is in the off position before plugging in Carrying power tools with your finger on the switch or plugging in power tools that have the switch on invites accidents Remove any adjusting key or wrench before turning the power tool on A wrench or a key left attached to a rotating part of the power tool may result in personal injury Do not overreach Keep proper footing and balance at all times This enables better control of the power tool in unexpected situations Dress properly Do no wear loose clothing or jewelry Keep your hair clothing and gloves away from moving parts Loose clothes jewelry or long hair can be caught in moving parts If devices are provided for the connection of dust extraction and collection facilities ensure these are connected and properly used Use of these devices can reduce dust related hazards POWER TOOL USE AND CARE a b Do not force the power tool Use the correct power tool for your application The correct power tool will do the job better and safer at the rate for which it was designed Do not use the power tool if the switch does not turn it on and off Any power tool that cannot be controlled with the switch is dangerous and must be repaired This product is designed to be used in combination with AcraDyne
78. r tool id communication problem _4095 Target Value Fault target out of range of tool parameter set not correct for tool range tool parameter corrupt E ee 1 TID EE Write communication timeout when writing to tool memor tool id communication problem 2 Drive Comm communication timeout reading writing to motor drive motor drive communication problem 4 bus measured controller voltage is not within required limits corrupt message from motor drive to controller controller plugged into illegal voltage 8 Drive Update firmware not compatable with low speed control Low speed speed mode controller parameter selection requires drive firmware update Fault codes that are displayed represent the sum of the fault codes indicated in the table Example Fault code AUT1 129 represents code 128 and code 1 In this example there would be a Tool ID board timeout and a Button timeout Figure Add 3 1 Fault Codes 46 3 2 Trouble Shooting Fault Description TID Timeout No Communication between the tool and controller This fault condition is usually caused by a problem in the tool ID board Try connecting another tool to the controller Tool GND The tool ground loop is broken This fault condition is usually caused by a problem in the controller or tool Try the tool and cable on another controller The fault can be intermittent Power on Throttle The System thinks that the throttle is being activated or the run
79. re with MS csv extension This file type can be generated in the Rundowns page by receiving rundown data then saving the data to a type MS csv file We can open this using the File gt Open option 41 1 19 2009 1 19 2009 1 19 2009 Time 16 19 35 16 25 17 17 12 55 17 22 26 14 17 28 8 45 23 iEC Connected USB 2 AEN 3040 AEN 13300 AEN 3040 AEN 13300 AEN 3040 AES 12020 Dox ToolWare iEC Series Torque Units NM iEC Connected USB File newrandown MS csv Pop The histogram shows the frequency count of the number of times that a specified interval or bin occurs in the collection of final torque samples The range of the histogram is equally divided in to a specified number bins A 8 B For reference the Parameter Set values for Torque Hi Torque Low and Torque Target are taken from the first rundown in the collection and plotted as horizontal lines Final Torque Samples 1 9 79 82 5 Historgram Adjust Number of Bins 0 1 1 1 1 1 1 1 1 0 0 5 1 1 5 2 2 5 3 85 4 90 Range Ceiling 80 Range Floor Bin Width 0 333 AU Figure 2 10 Statistics screen example PSet Selection Parameter Set a Only rundowns with the PSet selected are used in the collection In addition Only Rundowns with settings for Torque High Limit Torque Low Limit and Target that match the first rundown are used in the collection b If
80. s locked until reverse is selected on the tool or from the Logic IO Reverse Input The Default setting is off Batch Hold Reset Batch Control Reset Options for Disable Tool Hold Count amp Output Batch Complete The following are options to re enable the tool after it has been disabled in batch control Option 1 Re enable the tool by toggling the RESET BATCH Logic I O input default e Option 2 Re enable the tool by selecting a new PSET or by toggling the RESET_BATCH input This option gives the operator that ability to manually re enable the tool from the Controller front panel by pressing the CHANGE PSET button Low Speed Control Mode Low Speed Control mode is designed to allow a tool to apply torque energy more consistently to a joint at lower RPM s The feature precisely manages power delivery to the tool motor from the servo insuring the rotation of the fastener is done at a constant velocity 31 even when the desired RPM is extremely slow IEC controllers are able to run this feature assuming the servo in the controller is REVB or higher and SCC code is 1 16 or higher SCC installed code and Servo REV level is indicated each time the controller is powered on This information is visible on the LED display Controllers capable of Low Speed Control mode default to standard control unless selection of Low Speed Control is consciously made Confirmation of Low Speed Control being in effect is shown in red type
81. s the Controller configuration to its factory default state 33 2 7 2 7 1 View Tool Parameters Reads all the tool parameters and displays on the screen Torque Cal Value Shows the current calibration value of the tool as well as the factory calibration RPM s Performing this test will determine the actual RPM of the tool Cycle Count Displays the total number of rundowns on the tool good or bad 2 7 2 Edit Tool Setup Each tool has a special parameter file that defines the tool You can view the parameter file for that tool and how it differs from what is in the tool The tool Information such as Tool Id Tool Model number Tool cycle count and Tool Multiplier value are displayed The User can change the Tube nut Parameters according to their application need and send it to the tool 34 2 ToolWare iEC Series SBE Torque Units NM iEC Connected USB Tool Setup Tool Parameters Tool Info Open Parameter File Loc File Val Tool Tool Id 19905 Tool Model Number AEN 12015 Receive From Tool Tool Cycle Count 7875 Tool Multiplier 0 00 Tube Nut Parameters Obstruction Torque InLb Open Loop InLb Home InLb Cycle Count Enter New Cycle Count 7875 E Send Cycle Count To Multiplier Enter Multiplier Value 0 00 Remove Multiplier Add Multiplier Figure 2 7 2 Tool Configuration and tubenut tool setup Mul
82. sh and the horn will beep to signal the tool is in homing mode Pressing the throttle s will start the homing move After the homing is complete and the throttle s released the tool will return to fastening mode LEDs and horn will return to the previous state disable will be ignored during the retry homing cycle e Arming TubeNut Tool Default Tapping MFB button arms activates the start function but does not start the tool Blue status light illuminates to indicate tool is Armed Arming will reset in 3 seconds if tool start is not initiated Change PSET Tapping MFB button toggles between PSET A and PSET B Status lights flash indicating PSET A is selected or twice if PSET B is selected e Reset Reject Tone Tapping MFB button silences reject tone 23 Tap Disabled Tapping MFB button has no effect on tool Hold MFB Function Options Actions will commence after Hold timer preset time has elapsed Adjustable in Hold Time window Default value is 1 second Home Retry Holding the MFB button puts the tool into homing mode All LEDs will flash and the horn will beep to signal the tool is in homing mode Pressing the throttle s will start the homing move After the homing is complete and the throttle s released the tool will return to fastening mode LEDs and horn will return to the previous state Tool disable will be ignored during the retry homing cycle e Arming TubeNut Tool Default Holding MFB button arms ac
83. t Default Control Source allows user to choose the source that controls the tool operation Buttons from Tool IO Determines the source of the Trigger Forward Reverse and Aux Commands 26 Tube Nut Homing Type There are three options e Home e Home on release and repress of main trigger e Auto Home on release of Main trigger Tube Nut Back off RPM The speed expressed in RPM which a tube nut tool will return to the open position upon release of throttle The default setting for this is 100 RPM Reverse Dwell The amount of time before the output tries to return to home after the throttle is released default 500 ms Home Dwell The amount of time that the output is held at home position default 500 ms WARNING If Latching Throttle is Enabled and Tubenut Homing Option is set to Auto Home on Release of Main Trigger the Tubenut will attempt to home prematurely Gen 4 Tubenut Multi Function Button MFB Tap action triggered if button held less than hold time Hold action triggered if button held to hold time or longer Hold Time Amount of time required to hold the MFB until Hold Action is triggered e Arming Timeout Amount of time after the tool is armed that the tool will automatically disarm Tap MFB Function Options Actions will commence upon release of the MFB button on the tool as programmed Home Retry Tapping the MFB button puts the tool into homing mode All LEDs will fla
84. t angle count at threshold default The angle count is started when the tool crosses threshold torque e Start angle count on throttle The angle count is started when the tool is activated Gen 3 4 Buzzer and Headlight Buzzer ON When enabled the Buzzer serves two purposes o In disassembly mode the buzzer beeps When a rundown is rejected the buzzer also beeps 32 o Ifa rundown is rejected the beeping can be stopped by making a successful rundown or using the MFB option Stop Reject Tone Headlight ON Enables or Disables the Headlight 2 6 3 Angle Offset Calibration Angle Calibration Value The value for this will determine how much to add or subtract to the angle measured and reported by the iEC controller The offset is added at the start of threshold The default value for this is 100 The range is 1 to 200 The units are value 100 degrees of correction Examples A value of 100 No correction This is the default value e A value of 90 10 degrees added to iEC angle measurement e A value of 110 10 degrees subtracted from angle measurement Reset to Factory Calibration The angle calibration value will be set to 100 No correction Angle Offset Calibration Routine Toolware will automaticity calculate and send the angle offset calibration value to the controller 2 6 4 View Edit Date Time Sets the date and time in the Controller 2 6 5 Reset Controller to Defaults This option reset
85. t stack back into its normal operation Pesce Tool Enable function 6 2 11 Sequence Number 10 character Sequence Number 12 34 EM Serial Number 20 character Serial Number 32 Error Proofing Barcode Reader The max length of a barcode is 20 characters if it is longer the leading characters will be lost and the last 20 will be used Since barcode readers send their characters in burst there is no need to program in a length The software just waits for the reader to stop sending Once the barcode is read the results are stored as the VIN Barcode Options When a good barcode is received it can optionally reset the batch and or enable the tool A good bar code is determined by the VIN Pattern Matching option If the barcode matches one of the parameter sets VIN matching patterns it will be considered a good read Reset Batch on Good Barcode scan If enabled controller will reset the batch count on a good barcode scan Enable Tool on Good Barcode scan If enabled controller will enable the tool on a good barcode scan VIN Pattern Matching All new VINs from barcode readers Profibus DeviceNET Ethernet IP or protocols are checked against fora VIN match against each PSET starting from 1 and through 8 If a match is found the PSET is changed In order to qualify as a match the received barcode must be at least as long as the match string The match string can contain don t care characters as a wild card In t
86. t the next rundown cycle Notes Using Logic I O to run a Tubenut Tool e Once the rundown is complete the run signal will need to be toggled in order to start homing Once the homing is complete the run signal will need to be toggled in order to start the next rundown cycle e Lever positions are ignored when using logic 42 APPENDIX FAQ S HOW CAN I IMPROVE THE TOOL S REPEATABILITY Generally speaking slowing the tool down will improve its repeatability Reducing the RPM FREE value will give the tool more time to react as it approaches the target torque Reducing the DOWNSHIFT TQ and or RPM DOWN may also have the same effect Keep in mind that tool s RPM and Downshift points can affect ergonomics and overall productivity also testing and running the tool on an application are the only ways to verify that the parameter set meets all requirements of the manufacturing process Consistency of the joint characteristics must also be considered Q HOW SHOULD ADJUST THE SETTINGS FOR HARD JOINTS Because of how quickly torque rises upon reaching threshold torque the tool should slow down to minimize overshooting the target torque Two speed adjustments may be necessary Main tain a reasonable RPM FREE and RPM DOWN during the rundown Reduce the DWNSHIFT downshift torque setting to give the tool more time to react once hitting the threshold torque A value slightly above the THOLD threshold torque is rec ommend
87. the data from the controller to the PC 38 2 8 2 Select Parameter Set e To view results of all saved rundowns regardless of Parameter Set select zero 0 e To view results of rundowns for a specific Parameter Set select the appropriate Parameter Set number e To select the colums you want to see select custom and choose the columns from the selection menu e You can restrict the number of rundowns you want to see by selecting the Max Rows 0 means all e The Rundowns are ordered by latest first So the Recent Rundown will be the first record to be downloaded You can stop download at any time and analyse the records that are downloaded To begin rundown data download click Start Rundown Receive Note Statistics functionality requires All Data to be selected 39 ToolWare iEC Series SER Rundowns DEX Select Parameter Set 0 for Download Data All Data Needed for Calculating Statistics Custom 10 5 Unit AutoReset Cycle Ext Faults Faults Faults NM 0 Time Torque Ande imus PSet 10 25 2011 11 10 25 10 0 161 Accept 10 25 2011 0 10 25 2011 11 10 11 Accept 10 25 2011 11 10 07 Accept 10 25 2011 11 10 02 Accept 10 25 2011 11 09 57 Accept 10 25 2011 11 09 47 10 25 2011 11 09 42 Accept 10 25 2011 11 09 37 10 25 2011 11 09 32 6 5 E
88. tion Tool Enable The enabled state of the tool Tool Ready On if the tool is ready to run Will be off if tool is disabled or there is a fault on the controller Bit EX Status OK Rundown status on for an accept This bit is timed and will be on for 7 sec ond 1 Status NOK Rundown status on for a reject This bit is timed and will be on for 76 sec ond Byte LINE Batch Complete Indicates the batch is complete Will go off when batch is reset or when the tool enable is turned off State of the bypass input 31 Networking The reading of the results data should be done at the rising edge of the Status OK and Status This will insure the correct results are captured consistently All the results are zeroed after the Status and Status are turned off The controller consumes thirty two bytes of inputs Assembly instance 112 Controller Inputs PLC White Enable Flash Enable Sequence Number 31 Serial Number Byte Bit Name Function 0 7 PSET Set the active parameter set of 1 32 If 0 the active parameter set is left un changed Tool Enable If PLC Enable is 0 this input is ignored If PLC Enable is 1 this bit can be used enable or disable the tool MEN stack back into its normal operation pe eee Setting White Flash to 1 cause the light stack to flash the white light Setting it to 0 put the ligh
89. tiplier Configures the tool to include gearing added to the base model Units Gear Ratio 100 a Example Adding a multiplier with a gear ratio of 5 1 Multiplier setting 5 Obstruction Torque In 1st 90 degrees of rotation in the tightening 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 35 Open Loop After reaching the open position this open loop torque prevents the 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 the reverse direction reaching this torque indicates to the controller the socket is in the open position If the socket does not attempt to return to the open position or returns at an extremely fast rate this value is too low AcraDyne recommends starting at about 12 in Ibs 2 7 3 Calibrate Torque This is used to calibrate the tool Following are the steps that need to be followed to calibrate the Tool Press the Start To Test Button Run the Tool to Final Torque Put the External transducer value in the Measured Torque box Press Send to Tool Button The new Cal value is calculated automatically and assigned to the tool ee O N ToolWare iEC Series Eel File Help Torque Units NM iEC Connected USB Torque Transducer Calibration Tool Info Tool Model Number AES 12020 Tool Id 28025 Too
90. tivates the start function but does not start the tool Blue status light illuminates to indicate tool is Armed Arming will reset in 3 seconds if tool start is not initiated Change PSET Holding MFB button toggles between PSET A and PSET Status lights flash indicating PSET A is selected or twice if PSET B is selected Reset Reject Tone Holding MFB button silences reject tone Hold Disabled Default Holding MFB button has no effect tool Homing Type There are three options No Home e Home on release and repress of main trigger e Auto Home on release of Main trigger Tube Nut Back off RPM The speed expressed in RPM which a tube nut tool will return to the open position upon release of throttle The default setting for this is 100 RPM Reverse Dwell The amount of time before the output tries to return to home after the throttle is released default 500 ms Home Dwell The amount of time that the output is held at home position default 500 ms Note If Latching Throttle is Enabled and Tubenut Homing Option is set to Auto Home on Release of Main Trigger the Tubenut will attempt to home prematurely Latching Throttle Pull trigger and tool finishes cycle automatically A second trigger tap stops tool Tool will unlatch automatically at the end of the rundown Latching Throttle Options e Latch by Using the MFB Option 28 1 Press and hold trigger 2 Press and hold MFB 3 Release trigger 4 Rel
91. ucer Using the Calibrate Torque or Calibrate Angle features in Toolware with a Master Transducer can insure that your AcraDyne tool is operating in specification against the Master Transducer in your facility Refer to the Toolware user s guide for details Q WHAT OTHER METHODS EXIST FOR PROGRAMMING THE iEC CONTROLLER By connecting the controller to a computer through the CAN connection or an existing Ethernet system ToolWare can be used to conduct a wide range of programming diag nostic and analytical procedures For more information on ToolWare refer to the Tool Ware Users Guide section of this manual or contact your AIMCO sales representative 44 RF craDyne A Division of AIMCO ToolWare Operations Manual for PC Software Package to Interact with iEC AcraDyne Tool Control Systems Version 3 IGalMare AIMCO PO Box 16460 Portland OR 97292 0460 800 852 1368 Fax 800 582 9015 www aimco global com Introduction ToolWare Version 3 is the software package designed for communicating with AcraDyne DC Electric Tool Controllers ToolWare provides an easy to use Windows based platform that can be used for Tightening strategy programming Maintenance and calibration alert programming Collection and viewing of rundown data Controller configuration programming Statistical analysis Tool calibration Rundown curve analysis Batch programming monitoring and configuration Networ
92. unctions can be accessed through the KDM Programming calibration controller set up security set up and error analysis can all be achieved through properly using the KDM The following sections will detail the Menu Structure of the KDM and the various functions within each area Setting Up Parameter Sets This section will detail how to set up parameter PSETS sets for assembly by using the KDM There are two methods of programming PSET Quick Start or Configure QUICK START Quick Start Mode only requires the user to select the desired parameter set and target torque All other values are set according to the system defaults further explained in the ADMIN section see Page 17 CONFIGURE Configure Mode allows the operator to set up a new parameter set or edit all programmable operating functions for an existing parameter set 12 Using the Optional Keypad Display Module Accessing Quick Start Parameter Sets From the MAIN MENU press 1 for SETUP PSET Press 1 for QUICK START The following text will be displayed on the KDM display screen Choose from EDIT PSET or CONFIG PSET See the following sections for instructions on editing or configuring Quick Start parameter sets Editing Quick Start Parameter Sets Depending on the number of Parameter Sets that have previously been programmed into the iEC Controller the user will have the option of choosing from 1 to 8 parameter sets to edit Press the number
93. und the target value Tq Downshift the torque value at which the tool changes the speed from Freespeed RPM to Downshift RPM in order to provide better accuracy of a final torque Tq Threshold specifies torque threshold value as a start point for the rundown cycle data acquisition Cycle Complete the torque value that defines the completion of a fastening cycle The cycle is complete if after rising above the Tq Threshold value torque drops below the Cycle Complete value Angle High Limit is used for Accept Reject decision Rundown does not pass if the measured final angle exceeds this limit Angle Target the target angle value Angle Low Limit used for Accept Reject decision Rundown does not pass if the final angle is below this limit Rpm Freespeed specifies initial tool output drive speed The parameter is expressed as a percentage of the tool s maximum rated speed Rpm Downshift specifies the speed of the tool after the Tq Downshift value is reached The value is expressed as a percentage of the tool s maximum rated speed Ergo Mode activates tool power ramping down mode when fastening achieves Target Torque or Target Angle value This feature reduces torque reaction in the hand held tool as final torque or angle is achieved Soft Start activates tool power ramping up from zero to Rom Freespeed value This allows for slower engagement of the fastener into the application Linked PSets creates
94. utput 1 Accept DB25 pin 1 The relay closes after achieving the target torque or target angle The output is programmable for latched or timed operation using ToolWare Output 2 Reject DB25 pin 2 The relay closes if the final torque or angle is outside of the High Low limits The output is programmable for latched or timed operation using ToolWare Output 3 In Cycle DB25 pin 3 The relay is programmable for operating at threshold torque or on throttle pull The relay closes when the torque level passes the threshold torque value when setup for at threshold The relay closes when the throttle is pulled when setup for at throttle Output 4 Torque High DB25 pin 4 The relay closes if the final torque exceeds the torque high level The output is programmable for latched or timed operation using ToolWare Output 5 Torque Low DB25 pin 14 The relay closes if the final torque falls below the torque low level The output is programmable for latched or timed operation using ToolWare Output 6 Angle High DB25 pin 15 The relay closes if the final angle exceeds the angle high level The angle is measured from the torque threshold level The output is programmable for latched or timed operation using ToolWare Output 7 Angle Low DB25 pin 16 The relay closes if the final angle falls below the angle low level The angle is measured from the torque threshold level The output is programmable for latched or timed operation usin
95. ve access to the controller s status internal data files and parameters The pages do not automatically refresh but selecting refresh from the browser will reload the latest infor mation from the controller Data files will be standard ASCII text in CSV comma separated variables format that can be opened in Microsoft Excel and other programs On pages with parameters there will be a submit button to apply any changes All parameters on the page are submitted when the button is hit When submitted each parameter will get range checked against allowable limits If a parameter is outside of its range it will be limited to its minimum or maxi mum value When the page is redrawn the edit fields will contain each parameters final value Security The web interface has an option to add a user password for security A password is never required to view the web pages on the controller It is only required to make a change to a parameter If the con troller password is not set a zero length string the user will not be prompted to enter a password for any changes The controller is shipped from the factory without a password 22 Networking The security feature utilizes the authentication built into the browser When a change to a parameter is made the controller checks the programmed password If a password is required the controller will re quest it from the browser and in turn the browser will prompt the user The browser will request a User n
96. ware of the controller s servo module These messages are normal and will clear as the system finishes initializing INITIAL SETUP If the controller is powered on without a tool connected the following message will be shown on the display AUT FLT 129 This message is normal and will clear once a tool is connected Step 6 To turn the controller off rotate the Power Disconnect Switch to the POWER OFF position represented by the 0 symbol To reboot the controller without turning off the Power Disconnect press and hold the NEXT SET buttons simultaneously for 3 seconds Factory amp Default Parameter Sets Before the user programs the iEC controller for the first time or after resetting the controller to factory default settings one of three different groups of parameters may be present in the controller DEFAULT WITH NO TOOL CONNECTED These parameters will start at 10 Nm and increase up to 80 Nm in increments of 10 Nm DEFAULT WITH TOOL CONNECTED This will create a group of 3 individual parameter sets one each at 30 60 and 80 of the connected tools maximum torque capacity TEST PARAMETER SETS Because every AcraDyne controller is tested before being shipped some parameter sets that were used in this testing may be present in the controller If a parameter set is selected that has a target torque above the maximum capability of the tool the following message will be shown on the display
97. wer and Key Bypass Light Color Judgment Green Accept Red High Torque Red Flashing Low Torque Yellow High Angle Yellow Flashing Low Angle Blue Bypass White Tool Enabled White Flashing Assignable Lights Strobe Assignable APPENDIX E Dual Trigger Lever Functionality for Gen 3 4 tools Tool will not run unless both switches are pressed within 1 second of each other If the 1 second timer times out both switches must be released to reset the timer If either trigger is released the tool stops To restart the tool both switches must be released and pressed within 1 second of each other again Note Logic Run Forward Run Reverse commands bypass the second trig ger functionality Note Exceptions to second trigger function exist for Tube Nut Homing sequence Note The latching throttle feature is prevented in tools with dual triggers APPENDIX F TUBE NUT Homing Sequence e Tubenut Homing Option Home on Release and Repress of Trigger e If Single Trigger Lever Once the rundown is complete releasing the lever and pressing it again is required to return the socket to home The tool will stop if the lever is released during homing and will con tinue when the lever is again pressed Once the homing is complete releasing the lever and pressing it again is required to start the next rundown cycle e If Dual Trigger Levers are Installed e Once the rundown is complete releasing
98. will use the same unit of measure Q SHOULD USE ERGO MODE At higher torque settings using the Ergo Mode may seem more comfortable for some opera tors The Ergo Mode releases the torque over a longer period of time resulting in more gentle torque reaction It s a personal preference some operators prefer the Ergo Mode and some prefer to disable it Ergo is enabled with 2000 series AcraDyne tools and may have a negative effect on cPk calculations 43 APPENDIX FAQ S Q ANGLE MEASUREMENT SEEMS TOO HIGH The controller starts to measure angle of rotation during the rundown when THOLD threshold torque is reached If the threshold torque setting is below the prevailing torque of the joint the tool will start measuring angle before the fastener is seated resulting in a higher angle reading than anticipated Ensure that the threshold torque value is above any anticipated prevailing torque of the joint Q HOW CAN RESET TO ALL THE FACTORY SETTINGS There are three groups of settings that can be reset parameter sets logic inputs outputs and calibration value Within the ADMIN menu of the KDM select RESET DE FAULTS Resetting the parameter sets will erase all existing parameter set values Re setting logic inputs outputs will revert to the factory installed settings Resetting the cali bration value will revert the tool s calibration value to the factory setting burned into the tool s identification board
99. xsuausussunsauususumssussausuausuusussuausauususeusuuuuusunuusunuuunsunusuunus 33 Appendix A Error Codes and Descriptions sssausasussuuussuussussaussussuuyua5uususuns 34 Appendix B Menu Structures of KDM sasssunsusunssunssunsauusuasuususunusuuusuauunusunuus 35 Appendix 6 Diagram amp Definitions 7 37 Appendix D Light Assignment for Light Tower and Key Bypass 41 Appendix Dual Trigger Lever Functionality for Gen 3 4 5 41 Appendix F TUBE NUT Homing Sequence ssssssussunssuusauusssususussaussousasn 42 Appendix G Frequently Asked Questions sasssunsasunsusuauuusunsausussausauusuauusa 43 AppendixH Toolware Users Guide Separate Table of Contents 45 2 Safety Information SAVE THESE INSTRUCTIONS 1 2 3 3 4 WORK AREA a Keep work area clean and well lit Cluttered and dark areas invite accidents b Do not operate power tools in explosive atmospheres such as the presence of flammable liquids gases dust Power tools create sparks which may ignite the dust or fumes c Keep children and bystanders away while operating a power tool Distractions can cause you to lose control ELECTRICAL SAFETY a b 9 Power to plugs must match the outlet Never modify the plug any way Do not use any adapter plugs with earthed grounded power tools Unmodified plugs and matching outlets will reduce risk of electric shock Avoid body contact with earthed or grounded surfac

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