Ingersoll Rand 4581740 - Manuals

04581740_ed2 9 Section 2 – Installation 2.1 Mounting Bolt the Insight controller enclosure to a suitable rigid surface near the assembly area using the mounting brackets on the back of the enclosure. See the drawings below for dimensions, information on bracket hole spacing, recommended mounting bol...

10 04581740_ed2 Figure 7 - Side and Back Dimensional Drawings 2.2 Electrical Connection Make sure the Main Power Switch is in the Off position. Insight controllers are available with various power cord options. Some options include a pigtail power cable, and the user must supply the correct power co...

04581740_ed2 11 2.3 Attaching Peripheral I/O Devices To remove the I/O cover, first remove the retaining screw on the right-hand side of the cover, and then press in the locking tab below the screw and lift up the cover. Serial Port Rotary Switches (CA2 Address) Termination Resistor Switch USB Port ...

04581740_ed2 13 2.3.4 PLC Connection and Setup NOTE: All connections to a PLC are made via the Insight’s 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 via the serial or Ethernet por...

16 04581740_ed2 2.5.3 E-Stop Not Present If E-stop is not being used, the E-stop relay must still be energized to permit normal operation. This is accomplished by connecting JP21 pin 1 to JP21 pin 3 and JP21 pin 2 to JP21 pin 4. This allows the module’s internal 24 VDC to energize the relay. The wir...

18 04581740_ed2 Section 3 – Programming the IC-D 3.1 Setup Menu The Setup menu and its sub-menus are used to program tightening strategies and to set a broad variety of important system parameters. Basic tightening strategies are created in the Setup menu. In addition to strategies, you can use the ...

20 04581740_ed2 If the Gang Count is successfully completed, in addition to displaying “Gang Complete” on the screen, the controller provides a gang complete output signal on the spindle’s I/O connector. There are two ways to reset the Gang Count. 1. Use the dedicated reset palm switch on the Gang R...

04581740_ed2 21 3.3.3 Job Number and CAN Address The Job Number and CAN (Controller Area Network) Address parameters found at the top of the System Setup screen are used to set a Location ID for a particular Insight controller. The Location ID is used as a unique identifier for each unit on the netw...

04581740_ed2 23 When Tube Nut 1 is selected, the spindle operates in tube nut reverse when the momentary position of the switch is activated. No trigger press is necessary to operate the spindle in tube nut reverse in this mode. When the momentary switch is released, the spindle stops, and it is the...

24 04581740_ed2 3.5.6 Host Address The Host Address is only used when Host Data Out has been selected in the Protocol parameter. For more information on applying the Serial Setup screen to particular devises, see section 2.4.1 Printer Connections and Setup. 3.6 PC Connection When a PC is connected t...

26 04581740_ed2 Section 4 – Operating the IC-D System 4.1 Introduction This section provides the information that you need to operate the Insight controller. At this point, the system should be properly installed and programmed. The Main screen from the Run menu is where system operation takes place...

04581740_ed2 27 4.3 Monitoring Operation 4.3.1 Torque and Angle Values The middle section of the Run Main screen on the IC-D displays torque and angle information for each tightening operation. The larger value is the primary one, and it reflects the strategy that applies to the selected Configurati...

28 04581740_ed2 4.4 Message Area The Message Box at the bottom of the Main screen summarizes system status and provides warnings and alarms on the IC-D. On the IC-M LED display, only the Event Code number is displayed in the event of an error. See Event Code Table on page 44 for a listing of these e...

04581740_ed2 29 Section 5 – Quality Control 5.1 Statistics Menu The Statistics menu allows you to access a variety of statistical data on completed fastenings. For example, you can view actual fastening parameters, as well as statistical calculations, and can compare them to target values. This sect...

34 04581740_ed2 Section 6 – Diagnostics and Troubleshooting 6.1 Diagnostics Menu The Diagnostics menu allows you to check the overall system health of the Insight IC-D. This functionality also diagnoses system problems. This section discusses the four Diagnostics sub-menu screens, including: System ...

04581740_ed2 37 To access and use Tool Test : 1. Press the Diag button on the Insight controller. 2. On the Diagnostics menu , select Tool Test and press Enter . 3. A pop-up message warns you that running the test interrupts spindle operations. Press Enter to continue. 4. For a fixtured spindle, use...

38 04581740_ed2 Appendix 1 – System Specs and Spare Parts Insight Technical Specifications The specifications for the Insight IC Tightening System are shown below. Measurement Accuracy ±0.2% of torque full scale±1 count of angle (degrees) Measurement Resolution ±0.025% of torque full scale Torque Tr...

04581740_ed2 39 Outputs Output Behavior Block # Pin # Spindle In cycle 2 O-1 Cycle Complete 2 O-2 Accept 2 O-3 Torque High 2 O-4 Torque Low 2 O-5 Angle High 2 O-6 Angle Low 2 O-7 Gang Complete 2 O-8 Recommended Spare Parts List See the illustrations following the Parts List. Detail Number Part Numbe...

04581740_ed2 43 Appendix 2 – Event Codes The following table lists the Event Codes for the IC-D and IC-M. Below is an explanation of table columns. Event Code Explanation Event Code This is the event code number. On an IC-M controller, the code is displayed on the screen as “E” and then the code num...

04581740_ed2 45 Index A Activating an Input 12 Attaching Peripheral Devices 11 Attaching The Spindles 11 Auto Increment 20 B Backspace Key 6 Bar Code Active Mode 14 Compatibility With Other Functions 14 Auto Increment 14 Gang Count 14 Powerhead 14 Connection and Setup 14 Description 14 Operation 14 ...

46 04581740_ed2 Q Quality Control 29 Quick Setup screen 18 R Radio Button 7 Receiving an Output 12 Run Menu Statistic Summary Screen 31 Run Menus Cycle Log Screen 29 S Screen Elements 7 Serial Port 16 Serial Printer 13 Setup 23 Shutdown Code 30 Spare Parts List 39 Specifications 38 Spindle Operation...