Download - 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.
ICT LAUNCH MANAGEMENT
NAFTA Region PLANT FLOOR DEVICE STANDARD
Fuel Fill Machines
(FCA US LLC ICT Requirements)
Owner: ICT Launch Management Page 3 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
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.
ICT LAUNCH MANAGEMENT
NAFTA Region PLANT FLOOR DEVICE STANDARD
Fuel Fill Machines
(FCA US LLC ICT Requirements)
Owner: ICT Launch Management Page 4 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
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
ICT LAUNCH MANAGEMENT
NAFTA Region PLANT FLOOR DEVICE STANDARD
Fuel Fill Machines
(FCA US LLC ICT Requirements)
Owner: ICT Launch Management Page 5 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
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[09-15] SPARES SPARES
7[16-23] FAULTED xxxNxx SHORTED SOLENOID FAULT
7[24-28] FAULTED xxxNxx OPENSOLENOID FAULT
7[29-31] SPARES SPARES
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
13[16-31] SPARES SPARES
ICT LAUNCH MANAGEMENT
NAFTA Region PLANT FLOOR DEVICE STANDARD
Fuel Fill Machines
(FCA US LLC ICT Requirements)
Owner: ICT Launch Management Page 6 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
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
ICT LAUNCH MANAGEMENT
NAFTA Region PLANT FLOOR DEVICE STANDARD
Fuel Fill Machines
(FCA US LLC ICT Requirements)
Owner: ICT Launch Management Page 7 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
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.
ICT LAUNCH MANAGEMENT
NAFTA Region PLANT FLOOR DEVICE STANDARD
Fuel Fill Machines
(FCA US LLC ICT Requirements)
Owner: ICT Launch Management Page 8 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
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)
83 86 4 Step 2 Pause Time (xx.xx)
87 90 4 Step 3 Fill Time (xx.xx)
91 94 4 Step 3 Fill Rate (xx.xx)
95 98 4 Step 3 Pause Time (xx.xx)
ICT LAUNCH MANAGEMENT
NAFTA Region PLANT FLOOR DEVICE STANDARD
Fuel Fill Machines
(FCA US LLC ICT Requirements)
Owner: ICT Launch Management Page 9 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
99 102 4 Step 4 Fill Time (xx.xx)
103 106 4 Step 4 Fill Rate (xx.xx)
107 110 4 Step 4 Pause Time (xx.xx)
111 114 4 Step 5 Fill Time (xx.xx)
115 118 4 Step 5 Fill Rate (xx.xx)
119 122 4 Step 5 Pause Time (xx.xx)
123 126 4 Step 6 Fill Time (xx.xx)
127 130 4 Step 6 Fill Rate (xx.xx)
131 134 4 Step 6 Pause Time (xx.xx)
135 138 4 Step 7 Fill Time (xx.xx)
139 142 4 Step 7 Fill Rate (xx.xx)
143 146 4 Step 7 Pause Time (xx.xx)
147 150 4 Step 8 Fill Time (xx.xx)
151 154 4 Step 8 Fill Rate (xx.xx)
155 158 4 Step 8 Pause Time (xx.xx)
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)
ICT LAUNCH MANAGEMENT
NAFTA Region PLANT FLOOR DEVICE STANDARD
Fuel Fill Machines
(FCA US LLC ICT Requirements)
Owner: ICT Launch Management Page 10 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
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)
ICT LAUNCH MANAGEMENT
NAFTA Region PLANT FLOOR DEVICE STANDARD
Fuel Fill Machines
(FCA US LLC ICT Requirements)
Owner: ICT Launch Management Page 11 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
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
ICT LAUNCH MANAGEMENT
NAFTA Region PLANT FLOOR DEVICE STANDARD
Fuel Fill Machines
(FCA US LLC ICT Requirements)
Owner: ICT Launch Management Page 12 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
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
ICT LAUNCH MANAGEMENT
NAFTA Region PLANT FLOOR DEVICE STANDARD
Fuel Fill Machines
(FCA US LLC ICT Requirements)
Owner: ICT Launch Management Page 13 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
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