Leak Test Machines ICT Requirements

Manufacturing Engineering

General Assembly

ICT LAUNCH MANAGEMENT PLANT FLOOR DEVICE STANDARD

(MEGA.ICT-8519-10_A.01)

Leak Test Machines ICT Requirements

ICT LAUNCH MANAGEMENT

NAFTA Region PLANT FLOOR DEVICE STANDARD

Leak Test Machines

(FCA US LLC ICT Requirements)

Owner: ICT Launch Management Page 2 of 13 Revision: 2.3

Document: Leak Test Machine Revised: 05/08/2019

Leak Test Machine Rev 2.3(MEGA.ICT-8519-10_A.01) .DocxPROPRIETARY

1) OVERVIEW

This document summarizes the current ICT requirements for new Leak Test Machines to be

purchased and installed in Fiat Chrysler Automobiles (FCA) US LLC Assembly Plants.

This document is managed by the ICT Assembly System Launch Management Group

(ASLM) of FCA US LLC. For the latest version of this document, please contact a member

of this group.

Please refer to the latest Corporate Controls Standards (previously known as the BOIG; Book

of Implementation Guidelines) for specific controls information.

Deviations to equipment from this document must be approved through the launch deviation

process.

2) SCOPE

This document applies to new equipment built from 12/1/2003 forward. It does not imply that

any existing equipment shall be modified to meet these requirements. It can be used as a

reference for existing equipment that is being refurbished.

3) OPERATION OF EQUIPMENT

QAS operation guideline (Refer to ICT documentation for additional requirements)

1) A standard Fill machine is CLx based

2) A single Ethernet connection is required, 2 communications ports will be utilized, and one

for solicited PFS data, the second for unsolicited QAS downloads.

3) QAS will be utilized to deliver style information to the processor.

4) Limit switches will be used by the OEM to track the position of their fill heads

5) The operation shall not be performed without a known valid VIN number

6) Pass/Fail fields should default to a Z (bypass) at the start of a cycle. As each test or

function is executed, the appropriate Pass or Fail should be entered in the correct field.

7) A Handheld scanner is required for backup; Hand scanned data will override all VIN's

currently in the machine.

8) Utilize a Panel view to allow the operator to correct failed read conditions; this Panel view

will allow the operator to enter the correct VIN number, hand scanning should be

performed prior to going to Panel-view and inputting manually the VIN



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4) GENERAL PROCESS FLOW

This is a general process flow from the ICT perspective:

1) Vehicle enters station

2) QAS downloads unsolicited style information to processor

3) Processor acknowledges on same port that it has received the information

4) If no information received:

a) Hand Scan VIN

b) ALS (See ICT integrator for more information)

c) Manual VIN entry

5) Operator performs fill operation

6) Machine send data to PFS

5) AVI (AUTOMATIC VEHICLE IDENTIFICATION)

If a scanner is used in the system, then AVI standards apply, specifically to hardware model

numbers and the requirement for items such as beam control and stack lights.

Refer to BOIG documents 14.1.1, 14.2.2 (PLC-5 implementations) or 14.3.2 (CLx

implementations), and 14.2.3 (PLC-5 implementations) or 14.3.3 (CLx implementations), for

detailed AVI Reader Implementation information.

If the system is CLx based:

1) A Barcode reader requires an ICT Clx processor in slot 9. AVI and PFCS drivers

will be installed in this processor.

2) A QAS download with no barcode reader will require that PFCS drivers are installed

in the OEM processor and no ICT CLX is required.

3) A QAS Download will require a handheld scanner as a backup.

6) FIS (FACTORY INFORMATION SYSTEM)

This equipment is required to connect to FIS for diagnostic and production information

reporting. Use the following bitmap to configure the equipment for FIS reporting.



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LEAK TEST BITMAP Word[Bit

Number] DINT state_code TEXT

0[02-15] FAULTED GLx WRONGPROGRAM DOWNLOADED

0[16-31] FAULTED GLx MODULE FAULT

1[00-09] FAULTED Ipxx POWER CB NOT ON

1[10-12] POWER OFF DIAGNOSTIC POWER OFF

1[13-15] POWER OFF CONTROL POWER OFF

1[16-31] POWER OFF E-STOP PUSHED/SAFETY PINS PULLED

2[00-15] FAULTED E-STOP /C-STOP /SAFETY PINS FAULT

2[16-19] PROD STOP CYCLE STOP

2[20-31] SPARES SPARES

3[00-10] FAULTED I/O RACK FAULT

3[11-31] FAULTED MRS SAFETY FAULT

4[00-09] POWER OFF MASTERRESET REQUIRED

4[10-13] OUT OF AUTO CYCLE ENABLERESET REQUIRED

4[14-18] OUT OF AUTO FAULT RESET REQUIRED

4[19-25] OUT OF AUTO NOT READYFOR AUTO

4[26-31] OUT OF AUTO WAITING FORSTARTUP

5[00-01] OUT OF AUTO NO MODE SELECTED

5[02-12] OUT OF AUTO MACHINE MODES "MANUAL/ CALIBRATEMODE/ MAINTENANCE MODE/ NO MODE….etc"

5[13-14] BYPASS BYPASS MODE

5[15-16] BYPASS ADAPTOR REMOVED PHOTO-EYE BYPASSED

5[17-22] IDLE IN IDLE STATE

5[23-27] FAULTED MOTOR OFF

5[28-29] FAULTED AIR OFF

5[30-31] FAULTED FLUID OFF

6[00-09] FAULTED FILL MOTOR OVERLOAD TRIPPED

6[10-31] FAULTED TANK xx OVERFILL FAULT

7[00-09] FAULTED VALVE O/L TRIPPED FAULT

7[10-16] FAULTED VOLUME TRANSDUCER FAULT

7[17-31] FAULTED VOLUME SENSOR FAULT



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8[00-16] FAULTED VACUUM TRANSDRE FAULT

8[17-31] MAINT. ASSIST TANK xx OVERFILL FAULT

9[00-09] FAULTED BOOSTER EXTEND/EXTRACT FAULT

9[10-15] FAULTED ADAPTER CLAMP PRESS LOW

9[16-25] FAULTED ABS CPU FAULTS


10[00-31] MAINT. ASSIST TANK xx LOW FAULT

11[00-15] FAULTED VACUUM SENSOR FAULT

11[16-31] SPARES VACUUM FAULTS/ALARMS

12[00-15] FAULTED PRESSURE SENSOR FAULT

12[16-31] FAULTED FILLOVER-PRESSURE FAULT


14[00-15] FAULTED xxxNxx SHORTED SOLENOID FAULT

14[16-31] FAULTED xxxNxx OPENSOLENOID FAULT

15[00-31] FAULTED DNETNODE xx FAULT

16/17[0-31] FAULTED PFCS FAULTS

EX. MAINT. ASSIST PFCS DRIVER'S FAULTS

EX. MAINT. ASSIST PFCS SOL.RESPONSE ERROR

EX. MAINT. ASSIST PFCS SOL.MESSAGE ERROR

EX. MAINT. ASSIST PFCS SOL. MESSAGE RESP. TIMEOUT

EX. MAINT. ASSIST PFCS UNSOL. RESPONSE ERROR

EX. MAINT. ASSIST PFCS UNSOL. MESSAGE ERROR

EX. MAINT. ASSIST PFCS UNSOL. MESSAGE RESP. TIMEOUT

EX. MAINT. ASSIST PFCS NOCLIENT COMM DETECTED

EX. MAINT. ASSIST PFCS ETHERNET SLOT ERROR

EX. MAINT. ASSIST PFCS ETHERNET WCC IP ERROR

EX. MAINT. ASSIST PFCS UNDEFINED STYLE RECEIVED

18[00-31] FAULTED E-NET COMMLOST TO CLX(xxx) FAULTS

19[00-10] ALARM STYLE CHANGED MANUALLY

19[11-15] FAULTED HMIxx COMMUNICATION LOST

19[16-19] STARVED BLOCKEDUP STREAM

19[20-23] BLOCKED DOWN BLOCKED DOWNSTREAM

19[24-31] ALARM PROCESSOR's ALARMS/CLx BATTERYLOW,….,etc



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20[00-15] FAULTED MODULES FAULTS


21[00-31] QUALITY ALERT CYCLES FAULTS

EX. QUALITY ALERT ADAPTOR VACUUM TEST CYCLE FAULT

EX. QUALITY ALERT INITIAL PRES. CHECK CYCLE FAULT

EX. QUALITY ALERT LEAKE TEST OVERALL TEST (P)ass/(F)ail

EX. QUALITY ALERT VACUUM LARGE LEAK CYCLE FAULT

EX. QUALITY ALERT VACUUM SMALL LEAK CYCLE FAULT

EX. QUALITY ALERT FINAL VACUUM CYCLE FAULT

EX. QUALITY ALERT VACUUM LEAK DECAY CYCLE FAULT

EX. QUALITY ALERT FILL ABORT CYCLE FAULT

EX. QUALITY ALERT FILL TIME EXCEEDED CYCLE FAULT

EX. QUALITY ALERT STABALIZE TEAT (P)ass/(F)ail/(Z)NO TEST

EX. QUALITY ALERT AIR TOLERANCE ALARMS

EX. QUALITY ALERT AIR PRESSURIZATION TEST(P)ass/(F)ail/(Z)NO TEST

EX. QUALITY ALERT FILL OVERPRESSURE CYCLE FAULT

EX. QUALITY ALERT FILL VOL.< MINIMUM CYCLE FAULT

EX. QUALITY ALERT/FAULTED PREMATURE PRESSURE FAULT

EX. QUALITY ALERT/FAULTED HIGH CAR PRESSURE FAULT

EX. QUALITY ALERT FILL VOL.> MAXIMUM CYCLE FAULT

22[00-01] MAINT. ASSIST PARAMETER CHANGES ADJUSTMENT/MODIFICATION

22[02-03] MAINT. ASSIST FLUID FILL PASS/FAIL-QUALITY ALERT

22[04-05] MAINT. ASSIST PARAMETER SCREEN NOTIFICATION/CHANGES USED BY PASSxxx

22[06-07] MAINT. ASSIST NOTIFICATION PASS. CHANGED

22[08-09] MAINT. ASSIST TIME COUNTER EXCEEDED LIMIT -MAINT. ACTIVITY

22[10-13] MAINT. ASSIST CALIBRATION CHECK/VERIFICATION VALUES CHANGED

22[14-15] MAINT. ASSIST FLUID PRESSURE SUPPLIES LOW-"UNDER SET POINT"

22[16-17] MAINT. ASSIST PORTABLE PUMPING STATION TOTES LOW

22[18-19] MAINT. ASSIST PORTABLE PUMPING STATION TOTES EMPTY

22[20-31] MAINT. ASSIST SPARES

23[00-31] POWER OFF/FAULTED/ALARM CIRCUIT BREAKERS/FUSES ALARMS

24[00-31] FAULTED SPARES



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25[00-31] FAULTED SPARES

7) PFCS (PLANT FLOOR COMMUNIATIONS SYSTEM)

The device shall conform to PFCS Vendor Specifications:

1. The connection to PFCS shall be made via Ethernet (TCP/IP). (Must be made through a

dedicated NIC, not through a switch or router internal to the machine)

2. Have a unique IP address assigned by the plant.

3. Have a unique Machine ID(s) and DCNO Port(s) assigned by the Plant ICT group.

4. Use PFCS group-certified communication software (a combination of the hardware,

firmware and software). No device will be connected to the FCA US LLC network until

this certification process has been completed.

5. If operation requires unsolicited data downloads from PFCS (QAS), it must receive this

download on a separate port. One port sends data to PFS and VIN requests to AVI, the

other port receives unsolicited QAS VIN and Style data.

6. Utilize the USD communications driver.



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8) PFS (PERFORMANCE FEEDBACK SYSTEM)

Every machine will be tested at the OEM's facility for its ability to communicate to PFS

before delivery to the assembly plant. Please contact your ICT ASLM representative for more

information.

DATA FORMAT

Start End Length Description Format

1 4 4 Machine ID, PC01, etc.

5 7 3 Ack/Nak Area (spaces)

8 13 6 Message Sequence Number (refer to PFCS vendor specs)

14 17 4 Request Type (0002)

18 21 4 Data Byte Count (position 22 to the end, exclude <CR>)

22 25 4 Number Of Records In Block (0001)

26 27 2 Filler Spaces

28 33 6 Last 6 Of VIN

34 39 6 Last 6 Of Track Number If VIN Is Zero

40 51 12 Date and Time (YYMMDDHHMMSS)

52 52 1 Leak Test Overall (P)ass/(F)ail/(Z)No Test (P/F/Z)

53 53 1 Occlusion Test (P)ass/(F)ail/(Z)No Test (P/F/Z)

54 59 6 Occlusion Test Pressure Value (iWC) (xx.xxx)

60 65 6 Occlusion Test Pressure High Limit (iWC) (xx.xxx)

66 71 6 Occlusion Test Pressure Low Limit (iWC) (xx.xxx)

72 77 6 Occlusion Maximum Pressure Value (iWC) (xx.xxx)

78 79 2 Occlusion Test Phase Evaluation Code (xx)

80 83 4 Occlusion Test Time (sec) (xx.xx)

84 87 4 Occlusion Exhaust Time (sec) (xx.xx)

88 88 1 Severe Leak Test (P)ass/(F)ail/(Z)No Test (P/F/Z)

89 94 6 Severe Leak Test Maximum Pressure (iWC) +/(xx.xxx)

95 99 5 Severe Leak Test Minimum Pressure (iWC) +/(x.xxx)

100 105 6 Fill Phase Pressure Value (iWC) (xx.xxx)

106 109 4 Fill Phase Time (sec) (xx.xx)

110 113 4 Balance Phase Time (sec) (xx.xx)



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114 118 5 Stabilize Phase Test Pressure Value (iWC) (x.xxx)

119 122 4 Stabilize Phase Time (sec) (xx.xx)

123 127 5 Test Phase Test Pressure Value (iWC) (x.xxx)

128 132 5 Test Phase Differential Pressure Loss Value (∆iWC) +/(x.xxx)

133 133 1 Leak Rate (P)ass/(F)ail/(Z)No Test (P/F/Z)

134 139 6 Leak Rate (sccm) +/(xxx.xx)

140 145 6 Leak Rate High Limit (sccm) +/(xxx.xx)

146 151 6 Leak Rate Low Limit (sccm) +/(xxx.xx)

152 155 4 Leak Rate Test Time (sec) (xx.xx)

156 157 2 Leak Rate Evaluation Code (xx)

158 161 4 Leak Test Exhaust Timer (sec) (xx.xx)

162 164 3

Overall Cycle Time From Cycle Start to Exhaust Complete

(Sec) (xx.x)

165 166 2 Leak Test Cycle Evaluation Code (xx)

167 169 3 Temperature Reading at end of Test Time (F) (xx.x)

170 172 3 Temperature Change from Start to End of test (F) (xx.x)

173 173 1 Leak Tester Used (1,2,3) or (A,B,C) (x)

174 174 1 Operator Abort During Cycle (Y)es/(N)o (Y/N)

175 175 1 Late Start (Past Start Zone) (Y)es/(N)o (Y/N)

176 176 1 End of Travel Actuated During Cycle (Y)es/(N)o (Y/N)

177 177 1 (H)and Scanner/(Q)as (x)

178 179 2 Internal Program Style Selected (I28) (xx)

180 181 2 Broadcast/QAS Download Style Received (xx)

9) QAS DOWNLOAD

QAS Downloads will be sent unsolicited on the machine ID ending with a letter (example:

DF0A). A handheld scanner shall be used as a backup device should QAS not be functioning.

The handheld scanner will make its request, and gets its reply, on the machine ID ending with

a number (example: DF01).

This is a sample QAS style download for a Leak Test machine:



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Start End Len Field Name Description

1 4 4 Machine ID’s: DF0A, DF0B…

5 7 3 Spaces

8 13 6 Message Sequence Number Refer to PFCS vendor specs

14 17 4 0003

18 21 4 Data byte count Position 22 to end, exclude <cr>

22 23 2 Aa Broadcast Message Type Code

24 25 2

Bc

B=Model year

C=plant code

26 31 6 Last 6 of the VIN

32 41 8 Label Barcode

42 43 2 Vehicles status

44 49 6 Track Sequence number

50 51 2

Style download to device 00 – Invalid style

01-89 plant specific engine type

90 No Op condition



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10) ACCEPTANCE CRITERIA

This is a summary of the ICT acceptance criteria required of the vendor; please refer to the

FCA US LLC Do’s and Don’ts for more detail.

1. PFCS certification must be completed before:

The device can be attached to the plant network

PFS data certification can be conducted

2. PFS certification must be complete before the device ships to the plant.

3. AVI standard point certification must be followed if an AVI barcode reader is used;

this includes testing at the OEM prior to equipment shipping.

4. FIS certification is required.

5. The following line items are examples of what must be tracked in the OEM timeline:

1. ICT Hardware Design

2. ICT Software Design

3. ICT Communications Testing At FCA US LLC (PFCS)

4. ICT System Testing At OEM (PFS Functionality)

5. ICT System Testing at FCA US LLC Assembly Plant



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DOCUMENT REVISIONS

Doc.

Rev.

Date

Doc.

Rev.

Number

Doc. Rev.

Description

Section No.

Revised

5/4/17 2.1 Change Chrysler to FCA US LLC All

Added step 3 in section 7. 7

Updated PFS Data String 8

6/26/17 2.2 Added FIS bit map 6

5/08/19 2.3 Updated PFS Data String 8



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Leak Test Machines ICT Requirements