Aimco Brakes AcraDyne iEC iControl DC Tool Controller Users Guide

							 15
Angle High Limit
 - is used for Accept / Reject decision. Rundown does not pass 
if the measured final a ngle exceeds this limit. 
             Angle Target -  the target angle value 
  Angle Low Limit -  used for Accept / Reject decis ion. Rundown does not pass if 
the final angle is below this limit. 
 
Rpm Freespeed % -  specifies initial tool output-drive speed. The parameter is 
expressed as a percentage of the tool’s maximum rated speed. 
 
Rpm Downshift % -  specifies the speed of the tool  after the Tq Downshift value 
is reached. The value is expressed as a percentage of the tool‘s maximum rated 
speed. 
 
Ergo Mode - activates tool power rampi ng-down mode when fastening achieves 
Target Torque or Target Angle value. Th is feature reduces torque reaction in the 
hand-held tool as final tor que or angle is achieved. 
   
Soft Start - activates tool power  ramping-up from zero to Rpm Freespeed% 
value.  This allows for slower engagement  of the fastener into the application. 
 
Linked PSets –  creates a group of sequential Parameter Sets actuated by a 
single trigger pull.  To define the last Parameter Set in the group, unselect “Link 
PSet” by placing a 0 in the field.  
 
Link Delay  - used to add a delay time between the linked steps. 
 
Running a Linked PSet rundown: 
 
  To run a Linked PSet group, select  the first PSet in the group as the 
“Current PSet”. (Via the CHANGE PSET  button on the controller, or using 
Logic IO, or using the “Current” PSet selection in Toolware)  
   Link the PSets by selecting the next PSet in the Current PSet’s “Link PSet” 
Drop down. If you want to have a delay  between the rundowns enter that in   
the “Link Delay” Drop Down box.  If you want to link more PSets then 
repeat this step.  
   Run the tool as usual by pre ssing and holding the throttle.  
   The tool will sequence thru each PSet in the Linked PSet group.  
   At the completion of last the PSet of the group, the controller will signify the 
Linked PSet rundown is complete by li ghting the cycle accept (or reject) led 
and turning off the blue In-cycle led. 
   The current PSet will automatically re set to the first PSet in the group to 
ready for the next rundown.  
   A release and repress of  the trigger is necessary to start the next Linked 
PSet rundown.  
						

							 16
           Linked PSet Results Reporting: 
 
The angle count is reset to 0 at the  end of each linked step of a Linked PSet 
rundown.  
 
RBR Combined with a Linked PSet Rundown Note: 
 
The RBR, RB, and RBsp,  options are only  preformed at the end of the last step 
of a Linked PSet rundown 
 
Results Reporting: 
  The results of the last PSet Step  in the group are used to report. 
 
If the trigger is released before the rundown sequence is complete, the results 
from the step that the cont roller was currently running, before being interrupted, 
are reported. 
 
The controller reports curve data from  the last rundown step and any linked 
previous steps if not separated by a delay time. 
 
Batch Processing: 
 
ToolWare allows the user to specify PSets for the sequence of rundowns. During 
the batch process the controller moni tors each rundown and switches PSets 
automatically. We can contro l the actions of the controller as each step in the 
batch is completed. When PSets are link ed only the last PSet has batch settings.  
 
 
Count Preset –  defines the number of accepted  (ACCEPT) rundowns that must 
be completed for the associated parameter set 
 
Action At Preset Count Complete  - The choice of options for end-of-batch 
events is: 
  Act1 - Reset count and output batch complete 
   Act2 - Hold count and output batch complete 
   Act3 - Disable tool – Hold count and output batch complete 
   Act4 - Go to next PSet & do not output batch complete 
   Act5 - Go to next PSet  and output batch complete 
 
Next PSet –  determines the parameter set that is automatically activated when 
the count for the associated PSet is reached 
  
						

							 17
2.2.2 Parameter Sets 
 
Parameter Enable - check boxes allow the user to generate up to 32 different sets of 
parameters. Each set can be used individua lly or sets can be arranged into batch 
sequence. If the box is unchecked and the param eters are sent to the controller it 
deletes the parameter set. 
   
Copy -  button allows the user to copy one set  of parameters into another. The user 
must specify the destination parameter set number. 
 
Delete -  removes parameter from overall set. 
  
Receive -  downloads parameters from the iE C Controller to PC. Downloaded 
parameters are displayed but  not saved in the PC. 
 
Send -  uploads  the  current  parameters  from  ToolWare  to  the  controller.    The 
controller  will  automatically  switch  to  Parameter  Set  #1  a fter  all  parameter  sets  have 
been loaded. 
 
New  - allows the user to create a new set of  parameters, regardless of what set is 
selected as currently active in t he Controller or in the ToolWare. 
 
Open  -  opens  a  saved  Parameter  file  stored  in   the  computer  and  displays  it  in  the 
ToolWare Screen.  Paramete r set must be SENT to the controller to be used. 
  
Save - saves the parameter sets displayed on  the ToolWare screen as a file to a 
designated location on the computer. 
  
Reset to Factory Defaults  - resets the controller’s parame ters to the factory settings. 
   If Reset To Factory Defaults  is selected while tool is connected to 
controller, three parameter sets will  be configured at 30%, 40% and 60% of 
the tool’s maximum rated torque 
   If Reset To Factory Defaults  is selected while tool is disconnected from 
controller, eight parameters sets wi ll be configured at 10 Nm, 20Nm, 30 
Nm, 40 Nm, 50 Nm 60 Nm, 70 Nm and 80 Nm 
 
Change units - changes the torque units in the ToolWare. Select SEND to change 
units in the Controller also. 
 
Convert Units in Controller and ToolWare -  if checked, automatically converts 
units in controller and ToolWare to new  units when new unit of measurement is 
selected. 
 
If Rundown-Backoff-Rundown or Low Speed Control are active in the 
controller, User will be notified on this screen.   
						

							 18
2.3 CurveWare 
In ToolWare, select   from the top menu or select 
  directly from the lower menu to open   window shown in the 
Figure 2.3. Only rundown information after most  recent Power On of the controller can be 
graphed. 
 
 
 
Figure 2.3 CurveWare example 
 
 
Max Torque - is the upper torque limit of the rundown 
 
Max Angle - is the upper angle  limit of the rundown 
 
No. of Data Points  - is the number of data points that should be used in the plot. Maximal 
number of acquired data points is 4000. 
 
Current Plot  - the N
th rundown that has been recorded is  highlighted in the graph.  
 
Receive  – downloads last rundown data  from the Controller.  
						

							 19
 
Save -
 saves data points of all curves in the plot in ASCII file. 
 
Remove - removes the currently selected plot from the graph. 
 
Receive/View -  Receive/View allows the user to choose the display features  of the graph.  
Torque  – downloads and displays torque data points. 
Angle  – downloads and disp lays angle data points.  
PSet  - displays markers indicati ng parameter set values.  
View Controls   
Pan - reposition the view in the drawing area. 
Pan/Zoom  – change magnification.  
View All  – return to the or iginal dimensions. 
Show All Plots  - displays all the plots.  
 
Cursor mode -  restricts cursor locations to curve data points. 
 
Plot Axis -  allows user to choose between  Torque/Angle Vs Time and Torque Vs Angle .  
The axes of the graph will change accordingly
. 
 
Plot Name  – allows the user to rename the plot.  By default, the plot name is formed by 
using the date and time at which the plot was created. 
 
CurveWare allows for 10 sequential curv es to be overlaid upon each other for 
analysis purposes. 
 
 
2.4 Monitoring I/O 
In ToolWare, select    from the top menu or select  directly from the lower menu to open   window shown in the Figure 2.4. 
 
The I/O function is only available in iEC2,  iEC3 and iEC4 models.  A connector kit is 
available from AIMCO that allows the user  to connect and route wiring to a variety of 
devices, including light-towers, socket trays,  audible signals and PLC modules.   The part 
number is #23490.  Contact your AIMC O representative for this item.  
 
This screen allows the user to activate and  display the operation of the input and output 
signals to the controller.   Off Delays of outputs in this screen and send it to the controller or 
receive the same from the controller. For  testing and setting purposes the physical outputs 
and logical inputs can be forced ON/OFF temporal ly. This screen also shows the state of 
the physical I/O. We can temporally change the control source between Tool buttons and 
Logic I/O port. 
Selection of PSets through IO is limited to PSe ts 1-8.  Selection of entire 32 PSets library 
requires network connectivity.  
						

							 20 
Figure 2.4 Monitor I/O screen 
 
Off Delay
 - specifies how long the output signal will  be ON before turning OFF. Each of the 
8 input fields corresponds to the output field.  Example: If 200 is the value in the first field 
that the output signal for Accept  will be ON for duration of 200 mSec. If the value is 0, then 
the corresponding output will re main ON indefinitely or until the next rundown starts. 
 
Control Source  – allows user to choose the source  that controls the tool operation 
Buttons From Tool  – Normal operating condition; t ool lever and control ring control 
tool operation 
Buttons From I/O  – For testing purposes; allows the tool lever and control ring to be 
over-ridden by buttons on the Monitor I/O screen 
 
Force Enable –  When Buttons From I/O is selected,  this field selects which inputs and 
outputs can be forced through the Monitor I/O screen 
 
Function/State  – When Buttons From I/O is selected and the operation is selected by 
checking Force Enable, clicking on this field will force the respective operation to take place, 
regardless of tool button positions. 
This field will be red when the operation is off and will turn green  when the operation is on. 
 
I/O Connector Physical States  - this diagram is a real time  display of the I/O connector.  
Each position corresponds to the indicated terminal on the 25-pin I/O connector on the 
bottom of the controller. 
 
2.5 File Menu 
In ToolWare, select   from the top menu. File M enu enables us to select the 
Connection type with which we want the T oolWare to connect to the Controller.  
2.5.1 Connection 
This enables the user to specify how ToolWare  will connect with and communicate to the 
Controller. The options are as follows:  
						

							 21
    
USB -
 is used if the computer is  connected with the controll er using the USB connection in 
the computer. 
 
Ethernet -  can be selected to set the IP address the connection should use.  
 
Offline mode - gives the user the opportunity to -edi t parameter files and configuration files 
to save  without being c onnected to the controller 
 
2.5.2 Open 
Enables the user to select the file to open 
2.5.3 Save 
Saves the file to the PC in the specified directory 
 
2.5.4 Print 
Print the Screen or the Data.  
2.5.5 Login 
Login is not required for general access, t hough advanced features are not available in 
this mode.  On occasion, when advanced feat ures need to be accessed, a password will 
be given and can be entered here. 
 
An  AcraDyne  technician  or  an  AIMCO  sales person  can  create  a  temporary  password  to 
give to a customer.  This password will be vali d for the day it is given.  This can be used 
when  a  customer  needs  to  access  technical  areas  on  a  temporary  basis.    It  is  based  on 
the calendar date and will be vali d until midnight of that date. 
 
Contact  your  AIMCO  sales  representative  to  get  more  information  on  passwords  for  use 
with ToolWare. 
 
2.5.6 Language 
User can change language and locale either for the particular session or set it as default for 
the system. The application switches to  the language the  User selects.  
 
2.5.7 Logoff 
Log out of the user level the user is in.  
 
2.5.8 Exit  
Exits ToolWare  
						

							 22
2.6 Controller 
2.6.1  View Firmware Rev  
    Displays the current DSP revision and Servo Rev 
2.6.2 Edit Configuration Parameters 
The user can Edit the controller configuration from this screen.   The screen is shown 
in Figure 2.6.2. 
 
 
Figure 2.6.2 Edit Controller Parameter screen 
 
 
Adaptive Control
 
 
Enable - Adaptive  control is a useful option when a high CPK (Process Capability) is 
chosen as the most important variable.   This is done by adjusting the control to 
ensure the average applied torque is cent ered between the upper and lower control 
limit. 
This feature has three options, which are explained below. 
 
 
  
						

							 23
Off
 - Turns adaptive control off.  The tool wi ll produce torque until the target torque is 
achieved.  Therefore, all resu lts will be equal to or greater than the target. This will 
cause the average torque to be greater t han the target torque, thus making it 
extremely difficult to produce a high CPK. 
First Ten  - Takes an average of the first ten  readings in a new parameter set and 
adjusts the control to make the average to rque correspond with the target torque.  
Therefore, there will be  readings both above and below  the target torque, thus 
maximizing CPK. 
   All  - Similar to above, but continually adjusts the control based on the average of 
the previous ten readings in an attempt to maximize CPK. 
 
Pct Adjustment: % Adjustment - Determines how much of a correction adaptive 
control will try to make.  The higher the number, the gr eater the correction adaptive 
control will make. 
 
 
In Cycle Configuration
 
At Threshold  – the tool status is switched to   when torque reaches 
torque threshold set point. 
 
At Throttle  – the tool status is switched to   immediately when rundown is 
triggered. 
 
Note: In Cycle Configurati on “At Throttle” and Rehit Reje ct are mutually exclusive 
selections. 
 
 
Rehit Reject
   
This feature prevents operator from atte mpting to tighten the fastener that has 
already been tightened. If this  feature is enabled, the rundown will stop if the angle of 
rotation between cycle complete and threshol d torque is less than a specified number 
of degrees. 
  Rehit Reject On/Off  - If Enabled will abort the a ttempt to fasten a pre-tightened 
fastener. The default setting for this option is off. 
  
Rehit Reject Angle  - Used to determine if a fastener  is already tightened.   
If the angles of rotation between cycles comp lete torque and cycle threshold torque is 
less than the programmed angle, then the fastener is assumed tightened and no 
pass/reject will be reported. 
 
Note: Rehit Reject and In Cycle Configurat ion “At Throttle” are mutually exclusive 
selections. 
 
 
  
						

							 24
Rundown-Backoff-Rundown
 
This feature includes three modes t hat engage reverse rotation of the tool. 
 
Enable  – activates the feature. There are four  options available when the feature is 
enabled. 
 
  Rundown Backoff SP  -  Tool will rundown to selected PSet torque, reverse 
the fastener a set number of degrees defined by Back Off Degrees.  Reports 
the Torque and Angle from the rundown. 
 
   Rundown-Backoff-Rundown – Rundown to the 1
st Rundown torque 
(specified below) then reverse the fa stener a set number of degrees and re-
tighten the fastener to the  target torque established in the parameter set.  
Reports the Torque and Angle at end of cycle. 
 
  Rundown-Backoff - Tool will rundown to 1st  Rundown Torque, reverse the 
fastener a set number of degrees. Repor ts the Torque and Angle at end of 
cycle. 
 
  Off  -  Switches the Rundown-Backoff or Rundown-Backoff-Rundown to off 
mode 
 
 
1
st Rundown (in-lbs)  - The initial rundown torque,  measured in (in-lbs). 
 
Dwell Time before Back Off  - Dwell time [ms] between fi rst rundown and the start of 
back off.  
 
Back Off Degree - The amount of rotational degrees the fastener is backed off after 
reaching 1st rundown torque.  
Back Off Torque Limit –  This is the backoff torque limit, measured in (in-lbs)   
Dwell Time before Second Rundown  - Dwell time [ms] between back off and the 
start of second rundown. 
 
 
 
Soft Start
 
  
This feature allows the user to set the speed and timing of how quickly the tool ramps 
up to Freespeed RPM 
 
Dwell (ms)  -  the amount of time that the tool will rotate at slow speed before 
progressing to the Freespeed RPM (default 500 ms) 
 
Dwell (RPM)  - the RPM at which the tool will run during soft  start period (default 90)