Aimco Brakes AcraDyne iEC iControl DC Tool Controller Users Guide

							31 
 
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. 
 
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. 
 
 
   
  
Controller Outputs
 
    
Bit 
     
7  6 5 4 3 2 1 0 
Byte   0 
                  Tool 
Ready  Tool 
Enable 
1           Bypass  Batch 
Com-
plete   
Status 
NOK  Status 
OK 
2-5  
Final Torque (Real) 
6-9  
Torque Low Limit (Real) 
10-13  Torque Target (Real) 
14-17  Torque High Limit (Real) 
18-21  Final Angle (Real) 
22-25  Angle Low Limit (Real) 
26-29  Angle Target (Real) 
30-33  Angle High Limit (Real) 
Byte Bit Name  Function 
0  0 
Tool Enable  The enabled state of the tool. 
1  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. 
2-7  Not used    
1  0 
Status OK  Rundown status on for an accept. This bit is timed and will be on for ½ sec-
ond. 
1  Status NOK  Rundown status on for a reject. This bit is timed and will be on for ½ sec-
ond. 
2  Not used    
3  Batch Complete  Indicates the batch is complete.  Will go off when batch is reset or when the 
tool enable is turned off. 
4  Bypass  State of the bypass input. 
5-7  Not used 
   
						

							32 
 
Networking 
The reading of the results data sh
ould be done at the rising edge of  the “Status OK” and “Status NOK”.  
This will insure the correct results are captured cons istently.   All the results are zeroed after the “Status 
OK” and “Status NOK” are turned off. 
 
The controller consumes thirty two by tes of inputs (Assembly instance 112). 
 
 
   
  
Controller Inputs
 
    
Bit 
     
7  6  5 4  3 2  1 0 
Byte   0 
PSET 
1    PLC 
Enable  White 
Flash  Pause           Tool 
Enable 
2-11  Sequence Number 
12-31  Serial Number 
Byte Bit Name  Function 
0 0-7  PSET  Set the active parameter set of 1-32.  If 0 the active parameter set is left un-
changed. 
1  0 
Tool Enable  If PLC Enable is 0 this input is ignored.  If PLC Enable is 1 this bit can be used 
to enable or disable the tool. 
1-3  Not used    
4  Pause  Setting Pause to 1 cause the light stack to strobe.  Setting it to 0 put the light 
stack back into its normal operation. 
5  White Flash  Setting 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. 
6  PLC Enable  Setting PLC Enable to 1 allows the T
ool Enable bit.  Setting it to 0 disables the 
Tool Enable function. 
7  Not used    
2-11 0-7  Sequence Number  10 character Sequence Number. 
12-31 0-7  Serial Number 
20 character Serial Number.  
						

							33 
 
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 st op sending.  Once the barcode is read the results are 
stored as the VIN. 
 
Barcode Options
 
When a good barcode is received it can optionally re set the batch and/or enable the tool.  A good bar-
code is determined by the VIN Pattern Matching opt ion.  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 w ill reset the batch count on a good barcode scan. 
 
  Enable Tool on Good Barcode scan 
  If enabled, controller will enable t he tool on a good barcode scan. 
 
VIN Pattern Matching
 
All new VINs from barcod e readers,  Profibus,  DeviceNET, Ether net/IP or protocols are checked against 
for a  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 rece ived 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 the example below a 
barcode of “Abc123” selects PSET  #1, “abc567” selects PSET #2, “def” selects PSET #4, “ABc” selects 
PSET #5, and “AB” does nothing. 
 
 
  
						

							34 
 
APPENDIX A: Error Codes & Descriptions 
 
Error Code #
 Fault   Description      
 
AUT1
 
1      TID Timeout    Tool ID board communication timeout 
32    Tool GND    Ground circuit problem between controller and tool 
64      Power On Throttle  RUN command on during power up 
128     Button Timeout    Button (run, fwd, rev) communication timeout 
256   Button State  Illegal bu tton state (example fwd and rev) 
512     Undefined Voltage  Tool voltage parameter undefined 
2048    Tool Update Req’d.  Tool parameter file  is not compatible with controller version 
4096    Illegal Tool    Tool type is not compatible with controller 
 
 
CYC1
 
1      Free Run Timeout  Tool has run below threshold level with no load for 5+ seconds 
2      Load Run Timeout  Tool has run above threshold level for 15+ seconds 
4      Hall Error    Motor communication signal error 
8      Tool Offset    Tool cannot reach target torque due to transducer error 
64      Tool Level    Tool transducer output beyond electrical limits 
512   Locked Rotor  Motor ha s stalled for 100+ milliseconds 
1024    Drive Fault    Motor drive shut down or not responding 
 
 
EXT1
 
1      PSet Value    Illegal parameter set value 
8      TID Param Value  Tool ID board communication error 
32      TID Param Timeout  Tool ID board communication error 
4096    Target Value Fault  Torque target  out of range of tool capabilities 
 
 
EXT2
 
1    TID EE Write    Communication timeout while writing to tool memory 
2    Drive Comm    Communication timeout reading / writing to motor drive 
4    Vbus      Measured controller voltage is not within required limits 
8   Drive Update Req
  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 represe nts AUT1: 128 and AUT1: 1, which would be a 
tool ID board timeout and a button timeout  
						

							35 
 
Appendix B: KDM Menu Structures 
Main Menu Structure 
Parameter Set-up Menu  
						

							36 
 
APPENDIX B: KDM Menu Structures 
Administration Menu  
						

							37 
 
APPENDIX C: I/O Diagram & Definitions 
1 2 
10 
9 8 7 6 5 4 3 
25 
19 18 17 16 15 14  13 12 
11  
24 23 22 21 20 
1 
25 
14  13 
Pin #  
Definition 
1    Output—Accept 
2    Output—Reject 
3      Output—In Cycle 
4      Output—Torque High 
5      Output—1-4 Common 
 
6      Input—Run Forward 
7      Input—Run Reverse 
8      Input—Disable Tool 
9       Input—PSET Bit 1 
10      Input—PSET Bit 2 
11       Input—PSET Bit 3 
12     Input—Reset Batch 
13     Input—Decrement  Batch  Pin #  
Definition 
14   Output—Torque Low 
15   Output—Angle High 
16   Output—Angle Low 
17   Output—Batch Complete 
18   Output—5-8 Common 
 
19   Input—Analog 1 
20   Input—Analog 2 
 
21   GND 
22   GND 
23   +24VDC 
24   +24VDC 
25   +24VDC 
 
  
iEC2, iEC3 and iEC4 series controllers have a range of Input / Output (I/O) capab\
ilities.   
By referencing the diagram below , the user can access the controllers I/O 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.  
						

							38 
 
LOGIC I/O 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. 24V dc is logic ON and 0Vdc is logic OFF. 
 
 
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 solenoi d or large relay, it is recommended to add a diode in parallel with the load  
to prevent voltage surges. 
 
 
 
APPENDIX C: I/O Diagram & Definitions  
						

							39 
 
APPENDIX C: I/O Diagram & Definitions 
I/O Definitions 
 
Output 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 t he 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 t he 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 using 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 co mmon 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.  
						

							40 
 
APPENDIX C: I/O Diagram & 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.  0VDC. 
 
+24VDC 
 
DB25 pins 23-25.  +24VDC 
 
 
Parameter selection chart 
 
   
  Pset 
1  Pset 
2  Pset 
3  Pset 
4  Pset 
5  Pset 
6  Pset 
7  Pset 
8 
Bit 1   0  1  0  1  0  1  0  1 
Bit 2   0  0  1  1  0  0  1  1 
Bit 3   0  0  0  0  1  1  1  1