Aimco Brakes AcraDyne iEC iControl DC Tool Controller Users Guide

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Using the Optional Keypad Display Module (KDM) 
 
Adaptive Control 
 
ADAPTIVE CONTROL provides the user with a function to allow the iEC Controller to adapt to the joint 
dynamics of a particular application and to adjust the 
target torque accordingly in order to provide  
accurate and repeatable performance. 
 
ADAPTIVE CONTROL works only in  Torque Control or Torque Control / Angle Monitor Strategies. 
 
The user may access the ADAPTIVE CONTRO L function by following these steps: 
 
 
From the MAIN MENU, press 
3 for ADMIN 
 
Press  
7 for ADAPTIVE CONTROL 
 
The following text will be disp layed on the KDM display screen: 
 
 
 
 
 
 
 
 
The currently active choice is noted by an  asterisk to the right of the option. 
 
The Factory Default setting for ADAPTIVE CONTROL is  1) OFF. 
 
 
To enable or disable ADAPTIVE CONTROL, press  the number on the keypad corresponding to the  
desired choice. 
 
There are two modes of operation for ADAPTIVE CONTROL: 
 
  Adapt To 10 Rundowns:   
  
  The Control Target Torque is adjusted by  the difference between the mean of the first  
  10 rundowns and the hi/lo limit mean. 
 
  Adapt To All Rundowns:  
 
  The Control Target Torque is adjusted by a  percentage of the  
  difference between the mean of each consecutive 10 rundowns and the high/low limit mean. 
  This percentage is programmable through advanced user access. 
 
ADAPTIVE CONTROL should be used only in specific  situations. Please contact AcraDyne Technical 
Support or your AIMCO representative for information on using and adjusting ADAPTIVE CONTROL. 
! 
						

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The controller has several networking options availa
ble including Ethernet and hardwired field bus.  All 
parameters pertaining to networking are conf igured in the web interface via its Ethernet. 
Ethernet
 
Each Ethernet connection can be configured to communicate with most popular plant equipment includ-
ing data collection servers, laptop software, and PLCs. 
Ethernet ports by default are set to an IP address of  10.10.30.150 and need to be changed before being 
put into service. 
 
To gain initial access to the controller: 
• Configure a computer’s Ethernet port to an IP address of 10.10.30.xxx.  Do not set it to 
10.10.30.150 that address is assi gned to the controller.  10.10.30.99 works in most cases. 
• Connect an Ethernet crossover cable from  the computer to the controller. 
• Launch the computers web browser.  Type the c ontroller IP address (10.10.30.150) into its ad-
dress bar. 
• Navigate to the communications page. 
• Set the desired IP Address, IP Mask, and Gateway. 
• Cycle power on the controller and connect it to the network. 
 
Web Interface
 
The controller’s web interface is available from any  computer on that has access on the local network.  
To access the web interface launch a browser and type the controller IP address into its address bar. 
 
From the interface you will have acce ss to the controller’s status, internal data files, and parameters.  
The pages do not automatically refres h but selecting refresh from the browser will reload the latest infor-
mation from the controller.  Data files will be st andard ASCII text in CSV (comma separated variables) 
format that can be opened in Micr osoft Excel and other programs. 
 
On pages with parameters there will be a submit but ton to apply any changes.  All parameters on the 
page are submitted when the button is hit. When submitted each parameter will get range checked 
against allowable limits.  If a parameter is outside of  its range it will be limited to its minimum or maxi-
mum value.  When the page is  redrawn the edit fields will contain each parameters final value. 
 
Security
 
The web interface has an option to add a user passwor d for security.  A password is never required to 
view the web pages on the controller.  It is only requir ed to make a change to a parameter.  If the con-
troller password is not set (a zero  length string) the user will not be prompted to  enter a password for 
any changes.  The controller is shipped from the factory without a password. 
Networking  
						

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The security feature utilizes the aut
hentication built into the browser.  When a change to a parameter is 
made the controller checks the progra mmed password.  If a password is required the controller will re-
quest it from the browser and in tu rn the browser will prompt the user .  The browser will request a “User 
name” and “password”.  Since the controller only cont ains one password (one user) the “User name” 
can be left blank.  Once the passwor d is entered it is returned to the controller were it will be checked 
and if it is correct the parameters  are saved.  If it is incorrect the controller will request it from the 
browser again. 
 
After a password has been ent ered most browsers will cache it and return on subsequent request with-
out prompting the user.  So as long as the browser is not closed it would not  be necessary to enter the 
password on every change to the parameters. 
 
To remove a password from the cont roller it just needs to be set to a zero length string and saved via 
the submit button.  Of course this action requires the existing password.  If the password is lost or un-
known contact your AIMCO representat ive for a method of retrieval. 
 
Toolsnet
 
The controller has the ability to s end rundown data to a ToolsNet server .  Once the controller is on the 
local network there are five parameters that must  be set to store data correctly on the server. 
  1. Server IP Address:   This is the IP address of the Toolsnet server.   If the server is on an-
other subnet you will also have to verify the gateway in the Ethernet settings. 
2.  Server Port Number:   This is the TCP port the server is listening on for a new connection.  
The default for this is 6547 but it should be veri fied with the local Toolsnet server administra-
tor. 
3.  Station Id:   This is used to identify the data in the  Toolsnet database.  Work with your local 
Toolsnet server administrator to set this correctly. 
4.  System Number:   This is used to identify the data  in the Toolsnet database.  Work with 
your local Toolsnet server adminis trator to set this correctly. 
5.  Station Number:   This is used to identify the data in  the Toolsnet database.  Work with your 
local Toolsnet server administ rator to set this correctly. 
 
PFCS
 
The controller has the ability to communicate over t he Chrysler PFCS protocol over Ethernet or one of 
the serial ports.  Once the cont roller is connect to the desired network there are several parameters 
used to configure it’s behavior on the PFCS network. 
 
1. Server IP Address:   This is the IP address of the PFCS  server.   If the server is on another 
subnet you will also have to verify the gateway  in the Ethernet settings.  This parameter is 
not used for a serial connection to PFCS. 
2.  Server Port Number:   This is the TCP port the server is listening on for a new connection.  
This parameter is not used for a serial connection to PFCS. 
3.  Ack Time Out (sec):  The amount of time the controller  will wait for an acknowledge from 
the PFCS server. 
4.  No. Retries:  The number of times the controller will retry a message if  it is not answered 
by the PFCS server. 
5.  Reconnect Time Out (sec):   The amount of time the cont roller will wait before attempting  
to reconnect to the PFCS server. 
6.  Connection Inactivity Time (sec):   The amount of time the controller will wait before send 
a keep alive message. 
7.  Auto Machine Id:    If set to a 1 the controller will reques t a machine ID from PFCS.  If it is a 
0 it will use the programmed  one from each parameter set. 
Networking  
						

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Networking 
Open Protocol 
The controller has the ability to accept an “Open” pr otocol connection.  This connection is available 
over Ethernet and/or the standard serial ports.   Through this connection you can enable/disable the 
tool, set the active parameter set,  collect rundown data, and much more. 
 
1. Port Number:   The TCP port number the controller listens on to accept an Open protocol 
connection via Ethernet.  The default port is 4545 but can be changed if required. 
2.  Cable Loss Detection:   Only used for a serial Open protocol connection.  If set to 1 the 
controller will close the connecti on on a time-out.  If it is set to 0 the controller will not 
close the connection.  See the latest Open protocol specification for details on time-outs 
and keep alive messages. 
3.  Cell ID:   Optional variable that is passed through the Open protocol connection. 
4.  Channel ID:   Optional variable that is passed th rough the Open protocol connection. 
5.  Controller Name:   Optional variable that is passe d through the Open protocol connec-
tion. 
 
To set up a serial port for Open protocol set the  function on the desired COM port to “Open Protocol” 
and cycle the power on the controller. 
 
 
 
 
  
						

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Networking 
The Controller supports the following MIDs.  See the 
latest Open protocol specification for details on 
each MID. 
 
 
  
 
 
MID  Description  Note 
0001  Communication start     
0003  Communication stop     
0010  Parameter set numbers upload request    
0012  Parameter set data upload request    
0013  Parameter set data upload reply    
0018  Select Parameter set     
0020  Reset Parameter set batch size   
0042  Disable tool     
0043  Enable tool    
0050  Vehicle Id Number download request    
0051  Vehicle Id Number upload subscribe    
0054  Vehicle Id Number upload unsubscribe    
0060  Last tightening result data subscribe  Rev 1-2 and 999 supported 
0063  Last tightening result data unsubscribe   
0070  Alarm subscribe     
0073  Alarm Unsubscribe     
0080  Read time upload request    
0082  Set Time in the Torque 
Co

ntroller    
0150  Identifier download request    
214-215  IO device status messages    
216-219  Relay function subscription  Relays 1 ,2, 5-8, 11, 19-22, 24 only 
220-223  Digital In function subscription  Input 1, 3, 8, 9, 16-18, 53 only  
9999  Keep alive message      
						

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Networking 
Chrysler PFCS 
 
The controller has the ability to c onnect to the Chrysler PFCS network .  Once the controller is on the 
local network there are several parameters  that must be set to work correctly. 
 
1.  Server IP Address:   This is the IP address of the Chrysler  server.   If the server is on another 
subnet you will also have to verify  the gateway in the Ethernet settings. 
2.  Server Port Number:   This is the TCP port the server is listening on for a new connection. 
3.  Ack Time Out:  This is the amount of time the contro ller will wait for an acknowledge message 
from the server.  The default is 3 seconds. 
4.  No. Retries:   The number of retries the controller will a ttempt before disconnecting.  The default 
value is 3. 
5.  Reconnect Time Out:   The amount of time the controller will  wait before attempting to re-connect 
to the server.  The default value is 20 seconds. 
6.  Connection Inactivity Time:   The amount of time the controlle r will wait between connection at-
tempts.  The default value is 120 seconds. 
7.  Auto Machine Id:  If set to “Yes” (default) the machine ID will be provided by the Chrysler PFCS 
server upon connection.  If set to “No” the ma chine ID is entered per parameter set on the 
“Advanced” tab on the web  interface.  This will result in  each parameter set having its own ID. 
 
 
  
						

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Networking 
AIMCO Database 
 
The controller has the ability to  send rundown data to an AIMCO data collection server.  Once the con-
troller is on the local network there are two paramete rs that must be set to store data correctly on the 
server. 
1. Server IP Address:   This is the IP address of the AI MCO data collection server.  If the 
server is on another subnet y ou will also have to verify the  gateway in the Ethernet settings. 
2.  Server Port Number:   This is the TCP port the server is listening on for a new connection.  
See your local AIMCO data collection server administrator for the correct port number. 
 
 
  
						

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Networking 
Modbus TCP 
The controller will accept a conn ection from a Modbus TCP master. 
 
Controller Outputs
 
The Controller’s outputs are located at address 0 and contain one status word. 
 
 
 
 
 
Controller Inputs
 
The Controller inputs are located at address 1024 and 1036.  Address 1024 contains one control word and 1036 con-
tains the 20 character VIN. 
 
 
 
 
 
 
Controller Outputs  
   Bits 
15  14 13  12  11  10  9  8  7 6 5 4 3 2 1 0 
Address 0  Handshake        Job Complete        Healthy  Running  Process number 
Bit
 Name  Function  
0-7  Process Number  Process number echo.   Latched while it is in a job. 
8  Running  Indicates the tool is running. 
9  Healthy  Indicates the controller has no faults. 
10  Not used    
11  Not used    
12  Job Complete  Indicates the job is comple te.  Will go off when Enable input goes off. 
13  Not used    
14  Not used    
15 Handshake  Echo of the Handshake input 
  Controller Inputs  
   Bits 
15  14 13 12 11 10  9  8  7  6  5  4  3  2  1  0 
 Address  1024  Handshake                Abort  Enable  Process number 
Bit  name Function 
0-7 Process Number  Process number input.  The enable must be off to change the Process Number.  On 
a change to the Process Number the batch is also reset. 
8  Enable  On the rising edge of Enable the tool will be enabled. 
9  Abort  If Abort is on the tool will be disabled. 
10  Not used    
11  Not used    
12  Not used    
13  Not used    
14  Not used    
15 Handshake  Will be echoed to the Handshake output  
						

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Networking 
Profibus/DeviceNET 
The controller can have an optional  Profibus or DeviceNET interface.  These interfaces are accom-
plished through the use of a serial bridge.  The serial  bridge is provided by MKS Instruments, Inc .  See 
the latest MKS documentation for detai ls on sending and receiving messages. 
 
Logical I/O
 
The controller has five st atus bytes of outputs. 
    
Controller Outputs
 
    
Bit 
     
7  6  5 4 3 2 1 0 
Byte   0 
                  Tool 
Ready  Tool  
Enable 
1           Bypass  Batch 
Complete  Msg  
Received  Status 
NOK  Status OK 
2                         
3     Buzz Slow  Buzz Fast  Red  Yellow  Green  Blue  White 
4        Pause  Red 
Flashing  Yellow 
Flashing  Green 
Flashing  Blue 
Flashing  White 
Flashing 
 
 
Byte  Bit Name  Function 
0  0  Tool Enable 
The enabled state of the tool. 
1 Tool Ready  On if the tool is ready to run.  Will be off if tool is disabled or there is a fault 
on the controller. 
2-7  Not used    
1  0 Status OK 
Rundown status on for an accept. This bit is timed and will be on for ½ 
second. 
1 Status NOK  Rundown status on for a reject. This bit is timed and will be on for ½  
second. 
2 Msg Received  On to indicate a message has been received from the MKS module and the 
inputs have changed.  This bit is timed and will be on for ½ second. 
3 Batch Complete  Indicates the batch is complete.  Will go off when batch is reset or when the 
tool enable is turned off. 
4  Bypass  State of the bypass input. 
5-7  Not used    
2  0-7  Not used    
3  0-6  Light Tower Status  Bitwise status of the Light Tower lights. 
7  Not used    
4  0-5  Light Tower Status  Bitwise status of the Light Tower lights. 
6-7 Not used 
  
   Controller Inputs
 
    
Bit 
     
7  6  5 4 3 2 1  0 
Byte   0 
 PSET 
1    PLC 
Enable  White 
Flash  Pause        Tool  
Enable 
2-11  Sequence Number 
12-31  Serial Number  
						

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Ethernet/IP
 
The controller will accept a conn ection from an Ethernet/IP master.   The controller has two connection 
assemblies.  One for the controller’s output image (Assem bly Instance 100).  The default size of this is 
34 bytes.  If fastening results are not included then the size is 2 bytes.  And one for the controller’s input 
image (Assembly Instance 112) with a size of 32 bytes. 
 
Logic I/O
 
The controller has two status bytes of outputs (Assembly instance 100). 
 
 
    
Controller Outputs
 
    
Bit 
     
7  6 5 4  3  2 1 0 
Byte   0 
                  Tool 
Ready  Tool 
Enable 
1           Bypass  Batch 
Complete   Status 
NOK  Status 
OK 
Byte  Bit Name  Function 
0 0-7  PSET  Set the active parameter set of 1-32.  If 0 the active parameter set is left  
unchanged. 
1  0 
Tool Enable  If PLC Enable is 0 this input is ignored.  If PLC Enable is 1 this bit can be used 
to enable or disable the tool. 
1-3  Not used    
4  Pause  Setting Pause to 1 cause the light stack to strobe.  Setting it to 0 put the light 
stack back into its normal operation. 
5  White Flash  Setting White Flash to 1 cause the light stack to flash the white light.  Setting it 
to 0 put the light stack back into its normal operation. 
6  PLC Enable  Setting PLC Enable to 1 allows the T
ool Enable bit.  Setting it to 0 disables the 
Tool Enable function. 
7  Not used    
2-11 0-7  Sequence Number  10 character Sequence Number. 
12-31 0-7  Serial Number 
20 character Serial Number. 
Networking