AcraDyne 1000 Series User manual

PO Box 16460, Portland OR 97292-0460 • 800-852-1368 • Fax [phone]
www.aimco-global.com
AcraDyne
1000 Series Nutrunners
Operations Manual

Introduction
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 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 electricshockifyour
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 of outdoor use reduces the risk of electric
shock
f) It is not recommended to use AcraDyne controllers or tools outside or to use an extension cord to connect the controller to a power source.
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 hearing protection used for
appropriate conditions will reduce personal injuries. If the maximum duty cycle of the attached tool is exceeded or the tool temperature exceeds 50° C.,
then the operator should wear protective hand wear (gloves).
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
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 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 the AcraDyne iEC DC tool controller for intermittent hand-held or fixtured assembly processes.
Safety Information
Thank you for purchasing this AcraDyne DC electric assembly tool, one of the lightest and fastest DC electric
assembly tools on the market. When used with the AcraDyne iEC tool controller, this tool will provide excellent
productivity, ergonomics, reliability and quality on a wide range of industrial assembly applications.
2

OPERATIONS
Angle Head Tool Body
Start Lever
Cable
Connection
Square/
Hex Drive
3
Multi Function
Button
1. Connect tool cable to the iEC controller and the tool:
The tool cable has curved alignment tabs and slots
built into the connectors at each end to ensure proper
alignment and connection with the tool and controller.
Make sure that power is not turned on at the controller
before making any connections. Align the female connec-
tor on the cable with the male connector on the tool and insert
the cable onto the tool, then slide the connector nut onto the
threads on the cable and turn clockwise until hand-tight.
Align the male connector tab on the other end of the tool
cable with the female slot on the controller and insert the
cable into the connector, then slide the metal outer cover
onto the connection threads on the controller and turn clock-
wise until hand-tight.
2. Multifunction Button Operation:
The tool will flash all LED lights three times when power is
first turned on at the controller. After the controller finishes
initializing and displays a target toque value, the multifunction
button (MFB) is used to toggle the tool from clockwise mode
(FWD) to counter-clockwise operation mode (REV). The MFB
is the small button opposite the trigger.
The tool will initially start in clockwise mode and will have no
LED lights turned on. If the trigger is pressed, the tool will
turn on the blue LED meaning the tightening operation is
underway. Pressing the MFB will cause the tool to flash yel-
low and red LED lights. Pressing the MFB again will switch
the tool back FWD mode and will indicate this with no LED
lights turned on.
3. Start Lever Operation:
To start the tool, depress the start lever. Blue LED lights will
be displayed while tightening a bolt. The tool will stop auto-
matically when it senses its target torque value or if no torque
is sensed in a specified time period. After a cycle is complete,
the tool will display green LED lights for a success, or red
LED lights for failure to reach torque/angle.
Light Ring Light Assignment
The Buzzer and Multi-Function Button are programmable in the
DSP Menu of ToolWare.
Light Color Meaning
Green Solid OK
Red Flashing Torque Low
Red Solid Torque High
Yellow Flashing Angle Low
Yellow Solid Angle High
Blue Solid Tool In-Cycle/Tool Armed
Blue Flashing P-Set Change thru MFB
All On Flashing Tool in Disassembly
Buzzer Bad Assembly/Tool in Disassembly/Power Up
A complete tool system consists of the following items:
Controller Power cord Tool Tool Cable

4
PAGE HEADER HERE
1000 SERIES ANGLE NUTRUNNERS
6
3
2
1
5
7
8
SEE NOTE # 1
APPLY LOCTITE 243 (BLUE) PRIOR
TO INSTALLATION INTO ITEM # 7
TIGHTEN TO 40 Nm (29.5 FT-LBS)
APPLY LOCTITE 242 (BLUE) PRIOR
TO INSTALLATION OF ITEM # 7
34.9MM (1-3/8") FLATS
40Nm (30 FT-LBS.)
4
PRESS INTO ITEM 2
UNTIL FLUSH WITH
SURFACE
11 10 9
SHIM AS REQUIRED
WITH ITEMS 9-11 TO
ALIGN ANGLE HEAD
TO LEVER
B
Assembly for: AEN4B12004A, AEN4C12008A, AEN4C12014A, AEN4C12018A, AEN4C12022A
4
ITEM# AEN4B AEN4C AEN4C AEN4C AEN4C QTY. PART # DESCRIPTION
12004A 12008A 12014A 12018A 12022A
1 X X X X X 1 24703 HANDLE ASSEMBLY- 1000 SERIES
2 X X X X X 1 24719 TRANSDUCER ADAPTOR
3 X X X X X 1 24729 KEY
4 X X X X X 1 24688 ROLL PIN, 1/16 x 5/16” LONG
5 X X X X X 1 24780 MOTOR COUPLER SUB-ASM.
6 X X 1 24778 TRANSDUCER SUB-ASM., 8Nm
X X X 1 24779 TRANSDUCER SUB-ASM., 20Nm
7 X 1 25531 ASSY, GEAR CASE, 4 Nm ANGLEHEAD
X 1 24860 GEAR CASE SUB-ASM 6T
X 1 24709 GEAR CASE SUB-ASM, 14T/14T
X 1 24792 GEAR CASE SUB-ASM., 12T/12T
X 1 24710 GEAR CASE SUB-ASM, 8T/14T
8 X 1 4A9116 ASSY, ANGLE HEAD, 4 Nm
X X X X 1 24890 ANGLE HEAD ASM, STUBBY, 3/8”” SQ. DR.
9 X X X X X A/R 24855 SHIM .1MM, 14MM ID X 20MM OD
10 X X X X X A/R 24856 SHIM .2MM, 14MM ID X 20MM OD
11 X X X X X A/R 24857 SHIM .3MM, 14MM ID X 20MM OD

5
PAGE HEADER HERE
1000 SERIES IN-LINE NUTRUNNERS
1
2
3
4
5
6
7
APPLY LOCTITE
#242 BLUE
TIGHTEN TO GEAR CASE
TO 40Nm (30 FT.LBS.)
SEE NOTE 1
34.9mm (1 3/8") FLATS
40Nm (30 FT.LBS.)
SEE NOTE 1
APPLY LOCTITE
#242 BLUE
TIGHTEN TO GEAR CASE
TO 40Nm (30 FT.LBS.)
8
30.2mm (1 3/16") HEX
25Nm (18 FT.LBS.)
APPLY LOCTITE
#242 BLUE
9
PRESS INTO ITEM 2
FLUSH WITH SURFACE
Assembly for: AES4A12003A, AES4A12006A, AES4A12011A, AES4A12014A, AES4A12018A, AES4A12022A
ITEM# AES4A AES4A AES4A AES4A AES4A AES4A QTY. PART # DESCRIPTION
12003A 12006A 12011A 12014A 12018A 12022A
1 X X X X X X 1 24703 HANDLE ASSEMBLY- 1000 SERIES
2 X X X X X X 1 24719 TRANSDUCER ADAPTOR
3 X 1 24777 TRANSDUCER SUB-ASM., 3Nm
X 1 24778 TRANSDUCER SUB-ASM., 8Nm
X X X X 1 24779 TRANSDUCER SUB-ASM., 20Nm
4 X X X X X X 1 24729 KEY
5 X X X X X X 1 24780 MOTOR COUPLER SUB-ASM.
6 X X 1 24860 GEAR CASE SUB-ASM 6T
X 1 24709 GEAR CASE SUB-ASM, 14T/14T
X 1 24792 GEAR CASE SUB-ASM., 12T/12T
X 1 24710 GEAR CASE SUB-ASM, 8T/14T
X 1 24781 GEAR CASE ASM, 6T/14T
7 X X X X X X 1 24896 STRAIGHT OUTPUT ASM, 1/4”” HEX Q.C.
8 X X X X 1 24696 REACTION BAR, ALUMINUM, 1000 SERIES
9 X X X X X X 1 24688 ROLL PIN, 1/16 x 5/16” LONG

PAGE HEADER HERE
1000 SERIES PUSH-TO-START NUTRUNNERS
6
7
4
3
5
1
9
10
11
ALIGN CABLE CONNECTOR
WITH SLOT ON GEAR CASE
HOUSING THEN GLUE TO SHOULDER
ON GEAR CASE HOUSING
WITH RTV
8
13
14
12
HOLD FLATS SECURE WITH TOOL # 1354
WHILE TIGHTENING ITEM #11
38.1mm (1½") FLATS
TIGHTEN TO MOTOR WITH LOCTITE 242
40 Nm (30 Ft*LBS)
2
38.1mm (1½") FLATS
TIGHTEN TO ITEM #8 WITH LOCTITE 242
PRIOR TO INSTALLING ITEMS 12-14
40 Nm (30 FT*lbs)
SEE NOTE 3
SEE NOTE 1
Assembly for: AEL4A12003A, AEL4A12006A, AEL4A12011A, AEL4A12014A, AEL4A12018A, AEL4A12022A
6
ITEM# AEL4A AEL4A AEL4A AEL4A AEL4A AEL4A QTY. PART # DESCRIPTION
12003A 12006A 12011A 12014A 12018A 12022A
1 X X X X X X 1 24703 HANDLE ASSEMBLY- 1000 SERIES
2 X X X X X X 1 24762 PTS FLEX CIRCUIT
3 X X X X X X 1 24719 TRANSDUCER ADAPTOR
4 X X X X X X 1 24729 KEY
5 X X X X X X 1 24688 ROLL PIN, 1/16 x 5/16” LONG
6 X X X X X X 1 24780 MOTOR COUPLER SUB-ASM.
7 X X 1 24778 TRANSDUCER SUB-ASM., 8Nm
X X X X 1 24779 TRANSDUCER SUB-ASM., 20Nm
8 X X X X X 1 25521 ADAPTER, PTS GEAR HOUSING
9 X X 1 24786 GEAR CASE ASSEMBLY, P-T-S, S.S., 8
X 1 24791 GEAR CASE ASSEMBLY, P-T-S, 14/14
X 1 24807 GEAR CASE ASSY, P-T-S, D.S. 12/12
X 1 24784 GEAR CASE ASM, P-T-S, 8/14
X 1 24776 GEAR CASE ASM, P-T-S, 6T/14T
10 X X X X X X 1 24566 P-T-S LIGHT RING ASM.
11 X X 1 24744 P-T-S G.C. HSG COVER- S.S.
X X X X 1 24757 GEAR CASE HOUSING COVER, P-T-S, D.S.
12 X X X X X X 1 25590 O-RING, Ø13/16 X Ø1/16
13 X X X X X X 1 25591 O-RING, Ø1¼ X Ø1/16
14 X X X X X X 1 24753 P-T-S LIGHT RING LENS

PAGE HEADER HERE
1000 SERIES FIXTURED NUTRUNNERS
1
2
3
4
5
6
7
APPLY LOCTITE
#242 BLUE
TIGHTEN TO GEAR CASE
TO 40Nm (30 FT.LBS.)
SEE NOTE 1
34.9mm (1 3/8") FLATS
40Nm (30 FT.LBS.)
SEE NOTE 1
APPLY LOCTITE
#242 BLUE
TIGHTEN TO GEAR CASE
TO 40Nm (30 FT.LBS.)
8
30.2mm (1 3/16") HEX
25Nm (18 FT.LBS.)
APPLY LOCTITE
#242 BLUE
9
PRESS INTO ITEM 2
FLUSH WITH SURFACE
Assembly for: AEF4A12003A, AEF4A12006A, AEF4A12011A, AEF4A12014A, AEF4A12018A, AEF4A12022A
7
ITEM# AEF4A AEF4A AEF4A AEF4A AEF4A AEF4A QTY. PART # DESCRIPTION
12003A 12006A 12011A 12014A 12018A 12022A
1 X X X X X X 1 24888 TID BOARD ASM
2 X X X X X X 1 24913 CIRCUIT BOARD MOUNTING PLATE
3 X X X X X X 2 24914 BHCS, #4-40 x .25 LG
4 X X X X X X 1 24912 COVER, CIRCUIT BOARD
5 X X X X X X 2 24917 BHCS, #4 x .38 LG TAP-TITE
6 X X X X X X 1 24863 PISTOL MOTOR ASM., 1000 SERIES
7 X X X X X X 2 24930 SCREW, AMP BOARD
8 X X X X X X 1 24886 CIRCUIT BOARD ASM - PISTOL/ FIXTURED TOOLS
9 X X X X X X 1 24873 LIGHT RING
10 X X X X X X 1 24909 STRAIGHT ADAPTOR, PISTOL TOOL CONNECTOR
11 X X X X X X 1 24677 TOOL CONNECTOR ASSEMBLY
12 X X X X X X 1 25419 SCREW, PHM 4-40 X .188 , STEEL, PLAIN
13 X X X X X X 4 24933 FLAT HEAD CAP SCREW
14 X X X X X X 1 24687 O-RING, LIGHT RING, LEVER
15 X X 1 24860 GEAR CASE SUB-ASM 6T
X 1 24709 GEAR CASE SUB-ASM, 14T/14T
X 1 24792 GEAR CASE SUB-ASM., 12T/12T
X 1 24710 GEAR CASE SUB-ASM, 8T/14T
X 1 24781 GEAR CASE ASM, 6T/14T
16 X X X X X 1 24719 TRANSDUCER ADAPTOR
17 X X X X X 1 24688 ROLL PIN, 1/16 x 5/16” LONG
18 X X X X X 1 24729 KEY
19 X 1 24777 TRANSDUCER SUB-ASM., 3Nm
X 1 24778 TRANSDUCER SUB-ASM., 8Nm
X X X X 1 24779 TRANSDUCER SUB-ASM., 20Nm
20 X X X X X X 1 24780 MOTOR COUPLER SUB-ASM.
21 X X X X X X 1 24918 RETRACTABLE OUTPUT SPINDLE ASM, 3/8 SQ
22 X X X X X X 1 24924 MOUNTING FLANGE
23 X X X X X X 2 24934 FLAT HEAD CAP SCREW
24 X X X X X X 1 24686 RETAINING RING, LEVER LIGHT RING

ADJUSTING THE THROTTLE LEVER TO ANGLE HEAD LOCATION
REQUIRES OPTIONAL P/N 25444
1. REMOVE THE ANGLE HEAD
1.1.Hold the angle head and with a 1-3/8" crows foot loosen and remove the gear casing
from the angle head.
2. INSTALL ADJUSTMENT SHIMS
2.1.Shim kit part number 25444 is needed for the 1000 series.
2.2.Add adjustment shims as needed to align the angle head with the throttle lever.
3. REINSTALL THE ANGLE HEAD
3.1.Apply Loctite 243 to the threads on the angle head.
3.2.Hold the angle head and tighten the gear casing to 40NM using the 1-3/8" crows foot.
8
6
3
2
1
5
7
8
SEE NOTE # 1
APPLY LOCTITE 243 (BLUE) PRIOR
TO INSTALLATION INTO ITEM # 7
TIGHTEN TO 40 Nm (29.5 FT-LBS)
APPLY LOCTITE 242 (BLUE) PRIOR
TO INSTALLATION OF ITEM # 7
34.9MM (1-3/8") FLATS
40Nm (30 FT-LBS.)
4
PRESS INTO ITEM 2
UNTIL FLUSH WITH
SURFACE
11 10 9
SHIM AS REQUIRED
WITH ITEMS 9-11 TO
ALIGN ANGLE HEAD
TO LEVER
B

9
Specifications
Environmental
•Operating Temperature: 0°C to 32°C
•Storage Temperature: 0°C to 65°C
•Humidity:
o5% to 90% RH, Non-Condensing, for temperatures 0°C to 40°C
o5% to 60% RH, Non-Condensing, for temperatures 0°C to 65°C
•Maximum Altitude of Operation: 3000m
• Maximum decibel level: 73 dB(A)
Electrical
•Motor Type: BLDC
oMotor Phase Voltage: 160 Volts Pulse DC @ Controller Supply Voltage of
120 RMS, or 320 Volts Pulse DC @ Controller Supply Voltage of 230 RMS
•Duty Cycle: The Nutrunner tools are intended for intermittent operation with recommended
maximum duty cycles not to exceed 33%. Note: actual maximum duty cycles are dependant
upon several factors including: Ambient Temperature, Tool selection, Joint conditions,
Fastening-parameter programming, and different applications and strategies. For optimum
duty cycle determination, please contact your AcraDyne sales representative.
Physical
•1.5 lbs/.68 kg - 2.6 lbs/1.18 kg
Performance
•Torque Range: 3 - 22 NM
•Speed Range: 560 - 2625 RPM