Aimco Brakes AcraDyne iEC iControl DC Tool Controller Users Guide

							41 
 
 
Q: 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 als
o 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 wa ys 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 I 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-
ommended. 
 
Q: HOW SHOULD I 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 impr oper 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” 
will be displayed on the Main 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 I/O. 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 will use the same unit of measure. 
 
Q: SHOULD I 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 Mode  is only enabled with 2000 series  
AcraDyne tools and may have a negative effect on cPk calculations. 
 
APPENDIX D: FAQ’S  
						

							42 
 
APPENDIX D: FAQ’S 
 
Q: ANGLE MEASUREMEN
T SEEMS TOO HIGH. 
The controller starts to measure angle  of rotation during the rundown when THOLD 
(threshold torque) is reached. If the thre shold torque setting is below the prevailing 
torque of the joint, the tool will start m easuring angle before the fastener is seated,  
resulting in a higher angle r eading than anticipated. Ensure  that the threshold torque 
value is above any anticipated prevailing torque of the joint. 
 
Q: HOW CAN I RESET TO ALL THE FACTORY SETTINGS? 
There are three groups of settings that c an 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 er ase all existing parameter set values. Re-
setting logic inputs/outputs will revert to the factory instal led settings. Resetting the cali-
bration value will revert the tool’s calibration value to t he factory setting burned into the 
tool’s  identification board.  Resetting defaults is easily done usin\
g Toolware as well.  
Refer to the Toolware users guide for details. 
 
Q: WHAT IS ADAPTIVE CONTROL? 
Upon reaching target torque, the controller signa ls the tool to shut off and the tool stops. 
Depending on the speed of the tool and the jo int 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 tor que readings around the target torque value.  
It averages the overshoot torque on 10 consecut ive 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. Fo r example, if the target torque  is 10 Nm, and the average of 10  
readings is 10.2 Nm, using adap tive 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 cent ered 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 t ool’s transducer can be correlated with a 
torque value as determined by a master cali bration transducer.  Using the Calibrate 
Torque or Calibrate Angle features in Toolware  with a Master Transducer can insure that 
your AcraDyne tool is operati ng in specification against the  Master Transducer in your 
facility.  Refer to the Tool ware 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 program\
ming, 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.  
						

							43 
 
APPENDIX E: Dual Trigger Lever Functionality for Gen 3-4 tools 
 
•  Tool will not run unless both switches ar e pressed within 1 second of each other.  
•  If the 1 second timer times out, both switc hes 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 I/O Run Forward and Run Re verse commands bypass the second trig-
ger functionality. 
•  Note: Exceptions to second trigger f unction exist for Tube Nut Homing sequence. 
•  Note: The latching throttle feature is  prevented in tools with dual triggers.  
						

							44 
 
APPENDIX F: TUBE NUT Homing Sequence 
• 
Tubenut Homing Option: Home on Release and Repress of Trigger:   
•  If Single Trigger Lever:
 
•  Once the rundown is complete, releasing the lever and pressing it  again is required to retu rn 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, rel easing the lever and pressing it 
again is required to start the next rundown cycle. 
•  If Dual Trigger Levers are Installed:
 
•  Once the rundown is complete, releasing 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. 
•  If either lever is released before t he homing is complete the tool will 
stop. Homing will continue when both levers are again pressed. 
•  Once the homing is complete, re leasing both levers and pressing 
them again (within 1 second of each other) is required to start the next 
rundown cycle. 
• Arming Note:
 
•  If the arming timer times out the t ool must be re-armed before homing 
can continue 
 
•  Tubenut Homing Option: Auto Home on Release of Trigger:   
•  If Single Trigger Lever
 
•  Once the cycle is complete releasing the lever is required to return the  socket to home. 
•  Homing will continue until comple te, regardless of lever position. 
•  Once the homing is complete, rel easing the lever and pressing it 
again is required to start the next rundown cycle. 
•  If Dual Trigger Levels are Installed
 
•  Once the cycle is complete releasing  either lever is required to return 
the socket to home. 
•  Homing will continue until complete , regardless of either lever posi-
tion. 
•  Once the homing is complete, re leasing 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 start the next 
      rundown cycle. 
 
Notes: Using Logic I/O to run a Tubenut Tool. 
•  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 signa l will need to be toggled in order to start 
the next rundown cycle.  
•  Lever  positions are ignored when using logic IO  
						

							 
 
  
ToolWare 
Operations Manual for PC Software Package to Interact 
with iEC AcraDyne Tool Control Systems  Version 3.0.1.0  
 
 
   
 
   
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
PO Box 16460, Portland OR 97292-0460 • 800-852-1368 • Fax 800-582-9015 
www.aimco-global.com 
						

							Introduction 
ToolWare Version 3.0.1.0 is the software package designed for communicating with AcraDyne DC Electric 
Tool Controllers. 
 
ToolWare provides an easy-to-use, Window s-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 
■  I/O monitoring and configuration                                   ■ Network communication configuration  
 
This version of ToolWare is designed to be fully com patible with all iEC series AcraDyne Tool Controllers 
and the iControl AcraDyne Tool Systems.  In additi on, 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 so ftware have been completely backwards compatible, 
version 2.1.0.0 marks the first version that is no lon ger compatible with the discontinued Evolution series 
controllers.  Should you require software to run the ol der Evolution or iControl controllers, please visit 
www.aimco-global.com and look to t he “Downloads” tab.  There you will find older versions of ToolWare 
that will function with the Evolut ion or iControl controllers and are downloadable free of charge. 
  
						

							 1
Contents 
 
Contents........................................................................\
....................................................... .......... 1
 
1. Getting Started with ToolWare .......................................................................\
....................  3 
1.1 Terminology and Abbreviations  .......................................................................\
............  3 
1.2 Introduction to ToolWare .......................................................................\
.......................  3 
1.2.1 About this document .......................................................................\
.......................  3 
1.2.2 ToolWare Overview .......................................................................\
........................ 3 
1.3 ToolWare Installation .......................................................................\
............................. 4 
1.3.1 PC Requirements .......................................................................\
............................  4 
1.3.2 Installing ToolWare  .......................................................................\
......................... 4 
1.4 Introduction to ToolWare User Interface  ....................................................................  5 
1.4.1 ToolWare Menu Structure .......................................................................\
..............  6 
1.4.2 Lower Menu Bar .......................................................................\
.............................. 7 
1.4.3 Status Bar .......................................................................\
.........................................  7 
1.5 Connecting IEC Controller with PC  .......................................................................\
......... 8 
1.5.1 Connecting to USB port .......................................................................\
............... 10 
1.5.2 Connecting to Ethernet Port  .......................................................................\
........ 10 
1.5.3 Connecting to the network .......................................................................\
...........  10 
2. Working with ToolWare .......................................................................\
..................................  10 
2.1 Connecting PC with the Controller  .......................................................................\
.....  10 
2.1.1 Setting up USB Connection .......................................................................\
.........  10 
2.1.2 Setting up Ethernet Connection  .......................................................................\
..  11 
2.2 Setting Parameters .......................................................................\
...............................  13 
2.2.1 Parameter Entry Fields .......................................................................\
.................  14 
2.2.2 Parameter Sets .......................................................................\
..............................  17 
2.3 CurveWare .......................................................................\
.............................................  18 
2.4 Monitoring I/O .......................................................................\
........................................  19 
2.5 File Menu .......................................................................\
............................................... 20 
2.5.1 Connection  .......................................................................\
..................................... 20 
2.5.2 Open .......................................................................\
................................................  21 
2.5.3 Save .......................................................................\
................................................ 21 
2.5.4 Print .......................................................................\
................................................. 21 
2.5.5 Login  .......................................................................\
................................................  21 
2.5.6 Language  .......................................................................\
........................................  21 
2.5.7 Logoff .......................................................................\
.............................................. 21 
2.5.8 Exit .......................................................................\
...................................................  21 
2.6 Controller ........................................................................\
............................................... 22 
2.6.1 View Firmware Rev  .......................................................................\
.......................  22 
2.6.2 Edit Configuration Parameters  .......................................................................\
....  22 
2.6.3 Angle Offset Calibration .......................................................................\
............... 33 
2.6.4 View/Edit Date Time .......................................................................\
..................... 33 
2.7 Tool .......................................................................\
....................................................... .. 33 
2.7.1 View .......................................................................\
.................................................  33 
2.7.2 Edit .......................................................................\
...................................................  34  
						

							 2
2.7.3
 Calibrate........................................................................\
......................................... 35 
2.8 Rundowns
 .......................................................................\
..............................................  38 
2.9 Log Info .......................................................................\
.................................................. 40 
2.10 Statistics .......................................................................\
............................................. 41 
2.11 AcraVision  .......................................................................\
..........................................  45 
2.12 System .......................................................................\
................................................  45 
2.12.1 Serial Test  .......................................................................\
...................................  46 
3. Addendum  .......................................................................\
....................................................... . 46 
3.1 Fault codes .......................................................................\
............................................ 46 
3.2 Trouble Shooting  .......................................................................\
.................................. 46 
 
 
 
 
 
 
 
  
						

							 3
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 includ ing 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 Tool Ware software. It consists of three 
parts: 
Chapter 1: “Getting Started with Tool Ware” introduces the software and gives 
step-by-step instructions on usin g it to run AcraDyne tools. 
Chapter 2: “Working with ToolWare”  gives detailed explanation of the 
software features and functions. 
Chapter 3: “Addendum” provides  reference information needed for 
troubleshooting and g eneral knowledge. 
1.2.2 ToolWare Overview 
ToolWare is a software program design ed for configuring AcraDyne electric 
tools and controllers directly from PC for threaded assembly applications. 
The ToolWare version in use must be co mpatible with the firmware of the 
Controller which consists of DSP firmware and CNC (Communication 
Network Card) firmware.   
ToolWare compatibility with To rque Tool Controller Firmware 
ToolWare Version Compatible Firmware Release 
DSP CNC card 
3.0.1.0  3.0.5 6.11 
 
Note.  If you wish to update your contro ller software, please contact your 
AIMCO sales representative.   
						

							 4
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: 
   Insert the installation CD and instal lation will start automatically. You can 
also manually start it by  double clicking on “Setup.exe”.  
   Follow instructions on screen to complete installation. 
   User should have Administrative Privileges to install ToolWare.  
 
  It is recommended to have your ToolWa re CD files or Download files stored 
on your Hard Drive.