Ingersoll-Rand 4581740 manual

Insight IC-D and IC-M DC Elec tric T ool C ontr oller U ser Manual Sav e T hese Instruc tions 04581740 Edition 2 December 2007[...]

2 04581740_ed2 T able of C ont ents Sec tion 1 – Introduction - 5 1.1 Contr ol P anel ................................................................................................................................................................................... 5 1.1.1 Navigation Keypad ........................................................[...]

04581740_ed2 3 3.3 System Setup ............................................................................................................................................................................... 20 3.3.1 P asswor ds .........................................................................................................................[...]

4 04581740_ed2 Appendix 1 – Sy stem Specs and Spare P ar ts - 38 Insight T echnical Specications ..................................................................................................................................................... 38 Pinout T ables ................................................................................[...]

04581740_ed2 5 Sec tion 1 – Introduction The Insight IC-D and IC-M F astening Systems are electronic tightening con trollers that can be prog rammed to operat e Ingersoll Rand QE- and QM-series spindles, depending on the model, to perform repetitive fastening operations . The spindles may be individual hand-held spindles, or sev eral may be mount[...]

6 04581740_ed2 Enter Key Escape Key Expand Key Directional Arrow Keys F igure 2 - Directional Keypad A screen element containing the Expand symbol indica tes the element can be opened to r eveal additional options. Pr essing the Expand key located in the center of the na vigation keypad will open the element and display the options . Y ou can then [...]

04581740_ed2 7 1.1.4 Screen Elements All the dier ent screens that can appear on the Insight IC-D display ha ve certain design elements in common. These design elements, called scr een elements, ar e shown in the graphics below . In actual operation, you use the arrow keys on the Naviga tional keypad to navigate the cursor t o the individual scr[...]

8 04581740_ed2 1.1.5 Using Menus and Screens 1. Push the corr esponding button to select the menu section you want to view . Ther e are f our sets of menu screens from which you can select. The selec tion buttons for these f our menus are locat ed above the display scr een in the upper part of the front panel. Run The Run screen displa ys fastening[...]

04581740_ed2 9 Sec tion 2 – Installation 2.1 Mounting Bolt the Insight controller enclosure t o a suitable rigid sur face near the assembly area using the mounting brackets on the back of the enclosure. See the dra wings below for dimensions , information on bracket hole spacing , recommended mounting bolts, door opening clearanc es, and other mo[...]

10 04581740_ed2 F igure 7 - Side and Back Dimensional Drawings 2.2 Elec trical Connection Make sure the Main Po wer Swit ch is in the O position. Insight controllers are a vailable with various power c ord options. Some options include a pigtail pow er cable, and the user must supply the correct power cor d connector . Review the elec trical cir[...]

04581740_ed2 11 2.3 A ttaching P eripheral I/O De vices T o remov e the I/O cover , rst remov e the retaining screw on the right -hand side of the cover , and then press in the locking tab below the screw and lift up the cover . Serial Port Rotar y Switches (CA2 Addr ess) T ermination Resistor Switch USB Port P owerhead Synchr onization Bus Ethe[...]

12 04581740_ed2 2.3.1 Activating an Input All input signals operate a t 24VDC. The Return for the 24V sig nal must be connected to C OM IN for each input bank. It is recommended that y ou use the internal 24VDC located at the t erminals marked 24VDC OUT +/-. Switch the 24VDC back to the desired input signal (FORW ARD , REVERSE, FREE SPEED , etc.). [...]

04581740_ed2 13 2.3.4 PL C Connection and S etup NO TE: All connections to a PL C are made via the Insight’ s terminal blocks, ex cept data collection. Data collection is done via the serial Fieldbus and/or E thernet por ts. F or data collection, follo w the procedur es for setup via the serial or Ethernet por t. T o connec t a PL C to the t ermi[...]

14 04581740_ed2 2.4.2 Bar Code C onnection and Setup Description The bar code function allows the Insight IC contr oller to be connected to any serial ASCII bar code scanner or E thernet bar code scanner . Each spindle can be equipped with its own scanner or , in the case of a powerhead, one scanner can be assigned to the pow erhead. The bar code f[...]

04581740_ed2 15 2.5.1 Single Spindle Operation If the E-stop is being used, JP21 pin 2 (relay c oil (-)) is routed to one c ontact of a remote (normally closed) SPST palm button switch (PBS). The switch ’ s other contact is routed back to JP21 pin 4. JP21 pin 1 r emains connected to JP21 pin 3. If an emergency occurs the spindle operator can depr[...]

16 04581740_ed2 2.5.3 E-Stop Not P resent If E-stop is not being used, the E-stop rela y must still be energized t o permit normal operation. This is ac complished by connecting JP21 pin 1 to JP21 pin 3 and JP21 pin 2 to JP21 pin 4. This allows the module’ s internal 24 VDC to energize the relay . The wiring is the same regardless of single or mu[...]

04581740_ed2 17 2.7 P ow erhead Setup A group of Insight units synchroniz ed together to perform a multiple bolt tightening task is called a Po werhead . If you are arranging a series of Insight contr ollers together in this way , you must link them in a “ daisy chain ” fashion to create a Po werhead S ynchronization Bus . These can comprise up[...]

18 04581740_ed2 Sec tion 3 – Progr amming the IC-D 3.1 Setup Menu The Setup menu and its sub-menus are used to program tigh tening strategies and t o set a broad variety of important system parameters . Basic tightening strat egies are cr eated in the Setup menu. In addition to strateg ies, you can use the Setup menu to set many basic system par [...]

04581740_ed2 19 F igure 17 - Quick Setup Screen T o complete the parameters in the Quick Setup sub-menu: 1. Pr ess the Setup menu button, then press Enter to choose the rst sub-menu, Quick Setup . 2. Use the arrow key s to move t o one of the eight lines representing C ongurations 1 thr ough 8. 3. Pr ess Enter to bring up the Step 2, the r[...]

20 04581740_ed2 If the Gang Count is successfully completed , in addition to displaying “Gang Complete ” on the screen, the controller provides a gang complet e output signal on the spindle ’ s I/O connector . There ar e two ways to r eset the Gang Count. 1. Use the dedicated r eset palm switch on the Gang Reset Input. 2. While on the Run Mai[...]

04581740_ed2 21 3.3.3 Job Number and CAN Address The Job Number and CAN (C ontroller A rea Network) A ddress paramet ers found at the top of the S yst em Setup screen are used t o set a Location ID f or a particular I nsight controller . The L ocation ID is used as a unique identier f or each unit on the network. The Job Number is a 4-digit entr[...]

22 04581740_ed2 F igure 19 - Spindle Setup Screen The rst parameter , T ransducer Range ( TR), allows you to enter a desir ed TR value in Nm to calibrat e the torque output of the connected spindle. The second parameter is A ngle Constan t . This is wher e you set a value to calibra te the angle output of the spindle. Cong Selection is the pa[...]

04581740_ed2 23 When T ube Nut 1 is selected, the spindle operates in tube nut rev erse when the momentary position of the switch is activated. No trigger press is nec essary to operate the spindle in tube nut reverse in this mode . When the momentary switch is released, the spindle stops, and it is then r eady for f orward operation. When T ube Nu[...]

24 04581740_ed2 3.5.6 Host Addr ess The Host Addr ess is only used when Host Data Out has been selected in the Protoc ol parameter . F or more inf ormation on applying the Serial Setup screen to par ticular devises, see section 2.4.1 Print er Connections and Setup. 3.6 PC C onnec tion When a PC is connected to the Insight controller via the E thern[...]

04581740_ed2 25 3.7 USB Stor age Device Da ta T ransf er 3.7.1 Inser tion A USB Storage device or key can be inserted into the contr oller at either run time or prior to booting. Such a devic e is conv enient for transf erring setup les to the controller , or for r etrieving data les from it. F or instance, you can copy an entire setup to an [...]

26 04581740_ed2 Sec tion 4 – Operating the IC-D S y stem 4.1 Introduction This section provides the information tha t you need to operat e the Insight controller . At this point, the syst em should be properly installed and progr ammed. The Main screen from the Run menu is where syst em operation takes place. It is made up of three parts: the Con[...]

04581740_ed2 27 4.3 Monitoring Operation 4.3.1 T orque and Angle V alues The middle section of the Run Main screen on the IC-D displays tor que and angle information f or each tightening operation. The larger value is the primar y one, and it reects the strategy tha t applies to the selected Conguration. In the cutout of the screen shown belo[...]

28 04581740_ed2 4.4 Message Area The Message Box a t the bottom of the Main screen summarizes syst em status and provides warnings and alarms on the IC-D . On the IC-M LED display , only the Event Code number is display ed in the event of an error . See Event C ode T able on page 44 for a listing of these events . 4.5 Stats and P M Alarms 4.5.1 Sta[...]

04581740_ed2 29 Sec tion 5 – Qualit y C ontr ol 5.1 Statistics Menu The Statistics menu allow s you to acc ess a variety of statistical data on completed fastenings . F or example, you can view actual fastening parameters, as w ell as statistical calculations, and can compar e them to target values . This section discusses the four Statistics sub[...]

30 04581740_ed2 The SD C ode column on the Cy cle Log show s the Shutdown C ode for each cycle. The shutdown code is a 2-digit code that gives the r eason why the cycle stopped. See a list of the shutdo wn codes in the table below . Shutdown Code # Description 0 Normal Completion of C ycle 1 Handheld – T rigger released before cycle was complete [...]

04581740_ed2 31 Shutdown Code # Description 121 Po werhead – MCE step sequence err or 122 Po werhead – MCE software fault 123 Po werhead – MCE IGBT fault 124 Po werhead – MCE low bus v oltage fault 125 Po werhead – MCE hardwar e watchdog fault 126 Po werhead – MCE calibration failed due to EEPROM mode 127 Po werhead – MCE calibration [...]

32 04581740_ed2 2. On the Statistics menu , select Spindle Statistics and press En ter . 3. Select the dropdown Congur ation box and pr ess the Expand button to view a list of the av ailable Congurations with statistics that can be viewed . 4. Select the Conguration you wish to use and pr ess Enter . 5. Scroll through the various parameter[...]

04581740_ed2 33 The nal selection on the Statistics menu is P ow erhead Stats . This screen provides useful data when the IC-D is part of a powerhead Congur ation.These statistics ar e only available when the contr oller is a powerhead master (the con troller can2 rotary switches must be set to 01). F igure 29 - P owerhead Stats Note that the[...]

34 04581740_ed2 Sec tion 6 – Diagnostics and T roubleshooting 6.1 Diagnostics Menu The Diagnostics menu allows y ou to check the over all system health of the Insight IC-D . This func tionality also diagnoses system pr oblems. This section discusses the four Diagnostics sub-menu screens, including: Sy stem T est Display Inputs Set Outputs T ool T[...]

04581740_ed2 35 T est Data Element Explanation T ool Motor temperatur e Checks motor temperatur e and reports P ASS or F AIL. Amplier oset MCE’ s oset voltage (as % of Shunt C al voltage). Shunt calibration F ront-end electronics gain (as % of ideal Shunt Cal voltage). Sine Oset The oset in A/D coun ts of the resolver sine analog i[...]

36 04581740_ed2 F igure 33 - Discrete Outputs Menu T o access and use Set Outputs : 1. Pr ess the Diag button on the Insight controller . 2. On the Diagnostics menu, select Set Outputs and press Enter . 3. Scroll through the listed outputs using the arr ow keys to the Output you wish t o test. 4. Pr ess the Enter key to send an output signal fr om [...]

04581740_ed2 37 T o access and use T ool T est : 1. Pr ess the Diag button on the Insight controller . 2. On the Diagnostics menu , select T ool T est and press En ter . 3. A pop-up message warns you that running the test interrupts spindle operations . Pr ess Enter to con tinue. 4. F or a xtured spindle, use the arrow key s to the Start T ool b[...]

38 04581740_ed2 Appendix 1 – S y stem Specs and Spar e Parts Insight T echnical Specications The specications for the Insight IC Tightening Syst em are shown belo w . Measurement Ac curacy ±0.2% of torque full scale ±1 count of angle (degr ees) Measurement Resolution ±0.025% of torque full scale T orque T ransducer Bridge Excitation ±5V[...]

04581740_ed2 39 Outputs Output Behavior Block # Pin # Spindle In c ycle 2 O-1 Cy cle Complete 2 O -2 Accept 2 O-3 T orque High 2 O -4 T orque Lo w 2 O -5 Angle High 2 O -6 Angle Low 2 O -7 Gang Complete 2 O-8 Recommended Spar e Parts List See the illustrations following the P ar ts List. Detail Number Part Number Description 04581740 IC-D , IC-M Op[...]

40 04581740_ed2 Outside the Co ver 6 2 3 8[...]

04581740_ed2 41 Inside the Co v er 1 4 5 7[...]

42 04581740_ed2 Side 9[...]

04581740_ed2 43 Appendix 2 – E v ent C odes The follo wing table lists the Event C odes for the IC-D and IC-M. Below is an explanation of table c olumns. Ev ent C ode Explanation Ev ent Code This is the event c ode number . On an IC-M controller , the code is displayed on the screen as “E” and then the code number , for example, E002. F or a [...]

44 04581740_ed2 Ev ent Code Description/C ondition Critical Error Action Required/Explanation Display on D , M GUI USB Ev ents 081 to 100 081 Not enough space to sav e controller data to USB key No Remove excess les f or USB key D , M 082 Time out while saving data t o the USB Disk No Check that USB key is approv ed to function with controller D[...]

04581740_ed2 45 Inde x A Activating an Input 12 Attaching P eripheral Devices 11 Attaching The Spindles 11 Auto Increment 20 B Backspace Key 6 Bar Code Active Mode 14 Compatibility W ith Other Functions 14 Auto Increment 14 Gang Count 14 P owerhead 14 Connection and Setup 14 Description 14 Operation 14 P assive Mode 14 Button 7 C Check Box 7 Circui[...]

46 04581740_ed2 Q Quality Control 29 Quick Setup screen 18 R Radio Button 7 Receiving an Output 12 Run Menu Statistic Summary Screen 31 Run Menus Cy cle Log Screen 29 S Screen Elements 7 Serial Port 16 Serial Printer 13 Setup 23 Shutdown Code 30 Spare P arts List 39 Specications 38 Spindle Operation 22 Spindles Attaching 11 Startup 17 Statistic [...]

04581740_ed2 47 Notes:[...]

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