48619696

Edition 3
September 2013

Insight Control Software (ICS)

User Manual

Save These Instructions

Table of Contents
Section 1 – Introduction - 1
1.1 Summary ..........................................................................................................................................................................................1
1.2 Process Communication Module (IC-PCM) ..........................................................................................................................1
1.2.1 IC-PCM 1:1 ..............................................................................................................................................................................................1
1.2.2 IC-PCM 10:1 ............................................................................................................................................................................................1
1.2.3 Rotary Switch Settings .......................................................................................................................................................................1
1.2.4 Dip Switch Settings .............................................................................................................................................................................1
1.2.5 LED Indicators ......................................................................................................................................................................................2

Section 2 – Installation - 3
2.1 Mounting ..........................................................................................................................................................................................3
2.2 Electrical Connection ...................................................................................................................................................................3
2.3 Attaching Peripheral I/O Devices .............................................................................................................................................4
2.3.1 Activating an Input & Receiving an Output ...............................................................................................................................5

2.4 Setting up Network Connections for IC-PCM ......................................................................................................................6

2.4.1 Ethernet Connection .........................................................................................................................................................................6
2.4.2 Configure IC-PCM using serial terminal.......................................................................................................................................6
2.4.3 Assigning a Static IP address to the PC Host........................................................................................................................... 10
2.4.4 Assigning a Static IP address to the IC-PCM............................................................................................................................ 11
2.4.5 Assigning a Dynamic IP address to the PC Host .................................................................................................................... 11
2.4.6 Assigning a Dynamic IP address to the IC-PCM ..................................................................................................................... 11

2.5 Database Manager ..................................................................................................................................................................... 12

2.5.1. Local Database:.................................................................................................................................................................................. 12
2.5.1.1. Create New:...............................................................................................................................................................................................13
2.5.1.2. Migrate Database: ..................................................................................................................................................................................13
2.5.1.3. Connect to Existing: ...............................................................................................................................................................................14

2.5.2. Archive Database: ............................................................................................................................................................................. 14

2.5.2.1 Create New Database: ...........................................................................................................................................................................15
2.5.2.2 Migrate Database: ..................................................................................................................................................................................15
2.5.2.3 Connect to Existing: ...............................................................................................................................................................................15

2.5.3. Status Messages ................................................................................................................................................................................ 16

Section 3 – Programming a Tool - 17

3.1 Quick Setup .................................................................................................................................................................................. 17
3.1.1 Torque Settings: ................................................................................................................................................................................ 18
3.1.2 Angle Settings:................................................................................................................................................................................... 19
3.1.3 Prevailing Torque Settings:............................................................................................................................................................ 19

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3.2 General Setup .............................................................................................................................................................................. 20
3.2.1 Tool Setup............................................................................................................................................................................................ 21
3.2.2 Wireless Setup.................................................................................................................................................................................... 22
3.2.3 Password Settings ............................................................................................................................................................................ 22

3.3 Advanced Setup ......................................................................................................................................................................... 22

3.3.1 Common Settings............................................................................................................................................................................. 23
3.3.2 Torque Control Step ......................................................................................................................................................................... 24
3.3.3 Angle Control Step ........................................................................................................................................................................... 25

3.4 IC-PCM 1:1 General Setup....................................................................................................................................................... 26

3.4.1 Version Information ......................................................................................................................................................................... 26
3.4.2 General Settings ................................................................................................................................................................................ 26
3.4.2.1 Tightening Control Settings ...............................................................................................................................................................26
3.4.2.2 IO (Input/Output) Settings ..................................................................................................................................................................27
3.4.2.3 Socket Tray and Configuration Switch Connection and Setup using IC-PCM 1:1 ...........................................................29
3.4.2.4 Light Box Connection and Setup ......................................................................................................................................................30
3.4.2.5 Date Time Settings .................................................................................................................................................................................30

3.4.3 Protocol Settings............................................................................................................................................................................... 31

3.4.3.1 PCM Serial Port Settings.......................................................................................................................................................................31
3.4.3.2 Barcode/VIN Settings ............................................................................................................................................................................32
3.4.3.3 Barcode Connection and Setup using IC-PCM 1:1......................................................................................................................33
3.4.3.4 Serial EOR Settings .................................................................................................................................................................................33
3.4.3.5 Serial EOR Settings Setup: ...................................................................................................................................................................35
3.4.3.6 Ethernet EOR Settings ...........................................................................................................................................................................36
3.4.3.7 Ethernet EOR Setup ...............................................................................................................................................................................38
3.4.3.8 PFCS Settings ...........................................................................................................................................................................................39
3.4.3.9 Communication via Serial:...................................................................................................................................................................39
3.4.3.10 Communication via Ethernet: ............................................................................................................................................................39
3.4.3.11 PLUS Settings ...........................................................................................................................................................................................40
3.4.3.12 XML Settings.............................................................................................................................................................................................42
3.4.3.13 XML setup using IC-PCM 1:1 ...............................................................................................................................................................42
3.4.3.14 Open Protocol Settings ........................................................................................................................................................................43
3.4.3.15 Open Protocol Setup .............................................................................................................................................................................43
3.4.3.16 Label Printing Settings .........................................................................................................................................................................43
3.4.3.17 Printer Connections and Setup for IC-PCM 1:1 ............................................................................................................................44

3.4.4 FieldBus Settings............................................................................................................................................................................... 44

3.4.4.1 ProfiBus Settings .....................................................................................................................................................................................44
3.4.4.2 InterBus Settings .....................................................................................................................................................................................45
3.4.4.3 Devicenet Settings .................................................................................................................................................................................45
3.4.4.4 Modbus RTU Settings............................................................................................................................................................................46
3.4.4.5 Modbus TCP/IP/Ethernet IP Settings ...............................................................................................................................................47
3.4.4.6 ProfiNet Settings .....................................................................................................................................................................................48

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3.5 Parameter Assignment ............................................................................................................................................................. 49
3.6 Wireless Tool Settings................................................................................................................................................................ 50
3.6.1 IC-PCM Settings ................................................................................................................................................................................. 50
3.6.1.1 Ethernet Settings ....................................................................................................................................................................................51

3.6.2 Radio Settings .................................................................................................................................................................................... 51

3.6.3 SNTP Settings ..................................................................................................................................................................................... 52
3.6.4. Channel Hopping Settings ............................................................................................................................................................ 52
3.6.4.1 Secondary Channel Settings ..............................................................................................................................................................52
3.6.4.2 Selectable Radio Channels ..................................................................................................................................................................52
3.6.4.3 Mapped Tool Settings ...........................................................................................................................................................................52
3.6.4.4 Local Settings ...........................................................................................................................................................................................52

3.7 Download Software ................................................................................................................................................................... 52

3.7.1 Download firmware Procedure for the Tool Connected to USB ...................................................................................... 53
3.7.1.1 MCE Firmware ..........................................................................................................................................................................................53
3.7.1.2 Display Firmware ....................................................................................................................................................................................55
3.7.1.3 Radio Firmware........................................................................................................................................................................................58

3.7.2 Download firmware procedure for a IC-PCM on the Network ......................................................................................... 61

3.7.2.1 RISC Firmware ..........................................................................................................................................................................................61
3.7.2.2 Radio Firmware........................................................................................................................................................................................63
3.7.2.3 Clear Data ..................................................................................................................................................................................................65

3.8 Reboot ............................................................................................................................................................................................ 66

3.8.1 Reboot IC-PCM .................................................................................................................................................................................. 66
3.8.2 Reboot Radio Modules ................................................................................................................................................................... 67

3.9 PCM Wireless Energy Detector............................................................................................................................................... 67

Section 4 – Monitoring Cycle log and Event Log of IC-PCM 1:1 / QX Tool - 68
4.1 Run Main Cycle Log.................................................................................................................................................................... 68
4.1.1 Run Main View Tab ........................................................................................................................................................................... 68
4.1.2 View Cycle Log Tab ........................................................................................................................................................................... 69
4.1.2.1 Data Saved/Retrieved from PC Local Database ...........................................................................................................................71
4.1.2.2 Data retrieved from the Archived Database .................................................................................................................................72

4.2 Run Main View All ....................................................................................................................................................................... 72

4.3 IC-PCM 1:1/ Tool Event Log ..................................................................................................................................................... 73
4.3.1 IC-PCM 1:1 Event Log ...................................................................................................................................................................... 73
4.3.2 Tool Event Log ................................................................................................................................................................................... 75

4.4 Status/View Network ................................................................................................................................................................. 78

4.4.1 IC-PCM 1:1 ........................................................................................................................................................................................... 78
4.4.2 IC-PCM 10:1 ......................................................................................................................................................................................... 79
4.4.3 USB Direct Tool Connection .......................................................................................................................................................... 79

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4.5 Create Report ............................................................................................................................................................................... 79
4.5.1 Tool Report.......................................................................................................................................................................................... 79
4.5.2 VIN Report ........................................................................................................................................................................................... 80
4.5.3 Report Generator .............................................................................................................................................................................. 80

Section 5 – Archiving Data - 81

5.1 Archival Settings Screen .......................................................................................................................................................... 81

Section 7 – System Diagnostics - 82

7.1 Tool Test.......................................................................................................................................................................................... 82
7.2 Tool Status ..................................................................................................................................................................................... 83
7.3 Keypad, LED and Audio Diagnostics.................................................................................................................................... 84
7.3.1 Keypad Status .................................................................................................................................................................................... 84
7.3.2 LED Test ................................................................................................................................................................................................ 85
7.3.3 Audio Diagnostics ............................................................................................................................................................................ 85

7.4 Tool Calibration ........................................................................................................................................................................... 85

7.5 PM Alarms ..................................................................................................................................................................................... 86
7.6 System Diagnostics – View Inputs ........................................................................................................................................ 88
7.7 System Diagnostics – View/Set Output .............................................................................................................................. 88
7.7.1 View Outputs Mode (Normal Mode) ......................................................................................................................................... 88
7.7.2 Set Outputs Mode (Diagnostic Mode) ...................................................................................................................................... 89

7.8 Direct Controller Discovery ..................................................................................................................................................... 89

Section 6 – Quality Control - 90

6.1 Statistics ......................................................................................................................................................................................... 90
6.1.1 Statistical Data Saved/Retrieved from Local Database ....................................................................................................... 91

Section 8 – Wireless Diagnostics - 92

8.1 Wireless statistics of USB Connected Tool ........................................................................................................................ 92
8.2 Wireless Statistics of the IC-PCM ........................................................................................................................................... 92

Section 9 – General Screen Layout - 93

9.1 ICS Screen Components ........................................................................................................................................................... 93
9.1.1 Title Bar ................................................................................................................................................................................................. 93
9.1.2 Selection of Family Type................................................................................................................................................................. 93
9.1.3 Menu Bar.............................................................................................................................................................................................. 94
9.1.3.1 File Menu ...................................................................................................................................................................................................94
9.1.3.2 Run Menu ..................................................................................................................................................................................................94
9.1.3.3 Setup Menu ..............................................................................................................................................................................................95
9.1.3.4 Status Menu ..............................................................................................................................................................................................95

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 9.1.3.5 Statistics Menu ........................................................................................................................................................................................95
9.1.3.6 Diagnostic Menu .....................................................................................................................................................................................96
9.1.3.7 ICS Menu ....................................................................................................................................................................................................96
9.1.3.8 Data Source Menu ..................................................................................................................................................................................97
9.1.3.9 View Menu ................................................................................................................................................................................................97
9.1.3.10 Window Menu .........................................................................................................................................................................................97
9.1.3.11 Help Menu .................................................................................................................................................................................................97

9.1.4 Main Tool Bar ...................................................................................................................................................................................... 98

9.1.5 Communication Tool Bar................................................................................................................................................................ 98
9.1.6 Database Tool Bar ............................................................................................................................................................................. 98
9.1.7 Work Space ......................................................................................................................................................................................... 99
9.1.8 Graphics Screens............................................................................................................................................................................... 99
9.1.9 Status and Progress Bar .................................................................................................................................................................. 99
9.1.10 Icons ...................................................................................................................................................................................................... 99

Section 10 – Assigning a Name - 100

10.1 IC-PCM/QX Name Assignment.............................................................................................................................................100
10.1.1 Steps to assign a name to an IC-PCM/QX Tool: ....................................................................................................................101
10.1.2 Steps to Unassign a name for an IC-PCM/QX Tool: .............................................................................................................101
10.1.3 Steps to Unassign all names for the IC-PCM/QX Tools: .....................................................................................................101

10.2 Configuration Name Assignment .......................................................................................................................................101

10.2.1 Steps to assign name to Configuration Number:................................................................................................................102
10.2.2 Steps To Unassign a name for a Configuration Number: .................................................................................................102
10.2.3 Steps To Unassign All Configuration Names: ........................................................................................................................102

Contact Information - 103

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Section 1 – Introduction

1.1 Summary
ICS software is designed to give a programming interface and archiving functionality to extend the functionality
of the controllers and QX series tools. Each version of ICS is designed to satisfy a specified customer environment.
Unless otherwise noted, the controllers have all functionality within their operating software. Functionality is
restricted through the version of ICS software used to interface with the controller or tool. when a controller has been
programmed, ICS can be disconnected and the controller will run independently.

Wireless tools that can communicate with the IC-PCM are designated as QXX. Non-wireless tool that communicate with
ICS directly through USB are designated as QXC.

This document will only detail the scope of functionality for the ICS software products. This document will not detail
use of any IC family of controllers, tools or the interface necessary to communicate.

1.2 Process Communication Module (IC-PCM)

The IC-PCM‘s (Process Communication Module) are Fastening Systems which can wirelessly communicate to QX tool
and can be programmed to send commands to control the way the tool behaves. Programming functions for the two
units (IC-PCM 1:1 and 10:1) are done through ICS software. Tool and the IC-PCM communicates to each other wirelessly.
IC-PCM devices can be configured to work in following modes.

1.2.1 IC-PCM 1:1

In this mode the IC-PCM can communicate to only one QX tool. This mode offers below functions in addition to the
communication with ICS:

1. Protocols (PFCS, PLUS, XML, Ford Open Protocol, Label Printing, Ethernet EOR, Serial EOR etc.)
2. Field bus support
3. Smart socket
4. Programmable I/O
5. Config Selection
1.2.2 IC-PCM 10:1
In this mode, the IC-PCM can communicate to maximum of 10 QX tools, it acts as a bridge to send messages between
tools and ICS.

1.2.3 Rotary Switch Settings

If the rotary switches are set to “00”, then the device will be in IC-PCM 1:1 mode. If the rotary switches are set to “01”,
then the device will be in IC-PCM 10:1 mode.

IC-PCM 1:1 IC-PCM 10:1

1.2.4 Dip Switch Settings

With the switch number 2 ‘ON’, serial debug information will be sent to serial port of the IC-PCM at the baud rate 38400.

NOTE: If serial debug switch is ON, all Serial Protocol (Serial Barcode, Serial EOR, PLUS, etc.) functionality will be in
disabled condition.

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1.2.5 LED Indicators
Power LED LED must turn ON when IC-PCM is ON
System Ready LED LED must turn ON when the IC-PCM is fully booted and ready to communicate.
Wireless Activity LED LED must turn ON when there is a wireless transaction between the IC-PCM and a tool.
Ethernet Activity LED LED must turn ON when Ethernet cable is connected to the Port.

Power LED

System Ready LED

Wireless Activity LED

Ethernet Activity LED

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Section 2 – Installation
This section gives information on how to install, setup, program, operate, and troubleshooting IC-PCM. The figure below
shows the major elements of the IC-PCM.

2.1 Mounting
IC-PCM must be installed on a suitable rigid surface near the assembly area using the mounting brackets behind the en-
closure. See the drawings below for dimensions, information on bracket hole distance. Make sure that the mounting is
stable, secure within range. The IC-PCM enclosure is rated for ingress protection of IP52 installed in an vertical position
as shown.
NOTE: If environmental more than than IPX0 is necessary, more protection will be necessary for the external power
supplies.

210 mm 191 mm
(8.27 in) (7.52 in)

291 mm 150 mm
(11.45 in) (5.91 in)

103 mm
(4.06 in)

2.2 Electrical Connection

IC-PCM is available with different power cord options. Review the electrical circuit information on the label (on the Bottom
panel) and in the safety information manual. Make sure that your electrical circuit meets the power requirements and circuit
breaker ratings. Plug the AC power cord into an appropriate receptacle.
WARNING

It is the user’s responsibility to make sure that the IC-PCM is installed and wired by a qualified electrician.

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2.3 Attaching Peripheral I/O Devices

Optional Fieldbus
Serial Port

Rotary Switches

Termination Resistor Switch (Dip Switch)

USB Port (N/A)

Powerhead Synchronization Bus (N/A)

Ethernet

Base Inputs / Outputs

5v DC

NOTE: The Power-head synchronization bus and USB port are not in use.

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2.3.1 Activating an Input & Receiving an Output
All input signals operate at 24VDC. The Return for the 24V signal must be connected to COM IN for each input bank.

All output signals operate at 24VDC. The 24V signal and its return must be connected to the terminal blocks labeled
+/- 24VDC EXT on each output connector bank. The output signals will be switched back from the appropriate output
signal (ACCEPT, REJECT, HIGH TORQUE, etc...).

Example: PLC Connection and Setup

All connections to a PLC are made via the IC-PCM 1:1 I/O terminal blocks, except data collection. Data collection is
done via the serial Fieldbus and/or Ethernet ports. For data collection, follow the procedures for setup using the serial
or Ethernet port. Through the terminal blocks, a PLC can send inputs to the IC-PCM 1:1 and receive outputs from the
IC-PCM 1:1. It is important to always use a shielded cable (to avoid external noise and interference) for all PLC signals to
IC-PCM 1:1 and the shield should be terminated at the IC-PCM 1:1 end.

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2.4 Setting up Network Connections for IC-PCM
2.4.1 Ethernet Connection
An Ethernet port can be found on the connector panel of the IC-PCM unit. ICS can communicate with IC-PCM only
using Ethernet connection.

To change Ethernet settings of the IC-PCM, go to the Wireless Settings screen. The settings for IP Address, Subnet Mask,
and Gateway can be viewed/modified. User has an option to Enable/Disable Dynamic Host Communications Protocol
(DHCP). When DHCP is turned ON, it lets the network server to set the IP addresses for the IC-PCM.

2.4.2 Configure IC-PCM using serial terminal

IC- PCM network settings can be configured using and terminal emulator software (Hyper Terminal, Clear Terminal etc.).
Following are the settings that can be changed.
1. IP Address.
2. Subnet Mask.
3. DHCP.
4. Default Gateway.
If Hyper Terminal software is not available in the computer then Clear Terminal software can be downloaded from
following location.

http://www.clearconnex.com/content/clearterminal

Follow the steps below the configure IC-PCM.

1. Push dip switch 2 to ON Position to place into debug mode as shown below.

2. Connect serial port cable (DB 9) to the computer and IC-PCM.

3. Open terminal emulator software.

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4. Select the connected COM Port.
5. Select following parameter for COM Port.
a. Baud Rate : 38400
b. Data bits : 8
c. Stop bits : 1
d. Parity : None
e. Flow Control : None

6. Click on Connect Button. Following screen will appear with some data.

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7. Type ‘nc’ and press ‘Enter’ key to view current settings.

8. Following is the format to change the settings

nc <code> <new value> 8
Following are the codes that can be used to change the settings
# Code Value Description
1 i xxx.xxx.xxx.xxx New IP address will be assigned.
2 n xxx.xxx.xxx.xxx New sub net mask will be assigned.
3 p on/off DHCP will be enabled or disabled.
4 g xxx.xxx.xxx.xxx New gateway address will be assigned.
NOTE:
• Make sure that Ethernet Address is not changed, if changed it must be unique in the network else the IC-PCM
is not discovered in network. To change Ethernet Address (MAC Address) enter nc e xx:xx:xx:xx:xx:xx where xx is
number between 00 to FF in hexadecimal.
• To change the IP address DHCP should be disabled (OFF) else the IP address is taken from DHCP server.
• Default Gateway value should be same as system where is ICS is running.
9. Send save command to apply the changes and restart after 30 seconds. Command to save the settings is ‘nc s’ 8 .
Follow the procedure to assign static IP.
• Type ‘nc p off’ to disable the DHCP.

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• Set IP address to 192.168.1.1 ‘nc i 192.168.1.2’.

• Set default gateway to ‘nc g 192.168.1.1’.

• Type ‘nc s’ to save any changes made.

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• Reboot after 30 seconds for the changes to take place.
• Once rebooted verify the settings using nc command. (Type nc 8 )

NOTE: Enable DHCP to acquire IP from DHCP server.

2.4.3 Assigning a Static IP address to the PC Host

When using a one-to-one connection between the IC-PCM and a PC, find the TCPIP properties in the control panel
in the local network connections. Select ‘Use the following IP address’ and configure as below which requires a one-
to-one connection a crossover cable needs to be used. If connecting to an existing local network, use values that are
compatible with the network using a standard Ethernet cable.

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2.4.4 Assigning a Static IP address to the IC-PCM
• Turn OFF the IC-PCM and set the RED DIP switch to ON for switch 2.
• Connect serial null-modem cable from IC-PCM to the PC.
• Launch HyperTerminal or other terminal emulation software such as Clear Terminal.
• Reboot the IC-PCM. Type ‘NC’ in the serial terminal to start serial activity.
• Type ‘NC P off’ to disable the DHCP and then Type ‘NC S’ to save the settings.
• Type ‘NC I xxx.xxx.xxx.xxx’ using serial terminal where xxx.xxx.xxx.xxx is the desired IP address.
• Set subnet if different Default Gateway should take on the form xxx.xxx.xxx.1. Where the x values match the IP Ad-
dress. If using crossover cable, use IP :192.168.4.4.
• Type ‘NC S’ to save any changes made.
• Reboot the IC-PCM after 30 seconds for the changes to take place.

2.4.5 Assigning a Dynamic IP address to the PC Host

Find the TCP/IP properties in the control panel in the local network connections. Select ‘Obtain an IP address
automatically’ as below.

2.4.6 Assigning a Dynamic IP address to the IC-PCM

Using the ‘NC’ command, configure as follows. Make sure that the IP Address, Gateway address and Net Mask match the
network structure.

• Type ‘NC P ON’ and then type ‘NC S’ to save the settings.
• Type ‘NC N xxx.xxx.xxx.xxx’ and then type ‘NC S’ to save the new Subnet address. The Subnet address should match
the Subnet address of the host PC.
• Type ‘NC G xxx.xxx.xxx.1’ and then type ‘NC S’ to save the new Gateway address. The xxx.xxx.xxx should match the
IP Address.
• Reboot the IC-PCM after 30 seconds for the changes to take place.

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2.5 Database Manager
The Database Manager handles all database operations like create, migrate or use existing database.

Following are the two main functionalities of the database manager

• Local Database
• Archive Database

2.5.1. Local Database:

The Local Database is a database which can be used to save Configurations, Tool General Set-tings, PCM General
Settings, Tightening EORs, Controller and tool Event Logs, Statistics and User profiles. This database can reside local to
the machine where ICS is present or on a remote machine.

Following are the operations that can be performed.

• Create New
• Migrate
• Existing

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2.5.1.1. Create New:
This option will create a new database.

NOTE: If this option is selected, the existing database will be deleted and old data will be over-written. All the saved
data is stored in this database.

Provide administrative server credentials (user name and password) and click on Create New, this will create the data
base.

2.5.1.2. Migrate Database:

This option can be used to migrate the existing data to the new database.

Check for the appropriate path of the ICS.mdb file in ‘Local database File’ before proceeding with migration, if necessary

modify or change the path using the button.

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NOTE:

1. Only selected option, such as configurations, general parameters and EOR will be migrated.

2. Provide administrative server credentials (user name and password)

2.5.1.3. Connect to Existing:

This option can be used to connect to an existing database.

NOTE: This option should be used only if latest database is available; else software compatibility issues may arise and
the software may not behave as excepted.

NOTE:

1. Creating a database may take more time based on the server location; typically it takes 5 mi-nutes if data-
base is local to the installed system.

2. ICS version 6.1.0.1 and later does not support MS-Access database. Minimum requirement, for ICS installa-
tion is Microsoft SQL Server 2005 Express Edition or later versions.

2.5.2. Archive Database:

The Archive Database is a database which can be used to archive Configurations, Tool General Settings, PCM General
Settings and Tightening EORs on a periodic basis. This database can re-side local to the machine where ICS is present or
on a remote machine.

14 48619696_ed3
Following are the operations that can be performed.

• Create New
• Migrate
• Connect to Existing

2.5.2.1 Create New Database:

This option will create a new database.

NOTE: If this option is selected, the existing database will be deleted and old data will be over-written.

After providing the necessary credentials, click on Create New, this will create the Archive Da-tabase.

2.5.2.2 Migrate Database:

This option will make the necessary changes to the existing database schema so that the new database is compatible
with the new version of software.

2.5.2.3 Connect to Existing:

This option can be used to connect to an existing database.

NOTE: This option should be used only if latest database is available; else software compatibility issues may arise and
the software may not behave as excepted.

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2.5.3. Status Messages
This window will display appropriate messages during database creation or migration. All ac-tions that are performed
will be logged in this list.

16 48619696_ed3
Section 3 – Programming a Tool
Use Setup Menu from ICS Main Menu Bar for programming a tool. This section explains how to program a tool.

3.1 Quick Setup

The Quick setup screen is used to program the QX series tool. Torque / Angle / Prevailing Torque strategies can be setup
from this screen.
The Configuration sets that are created using this screen can be sent to a tool (in Network mode) or they can be stored
locally.
Configuration sets can also be created and stored in the Local Database Mode. The locally stored Configuration Sets can
then be sent to a tool using the Parameter Assignment screen.
The user can also view the archived configuration data stored in the archived database.

Location ID Drop box Location ID is used as a unique identifier for each tool on the network.
Lets the selection of all available configurations, 1 through 8, for Programming and/or
Config Drop box
Viewing the Tightening settings.
Lets selection of valid fastening strategies: Torque control, Angle control and Prevailing
Strategy
Torque. Torque control is the default Strategy.
Lets selection of all available Torque Units: Nm, Ft-lbs, In-lbs, and d-Nm. All the Torque values
Torque Display Units
will be displayed with the selected units. Nm is the default unit.
Gang Count can be used if the assembly requires multiple bolts to be fastened in a group. The
Gang Count
default value is 0 and the range is between 0 – 99.
Time interval between each fastening cycle. The tool will be in a locked state until the time
Cycle Delay (Sec)
interval elapses. The default value is 0 and the range is 0 – 10 seconds.
Auto increment can be used to move through a specified sequence of fastening
configurations. After a Pass cycle or gang complete if gang count is set more than 1, the tool
Auto increment
will automatically increment to the Configuration programmed in this field. The default value
is 0 and valid values are Config 1 through 8.

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 Lets selection of Joint Type. There are two options – Hard and Soft. Hard will be selected by
Joint Type
default.
Sets the tool tightening direction to CW (Clockwise) or CCW (Counter-clockwise). CW is
Direction
selected by default.
Turns ‘ON’ or ‘OFF’ the tool buzzer. The Audible Alarm will sound for any Failed cycle, when
Audible Alert
this feature is turned ‘ON’.
Smart socket is intended as an interlock for the user. On selection of the configuration, the
tool will be disabled and an LED will glow in socket tray, indicating which socket the user
must select (the one programmed in this field). The tool will only be enabled when all other
Socket Selection
sockets are in place and the required socket removed from the tray. The default value is 0 and
correct values are 1 through 8. This selection is only pertinent if the Smart Socket feature is
enabled in the quick setup.
The maximum permitted Torque for the connected tool. This Field is not applicable in the
Tool Max Torque
Local Database Mode. This field is read-only.
The Reverse Target Torque parameter is used to set the Target Torque for the Reverse step for
Reverse Target Angle Tubenut Tools.
Torque
For tools other than Angle Tubenut Tools, this field is read only.
The Reverse Forward Speed parameter is used to set the speed for the Reverse step for Angle
Reverse Forward Tubenut Tools.
speed
For tools other than Angle Tubenut Tools, this field is read only.
When checked, the tool will send an Assembly Complete Event to the IC-PCM 1:1 which will
Assembly Complete
then turn on a programmed External Output.
Disable Reverse When checked, the tool will not run in the Reverse direction.
Reverse Speed (%) The percent of Max Speed at which the tool will run in the reverse direction. The default value is 100%.
For prevailing torque strategy in quick setup screen on ICS will have an option to enable/disable. If
Tare Compensation is enabled, Average torque from the prevailing zone will be added to the target
Tare Compensation torque to create a new modified Target torque (to compensate for the Prevailing torque). The modified
Target is checked against the Torque Control’s High Torque Limit for violation. If the limit is exceeded,
the step declares an error.

There are three strategies as described below:

3.1.1 Torque Settings:
Target Torque Target Torque is the value of selected configuration. Must be ≤ Tool Max Torque.
The maximum acceptable torque value for a fastening. Must be ≥ the Target Torque and
Torque High Limit cannot exceed 120% of the tool max torque value. Once the Target Torque value is entered,
this value will be populated as 120% of the Target.
The minimum acceptable torque value for a fastening. Must be ≤ the Target Torque. Once the
Torque Low Limit
Target Torque value is entered, this value will be populated as 80% of the Target.
Angle high Limit The maximum acceptable angle through which the fastener may turn. Maximum value
(deg) cannot exceed 32000 degrees, which is the default value.
Angle Low Limit (deg) The minimum angle through which the fastener must turn. The default value is 0.
The torque required to seat the fastener in the joint. This is the torque point at which angle
Torque Threshold for
begins to be measured. Must be <= the Target Torque. Once the Target Torque value is
Count Angle
entered, this value will be populated as 50% of the Target.
The Torque point during tightening at which the tool shifts to a lower speed (to improve
Torque Threshold for
accuracy). Must be <= the Target Torque. Once the Target Torque value is entered, this value
Shiftdown
will be populated as 25% of the Target.
Maximum allowable time for completing the step. The default value is 15 seconds and the
Step Timeout (Sec)
range is 1- 65 seconds.
Tool motor acceleration at the start of a tightening. The default value is 90% and the range is
Acceleration (%)
5% to 100%.

18 48619696_ed3
 Speed at which tool will run before reaching Torque Threshold for Shiftdown. The default
Free Speed (%)
value is 100% and the range is 10% to 110%.
Speed at which tool will run after reaching Torque Threshold for Shiftdown. Must be ≤ Free
Shiftdown Speed (%)
Speed. The default value is 10% and the range is 10% to 100%.

3.1.2 Angle Settings:

Target Angle (deg) Target Angle value for the selected configuration in degrees.
The maximum acceptable angle through which the fastener may turn. Must be ≥ the target
Angle high Limit
and cannot exceed more than 35200 degrees. When the Target Angle value is entered, this
(deg)
value will be populated as 120% of the Target.
The minimum angle through which the fastener must turn. Must be ≤ the target value. When the
Angle Low Limit (deg)
Target Angle value is entered, this value will be populated as 80% of the Target.
The maximum acceptable torque value for a fastening. Cannot exceed the Tool Max torque
Torque High Limit
value. The default value is 0.
The minimum acceptable torque value for a fastening. Cannot exceed the Tool Max torque
Torque Low Limit
value. The default value is 0.
Torque Threshold for The torque required to seat the fastener in the joint. This is the torque point at which angle
Count Angle begins to be measured. Must be <= Torque High Limit.
Torque Threshold for The Torque point during the tightening at which the tool shifts to a lower speed (to improve
Shiftdown accuracy). Must be <= Torque High Limit.
Maximum allowable time for completing the step. The default value is 15 seconds and the
Step Timeout (Sec)
range is 1- 65 seconds.
Tool motor acceleration at the start of a tightening. The default value is 90% and the range is
Acceleration (%)
5% to 100%.
Speed at which tool will run before reaching Torque Threshold for Shiftdown. The default
Free Speed (%)
value is 100% and the range is 10% to 110%.
Speed at which tool will run after reaching Torque Threshold for Shiftdown. Must be ≤ Free
Shiftdown Speed (%)
Speed. The default value is 20% and the range is 10% to 110%.

3.1.3 Prevailing Torque Settings:

Cut In Zone Settings
Target Cut-In Angle
Target Angle value for the Cut-In Zone step in degrees.
(deg)
Maximum torque that is allowed during the Cut In Zone. If the measured torque is ≥ this
Torque High Limit
value the step is halted and a fault declared. Value must be ≤ the Tool Max Torque.
Snug Torque The torque point at which angle begins to be measured. Must be ≤ the Torque High Limit.
Prevailing Zone Settings
Target Prevailing
Target Angle value for the Prevailing Torque Zone step.
Angle (deg)
Angle High Limit Maximum angle of rotation allowed during the Prevailing Torque Zone. If the measured
(deg) Angle is ≥ this value the step is halted and a fault declared.
Minimum angle of rotation that must be turned during the Prevailing Torque Zone. When the
Angle Low Limit (deg) Prevailing Torque Zone is exited the measured Prevailing Angle is checked to make sure it is
greater than this limit. If it is not an Under Angle Fault is indicated.
The maximum allowable torque during the Prevailing Torque Zone. If the measured torque
Torque High Limit
equals or exceeds this limit the step is halted and a fault declared.
Minimum torque that should be achieved during the Prevailing Torque Zone. If the cycle is
stopped during the Prevailing Torque Zone Step (trigger release or some other failure) and
Torque Low Limit
the measured torque value is below the Torque Low Limit, a failure will be indicated (Yellow
LED). If Low Torque is the only fault, the tool will continue to the Torque Step.
Common Settings

48619696_ed3 19
 Speed at which tool will run during the Cut In and Prevailing Torque Zones. The default value
Free Speed (%)
is 80%.
Final Torque Settings
Same as for a normal Torque Strategy.
Steps to program a configuration:
1. From the Setup menu, click Quick Setup, ICS opens the Quick Setup window.
2. Select the desired tool from the Location ID drop box.
3. Select the desired configuration from the Config drop box.
4. If the configuration is programmed, the data will display on the screen. Make any changes required, and then click
the Send button on the toolbar to send the data.
5. If the configuration is not programmed, all the default values will be populated.
Enter all parameters as required and click the Send button on the toolbar to send the data to the tool.
6. To save this Configuration locally click the Save icon on the toolbar. Select ‘Yes’. Enter a Config Name when
prompted and select ‘OK’.
To save a configuration:
1. From the Setup menu, click Quick Setup, ICS opens the Quick Setup window.
2. Click the Database Mode button on the toolbar.
3. Program all parameters with desired values.
4. Enter a name for the configuration in the Config Set Name entry box.
5. Choose Save from the File menu to save the configuration into local database.
6. Once saved to the Local Database the user can send the Configuration to the tool using the Parameter Assignment
screen.

3.2 General Setup

The General Setup tab lets the user to retrieve, edit and send the general settings for the selected tool in Network Mode
or retrieve and save settings in the Local Database Mode. When saved to the Local Database the user can send the
saved General Settings to the tool using the Parameter Assignment screen. When saved to the Local Database the user
can send the saved General Settings to the tool using the Parameter Assignment screen.

General Setup tab has three sub sections as follows;

20 48619696_ed3
3.2.1 Tool Setup
Used to set a Location ID for a particular tool. The Location ID is used as a unique identifier
Location ID for each tool on the network. Location ID Number is a four-digit entry that represents a
location on the assembly line. Each tool must have a unique Location ID.
Sets how Configurations are selected. The options available from the dropdown box for this
parameter are Internal, External and Any.
Internal: Tightening Configuration number can be selected using tool display only.
Configuration Mode
External: Tightening Configuration number can be selected using external media such as
IC-PCM 1:1 or ICS only.
Any: Tightening Configuration number can be selected using Internal or External Modes.
If the Headlight is Enabled, it will turn OFF after the specified duration set in the Headlight
Headlight Timeout
Timeout field.
The tool will switch to ‘Sleep Mode’ if the trigger on the tool has not been pressed for the
Sleep Timeout duration specified in this field. This is used to preserve battery life. Using the display keypad
or ICS to communicate with the tool will not prevent the tool from entering ‘Sleep Mode’.
If EOR Buffer is Enabled, once out of range of the PCM, the tool will run cycles until it reaches
the specified EOR Buffer count. The tool will then become disabled and gives an Error Code
EOR Buffer Count F-01 on the display when the trigger is pulled.
See section Enable EOR Buffer for more information.
Momentary Toggle Direction of the tool:
The following are the options available.
• Momentary Reverse : In this mode the tool runs forward when the trigger alone is
pressed and runs reverse when the momentary switch alone is pressed
• 2 Handed Reverse: In this mode the tool runs forward when the trigger alone is pressed
and reverse when the trigger and momentary switch are pressed simultaneously.
Tubenut Mode • Trigger Only: In this mode the tool runs forward on the first trigger press and re-verses
on the next. The direction will continue to toggle with each trigger press.
• Momentary Toggle Direction: In this mode the tool runs forward or reverses when the
trigger alone is pressed. The direction is toggled when the momentary switch is pressed
• Full 2 Handed Operation: In this mode the tool runs forward when the trigger and mo-
mentary switch are pressed simultaneously and runs in reverse the next time the trigger
and momentary switch are pressed.
For tools other than Angle Tubenut Tools, this field is read only.
When checked, this function disables the tool after Pass cycle, after a Gang Complete, or after the
Interlock Active last Configuration in a chain is complete. The tool will stay disabled until a new Configuration is
selected.
When checked, the keypad on the tool is locked so that the user is not able to enter the
Keypad Lockout Password screen and change Configuration settings. The user will still have the ability to
scroll through the tool settings.
Enable Headlight When checked, the Tool Headlight is enabled.
When checked, the EOR Buffer feature is enabled.
The EOR Buffer feature is a EOR Data protection feature where the user sets a EOR Buffer
Enable EOR Buffer count. Once out of range of the PCM, the tool will run cycles until it reaches the specified
EOR Buffer count. The tool will become disabled and gives an Error Code F-01 on the display
when the trigger is pulled. The tool will remain locked until it is within range of the PCM. The
counter will then be reset.
Enable EOR Retries When checked, EOR retries are enabled.
Enable Wireless Retries When checked, communication retries for the RF Module connected to the tool are enabled.
Enable Smart Socket When checked, the tool will be locked until the proper socket is selected.
When checked, the tool LED outputs will be invert. A high fault (torque or angle) will light
Invert Tool LED Output
the yellow LED and a low fault (torque or angle) will light the red LED.

48619696_ed3 21
3.2.2 Wireless Setup
Wireless parameters of the tool can be set only when tool is connected to USB.
Enable Wireless Enables wireless functionality of the tool.
Enable Channel Disables channel hopping functionality on tool. Channel hopping is enabled via the PCM
Hopping settings only.
Local MAC Address Displays the tool MAC address for the connected tool. User cannot modify the MAC address.
PAN ID 16 bit value which is used uniquely to identify one node from the collection of nodes on the
physical channel.
RF Channel Identifier for the radio frequency channel being used. As defined by the 802.15.4 specification.
Transmit Power Used to control the db level of the radio transmitter

3.2.3 Password Settings

The Password Setup module is used to set the password for the connected tool. The password is defined as a four digit
numeric value. The Password settings module of the tool can be set only when tool is connected to USB.

3.3 Advanced Setup

The Advanced Setup Screen is used to program the QX series tool with access to all configuration parameters, allowing
programming of multistep strategies. Torque control or/and Angle control steps can be setup from this screen.
The Configuration sets that are created using this screen can be sent to a tool (in Network mode) . Configuration sets
can also be created and stored in the Local Database Mode. The locally stored Configuration Sets can then be sent to a
tool using the Parameter Assignment screen.
The user can also view the archived configuration data stored in the archived database.

Modify: Click on Modify button to add/modify the tightening control steps.

Prev: It is used to traverse previous step from selected strategy. This button will be disabled if current step is in first
step.
Next: It is used to traverse to next step from selected strategy. This button will be disabled if current step is last step

22 48619696_ed3
Following are the settings which can be programmed for the selected QX tool:
1. Common Settings
2. Torque Control Step
3. Angle Control Step

3.3.1 Common Settings

Common settings screen is used to configure the general settings of the multistep configuration. It includes user-set
parameters that are common across all steps.

Controller ID Drop box Controller ID is used as a unique identifier for each tool on the network.
Lets the selection of all available configurations, 1 through 8, for Programming and/or
Config Drop box
Viewing the Tightening settings.
Lets selection of all available Torque Units: Nm, Ft-lbs, In-lbs, and d-Nm. All the Torque
Torque Display Units
values will be displayed with the selected units. Nm is the default unit.
48619696_ed3 23
 Gang Count can be used if the assembly requires multiple bolts to be fastened in a group.
Gang Count
The default value is 0 and the range is between 0 – 99.
Time interval between each fastening cycle. The tool will be in a locked state until the time
Cycle Delay (Sec)
interval elapses. The default value is 0 and the range is 0 – 10 seconds.
Auto increment can be used to move through a specified sequence of fastening
configurations. After a Pass cycle or gang complete if gang count is set more than 1, the
Auto increment
tool will automatically increment to the Configuration programmed in this field. The default
value is 0 and valid values are Config 1 through 8.
Lets selection of Joint Type. There are two options – Hard and Soft. Hard will be selected by
Joint Type
default.
Sets the tool reverse direction to CW (Clockwise) or CCW (Counter-clockwise). CCW is
Reverse Direction
selected by default.
Turns ‘ON’ or ‘OFF’ the tool buzzer. The Audible Alarm will sound for any Failed cycle, when
Audible Alert
this feature is turned ‘ON’.
Smart socket is intended as an interlock for the user. On selection of the configuration,
the tool will be disabled and an LED will glow in socket tray, indicating which socket the
user must select (the one programmed in this field). The tool will only be enabled when all
Socket Selection
other sockets are in place and the required socket removed from the tray. The default value
is 0 and correct values are 1 through 8. This selection is only pertinent if the Smart Socket
feature is enabled in the tool setup.
The maximum permitted Torque for the connected tool. This Field is not applicable in the
Tool Max Torque
Local Database Mode. This field is read-only.
When checked, the tool will send an Assembly Complete Event to the IC-PCM 1:1 which will
Assembly Complete
then turn on a programmed External Output.
Disable Reverse When checked, the tool will not run in the Reverse direction.
The percent of Max Speed at which the tool will run in the reverse direction. The default
Reverse Speed (%)
value is 100%.
The Reset to parameter is used to indicate which configuration the tool should be set to
Reset To
after the Configuration Reset lnput is received by the IC-PCM 1:1.

3.3.2 Torque Control Step

ICS allows the user to program the following torque control settings parameters.

For Torque step parameter field details Refer Section 3.1.1 Torque settings.

24 48619696_ed3
3.3.3 Angle Control Step
ICS allows the user to program the following Angle control settings parameters.

For Angle step parameter field details Refer Section 3.1.2 Angle settings.
Steps to program a multistep configuration:
1. From the Setup menu, click Advanced Setup, ICS opens the Advanced Setup window.
2. Select the desired tool from the Location ID drop box.
3. Select the desired configuration from the Config drop box.
4. If the configuration is programmed, the data will display on the screen. Make any changes required, and then click
the Send button on the toolbar to send the data.
5. If the configuration is not programmed, click the Modify button to bring up the Advanced Setup Sequence dialog
screen.
6. Choose the desired steps in the proper sequence from the Available Parameters box on the right side of the dialog

screen, moving them to the Configuration Step box on the right side by clicking the transfer button.
NOTE: The Common Settings must be selected for the first step in any multistep strategies. The software warns you if
you choose a step that does not follow proper multistep sequence.
7. Use the Insert button to place a blank step above an existing step. Also, use the Delete button to remove an
unwanted step.
8. Click the OK button when you have added all the necessary steps.
9. Choose individual steps from the left side of the advanced setup screen to bring up the setup parameters for each of
the steps.
10. Make any required changes to the default settings for each step. Enter all parameters as required and click the Send
button on the toolbar to send the data to the tool.
To save a configuration:
1. From the Setup menu, click Advanced Setup, ICS opens the Advanced Setup window.
2. Click the Database Mode button on the toolbar.
3. Program all parameters with desired values.
4. Enter a name for the configuration in the Config Set Name entry box.
5. Choose Save from the File menu to save the configuration into local database.
6. Once saved to the Local Database the user can send the Configuration to the tool using the Parameter Assignment
screen.

48619696_ed3 25
3.4 IC-PCM 1:1 General Setup
The IC-PCM 1:1 General Setup screen gives an option to setup the general settings for the selected IC-PCM 1:1 and lets
to save the settings to the Local Database.
This screen also lets viewing of archived general settings of the IC-PCM 1:1 by retrieving the information from archived
database.

Following are the settings which can be programmed/Viewed for the selected IC-PCM 1:1;
- Version Information
- General Settings
- Protocol Settings
- FieldBus Settings

3.4.1 Version Information

Version information selection displays the currently installed IC-PCM RISC version for the selected IC-PCM 1:1.

3.4.2 General Settings

Following are the settings which can be programmed from General settings tab for the selected IC-PCM 1:1;
- Tightening Control Settings
- IO Settings
- Date Time Settings
3.4.2.1 Tightening Control Settings
Tightening control settings allows programming the type of “Configuration selection mode”, “Remote Tool Enable/
Disable Mode” and Enable/Disable option for Smart Socket feature.

26 48619696_ed3
 Lets the user to enable/disable the tool tightening operation remotely.
“1-Line” option: The “Enable” input pin of the IC-PCM 1:1 must be ON in order to start the tightening
Remote Tool operation for the tool. To disable the tool,, “Enable” input pin should be OFF.
Enable/Disable “2-Line” option: The “Disable” input pin of the IC-PCM 1:1 must be ON in order to disable the tool
Mode from tightening operation. To enable the “Tightening operation”, the “Disable” input pin should be
OFF and “Enable Input pin” bit should be pulsed
“None”: sets the tool mapped to the IC-PCM 1:1, always in enabled mode for tightening operation
Configuration Selection feature sets the selection method in the IC-PCM 1:1 of the mapped tool.
“External Discrete” option: Lets to select the configuration of the mapped tool by activating specific
input pin for which configuration number input behaviour is assigned.
“External Binary” option lets to select the configuration numbers (1 to 8) for the mapped tool using
the combination as shown below Assign Config 1, 2, 3 input behaviours to Input pin 1, 2, 3.
Config Input 1 Input 2 Input 3
1 0 0 0
2 1 0 0
Configuration 3 0 1 0
Selection
Mode 4 1 1 0
5 0 0 1
6 1 0 1
7 0 1 1
8 1 1 1
“External Ethernet” option in the IC-PCM 1:1 allows selecting the configuration number of the
mapped tool based on the configuration selection message which is received on its Ethernet port.
IC-PCM 1:1 will always be listed on the Port Number 61000 for configuration selection message.
NOTE: This Port number cannot be configured by the user.
“Enable Smart Socket” check box enables the smart socket tray selection feature on the IC-PCM 1:1.
Enable smart
This function requires that the user remove the assigned socket from the tray in order for the tool to
Socket
be enabled. The socket is assigned by the configuration settings.
3.4.2.2 IO (Input/Output) Settings
Assign Input
The Assign Inputs tab gives a method of assigning input behaviours to physical input pin of the IC-PCM 1:1. The screen
gives a list of input behaviours for programming the input pins. The screen also gives the flexibility of positioning the input
behaviours and prevents duplicate assignments of same behaviours for different input pins of the IC-PCM 1:1.

Input Pin/Behaviours
This List displays the Current inputs behaviours versus input pins (2-I-1 to 2-I-8).
List

48619696_ed3 27
 The “Behaviours” List displays all the available behaviours which are not been assigned to
any of the input pins. Following are the list of input behaviours
-“Configurations 1-8” behaviours select the configuration number of the tool mapped tool
to the IC-PCM 1:1
-“Enable” behaviour Enables the tool to perform the tightening operation
-“Disable” behaviour disables the tool from performing the tightening operation
-“Gang Reset” behaviour resets the Current gang count to 0.
-“Gang Advance” behaviour Advances the current Gang Count by one in case of Fail cycle.
-“Config Reset” behaviour resets back to the Configuration number of the mapped tool to
configuration number which is programmed in the active configuration
-“Reset Outputs” behaviour resets all output pins to non-active condition.
Behaviour’s list - “Config Advance” behaviour advances to the next configuration number which is
programmed in the active configuration.
-“Socket Select 1-8” behaviour which is used in a socket tray setup to know which socket
number is selected for the corresponding configuration.
-“User Input 1-8” behaviours are used for receiving the Field bus device input commands
to the IC-PCM 1:1.
-“Reprint Label” behaviour is used to resend a label to the label printer connected to the
IC-PCM 1:1.
“PLUS Manual Reset” behaviour resets the PLUS communication in the IC-PCM 1:1.
“PLUS Reset Communication” behaviour resets the communication with the PLUS Server.
“PLUS Sync” behaviour synchronizes the communication between the PLUS server and
IC-PCM 1:1
The “Assign” Input button is used to assign the selected input behaviour to the selected
input pin of the IC-PCM 1:1.
Assign Input button
Select the input pin (2-I-1) from “Input Pin /Behaviours List” and the appropriate
behaviours from “Behaviours” list and click on Assign button (left pointing arrow) for
assigning the behaviour to the selected input pin.
The “Un-Assign” Input button is used to un-assign an input behaviour from the
Un-Assign Input button programmed input pin.
Select the input pin (2-I-x) from “Input Pint/Behaviours List” and click on the “Un-Assign”
(right pointing arrow) button to un-assign the behaviour from the selected input pin.
“Un-Assign All” button The “Un-Assign All” button is used for un-assigning all the input behaviours from the
programmed input pins (2-I-1 to 2-I-8).

Output settings
The Assign Outputs tab gives a method of assigning output behaviours to physical output pins of the IC-PCM 1:1.
The screen gives a list of output behaviours to select and assign to the desired output pins. The screen also gives the
flexibility of positioning the output behaviours to the output pins of the IC-PCM 1:1. The Outputs will stay ‘ON’ (active)
until the specified ‘Time’ interval has elapsed. The default ‘Time’ is 0. With this value the Outputs will remain ‘ON’ (active)
until the next EOR data is received or the ‘Reset Outputs’ Input is turned ‘ON’.

28 48619696_ed3
 Output Pin/
Behaviours This List displays the Current output behaviours versus output pins (1-O-1 to 1-O-8) on to the IC-PCM 1:1
List
The “Output Behaviours” List displays all behaviours. Following are the list of output behaviours
-“Accept” behaviour is HIGH when tightening sequence is “OK” for the tool mapped to the IC-PCM
1:1.
-“Reject” behaviour is HIGH when tightening sequence is “NOT OK” for the tool mapped to the IC-
PCM 1:1.
-“Cycle Complete” behaviour is HIGH when the tightening sequence is completed irrespective to the
Pass/Fail status of the tool mapped to the IC-PCM 1:1
-“High Torque” behaviour is HIGH when the final Torque result is greater than or equal to Torque High
Limit programmed for the configuration.
-“Low Torque” behaviour is HIGH when the Final torque result is below the Torque Low Limit
programmed for the configuration.
-“High Angle” behaviour is HIGH when the final Angle result is greater than or equal to the Angle
High Limit programmed for the configuration
Behaviour’s
list -“Low Angle” behaviour is HIGH when the Final angle value of the tightening results is less than the
angle Low Limit of the tool mapped to the IC-PCM 1:1.
“Reject Buzzer” is HIGH when the tightening sequence is “NOT OK”
“Paint Marker” is HIGH when the tightening sequence is “OK”
“System Fault” HIGH Indicates a problem with the IC-PCM 1:1.
“Gang Complete” is HIGH when “Gang Complete” occurs
“Config 1-8” is HIGH when the particular Configuration is selected on the tool.
“Socket Select 1-8” is HIGH when a Configuration is selected that has the particular Socket Selection
Number assigned to it.
User Output 1-8” is HIGH when turned ‘On’ by one of the Fieldbus Protocols.
“Protocol Online” is HIGH when any one of the protocols are active.
“Green LED 1-4” is HIGH when the particular LED is turned on by XML Server.
“Assembly Complete” is HIGH when the assembly complete signal is received from tool.
The “Assign” output button is used for assigning the output behaviours to the selected output pin of the
IC-PCM 1:1.
Assign output
Select the output pin (1-O-x) from “output Pin /Behaviours List” and the appropriate behaviour from
button
“Behaviours” list. Click on Assign button (left pointing arrow) to assign the behaviour to the selected output
pin.
The “Un-Assign” output button is used for un-assigning the output behaviours from the programmed
Un-Assign output pin.
Input button Select the output pin (1-O-x) from “Output Pin /Behaviours List” and click on the “Un-Assign” (right
pointing arrow) button to un-assign the behaviour from the selected output pin.
“Un-Assign The “Un-assign All” button is used for un-assigning all the output behaviours from the programmed
All” button output pins (1-O-1 to 1-O-8).
To set a time out period for the output pin, enter a time in seconds in the Time column. If output
Set time time is set to zero, the output pin will remain active until the next cycle is complete. Otherwise the
output pin will go low after the time out period.
NOTE: For safety reasons, newly assigned Input or Output behaviours on the IC-PCM-1:1 will not take effect until the
IC-PCM 1:1 is rebooted.
3.4.2.3 Socket Tray and Configuration Switch Connection and Setup using IC-PCM 1:1
• Map the QX Series wireless tool to the IC-PCM 1:1.
• Using ICS Application, Enable the Smart socket feature in the IC-PCM 1:1 from General setup screen.
• Program Behaviours of configuration number and socket numbers to Inputs/Outputs behaviours of the IC-PCM 1:1
from IC-PCM 1:1 General setup screen.

48619696_ed3 29
• Enable the “Enable Smart Socket” check box from Tool general setup screen.
• For above assigned configuration numbers, program the Tightening configuration and its corresponding socket
number from tightening configuration screen.
• Connect the Socket Tray Input lines/Output lines to the IC-PCM 1:1 terminal blocks and make sure all the pins are working
correctly using the diagnostics View Input/ Output screen. To run the tool, select configuration number using the external
input signal to the IC-PCM 1:1 , ICS or Fieldbus, or from the tool display. The IC-PCM 1:1 then sends out the corresponding
socket number output signal to the Socket tray. Lift the corresponding socket for the selected configuration. Tool will now
be in unlocked condition to run its configuration.
NOTE: Tool will not run its configuration if more than one socket removed from the tray or wrong socket is removed.
3.4.2.4 Light Box Connection and Setup
• Locate the active wire colors for light boxes.
• Connect the light box to the IC-PCM 1:1 terminal blocks with the appropriate accessory cable.
• Ensure a QX Series wireless tool is mapped to the IC-PCM 1:1.
• From IC-PCM 1:1 General Setup screen, assign the output behaviours for the corresponding terminal blocks.
• In a standard setup, the colored lamps indicate the following:
Red : Torque/Angle High.
Green : Accept output.
Yellow : Torque/Angle Low.
3.4.2.5 Date Time Settings
The Date Time settings lets the user to set the Date and Time settings for IC-PCM 1:1.

30 48619696_ed3
 Date Format drop box allows the user to set the date format for the IC-PCM 1:1 (MMDDYY
Date Format
and DDMMYY).
Offset drop box allows the user to set the current time zone for the IC-PCM 1:1. Following
are the options for Offset time zone – GMT-12, GMT-11, GMT-10, GMT-9, GMT-8, GMT-7,
Offset GMT-6, GMT-5, GMT-4, GMT-3:30, GMT-3, GMT-2, GMT-1, GMT, GMT+1, GMT+2, GMT+3,
GMT+3:30, GMT+4, GMT+5, GMT+5:30, GMT+5:45, GMT+6, GMT+6:30, GMT+7, GMT+8,
GMT+9, GMT+9:30, GMT+10, GMT+11, GMT+12, GMT+13.
Daylight Saving option is used for enabling or disabling automatic time adjustment for
Daylight Saving Enable
daylight savings of selected country
In DST The time format which received from the IC-PCM 1:1 is in daylight savings format.
Time Format Time Format allows setting the current time in 12/24 Hour format.

3.4.3 Protocol Settings

The Protocol Assignment settings tab gives options for assigning protocols and customizing them for the various
communications ports. The following are the different protocols that can be assigned to each available port.
3.4.3.1 PCM Serial Port Settings
This setting allows to set the “serial Port settings” of the IC-PCM 1:1.

48619696_ed3 31
 Baud Rate sets the speed for communications of serial port. Following are the baud rates
Baud Rate which can be set from ICS 110, 1200. 2400, 4800, 9600. 14400, 19200, 28800, 38400, 57600,
76800, 115200.
Parity Parity sets the parity for the serial connection to None, Odd, Even
Stop Bits Stop Bits sets the number of Stop bits to 1 or 2
Bits Per Character Bits Per Character sets the Bits Per Character parameter to 7 or 8
Multi Drop Address Multi Drop Address sets the address number for use with Host Data Out protocol.
Protocol indicates which protocol is set for the Serial port, such as “Serial Barcode”, “Serial
Protocol
EOR”, “PLUS Barcode” and “Label Printing”
3.4.3.2 Barcode/VIN Settings
Barcode/VIN settings allow the user to set the Barcode related settings such as length, criteria, From/To characters for
criteria match. Barcode scanner input can be set for different types of Standard communications ports (Ethernet /Serial)
of the IC-PCM 1:1.
Other protocols such as ProfiBus or DeviceNet can also input a Barcode or VIN number to the IC-PCM 1:1, but the
barcodes are not subject to criteria checking.

Modes in the Barcode settings allows to set Two Types of mode “Passive” & “Active”
Passive mode: Attaches the barcode string to the End Of Run Data received from the tool without any
criteria comparison. Barcode information is stored locally in the IC-PCM 1:1 cycle log data but not in the
tool cycle log data.
Active mode: Has all the functionality of Passive mode and the additional functionality of allowing the
Mode Barcode/VIN to select configuration number on the tool.. Valid Barcode/VINs are identified based on the
characters in the barcode that should match the criteria set for corresponding configuration number. If
successful then it attaches the Barcode string to the EOR data.
OFF mode: Disables the barcode operation for the IC-PCM 1:1. “No BCode” will be attached to the EOR
data. OFF mode will set the barcode operation in disabled mode for IC-PCM 1:1. “No BCode” will be
attached for the tightening cycle received from the mapped tool.
Set the max length of the Barcode string (this is the total number of characters in the barcode.) The Max
Length
length for the Barcode string for the IC-PCM 1:1 is 40.
Source Source can be either Serial/Ethernet of the IC-PCM 1:1.
From Sets the beginning (character #) of the criteria string range
To Sets the end (character #) of the criteria string range.

32 48619696_ed3
 Criteria settings displays all the criteria strings programmed for the configuration number (1-8).
Double clicking on a row entry opens up the Criteria Editor dialog Box. Select the Configuration from the
drop down list and then double click on the Config Criteria text entry box. Enter the character strings with
length matching the From/To value to identify a valid Barcode/VIN. Click OK to save the settings in the
criteria settings list.

Criteria
Settings

Enable “Ignore duplicate scan” will ignore the scanned barcode from the IC-PCM 1:1 if it is identical to
Ignore previously scanned barcode.
Duplicate
Scan “Invalid BC” is recorded as the scan data for passive mode. In the case of Active mode, the configuration
selection will not be sent to the tool mapped to the IC-PCM 1:1.
Length check allows the user to set the maximum allowable length of the barcode.
“None” option: Will not restrict the scanned barcode length.
“Restrict” option: Will validate the scanned Barcode length with the value set in the length input box. If
it exceeds the set length value, “Invalid BC” is recorded as the scan data for passive mode. Configuration
Length
number will not be selected in the tool in active mode .
Check
“Truncate Left”: Truncates the scanned barcode string from left hand side until it matches the value set in
the length input box.
“Truncate right”: Truncates the scanned barcode string from right hand side until it matches the value set
in the length input box.
NOTE: one serial protocol settings can be programmed on the IC-PCM 1:1 serial port at a time.
3.4.3.3 Barcode Connection and Setup using IC-PCM 1:1
• Connect ASCII barcode scanner to the serial port of the IC-PCM 1:1. For Ethernet Barcode scanner, connect the scan-
ner to the Ethernet port of a serial to Ethernet device on the network.
• Using ICS application, program the IC-PCM 1:1 serial port settings to match settings on the bar code scanner.
• The barcode scanner must be configured to add a CR/LF at the end of each barcode.
• Using ICS application, enable the Serial Barcode Protocol for the IC-PCM 1:1
• The barcode function has two main operating modes, Passive and Active. The Barcode settings can be programmed
using ICS software.
• Using Active mode, a particular configuration number can be selected using Barcode.
• Turn on Barcode scanner.
• When the barcode function is enabled for a IC-PCM 1:1 and when the cycle data is sent by the tool, the scanned
bar code data is added to EOR data. If a cycle is run before a barcode is scanned then the bar code data is recorded
as “No BCode”. When a barcode is scanned and is of valid length, then the scan data is recorded to all subsequent
cycles until a new scan is initiated. If an invalid barcode is scanned, “Invalid BC” is recorded as the scan data.
3.4.3.4 Serial EOR Settings
The Serial EOR Settings screen enables sending of EOR data for every tightening cycle of the mapped tool to the Serial
port.

48619696_ed3 33
Enable Serial EOR Enables “Serial EOR Data out” to IC-PCM 1:1.

Enable Custom This enables the customized EOR.

EOR NOTE: Do not use this check box unless customized EOR is required.
Output Positions The Output Positions list view, displays all EOR fields and current status (Yes/No) and also the
List View order in which the Fields appear in over the Serial port separated by the delimiter.
Yes/No Check Box Select the Checkbox next to the EOR field to include it as the part of the EOR Data Out Message.
The order in which EOR fields appear can be changed by clicking on a parameter to highlight,
Up/Down Arrow
and then using the up/down arrows to the right side of “Output Positions” List.
The Default Filter will enable the IC-PCM 1:1 to use only the default set of EOR fields for EOR Data
Out to the serial port. Following are the default EOR fields and the order in which they appear in the
Serial outputs message string.
1. Cycle No 8. Torque Units 15. Torque Low Limit
2. Config No 9. Peak Angle 16. Angle High Limit
Default Filter
3. Date 10. Angle Result 17. Angle Low Limit
4. Time ID 11. Peak Current 18. Control Point
5. Cycle Result 12. Cycle Time 19. Barcode
6. Peak Torque 13. Strategy Type
7. Torque Result 14. Torque High Limit

34 48619696_ed3
 The Select All Filter will enable IC-PCM 1:1 to use all EOR fields for EOR Data Out to the serial port.
Following are the EOR fields and the order in which they appear in the Serial output message
string.
1. Cycle No 20. Job ID 40. Peak Cut-In Torque
2. Config No 21. Powerhead Cycle No 41. Peak Prevailing Torque
3. Date 23. Spindle No 42. Avg Prevailing Torque
4. Time ID 24. Step No 43. Peak Drag torque
5. Cycle Result 25. Downshift Speed 44. Avg Drag Torque
6. Peak Torque 26. Free Speed 45. Total Gang Count
7. Torque Result 27. TR 46. Current Gang count
8. Torque Units 28. Dual Slope A High 47. Tool Serial Number
9. Peak Angle 29. Dual Slope A Low 48. Shutdown Code
Select All Filter
10. Angle Result 30. Dual Slope B High 49. CP Result
11. Peak Current 31. Dual Slope B Low 50. Gradient Result
12. Cycle Time 32. Gradient High 51. Dual Slope A Result
13. Strategy Type 33. Gradient Low 52. Dual Slope B Result
14. Torque High Limit 34. Final Slope 53. Unusual Fault
15. Torque Low Limit 35. Torque At Seat 54. Motor Torque Constant Test
16. Angle High Limit 36. Angle At Seat 55. Free Speed test
17. Angle Low Limit 37. Min Drag Torque 56. Max Tool Speed
18. Control Point 38. Peak Slope 57. Total Angle
19. Barcode 39. Prevailing Torque Slope
NOTE: Some of the above EOR fields are not part of EOR data generated by the QX Series Tools.
For those fields, the default values will be generated.
This Drop Box shows the Delimiter criteria available to separate each EOR field in the serial EOR
Data out message of the IC-PCM 1:1.
Delimiter
Following are the Delimiter criteria available for Serial EOR Data out protocol – “Comma”, “Space”,
“Semi Colon”, and “Colon”.
NOTE: Only one Protocol (Barcode/VIN, Serial EOR Data Out, PFCS, PLUS, Label Printing) can be enabled on the serial
port at a time.
3.4.3.5 Serial EOR Settings Setup:
The Serial EOR Settings Screen allows the user to enable the sending of EOR data for every cycle over the Serial port.
Setup:
1. Turn OFF the IC-PCM 1:1 and set the RED DIP switch 2 to OFF.
2. Connect a serial null-modem cable from the IC-PCM 1:1 to the PC.
3. Launch HyperTerminal or other terminal emulation software utility such as Clear Terminal.
4. Reboot the IC-PCM 1:1.
5. The Generated EOR will be displayed in the serial terminal emulation software.
Example: If the user selects the default settings as shown below from the IC-PCM 1:1 General Setup screen, the
corresponding EOR will be sent to the Serial Port and can be viewed in HyperTerminal or other terminal emulation
software such as Clear Terminal.

48619696_ed3 35
3.4.3.6 Ethernet EOR Settings
The Ethernet EOR Settings screen allows the user to enable sending of EOR data over the standard Ethernet
communication port.

Enable Ethernet EOR Enables the “Ethernet EOR Data out” protocol for the IC-PCM 1:1
Output Positions The Output Positions list view displays all the EOR fields and current status (Yes/No) and also
List View the order in which the Fields appear over the Ethernet port.

36 48619696_ed3
 Select the Checkbox next to the EOR field to include it as the part of the EOR Data Out
Yes/No Check Box
message.
The Ethernet Port which is used to output the EOR data. By Default ICS sets the Port number to
Port No
“1069”.
The order in which EOR fields appear can be changed by clicking on a parameter to highlight,
Up/Down Arrow
and then using the up/down arrows to the right side of “Output Positions” List.
The Default Filter will enable the IC-PCM 1:1 controller to use only the default set of EOR fields
for EOR Data Out to the Ethernet port. Following are the default EOR fields and the order in
which they appear in the Ethernet output message string.
1. Cycle No 8. Torque Units 15. Torque Low Limit
2. Config No 9. Peak Angle 16. Angle High Limit
Default Filter 3. Date 10. Angle Result 17. Angle Low Limit
4. Time ID 11. Peak Current 18. Control Point
5. Cycle Result 12. Cycle Time 19. Barcode
6. Peak Torque 13. Strategy Type
7. Torque Result 14. Torque High Limit
The Select All Filter will enable the IC-PCM 1:1 controller to use all EOR fields for EOR Data Out
to the Ethernet port. Following are the EOR fields and the order in which they appear in the
Ethernet output message string.
1. Cycle No 20. Job ID 39. Peak Cut-In Torque
2. Config No 21. Powerhead Cycle No 40. Peak Prevailing Torque
3. Date 22. Spindle No 41. Avg Prevailing Torque
4. Time ID 23. Step No 42. Peak Drag torque
5. Cycle Result 24. Downshift Speed 43. Avg Drag Torque
6. Peak Torque 25. Free Speed 44. Total Gang Count
7. Torque Result 26. TR 45. Current Gang count
8. Torque Units 27. Dual Slope A High 46. Tool Serial Number
9. Peak Angle 28. Dual Slope A Low 47. Shutdown Code
Select All Filter
10. Angle Result 29. Dual Slope B High 48. CP Result
11. Peak Current 30. Dual Slope B Low 49. Gradient Result
12. Cycle Time 31. Gradient High 50. Dual Slope A Result
13. Strategy Type 32. Gradient Low 51. Dual Slope B Result
14. Torque High Limit 33. Final Slope 52. Unusual Fault
15. Torque Low Limit 34. Torque At Seat 53. Motor Torque Constant Test
16. Angle High Limit 35. Angle At Seat 54. Free Speed test
17. Angle Low Limit 36. Min Drag Torque 55. Max Tool Speed
18. Control Point 37. Peak Slope 56. Total Angle
19. Barcode 38. Prevailing Torque Slope
NOTE: Some of the above EOR fields are not part of EOR cycle generated by QX Series Tool. For
those fields, the default values will be generated.
This Drop Box shows the Delimiter Criteria available to separate each EOR field in the Ethernet
EOR Data out message of IC-PCM 1:1 controller.
Delimiter
Following are the Delimiter criteria available for Ethernet EOR Data out protocol – “Comma”,
“Space”, “Semi Colon”, “Colon”.
Option provided for Enable/Disable Handshaking.
Enable Handshaking requires an acknowledgement to be sent to the IC-PCM 1:1 controller for each
Enable
EOR.
Handshaking
With Handshaking Disabled, the IC-PCM 1:1 controller will not expect an acknowledgement after
every EOR.
NOTE: The IC-PCM 1:1 requires a Reboot after any Ethernet Settings change.

48619696_ed3 37
3.4.3.7 Ethernet EOR Setup
Ethernet EOR Settings enables sending of EOR data for every EOR over Ethernet port. IC-PCM 1:1 sends EOR to
programmed Ethernet port. This can be verified using Ethernet EOR Test Tool.
Ethernet EOR Test Tool Setup:
• Click on Option Button. Enter IC-PCM 1:1 IP Address. Click on OK button
• Click on Connect button to IC-PCM 1:1 establishes the communication. Click on Login PREAD and then click on
“Standard EOR Act” to view the default EOR Field format.

• IC-PCM 1:1 sends Received EOR data to programmed Ethernet port in Standard EOR Format which can be viewed in
the Ethernet EOR test tool.

To view the Customized EOR fields, click on “Customer EOR Act”. IC-PCM 1:1 sends EOR data to programmed Ethernet
port in Customized EOR Format which can be viewed in the Ethernet EOR test tool.
NOTE: If standard EOR act is activated then deactivate by clicking on “Deactivate Standard EOR Act” button and Click on
“Customer EOR Act”.

38 48619696_ed3
3.4.3.8 PFCS Settings
PFCS Settings gives ability to program the settings to communicate between Plant Floor Communication System (PFCS)
and IC-PCM 1:1. The PFCS interface acquires EOR Cycle Data and sends it to their system for acquisition, archiving and
analysis purposes.

Enable PFCS Enables “PFCS” protocol on to the IC-PCM 1:1 Ethernet port.
Maximum Retries Maximum number of retries for each message.
Keep Alive timeout Keep alive timeout (0-9999) is the timeout value for the Keep alive message to the PFCS Server
ACK Timeout Timeout value for receiving the reply from PFCS server.
Type IC-PCM 1:1 can communicate with PFCS server using Serial/Ethernet.
IP Address IP address of PFCS Server
Port Port number to communicate with PFCS Server.

3.4.3.9 Communication via Serial:

1. Enable PFCS and select Type as Serial for IC-PCM 1:1 using ICS Application (Refer ICS Manual).
2. Connect Serial port cable from the IC-PCM 1:1 to the machine where PFCS in running.
3. Select appropriate serial Port number and establish a connection from PFCS Server to the IC-PCM 1:1.
NOTE: Make sure serial port cable is connected between IC-PCM 1:1 and system where PFCS protocol is running.
3.4.3.10 Communication via Ethernet:
1. Enable PFCS and select Type as Ethernet for IC-PCM 1:1 using ICS Application (Refer ICS Manual).
2. Reboot the IC-PCM 1:1 after 30 seconds.
3. Establish a connection from PFCS Server to IC-PCM 1:1.
NOTE: Make sure Ethernet port (RJ45) is connected.

48619696_ed3 39
3.4.3.11 PLUS Settings
Plus Settings gives ability to program the settings to communicate between PLUS server and IC-PCM 1:1 The PLUS
interface is used to control and acquire EOR Cycle Data and send it to their system for acquisition, archiving and
analysis purposes.

Enables the “PLUS” protocol on to the IC-PCM 1:1 Ethernet port.

Enable PLUS NOTE: PLUS also uses the Serial Port settings for reading Barcode information. Any other serial
protocols which are programmed for serial port settings will not allow enabling the PLUS Protocol.
Server IP Address IP address of PLUS Server.
Port Port number to communicate with PLUS Server.
The timeout value for all bolts to be completed for the part before the assembly is aborted and
EOR Cycle Time Out
the results sent to the server.
System ID The user specified system identification.
Retry Count The maximum number of times to retry a message before resetting communications.
Retry Interval The period of time to wait between message retries.
Check Point ID The user specified checkpoint identification.
Technical Attribute
Technical Attribute Timeout sets timeout between a Request/Replay for Technical Attributes
Timeout
VBA Mode Setting this value puts the PLUS into an asynchronous mode.
Bolt Description allows opening the dialog box for entering the bolt description for each bolt no.

Bolt Description

40 48619696_ed3
 Technical Attribute allows opening the Dialog box for entering all the technical Attribute
information

Technical Attribute

Identification Type allows opening the Dialog box for selecting three fixed Identification Type
to determine the message ID

Identification Type

Config Settings allows opening the Dialog box for Selecting configuration number and
entering next Configuration number in the auto increment chain and corresponding total Gang
count which is programmed for the selected configuration number.

Config Settings

48619696_ed3 41
3.4.3.12 XML Settings
XML Settings enable’s the IC-PCM 1:1 to communicate with the SPS/PC Master server and sends the EOR results in the
XML format.

Enable XML Enables “XML” protocol on to IC-PCM 1:1 Ethernet port.

Server IP Address IP address of the SPS/PC Master XML Server
Server Port Server Port number to communicate with SPS/PC Master.
Client Port Client Port number for IC-PCM 1:1 to communicate with SPS/PC Master.
Maximum Number Of Retries Maximum number of retries for each message.
Retry Interval Time interval between each retries.
Keep alive out (0-9999) is timeout value for Keep Alive message and SPS/PC Master
Keep Alive Timeout
Server.
3.4.3.13 XML setup using IC-PCM 1:1
The XML protocol communicates with an XML master control system, (SPS), as described in the VW XML Interface.
doc. The communication between master (PC I SPS) and Slave (PCM) is done based on TCP/IP-Protocol family via TCP-
Sockets.
• Two communication channels exist with their own Ports A and B that can be set by ICS software. The master acts
as the Client for checking the IC-PCM 1:1 (Port A) and sends corresponding commands to a server process of the
IC-PCM 1:1. The IC-PCM 1:1 sends event- controlled messages and process data (Port B) to a server process of the
master. The preset standard values for the port numbers are 4700 for Port A and 4710 for Port B. Enable XML proto-
col in the XML settings screen
• Set Configuration Selection Mode to External Ethernet in the Tightening Control Settings screen
• Using Aton software, connect the master to the network
• Select subscribe to EOR from the master
• View EOR data from the IC-PCM 1:1

42 48619696_ed3
3.4.3.14 Open Protocol Settings
Open Protocol Settings provides the ability to communicate between Open Protocol server and IC-PCM 1:1 to acquire
EOR or Cycle Data and send it to their system for acquisition, archiving and analysis purposes.
The Open Protocol is defined in detail in the OpenProtocol_W7_7.0 specification.

Enable Open Protocol Settings Enables the “Open” protocol on to IC-PCM 1:1 Ethernet port.
Server IP Address IP address of Open Protocol Server.
Listening Port Port number to communicate with Open Protocol Server.
Maximum Number Of Retries Maximum number of retry if Request is failed
Retry Interval Time interval between each retries.
NOTE: Option should be set to External Ethernet for IC-PCM 1:1 to communicate with Open Protocol Server.
3.4.3.15 Open Protocol Setup
1. Setup the open protocol connection for the IC-PCM 1:1 from ICS.
2. Assign Protocol Online output to any of outputs using Assign I/O configuration in ICS.
3. Make sure Open protocol client is running at the port setup in the configuration.
4. Protocol Online Output should be set if connection is successful with the client.
NOTE: Make sure Ethernet port (RJ45) is connected.
3.4.3.16 Label Printing Settings
The Label Printing Feature enables IC-PCM 1:1 to print the EOR data. Once EOR data received from tool, it is then
formatted and sent to serial port of IC-PCM 1:1 to which printer connected.

48619696_ed3 43
The IC-PCM 1:1 will have settings for Header, Data and Footer information that will be printed on the label.
There are two things that must be present in the IC-PCM 1:1 in order to use the label printer feature.
- status.txt (printer communications is defined in this text)
- body.txt (The label format is defined in this text)
NOTE: At a time only one Protocol (Barcode/VIN, Serial EOR Data Out, PFCS, PLUS, Label Printing) can be enabled on the
serial port.
3.4.3.17 Printer Connections and Setup for IC-PCM 1:1
• The IC-PCM 1:1 supports serial printers for printing EOR (End of Run) data.
• Connect the printer via a standard 9-pin serial cable to a serial port of the IC-PCM 1:1.
• Using ICS application, program the IC-PCM 1:1 serial port settings to match settings on the serial printer.
• Enable the Label Printing Protocol for the IC-PCM 1:1
• Make sure the necessary files are saved in the IC-PCM 1:1 for printing Header/ Data/ Footer sections. For more infor-
mation, refer IC-PCM 1:1 General Setup manual.
• Turn on the printer.
• Run a tightening cycle and verify that tightening result is being printed.

3.4.4 FieldBus Settings

3.4.4.1 ProfiBus Settings
Profibus is an industrial fieldbus used primarily for I/O and controls. The IC-PCM 1:1 can come equipped with this slave
card. The IC-PCM 1:1 can be controlled via this device as well as provide end of run status and torque and angle results.

This enables fieldbus operations for IC-PCM 1:1.

Field Bus Enabled
Output signals will be sent to the fieldbus master.
Field Bus Control This enables control of the IC-PCM 1:1 by allowing the fieldbus master to set I/O.
Node Address Each IC-PCM 1:1 on the fieldbus network needs to have a unique address.

44 48619696_ed3
3.4.4.2 InterBus Settings
InterBus is an industrial fieldbus used primarily for I/O and controls. The IC-PCM 1:1 can come equipped with this slave
card. The IC-PCM 1:1 can be controlled via this device as well as provide end of run status and torque and angle results.

This enables the fieldbus operations for IC-PCM 1:1

Field Bus Enabled
Output signals will be sent to the fieldbus master
Field Bus Control This enables control of the IC-PCM 1:1 by allowing the fieldbus master to set I/O.
3.4.4.3 Devicenet Settings
DeviceNet is an industrial fieldbus used primarily for I/O and controls. The IC-PCM 1:1 can come equipped with this
slave card. The IC-PCM 1:1 can be controlled via this device as well as provide end of run status and torque and angle
results.

This enables the fieldbus operations for IC-PCM 1:1.

Field Bus Enabled
Output signals will be sent to the fieldbus master
Field Bus Control This enables control of the IC-PCM 1:1 by allowing the fieldbus master to set I/O.
48619696_ed3 45
Node Address Each IC-PCM 1:1 on Fieldbus network needs to have a unique address.
This is the DeviceNet communication speed. Following are baud rate which can be used - 110,
Baud Rate
1200, 2400, 4800, 9600, 14400, 19200, 28800, 38400, 57600, 76800, 115200.
3.4.4.4 Modbus RTU Settings
ModBus RTU is an industrial fieldbus used primarily for I/O and controls. The IC-PCM 1:1 can come equipped with this
slave card. The IC-PCM 1:1 can be controlled via this device as well as provide end of run status and torque and angle
results.

This enables the fieldbus operations for the IC-PCM 1:1

Field Bus Enabled
Output signals will be sent to the fieldbus master
Field Bus Control This enables control of the IC-PCM 1:1 by allowing the fieldbus master to set I/O.
Node Address Each IC-PCM 1:1 on the fieldbus network needs to have a unique address.
This is the ModBus RTU communication speed. Following are the baud rate which can be used-
Baud Rate
110, 1200, 2400, 4800, 9600, 14400, 19200, 28800, 38400, 57600, 76800, and 115200.
Parity Select the Parity for the serial connection to None, Odd, or Even from the drop box list.

46 48619696_ed3
3.4.4.5 Modbus TCP/IP/Ethernet IP Settings
ModBus TCP/IP and Ethernet IP are industrial fieldbus used primarily for I/O and controls. The IC-PCM 1:1 can come
equipped with this slave card. The IC-PCM 1:1 can be controlled via this device as well as provide end of run status and
torque and angle results.

This enables the fieldbus for IC-PCM 1:1

Field Bus Enabled
Output signals will be sent to the fieldbus master.
Field Bus Control This enables control of the IC-PCM 1:1 by allowing the fieldbus master to set I/O.
IP Address Enter the IP Address of the ModeBus TCP/IP fieldbus device in a computer network.
Subnet Mask A range of logical addresses within the address space that is assigned to an organization
Gateway Gateway is a node on a computer network that serves as an access point to another network

48619696_ed3 47
3.4.4.6 ProfiNet Settings
ProfiNet is an industrial fieldbus used primarily for I/O and controls. The IC-PCM 1:1 can come equipped with this slave
card. The IC-PCM 1:1 can be controlled via this device as well as provide end of run status and torque and angle results.

This enables the fieldbus for IC-PCM 1:1

Field Bus Enabled
Output signals will be sent to the fieldbus master.
Field Bus Control This enables control of the IC-PCM 1:1 by allowing the fieldbus master to set I/O.
IP Address Enter the IP Address of the ProfiNet fieldbus device in a computer network.
Subnet Mask A range of logical addresses within the address space that is assigned to an organization
Gateway Gateway is a node on a computer network that serves as an access point to another network

48 48619696_ed3
3.5 Parameter Assignment
The Parameter Assignment Screen allows the user to assign any saved Configuration and/or General Parameter set to
the tool connected to USB and IC-PCM.
This screen also allows the user to edit the General Parameter settings of the IC-PCM 1:1 or Send a saved General
Parameter Set to the IC-PCM 1:1.
This screen works in the network mode only. The left side of the screen shows all the devices (IC-PCM 10:1 and assigned
(mapped) tools, IC-PCM 1:1 and mapped tools, and tools connected to USB) connected to the network.
Expanding a IC-PCM 1:1 node will display the “General Params” node and a node for the mapped tool. Expanding the
tool, Location ID node will display the “General Params” node and the “Configs” node for the mapped tool. Expanding
the “Config” node will display a node for each of the 8 allowable Configurations.
Expanding a IC-PCM 10:1 node will display all the tools mapped to the IC-PCM 10:1. Expanding each tool, Location ID
node will display the “General Params” node and the “Configs” node. Expanding the “Config” node will display a node for
each of the 8 allowable Configurations.
Expanding the USB Direct Tool will display the “General Params” node and the “Configs” node. Expanding the “Config”
node will display a node for each of the 8 allowable Configurations.
The upper right half of the screen displays a list of General Parameter Sets for IC-PCM 1:1 stored in the Local Database
that can be sent to a IC-PCM 1:1. The lower right half shows the available General Parameter Sets stored in the Local
Database that can be sent a tool.
The middle section of the screen displays the Configuration Sets stored in the Local Database that can be sent to a tool.

Button used to send Configurations to a tool that is connected to USB or IC-PCM.

Button used to send General Parameters to a IC-PCM 1:1 or to a tool.

Button used to refresh the screen.

Field indicates type of mode, which is always Network for this screen.

The stored General Parameters can be assigned to the “General Params” node of any IC-PCM 1:1 or tool by a simple
drag-and-drop operation. Similarly, Configuration Sets can be assigned to any “Configuration number” node of a tool by
drag-and-drop operation.
The color conventions for “General Params” nodes and “Configuration Number” nodes are as follows:
Green indicates that General Parameters and Configuration Parameters are already programmed and have not been
modified.
Yellow indicates that the General Parameters or Configuration Sets are currently programmed, but have been
updated, either by a Drag-and-Drop operation or by double clicking on the set and making changes.
Red indicates that the Configuration Set was initially not programmed, but a Configuration Set has been assigned
by a Drag-and-Drop operation.
White indicates that the Configuration Set is not programmed.
General Parameters or Configuration Sets can be viewed by double clicking on the corresponding node.
Double clicking on the “Configuration Number” node opens the Tightening Configuration Setup screen which can then
be viewed and/or edited. Double clicking on the “General Params” node of a tool opens the Tool General Setup screen
which can then be viewed and/or edited. Double clicking on an IC-PCM 1:1 General Setup node opens the IC-PCM 1:1
General Setup screen which can then be viewed and/or edited.

48619696_ed3 49
From the Parameter Assignment screen, Configurations can also be unassigned from any tool. For any programmed
Configuration, right click on the “Configuration Number” node. A float box with an “Unassign Config” option will be
created. Selecting this option removes the Configuration from the tool.

3.6 Wireless Tool Settings

This screen gives the ability to view all the IC-PCMs available in the network and also gives the connection status of the
tools mapped to each IC-PCM.
If a tool logs in successfully, this screen displays the current versions of display, MCE, and radio firmware as well as
device type icons changed to represent the tool type.
All connected IC-PCMs will have a row entry in this screen which displays Job id, IP address, Ethernet MAC address, RISC
Version, Radio versions of the two primary and secondary radio modules, and Primary and Secondary radio MAC addresses.

Following table gives brief description of each field available in screen.

Device Type This field indicates type of tool.
Name Name assigned to the respective device from the Name Assignment screen
Job ID of the IC-PCM. Job ID is a four-digit entry that represents location identification on
Job ID
assembly line. Each IC-PCM must have a unique number for identification on network.
IP Address IP Address of the IC-PCM
Ethernet Mac Mac Address of the IC-PCM
RISC Version Displays current IC-PCM RISC version
Primary Radio Version Displays the current version of the primary radio firmware.
Secondary Radio Version Displays the current version of the secondary radio firmware.
Primary Radio MAC Displays the MAC address of the primary radio module.
Secondary Radio MAC Displays the MAC address of the secondary radio module.
Location ID Location ID of the tool. Each tool must have a unique number for identification.
Display Version Current Tool Display version
MCE Version Current Motor control version
Wireless version Current Tool Radio version

3.6.1 IC-PCM Settings

User can edit the IC-PCM network settings. To change/view the settings double click on respective IC-PCM on Wireless
settings.
Sync Time button is used to set the current system Date and Time to IC-PCM.

50 48619696_ed3
This IC-PCM Settings dialog box has the following Settings.
1. Ethernet Settings
2. Radio Settings
3. SNTP Settings (Applicable only for IC-PCM 1:1)
4. Channel Hopping Settings
5. Mapped Tool Settings
6. Selectable Radio Channels
7. Local settings
3.6.1.1 Ethernet Settings
This section has the Network Settings. User can edit/view the following controls under Ethernet Setting group.
Ethernet MAC Address Network Mac ID of IC-PCM, which is read only.
IP Address IP Address of the IC-PCM. If DHCP is disabled then the user can set the IP Address.
Default Gateway Gateway is a node on a computer network that serves as an access point to another network.
Subnet Mask A range of logical addresses within the address space that is assigned to an organization.
DHCP (Dynamic If DHCP is enabled the IC-PCM acquires the IP Address dynamically from the Network.
Host Configuration If DHCP is disabled then the user has to enter the IP Address manually. It must be unique across
Protocol) the system.
NOTE: The changes of Ethernet settings require reboot of IC-PCM and changes take place only after the reboot has
completed .

3.6.2 Radio Settings

The Radio setting is used to set the settings of the Radio Module for establishing the wireless communication between
IC-PCM and the mapped tool.
The 5 digit number which is used to uniquely define a PAN (Personal Area Network) number. Based
Pan ID
on PAN ID, devices choose the radio network for communication.
Primary Radio channel is responsible for all communication. The set of available channels are from
RF Channel 1
11 to 25.
Secondary Radio channel scans energy levels of the available channels. This is to keep track of the
RF Channel 2 best available channels for communication with the tool.
If channel hopping is enabled, communication switches to the best available channel.
Lets to select the transmit power level up to 4 dBm based on radio environment.
Transmit Power
NOTE: For Channels 11 and 12, only transmit power levels of 0 and 1 are available.
NOTE: The IC-PCM Radio settings must match with the Tool Radio Settings to establish the communication with the tool.

48619696_ed3 51
3.6.3 SNTP Settings
Enabled Lets the time to be set via an SNTP server.
Server IP SNTP Server IP Address.
Port No SNTP Server port number
Update Interval Time interval to update the local time from the SNTP server.
NOTE: The changes of SNTP settings require reboot of IC-PCM and changes takes place only after the IC-PCM reboots.

3.6.4. Channel Hopping Settings

The Radio settings allow establishing the wireless communication between IC-PCM and the mapped tool.
Enable Enables the channel hopping feature

3.6.4.1 Secondary Channel Settings

These settings are specific to secondary radio channel.
The secondary channels starts scanning of the energy levels of the channel. This interval is
Scan Interval
in minutes.
Noise Threshold Threshold Noise %, where secondary channel will switch.
Scan Time per channel Time to scan each channel

3.6.4.2 Selectable Radio Channels

User can select set of channels from the Available Channels list. User can select one channel or all channels from
Available Channel list.
3.6.4.3 Mapped Tool Settings
User can Add, Edit or Delete the tool location id to the tool map of the IC-PCM.
The tool must be mapped to the IC-PCM 1:1 in order for any communications to take place. Only one tool can be
mapped to IC-PCM 1:1. Only one tool can be mapped to IC-PCM 1:1.
Any change in the IC-PCM 1:1 tool map requires clearing the cycle log of the IC-PCM 1:1 for data consistency. If the tool
map is modified the IC-PCM 1:1 prompts the user with the Clear Cycle Log request. The tool map change request will be
sent only upon clearing the IC-PCM 1:1 cycle log data.
For the IC-PCM 10:1, a maximum of 10 tools can be mapped.
3.6.4.4 Local Settings
This lets the user to assign/view the system name and location id to the IC-PCM.

3.7 Download Software

The Download Software screen allows the user to download “Display”, “MCE”, and “Wireless Radio” firmware to the tool
connected via USB. This screen can also be used to download PCM “RISC” software and PCM “Wireless Radio” firmware to
a selected IC-PCM.

Tool/Controller Selection List

Selected File List

52 48619696_ed3
 Select the type of device for the download operation such as USB/ IC-PCM. The device of the
Device Type Drop Box
selected type presently on the network is displayed in the Tool/ IC-PCM Selection List below.
Tool/Controller
Select the Tool/IC-PCM for download operation by checking in the associated check box.
Selection List
Opens a file browser dialog to select the file to be downloaded. Choose the RISC/Radio
Browse Button
firmware for IC-PCM or MCE/Display/Radio firmware files for the tool connected to USB.
Files to Download File selected from File Browser Dialog is displayed.
Selected File List File selected to be downloaded is displayed.
Start Button Starts downloading on user confirmation.
Close Button Closes the Download Software screen.
Clears the setup and data files on the selected IC-PCM. The IC-PCM must be rebooted after
Clear IC-PCM Data
this operation.

3.7.1 Download firmware Procedure for the Tool Connected to USB

3.7.1.1 MCE Firmware
This Firmware runs on the Motor Controller Electronics (MCE) module of the tool.
1. Select the device type as “USB Tool” from the dropdown list and select the Firmware Type as “MCE”.
2. Select the tool location ID check box.

3. Browse the file “qx_mce.out” to download the MCE firmware.

NOTE: By default all the Firmware files can be found in the ICS install path\Others folder.
An Error Message will prompt the user in case of an Invalid File selection.

48619696_ed3 53
4. Click start button to start the MCE firmware downloading process to the tool. A message will prompt the user for
confirmation.
5. Click Yes button of the message box.

54 48619696_ed3
6. At the end of the download process, ICS prompts with “Tool Wake up” Message.

7. Wake up the tool (pull the trigger) and then click OK button of the message box to complete the download process.
NOTE: Waking up the tool is essential because the MCE can go into sleep mode during the firmware download, it is
required that the MCE be in an active state to complete the download process.

8. The tool reboots immediately after sending the “Wake up” message.
The Display will show the Ingersoll Rand logo and the LEDs will blink for 2 – 3 minutes until it has completed the
internal loading process.
9. Restart the tool after the tool reboots successfully. The uploaded MCE version can be viewed on the wireless
setting screen once ICS has successfully logged into the tool.

3.7.1.2 Display Firmware

48619696_ed3 55
This Firmware runs on the display module of the tool
1. Select the device type as “USB Tool” from the dropdown list and select the Firmware Type as “Display”.

2. Select the tool location ID check box.

56 48619696_ed3
3. Browse to the file “qx_display.hex” to download the Display firmware.
NOTE: By default all the Firmware files can be found in the ICS install path\Others folder.
An Error Message will prompt the user in case of an Invalid File selection.

4. Click start button to start the Display firmware downloading process to the tool. A message will prompt the user for
confirmation.
5. Click Yes button of the message box.

48619696_ed3 57
6. The tool display will automatically reboot after the downloading process is completed.
The Display will then show the Ingersoll Rand logo until it has completed the internal loading process. Once the
internal loading process is complete for the display, the display will again reset automatically.

7. Restart the tool after it resets successfully. The uploaded Display version can be viewed on the wireless setting
screen once ICS has successfully logged into the tool.
3.7.1.3 Radio Firmware
This Firmware runs on the Wireless Radio Board of the tool.
1. Select the device type as “USB Tool” from the dropdown list and select the Firmware Type as “Radio”.

58 48619696_ed3
2. Select the tool location ID check box.

3. Browse to the file “qx_wireless.hex” to download the Radio firmware.

NOTE: By default all the Firmware files can be found in the ICS install path\Others folder.
An Error Message will prompt the user in case of an Invalid File selection.

48619696_ed3 59
4. Click on start button to start the Radio firmware downloading process to tool. A message will prompt the user for
confirmation.
5. Click on the Yes button of message box.

6. Once downloading is completed, tool reboots automatically.

The Display will go blank and the LEDs will blink. This process will happen for approximately 3 - 5 minutes until it
60 48619696_ed3
 has completed the internal loading process. Once the internal loading process is complete for the radio board, the
display will again reboot automatically.

7. Restart the tool after it reboots. The uploaded Radio Firmware version can be viewed on the wireless setting
screen once ICS has successfully logged into the tool.

3.7.2 Download firmware procedure for a IC-PCM on the Network

3.7.2.1 RISC Firmware
This Firmware runs on the RISC Board of the IC-PCM.
1. Select the device type as “IC-PCM” from dropdown list and select Firmware Type as “RISC”.
2. Select the IP check box.
NOTE: User can also select multiple IP Addresses for RISC software download.

48619696_ed3 61
3. Browse to file “qx_risc.irb” to download the RISC firmware.
NOTE: By default all the Firmware files can be found in the ICS install path\Others folder.
An Error Message will prompt the user in case of an Invalid File selection.

4. Click on the start button to start the RISC firmware downloading process to the controller.
A message will prompt the user for confirmation.
5. Click on the Yes button of the message box.

62 48619696_ed3
6. After download, the IC-PCM automatically reboots.
NOTE: If the IC-PCM does not reboot automatically after 10-15 minutes, reboot manually.

7. Once IC-PCM successfully reboots and is logged into ICS, the version of RISC firmware can be viewed on wireless
setting screen.
3.7.2.2 Radio Firmware
This Firmware runs on the Wireless Radio Board of the IC-PCM 1:1.

48619696_ed3 63
1. Select device type as “PCM” from the dropdown list and select Firmware Type as “Radio”.

2. Select the PCM IP check box.

NOTE: User can also select multiple PCM IP Addresses for Radio software download.
3. Browse to the file “qx_wireless.bin” to download Radio firmware.
NOTE: By default all the Firmware files can be found in ICS install path\Others folder.
An Error Message will prompt the user in case of an Invalid File selection.

4. Click on start button to start Radio firmware downloading process to the tool. A message will prompt user for

64 48619696_ed3
 confirmation.
5. Click on Yes button of message box.

6. After download, IC-PCM automatically reboots.

NOTE: Reboot IC-PCM manually if it does not reboot automatically.
3.7.2.3 Clear Data
Clears the selected IC-PCM data.
1. Select the device type as IC-PCM from the dropdown and select one or multiple IC-PCM.

2. Click Clear Controller Data button. A message will prompt user for confirmation.

48619696_ed3 65
3. Click Yes button of message box.
NOTE: This clears all data including cycle logs, PCM settings, and tool map information.
4. ICS prompts with a message “Please Reboot PCM after 30 secs: xxx.xxx.xxx.xxx”, where xxx.xxx.xxx.xxx is PCM IP
Address.
5. Click OK button of the message box and reboot PCM after 30 seconds.

3.8 Reboot
The Reboot screen lets user to reboot the selected IC-PCM currently on network.
Also, primary and secondary radio modules of the IC-PCM can be rebooted.

3.8.1 Reboot IC-PCM

1. Expand the IC-PCM.
2. Select required IP addresses that needs to be rebooted and then click on ‘Reboot’ button.

66 48619696_ed3
3. A reboot message is sent to the selected IP addressed which reboots the device(s).
4. The controller(s) reboot(s).

3.8.2 Reboot Radio Modules

1. Expand required IP addresses for which reboot radio command need to be sent.
2. Select primary or secondary or the two (primary and secondary) radio modules and click on reboot button.
3. A reboot message is sent to reboot the radio modules.
NOTE: This does not reboot entire system and wireless transaction will happen only after successful reboot of radio
module.

IC-PCM 1:1 Displays list of IC-PCM 1:1 present on the network.

IC-PCM 10:1 Displays list of IC-PCM 10:1 present on network.
Reboot Reboots the selected IC-PCM or radio modules that are checked in the associated check box.
Refresh Refreshes and updates the list with latest IC-PCMs present on the network.

3.9 PCM Wireless Energy Detector

This screen can be used to view energy level in each RF channel. The energy level for each channel is displayed against
their respective channel number starting from 11 to 25.

Initially when IC-PCM is selected from drop box last stored data will be displayed. To receive the current level of wireless
energy click on “Start Scan” button with specific time required to scan each channel.

The drop box “Scan Duration per Channel (Seconds)” is the set to scan each channel. For example if the time is selected
as 0.9984 then time required to complete the scan is given below.
0.9984 * 15 = 14.976 seconds.

NOTE: Scanned energy value for a particular channel is proportional to the amount data being transferred in the channel.

48619696_ed3 67
Section 4 – Monitoring Cycle log and Event Log of IC-PCM 1:1 / QX
Tool

4.1 Run Main Cycle Log

The Run Main Cycle Log window has two tabs, Run Main View and View Cycle Log.

4.1.1 Run Main View Tab

The Run Main View tab Displays EOR of the latest cycle for a selected tool.

The values shown on this screen include:

Location ID This drop box is used to select the tool connected to USB / IC-PCM.
Config No Displays configuration number of the latest cycle and also allows user to select the desired
configuration number of the tool connected to USB.
Send Button This button allows user to set desired configuration of tool connected to USB.
Pass / Fail Displays an overall status (PASS/FAIL) of the tightening operation. An “OK” image is displayed, if the
Indicator operation passes, otherwise, displays failure (FAIL) image.

PASS FAIL

Torque status Displays the status of torque. The downward arrow (YELLOW) indicates that the torque is less than
indicator the torque low limit and the upward arrow (RED) indicates that the torque is greater than or equal
to torque high limit. If the torque is between low torque and high torque limit, then an OK image is
displayed.

Within Limits High Limit Low Limit

Angle status Displays the status of angle. The downward arrow (YELLOW) indicates that the angle is less than
indicator the angle low limit and the upward arrow (RED) indicates that the angle is greater than or equal to
the angle high limit. If the angle is between low angle and high angle limit, then an OK image is
displayed.

Within Limits High Limit Low Limit

68 48619696_ed3
 Gang complete The OK image is shown when ‘Gang Complete’ occurs. If the total gang count is 3 then for each pass
indicator cycle the screen shows (1/3, 2/3 and OK) as shown below. If the cycle fails, the gang count value in
the screen remains same.

1/3 2/3 Complete (3/3)

Faults Displays the Faults description of the tightening data.

NOTE: Green indicates that the particular fault did not occur, where as Red indicates the fault has
occurred.

If Location ID is
Fault No Fault
not selected

EOR Field/ Displays the EOR fields and values at the end of fastening. Clicking the up/down arrow below the
Value table main window, allows the user to hide/ show the EOR List.

4.1.2 View Cycle Log Tab

The View Cycle Log Tab allows the user to retrieve the stored tightening EOR records from the tool connected to USB/IC-
PCM10:1. It also allows retrieving of the tool tightening records that are stored on anIC-PCM 1:1. The tool/IC-PCM is
limited to store a maximum of 76800 bytes (75 Kbytes) of data.
User can view data stored in archive DB and local DB.

Fault group displays the fault code indicators for each of the selected cycle.

Cycle log data can be filtered using below mentioned criteria:

• Configuration Number (1 to 8)
• Overall status (Pass or Fail)
• Torque status (Pass, High or Low)
• Angle status (Pass, High or Low).
“Reset Filter” clears the filter applied to the data.

By default, the cycle log screen displays all columns. The number of columns displayed on the screen can be adjusted
by clicking on “Select Columns” button.

Activate the check box next to the column (if you want the data to be displayed). When finished, click on OK button.

48619696_ed3 69
Life Time Cycle Count Displays total number of cycles the tool has run. User cannot reset this value.
Cycle Count Displays total number of cycles the tool has run since last reset cycle count.
Configuration No The Configuration Number for tightening cycle
Date/Time of Cycle Displays Date and Time of the EOR cycle.
Cycle Result Displays overall result (Pass / Fail).
Peak Torque Displays peak torque reached during tightening cycle.
Torque Result Displays result of the torque, Pass if it is within Low and High limit values, Low if peak torque is
less than Low limit and High if peak torque is greater than or equal to high limit.
Peak Angle Displays maximum angle rotated during tightening cycle.
Angle Result Displays the result of the angle, Pass if it is within the Low and High limit values, Low if Maximum
angle is less than Low limit and High if maximum angle is greater than or equal to high limit.
Current Gang Count Displays number of similar joints that are fastened. Current gang count is incremented only for
passed cycle. For example, if the gang count is 3 bolts, then current gang count is reported as
1, 2, and 3 for these three EORs.
Total Gang Count Displays total number of similar joints that are set to be fastened for configuration.
Torque Units Displays selected units for the tightening cycle: Nm, In-lbs and Ft-lbs.
Target Value Displays target value for Torque/Angle Control
Tightening Mode Displays type of fastening mode (Angle and Torque)
Joint Type Displays type of Joint (Hard and Soft)
Torque Hi Limit Displays Torque High Limit set for configuration.
Torque Lo Limit Displays Torque Low Limit set for configuration.
Angle Hi Limit Displays Angle High Limit set for configuration.
Angle Lo Limit Displays Angle Low Limit set for configuration.
Step Number Displays Step Number of the cycle.
Motor Status Displays Motor Status of the cycle. ‘No Fault’ is highlighted in Green if no fault has occurred or
‘Fault’ is highlighted in Red if fault has occurred.
Peak Current Displays maximum current drawn during the tightening cycle.

70 48619696_ed3
Following table shows the additional fields that are present in IC-PCM 1:1 tightening records
Barcode Displays Barcode information.
Tool Serial Number Displays factory provided identification number of the tool.
Free Speed Displays programmed Free Speed for the configuration.
Downshift Speed Displays programmed tool speed during shift down phase.
Max Tool Speed Displays maximum speed of the tool.
TR Displays Transducer Range value.

At any instance, click button to save the currently displayed data to local database with current time stamp. Click
on button to delete locally stored data with particular time stamp, confirmation message is displayed before
deleting the data.

To view the latest cycle on this screen, click on Refresh button in communication tool bar.

Clear Cycle log button - clears the cycle log present in the tool or IC-PCM 1:1.

Reset Cycle Counter button - resets the cycle count of tool.

Launch Statistical Parameter button will open the Statistics Screen for selected set of cycles entered in the filter
criteria.

4.1.2.1 Data Saved/Retrieved from PC Local Database

Once data has been retrieved from a IC-PCM 1:1/tool, it can be saved to the PC local database for later viewing and
analysis.
To save cycle log data to the PC, select Save from File menu.
To retrieve an already saved cycle log, first click on Database button in main tool bar and then select the Location ID.
The Date-Time Stamp drop box will then be populated with all saved cycle logs.
Select one from this list to view it.
Once this data is displayed; it can be filtered and statistics can be calculated.

48619696_ed3 71
4.1.2.2 Data retrieved from the Archived Database
Once the tool is set to archive EOR data from archival setting screen, user has an option to view the archived EOR data
by clicking archival button in main tool bar.
Select desired Location ID from Location ID drop box.
Select required range from From Date and To Date and click on Fetch cycles.
Cycles archived during the specified range will be displayed.

To print (default printer) or export (.csv (Comma separated value), .pdf and .rtf (rich text format)) cycle log data, select
the appropriate option from the File menu.

4.2 Run Main View All

Displays the latest EOR data of all tools connected to USB / IC-PCM that are in network.

72 48619696_ed3
To view only a subset of available tools on the Run Main View All screen:

1. Click the Filter button to display the Select Controllers Dialog screen shown in the following Figure.

2. On the Select IC-PCM Dialog, choose IC-PCM from ‘IC-PCM On Network’ list box on the left side of the dialog. Click
the right arrow (>) button to move them to the Selected IC-PCM box. Use double right arrow (>>) button to select
all IC-PCM. All Tools mapped to selected IC-PCM are displayed on the screen.
3. To deselect IC-PCM from the Selected IC-PCM dialog, choose IC-PCM to be removed and click the left arrow (<)
button. Use the double left arrow (<<) button to deselect all.
4. Once the selection is made, click OK button to view the tools mapped to the selected IC-PCM in Run Main View All
screen.
NOTE:
• Select Columns is same as cycle log screen.
• All columns are selected by default.

4.3 IC-PCM 1:1/ Tool Event Log

This screen allows user to view the event log that is recorded on the tool/ IC-PCM 1:1.

4.3.1 IC-PCM 1:1 Event Log

Select required IC-PCM 1:1 location id to view the IC-PCM 1:1 event log. The recorded event log is displayed with date,
time, event code and description of the event. Following Figure displays the IC-PCM 1:1 event log:

48619696_ed3 73
Below is the list of events that are recorded in IC-PCM 1:1 with their respective event codes:

Event Code Event Description

0 Undefined
1 Tool Disabled
2 Tool Enabled
3 Start Diagnostic Mode
4 Stop Diagnostic Mode
5 Date-Time Set
6 General Setup Change
7 PLUS Server Connected
8 PLUS Server Disconnected
9 Unknown Server Attempted Connection
10 An incoming message contained a non-numeric first character
11 Invalid block counter
12 Unexpected message
13 Invalid message length
14 Receive Buffer is full
15 Too many messages in the receive buffer
16 Plus terminal has stopped
17 Plus is not ready to send
18 The incoming message is from a backup node
19 An unknown error string was encountered
20 An NNEG Error was received
21 An NTMU Error was received
22 An NSCR Error was received
23 An NSTR Error was received
24 The PLUS assembly timeout occurred
25 Manual reset was pressed
26 IC-PCM 1:1 received NAK-A from PFCS
27 IC-PCM 1:1 received NAK-B from PFCS
28 IC-PCM 1:1 received NAK-E from PFCS
29 IC-PCM 1:1 received NAK-H from PFCS
30 IC-PCM 1:1 received NAK-J from PFCS
31 IC-PCM 1:1 received NAK-I from PFCS
32 IC-PCM 1:1 received NAK-D from PFCS
33 IC-PCM 1:1 sending a retry
34 Printer not responding to the status request
35 Printer not responding state cleared
36 Printer Jam
37 Printer jam state cleared
38 Printer out of paper
39 Printer out of paper state cleared
40 Printer ink error
41 Printer ink error state cleared
42 Printer off line
43 Printer off line state cleared
44 Printer mechanical error

74 48619696_ed3
 45 Printer mechanical error state cleared
46 Printer communication error
47 Printer communication error state cleared
48 Printer buffer empty
49 Printer buffer empty state cleared
50 Printer buffer overflow error
51 Printer buffer overflow error state clear
52 General Setup File Reset
53 Plus Check Settings
54 Plus Duplicate Scan
55 Plus Ident Not to be processed
56 Plus Manual Abort
57 Plus Technical Attributes Timeout
58 Plus Unknown Production Number
59 Plus No Tightening Job Found
60 Open Protocol Connection Created
61 Open Protocol Connection Terminated
62 XML Connection Created
63 XML Connection terminated

4.3.2 Tool Event Log

Select the Tool connected to USB or mapped to IC-PCM to view the tool’s event log. The tool records the Fault Codes
and Descriptions with date/time stamps along with motor fault codes (Status Mask).

Following are the Fault Codes and their description:

Fault Code Description

F-01 Tool Disabled (by external control)
F-02 Cycle Delay fault -- trigger was pulled before cycle delay timer expired
F-03 Tool Locked by Smart Socket Function -- user needs to select the correct socket at the PCM

48619696_ed3 75
F-04 SPI EEPROM EOR write failure
F-05 SPI EEPROM EOR read failure
1-FF USB enumeration fault
2- <Alarm ID> PM Alarm Time Fault for corresponding Alarm ID normally configured by the user
3- <Alarm ID> PM Alarm Cycle Fault for corresponding Alarm ID normally configured by the user
A-10 Motor controller communication timeout
A-55 A display software version update was detected
A-AA The display memory was re-initialized to factory defaults
B-01 Failure to update Motor Controller Software
B-50 Duplicate Tool Location ID detected
B-80 No RF Network Detected after 20 seconds
B-85 RF ACK Timeout
B-E1 RF Transmit NAK – “Channel Access Failure”
B-E5 RF Transmit NAK – “Frame Too Long”
B-E9 RF Transmit NAK – “No ACK Received”
C-01 Configuration ID value is 0 or greater than 8
C-02 Number of configuration steps is greater than 8
C-03 Current Step ID is greater than the current number of steps
C-04 Total Gang is greater than 8
C-05 Current Gang count is greater than Total Gang
Current Torque High Limit is greater than Tool’s maximum Torque value (Tool’s max torque value is
C-06
configured in the Factory Set Points) OR Current Torque High Limit is less than 0
Current Torque Low Limit is greater than Tool’s maximum Torque value OR Current Torque Low Limit is
C-07
less than 0
C-08 Current Torque High Limit is less than Current Torque Low Limit
C-09 Current Torque Low Limit is greater than Current Torque High Limit (Fault code to be removed)
C-0A Current Angle High Limit is greater than Tool’s maximum Angle value (to be set to 9999)
C-0B Current Angle Low Limit is greater than Tool’s maximum Angle value (to be set to 9999)
C-0C Current Angle High Limit is less than Current Angle Low Limit
C-0D Current Angle Low Limit is greater than Current Angle High Limit (Fault code to be removed)
C-0E Tool configuration step is a Torque target and target value is outside torque high and low limits
C-0F Tool configuration step is an Angle target and target value is outside angle high and low limits
C-10 Tool configuration step is not set for either Angle or Torque
C-11 Current Threshold value is greater than maximum tool torque OR Current Threshold value is less than 0
C-12 Current Free Speed is greater than maximum motor speed
C-13 Current Shiftdown Speed is greater than maximum motor speed
C-14 Current display unit value is unsupported
Current Shiftdown Point if above target or above Target (for torque strategy) or above tool’s torque
C-15
limit (for angle strategy).
C-16 Number of configuration steps is set to 0
C-77 Invalid Time Stamp value in set time message.
E-00 Using MC Software 1.0.1.2, Battery Fault
E-01 Using MC Software 1.0.1.2, Invalid Hall State
E-02 Using MC Software 1.0.1.2, I2T Fault
E-03 Using MC Software 1.0.1.2, Motor Stall
E-04 Using MC Software 1.0.1.2, Over Current
E-05 Using MC Software 1.0.1.2, Over Temperature

76 48619696_ed3
E-06 Using MC Software 1.0.1.2, Current Offset
E-07 Using MC Software 1.0.1.2, Shunt Cal
E-08 Using MC Software 1.0.1.2, Torque Offset Fault
E-09 Using MC Software 1.0.1.2, Transducer Fault
E-0A Using MC Software 1.0.1.2, Step Execution Timeout
E-0B Using MC Software 1.0.1.2, Configuration Execution Timeout
E-0C Using MC Software 1.0.1.2, Over Torque Limit
E-0D Using MC Software 1.0.1.2, Over Angle Limit
E-0E Using MC Software 1.0.1.2, Current Plausibility High
E-0F Using MC Software 1.0.1.2, Under Torque
E-10 Using MC Software 1.0.1.2, Under Angle
E-11 Using MC Software 1.0.1.2, Current Plausibility Low
E-12 Using MC Software 1.0.1.2, Early trigger Release
E-13 Using MC Software 1.0.1.2, Motor Controller Watchdog Reset
E-14 Using MC Software 1.0.1.2, Motor Controller Stop Timeout
E-15 Using MC Software 1.0.1.2, Motor Controller to Display EOR message failure
E-18 Using MC Software 1.0.4.2, Motor Controller did not run all steps (mainly affects Prevailing Torque)
E-1B Using MC Software 1.0.1.2, Battery Cell Fault (detected by Motor Controller)
E-1C Using MC Software 1.0.1.2, Low Battery Fault (detected by Motor Controller)
E-1D Using MC Software 1.0.1.2, Critical Battery Fault (detected by Motor Controller)
E-1E Using MC Software 1.0.1.2, Motor Controller is shutting down
E-1F Using MC Software 1.0.1.2, Wakeup Code received (but not expected)
E-81 The configuration ID in the Motor controller’s EOR did not match the currently selected configuration
10-01 Configuration Page Update from Communication interface (USB or Wireless)
10-02 Tool Locked by Communication Interface (USB or Wireless)
10-03 Tool disabled by Communication Interface (USB or Wireless)
10-04 Configuration Selected by Communication Interface (USB or Wireless)
10-05 Gang Advanced by Communication Interface (USB or Wireless)
10-06 Gang reset by Communication Interface (USB or Wireless)
10-07 Configuration advanced by Communication Interface (USB or Wireless)
10-08 Configuration Reset by Communication Interface (USB or Wireless)
10-09 SPI Memory erased by Communication Interface (USB or Wireless)
10-0A Tool Reset by Communication Interface (USB or Wireless)
10-0B Factory calibrations restored by Communication Interface (USB or Wireless)
10-0C Cycle log cleared by Communication Interface (USB or Wireless)
10-0D Event log cleared by Communication Interface (USB or Wireless)
10-AA Time updated by Communication Interface (USB or Wireless)
20-01 Complete Tool memory reset to defaults
20-02 Tool reset configuration to Defaults
EE-E0 RF Protocol Error - RF Message Packet too small
EE-E1 RF Protocol Error - RF Packet too long
EE-F0 MC Protocol Error -- Invalid Image Checksum
EE-F1 RF Protocol Error -- Invalid Image Checksum
EE-F2 DIS Protocol Error -- Invalid Image Checksum

48619696_ed3 77
Motor Status Code description;
Bit Position Fault Description
1 Battery
2 Invalid Hall State
3 I2T
4 Motor Stall
5 Over Current
6 Over Temperature
7 Current Offset Fault
8 Shunt Cal
9 Torque Offset Fault
10 Transducer Fault
11 Step Time Out
12 Configuration Timeout
13 Over Torque
14 Over Angle
16 Under Torque
17 Under Angle
19 Early Trigger Release
20 Watchdog
25 Missed Run Steps

4.4 Status/View Network

The Status->View Network Screen is a read only screen which provides a clear overview of all USB Tools / IC-PCM
connected to the network. Information is displayed in a tree view structure.

This screen contains:

4.4.1 IC-PCM 1:1

Expanding this node will list all the IC-PCM 1:1 available on the network.
Expanding on a IC-PCM 1:1 node will display the IC-PCM 1:1 “General Params” node and a node for the tool that is
mapped to the IC-PCM 1:1.
Double clicking on the “General Params” node of the IC-PCM 1:1 will display the IC-PCM 1:1 General Parameters on the
right hand side of the screen.

Expanding the mapped “Tool Location ID” node will display the “General Params” node and the “Configs” node for tool.

Expanding the “Configs” node will display a node for each of the 8 allowable Configurations.

Double clicking on a particular “Configuration Number” node will display the Configuration Parameters of the tool on
the right hand side of the screen, if the Configuration is programmed (Green icon).

78 48619696_ed3
Double clicking on the tool’s “General Params” node will display the General Parameters of the tool on the right hand
side of the screen.

4.4.2 IC-PCM 10:1

Expanding this node will list all IC-PCM 10:1 available on network.

Expanding a IC-PCM 10:1 node will display all Location IDs of the tools that are mapped to IC-PCM 10:1.

Expanding a mapped “Tool Location ID” node will display the “General Params” node and the “Configs” node for tool.

Expanding the “Configs” node will display a node for each of 8 allowable Configurations.

Double clicking on a particular “Configuration Number” node will display the Configuration Parameters of tool on the
right hand side of the screen, if the Configuration is programmed (Green icon).

Double clicking on a tool’s “General Params” node will display the General Parameters of tool on right hand side of the
screen.

4.4.3 USB Direct Tool Connection

Expanding this node will display the “General Params” node and “Configs” node for a tool connected with a USB cable.

Double clicking on the tool’s “General Params” node will display General Parameters of tool on right hand side of the
screen.

Expanding the “Config” node will display a node for each of 8 allowable Configurations.

Double clicking on a particular “Configuration Number” node will display the Configuration Parameters of tool on the
right hand side of the screen, if Configuration is programmed (Green icon).

4.5 Create Report

To create a specific type of report, this screen can be used. The same can be exported to a file or printed to the default printer.

Create report screen contains three tabs.

1. Tool Report.
2. VIN Report.
3. Report Generator.

Tool Report and VIN Report tabs will generate reports for only EORs that are from IC-PCM 1:1. Using Report Generator
tab will generate reports for both tools mapped IC-PCM.

4.5.1 Tool Report

This report is generated based on the tool serial number as primary criteria.

Filter criteria can be provided for Tightening Result (Pass or Fail), Angle Result (Pass, High or Low), Torque Result (Pass,
High or Low) and VIN code (Vehicle Identification Number/Code, also called as Barcode). Date and Time Criteria should
be provided, and records within the From/To Date and Time will be displayed.

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4.5.2 VIN Report
This report is generated based on the VIN (Vehicle Identification Number).

Filter criteria can be provided for Tightening Result (Pass or Fail), Angle Result (Pass, High or Low), Torque Result (Pass,
High or Low) and Tool serial number. Date and Time Criteria should be provided, and records within the From/To Date
and Time will be displayed.

4.5.3 Report Generator

Report generator can be used to have multiple criteria for report generation. Provide Filter criteria in “From” and “To”
column and check “Enable Filter” check box to enable particular filter.

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Section 5 – Archiving Data

5.1 Archival Settings Screen

The Archiving feature allows the storing EOR, configurations and general settings of tools that are mapped to IC-PCM
and also archives IC-PCM 1:1 General Settings.

Archiving is only available for MultiSync and Enterprise versions of ICS software installed with SQL database option.
A master license can be used to set and view the archival setting, and is needed to archive data. A slave license can be
used to view Archival settings and view archived data.

NOTE: For better performance, it is recommended to install SQL server in the same facility as ICS and tools.

The Archival Settings screen is enabled only when ICS is installed with SQL server as the Database option.

The Data Dropdown list has three items as mentioned below:

EOR Data – EOR Data can be archived for a tool connected to an IC-PCMx:1

Data Parameters (IC-PCM 1:1 General Setup) – General Setup Parameters of an IC-PCM 1:1 controller can be
archived for each IC-PCM 1:1 controller on the Network.
Parameters (Config and General) – Configurations and General Parameter settings of a tool connected to
an IC-PCMx:1 controller can be archived for each controller on the Network.
Location ID The Location ID Dropdown list will display all tools connected to an IC-PCM.
Time/Freq The Time/Freq dropdown list displays options for how often the data will be archived.
Add The Add button is used to add the location ID and Data that is to be archived to list.
Update The Update button is used to modify Archival settings and update changes for selected Location ID.
Delete The Delete button is used to delete the selected Location ID from the Archival list.
Delete All The Delete All button is used to delete all the existing Location IDs from the Archival list.
OK/Cancel OK button is used to save the changes and Cancel button is used to exit without saving the changes.
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Section 7 – System Diagnostics
The System Diagnostics screen allows you to check the overall system status of the tool Connected to USB. This
functionality also assists in diagnosing tool problems, calibrating the tool and also sets the Preventive Maintenance
Alarms.

The PM alarm , tool status and tool calibration functionalities are also applicable for the tools connected to IC-PCM

1. Tool Test
2. Tool Status
3. Keypad Status (contains LED and Speaker diagnostics)
4. Tool Calibration
5. PM Alarm (Preventive Maintenance).

7.1 Tool Test

The Tool Test tab allows the user to view the tool readings for the selected Location ID. Proceeding with this shall
put the tool in diagnostic mode. The tool is put into Diagnostic mode, but normal operation is not suspended. It is
recommended that user does not perform normal operations (tightening) when tool is in diagnostic mode. When the
too trigger is pulled the currently selected configuration will be run. The user can read the following values on the
screen while the tool is running:

Angle Degrees of Rotation

Current Current drawn in amps

Speed Rotational speed in RPM

Temperature Measured temperature of the tool in degree Celsius

Torque Dynamic Torque achieved

Battery Voltage Current Battery Voltage of the tool

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7.2 Tool Status
Tool Status tab displays system data for diagnostics purpose.

Tool Status Tab displays the following Tool Status;

Displays Pulled/Released status of trigger switch.

Trigger State
(Pulled Released )

Displays CW/CCW status of direction switch.

Direction State
(CW CCW )

Displays ON/OFF Status of Headlight LED.

Headlight Status
(On Off )

Displays whether tool can perform the tightening operation. The checked tool can
Enabled state
perform the tightening operation, if configuration selected is valid.

Current Phase U offset Displays Current Phase U offset status of motor.

Current Phase W offset Displays Current Phase W offset status of motor.

Torque Signal Zero Offset Displays status of Torque Signal Zero Offset.

Signal Strength Displays Wireless signal strength.

Motor Temperature Displays motor temperature of the tool.

Battery Voltage Displays Current Battery Voltage in Volts.

Shunt Calibration Displays value of Shunt Calibration.

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7.3 Keypad, LED and Audio Diagnostics
This screen can be used to diagnose status of Keypad, Led and Speaker of the tool.

7.3.1 Keypad Status

Displays the current status of the keys.

Sl no. Key Pressed Released

1 Up

2 Down

3 Right

4 Left

5 Esc

6 Enter

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7.3.2 LED Test
Displays the current status of the LEDs and also can switch on or off particular LED by clicking on the particular LED button.

Sl no. Key Pressed Released

1 Yellow

2 Green

3 Red

4 Blue

7.3.3 Audio Diagnostics

Click on “AUDIO ON” button to turn ON the beep sound to test the speaker in the tool. This sound will remain for 5 seconds.

7.4 Tool Calibration

The tool calibration screen allows user to calibrate teh selected tool’s TR. It allows to SET/RESET the values for TR, ASC
and KT. Also it allows to send Gearbox Loss percentage value to the tool.

Manual Data Entry

User can Set/Reset TR, ASC, KT values to the tool, it also displays Factory & Current values for TR, ASC and KT. User can
enter TR & ASC value ± 20 % of the factory value of TR and ASC.

By default, User TR & User ASC is set to Factory setting value of ASC and TR.

User can enter the KT sensitivity value between 0.01 and 1.00 (by default, it is set to 1.00).

Gearbox Loss %
The user can enter a value of ± 40% in the Gearbox Loss data box. When this value is sent to the tool, the TR value of the
tool will change according to the following: User_TR = Factory_TR - [Gear_box_Percentage * Factory_TR /100]

Calibration Settings
There are two types of calibration modes: Auto and Manual.

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This screen allows Auto calibration to run, which can calibrate the Transducer Range (TR) for the tool using an
Ingersoll Rand ETA5 series Torque Analyzer or an Ingersoll Rand EXT Series Torque Analyzer.

Upon receiving the EOR record from the tool, the torque value is displayed in the list. The ICS software then reads
the ETA5/EXT torque value measured for the active cycle number and displays the received value in the ETA5 Torque
column.

Click the Reject Reading button to reject any individual run throughout the calibration procedure.

The new TR value is calculated when the STOP is pressed. The new TR value is displayed as Resultant TR Value. The
Resultant TR Value can be set to the tool using send button.

New TRs are calculated after each tightening. Rejecting any reading results in recalculation of the resultant TR.

In case of manual mode calibration, click Auto button to change to manual mode. In manual mode, user should enter
the measured value read from some external torque monitoring device.

User can Print or Save an Auto calibration report via the File menu.

NOTE: Calibration results are not available for tools mapped to IC-PCM.

7.5 PM Alarms
PM Alarms are reminders for regular tool preventative maintenance. The PM Alarms section helps user keep track of the
preventative maintenance schedule for tool. Up to five different alarms can be set with duration as “number of cycles” or
“Number of Days”.

The Preventive Maintenance (PM) Alarm screen displays all PM alarms set on tool and allows editing settings. In
addition, this screen allows resetting any PM alarm.

The screen shows Alarm, the Duration, the Start Count/Set Date, and Expiration Count/Date for each alarm. Use the
Reset button to reset start and expiration count/date.

Disable Tool checkbox feature allows to disable tool when the alarm is triggered.

The Alarm can be set for following items:

Grease Gear case
Grease Angle head
Grease Offset head
Grease Tube nut head

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 Check Tool calibration
Following are the duration (cycles) for setting up the alarm:
5000
10000
20000
50000
100000
500000
1000000
If Wireless is enabled in the tool, following are the additional option available for duration:
Days
1
5
7
14
30
90
180
270
365
NOTE:

1. In case duration is set to “Number of days”, upon refreshing screen, ICS will only display end date not
“number of days” and “Start Date” as NA.
2. When an item is selected in the drop-box for PM alarm setting for warning or disabling the tool after an elapsed
time period or cycle, that item will NOT be available for selection in other drop-boxes.

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7.6 System Diagnostics – View Inputs
View Inputs screen displays dynamic status of all input pins for selected IC-PCM 1:1. This screen is useful for
troubleshooting an I/O problem.

View input screen displays the selected IC-PCM 1:1 8 input pins and respective behaviours assigned to each pin.

To change the current behaviors assigned to each input pin, user has to click on button. PCM General Setup
dialog box opens up for changing the current behaviors by navigating to Assign Inputs tab of the PCM General Setup.

NOTE: The modified behaviors will be applicable only after IC-PCM 1:1 reboots.

The status of Active input pin is indicated via a virtual Green LED .

The status of inactive input pin is indicated via LED .

7.7 System Diagnostics – View/Set Output

7.7.1 View Outputs Mode (Normal Mode)
Set/View Output screen displays the dynamic status of all Output pins for the selected IC-PCM 1:1. This screen lets user
manually activate an output signal for system diagnosis purpose.

To change the current behaviors assigned to each output pin, user has to click on button.

PCM General Setup dialog box opens and user can change the behaviors by navigating to Assign Outputs tab of the
PCM General Setup. The modified behaviors will be applicable after PCM reboots.

The status of Active input pin is indicated via a virtual Green LED .

The status of inactive input pin is indicated via LED.

Use this button to change from Normal mode to Diagnostic mode. This will put the IC-PCM 1:1 in diagnostic
mode.

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7.7.2 Set Outputs Mode (Diagnostic Mode)
Set Outputs mode, screen displays dynamic status of all output pins and provides a means to set manually status of the
outputs for selected IC-PCM 1:1 by sending 24v output signal to the respective pins.

The status of each output is indicated by virtual LEDs.

In Diagnostic mode, an output can be forced by sending output. When an output signal is forced, normal operation of
the system is interrupted. When the user leaves “Set Outputs” screen, the forced signals on to the respective output pins
will be reset to normal.

The status of Active output pin when “output signal is forced” is shown via Virtual green LED .

User can switch to Normal Mode (View Mode) by clicking on

NOTE: Forcing outputs will disable and enable normal tool operation.

Care should be taken to ensure the work area is safe prior to manually activating outputs. Ensure that devices
attached to the IC-PCM 1:1’s outputs will not create a hazardous condition if outputs are manually activated.

7.8 Direct Controller Discovery

This screen is used for direct discovery of the IC-PCM. If the user wants to discover only certain IC-PCM, check the
“Disable Discovery” check box.

Enter the IP Address for the selected device of interest.

NOTE: If disable discovery check box is not checked, ICS discovers all the IC-PCM available in the network.

48619696_ed3 89
Section 6 – Quality Control

6.1 Statistics
The Statistics Summary screen displays the statistics computed from the cycle log data for the selected tool and
Configuration. The screen displays Population and Sample Statistical data for both torque and angle results.

The statistical data can be saved to the local database by selecting Save from the File menu.

The Statistics Summary screen allows the user to select the tool Location ID and Configuration number. Internally, ICS
fetches the cycle log data, calculates, and displays both Population and Sample Statistics for the selected configuration
number.

The Statistics Summary screen displays the following parameters and their values for Population & Sample Statistics for
both Torque and Angle results:

Strategy - Selected Strategy

Target - Target Torque/Angle

X-Bar - Mean

Range - Max Value - Min Value

Mean Shift - Mean - Target

Capability - This is calculated as (6 * sigma / Mean) * 100

CAM - (Upper Limit - Lower Limit)/ (6*(W/dS))

Where W - Average dispersion, dS = 1.746

Sigma - Standard Deviation

PP - Capability Statistics parameter calculated as (Upper set limit – Lower set limit)/(6*sigma)

PPK - Capability Statistics parameters calculated as Min ( (mean- Lower set limit)/(3*sigma) or (Upper set limit – mean)/
(3*sigma))

The size of the Sample Statistics size can be set by clicking the Set Parameters button on the Tool Bar. This displays the
Set Statistics Parameters box. This box has a Sample Size entry field for setting the number of readings to be used for
computing Sample Statistics. The Sample Size is 25 by default.

90 48619696_ed3
The Statistics Summary screen can also be launched from the RunMain Cycle Log screen. After selecting a
Configuration and highlighting the desired Cycle Log results, click the Launch Statistical Parameters button. The
Statistics Summary screen will be launched with only the Population Statistics displayed.

NOTE: A minimum of three cycle log records have to be selected to calculate the statistics.

6.1.1 Statistical Data Saved/Retrieved from Local Database

Statistical data can be saved to the PC’s Local Database for later viewing and analysis. To save the Statistical data
to the PC, select Save from the File menu or use the Save icon from the main tool bar. To retrieve an already saved
Statistical data set, first click on the Database Mode button in the main tool bar. Next, select the tool Location ID and
corresponding Config number. Select the desired set from the Date/Time Stamp drop box.

48619696_ed3 91
Section 8 – Wireless Diagnostics
Displays wireless statistics of tool connected to USB or IC-PCM, also displays wireless statistics of IC-PCM for diagnostic
purpose.

8.1 Wireless statistics of USB Connected Tool

Displays the Location ID, Transmitted Packet Count, Received Packet Count and Signal Strength.

8.2 Wireless Statistics of the IC-PCM

Displays the following functions;

Location ID
Number of packets received and transmitted Signal Strength,
Signal Quality
Communication Status of IC-PCM with wireless module.

92 48619696_ed3
 Section 9 – General Screen Layout

9.1 ICS Screen Components

The ICS software Interface has following components:
• Title Bar
• Menu Bar
• Main Tool Bar
• Work Space
• Message Window
• Communication Tool Bar
• Status Bar

Title Bar Family Type

Menu
Bar

Main
Tool Bar

Graphics
Screen

Message
Window

Status
Bar

9.1.1 Title Bar

The title bar contains ICS icon and ICS name. In addition, there are standard Windows Close, Minimize, and Restore but-
tons. You can move the program window by clicking and dragging title bar.

9.1.2 Selection of Family Type

ICS is designed to provide a programming interface and archiving function to extend the functionality of family type
IC12D/M controllers and QX Series of tools.
NOTE: Based on family type selection, functions under menus will change.

48619696_ed3 93
9.1.3 Menu Bar
The Menu Bar contains the following menus;
9.1.3.1 File Menu

The File Menu is similar to the menus found on many Windows programs. It has the following functions:
New Opens a new instance of currently active window. This button will be greyed out for all
single instance windows.
ICS Event Log... Provides an option to open a previously saved ICS Event Log.
NOTE: It is only active when View Event Log screen is opened.
Save Saves data of the current active window to local Database.
Send Sends parameters in current active window to selected tool or controller.
Delete Database Record Deletes selected local database record.
Printer Setup Opens a dialog box, allowing user to set printer options.
Print Prints the data from current active window.
Export Exports data from current active window to a “.pdf” or “.csv” file.
Close Closes current active window.
Log Off Logs off current user and prompts with login window.
Exit Closes ICS program.
9.1.3.2 Run Menu

The Run Menu gives you access to the ICS control screen, providing the following options:

Runmain Cycle Log Contains Run Main View and View Cycle Log
Run Main View Displays EOR data for last cycle, for a single tool connected to USB/IC-PCM.
View Cycle Log Displays set of tightening results that are stored in tool/IC-PCM.
Runmain View All Displays last EOR data for all tools, that are connected via USB, IC-PCM.
IC-PCM/QX Event log Displays event log of IC-PCM and QX tool
Create Report Creates a report of EOR’s based upon various criteria.

94 48619696_ed3
9.1.3.3 Setup Menu

The Setup Menu contains all ICS settings. It contains the following options:

Tool Setup Contains Tightening Configuration and General Setup

Tightening Configuration Provides options to set up Torque/Angle/Prevailing Torque Strategy.

Provides options to set up general fastening settings. (Tool Setup, Wireless Setup and
General Setup
Password settings)

Provides you with ability to load, view, edit, create, and save general settings for
IC-PCM 1:1 General Setup
specified IC-PCM 1:1.

Provides options to assign any saved configuration and/or general parameter set to
Parameter Assignment any QX tool connected to USB or IC-PCM, and can also assign general parameter set
to IC-PCM 1:1.

Provides options to view, setup and adjust all Location and Ethernet parameters for
Wireless Tool Setup
all IC-PCM. Also, provides options to view, setup and modify wireless settings.

Provides options to download MCE/Display/Wireless Radio Firmware for tool

Download Software connected to USB, and RISC/Wireless radio firmware to selected IC-PCM which are
currently on the network.
Provides options to reboot selected IC-PCMs and individual radio modules present in
Reboot
an IC-PCM

IC-PCM Wireless energy

Provides options to scan the energy level of all channels (11-25)
detector

9.1.3.4 Status Menu

The Status Menu allows you to access the View Network screen.

The View Network screen provides a clear overview of all QX tools connected to USB/ IC-PCM
View Network
available on the network.
9.1.3.5 Statistics Menu

The Statistics Menu allows you to access the Summary screen.

Summary Provides the ability to view the calculated statistics of tool cycle log data connected to USB/ IC-PCM

48619696_ed3 95
9.1.3.6 Diagnostic Menu

The Diagnostic Menu contains options for diagnostics and troubleshooting.

System Diagnostics Tool Diagnostics is the dynamic test of tool functions for the tool connected to USB.
Tool Test Displays diagnostics data by streaming live motor data.
Tool Status Displays status of trigger switch, direction switch, head light and current system status.
Keypad Status Displays current status of Keypad and LED, and perform LED test.
Tool Calibration Allows to run calibration, which can calibrate Transducer Range (TR).
PM Alarms Allows to get/set PM alarm settings of tool.
View Inputs Allows viewing of input pin status of the IC-PCM 1:1
Set/View Outputs Allows to Set and view output pin status of IC-PCM.
Wireless Diagnostics Provides status used to diagnose the system based on different statistical values (TX, RX etc)

9.1.3.7 ICS Menu

The ICS Menu provides access to eight different options, most of which allow you to perform administrative functions
such as security and general system settings:
Communication Allows setting Serial Settings & Protocol Assignments.
View Event Log Opens ICS Event Log, which displays a log of ICS activity.
Archival Settings Opens Archival Settings screen, which allows user to set up tools and specific data (EOR or
Parameters) that require archiving.
Security Opens Password Setup screen, which allows, with Supervisor access, user to set password and
group permissions.
Change Language Opens Select Language screen, which allows language being used in ICS to be changed.
Available languages: Chinese, Czech, English, French, German, Italian, Polish, Portuguese,
Russian, and Spanish.
Upgrade License Opens Upgrade License screen, which allows user to upgrade License file.
Select Adapter Opens Select Adapter screen, which allows selection of Network Connection type being used
by ICS for connection with IC-PCM.
Database Opens Database Configuration screen, which allows user to modify Archive Database
Configuration configuration.
Direct Controller Opens Direct Controller Discovery screen, which allows user to enter IC-PCM IP Addresses for
Discovery direct discovery by ICS.

96 48619696_ed3
9.1.3.8 Data Source Menu

The Data Source Menu allows you to choose the ICS mode of operation: Database, Network, or Archive.
Database When checked, indicates user is operating in Local Database Mode.
Network When checked, indicates user is operating in Network Mode.
Archive When checked, indicates user is operating in Archive Database Mode.

9.1.3.9 View Menu

The View Menu allows you to toggle on and off the display of the Main Toolbar and the Message Window.
Main Toolbar When checked, Main Toolbar will be active. When unchecked, Main Toolbar will be hidden.

Message window When checked, Message Window will be active. When unchecked, Message Window will be
hidden.

9.1.3.10 Window Menu

The Window Menu functions either to open a new window or arrange the windows displayed.
New window When selected, a new instance of the active window is opened.
Cascade When selected, all active windows will be arranged in a cascaded manner.
Tile When selected, all active windows will be arranged in a tiled manner.
Close All When selected, all active windows will be closed.

9.1.3.11 Help Menu

The Help Menu provides access to the version and license information.
When selected, opens a window containing the software version number, copyright information and
About ICS
license information.

48619696_ed3 97
9.1.4 Main Tool Bar
The Main Toolbar is located at top of screen below menu bar.

Opens a new instance of currently active window. This button will be

New
greyed out for all single instance windows.

Close Closes current active window.

This button is active only when viewing the ICS event log screen, It
Load opens a window which allows loading a previously saved ICS Event
Logs.
Save Saves data of current active window to local Database.

Sends the parameters in current active window to selected tool or

Send
controller.

Delete Deletes selected local database record.

Print Prints data of current active window.

Export Exports the data of current active window to a “.pdf” or “.csv”

Archive Settings Opens Archival Settings screen.

This button allows switching current active window to Network

Network Mode mode. In this mode data can be sent and received directly to/from a
selected tool or a controller.
This button allows switching current active window to Local DB
Local DB Mode
mode. In this mode the data can be saved to local database.
This button allows switching current active window to Archive DB
Archive Mode mode. In this mode the data which is stored in the Archived database
can be viewed.
Family There are two ICS families: ICD/M and QX Series.
9.1.5 Communication Tool Bar
The Communication Toolbar is primarily used to select a controller, when working in Network mode. It is located at
the top of the graphics screen (window). Few of the controls may not be present depending on the screen type.

This tool bar contains the following elements:

Location Id This drop box displays all tools connected to USB/ IC-PCM by the ICS software. Select the
desired tool from this drop box.
9.1.6 Database Tool Bar
The Database Tool Bar is primarily used to perform the DB operations, such as saving and fetching the stored data.

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9.1.7 Work Space
The Work Space function has a desktop for all graphics screens. All graphics screen open within the working area.

9.1.8 Graphics Screens

The graphics screens contains data and setup parameters for one or more controllers. Each screen can be individually
minimized, maximized or closed. The title bar of each screen contains the screen name. The example below shows the
Tool Setup screen open in the Work Area.

9.1.9 Status and Progress Bar

When tools are connected, the Status bar will show a small icon for wireless tools, which will have a Green Tick mark.
Double clicking on this icon displays the Wireless Tool Settings screen.

9.1.10 Icons
There are different Icons used to represent tools connected to USB, IC-PCM.

Icons Descriptions

Tool Connected to USB

IC-PCM 1:1

IC-PCM 10:1

Pistol type Tool connected to IC-PCM

Tool Mapped but not connected to IC-PCM 1:1

Tool Mapped but not connected to IC-PCM 10:1

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Section 10 – Assigning a Name
Use ICS-> Name Assignment Menu from the ICS Main Menu Bar for assigning a name to controllers and configurations.
This section explains how to assign a name to controllers and configurations. The configuration names and the control-
ler names are stored in an SQL database.

10.1 IC-PCM/QX Name Assignment

The IC-PCM/QX screen is used to assign a name to IC-PCM and QX series tool. It allows naming the IC-PCM/QX tools
present on the network. These names shall be used in all screens to identify the controllers instead of IP addresses. For
unnamed IC-PCM/QX, IP addresses and Job-Ids will be used for identification.

Type of the device. This columns will have the icons

IC-PCM 1:1

IC-PCM 10:1
Device Type
Pistol type Tool connected to IC-PCM

Tool Mapped but not connected to IC-PCM 1:1

Tool Mapped but not connected to IC-PCM 10:1

Job ID Job ID of the IC-PCM or QX Series tool.
Name This column shows/updates the name of the IC-PCM/QX series tool
IP Address IP address of the IC-PCM.
Save Save button is used to save the assigned names to the data base
Unassign Unassign button is used to remove the assigned name from the selected job-id.
Unassignall Unassignall button is used to remove all assigned names from all job-ids

The List shows the names assigned to job-ids of the IC-PCM/QX series tools.

NOTE: For off-line controllers, the IP addresses will not be displayed.

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10.1.1 Steps to assign a name to an IC-PCM/QX Tool:
1. From the ICS menu, click Name Assignment and select IC-PCM/QX, ICS opens the IC-PCM/QX Name Assignment
screen.
2. Click on the respective “Name” column and enter the name.
3. Click on Save button.
4. The ‘name’ of the IC-PCM/QX tool will now be displayed in all screens.
NOTE: Following are the rules applied while assigning a name.
a) Only alphanumeric values are allowed.
b) Maximum allowed length is 30 characters.
c) Special characters ‘-‘.’_’, and ‘/’ are allowed.
d) The name must start with a letter.

10.1.2 Steps to Unassign a name for an IC-PCM/QX Tool:

1. From the ICS menu, click Name Assignment and select IC-PCM/QX, ICS opens the IC-PCM/QX Name Assignment
screen.
2. Select the job-id of the controller/tool you wish to un-assign.
3. Click on the Unassign button.
4. The IP Address / Job-Id of the IC-PCM/QX tool will now be displayed in all screens.

10.1.3 Steps to Unassign all names for the IC-PCM/QX Tools:

1. From the ICS menu, click Name Assignment and select IC-PCM/QX. ICS opens the IC-PCM/QX Name Assignment
screen.
2. Click on the Unassignall button.
3. The IP Addresses / Job-Ids of the IC-PCM/QX tools will now be displayed in all screens.

10.2 Configuration Name Assignment

This screen is used to assign names to configurations for a QX series tool.

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Job ID Job ID of the QX Series tool mapped to a IC-PCM
Config Number This column shows Configurations available for the QX series tool.
Config Name This column shows/updates the assigned name of the configurations for the selected tool.
Save Save button is used to save the configuration name
Unassign Unassign button is used to remove the assigned name from the selected configuration.
Unassignall Unassignall button is used to remove the assigned names from all configurations

10.2.1 Steps to assign name to Configuration Number:

1. From the ICS menu, click Name Assignment and select Configuration Number, ICS opens the Configuration
Name Assignment screen.
2. Select the job-id of the QX series tool mapped to the desired IC-PCM.
3. Click on respective “Config Name” column and enter the name.
4. Click on the Save button.
5. The Config Name will now be displayed on all applicable screens.
NOTE: Following are the rules applied while assigning a Config Name.
a) Only alphanumeric values are allowed.
b) Maximum allowed length is 30 characters.
c) pecial characters ‘-‘.’_’, and ‘/’ are allowed.
d) The Name must start with a letter.

10.2.2 Steps To Unassign a name for a Configuration Number:

1. From the ICS menu, click Name Assignment and select Configuration Number, ICS opens the Configuration
Name Assignment screen.
2. Select the configuration number you wish to un-assign.
3. Click on the Unassign button.
4. The name will be unassigned for the configuration number
5. The Config Name will now be displayed as Config 1 through 8 on all applicable screens.

10.2.3 Steps To Unassign All Configuration Names:

1. From the ICS menu, click Name Assignment and select Configuration Number. ICS opens the Configuration
Name Assignment screen.
2. Click on the Unassignall button.
3. All Configuration Names will be unassigned.
4. All Configuration Names will now be displayed as Config 1 through 8 on all applicable screens.

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Contact Information
Fastening Solutions
Joining components in today’s industrial environment is much more than putting wrench to bolt. It’s about finding
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