Fuel Fill Machines ICT Requirements

Manufacturing Engineering

General Assembly

ICT LAUNCH MANAGEMENT PLANT FLOOR DEVICE STANDARD

(MEGA.ICT-8519-05_A.01)

Fuel Fill Machines ICT Requirements

ICT LAUNCH MANAGEMENT

NAFTA Region PLANT FLOOR DEVICE STANDARD

Fuel Fill Machines

(FCA US LLC ICT Requirements)

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

Document: Fuel Fill ICT Standard Revised: 05/09/2019

Fuel Fill ITM Standard Rev 2.3 (MEGA.ICT-8519-05_A.01).Docx PROPRIETARY

Document Number: APGL148

1) OVERVIEW

This document summarizes the current ICT requirements for new 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

1. A standard Fill machine is CLx based.

2. Use a fixed barcode scanner to identify the Vehicle Identification Number (VIN).

3. Fixed scanner operations will request Style information from AVI utilizing the PFCS Ethernet

connection (DCM network not required).

4. Utilize a limit switch, beyond which the incoming VIN number scanned by the fixed reader is

buffered until the current operation is complete.

5. Utilize a Panelview to allow the operator to correct failed read conditions, this Panelview will

allow the operator to enter the correct VIN number.

6. Have a handheld scanner for backup purposes.

7. Hand scanning operations will request Style information through PFCS to AVI.

8. Hand scanned data will override all VIN's currently in the machine.

9. Send the VIN number to PFS along with the process data in the format specified below.

10. The operation shall not be performed without a known valid VIN number.

11. 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.



Fuel Fill Machines






4) GENERAL PROCESS FLOW

This is a general process flow from the ICT perspective:

1. Vehicle enters station

2. Limit switch signals the PLC to turn barcode scanner on

3. Scanner reads VIN into PLC

4. PLC turns scanner off

5. PLC Requests style information from AVI

6. Operator connects equipment to vehicle.

7. Equipment signals to operator valid style information read

8. If no information received,

a. Operator scans using handheld barcode reader.

b. Equipment requests style information from AVI.

9. If a valid VIN is identified, and style information is received, the Operator performs the

machine function.

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.



Fuel Fill Machines






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.

FUEL FILL 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

2[00-15] FAULTED E-STOP SAFETY FAULT

2[16-31] SPARES SPARES

3[00-31] 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[14-15] BYPASS ADAPTOR REMOVED PHOTO-EYE BYPASSED

5[16-22] IDLE IN IDLE STATE

5[23-28] FAULTED MOTOR OFF

5[29-30] FAULTED AIR OFF



Fuel Fill Machines






5[30-31] FAULTED FLUID OFF

6[00-09] FAULTED FILL MOTOR OVERLOAD TRIPPED

6[10-14] FAULTED TANK xx OVERFILL FAULT

6[15-25] MAINT. ASSIST TANK xx LOW FAULT

6[26-31] FAULTED PRESSURE SENSOR FAULT

7[00-08] FAULTED FILLOVER-PRESSURE FAULT


7[16-23] FAULTED xxxNxx SHORTED SOLENOID FAULT

7[24-28] FAULTED xxxNxx OPENSOLENOID FAULT


8[00-28] FAULTED DNETNODE xx FAULT

8[29-31] PROD STOP FUEL FILL NO STARTLINE STOP FAULT

9/10[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

11[00-31] FAULTED E-NET COMMLOST TO CLX(xxx) FAULTS

12[00-10] ALARM STYLE CHANGED MANUALLY

12[11-15] FAULTED HMIxx COMMUNICATION LOST

12[16-19] STARVED BLOCKEDUP STREAM

12[20-23] BLOCKED DOWN BLOCKED DOWNSTREAM

12[24-31] ALARM PROCESSOR's ALARMS/CLx BATTERYLOW,….,etc

13[00-15] FAULTED MODULES FAULTS




Fuel Fill Machines






14[00-31] QUALITY ALERT CYCLES FAULTS

EX. QUALITY ALERT INITIAL PRES. CHECK CYCLE FAULT

EX. QUALITY ALERT DIESEL/GAS FLOWRATE (GPM) ALARM

EX. QUALITY ALERT FUEL FILL OVERALL TEST (P)ASS/(F)AIL

EX. QUALITY ALERT FUEL FILL OVERALL TEST (P)ASS/(F)AIL/(Z)NO TEST

EX. QUALITY ALERT FILL VOLUME DISPENSE TOLERANCE FAULTS

EX. QUALITY ALERT FUEL FILL TIME TOLERENCE HI/LOW FAULTS

EX. QUALITY ALERT FILL ABORT CYCLE FAULT

EX. QUALITY ALERT FILL TIME EXCEEDED CYCLE FAULT

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

15[00-01] MAINT. ASSIST PARAMETER CHANGES ADJUSTMENT/MODIFICATION

15[02-03] MAINT. ASSIST FLUID FILL PASS/FAIL-QUALITY ALERT

15[04-05] MAINT. ASSIST PARAMETER SCREEN NOTIFICATION/CHANGES USED BY PASSxxx

15[06-07] MAINT. ASSIST NOTIFICATION PASS. CHANGED

15[08-09] MAINT. ASSIST TIME COUNTER EXCEEDED LIMIT -MAINT. ACTIVITY

15[10-13] MAINT. ASSIST SPARES

15[14-15] MAINT. ASSIST CALIBRATION CHECK/VERIFICATION VALUES CHANGED

15[16-17] MAINT. ASSIST FLUID PRESSURE SUPPLIES LOW-"UNDER SET POINT"

15[18-19] MAINT. ASSIST PORTABLE PUMPING STATION TOTES LOW

15[20-21] FAULTED PORTABLE PUMPING STATION TOTES EMPTY

15[22-31] MAINT. ASSIST SPARES

16[00-31] POWER OFF/FAULTED/ALARM CIRCUIT BREAKERS/FUSES ALARMS

17[00-31] FAULTED SPARES

18[00-31] FAULTED SPARES



Fuel Fill Machines






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. Simply put, 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.



Fuel Fill Machines






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 Fuel Fill Overall Test (P)ass/(F)ail (P/F)

53 53 1 Fuel Volume Fill Test (P)ass/(F)ail/(Z)No Test (P/F/Z)

54 56 3 Total Fuel Volume Dispensed (GAL or Liters) (xx.x)

57 59 3 Fuel Volume Dispensed High Tolerance (xx.x)

60 62 3 Fuel Volume Dispensed Low Tolerance (xx.x)

63 66 4 Step 1 Fill Time (Sec) (xx.xx)

67 70 4 Step 1 Fill Rate (GPM or LPM) (xx.xx)

71 74 4 Step 1 Pause Time (xx.xx)

75 78 4 Step 2 Fill Time (xx.xx)

79 82 4 Step 2 Fill Rate (xx.xx)







Fuel Fill Machines





















159 162 3 Chiller Glycol Temperature (°F) (xx.x)

163 166 3 Gasoline Inlet Pressure (PSI) (from tank farm) (xx.x)

167 169 3 Gasoline Skid Oulet Pressure (PSI) (xx.x)

170 172 3 Gasoline Inlet Temperature (°F) (from tank farm) (xx.x)

173 175 3 Gasoline Outlet Temperature (°F) @ Skid (xx.x)

176 178 3 Gasoline Temperature (°F) @ Nozzle (xx.x)

179 181 3 Diesel Inlet Pressure (PSI) (from tank farm) (xx.x)

182 184 3 Diesel Outlet Pressure (PSI) @ Skid (xx.x)

185 187 3 Overall Cycle Time (xx.x)

188 190 1 Fault During Cycle (Y)es/(N)o (Y/N)

191 193 3 Fault Code (xxx)

194 194 1 Fuel Type (G)as or (D)iesel (x)

195 197 2 Console Used (PR)imary,(SE)condary (xx)

198 198 2 Rail Used (IN)board or (OU)Tboard (xx)

199 200 1 Operator Abort During Cycle (Y)es /(N)o (Y/N)

201 202 1 Late Start (Past Start Zone) (Y)es/(N)o (Y/N)



Fuel Fill Machines






203 203 1 End of Travel Actuated During Cycle (Y)es/(N)o (Y/N)

204 204 1 (H)and Scanner/(M)anual VIN entry/(Q)as (H/M/Q)

205 205 2 Internal Program Number Selected (xx)

206 206 2 Broadcast/QAS Download Style Received (xx)



Fuel Fill Machines






9) ACCEPTANCE CRITERIA

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

FF0A). 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: BF01).

This is a sample QAS style download for a Fuel fill machine:

Start End Len Field Name Description

1 4 4 Machine ID’s: FF0A, FF0B…

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



Fuel Fill Machines






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



Fuel Fill Machines






Document Revisions

Doc.

Rev.

Date

Doc.

Rev.

Number

Doc. Rev.

Description

Section No.

Revised

11/24/03 1.0 Initial Draft N/A

12/11/03 1.1 Expand BOIG 1

Remove reference to Broadcast 3.7

Add statement about default PFS string values 3.10

Remove reference to Broadcast 4.8.b

Add Fixed Scanner Field 8

Add Console Letter Field 8

Acceptance criteria clarified 10.5

2/10/09 1.2 Removed all references to ‘Daimler’ & ‘DCX’ Header, All

5/28/13 1.3 Change ICT to ICT All

02/01/17 2.0 Converted to New MEGA form All

Added FCA Logo Header

Reorganize PFS Data, group Pass/Fail Fields 8

4/12/17 2.1 Updated PFS Data String 8

Change Chrysler to FCA US LLC All

Added step 3 in section 7. 7

6/26/17 2.2 Added FIS Bit map 6

509/19 2.3 Updated PFS data string 8

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