Aimco AcraDyne Gen 4 HT Series User manual

10000 SE Pine St., Portland OR 97216 • 503-254-6600 • 800-852-1368
www.aimco-global.com
High Torque DC Nutrunners
Operation Manual
Gen 4 HT Series
Gen 3 5000 HT Angle Series

2
Table of Contents
Introduction
Thank you for your purchase of an AcraDyne® HT Series Electric Transducerized Nutrunner. These Nutrunners deliver true,
traceable Torque and Angle tightening events with data recording abilities delivered by the connected AcraDyne Controllers.
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Reaction Bar Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Environmental & Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Tool Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Recommended Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
AIMCO Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
A complete tool system consists of the following items:
Controller Power cord Tool Tool Cable
Not to exceed 20M in length
Reaction Bar
Application specific

3
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 ammable 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. Unmodied 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.
3) PERSONAL SAFETY
Indicates Caution is required. Failure to exercise
caution and correct operating technique can result
in serious personal injury, loss of limb or death.
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 inuence
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).
Safety Information
c) Avoid accidental starting. Ensure the switch is in the
off-position before plugging in. Carrying power tools
with your nger 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 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.
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 xtured assembly
processes.
CAUTION – DO NOT USE THE ACRADYNE® HT NUTRUNNING SYSTEM WITHOUT FULLY READING THIS MANUAL AND HAVING A COMPLETE
UNDERSTANDING OF THE CORRECT USAGE OF A HIGH TORQUE DELIVERING TOOL AND ANY ASSOCIATED REACTION BARS/ACCESSORIES.
SAVE THESE INSTRUCTIONS

4
Operation
CAUTION IS REQUIRED. FAILURE TO EXERCISE CAUTION AND CORRECT OPERATING TECHNIQUE CAN
RESULT IN SERIOUS PERSONAL INJURY, LOSS OF LIMB OR DEATH.
AcraDyne® HT Series Nutrunners are a part of a complete system including Controller, Tool Cable and Tool.
Specic instructions on setup, programming and features are described in greater detail within the AcraDyne®
Controller Manuals and ToolWare software manuals that are provided with those components.
# Part
1Square/Hex Drive
2Multi-Function Button
3LED Status Lights
4 Trigger/Lever
5Cable Connection
Gen III 5000 Series AEN Angle Model
35
Gen IV 5000 Series
AEN Angle Model
1
2
2
3
4
4
1
5
2
AEP Pistol Model
AED Rear Mounted Pistol Model
AEJ Axial Type Model
AEF Fixtured Model
AES Straight Model
2
2
2
4
4
3
3
3
3
3
4
4
3
1
2
4
4
5
AEF Dual Lever
Model
1
2
3
2
44
5
AEJ Dual Lever
HTXD Model

5
Make sure that power is not turned on at the controller
before making any connections to tool.
1) Connect the tool cable to the iEC controller and the tool:
AcraDyne recommends not exceeding 20m length of
cable. 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.
Align the female connector 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
clockwise 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 torque 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 MFB is user configurable in the controller
software so this applies to factory default settings only.
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 once In Cycle Torque is reached
meaning the tightening operation is underway. Pressing
the MFB will cause all tool LED lights to flash. Pressing the
MFB again will switch the tool back to FWD mode and will
indicate this with no LED lights turned on (factory default
setting). For further functionality, see the AcraDyne iEC
controller manual.
3) Start Lever Operation:
To start the tool, depress the start lever. Blue LED lights
will be displayed while tightening a bolt once In Cycle
Torque is reached. The tool will stop automatically 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. Previous
cycle result will remain lit until a new cycle is started and
surpasses In Cycle Torque setting.
4) Free Run Timeout (Controller Program Setting):
For tools with Catalog rated speeds below 60 RPM, it is
recommended that the Free Run Timeout in the Controller
DSP menu under Timeout Settings be changed to 30
seconds from the default setting of 5 seconds.
LED 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
Operation

6
ENSURE THAT POWER TO THE CONTROLLER
IS DISCONNECTED OR PROPER LOCK OUT/TAG
OUT PROCEDURES ARE BEING FOLLOWED
• Orient the Reaction Bar so that the recess
above the spline on the Reaction Bar is oriented
towards the rear of the tool and any reaction
foot is oriented away from the tool anvil
• Install the Reaction Bar onto the splines of
the gearbox ensuring that the Reaction Bar is
staying true to the splines.
• Install the Reaction Bar retaining ring/
plate onto the end of the Gearbox securing
the Reaction Bar in place on the Gearbox.
FAILURE TO SECURE THE REACTION BAR
PROPERLY CAN RESULT IN SEVERE INJURY
TO THE OPERATOR AND/OR DAMAGE TO THE
TOOL/APPLICATION
• Restore power/disengage Lock Out/Tag Out
and prepare for use
THE TOOL HANDLE MUST NOT BE
LOCATED AGAINST AN OBJECT OR
RESTRICTION DURING OPERATION
OF THE TOOL TO AVOID CREATION
OF A PINCH POINT. AN OEM SOURCED OR
APPROVED REACTION BAR OR PROPER
REACTION ABSORPTION DEVICE MUST BE IN
USE AND IN GOOD CONDITION ANY TIME THE
TOOL IS OPERATED. PROPER TORQUE REACTION
MANAGEMENT PRACTICES MUST BE OBSERVED
AT ALL TIMES. FAILURE TO UNDERSTAND AND
EMPLOY SAFE OPERATING TECHNIQUES CAN
RESULT IN TOOL DAMAGE, APPLICATION DAMAGE,
SEVERE PERSONAL INJURY, OR DEATH
When ready to begin tightening:
• Swivel the reaction bar (Slip Ring Equipped
Models only) into position minimizing or ideally
eliminating any gap between the Reaction Bar
and the Reaction Surface of the application. On
Fixed Gearcase models, ensure that reaction
absorption device is congured properly.
• Complete the tightening event.
Slip Ring Models
An optional feature (AEx4Bxxxxxxx models) on AcraDyne HT Series Nutrunners is a Slip Ring that allows the Gearbox to
rotate 360 degrees in either direction related to the motor/handle assembly. This feature is useful in enabling the operator
to position the reaction bar against a reactive point of sucient structure prior to commencing tightening of the bolt.
Operators MUST ensure that no hands, body parts, or other non-suciently structural elements are between the reaction
bar and reactive point when positioning the reaction bar. Care MUST be taken to avoid tool start while positioning of the
reaction bar is undertaken. Failure to practice safe reaction bar handling can result in SEVERE injury to person or damage
to tool/application.
Operation
Gen III 5000 Series Angle Tools Gen IV 5000 Series Angle Tools
Reaction Bar
Retaining
Ring
Gear Box
6000 & 7000 Series Tools 8000 Series Tools
Reaction Bar
Retaining Ring Gear Box
8900 Series Tools X Series Tools
Y Series Tools

7
Sockets
CAUTION IS REQUIRED. FAILURE TO EXERCISE
CAUTION AND CORRECT OPERATING TECHNIQUE
CAN RESULT IN SERIOUS PERSONAL INJURY, LOSS
OF LIMB OR DEATH.
Only Impact Grade, Industrial Sockets should be used with
AcraDyne® HT Series Nutrunners. Mechanic-grade chrome
sockets are not to be used as they do not have sucient
structural strength required to deliver the higher torque
loads that an AcraDyne® HT Series Nutrunner is capable of
delivering. In addition, the use of Socket Extensions of any
length are strongly discouraged as they also will experience
failure to an extent where tool damage or operator injury
may occur.
Pinch Point
CAUTION IS REQUIRED. FAILURE TO EXERCISE
CAUTION AND CORRECT OPERATING TECHNIQUE
CAN RESULT IN SERIOUS PERSONAL INJURY, LOSS
OF LIMB OR DEATH.
The nature of a Reaction Bar in any continuous drive tool is
to press against an object to counteract Torque Reaction as
the tool is delivering Torque.
The operator must take great care to keep body parts or
foreign matter clear of the area between the Reaction Bar
and the surface it is reacting against.
ANY BODY PART OR FOREIGN MATTER RESIDING
IN A SPACE BETWEEN THE REACTION BAR AND
THE SURFACE IT WILL REACT AGAINST WILL
ENCOUNTER SIGNIFICANT FORCES THAT CAN
CAUSE INJURY, LOSS OF LIMB OR DEATH.
Reaction Bar Guidelines
CAUTION IS REQUIRED. FAILURE TO EXERCISE
CAUTION AND CORRECT OPERATING TECHNIQUE
CAN RESULT IN SERIOUS PERSONAL INJURY, LOSS
OF LIMB OR DEATH.
The guidelines offered below are only guidelines. Should
there be any doubt as to the integrity of a proposed reaction
strategy, it is strongly advised to consult with an AcraDyne®
authorized representative prior to executing strategy.
Reaction force is equal to the point being applied. The
magnitude of the reaction force is dependent upon the
perpendicular distance between the point of reaction and
the centerline of the gearbox. In other words, the greater
the distance the lower force experienced. For this reason,
the point of reaction should be kept as far away from the
centerline of the tool gearbox as possible.
Figure 1 – Safe reaction window
Reaction Bar Safety
AcraDyne® HT Nutrunning Systems deliver high amounts of torque to an application in a continuous drive manner.
As is the nature with all tool systems that function in this manner, high amounts of torque reaction will occur.
AcraDyne® HT systems work with Reaction Bars that engage the tool with a secure spline and when used correctly
counteract the natural torque reaction in use by pressing against a part detail or adjacent nut/bolt.
It is essential that these forces are understood completely by the operator and that the Reaction Bars have been chosen with
the application’s specic geometry in mind.
AcraDyne® offers a range of Reaction Bars from stock and will design specic Reaction Bars to suit specic applications upon
request.
It is the user’s responsibility to ensure that the correct Reaction Bar or Tool Holding Fixture is in place PRIOR to use of the
AcraDyne® HT Series Nutrunner.

8
Environmental & Electrical Specications
Environmental
• Operating Temperature: 0°C to 32°C
• Storage Temperature: 0°C to 65°C
• Humidity:
- 5% to 90% RH, Non-Condensing, for temperatures 0°C to 40°C
- 5% to 60% RH, Non-Condensing, for temperatures 0°C to 65°C
• Maximum Altitude of Operation: 3000m
• Maximum decibel level: 77 dB(A)
Electrical
• Motor Type: BLDC
- Motor Phase Voltage: 320 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 a recommended maximum duty cycle of 25%
at 80% of maximum torque capacity on a standard B-joint application.
Note: Actual maximum duty cycles are dependent upon several factors including: Ambient Temperature, Tool Selection,
Joint Conditions, Operating Parameter Set Programming, and Operator Handling.
For optimum Duty Cycle determination, please contact your authorized AcraDyne® Product Representative.
• Motor Speed Setting Guidelines – All settings of AcraDyne HT Series Nutrunners should be made only by experienced,
well-trained technicians. Tools with maximum RPM ratings of 25 RPM or lower should be set to run at the tool’s maximum
rated speed. Specic application demands may require additional stages to achieve optimal results. Consult the
appropriate AcraDyne Tool Controller manual for guidelines and specic information related to programming procedures
and techniques.
If attempting to use tooling below 0°C, allow the system to warm up by running in a no-load
state until acceptable temperatures are reached.

9
5000 Series HT Angle Tools
Max. Free Dimensions
Torque* Torque Range Speed Weight Output A B C D E
MODEL NM FT-LB NM FT-LB RPM LB KG SQ Drive IN MM IN MM IN MM IN MM IN MM
AEN356540A 540 398 135 – 540 100 – 398 109 13.1 5.95 3/4” 22.58 573.6 2.31 58.7 4.75 120.6 4.05 102.8 1.33 33.7
AEN356910AG 900 664 225 – 900 166 – 664 27.9 12.2 5.5 3/4” 18.2 462.9 2.31 58.7 5.93 150.6 4.93 125.2 1.28 32.6
AEN3571000A 1,000 737 250 – 1,000 184 – 737 61 16.3 7.39 1” 22.92 582.2 2.31 58.7 5.36 136.1 4.44 112.7 1.53 38.7
AEN3571600A 1,600 1,180 400 – 1,600 295 – 1,180 33 16.7 7.57 1” 22.92 582.2 2.31 58.7 5.36 136.1 4.44 112.7 1.53 38.7
AEN3572600A 2,600 1,917 650 – 2,600 479 – 1,917 21 18.5 8.40 1” 22.92 582.2 2.31 58.7 6.77 171.9 5.86 148.8 1.53 38.7
Gen 3 5000 Series HT Angle Tools
Tool Specications
Gen 4 7000 Series HT Angle Tools
7000 Series HT DC Angle Tools
Max. Torque Torque Range
Free
Speed
Length
(Minus Reaction Bar) Weight Output
Model* NM FT-LB NM FT-LB RPM IN MM LB KG SQ DRIVE
AEN4B771200B(DL) 1,200 885 240 – 1,200 177 – 885 38 16.6 422 17.9 8.1 1”
AEN4B773000B(DL) 3,000 2,200 600 – 3,000 443 – 2,200 15 16.6 422 20.4 9.3 1”
* Add “DL” to Part Numbers for Dual Lever

10
Tool Specications
Pistol Type
(AEP)
Axial Type
(AEJ) Fixtured Type (AEF)
Straight Lever Type (AES)
Rear Mounted Pistol
(AED)
Fixed Gearcase HT Tools
HT Fixed Gearcase Tools
Approx.
Torque
Approx.
Speed Weight
Total Length
(incl sq. dr) Dia. Drive Sound Level
Model NM FT-LB RPM KG LB MM IN MM IN IN dB(A)
HT Series Fixed Gearcase Models (R) = Pistol Tool with Rear Exit Cable (B) = Fixtured Model with Bottom Exit Cable
6000 Series
AE(P) 4A66250B(R) 250 185 315 4.6 10.5
P = 289
P(R) = 331
D = 388
S = 440
J = 331
F = 331
F(B) = 353
11.4
13
15.3
17.3
13
13
13.9
66 2.6 0.75 66
AE(D) (S)(J) (F)4A66250B
AE(P) 4A66425B(R) 425 315 165 4.6 10.5 66 2.6 0.75 66AE(D) (S)(J) 4A66425B
AE(F) 4A66425B(B)
AE(P) A66625B(R) 625 460 106 4.8 10.5 66 2.6 0.75 66AE (D)(S) (J)4A66625B
AE(F) 4A66625B(B)
AE(P) 4A66925B(R) 925 682 72 4.8 10.5 66 2.6 0.75 66
AE(D) (S)(J) (F)4A66925B
7000 Series
AE(F) 4A76200BB 200 148 432 5.2 11.5 313 12.3 67.3 2.7 0.75 66
AE(P) (D)(S) (J)(F)4A771000B 1,000 738 65 6.6 14.5
P = 302
D = 397
S = 453
J = 343
F = 343
11.9
15.6
17.8
13.5
13.5
77.5 3.1 1 66
AE(P) (D)(S) (J)4A772500B 2,500 1,844 25 7.5 16.5
P = 337
D = 433
S = 488
J = 379
F = 379
13.3
17.0
19.2
14.9
14.9
77.5 3.1 1 66
AE(F) 4A772500B(B)
8000 Series
AE(P) (D)(J) (F)4A884200B1 4,200 3,100 12 11.1 24.5 P = 384
D = 480
S = 546
J = 410
F = 410
15.1
18.9
21.5
16.1
16.1
91.2 3.6
B1 = 1 66
AE(P) (D)(S) (J)(F) 4A884200B B = 1.5
AE(P) (D)(J) (F)4A885000B 5,000 3,700 9.3 11.1 24.5 1.5 66
AE(P) (D)(J) (F)4A896500B 6,500 4,800 7 15.7 34.5 P = 438
D = 533
S = 599
J = 463
F = 462
17.2
21
23.6
18.2
18.2
103.8 4.1 1.5 66
AE(F) 4A896500B(B)
AE(P) (D)(S) (J)(F) 4A898100B 8,100 6,000 5 15.7 34.5
* 8,100 Nm – 17,000 Nm models are not supported by the Gen III controller platform. The Gen IV controller platform is required.