Aimco Brakes AcraDyne Gen 3 Tubenut Runner Manual

							
www.aimco-global.com
AcraDyne Gen III 
2000 Series Tubenut runners
 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 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 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 plug- 
    ging 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 pro 
  cesses.
     
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
Tool Body
Start LeverCable 
Connection
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.
A complete tool system consists of the following items:
Controller Power Cord Tool Tool Cable
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 
						

							PAGE HEADER HEREGEN III 2000 SERIES TUBENUT RUNNERS 
 ITEM #  AET  AET  AET  AET    QTY.  PART #  DESCRIPTION
   32020A 32025A  32035A 32050A
 1 X X  X X  1 25064 MOTOR HOUSING
  2  X  X  X  X    1  25425  MOTOR ASM., 5:1, 2000 SERIES GEN III
 3 X X  X X  1 25063 LED BOARD ASM.
  4  X  X  X  X    2  25075  SCREW, SHC 4-40X.375, STEEL, BLACK OXIDE
  5  X  X  X  X    2  25429  STAND-OFF, LED, 2000 SERIES
  6  X  X  X  X    1  25073  SCREW, SET 4-40X.375, STEEL, BLACK OXIDE
 7 X X  X X  1 24254 SPACER, PILOT
 8 X X  X X  1 25298 SPIRAL RETAINING RING
 9 X X  X X  1 21122 TUBENUT ADAPTOR ASSEMBLY
 10 X X  X X  2 24272 ADAPTOR INSERT
  11  X  X  X  X    2  24324  DOWEL PIN 3/32 Dia x 7/8 LONG
  12  X  X  X  X    1  25418  TOOL CONNECTOR ASM GEN III TOOLS
 13 X X  X X  1 25271 SHIM. - .002
 14 X X  X X  1 25272 SHIM. - .005
 15 X X  X X  1 25273 SHIM. - .010
  16  X  X  X  X    1  25102  Screw, BHC4-40X.188, STEEL, BLACK OXIDE
  17  X  X  X  X    1  25402  T.I.D. BOARD ASM. - GEN III
  18  X  X  X  X    2  24934  FLAT HEAD CAP SCREW
 19 X X  X X  1 25071 SPRING, LEVER
 20 X X  X X  1 25074 LEVER ASSEMBLY
 21 X X  X X  2 20061 SCREW, LEVER
  22  X  X  X  X    1  25072  O-RING, LED LIGHT RING COVER
 23 X X  X X  1 20534 3000 SERIAL/MODEL LABEL
  24  X  X  X  X    1  25058  LIGHT RING COVER, LED
  25  X  X  X  X    1  25060  HANDLE COVER, REV. BUTTON
 26 X X  X X  1 24679 RETAINING RNG
 27 X X  X X  1 24683 SPRING, REV BUTTON
 28 X X  X X  1 24706 REV BUTTON SUB-ASSEMBLY
 29 X X  X X  1 25059 HANDLE COVER
  30  X  X  X  X    10  24940  SCREW, FHSC 4-40 X .25 LG., STEEL, BLACK OXIDE
 31 X X  X X  1 21748 LOCK NUT
  32  X          1  21631  TUBENUT HEAD ASM.
     X        1  21632
       X      1  21633
         X    1  21634
 33 X X  X X  1 22141 SAFETY LABEL
7
2
8
3
411
630
1729
16
24
15
14
13
22 25 1
28 27 19
20
26
21 23 33 9
30 10
18
31 325
12
Assembly for: AET32020A, AET32025A, AET32035A and AET32050A
4 
						

							SPECIFICATIONS
Environmental
   Operating Temperature: 0°C to 32°C 
   Storage Temperature: 0°C to 65°C 
  Humidity: 
      o   5% to 90% RH, Non-Condensing, for temperatures 0°C  to 40°C 
      o   5% 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
      o  Motor 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
   2.9 lbs/1.3 kg - 5.4 lbs/2.5 kg
Performance
   Torque range: 4 - 40 NM
   Speed Range: 240 - 580 RPM 
						

							6
OVERVIEW
The following describes the setup required for tube-nut tool operation.  This includes determining the values for tube-nut spe-
ci c TID parameters (parameters residing in the tool memory) and iEC Controller parameters.
TUBE NUT HOMING 
T
UBE NUT HOME TID PARAMETERS
The tube nut TID parameters can be viewed and modi ed from the Tool-> Edit->Tool Setup screen in ToolWare. The tool to be 
con gured must be connected to the controller.
Home Detection Torque - Home  (in*Lb)
 When the tool is homing, reaching this torque indicates to the controller the tool output socket has reached the home    
stop and is in the open position.
 If the tool output does not attempt to return or does not completely reach the home position, this value is too low.
 Attention: Setting this value too high can potentially damage the tool. 

 TID memory location: 53
Hold at Home Torque - Open Loop (in*Lb)
 After reaching the home position, this torque is applied against the home stop to prevent the socket from bouncing to a 
partially closed position. 
 This value is typically set to a value slightly lower than the home detection torque.
 If the socket is bouncing back to a partially closed position after reaching the home stop, this value is too low.
 Attention: Setting this value too high can cause the socket to snap back to the home stop too quickly and potentially 
damage the tool. 
 Units: lbf-in (approximation)
 TID memory location: 54

T
YPICAL PROCEDURE FOR SETTING THE TOOL’S TUBE NUT HOME TID PARAMETERS
 Set the Hold at Home Torque = 0
 Set the  Home Detection Torque = 1
 Free run the tool and watch the homing routine while making the adjustments below.
 Gradually increase the value for the Home Detection Torque until the tool reliably returns to the home position.
 Once a good value for the Home Detection Torque is found, if the tool is bouncing back to a partially closed position 
after hitting the home stop.
 Gradually increase the value for the Hold at Home Torque until bounce back is eliminated.
GEN III C
ONTROLLER PARAMETERS AFFECTING TUBE NUT HOMING
Controller parameters for tube-nut operation can be viewed and modi ed from the Controller->Edit Controller Parameter-
>Tube-nut screen in ToolWare.
 Tube Nut Backoff Speed:
  - This is the speed the tool output socket travels when returning to the home position.
  - Decreasing this can reduce the impact force when hitting the home stop. 
  - Attention: Care must be taken, increasing the speed above the default value. Too high of a value can greatly in   
    crease how hard the output will hit the home stop and potentially damage the tool. 
  - Units: RPM of the tool output socket in the homing direction
  - Default value: 100 RPM.
  - Range: 10 to 500 RPM
TUBE-NUT TOOL SETUP DETAILS 
						

							7  Tube Nut Homing Reverse Dwell Time:
  - The amount of time before the output is allowed to home, after the rundown is complete and the tool lever is re-   
  leased.
 - Units: Seconds
  - Default value: 0.5 Seconds
  - Range: 0 to 2 Seconds
 Tube Nut Home Dwell time:
  - The amount of time the tool holds at home to prevent bounce back
  - Too short of home dwell time can increase the occurrence of bounce back. However, decreasing the homing speed  
    can decrease the severity of bounce back after the home stop is reached and allow for a shorter dwell time.
  - Units: Seconds
  - Default value: 0.5 Seconds
  - Range: 0 to 2 Seconds
GEN IV C
ONTROLLER PARAMETERS AFFECTING TUBE NUT HOMING
Controller parameters for tube-nut operation can be viewed and modi ed from the Controller->Tool Setup->Disassembly and 
Tube-nut screen.
 Tube Nut Homing Max Speed:
    - This is the speed the tool output socket travels when returning to the home position.
    - Decreasing this can reduce the impact force when hitting the home stop.
    - Attention: Care must be taken, increasing the speed above the default value. Too high of a value can greatly in-   
      crease how hard the output will hit the home stop and potentially damage the tool.
    - Units: RPM of the tool output socket in the homing direction
    - Default value: 100 RPM.
    - Range: 1 to 200 RPM
 Tube Nut Homing Acceleration:
    - Rate at which the speed of the tool ramps to the homing speed.
    - Units: kRPM/second
    - Default value: 0.5
    - Range: 0.1 to 10
 Tube Nut Homing Reverse Dwell Time:
    - The amount of time before the output is allowed to home, after the rundown is complete and the tool lever is re-   
   leased.
    - Units: Seconds
    - Default value: 0.5 Seconds
    - Range: 0 to 2 Seconds
 Tube Nut Home Dwell time:
  - The amount of time the tool holds at home to prevent bounce back
  - Too short of home dwell time can increase the occurrence of bounce back. However, decreasing the homing speed   
    can decrease the severity of bounce back after the home stop is reached and allow for a shorter dwell time.    
  - Units: Seconds
  - Default value: 0.5 Seconds
  - Range: 0 to 2 Seconds 
						

							TUBE NUT PINCH DETECTION
T
UBE NUT HOME TID PARAMETERS
The tube nut TID parameters can be viewed and modi ed from the Tool-> Edit->Tool Setup screen in ToolWare. The tool to be 
con gured must be connected to the controller.
 Obstruction Detection Torque -  (in*Lb)
    - At the start of rundown before the output rotation has passed though the Obstruction Check Zone (where the    
      output is open at the start of the fasting cycle), the tool will stop and fastening cycle will be aborted if this torque is   
   exceeded.
    - If the tool stops, when the output is open during this  rst part of the rundown, without any obstruction, the value is    
   too low.
    - Units: lbf-in
    - TID memory location: 53
T
YPICAL PROCEDURE FOR SETTING THE TOOL’S TUBE NUT OBSTRUCTION DETECTION PARAMETERS
 Set the value for the obstruction torque just high enough so the tool will reliably overcome gear friction and make it    
  past the obstruction checking zone.
 Check the torque of the stop on obstruction feature by measuring the actual “pinch” torque the tube nut produces at    
  the start of the rundown when the jaws are open (within the obstruction detection angle range). This can be done on a   
  semi-tightened joint simulator set for a hard joint, while auditing the torque.
 Note: Gear friction in the tube-nut head can greatly affect the ability to reliably detect an obstruction.
GEN III C
ONTROLLER PARAMETERS AFFECTING TUBE NUT PINCH DETECTION
Controller parameters for soft-start operation can be viewed and modi ed from the Controller->Edit Controller Parameter->Soft 
Start in ToolWare.
 Soft Start Dwell Speed
  - The Soft Start Dwell Speed is used during the check for obstructions.
  - Decreasing this can reduce the impact force when hitting an obstruction.
  - Attention: Care must be taken, increasing the speed above the default value. Too high of a value can greatly in-   
    crease how hard the output will hit the obstruction.
  - Units: RPM of the tool output
  - Default: 90 RPM
  - Range: 1 to 500 RPM
GEN IV C
ONTROLLER PARAMETERS AFFECTING TUBE NUT PINCH DETECTION
Controller parameters for tube nut operation can be viewed and modi ed from the Controller->Tool Setup->Disassembly and 
Tube-nut screen.
 Obstruction Check Angle
    - Angle of travel from the start of the fasting cycle where if an obstruction is detected inside this zone, the tool will    
      stop and the fastening cycle will be aborted.
    - Units: Degrees of rotation of the output from home to where the output is closed.
    - Default value: 70 Degrees
    - Range: 0 to 180 Degrees
 Obstruction Check Speed Limit
    - Maximum speed the output will run during the check for obstructions.
    - Decreasing this can reduce the impact force when hitting an obstruction.
    - Attention: Care must be taken, increasing the speed above the default value. Too high of a value can greatly in-
        crease how hard the output will hit the obstruction. 
						

							  - Units: RPM of the tool output
  - Default: 90 RPM
  - Range: 1 to 200 RPM
  - Obstruction Check Acceleration Limit
  - Rate at which the speed of the tool ramps to Obstruction Check Speed.
  - Units: kRPM/second
  - Default value: 0.5
  - Range: 0.1 to 10
T
UBE NUT HOMING START INPUT LOGIC SELECTION:
The controller parameters for tube- operation can be viewed and modi ed from the Controller->Edit Controller Parameter-
>Tube Nut screen in ToolWare.
 Tube nut Home Strategy:
    - Lever action required to start the home sequence.
  - Options:
      Home on release and repress of the lever (default)
      Home on release of the lever GEN IV C
ONTROLLER PARAMETERS AFFECTING TUBE NUT PINCH DETECTION (CONT’D) 
						

							
Notes: