Ingersoll-Rand INSIGHTqc Reference guide

Close
Go Back
Introduction
INSIGHTqc Precision Fastening Controllers are designed to control the fastening operation of
threaded fasteners and communicate with external systems for data collection and control.
About this Manual
This manual provides detailed instructions on how to use the INSIGHTqc Precision Fastening
Controllers.
Browser Settings
JavaScript and pop-ups must be enabled to view INSIGHTqc WebHelp contents.
Compatibility
Device Browser Version
Desktop
Google
Chrome
35 or
later
Desktop
Mozilla
Firefox
37 or
later
Desktop
Internet
Explorer
11 or
later
Ipad (IOS
8.1)
Google
Chrome
47 or
later
Mobile
(Android
OS V5.1.1)
Mozilla
Firefox
42 or
later
Go to top
Close

Close
Go Back
Home
This screen gives an interface for the user to monitor Cycle Status, Batch Count, Angle or Torque
values achieved against the defined limits, System Alarms, Trace, Cycle Results, and connection
status of any external devices connected to the fastening controller.

Figure A: Home Screen
Icons displayed at top left corner of the home screen are described as follows:
Icon Description
Select to view menu options.
Green icon indicates that the tool
is connected.
Red icon indicates that the tool is
not connected.
Grey icon indicates no alarm.
Red icon indicates System alarm
has triggered to notify that the tool
or controller is faulty.
Yellow icon indicates Statistic
alarm has triggered to notify a
change in the statistical trend or
Preventive Maintenance alarm has
triggered to notify one or more
maintenance activities are due for
smooth functioning of the tool.
NOTE : In case of any alarm,
select the alarm icon to view log.
Selecting a Job
On the home screen, from Job field (refer to figure A), select a job from the drop down list. For
information on creating or editing a job, refer to Job section.
NOTE : Job selection is enabled when the selection mode is set to internal. To identify the
connection status using indicator icon, refer to Status Indicators .
Using Barcode
The barcode field displays barcode scanned by the user or supplied by the MES. In case the
barcode scanner is unavailable, the supervisor can enable manual entry of barcodes. When
enabled, this field allows edits. An operator can manually enter the barcode and associate with the
results.
This feature can be enabled from Barcode settings. To identify the connection status using
indicator icon, refer to Status Indicators .

Cycle Status
Parameters displayed on the cycle status area are described as follows:
Parameter Description
Cycle Status
Indicates pass or fail status of the
last tightening.
Total Batch Count
Specifies the total number of
fasteners to be fastened in a
group.
NOTE : Graphical representation
of Batch count and the numerical
values will be displayed on
configuration.
NOTE : For a quick identification of results using background
colors in cycle status area, refer to Background Colors .
Angle (°)
Parameters displayed on the angle (°) area are described as follows:
Parameter Description
Angle
Angle in degrees that a fastener
has turned past the torque
threshold point.
Target Angle
Indicates the target value for the
select configuration in degrees if
the strategy is Angle Control. Must
be less than or equal to 32000
degrees
(Angle High Limit)
Indicates angle high limit set for
the configuration.
NOTE: It triggers when angle
achieved is greater than or equal
to the set limit.
(Angle Low Limit)
Indicates angle low limit set for the
configuration.

NOTE : It triggers when angle
achieved is less than the set limit.
NOTE : For a quick identification of results using background
colors in angle (°) area, refer to Background Colors .
Torque (Nm)
Parameters displayed on the torque (Nm) area are described as follows:
Parameter Description
Torque Force applied to a fastener.
Target Torque
Indicates the target value for the
select configuration if the strategy
is Torque Control. Must be less
than or equal to max torque of the
tool.
(Torque High
Limit)
Indicates torque high limit set for
the configuration.
NOTE: It triggers when torque
achieved is greater than or equal
to the set limit.
(Torque Low
Limit)
Indicates torque low limit set for
the configuration.
NOTE : It triggers when torque
achieved is less than the set limit.
NOTE : For a quick identification of results using background
colors in torque (Nm) area, refer to Background Colors .
Cycle Results
Parameters displayed on the cycle results area are described as follows:
Parameter Description
PSET
Indicates the Pset assigned for the
current task.
Job Cycle
Incremental number of jobs run by
the controller.

Spindle Cycle
Incremental number of fastenings
performed by the connected tool.
NOTE : For more details, from the right hand corner of the
cycle results area, select .
Communication Protocol Status
This area displays the connection status of various communication protocols associated with the
controller.
Communication protocols displayed on the communication status area are described as follows:
Communication
Protocol
Description
Power Focus Open
Protocol
Indicates connection status of
Power Focus Open Protocol
(PFOP) station with the computer.
Barcode
Indicates connection status of the
barcode scanner.
EOR Data Out
Indicates connection status of
EOR Data Out with the Client.
Nissan EOR Out
Indicates connection status of
Nissan EOR Data Out with the
Client.
Ford Open Protocol
Indicates connection status of
Ford Open Protocol with the
Client.
Fieldbus
Indicates connection status of
Fieldbus protocol.
VWXML
Indicates connection status of
VWXML protocol.
Toolsnet
Indicates connection status of
Toolsnet protocol.
NOTE : To identify the connection status using background
colors displayed for these communication protocols, refer to
Communication Status Indicators .
At the home screen, on the controller display unit, IP addresses are displayed near the
communication protocol status area for reference. This feature is not available for remote access of

the controller.
Trace
This area will give graphical representation of the fastening operation result. The default view is
Torque vs Angle. For other views, from the right hand corner of the Trace area, select . In the
Trace Selection field, select a view from the drop down list.
To download trace result, select . The result displayed on the screen will be downloaded.
NOTE : User working on a local display must connect a USB pen drive to the controller before
downloading. For remote access, a default location must be set in the browser settings.
Go to top
Close

Close
Go Back
Cycle Results
This screen provides detailed results from each fastening performed by the tool connected to that
controller. Filters are added to allow the user to easily search through the data to view specific
records. Columns can be customized based on user requirements.
Parameters displayed on the cycle results screen are described as follows:
Parameter Description
Cycle Pass/Fail
Indicates the overall pass/fail
status of the fastening that
generated the fastening results.
Measured Torque
Maximum value of torque
achieved during fastening.
Date & Time
Date and time of completing the
fastening operation.
Torque Result
Torque result is 'High Torque'
failure, if the value of torque
exceeds the maximum torque limit.
Torque result is 'Low Torque'
failure, if the value of torque is
below the minimum torque limit.
Otherwise, the Torque result is a
Pass.
Angle Result
Angle result is 'High Angle' failure,
if the value of angle exceeds the
maximum angle limit. Angle result
is 'Low Angle' failure, if the value
of angle is below the minimum
angle limit. Otherwise, the Angle
result is a Pass.
Measured/Peak
Angle (°)
Maximum value of angle achieved
during fastening.
Reason for Shutdown
Indicates the cause for cycle abort
or termination.
Spindle Cycle
Number
Incremental number of fastenings
performed by the connected tool.

This is used to uniquely identify
fastening results for a particular
fastener.
Job Name Indicates the name given for the
user defined job.
Pset Name Indicates the name given for the
user defined Pset.
Job Cycle Number
Incremental number of jobs run by
the controller. This is used to
uniquely identify the fastening
results associated with the
execution of a particular job.
Barcode
If enabled, it displays barcode
scanned from a scanner.
Operator Name
Indicates the name of the operator
who performed the fastening.
Job ID Matched with a job and is used for
external job selection.
If available, user can select on the result page, to view Trace related information. To get
additional information on a specific result record, select . A pop-up with complete Cycle
Results will be displayed. To refresh the cycle results, select .
Customizing Columns
Do the following to customize columns while displaying cycle results:
Select Customize Columns.1.
To display all EOR parameters, check Select All. Else, proceed to step 3.2.
To display specific EOR parameters, un-check Select All and then check the required
parameters from list.
3.
To rearrange the EOR parameters, select the parameter and then select or to move
up/down.
4.
Select Apply .5.
Exporting to CSV
To download cycle results in CSV format, select Export to CSV. The cycle results displayed on
the screen will be downloaded. NOTE : User working on a local display must connect a USB pen
drive to the controller before downloading.

Creating Filter
To expand Filter contents, select . User can select one or more filters from the filter type fields
and then select Apply . The result will be displayed on the Cycle Results screen. To view unfiltered
result, user can select Clear to remove the filters and then select Apply .
Filter Type Action
Job Name
From the Job Name field, select a job from
the drop down list.
Pset
From the Pset Name field, select a Pset
from the drop down list.
Start date and End
date
In the Start Date field, select to choose
a start date.
In the End Date field, select to choose
an end date.
Start time and End
time
In the Start Time field, enter a start time.
In the End Time field, enter a end time.
Operator
From the Select Operator field, select an
operator.
Barcode If Barcode scanner is enabled, the
scanned barcode details will be displayed.
Shutdown Reason
From the Shutdown Reason field, select a
reason from the drop down list.
Result Under Result, select any one.
Go to top
Close

Close
Go Back
System Diagnostics
This screen provides the result for overall system status of the tool connected to the Fastening
Controller.
To enable communication log, select Enable MCE Communication Log field to show indicator in ON
position. Select Save. To update the diagnostic information of the controller, select .
Parameters displayed on the screen are described as follows:
Parameter Description
Motor Temperature
(°C)
Checks motor temperature and
reports PASS or FAIL.
Heatsink temp (°C)
Checks heatsink temperature
and reports PASS or FAIL.
Offset (% of ideal)
Tool Electronic's offset voltage
(as % of Shunt Cal voltage).
Shunt Calibration (%
of ideal)
Front-end electronics gain (as %
of ideal Shunt Cal voltage).
Sine Offset A/D value
Offset in A/D counts of the
resolver sine analog input signal
used for angle measurement.
Cosine Offset A/D
value
Offset in A/D counts of the
resolver cosine analog input
signal used for angle
measurement.
Estimated motor Kt(N
m/A)
Peak torque divided by peak
current in the units of Nm/Amp.
In case of a failure, contact your nearest Ingersoll Rand office or distributor for assistance.

Close
Go Back
Job Results
This screen provides the overall result for each execution of a specific job with the ability to view all
the individual cycle results that constituted the execution of the job. User can create a filter to
display results for a specific job.
Parameters displayed on the Job Results screen are described as follows:
Parameter Description
Result Result of the performed job.
Job Cycle Number
Incremental number of jobs run by
the controller. This is used to
uniquely identify the fastening
results associated with the
execution of a particular job.
Job ID
Matched with a job and is used for
external job selection.
Job Name Name given to identify the job.
Date & Time
Date and time of completing the
fastening operation.
Job Failure Mode
Indicates the reason for a job
failure.
To get additional information on a specific result record, select . Parameters displayed on the
Pset results for the corresponding job are described as follows:
Parameter Description
Cycle Pass/Fail
Indicates the overall pass/fail
status of the fastening that
generated the fastening results.
Measured Torque
Maximum value of torque
achieved during fastening.
Date & Time
Date and time of completing the
fastening operation.
Torque Result
Torque result is 'High Torque'
failure, if the value of torque
exceeds the maximum torque limit.

Torque result is 'Low Torque'
failure, if the value of torque is
below the minimum torque limit.
Otherwise, the Torque result is a
Pass.
Angle Result
Angle result is 'High Angle' failure,
if the value of angle exceeds the
maximum angle limit. Angle result
is 'Low Angle' failure, if the value
of angle is below the minimum
angle limit. Otherwise, the Angle
result is a Pass.
Measured/Peak
Angle (°)
Maximum value of angle achieved
during fastening.
Reason for Shutdown Indicates the cause for cycle abort
or termination.
Spindle Cycle
Number
Incremental number of fastenings
performed by the connected tool.
This is used to uniquely identify
fastening results for a particular
fastener.
Job Name Indicates the name given for the
user defined job.
Pset Name Indicates the name given for the
user defined Pset.
Barcode
If enabled, it displays barcode
scanned from a scanner.
Operator Name
Indicates the name of the operator
who performed the fastening.
If available, user can select on the result page, to view Trace related information. To get
additional information on a specific result record, select . A pop-up with additional information
will be displayed. To refresh the job results, select .
Exporting to CSV
To download job results in CSV format, select Export to CSV. The job results displayed on the
screen will be downloaded. NOTE : User working on a local display must connect a USB pen drive
to the controller before downloading.

Creating Filter
To expand Filter contents, select . User can select one or more filters from the filter type fields
and then select Apply . The result will be displayed on the Job Results screen. To view unfiltered
result, user can select Clear to remove the filters and then select Apply .
Filter Type Action
Job Name
From the Job Name field, select a job from
the drop down list.
Operator From the Operator field, select an operator.
Start date and End
date
In the Start Date field, select to choose
a start date.
In the End Date field, select to choose
an end date.
Start time and End
time
In the Start Time field, enter a start time.
In the End Time field, enter a end time.
Result Under Result, select any one
Go to top
Close

Close
Go Back
Tool Diagnostics
This screen provides real time information about the tool connected to the Fastening Controller.
Tool Information section gives information related to Tool Model Number and Tool Serial Number
along with values for the listed parameters. Tool Fault section gives information related to errors
along with date and time of the occurrence.
Select Enter diagnostics to start the tool diagnostics.
Select to view Tool Information and Tool Fault contents.
Tool Information
Parameters displayed on the screen are described as follows:
Parameter Description
Tool Model Number
Model number of the connected
tool.
Tool Serial Number
Serial number of the connected
tool.
Tool Max Torque
(Nm)
Maximum allowable Torque for
the connected tool.
Tool Max Speed
(RPM)
Displays maximum allowable
speed of the motor.
Tool Max
Temperature (°C)
Maximum allowable temperature
of the tool motor before alarm
activation.
Tool Cycle Count
Total number of cycles that the
tool has run. This is for the
lifetime of the tool.
Warranty Start Date
(mm/dd/yy)
Start date of the warranty for the
tool.
Tool Fault
The information shown is related to tool faults.
Parameters displayed on the screen are described as follows:
Parameter Description
Date and time of the fault reported.

Date & Time
Description Description of the recorded fault.
Running Diagnostics Test
This test will examine the overall status of the tool connected to the Fastening Controller.
Do the following to run a diagnostic test:
Select Enter Diagnostics .1.
At the Warning screen, select Yes. 2.
Display state on the screen are described as follows:
Display State Description
Trigger
Displays the Pulled/Released
status of the trigger switch.
Green indicates that the trigger is
pulled.
Grey indicates that the trigger is
released.
Direction
Displays the CW/CCW status of
the direction switch.
Momentary Switch
Green indicates that the switch is
active.
Grey indicates that the switch is
inactive.
Tool Test
In handheld mode, the user must pull the trigger to start the test. In machine mount mode, the
screen has a Start button under Tool Test section. Selecting the Start button activates the tool and
the values of the listed parameters will start updating. The Start button changes to a Stop button.
Selecting the stop button deactivates the tool and the values of the listed parameters will stop
updating. These results are displayed in a tabular form. For graphical representation, the user
needs to select the Trace area twice.
NOTE : The tool I/O relates to handheld tools (QE) and not for fixtured tools (QM).
Parameters displayed on the screen are described as follows:
Parameter Description
Current (A)
Dynamic Current value in Ampere
while tool is running.

Torque (Nm)
Dynamic Torque value in Nm while
tool is running.
Speed (RPM)
Dynamic Speed value in RPM
while the tool is running.
Angle (°)
Total number of degrees of rotation
while the tool is running.
Running LED Test
Do the following to run a LED test:
Under Tool Information, below LED Test, select Start.
LED lights on the tool connected to the Fastening Controller starts blinking for 5 seconds and
switches between red, green and yellow.
1.
To stop the LED test, select Stop. 2.
To exit from Tools Diagnostics - Run Diagnostic screen, select Exit Diagnostics. At the Warning
screen, select Yes. The Tool Information screen will be displayed.
NOTE : The tool I/O relates to handheld tools (QE) and not for fixtured tools (QM).
Go to top
Close

Close
Go Back
Audit Logs
This screen logs records associated with user actions. For an example, value for a parameter
updated by the user.
Parameters displayed on the Audit Log screen are described in the following table:
Parameter Description
Date & Time Date and time of the occurrence.
Username
Identify the person who performed
the operation.
Description
Description of action performed by
the user.
Field Modified
Name of the parameter that was
modified.
New Value New value entered by the user.
Old Value
Previous value of the parameter
before the user modified.
To download audit logs, select .

Close
Go Back
Event Log
This screen logs records associated with alerts and notifications.
Parameters
Parameters displayed on the Event Log screen are described as follows:
Parameter Description
Date & Time Date and time of the occurrence.
Description Description of the event.
To download event logs, select .

Close
Go Back
Spindle Management
This screen allows the user to configure the spindle settings.
Do the following to modify the settings:
NOTE : Tool type is a read only field. The tool type is read from the tool and presented to the user
for reference.
From the Spindle Operation field, select from the drop down list:1.
Handheld : In this mode, the user needs to pull the trigger in order to run the tool. x
Machine Mount : In this mode, the tool will run from an external input. This can be DIO
or Fieldbus for automated operation.
x
From the Start Mode field, select from the drop down list:2.
Throttle : In this mode, the tool runs when the start signal is applied and stops when
the signal is disabled.
x
Pulse : In this mode, the tool runs when the start signal is applied and continues to run
even if the signal is removed, until the cycle completes or times out.
x
Double : In this mode, free speed and safety latch switch closures are needed. This
applies to spindles that need the operator to activate two switches within a 2-second
interval. This makes sure the hands are safely away from the machinery. If either of the
inputs are not energized within the two-second interval, the spindle does not operate.
NOTE : Pulse mode and Double mode are available for machine mount operation only.
In this application, the user has a remote handle that forces two handed operation for
safety.
x
From the Remote Tool Enable Mode field, select from the drop down list:3.
None: In this mode, the remote tool enable mode is not available.x
NOTE : Even if None is selected tool can be enabled/disabled from MES protocol.
1 Line: In this mode, the tool is enabled anytime the enable signal is activated and
disabled when the signal is deactivated. Enabling or disabling of the tool is dependant on
the proper interlock that is configured.
x
NOTE : Enabling or disabling the tool depends on proper configuration of the interlock.
2 Line: In this mode, the tool will be enabled when the Spindle Enable signal has
pulsed high. The tool stays enabled until a high pulse is received on the Spindle disable
line. The signals can come from DIO or Fieldbus.
x
NOTE : Enabling or disabling the tool depends on proper configuration of the interlock.
To enable or disable tubenut, select within the Enable Tubenut field to show indicator in ON
4.