Spring Hill Assembly1 InnoSys Park Brake Tool Master Control Panel Screens 1 3-Mar-2008

Spring Hill Assembly2 MCP Screens Contents 3 MCP Screen Overview Main Select Screen 6 - 7Production Run Screen 8 – 10Verification/Calibration Screens and Procedures Manual Calibration Procedure and Screen 13Prox Switch alarm enable/disable Screen Parameter Screens and Settings Alarm Screen and Settings Alarm Status/History and Alarm Codes and Descriptions Manual Jog Screens 24Preventative Maintenance Screen 2

Spring Hill Assembly3 Production Run Screen Auto Verification/Cal Screen Manual Verification/Cal Screen PM Screen Alarm Screen History Screen 1 History Screen 2 Alarm Code Description Screen Select Screen Prox Enable and Lamp Test Screen Tension Parameter Setup Screen Alarm Setup Screen Manual Jog Screen Security Login Screen Master Control Panel Screens

Spring Hill Assembly4 Main Select Screen

Spring Hill Assembly5 Main Select Screen This screen enables the user to navigate to any other primary function screen. The Main Select Screen is accessible from all other screens

Spring Hill Assembly6 Production Run Screen 6

Spring Hill Assembly7 Production Run Screen This screen will always be displayed on the MCP while the tool is running a normal tension cycle in Normal Mode. This screen indicates when the tool is in cycle, the detailed job status and the outcome of the job such as pass or fail. This screen contains a reverse jog button that when held down, will enable the team leader to run the nut back off the job without having to switch to manual mode. It is the main screen from which other screens can be selected to run other modes. This screen contains a fault reset button that will turn off audible alarms and reset the system for the next job following a fault. 7

Spring Hill Assembly8 Auto Verification/Calibration Screen 8

Spring Hill Assembly9 Verification Procedure 1.From the Main Select Screen push the Calibrate Screen button. 2.Once in the Cal/Verification screen, push the Verification Mode button. 3.In the Verification/Calibration Screen and with no load applied to either the tool or the cal stand, press the “Zero Offset Button”. Wait 5 seconds for the system to establish the zero offset before installing the tool onto the stand. When zero offset is complete both tool and cal stand load cell with zero offset should show vales near zero. 4.Install the tool onto the cal stand and load the nut into the tool using the extended handle on the stand to cock the tool. 5.To begin the verification cycle press the start button on the tool handle. 6.When the cycle is complete the screen will indicate either verification passed or failed. 7.If cycle passes, return to Mode Select Screen, select Auto Mode and place the tool back into service for normal operation. 9

Spring Hill Assembly10 Auto Calibration Procedure 1.From the Main Select Screen push the Calibrate Screen button. 2.Once in the Cal/Verification screen, push the Calibration Mode button. 3.In the Verification/Calibration Screen and with no load applied to either the tool or the cal stand, press the “Zero Offset Button”. Wait 5 seconds for the system to establish the zero offset before installing the tool onto the stand. When zero offset is complete both tool and cal stand load cell with zero offset should show vales near zero. 4.Install the tool onto the cal stand and load the nut into the tool using the extended handle on the stand to cock the tool. 5.To begin the calibration cycle press the start button on the tool handle. 6.When the cycle is complete the screen will indicate either calibration passed or failed. 7.If cycle passes, return to Mode Select Screen, select Auto Mode and place the tool back into service for normal operation. 10

Spring Hill Assembly11 Manual Calibration Screen 11

Spring Hill Assembly12 Manual Calibration Procedure Manual Calibration Sequence From the Main Select Screen push the Calibrate Screen button. In the Auto Calibration Screen push the Manual Calibration button (lower left corner of screen) From Manual Calibration Screen select Calibration Mode (Verification Mode if running verification) Before connecting tool to calibration stand, press “Set Zero Offset” button. Install new nut onto threaded rod on calibration stand. Connect tool to the calibration stand. Cock tool. While watching the force on the cal stand scale, press and hold “Start” button on the articulating arm until the force on the scale is above 250 lbs. Read the force on the scale. Press the “Set Cal” button on the panel view and enter the force measured on the scale. Press the “Reverse Jog” button to remove the nut from the rod. Pull release ring to remove tool from calibration stand. 12

Spring Hill Assembly13 Prox Enable Screen This screen is accessed from the Main Select Screen. It is used to enable or disable the alarm that is set off when the prox switch does not detect a tool cocked position prior to pressing the start button at cycle start.

Spring Hill Assembly14 Tension Parameter Setup Screen 14

Spring Hill Assembly15 Setting Tension Parameters The Tension Parameters Screen is accessed from the Main Select Screen. You must press the Security button, navigate to the Security Screen and correctly enter the user ID and password. All tension parameters are set from this screen. – Target Tension. The stable high tension level achieved before running reverse revolutions. – Overshoot Delta. How many lbs above target tension to achieve during the final slow run up. – Restart Delta. How many lbs tension can drop below target before restarting the slow run up. – Accept Delta. The +/- allowable variation compared to the Target Tension at end of cycle to pass or fail the job. – Cycle Time Limit. Maximum time tool is allowed to run forward before running reverse revolutions. – Min. Run Time on Restart. Tool must run this minimum time at slow run on restart when attempting to achieve final tension. – Pre Tension Force Target. The percentage of target tension the tool will run at fast speed before going to slow run speed. – Stable Tension Time. How many seconds tension must be stable and not drop below the restart delta before tool restarts slow run up. – Reverse Revolutions. How many reverse revolutions the tool must run to release the brakes after target tension is achieved. – Slow and Fast Run Speeds. Selected applications from the Cooper Controller. The verification acceptance delta is set from this screen. This is the allowable variation between the tool load cell reading and the verification stand load cell reading after running the verification cycle. The Alarm Setup Screen is accessed from this screen. 15

Spring Hill Assembly16 Alarm Setup Screen 16

Spring Hill Assembly17 Setting Alarms Alarm Set Ups: – Misload Alarm Set-Up. These alarms are separate from the tool misload alarms triggered by the prox switch. These alarms are set to detect faults when a specific minimum level of tension is not achieved within a specified period of time after cycle start. They are set for Auto, Calibration and Verification modes. – Cal zero offset limit. This alarm is set when the tool load cell and cal stand load cell differ by more than this specified amount after running the zero offset routine. – Cal Cycle Start Tension Limit. The cal cycle will not start if the amount of tension on the cal stand exceeds this value. This would typically occur if the cal stand nut is already run up a certain amount before attempting to run the cal or verification cycle. – Cal Jog Forward Timeout. The maximum amount of time the tool is allowed to run forward during the cal or verification cycle. – Tool removed During Fast Run. This alarm is set to detect a significant drop in tension after a certain level of tension is achieved and is set above that level established in the Misload Alarm above. 17

Spring Hill Assembly18 Alarm Status Screen The Alarm Status Screen is displayed on the HMI when a fault occurs in any mode. It shows a description of the fault along with the fault code. Date and time of fault are shown. 18

Spring Hill Assembly19 History Screens Accessed from the Main Select Screen The Log Screens are used to review detailed job history according to date and time, tool number and alarm codes if they occur. The Log Screen has a “Codes” button allowing the user to access the alarm code screen. 19

Spring Hill Assembly20 Alarm Code Screen 20

Spring Hill Assembly21 Alarm Code Descriptions The Alarm Code Screen is accessed through the Alarm History Screens. This screen lists all of the Alarm codes and faults that can occur in auto, verification or calibration mode with the description of each alarm code. 21

Spring Hill Assembly22 Manual Jog Screen 22

Spring Hill Assembly23 Manual Jog Screen The Manual Screen is accessed from the Main Screen. After placing the system into Manual Mode, this screen can be used to test the operation of the nut runner and end effecter by using the panel buttons to jog the tool forward or reverse. 23

Spring Hill Assembly24 Preventative Maintenance Alert Screen The PM screen is displayed when PM is due on selected items. These items are primarily associated with replacement or repair of mechanical components in the end effecter and crows foot. 24