Aimco Brakes AcraDyne iEC iControl DC Tool Controller Users Guide

							  
 
AcraDyne 
iEC DC Tool Controllers 
 
User Guide  
						

							2 
 
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 c ontroller.  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.  Statisti cal analysis, communication and system diagnostic  
features are also built in.  
 
For more detailed programming, data analysis and sy stem monitoring information please refer to the 
AcraDyne ToolWare Operations sect ion at the back of this manual. 
 
For additional service and support, please contac t your AIMCO distributor or contact AIMCO  
at 1-800-852-1368 between the hours of  7:00 AM—4:00 PM Pacific Time. 
 
Table of Contents 
Safety Information ··················\
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··· 3 
Front Panel Diagram  (Figure 1)  ··················\
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Bottom Panel Diagra m (Figure 2)  ··················\
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 4 
Top Panel Diagram (Figure 3)  ··················\
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····· 4 
Main Display Panel Diag ram (Figure 4)  ··················\
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Dimensions ··················\
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Initial Se tup  ··················\
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Main Display Functions 
 Changing Parame ter Sets ··················\
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 8 
  Programming the Display Op tions (Steps 1-3) ··················\
········ 8 
  Display Optional Values for Individual Rundowns (Steps 1-2) ····· 10 
Using the Optional Keypad Display Module (KDM) 
 KDM Diag ram ··················\
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 Parameter Se t Terms ··················\
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  Turning the KDM  On / Off ··················\
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· 12 
  Main Menu: 1) Parameter Setup 
Setting Up Parame ter Sets ··················\
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······ 12 
    Accessing Quick Start Parameter Sets  ··················\
········ 13 
  Editing Quick Start  Parameter Sets ··················\
············ 13 
  Configuring New Quick Start Parameter Sets ················· 14 
  Configuring a Complete Paramete r Set ··················\
·······  
    Entering / Editing Values in th e KDM ··················\
·········· 15 
 Main Menu: 2)  Calibration ··················\
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 16 
  Main Menu: 3) Administration Functions 
  Parameter Set Defaults ··················\
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  Security ··················\
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  Tool Information ··················\
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·· 19 
  Reset Factory Defaults ··················\
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  Error Codes ··················\
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  Filter Frequency  ··················\
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··· 20 
  Adaptive Control ··················\
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·· 21 
Networking ··················\
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Error Proof ing ··················\
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Appendix A  Error Codes and Descriptions  ··················\
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·· 34 
Appendix B  Menu Struct ures of KDM ··················\
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Appendix C  I/O Diagram  & Definitions ··················\
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Appendix D  Frequently  Asked Questions ··················\
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··· 39 
Appendix E      Dual Trigger Leve r Functionality for Gen 3-4 tools ·········· 43 
Appendix F  TUBE NUT  Homing Sequence ··················\
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·· 44 
Appendix G      Toolware Users Guide - Separate Table of Contents ······· 45 
 
Introduction  
						

							3 
 
SAVE THESE INSTRUCTIONS  
 
1) 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 or 
  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. 
 
2) ELECTRICAL SAFETY  
 
a)  
Power to plugs must match the outlet. Never modify the plug in any way. Do not use any adapter plugs  
  with earthed (grounded) power tools.  
Unmodified plugs and matching outlets w ill  reduce risk of electric shock.  
 b)  
Avoid body contact with earthed or grounded surfaces such a s pipes, radiators, ranges and refrigerators.  
  There is an increased risk of electric  shock if your body is earthed or grounded. 
 c)  
Do not expose power tools to rain or wet conditions.  
Water entering a power tool will  increase the risk of electric 
  shock.  
 d)  
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. 
 e)  
When operating a power tool outdoors, use an extension cord suitable for outdoor use.  
Use of a  
  cord suitable for outdoor use redu ces the risk of electric shock. 
 
3) WIRING SAFETY 
    DANGER: Ground the system. There may an electric shock or fire  
  risk. 
 
    DANGER: Turn off the system before wiring. 
     There may be an electric shock or fire risk. 
 
    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.
 
 
3) PERSONAL SAFETY  
 a) 
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. 
 b)  
Use safety equipment. Always wear eye protection.  
Safety equipment such as dust mask, non-skid  
    safety shoes, hard hat, or heari ng protection used for appropriate conditions will reduce personal  injuries. 
 c)  
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 pow er tools that have the switch on invites  accidents. 
 d)  
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. 
 e)  
Do not overreach. Keep proper footing and balance at all times.  
This enables better control of the power tool in 
  unexpected situations.  
 f)  
Dress properly. Do 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.  
 g)  
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 . 
 
4)  POWER TOOL USE AND CARE  
 
a)  
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. 
 b)  
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.  
 C)  This product is designed to be used in combination with Ac
raDyne DC Electric assembly tools for intermittent  
  assembly processes. 
 
 
 
 
Safety Information 
120 /240 VAC +/- 10%  50 / 60 Hz 16 Amps  
						

							4 
 
Front Panel 
Top Panel 
Figure 1 
Figure 3 
1—Main 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 Int
erface 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)— Seri al-data output for communication with peripherals such as bar code 
readers 
iEC 
7 
6 
5 
4 
3 
2 
1 
 1—Tool Connector (26 Pin) —Standard connection point for tool cable 
 2—Serial data conn ection for peripherals 
 3—Ethernet connection port (2nd connection  optional with advanced communication packages) 
 4—Serial data conn ection for peripherals 
1 
2 3 
4  
						

							5 
 
Figure 4 
Main Display Panel 
1—Rundown Feedback Indicators 
  A—ACCEPT— Green LED indicates OK rundown 
  B—TORQUE—Steady red indicates HI, flashing red indicates LO 
  C—ANGLE—Steady yellow indicates HI, flashing yellow indicates LO 
  D—CYCLE—Blue LED indicates tool is in rundown cycle 
 
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 in the Secondary Display  
 
5—CHANGE PSET—Scrolls upwards th
rough programmed Parameter Sets 
 
6—PSET Indicator—displays PSET that is currently operating 
 
7—IR PORT ENABLED—Future function, not currently enabled 
Dimensions 
1 
2 
3 
7 
6 
5 
4 
A B C 
A B C D 
Inches / Millimeters  
						

							6 
 
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-P
in male connector with two opposing locating pins. 
Align the notch of the tool cable wi th the notch of the connector or the  male and female locating-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 us ed with the controller. 
AcraDyne pistol-style tools manufactured prior to Ja nuary 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 on 120V, the maximum speed of the tool is ½ 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 ½ of the speed run on 220V. 
 
Step 5 
 
Turn the controller on by rotating the Power Disconne ct Switch (Figure 1, pg. 4), to the POWER ON  
position, represented by the  
I  symbol. 
 
When an iEC with SCC code 2.0 and higher is power ed 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 B)  — indicates the firmware of the controller’s servo module  
 
These messages are normal  and will clear as the system finishes initializing.
 
!
! 
						

							7 
 
 
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 cl ear 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 
buttons simultaneously for 3 seconds.   
 
 
Factory & Default Parameter Sets
 
 
Before the user programs the iEC controller for the fi rst 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 iEC 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 
 
  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 wi thin the capabilities of the tool. 
 
 
 
! !
INITIAL SETUP 
NEXT  SET
 + ! 
						

							8 
 
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: 
 
 
 
 
 
 
   
 
 
 
 
 
 
 
Note:   SCC Firmware Version 3.00 extends the number of parameter se ts 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 t he 
first Pset of the Linked 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 featur e 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 re cent 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.
  
!
Example:  PSET #2, Torque Control 
Strategy, 25 ft-lb Target Example:  PSET #3, Angle Control  
Strategy, 270 Degree Target 
ALTERNATING 
Example:  PSET #4, Torque Control / Angle Control Strategy, 
25 ft-lb Target, 270 Degree Target 
Main Display Functions  
						

							9 
 
 
Step 2 
 
To scroll through the available disp
lay options, press and release the NEXT  button. Repeated presses 
will cycle the display options as follows 
  
 
DFLT > ANGL > BCNT > TOT > OK > NOK > CP > CPK > JTRT 
 
 
 
 
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 selected, 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 re set 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 re set 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  
						

							10 
 
 
Step 3 
 
When the desired Display Option is selected, press the SET  button (Fig. 4) to lock this option as the  
visible display. Once the SET bu tton is pressed, the display screens will clear. Upon completing a  
rundown cycle, the value for the selected Display Option will be sh own in the Secondary Display Field 
(Fig. 4). 
 
The selected Display Option will be displayed for  all Parameter Sets. 
 
Display Optional Values for Individual Rundowns 
 
By scrolling through the Display Options after a rund own cycle, the value for each option can be quickly 
viewed. 
 
Step 1 
 
Immediately after a rundown cycle, the selected Di splay Option will be shown in the Secondary Display 
Field. To view a different Di splay 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 display ed 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 re cent rundown, simply conduct another rundown or 
press CHANGE PSET to select  a different parameter set. 
 
 
 
 
!
!
Main Display Functions