AcraDyne Gen IV User manual

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MAN177 rev_01-10-19
Gen IV iEC Controller Operator Manual

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MAN177 rev_01-10-19
AcraDyne GEN IV iEC CONTROLLER
MANUAL
Important Safeguards
For your protection, please read these instructions completely. Keep this manual for future
reference. Carefully observe and comply with all warnings, cautions and instructions placed
on the equipment or described in this manual.
Contents
1 Safety Information.............................................................................................................................................................................. 5
2 Controller Diagram ............................................................................................................................................................................ 8
2.1 Bottom Panel .................................................................................................................................................................. 8
2.2 Front Console LED ............................................................................................................................................................ 9
3 Initial Set Up....................................................................................................................................................................................... 10
3.1 Connecting to the Controller ...................................................................................................................................... 11
3.2 Quick Set Up (Default PSets from Tool) ................................................................................................................... 16
4 Home Page (Main Menu)............................................................................................................................................................... 16
4.1 Run ...................................................................................................................................................................................17
4.2 PSet................................................................................................................................................................................... 20
4.2.1 Add New PSet ..................................................................................................................................................20
4.2.2 Edit PSet ............................................................................................................................................................22
4.2.3 Advanced Options ..........................................................................................................................................23
4.2.4 Manage PSets ..................................................................................................................................................23
4.2.5 PSet Stages .......................................................................................................................................................24
TC- Torque Control Stage.........................................................................................................................................24
TC_AM TorqueControl Angle Monitor Stage .........................................................................................................25
AC-TM Angle Control Torque Monitor Stage..........................................................................................................26
TC_AC Torque Control Angle Control Stage ..........................................................................................................27
Delay Stage...............................................................................................................................................................28
Ergo Stop Stage ........................................................................................................................................................28
Brake Stop Stage ......................................................................................................................................................28
Unfasten Stage..........................................................................................................................................................29
AC_TA Angle Control Torque Averaging Stage.....................................................................................................30
Sync Stage.................................................................................................................................................................31
Thread Forming Stage ..............................................................................................................................................31
AC_TCOMP Angle Control Torque Compensation Stage.....................................................................................32
Yield Control ..............................................................................................................................................................34
4.2.6 Multistage Rundown Evaluation and Reporting ...........................................................................................35
4.2.7 Multiple Stage Rundown Examples ................................................................................................................37

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MAN177 rev_01-10-19
4.3 Job .......................................................................................................................................................................39
4.3.1 Add New Job ...................................................................................................................................................39
4.3.2 Advanced Options ..........................................................................................................................................40
4.4 Results..................................................................................................................................................................42
4.4.1 Saving Rundown(s) ..........................................................................................................................................43
4.5 Controller......................................................................................................................................................................... 44
4.5.1 Tool Setup .........................................................................................................................................................44
4.5.1.1 Lock On Reject..............................................................................................................................................44
4.5.1.2 Buzzer .............................................................................................................................................................45
4.5.1.3 Headlight .......................................................................................................................................................45
4.5.1.4 Start Input Configuration ..............................................................................................................................45
4.5.1.5 MFB (Multi-Function Button) ......................................................................................................................46
4.5.1.6 Disassembly ...................................................................................................................................................47
4.5.1.7 Tubenut ..........................................................................................................................................................48
4.5.1.8 Past Service and Calibration........................................................................................................................48
4.5.2 I/O......................................................................................................................................................................49
4.5.2.1 Physical I/O ....................................................................................................................................................49
4.5.2.2 Physical IO Monitor .......................................................................................................................................49
4.5.2.3 Anybus/ Modbus TCP/Ethernet IP Inputs...................................................................................................50
4.5.2.4 Anybus/Modbus TCP/Ethernet IP Outputs ..................................................................................................51
4.5.3 Communication Interfaces .............................................................................................................................52
4.5.3.1 Ethernet/Second Ethernet............................................................................................................................52
4.5.3.2 System Port ....................................................................................................................................................52
4.5.3.3 Serial ...............................................................................................................................................................53
4.5.3.4 Anybus ...........................................................................................................................................................57
4.5.3.5 Spindle USB Port............................................................................................................................................58
4.5.4 Front Panel Buttons ..........................................................................................................................................58
4.5.5 Power Up...........................................................................................................................................................59
4.5.6 Bar Code Setup................................................................................................................................................59
4.5.7 Set Time.............................................................................................................................................................61
4.5.8 Remote Connections ......................................................................................................................................61
4.5.9 Master Spindle Setup .......................................................................................................................................62
4.5.10 Languages......................................................................................................................................................65
4.6 Tool ................................................................................................................................................................................... 65
4.6.1 Tool Setup .........................................................................................................................................................66
4.6.2 Service Log .......................................................................................................................................................66
4.6.3 Button Calibration............................................................................................................................................67
4.6.4 Torque Calibration ...........................................................................................................................................67
4.6.5 Torque Calibration Routine .............................................................................................................................68
4.6.6 Indicators ..........................................................................................................................................................68
4.6.7 TID Parameters .................................................................................................................................................69
4.7 Accessories .....................................................................................................................................................................70
4.8 Diagnostics...................................................................................................................................................................... 70
4.8.1 Controller Overview.........................................................................................................................................71
4.8.2 Controller Status ...............................................................................................................................................71
4.8.3 Tool Overview...................................................................................................................................................72

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MAN177 rev_01-10-19
4.8.4 Live Tool ............................................................................................................................................................73
4.8.5 Identify Controller............................................................................................................................................73
4.8.6 Record Logs.....................................................................................................................................................73
4.8.7 System Status ....................................................................................................................................................74
4.9 Login................................................................................................................................................................................. 74
4.10 Advanced..................................................................................................................................................................... 75
4.10.1 Login Setup.....................................................................................................................................................75
4.10.2 Results Archive................................................................................................................................................76
4.10.3 Import Settings..............................................................................................................................................76
4.9.4 Export Controller.............................................................................................................................................77
4.10.5 Update Controller ..........................................................................................................................................78
4.10.6 Backup Restore ..............................................................................................................................................79
4.10.7 Restore Factory Defaults................................................................................................................................80
4.10.8 Calibrate Touch Screen.................................................................................................................................81
4.10.9 Soft Reboot .....................................................................................................................................................81
5 Barcode Reader Details.................................................................................................................................................................. 82
6 Glossary of Terms.............................................................................................................................................................................. 85
7 Icons Defined.................................................................................................................................................................................... 87
7.1 Stop Codes ..................................................................................................................................................................... 88
8 Error Codes........................................................................................................................................................................................ 89
9 Dual Lever Tools Requiring Two Handed Operation .................................................................................................................. 93
10 24 Volt I/O ....................................................................................................................................................................................... 94
11 Assignable IO Details..................................................................................................................................................................... 97
11.1 Controller supported MIDs ....................................................................................................................................... 115
12 Dimensions .................................................................................................................................................................................... 118
13 Specifications ............................................................................................................................................................................. 118
14 Tubenut Tool Setup Details ......................................................................................................................................................... 119
14.1 Overview .....................................................................................................................................................................119
14.2 Tubenut Homing......................................................................................................................................................... 119
14.2.1 Tubenut Home TID parameters...................................................................................................................119
14.3 Setting the Tool’s Tubenut Home TID Parameters ........................................................................................119
14.4 Controller Parameters Affecting Tubenut Homing.......................................................................................120
14.5 Tubenut Pinch Detection................................................................................................................................120
14.5.1 Obstruction Detection TID Parameters ......................................................................................................120
14.5.2 Setting the Tool’s Tubenut Obstruction Detection ....................................................................................121
14.5.3 Controller Parameters Affecting Tubenut Pinch Detection .....................................................................121
14.5.4 Tubenut Homing Start Input Logic Selection .............................................................................................121
15 Trouble Shooting .......................................................................................................................................................................... 122
16 AIMCO Warranty.......................................................................................................................................................................... 124

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MAN177 rev_01-10-19
1 Safety Information
General Power Tool Safety Warnings
WARNING Read all safety warnings and instructions. Failure to follow the warnings and
instructions may result in electric shock, fire, and/or serious injury.
Save all warnings and instructions for future reference.
The term “power tool” in the warnings refers to your mains-operated (corded) power tool or
battery-operated (cordless) power tool.
1. Work area safety
a. Keep work area clean and well lit. Cluttered or dark areas invite accidents.
b. Do not operate power tools in explosive atmospheres, such as in 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
It is recommended that 5000, 6000, 7000 and 8000 series tools be supplied by 200-240VAC
a. Power tool 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 will reduce
risk of electric shock.
b. Avoid body contact with earthed or grounded
surfaces, such as 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 reduces the risk of electric shock.
IEC 320-C20
N
L
PE
100-120 / 200-240 VAC
Single Phase
50/60Hz
15Amps
Power Cord Receptacle

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MAN177 rev_01-10-19
f. If operating a power tool in a damp location is unavoidable, use a residual current
device (RCD) protected supply. Use of an RCD reduces the risk of electric shock.
NOTE:The term “residual current device (RCD)” may be replaced by the term
“ground fault circuit interrupter (GFCI)” or “earth leakage current breaker (ELCB)”.
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 personal protective equipment. Always wear eye protection. Protective
equipment such as dust mask, non-skid safety shoes, hard hat, or hearing
protection used for appropriate conditions will reduce personal injuries.
c. Prevent unintentional starting. Ensure the switch is in the off-position before
connecting to power source and/or battery pack, picking up or carrying the tool.
Carrying power tools with your finger on the switch or energizing power 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 not 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.
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. Disconnect the plug from the power source and/or the battery pack from the power
tool before making any adjustments, changing accessories, or storing power tools.
Such preventive safety measures reduce the risk of starting the power tool
accidentally.
d. Store idle power tools out of the reach of children and do not allow persons
unfamiliar with the power tool or these instructions to operate the power tool. Power
tools are dangerous in the hands of untrained users.
e. Maintain power tools. Check for misalignment or binding of moving parts, breakage
of parts and any other condition that may affect the power tools operation. If

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MAN177 rev_01-10-19
damaged, have the power tool repaired before use. Many accidents are caused
by poorly maintained power tools.
f. Use the power tool, accessories and tool bits etc., in accordance with these
instructions, taking into account the working conditions and the work to be
performed. Use of the power tool for operations different from those intended could
result in a hazardous situation.
5. Service
a. Have your power tool serviced by a qualified repair person using only identical
replacement parts. This will ensure that the safety of the power tool is maintained.

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2 Controller Diagram
2.1 Bottom Panel

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2.2 Front Console LED Display
Indicator Light.
Torque Display. (Always displays torque value)
Secondary Display.
Parameter Setting (PSet)/Job display and
Increment/Decrement buttons.
Toggle button
Indicator Lights:
Green LED: Indicates fastening cycle meets specified
parameters.
Red LED: Indicates fastening cycle rejected for
exceeding high torque.
Red Flashing LED: Indicates low torque. Fastening cycle was
rejected for not achieving low torque.
Yellow LED: Indicates High Angle. Fastening cycle was
rejected for exceeding high angle.
Yellow Flashing LED: Indicates Low Angle. Fastening cycle was
rejected for not achieving low angle.
Blue LED: Tool is In-cycle, above threshold.
•Increment and Decrement buttons change pset.
•Toggle button switches secondary display between
oUnits of measure
oEthernet IP address
oUSB (System Port) IP address
oCOMP: Torque Compensation Tare Value (See details in AC_TCOMP Stage)
oAngle report
NOTE: If Jobs are enabled refer to 4.3 Job section of the manual for Toggle Button
function.

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3 Initial Set Up
Step 1
Connect tool cable to Tool Connector. Cable consists of a male pin set housed in a
molded 19 pin connector with a polarizing notch. Align tool cable notch with tool
connector notch on the controller and insert cable. Securely thread connector
coupler to controller body.
Step 2
Repeat above process to connect tool cable to AcraDyne tool being used with the
controller.
Step 3
Plug female end of power cable into Power Cable Connector.
Step 4
Plug male end of power cable into appropriate power source.
Due to a variety of 230Vac power outlets, the standard power cable plug-end provided with
the controller may need to be modified in order to connect to local 230Vac power outlets.
AcraDyne has a wide variety of country specific power cord options available. Check with your
authorized AcraDyne representatives to see if your specific configuration is available. In any
case, connection to local power should be made in consultation with a qualified electrician.
Step 5
The Secondary Protective Earth Attachment (it is required) must be connected to
ground using the #14 AWG conductor, a green wire with a yellow stripe. Attach using a
#10-14AWG ring terminal and #10 star washer (see below).
1
1—Secondary Protective Earth Attachment
Step 6
Turn controller on by pushing the Power Disconnect Switch to the POWER ON position, a
light indicates power on.
NOTE: Warning will appear if the controller is power cycled too
quickly. If fault appears, Power Down controller, wait a
mimimum of 10 seconds between controller Power Down and
Power Up to clear error and restart controller.

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3.1 Connecting to the Controller
There are three ways to program/communicate with the controller:
•Controller touch-screen console
•System Port: (USB connection) Direct connection to controller.
•Ethernet Port: Via direct connection or LAN.
Touchscreen Console
Controller functions and programming can be accessed directly through the touch-screen.
1. Power on controller.
2. Run screen will appear.
3. Controller is ready for use.

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Connecting via The System Port directly to PC
The following is an example using Window 7. Your screen may look different depending on the
operating system.
Windows USB Setup
Step 1 Power on PC and controller, allow enough time for them to become fully operational.
Step 2 Attach controller to PC using a USB 2.0 A-B cable. If this is the first time connecting the
devices, wait for Windows to install the RNDIS driver. This should happen automatically.
Step 3 After the driver is installed, go to ‘Control
Panel’.
Step 4 Go to ‘Network and Internet’.

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Step 5 Go to ‘Network and Sharing Center’.
Step 6 Go to ‘Change adapter settings’.
Step 7 Find the Local Area Connection that is
using the ‘USB Ethernet/RNDIS Gadget’ network.
Right click this network and go to ‘Properties’.
Step 8 In Properties window select ‘Internet
Protocol Version 4’ and click ‘Properties’.

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Step 9 In ‘Properties’, set the IP address to a static address.
Type an IP address of 192.168.1.5 (Any address on
the same subnet as the controller will work).
Set subnet mask to 255.255.255.0
Step 10 To connect to the controller. Open a
browser such as Chrome or Firefox. Enter
192.168.1.4, the default system port IP address.
You will see the controller software on your computer sceen.

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Connecting using the Ethernet Port Directly or via LAN to PC
Turn on the computer and make a physical connection by using a straight through Ethernet
cable.
Turn on controller. Verify the controller IP address in ‘Communication Interfaces’. Or press toggle
button to verify the IP address. If defaulted 0.0.0.0 set desired IP address
Set a static IP address of the Computer/Laptop to 10.10.30.98 (example) and subnet mask to
255.255.255.0. (For instructions, see the example earlier in this section.)
To connect to the controller. In the Computer/Laptop open a browser such as Chrome or
Firefox. Enter 10.10.30.99, the default Ethernet port IP address.
You will see on your computer sceen the controller software
NOTE: Controller does not have a DHCP client, it will not automatically configure itself with a
useable IP address. Consult your Network Administrator for configuring a correct IP address for
your network. The PC, Laptop or Tablet IP address will need to be configured to communicate
with the controller.

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3.2 Quick Set Up (Default PSets from Tool)
On the Home Page press:
to accept default PSet Parameters.
This will generate three generic PSets for the tool connected to the controller. It will
automatically use the 40%, 60%, and 80% of the rated maximum torque of the tool in a two-
stage Torque Control Strategy (TC). A prompt will display rated Max Torque and Max RPM of the
connected tool for reference. These Psets can be modified to meet application requirements.
4 Home Page (Main Menu)

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4.1 Run
The Run Screen is essentially the dashboard of the Gen IV
controller and provides a look at real time information regarding
rundowns.
Indicates the current JOB.
Indicates the current PSet you are operating in.
Indicates accepted rundown.
Indicates failed rundown.
Displays Torque and Angle for current rundown.
Time (in-cycle) screen
Graph displays curves representing Torque (black trace) and Angle (blue trace). The blue left
arrow at the origin of the graph will change the X-axis of the rundown curve from Time (In –
Cycle) to Time (Overall) and Angle.
Below the graph is a historical table that will give information and status of the most recent
rundowns, including current PSet, accepted/failed rundown status,torque and angle.
Arrows allow user to scroll left or right for viewing real time Job
information such as Run Screen or rundown indicators.
Home tab will return user to the Home Page

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Time Overall Screen
Click for curve detail.
Click on arrow to change curve X axis.
Choose Time in-cycle,Time Overall
or Angle screen
Angle Screen

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Run Screen (Job display information)
Run Screen displays real time Job information.
Large Screen Indicators and Audit information
The large screen indicators are helpful in viewing real time results of the rundown from a
distance.
Failed
Accepted

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4.2 PSet
Parameter Settings (PSets) control the fastening process. The following describes the different
fastening stratagies and how to setup the basic PSet parameters necessary to perform a fastening.
Up to 256 PSets are available.
4.2.1 Add New PSet
On Home Page press the tab.
On PSets screen (right) press to add a new Pset.
Stage Torque and RPM at
Glance.