Aimco AcraDyne Gen IV Manual

Gen IV Controller with Smart Arm Setup
Instruction Manual
10000 SE Pine St., Portland, OR 97216 • 800-852-1368 • 503-254-6600 • Fax [phone]
www.aimco-global.com

2
Gen IV Controller with Smart Arm Setup Instruction Manual
1. Introduction . . . . . . . . . . . 2
2 Equipment/Software. . . . . . . . . 2
3. Hardware Setup . . . . . . . . . . 2
4. Hardware Connection . . . . . . . . 3
Connecting the Encoders . . . . . . . 3
Encoder Compatibility . . . . . . . . 3
Connecting the Remote Home . . . . . 3
5. Care Setup Steps Overview . . . . . . 3
6. Functionality Overview . . . . . . . . 3
7. Configuration Screen Summary . . . . . 4
Configuration Screens . . . . . . . . 4
Accessory Setup Screen. . . . . . . 4
Accessory Scanning and IP Setup Screen 4
Main Configuration Screen . . . . . . 4
Location Setup Screen . . . . . . . 4
Icon Reference. . . . . . . . . . 5
Smart Arm Function . . . . . . . . . 5
Homing . . . . . . . . . . . . . 5
Locations . . . . . . . . . . . . 5
8. System Connections. . . . . . . . . 6
Smart Arm Accessory Connections . . . . 6
Controller Connections . . . . . . . . 6
9. Initial Setup. . . . . . . . . . . . 6
10. Example: Select PSets Based on Location . 6
PSet Setup . . . . . . . . . . . . 6
Accessory Setup . . . . . . . . . . 6
11. Example: Command Bolt Locations
via External Source . . . . . . . . . 7
PSet Setup . . . . . . . . . . . . 7
Job Setup . . . . . . . . . . . . 7
Accessory Setup . . . . . . . . . . 7
External Control . . . . . . . . . . 8
12. Adding a Proximity or Limit Switch . . . . 8
13. Smart Arm Runscreen . . . . . . . . 8
Configuration Overview. . . . . . . . 9
Icon Reference . . . . . . . . . . 9
Clearing locations . . . . . . . . . 9
14. Example: Select PSets Based on Location . 9
Upload the image . . . . . . . . . 9
Add locations on the image . . . . . 10
Runscreen Behavior . . . . . . . . 10
15. Example: Command Bolt Locations
via External Source with Image . . . . 10
Setup details . . . . . . . . . . 11
Runscreen Behavior . . . . . . . . 11
16. References . . . . . . . . . . . 11
Table of Contents 1. Introduction
The Smart Arm Accessory allows an articulated arm
with encoders to be used with the GenIV controller.
Fastener locations can be programmed into the
controller so that the controller will perform specic
actions when the tool is located on a specic
fastener. The controller can also be congured to
show a custom image on the Runscreen with fastener
locations that update as fastenings are performed.
2 Equipment/Software
• AIMCO Gen 4 controller.
• Power Supply Cable.
• Smart Arm Accessory – Encoder Interface - 30860
• Ethernet Cable
3. Hardware Setup
• Connect power to the GenIV controller
• Connect power to the Smart Arm Accessory
• Connect an Ethernet cable from the Accessory
box to the second Ethernet port on the GenIV
Controller.
• Connect the encoders from the arm to the
accessory box via M12 cables.
• Power up the Smart Arm Accessory
• Power up the GenIV Controller

3
Gen IV Controller with Smart Arm Setup Instruction Manual
4. Hardware Connection
Connecting the Encoders
The encoders from the arm connect to the controller
via M12 connectors. The pinout is shown below.
Encoder Circuit M12-8 Bulkhead Connector Pin
0V 1
+12Vdc 2
A 3
B 5
Encoder Compatibility
The system is compatible with incremental encoders
with the following specications:
• Voltage: 12V
• Signal output: Quadrature with A B outputs
• Pulse rate: System veried with 2048 pulses per
revolution and lower
Connecting the Remote Home
An external remote home button can be added to
the accessory if needed. This will perform the same
function as the ‘Home’ button on the accessory
box. The homing function will be triggered when pin
4 on the M8 connection is pulled high to +12V.
External Circuit M8-3 Bulkhead Connector Pin
0V 3
+12Vdc 1
Signal 4
5. Care Setup Steps Overview
This document covers the details of interfacing an
arm outtted with encoders to a GenIV Controller.
The general steps of the setup are:
1. Make all hardware connections
2. Power on the Smart Arm Accessory and GenIV
Controller
3. Congure the accessory IP settings from the
controller
4. Add the Smart Arm accessory in the GenIV
controller settings
5. Congure the accessory settings and add arm
locations
6. Add runscreen image (if required)
7. Congure line side control (if required)
6. Functionality Overview
The Smart Arm Accessory can interface with an
arm tted with up to four encoders and/or proximity
sensors. A runscreen can be congured to show
fastener locations on a user uploaded image.
The controller is able to read the arm position
from the accessory box and perform an array of
different functions based on arm position. Setup
can be as simple as just selecting a PSet when the
arm is positioned over a fastener. It can also be
as complicated as combining line side control to
determine which fastener to insert with a Job and
Arm ensuring that the correct fastener is inserted in
the correct sequence while preventing fasteners
from being re-inserted.
Triggering the ‘Job Reset’ IO will clear the OK/NOK
status of any fasteners.

4
Gen IV Controller with Smart Arm Setup Instruction Manual
is the intended accessory by matching the MAC
address on the screen to the MAC address labeled
on the accessory box.
Main Conguration Screen
This is the primary setup screen. It contains the basic
settings for what action will be taken when the arm
is in position and a list of valid locations. Settings are
not saved until the OK/Check button is clicked.
• Enabled: Toggles whether the smart arm accessory
is active. If this is unchecked then the smart arm will
not control the enabled state of the tool.
• IP Address: This is the IP Address of the smart arm
accessory.
• Function: Selects what action the smart arm
position activates
• Part Image: Upload a custom image for the
runscreen
• Locations: List of saved smart arm locations
Location Setup Screen
This screen is where a new location is congured.
The ‘Parameter’ eld is a multi-purpose eld. This
7. Conguration Screen Summary
Conguration Screens
Accessory Setup Screen
This screen shows accessories congured in the
controller. New accessories can be added, edited,
and deleted using the buttons at the bottom of the
table. The gear icon navigates to the Accessory
Scanning and Setup page.
Accessory Scanning and IP Setup Screen
This screen is used to congure the IP settings of the
accessory. Clicking the magnifying glass will search
for AcraDyne Accessories on the network. Any
accessories found will show up in the list. Click on the
accessory to be congured to edit its settings. Once
clicked, the current settings will autoll in the edit
elds. Edit these and click ‘Send’ to send the new
settings to the accessory that matches that MAC
address. Ensure that the accessory being modied

5
Gen IV Controller with Smart Arm Setup Instruction Manual
Smart Arm Function
The accessory can be congured to take one of
four different actions when a location is matched.
• Select PSet
○This will pair a location to a PSet and the
controller will select the PSet when this
location is matched
• Verify PSet
○The tool will be disabled until the PSet is
selected that matches the required PSet
from the location conguration
• Select Job Sequence
○This will pair a location to a job sequence.
The controller will select a specic job
sequence when the location is matched
• Verify Job Sequence
○The tool will be disabled until the correct job
sequence is selected that matches the job
sequence from the location conguration
Homing
• Pressing the ‘Home’ button on the accessory will
set the ‘0’ position of the arm. All locations will
be referenced off this position. This can be the
location of a specic bolt or another position in
the station that has a xed location.
• The system will need to be ‘homed’ whenever
the station is powered up.
• The encoder accessory has an M8 connector
that allows for a remote homing button to be
wired in in the case that the homing button on
the box is inconvenient.
Locations
Locations are dene by encoder counts. After
the system is homed then locations can be
programmed via the Accessories->Smart Arm
conguration page. Clicking the Add(+) button will
add a new location. The ‘Current’ column shows
the current position of the encoders. Clicking ‘Use
Current Position’ will use those values and ll in the
target encoder values for this location. The ‘Range’
eld will dene the acceptable distance around the
target that will enable this location. Increasing the
‘Range’ value will allow for a wider area that allows
the location to be selected.
eld corresponds to the ‘Function’ option on the
previous page so this eld can correspond to PSet
or Job Sequence number. The right column labelled
‘Current’ shows the current state of the encoders
being read from the Arm. The ‘Range’ eld denes
the window around the target that is acceptable for
enabling that location. Reducing the range narrows
the acceptability window and increasing the range
widens the window. The software will show an error if
any encoder locations overlap.
Clicking ‘Use Current Position’ will grab the current
state of the encoders and use it as the target. Use
this to easily add a location by locating the tool
on the bolt for that location and click ‘Use Current
Position’. Click OK at the bottom of the screen and
this location will be added to the list.
Icon Reference
Icon Function Denition
Position not
valid
The current position of the arm does
not match any locations in the smart
arm conguration. This error will clear
when the arm is in a valid position.
‘SARM’ will show on the top LED
display.
Location
Complete
This will appear when Jobs are
enabled and the current location
has already had an OK fastening.
Only appears when the custom
runscreen image is congured.
‘SARM’ will show on the top LED
display.
PSet or Job
Sequence
Mismatch
The currently selected PSet or Job
Sequence does not match the PSet
or Job Sequence number required
by the current location. This error
will clear when one of the following
happens:
• The arm moves to a position that
requires the currently selected
PSet/Sequence
• The active PSet/Sequence is
changed to match what is
required for this position
‘PSET’ or ‘JSEQ’ will show on the top
LED display.
Connection
Error
The controller is not communicating
with the accessory. Commonly
caused by incorrect IP settings in the
controller or accessory.
‘SARM’ will show on the top LED
display.

6
Gen IV Controller with Smart Arm Setup Instruction Manual
○Live encoder values
▪Navigate to Accessories and edit the
smart arm accessory
▪Click the the Add(+) button to add a
new location. The elds under ‘Current’
should change as the arm is moved.
This shows that the accessory is sending
over valid encoder values.
10. Example: Select PSets Based on Location
This example shows how to set up the most basic
control option. Three locations will be programmed
in the controller so that the controller will enable
the tool and select a specic PSet when the tool is
located over a fastener.
PSet Setup
Create three PSets. These can be named in the
advanced settings to make it more clear which PSet
is for which bolt.
Accessory Setup
Navigate to the Accessories screen, select the
Smart Arm accessory congured in the ‘Initial Setup’
portion and click the edit button.
Set up the accessory function as ‘Select PSet’. This
allows the controller to select the correct PSet for
the arm location.
Before adding locations be sure to move the arm to
the home position and press the ‘Home’ button on
the accessory box. This will be the reference position
for all added locations.
Add three fastener locations. Click the Add(+)
button to add a new location. Move the tool onto
the rst fastener. The encoder values in the ‘Current’
column will update with the encoder counts for
this position. Click ‘Use Current Position’ to use
the current arm position for the location. Set the
‘Parameter’ eld to 1 to select PSet 1 for this position.
Click OK/Check to save this position.
Repeat this sequence for fasteners 2 and 3. Set
PSet 2 for location 2 and PSet 3 for location 3. Click
the OK/Check button on the main Smart Arm
conguration screen to save all the location.
The controller will now select the correct PSet when
it is located over a dened location. Once located
over the fastener all Smart Arm stops will be cleared,
the correct PSet will be selected, and the tool will
become enabled.
8. System Connections
Smart Arm Accessory Connections
• 4x Encoder Connections – M12
○Connect each encoder to an encoder
connector starting at encoder 1
• 1x Remote Home Button Connection – M8
• Ethernet
Controller Connections
• Use second ethernet port to connect to
accessory
9. Initial Setup
Conguring the Controller to communicate with the
accessory
• Congure the second ethernet port on the
controller
○This example is set up to work with the default
IP settings on the second ethernet port of the
controller
▪Controller IP Address: 192.168.100.1
▪Subnet: 255.255.255.0
• Set up the accessory ethernet settings
○Go to the Accessory screen and click the
gear icon
○The accessory attached to the second
ethernet port will appear in the list
○Verify the MAC address shown matches the
MAC printed on the accessory box.
○Click on the accessory in the list and the edit
elds below will autoll.
○Congure the accessory to have the
following settings:
▪IP Address: 192.168.100.5
▪Subnet: 255.255.255.0
▪Gateway: 0.0.0.0
○Click ‘Send’
○The accesory list will refresh and the
accessory will show with its new settings.
• Add the smart arm accessory
○Navigate to the main accessory screen and
click Add(+)
○Enter the IP address that was just congured
for the accessory
▪IP Address: 192.168.100.5
○Click OK/Check
• Verify connection
○Runscreen status header
▪The main runscreen will now show an
arm icon indicating that it is not in a
valid location.

7
Gen IV Controller with Smart Arm Setup Instruction Manual
The setup should result in a job that is shown below.
In job 2 set up the job sequence as the following:
• Sequence 1: PSet 4
○Action: None
○Count: 1
• Sequence 2: PSet 5
○Action: None
○Count: 1
• Sequence 3: PSet 6
○Action: None
○Count: 1
The setup should result in a job that is shown below.
Accessory Setup
Navigate to the Accessories screen, select the
Smart Arm accessory congured in the ‘Initial Setup’
portion and click the edit button.
Set up the accessory function as ‘Verify Job
Sequence’. This allows an external system to select
the job number and job sequence number to dene
which fastener needs to be run and whether it
should be from the ‘Initial work’ job or the ‘Rework’
job.
Add three fastener locations. Click the Add(+)
button to add a new location. Set ‘Parameter’ to
1 so that job sequence 1 needs to be selected for
the tool to be enabled. Move the tool onto the
fastener for this location. Click ‘Use Current Position’
11. Example: Command Bolt Locations via
External Source
This example shows how to set up a more complex
control scheme. This application will have the
following requirements:
• Three fasteners
• Each fastener has two unique tightening
specications
○Initial work
○Re-work
This application will use jobs to select the work type
(initial or rework) and then select a job sequence
number that is tied to the fastener number. Two jobs
will be created (initial and re- work). Each job will
have three job sequences (one for each fastener).
Each of the three fasteners have two tightening
specs so this gives six PSets. Job 1 will use PSets 1-3
for the ‘Initial’ work PSets, and Job 2 will use PSets 4-6
for ‘Rework’ PSets.
PSet Setup
Set up six PSets. These can be named in the
advanced settings to make it more clear which PSet
is for which bolt.
Job Setup
Set up two Jobs. Name Job 1 as ‘Initial’ and Job 2 as
‘Rework’.
In job 1 set up the job sequence as the following
• Sequence 1: PSet 1
○Action: None
○Count: 1
• Sequence 2: PSet 2
○Action: None
○Count: 1
• Sequence 3: PSet 3
○Action: None
○Count: 1

8
Gen IV Controller with Smart Arm Setup Instruction Manual
12. Adding a Proximity or Limit Switch
A proximity switch or limit switch can be wired in
to one of the encoder inputs. This will allow one
of the encoder readings to read as 0/1 or 0/-1
depending on how the switch is wired. The switch
will always read one of two states so the range
for that encoder will need to be set to 0. For the
conguration in the image below the 3rd encoder
is set to work with a proximity switch. The location
is only valid when the encoder is reading a -1. The
range is 0 so that the target has to be an exact
match.
Use the pinouts in “Hardware Connections” to wire
in the proximity switch to an M12-8 connector. Use
0V (pin 1) and 12V (pin 2) to power the switch and
connect the signal wire to the ‘A’ input (pin 3)
13. Smart Arm Runscreen
A runscreen is available that can show the fastening
locations on an uploaded image. Only one custom
image (470 x 550 pixels) is supported. The basic steps
to set up the runscreen are below:
1. Perform all steps previously shown to connect to
the smart arm, add all fastener locations, and
determine whether the arm position changes
pset/job sequence/etc.
2. Upload an image that will show the locations of
fasteners
3. Associate the fastener locations to locations on
the image
Notes: An image is not required to use the smart
arm. The system can be run without a custom image
using the setup before this section. This feature was
added in SYSREL 3R18 (Application version 1.95)
to populate the target elds with this locations
encoder values. Click OK/Check. Repeat this for
location 2 and 3. Set ‘Parameter’ to 2 for location 2
and 3 for location 3. Click OK/Check until all Smart
Arm congurations are saved.
Each location is now paired with a job sequence
number. Now congure the line side control to
select the job and job sequence paired to the
fastener and the tool will not be enabled until the
tool is located over the correct fastener.
External Control
Line side control can be used to command which
fastener needs to be run. Select the Job that
matches the work type (initial or rework) and
select the job sequence number that is tied to the
fastener location. Congure the assignable IO for
the required interface type (CC-Link, Anybus, etc.)
to select a job number and job sequence number.
Refer to the white paper for the specic interface for
conguration details.
In this example, selecting Job 1 and Job Sequence
2 will select PSet 2 and disable the controller until the
arm is in the correct position for fastener 2.
Selecting Job 2 and Job Sequence 3 will select PSet
6 and disable the controller until the arm is in the
correct position for fastener 3.
The front panel and physical IO can be used to
select job number, sequence number, and reset
job if needed for testing. The job can be changed
by holding the toggle button and pressing an up/
down button. Job sequence can be changed by
just pressing an up or down button when jobs are
enabled.

9
Gen IV Controller with Smart Arm Setup Instruction Manual
Icon Reference
Icon Function Denition
Current
Location
The encoder states match the
encoder location tied to this smart
arm screen location
Valid
Location
This location is a valid position to
move the arm to enable the tool.
Invalid
Location
This is a position that is registered but
the tool will not be enabled when
the arm is in this location. The IO or
Job is commanding that a different
position be run.
Location
OK, Current
Location
A rundown has been successfully
run in this position and the arm is
currently positioned in this location
Location
NOK, Current
Location
A rundown has failed in this position
and the arm is currently positioned in
this location.
Location OK A rundown has been successfully run
in this position
Location
NOK
A rundown has failed in this position
Clearing locations
The ‘Reset Job’ input will always clear the Smart Arm
Runscreen. Any positions marked as complete will
be reset.
14. Example: Select PSets Based on Location
This example expands on the previous example
‘Select PSets Based on Location’. Follow that
example before proceeding. Once that example is
complete there will be three locations programmed
in the controller so that the controller will enable
the tool and select a specic PSet when the tool is
located over a fastener. Now a runscreen will be
added so that these three locations.
Upload the image
Click on the ‘Part Image’ button on the Smart Arm
conguration screen and then ‘Choose File’ from
the image selection screen. The image can be
uploaded from a USB drive from the controller touch
screen or uploaded from a PC when accessing the
controller over a web connection.
Conguration Overview
The smart arm and runscreen can be congured in
many different ways to t the user’s needs. Almost
any IO functionality works in conjunction with the
smart arm display. The most common setups are
shown below but a wider array of IO, Job, and Arm
functions are available.
1. Arm position selects PSets
a. The controller changes PSet based on arm
location. No fastening sequence is needed
by the application. The screen will show all
locations as valid positions to insert a fastener.
2. Job enabled, Arm selects job sequence
a. The sequence of inserting fasteners is
determined by the arm. The job system will
disable the controller if the arm is positioned
over a fastener that is part of has already
been completed. The locations on the screen
will reset when the job is complete or the
‘Job Complete’ IO is triggered. This system
also allows more exibility with PSet choice.
If a set of fastenings have different torque/
angle requirements depending on if the
part is new or being reworked then the job
can be changed so a different set of PSets is
associated with the same fastener locations.
3. Job enabled, IO Selects job sequence, Arm
veries job sequence
a. This setup works best if the line side control
determines which fasteners can be inserted.
The IO will select the job sequence and
the controller will be disabled until the
arm is positioned over a location in that
job sequence. This is a good option when
each fastener needs to be individually
commanded to be run via IO.
Each job sequence can contain one fastener and
the job sequence is equivalent to the location
number. This way the smart arm position location
number and parameter can be matched to the
job sequence number. This way the same PSet
can be used for multiple fasteners because the
job sequence number is the value tied to the
location number. The job number can be changed
which allows different fastening parameters to be
connected to the same locations.

10
Gen IV Controller with Smart Arm Setup Instruction Manual
Image 2
Current valid position
is marked blue. Other
valid locations marked
with green targets.
Image 3
Fasteners are
marked as they are
completed. Failed
fastenings are marked
NOK. Status icons
will clear when all
fasteners have been
successfully inserted.
15. Example: Command Bolt Locations via
External Source with Image
This example expands on the sample setup where
an external source is commanding which fastener
needs to be inserted. Go through the setup in the
‘Command Bolt Locations via External Source’
before proceding. At this point the system will be set
up as follows:
• Summary – A xture with three bolts to be
inserted. Each of the three bolts has a xed
location. Each bolt has specic torque
requirements depending on if this is the rst time
the bolt has been inserted or if the bolt is being
reworked. The input on the IO determines which
bolt is to be inserted.
• Two jobs – One for initial fastening and one for
rework fastenings
○Job 1 contains the three PSets for the initial
fastening
Add locations on the image
Once an image is selected it will show up in the
space below. Now select a previously set up
location from the top right and then select the
space to associate with that location. Do this for
every location and then save. Save again on the
Smart Arm conguration screen.
Image 1
Adding locations #1
Runscreen Behavior
Return to the main runscreen and click left/right
arrows until the screen with the part image is shown.
The system is now set up to allow the controller to
change psets based on the arm position. All valid
positions will be blinking with a green target. When
the arm encoder values match an associated
location then the active location will turn blue
indicating the current position and the active PSet
will change.

11
Gen IV Controller with Smart Arm Setup Instruction Manual
Image 6
Job Seq 3 is selected.
Arm is in position
1 (shown in red as
incorrect position)
and screen shows
green target
highlighting fastener
to be inserted.
Stopped icon
appears showing that
the tool is disabled.
Image 7
First fastener has been
inserted successfully.
Current position is
marked OK. Status
bar shows 'Job
Sequence Complete'
and 'Location
Complete'.
Image 8
All fasteners inserted.
Tool is disabled.
Status bar shows job
complete. Reset job
to start new part.
16. References
• 30887 – Smart Arm Assembly
• Encoder - Kubler 8.3620.525E.2048
• 30860 - Smart Arm Accessory – Encoder Interface
○Job 2 contains the three PSets for rework
fastenings
• Six PSets – Two for each bolt (initial fastening or
rework)
• Jobs are enabled
• The accessory ‘Function’ is set to ‘Verify Job
Sequence’
• Assignable inputs are set to ‘Select job sequence’
Setup details
Add the image and three locations as shown in the
last example.
Runscreen Behavior
Return to the runscreen and navigate to the screen
with the part image. The image will now direct the
user to fasten the bolt that is being commanded
from the ‘Select Job Sequence’ input.
The next images show what happens when the
Arm is over location 1 but the commanded Job
Sequence from IO changes from 1, 2, and then 3.
Image 4
Job Seq 1 is selected.
Arm is in correct
position.
Image 5
Job Seq 2 is selected.
Arm is in position
1 (shown in red as
incorrect position) and
screen shows green
target highlighting
fastener to be
inserted. Stopped icon
appears showing that
the tool is disabled.

AIMCO CORPORATE HEADQUARTERS AIMCO CORPORATION DE MEXICO SA DE CV
10000 SE Pine Street Ave. Cristobal Colon 14529
Portland, Oregon 97216 Chihuahua, Chihuahua. 31125
Phone: [phone] Mexico
Toll Free: 1-800-852-1368 Phone: [phone]
Fax: [phone]
LIT-MAN275 Rev. 04-07-21
Printed in USA ©2021 AIMCO