200

DG
A0862 OP5060

OF
APR 2017
CHECKED BY

DRAWN BY

SHEET NO

00
JOB NO

DATE

TABLE OF CONTENTS
MAGNETI MARELLI

DWG NO A0862OP5060-000

DT ASSEMBLY LINE MID/PREMIUM

DWG DESCRIPTION

SCREWING STATION
ACTIVE INDUSTRIAL SOLUTIONS JOB# A0862 OP5060

OP5060
BY
FILENAME SH DWGDESC A0862OP5060-103 103 S7 1217C & 16DI

REVISION

JOB DESCRIPTION
A0862OP5060-000 00 TABLE OF CONTENTS A0862OP5060-104 104 S7 1217C & 16DI
A0862OP5060-001 01 LAYOUTS A0862OP5060-106 106 S7 1217C & 16DQ

DATE
A0862OP5060-020 20 120V DISTRIBUTION A0862OP5060-180 180 BACKPLATE LAYOUT
A0862OP5060-021 21 120V DISTRIBUTION A0862OP5060-181 181 ENCLOSURE LAYOUT
A0862OP5060-035 35 DC DISTRIBUTION A0862OP5060-182 182 PUSHBUTTON BOX
A0862OP5060-036 36 DC DEVICES A0862OP5060-187 187 HMI ENCLOSURE
A0862OP5060-037 37 SAFETY POWER DISTRIBUTION A0862OP5060-189 189 TERMINAL ROTATION
A0862OP5060-050 50 ESTOP SAFETY A0862OP5060-190 190 BOM
A0862OP5060-051 51 ANTI TIE DOWN SAFETY RELAY A0862OP5060-191 191 BOM
A0862OP5060-060 60 NETWORK LAYOUT A0862OP5060-192 192 BOM
A0862OP5060-070 70 RDB-3020 SCREWFEEDER
A0862OP5060-080 80 KOLVER SCREWDRIVER
A0862OP5060-100 100 PLC LAYOUT
A0862OP5060-102 102 S7 1217C

DT ASSEMBLY LINE MID/PREMIUM

SCREWING STATION OP5060
ELECTRICAL PRINTS
 120VAC 1 PHASE FROM ELEVATOR#1 PANEL

OF 200
PG FITTING

DG
FROM ELEVATOR#2 ETHERNET SWITCH

A0862 OP5060
7000-74711-7781500

APR 2017
CHECKED BY
ICOTEK 41202

DRAWN BY

SHEET NO
LED CBL6538 FROM ELEVATOR#1 ESTOP CIRCUIT

01
JOB NO
WORK LIGHT RECPT2014
AWP 1001603

DATE
120VAC #14/3C - 20'
120VAC #14/4C - 20'

PG FITTING

DWG NO A0862OP5060-001

DT ASSEMBLY LINE MID/PREMIUM

LAYOUTS
                       
SV20M-26-1A

SV20M-26-1A
SV20M-26-1A
SV20M-26-1A
                   

                  
               

DWG DESCRIPTION

SCREWING STATION
SMC
IZF10-P-ZB

MURR 7000-44711-7960500 5C/10M

OP5060
IFM EVC072 ICOTEK 41202
ICOTEK 41202 PRS10228
SMC
PRESSURE

BY
ISE40A-N01-T-D
SWITCH
KOLVER SCREW GUN#1 CONTROLLER
EDU 2AE-TOP-E TA
1002012-AWP

REVISION
RECPT2054 ICOTEK 41210

JOB DESCRIPTION
TRIPP LITE
602-15 1002018-AWP 1002007-AWP RITTAL
ICOTEK 41213 ICOTEK 39917 1555.500

DATE
1002012-AWP
ICOTEK 41210 MURR 7000-74711-7780500
ICOTEK 41202
1002012-AWP

MAIN PANEL
ICOTEK 41210
PB5006

EMERGENCY
STOP

RITTAL
SS10220

1002007-AWP
FAULT
RESET

8017667
PBLT5022

ICOTEK 41213
POWER
ON

WH

1001807-AWP (FROM ELEVATOR#1 MAIN PANEL)

CBL7006
AWP 1002003 SCREWFEEDER#1 RDB-3020
ICOTEK 41202
CBL10230
IFM EVC142

ICOTEK 41210

1002018-AWP
ABSOLUTE ROTARY ENCODER 'X' AXIS
ICOTEK 41213

CBL10376 1002018-AWP
SCREWDRIVER GUN#1 AT HOME
IFM EVC003 ABSOLUTE ROTARY ENCODER 'Y' AXIS
ICOTEK 41213
ICOTEK 41202

LH CYCLE START

IFM EVC072

DM8000-ECABLEC-05 ICOTEK 41202

RH CYCLE START

ICOTEK 41202 RITTAL

PL10370
BANNER
1039.500 IFM EVC072
K30LGRYPQ IFM EVC072
ICOTEK 41202
 120VAC 1PH 60HZ FROM ELEVATOR#1 MAIN PANEL

20 20101 20020 20

OF 200
CBL2114 GN CBL2114 WHT
CBL2114 BLK HUBBELL PART#HBL4729C SOOW 14/3 POWER BAR
20 20 38 120VAC N 38

DG
SOOW 14/3

A0862 OP5060
SOOW 14/3
RECPT2042

GN

2
1

APR 2017
00 40

CHECKED BY
E1 E1
CB2042

RED_14AWG

DRAWN BY

SHEET NO
GN

2
1
20 20 20101 20421 WEIDMULLER 20020 20020

20
SIEMENS

JOB NO
CBL2010A BLK HUBBELL PART#HBL4720C CBL2010A GN CBL2010A 5SJ4 110-7HG41
WHT 10A 991548000

DATE
TB1 TB1
02 SOOW 14/3 SOOW 14/3 SOOW 14/3 42

20 L1 N 20

120V DISTRIBUTION
04 44

DWG NO A0862OP5060-020
15ft (4M)

DT ASSEMBLY LINE MID/PREMIUM

20 20

WHT_14AWG
2006 DISC
06 46
SIEMENS

DWG DESCRIPTION
3LD25040TK51

SCREWING STATION
20 20

RED_14AWG
08 48

OP5060
20 20 RECPT2054

WHT_14AWG
TRIPP LITE
10 50 602-15

BY
LOCATED ON REAR
KOLVER SCREW GUN#1 CONTROLLER OF MACHINE FRAME
20 20 EDU 2AE-TOP-E TA

REVISION
ATDR12

12 52

JOB DESCRIPTION
FU2012
USCC1I
20 20 CBL8010A
AWP 1002012

14 54

DATE
CBL8010B
20101 AWP
CBL8028A
1002018

20 20 AWP 1002012 SCREWFEEDER

CBL8028B
#1
16 56 AWP 1002012
AVVITATURA
PROGRAMMING
RDB-3020
20 PORT 20
120VAC,
RECPT2020 SIMCO#40065993
18 58 IONIZING AIR GUN
50/60HZ
E1 E1
CB2020
20 20101 20201 MURR 20020 20
5A
20 TB1 SIEMENS 4000-68223-0000000 TB1
60 DATAMAN 8600
5SJ4 111-7HG41 4000-68000-0040000 2060SCN
4000-68000-1410000
20 20
22 62
OPERATOR OPERATOR
20 OPERATOR LIGHT RECEPTACLE
20
ENABLE RECPT2024 LIGHT
24 CR10634 LT2024 64
20261
EATON
E1
20 10634 2SLSTP2040DD120V 20
20020
26 TB1
66
TO ETHERNET SWITCH
20 20
28 68

20 20
30 70

20 20
32 72

20 20
34 74

20 20
36 76

20 20
2122

2160

2122

2160
38 20 20 78 21 21
40 40 00 00
20101 20020 20101 20020
 20101 20020 20101 20020 21

OF 200
20 20 21
21 78 78 21 38 38

DG
A0862 OP5060
WHT_14AWG

APR 2017
RED_14AWG
00 40

CHECKED BY
RED_14AWG

DRAWN BY

SHEET NO
21 21

21
JOB NO
24VDC POWER SUPPLY, 10A

DATE
02 SIEMENS#6EP1334-2BA20 42
E1 2104PS E1
CB2104
21 20101
SIEMENS 21041 20020 21
L1 N

120V DISTRIBUTION
5SJ4 111-7HG41
04 TB1 5A TB1
44

DWG NO A0862OP5060-021

DT ASSEMBLY LINE MID/PREMIUM

21 21

WHT_14AWG
13
24VDC
06 OK 46

DWG DESCRIPTION
14

SCREWING STATION
21 21
PE
08 + + - - 48

OP5060
21 21
10 50

BY
21 21

REVISION
12 52

JOB DESCRIPTION
CB2114 21141
21 21140 SIEMENS 21141 35 21
10A 5SJ4 110-7HG41 00
14 BLU_16AWG 54

DATE
21 21161 35 21
BLU/WHT_16AWG 00
16 56
21161
21 21
18 58

21 21
20 60

21 21
22 62

21 21
24 64

21 21
26 66

21 21
28 68

21 21
30 70

21 21
32 72

21 21
34 74

21 21
36 76

21 21
2122

2160

2012

2031
38 21 21 78
40 40
20101 20020 END END
 21161 35
21141 21161 21 35 21141

200
21
35 14 16 35 38 +24VDC 0VDC 38

DG
A0862 OP5060

OF
APR 2017
00 40

CHECKED BY
BLU/WHT_16AWG

DRAWN BY

SHEET NO
BLU/WHT_16AWG
35 65 46021 40301 65 35

35
JOB NO
FROM MAIN PANEL

BLUE_16AWG
36

DATE
02 36 42

BLUE_16AWG
CBL6536 1 CBL6536 2
35 AWP 1002003 AWP 1002003 35

DC DISTRIBUTION
1
04 IFM E11508 44

DWG NO A0862OP5060-035

DT ASSEMBLY LINE MID/PREMIUM

IFM E11504
35 35

2
06 35081 40301 46
CB3508

DWG DESCRIPTION

SCREWING STATION
35 SIEMENS 35081 51 TO SAFETY POWER 51 35
5SJ4 101-7HG41 00 00
1A
08 48

OP5060
35 35
10 50

BY
35 35

REVISION
12 52

JOB DESCRIPTION
E1
CB3514 35141 21161 E1
TO DIGITAL OUTPUTS
35 21141
SIEMENS 35141 103 103 21161 35
5SJ4 104-7HG41 00 00
TB2 4A TB2
14 54

DATE
35 35
16 56

35 35
18 58
E1
CB3520 35201 21161 E1

35 21141
SIEMENS 35201 102 TO DIGITAL INPUTS 102 21161 35
5SJ4 103-7HG41 00 00
20 TB2 3A TB2
60

35 104 104 104 104 104 35

01 11 21 31 41
22 62

35 35
24 64

35 35
26 66

35 35
28 68

35 35
30 70

35 35
32 72

35 35
34 74

35 35
36 76

35 35

21161
11541

11483

21141
35 35 36 36
38 78
40 40 00 00
21141 21161 21141 21161
 21161 21141 21161 36
21141 35 35 36

OF 200
78 38 38
36 78 36

DG
A0862 OP5060

APR 2017
00 40

CHECKED BY
BLU/WHT_16AWG

DRAWN BY

SHEET NO
BLU/WHT_16AWG
36 36

36
JOB NO
BLUE_16AWG

DATE
02 RITTAL 1555.500 42

BLUE_16AWG
E1 E1
CB3604
36 21141
HMI3604 21161 36
1A CBL3604 1
L+ M
SIEMENS CBL3604 2
AWP 1002007 KTP700PN AWP 1002007
TB2 SIEMENS TB2
04 5SJ4 101-7HG41 44

DWG NO A0862OP5060-036
GND

DC DEVICES

DT ASSEMBLY LINE MID/PREMIUM

36 36
TO ETHERNET SWITCH
06 46
E1

DWG DESCRIPTION

SCREWING STATION
ENET3608
36 36041 SIEMENS 21161 36
L+ M
08 6GK5008-0BA00-1AB2 TB2
48
NETWORK

OP5060
36 36
10 50

BY
36 36

REVISION
12 52

JOB DESCRIPTION
36 36
14 54

DATE
36 36
16 56

36 36
18 58

36 36
20 60

36 36
22 62
E1 E1
CB3624 DV3624
36 21141 1 2 SMC 21161 36
1A L+ M
24 TB2 SIEMENS IZF10-P-ZB TB2
64
5SJ4 101-7HG41 IONIZER 3

36 I00.5 36
26 4 102 66
24 IONIZER OK
36 36
28 68

36 36
30 70

36 36
32 72

36 36
34 74

36 36
36 76

36 36

21161
21141

21161

21141
36 36 37 37 21161
38 21141 21161 78 21141
40 40 00 00
 21161 21141 21161 37
21141 36 37

200
36
78 38 38
37 78 37

DG
A0862 OP5060

OF
APR 2017
00 40

BY
BLU/WHT_16AWG

DRAWN BY

SHEET NO
BLU/WHT_16AWG

CHECKED
37 37

37
JOB NO
BLUE_16AWG

DATE
02 42

BLUE_16AWG

SAFETY POWER DISTRIBUTION

37 37
04 44

DWG NO A0862OP5060-037

DT ASSEMBLY LINE MID/PREMIUM

37 37
06 46

DWG DESCRIPTION

SCREWING STATION
37 37
08 48

OP5060
E1 E1
CB3710
VB22000
37 21141 37101 BLU SMC CBL3710 BLK 21161 37
1A 1 3

10 TB2 SIEMENS EX260-SEN1 IFM EVC072

TB2
50
51

BY
5SJ4 101-7HG41 BRN
2 4
WHT 50
37 26 51261 40301 12
37

REVISION
12 52

JOB DESCRIPTION
37 37
14 54

DATE
37 37
16 56

37 37
18 58

37 37
20 60

37 37
22 62

37 37
24 64

37 37
26 66

37 37
28 68

37 37
30 70

37 37
32 72

37 37
34 74

37 37
36 76

37 37
21141

21161

2012

2031
38 37 21141 37 21161 78
40 40
END END
 200
50 # MANUFAC. PART# DESC.

DG
A0862 OP5060

OF
1 WEIDMULLER 1200000000 6 PIN MALE

APR 2017
00 1900900000 BASE W M32

CHECKED BY
2 WEIDMULLER
FITTING

DRAWN BY

SHEET NO
50 3 WEIDMULLER 1200200000 6 PIN FEMALE

50
JOB NO
4 WEIDMULLER 1787470000 HOOD W M32

DATE
02
5 LAPP S1521 M32 FITTING
RITTAL 8017.667
50
04

ESTOP SAFETY
LOCATED ON UPPER

DWG NO A0862OP5060-050
EMERGENCY STOP

DT ASSEMBLY LINE MID/PREMIUM

MACHINE FRAME
50 51321 51323
CON5132A CON5132A
06
PB5006
51321 51323
51 CON5132A 1 OP5060 1 OP5060 3 CON5132A 3 51

DWG DESCRIPTION

SCREWING STATION
AWP 1001807 1 AWP AWP 3 3 AWP 1001807
50 32 1
1001807
SCHNEIDER
1001807
32 TO A0862 ELEVATOR#1
TO A0862 ELEVATOR#1 XB4-BS84441
MAIN PANEL PAGE 50 MAIN PANEL PAGE 51
08
(CONVEYOR ESTOP CHAIN) 51361 51363 (CONVEYOR ESTOP CHAIN)

OP5060
50 51 CON5132A 2 OP5060 2 51361 51363 OP5060 4 CON5132A 4 51
AWP 1001807 2 2 AWP 1001807 AWP 1001807 4 4 AWP 1001807
10 36 36

BY
50 66223 E1 66223 40301 E1 40301
TO A0862 ELEVATOR#1 TO A0862 ELEVATOR#1

REVISION
12 MAIN PANEL PAGE 66 66 CBL6626 1 CBL5012 1 66223
51 37 40301 CBL5012 2 CBL6626 2 66 MAIN PANEL PAGE 66

JOB DESCRIPTION
AWP 1001603
(CONVEYOR ESTOP RELAY) 26
AWP 1001603 5 5 TB2 25 11 TB2
AWP 1001603 6 6 AWP 1001603
26 (CONVEYOR ESTOP RELAY)
50
14

DATE
5
3 1 5
50 4
2
16

50
18
I00.1
50 35201 102 35201 I00.1
35201 CBL5018 1 CBL5018 2 I00.1 102
20 16 AWP 1002007 AWP 1002007 16

50
22 POWER ON
50
PBLT5022 I00.2
35201 102 35201 35201 I00.2 I00.2
24 CBL5018 3 102
18 SCHNEIDER
AWP 1002007 18
50 XB4-BW31B5
26

50
28 PBLT5022
21161
50 Q01.0 103 Q01.0 Q01.0 21161 21161 103
30 34
CBL5018
AWP
5
1002007 W CBL5018
AWP
6
1002007 34

50
32

50
34 FAULT RESET
SS5034
50 I00.3
35201 102 35201 35201 I00.3 I00.3
36 CBL5018 4 102
20 XO SCHNEIDER AWP 1002007 20
50 XB4-BG61
38
 35081 40301

OF 200
35 35
51 08E1 04

DG
A0862 OP5060

APR 2017
00 35081

BY
BLUE_18AWG

BLU/WHT_18AWG

DRAWN BY

SHEET NO
TB2 SR5100

CHECKED
51

51
JOB NO
BANNER

DATE
02

ANTI TIE DOWN SAFETY RELAY

E1
AT FM 10K E1

51 35081 35201 21161 40301

TB2 TB2
04 A1 A2

DWG NO A0862OP5060-051

DT ASSEMBLY LINE MID/PREMIUM

51
06

DWG DESCRIPTION

SCREWING STATION
51 Y1
08

OP5060
51
10 Y2

BY
PB5114A PB5114B
51 LH OPERATOR SWIPE RH OPERATOR SWIPE

REVISION
12 BANNER BANNER

JOB DESCRIPTION
E1
STBVR81Q6 STBVR81Q6
51 35081 CBL5114A BRN 35081 51141 CBL5114A WHT CBL5114B WHT 51143 35081 CBL5114B BRN
IFM EVC072
1 2 IFM EVC072 IFM EVC072
2 1 IFM EVC072
TB2
14

DATE
VDC NC S12 S22 NC VDC
51
16 51181 CBL5114A GRY CBL5114B GRY 51183
5 IFM EVC072 IFM EVC072
5
51 RLY CMN S11 S21 RLY CMN
18
E1

51 CBL5114A BLU 40301 CBL5114A BLK CBL5114B BLK 51203 40301 CBL5114B BLU 40301
IFM EVC072
3 4 IFM EVC072 IFM EVC072
4 3 IFM EVC072 TB2
20 COM S13 S23
NO NO COM
I00.6 I00.7
51
102 102
22 26 28
51
K1 K2 51261 VALVEBANK
24 66223 50 66223 51261 37 SAFE POWER
12 12
51 13 14
26
I00.0 ANTI TIE
51 35201 102 35201 I00.0 DOWN SAFETY
102
28 14 14 RELAY OK
23 24
51
30

51
32

51 E1

34 40301

TB2
51
36

51
38
 200
DG
A0862 OP5060

OF
APR 2017
CHECKED BY
60

DRAWN BY

SHEET NO

60
00

JOB NO

DATE
60
02

NETWORK LAYOUT
DWG NO A0862OP5060-060
60

DT ASSEMBLY LINE MID/PREMIUM

04

DWG DESCRIPTION
60

SCREWING STATION
06

OP5060
60
08

BY
60
10

REVISION

JOB DESCRIPTION
60
12
VB 220000

DATE
60
MURR 7000-74711-7780100 MURR 7000-74711-7780500
14 RECPT2010

MURR 7000-74711-7780100 MURR 7000-44711-7960300

60
16
MURR 7000-74711-7780300

60
18

60
20

60
22

60
DATAMAN 8600
24 2060SCN BRN 51261
1
SV 24V
WHT 40301
60 2
SV 0V
CBL3710
26 IFM EVC072 BLU 37101
3
SI 24V
BLK 21161
60 4
SI 0V
28

60 DM8000-ECABLEC-05
30
FROM ELEVATOR#2 ETHERNET SWITCH

60
32

60
34

60
36
 200
DG
A0862 OP5060

OF
APR 2017
CHECKED BY
70

DRAWN BY

SHEET NO

70
00

JOB NO

DATE
70

RDB-3020 SCREWFEEDER
02
SCREWFEEDER#1 ENABLE

DWG NO A0862OP5060-070
70

DT ASSEMBLY LINE MID/PREMIUM

RDB-3020
04
CR10636 70063
CBL7006 1

DWG DESCRIPTION
70

SCREWING STATION
AWP 1002003 1 SCREWFEEDER #1
1
06 10636 RDB-3020
CON7006

OP5060
PART#N250M16P3FA
70
CBL7006 2 70061
08
AWP 1002003 2 2

BY
70
10

REVISION

JOB DESCRIPTION
3 3
70
12

DATE
70
14

70
16

70
18

70
20

70
22

70
24

70
26

70
28

70
30

70
32

70
34

70
36
36
80
34
80
32
80
30
80
28
80
26
80
24
80
22
80
20
80
18
80
16
80
14
80
12
80
10
80
08
80
06
80
04
80
02
80
00
80

1 1
CBL8028A 1 80341
GRN LED +24VDC
AWP 1002012

80342 2 2
CBL8028A 2
RED LED GND
AWP 1002012

3 3
CBL8028A 3 80343 CBL8010A 3 I02.0
YEL LED ERROR

42
AWP 1002012 AWP 1002012

103

I02.0
4 I02.1 4
CBL8028A 4 I03.0 CBL8010A 4
SEQ END MTR ON

62
44
AWP 1002012 AWP 1002012

103
103

I03.0
I02.1
I03.1 5 I02.2 5
CBL8028A 5 CBL8010A 5
NOK T&A SCRW OK

64
46
AWP 1002012 AWP 1002012

103
103

I03.1
I02.2
T&A INPUT
CN1

6 CR10604 6
CBL8028A 6 I03.2 CBL8010A 6 80163
PRG END T&A INPT
11 14

66
AWP 1002012 AWP 1002012

CN3

103
10604

I03.2
STOP MOTOR
7 CR10606 7
CBL8028A 7 I03.3 CBL8010A 7 80164
MTR ON 11 STOP MTR
14

68
AWP 1002012 AWP 1002012

103
E1

10606

I03.3
TB2
80170

REVERSE
8 CR10608 8
CBL8028A 8 I03.4 CBL8010A 8 80165
STP MTR EN REV
11 14

72
AWP 1002012 AWP 1002012

103
E1

10608

I03.4
TB2
80170

START
9 CR10610 9
CBL8028A 9 80344 CBL8010A 9 80166
NC START
AWP 1002012 11 14 AWP 1002012
E1

10610
TB2
80170

80345 10 10
CBL8028A 10 CBL8010A 10 80170
NC GND
AWP 1002012 AWP 1002012

11
CBL8028A 12 80346
GND
AWP 1002012
2AE/TOP/TA

I02.4 1 1
CBL8028B 1 CBL8010B 1 80180
OUTPUT#1 STOP MTR

52
AWP 1002012 AWP 1002018

103

I02.4
I02.5 2 2
CBL8028B 2 CBL8010B 2 80181
OUTPUT#2 MISSING PC

54
AWP 1002012 AWP 1002018

103

I02.5
I02.6 3 3
CBL8028B 3 CBL8010B 3 80182
OUTPUT#3 OK EXT

56
AWP 1002012 AWP 1002018
103

I02.6 I02.7 4 4
CBL8028B 4 CBL8010B 4 80183
OUTPUT#4 ESC EXT
58

AWP 1002012 AWP 1002018

103

I02.7

RESET
(IO CONNECTIONS ON BACK OF UNIT)

5 CR10622 5
CBL8028B 5 80351 CBL8010B 5 80184
OUTPUT#5 RESET EXT
AWP 1002012 11 14 AWP 1002018
CN4

10622

6 6
CBL8028B 6 80352 CBL8010B 6 80185
OUTPUT#6 INPUT#8
KOLVER SCREWDRIVER#1 CONTROL UNIT EDU

AWP 1002012 AWP 1002018

7 7
CBL8028B 7 80353 CBL8010B 7 80186 INPUT#7
OUTPUT#7
AWP 1002012 AWP 1002018
CN2

8 8
CBL8028B 8 80354 CBL8010B 8 80187
OUTPUT#8 INPUT#6
AWP 1002012 AWP 1002018

9 9
CBL8028B 9 80355 CBL8010B 9 80188 INPUT#5
GND
AWP 1002012 AWP 1002018

PROGRAM#4 SELECT
CR10630 10
CBL8010B 10 80189 INPUT#4
11 14 AWP 1002018
E1

10630
TB2
80200

PROGRAM#3 SELECT
CR10628 11
CBL8010B 11 80190
INPUT#3
11 14 AWP 1002018
E1

10628
TB2
80200

PROGRAM#2 SELECT
CR10626 12
CBL8010B 12 80191 INPUT#2
11 14 AWP 1002018
E1

10626
TB2
80200

PROGRAM#1 SELECT
CR10624 13
CBL8010B 13 80192 INPUT#1
11 14 AWP 1002018
E1

10624
TB2
80200

14
CBL8010B 14 80200 GND
AWP 1002018

DWG NO A0862OP5060-080 JOB NO

A0862 OP5060
DWG DESCRIPTION DATE
APR 2017
KOLVER SCREWDRIVER CHECKED BY
DATE REVISION BY
DRAWN BY
JOB DESCRIPTION
DG
DT ASSEMBLY LINE MID/PREMIUM

SCREWING STATION SHEET NO

OP5060 80 OF 200
 CPU1217C DC/DC/DC
6ES71217-1AG40-0XB0
6ES7221-1BH32-0XB0
16PT, DI

6ES7221-1BH32-0XB0
16PT, DI
PLC LAYOUT

6ES7221-1BH32-0XB0

6ES7222-1BH32-0XB0
16PT, DI 16PT, DQ

DWG NO A0862OP5060-100 JOB NO

A0862 OP5060
DWG DESCRIPTION DATE
APR 2017
PLC LAYOUT CHECKED BY
DATE REVISION BY
DRAWN BY
JOB DESCRIPTION
DG
DT ASSEMBLY LINE MID/PREMIUM

SCREWING STATION SHEET NO

OP5060 100 OF 200

 RACK R ,SLOT S
CPU 1217C CONT'D
RACK 1 ,SLOT 1
35201 21161 35201 21161

OF 200
CPU1217C 14DI/10DQ/1AO/1AI
35 SIEMENS#6ES71217-1AG40-0XB0
35 102 102
102 20 20 102 38 38

DG
A0862 OP5060

APR 2017
00 X10 40 X11

CHECKED BY
E1

DRAWN BY

SHEET NO
102 35201 1 102 1

102
35201

JOB NO
L+ 2M

DATE
TB2
02 42
E1

102 2
M
21161 102 2
2M
TB2
04 44

DWG NO A0862OP5060-102

DT ASSEMBLY LINE MID/PREMIUM

S7 1217C
102 3
PE
102 3
DI10.2+

06 46

DWG DESCRIPTION

SCREWING STATION
102 4
L+
102 4
DI10.2-
OUT
08 48

OP5060
102 5
M
102 5
DI10.3+
OUT
10 50

BY
102 6
IM
102 6
DI10.3-

REVISION
12 52

JOB DESCRIPTION
E1 I00.0 E1

102 35201
51 51 I00.0 7
DI0.0
ANTI TIE 102 7
DI10.4+
DOWN RELAY
14 TB2 27 27 TB3 OK 54

DATE
E1 E1

102 35201 CBL5018 I00.1 8 EMERGENCY 102 8

1 50 50 CBL5018 2
DI0.1 STOP PB DI10.4-

16 TB2 AWP 1002007 20 20 AWP 1002007 TB3 PRESSED

56
E1 E1
CONTROL
102 35201
50 50 CBL5018 3 I00.2 9
DI0.2 POWER ON
102 9
DI10.5+

18 TB2 24 24 AWP 1002007 TB3 PB PRESSED

58
E1 E1

102 35201
50 50 CBL5018 4 I00.3 10
DI0.3 FAULT RESET 102 10
DI10.5-
SS E1
20 TB2 36 36 AWP 1002007 TB3
60
21161
E1 E1
SMC MACHINE
102 35201
ISE40A-N01-T PRS10222 I00.4 11
DI0.4 AIR
102
TB2
TB2 TB3 PRESSURE
22 OK
62 X12
E1 E1

102 I00.5 36 I00.5 12 IZF10-P-ZB 102 1 21161

DI0.5 IONIZER 3M

24 26 TB3 OK
64 TB2
E1

102 I00.6 51 I00.6 13 102 2

DI0.6 LH SWIPE OK AQ0

26 22 TB3
66
E1

102 I00.7 51 I00.7 14 102 3

DI0.7 RH SWIPE OK AQ1
E1
22 TB3
28 21161
68
E1 CBL10230 BLU E1 E1
IFM EVC142 SCREW
102 35201 BRN PRS10230 BLK I01.0 15
DI1.0
102 4
4M
21161
PRESENT AT TB2
RDB-3020#1
TB2 TB3 FEEDER#1 TB2
30 FORK SENSOR 70
E1

102 I01.1 16
DI1.1
102 5
AI0
SPARE
TB3
32 72

102 TO ETHERNET SWITCH 102 6

AI1
X1
34 74

102 102
X2
36 76

102 102
21483
25101

35201

21161
38 102 35201 21161 102 78 103 35201 103 21161
40 40 40 40
 RACK 1 ,SLOT 2
RACK 1 ,SLOT 1 16 DI, PNP, 24VDC 21161 102
SIEMENS#6ES7221-1BH32-0XB0
35141 35 CPU 1217C CONT'D 21161 35 35201 102 78

OF 200
103 14 14 103 78 X10

DG
1

A0862 OP5060
PE E1

APR 2017
00 X13 40 3 21161

CHECKED BY
KOLVER CN1 E1
1M

DRAWN BY

SHEET NO
103 1 103 I02.0 4
TB3
35201 I02.0 KOLVER SCREW

103
80 CBL8010A 3

JOB NO
5M I02.0
GUN#1 ERROR
16 AWP 1002012

DATE
TB3
02 42
E1
I02.1
103 5M
2 103 80 CBL8010A 4 I02.1 5 KOLVER SCREW
I02.1 GUN#1
16 AWP 1002012 TB3
04 44

S7 1217C & 16DI

MOTOR ON

DWG NO A0862OP5060-103
E1

DT ASSEMBLY LINE MID/PREMIUM

I02.2 KOLVER
103 DQ0.0+
3 103 80 CBL8010A 5 I02.2 6
I02.2 SCREW GUN#1
16 AWP 1002012 TB3 SCREW OK
06 46
E1

DWG DESCRIPTION

SCREWING STATION
103 DQ0.0-
4 103 I02.3 7
SPARE
I02.3
TB3
08 48

OP5060
103 DQ0.1+
5 103 E1
X11
10 50 3

BY
21161
KOLVER CN4 E1
2M
103 6 103 I02.4 I02.4 4 KOLVER
TB3
DQ0.1- 80 CBL8028B 1 I02.4

REVISION
SCREW GUN#1
34 AWP 1002012 TB3
12 52 PROGRAM#1

JOB DESCRIPTION
E1

103 7 103 I02.5 I02.5 5 KOLVER SCREW

DQ0.2+ 80 CBL8028B 2
GUN#1
I02.5
34 AWP 1002012 TB3
14 54

DATE
PROGRAM#2
E1

103 8 103 I02.6 I02.6 6 KOLVER SCREW

DQ0.2- 80 CBL8028B 3
GUN#1
I02.6
34 AWP 1002012 TB3
16 56 PROGRAM#3
E1

103 9 103 I02.7 I02.7 7 KOLVER SCREW

DQ0.3+ 80 CBL8028B 4
I02.7 GUN#1
34 AWP 1002012 TB3
18 58 PROGRAM#4

103 DQ0.3-
10 103 E1
X12
20 60 3 21161
E1 E1
KOLVER CN3 3M
103 35141 11 103 I03.0 I03.0 4 KOLVER SCREW TB3
6L+ 80 CBL8028A 4 I03.0 GUN#1 SEQ.
22 TB2
62 34 AWP 1002012 TB3 END
E1

103 12 BANNER K30LGRYPQ 103 I03.1 I03.1 5 KOLVER

6M 80 CBL8028A 5
SCREW GUN#1
I03.1
24 PL10370 64 34 AWP 1002012 TB3 NOK T&A
E1 E1 E1
GRN I03.2 KOLVER SCREW
103 DQ0.4
13
Q00.4 Q00.4 CBL5018 BLK BLU 21161 GRN 103 80 CBL8028A 6 I03.2 6
I03.2 GUN#1 PRG
AWP 1002018 4 3 BEACON 34 AWP 1002012
TB3 TB2 TB3 END
26 66
E1 E1
RED I03.3
103 DQ0.5
14
Q00.5 Q00.5 BRN RED 103 80 CBL8028A 7 I03.3 7 KOLVER SCREW
1 BEACON I03.3 GUN#1 MOTOR
28 TB3
68 34 AWP 1002012 TB3 ON
E1
YEL
103 DQ0.6
15
Q00.6 Q00.6 WHT AMBER BEACON 103 E1
2
TB3 X13
30 70 3 21161
E1 E1 E1
4M
I03.4 KOLVER SCREW TB3
103 DQ0.7
16
Q00.7 Q00.7 CBL3604 3 AH10332 SCHNEIDER 4 21161 AUDIBLE ALARM 103 80 CBL8028A 8 I03.4 4
GUN#1 STOP
I03.4
TB3 AWP 1002007 XB5KSB TB2 34 AWP 1002012 TB3
MOTOR ENABLED
32 72
E1 Q01.0 21161 E1 E1

103 DQ1.0
15
Q01.0 Q01.0 CBL5018 5 50 50 CBL5018 6 21161 103 I03.5 5
CONTROL POWER I03.5 SPARE E1
34 TB3 AWP 1002007 30 30 AWP 1002007 TB2 ON PB LT
74 TB3
E1 E1 CBL10376 BLU E1 21161
IFM EVC003
103 DQ1.1
16
Q01.1 Q01.1 103 35201 BRN PRS10376 BLK I03.6 6
SCREW GUN#1
TB3
BALLUFF I03.6
TB3 E1 TB2 TB3 AT HOME
36 76 BES0068
E1
21161 21161
103 TB2
103 I03.7 7
SPARE
35141

21161

I03.7
38 106 35141 106 21161 78 TB3

21161
35201

00 00 104 104
35201
00 21161 00
 10435201
RACK 1 ,SLOT 3 RACK 1 ,SLOT 4
35201 103 16 DI, PNP, 24VDC 21161 103 16 DI, PNP, 24VDC 21161 104
SIEMENS#6ES7221-1BH32-0XB0 SIEMENS#6ES7221-1BH32-0XB0
78 78 38 38

OF 200
CBL10401 X10 X10
104 104 1

DG
1

A0862 OP5060
CBL10402 BRN WHT PE PE
IFM 1 1 IFM E12166

APR 2017
00 E18343 35201
3 40 35201
3

ABSOLUTE ROTARY ENCODER 'Y' AXIS

CHECKED BY
E1 35 E1 35 E1
22 1M CBL10442 22 1M

DRAWN BY

SHEET NO
'Y' AXIS
104 35201 I04.0 4 104 I06.0 4

104
BLK BRN 'X' AXIS GRY CBL10441 WHT ERGO ARM

JOB NO
I04.0 I06.0
2 2 ERGO ARM IFM 1 1 IFM E12166 BIT '6'

DATE
TB3 TB3 TB3
02 BIT '0' 42 E18343
E1 E1
'Y' AXIS
104 RED GRN I04.1 5 'X' AXIS 104 WHT BRN I06.1 5
ERGO ARM
I04.1 ERGO ARM I06.1
3 3 TB3 2 2 TB3 BIT '7'
04 44

S7 1217C & 16DI

BIT '1'
E1

DWG NO A0862OP5060-104
E1

DT ASSEMBLY LINE MID/PREMIUM

104 ORG YEL I04.2 6 'X' AXIS 104 BLK/WHT GRN I06.2 6 'Y' AXIS
DECIMAL I04.2 ERGO ARM I06.2 ERGO ARM
BINARY GRAY 4 4 3 3

Use Gray Code Card with a PLC or convert Gray Code to binary numbers
NUMBER TB3 BIT '2' TB3 BIT '8'
06 S
CODE CODE 46
E1 E1

DWG DESCRIPTION
0 0000 0000

SCREWING STATION
104 I04.3 7 104 I06.3 7 'Y' AXIS
1 0001 0001 YEL GRY 'X' AXIS RED/WHT YEL
I04.3 I06.3 ERGO ARM
5 5 TB3 ERGO ARM E1 4 4 TB3 BIT '9'
08 2 0010 0011 48

ABSOLUTE ROTARY ENCODER 'X' AXIS

BIT '3'

OP5060
3 0011 0010 BLU PNK 21161
104 4 0100 0110 6 6 TB3 104 E1
5 0101 0111 X11 X11
10 3 50 3

BY
21161
6 0110 0101
35 E1 35201 E1
22 2M 2M
SPARE TB3
104 7 0111 0100
GRN BLU I04.4 4
I04.4
'X' AXIS 104 I06.4 4
I06.4

REVISION
ERGO ARM
8 1000 1100 7 7 TB3 TB3
12 BIT '4' 52

JOB DESCRIPTION
9 1001 1101 E1 E1
10 1010 1111
104 PUR RED I04.5 5 'X' AXIS 104 I06.5 5 SPARE
11 1011 1110 I04.5 ERGO ARM I06.5
8 8 TB3 TB3
14 BIT '5' 54

DATE
12 1100 1010 E1 E1
CBL10416 CBL10415
13 1101 1011
104 GRY WHT I04.6 6 'X' AXIS 104 I06.6 6 SPARE
14 1110 1001 I04.6 ERGO ARM I06.6
IFM 1 1 IFM E12166 TB3 TB3
16 15 1111 1000 E18343
BIT '6' 56
E1 E1

104 WHT BRN I04.7 7 'X' AXIS 104 I06.7 7 SPARE

I04.7 ERGO ARM I06.7
2 2 TB3 TB3
18 BIT '7' 58

104 104 E1
X12 X12
20 3 60 3 21161
35 E1 35201 E1
22 3M 3M
TB3
104 BLK/WHT GRN I05.0 4 'X' AXIS 104 I07.0 4
I07.0 SPARE
I05.0 ERGO ARM
3 3 TB3 BIT '8' TB3
22 62
E1 E1

104 RED/WHT YEL I05.1 5 'X' AXIS 104 I07.1 5

SPARE
I05.1 ERGO ARM I07.1
4 4 TB3 TB3
24 BIT '9' 64
E1 E1 E1
CON10426 CBL10426
35201
104 CBL10426 BRN CBL10425 1 BLK CBL10425 BRN I05.2 6 'Y' AXIS 104 I07.2 6
I05.2 ERGO ARM I07.2 SPARE
TB3 1 1 IFM 2 2 IFM E12166 TB3 TB3
26 BIT '0' 66
E18343
E1 E1

104 RED GRN I05.3 7 'Y' AXIS 104 I07.3 7

I07.3 SPARE
Use Gray Code Card with a PLC or convert Gray Code to binary numbers

I05.3 ERGO ARM

3 3 TB3 TB3
28 BIT '1' 68

104 104 E1
ABSOLUTE ROTARY ENCODER 'Y' AXIS

X13 X13
30 3 70 3 21161
35 E1 35201 E1
22 4M 4M
'Y' AXIS TB3
104 ORG YEL I05.4 4
I05.4 ERGO ARM 104 I07.4 4
I07.4 SPARE
4 4 BIT '2' TB3
TB3
32 72
E1 E1
'Y' AXIS
104 YEL GRY I05.5 5
ERGO ARM
104 I07.5 5
I05.5 E1 I07.5 SPARE
5 5 TB3 BIT '3' TB3
34 21161 74
BLU PNK E1 E1
6 6 TB3
104 GRN BLU I05.6 6 'Y' AXIS 104 I07.6 6
I05.6 ERGO ARM I07.6 SPARE
7 7 TB3 BIT '4' TB3
36 76
E1 E1

104 PUR RED I05.7 7 'Y' AXIS 104 I07.7 7

ERGO ARM SPARE
35201

21161

I05.7 I07.7
8 8
38 104 TB3 BIT '5' 104 78 TB3

40 40
35201 21161
35141 103 RACK 1 ,SLOT 5 21161 103 35141 106 21161 106
16 DQ, PNP, 24VDC
38E1 SIEMENS#6ES7222-1BH32-0XB0 38 38 38

200
X10
106 106

DG
35141 1

A0862 OP5060
L+

OF
TB3

APR 2017
00 40

CHECKED BY
E1

DRAWN BY

SHEET NO
106 2 21161 106

106
JOB NO
M

DATE
TB2
02 42
E1 E1
CR10604 KOLVER SCREWDRIVER#1
106 Q02.0
4
Q02.0 Q02.0 SIEMENS
21161 T&A INPUT 106
3RQ3118-1AM00 NO 8014
TB3 TB2

S7 1217C & 16DQ

04 NC 44

DWG NO A0862OP5060-106
E1 E1
CR10606

DT ASSEMBLY LINE MID/PREMIUM

KOLVER SCREWDRIVER#1
106 5
Q02.1 Q02.1 SIEMENS
21161 STOP MOTOR 106
Q02.1 3RQ3118-1AM00 NO 8014
TB3 TB2
06 NC 46
E1 E1

DWG DESCRIPTION
CR10608 KOLVER SCREWDRIVER#1

SCREWING STATION
106 6
Q02.2 Q02.2 SIEMENS
21161 REVERSE 106
Q02.2 3RQ3118-1AM00 NO 8014
TB3 TB2
08 NC 48

OP5060
E1 E1
CR10610 KOLVER SCREWDRIVER#1
106 7
Q02.3 Q02.3 SIEMENS
21161 START 106
Q02.3 3RQ3118-1AM00 NO 8014
TB3 TB2
10 NC 50

BY
X11
106 PE
1 106

REVISION
BANNER
12 TL50GYRAQ 52

JOB DESCRIPTION
E1
GREEN
106 Q02.4
4
Q02.4 Q02.4CBL10614 BLK BLU GREEN BEACON 106
IFM EVC072
TB3
14 54

DATE
E1
AMBER
106 5
Q02.5 Q02.5 BRN AMBER BEACON 106
Q02.5
TB3
16 56
E1
RED
106 6
Q02.6 Q02.6 WHT RED BEACON 106
Q02.6
TB3
18 58
E1

106 7
Q02.7 Q02.7 GRY AUDIBLE ALARM 106
Q02.7
TB3
20 60
E1 E1
CR10622 KOLVER SCREWDRIVER#1
X12
106 Q03.0
4
Q03.0 Q03.0 SIEMENS
21161 RESET 106
3RQ3118-1AM00 NO 8014
TB3 TB2
22 NC 62
E1 E1
CR10624 KOLVER SCREWDRIVER#1
106 5
Q03.1 Q03.1 SIEMENS
21161 PROGRAM#1 SELECT 106
Q03.1 3RQ3118-1AM00 NO 8014
TB3 TB2
24 NC 64
E1 E1
CR10626 KOLVER SCREWDRIVER#1
106 6
Q03.2 Q03.2 SIEMENS
21161 PROGRAM#2 SELECT 106
Q03.2 3RQ3118-1AM00 NO 8014
TB3 TB2
26 NC 66
E1 E1
CR10628 KOLVER SCREWDRIVER#1
106 7
Q03.3 Q03.3 SIEMENS
21161 PROGRAM#3 SELECT 106
Q03.3 3RQ3118-1AM00 NO 8014
TB3 TB2
28 NC 68
E1 E1
CR10630 KOLVER SCREWDRIVER#1
X13
106 Q03.4
4
Q03.4 Q03.4 SIEMENS
21161 PROGRAM#4 SELECT 106
3RQ3118-1AM00 NO 8014
TB3 TB2
30 NC 70
E1

106 5
Q03.5 Q03.5 SPARE 106
Q03.5
TB3
32 72
E1 E1
CR10634 OPERATOR LIGHT
106 6
Q03.6 Q03.6
SIEMENS
21161 ENABLE 106
Q03.6 3RQ3118-1AM00 NO 2016
TB3 TB2
34 NC 74
E1 E1
CR10636 RDB-3020
106 7
Q03.7 Q03.7 SIEMENS
21161 SCREWFEEDER#1 ENABLE 106
Q03.7 3RQ3118-1AM00 NO 7006
TB3 TB2
36 NC 76

106 106
35261

21161

38 106 106 78
40 40
35141 21161
 355.00"
12A

CB2020
5A 10A

CB2042
CB2104
5A 10A

CB2114
4A

CB3514
3A

CB3520
1A

CB3604
1A

CB3624
1A

CB3710

CR10604

549.00"
CR10606
CR10608
CR10610
CR10622
CR10624
CR10626
CR10628
CR10630
CR10636
AE 1039.500

SR5100
BANNER

ATFM10K
600 X 380 X 210

DWG NO A0862OP5060-180 JOB NO

A0862 OP5060
DWG DESCRIPTION DATE
APR 2017
BACKPLATE LAYOUT CHECKED BY
DATE REVISION BY
DRAWN BY
JOB DESCRIPTION
DG
DT ASSEMBLY LINE MID/PREMIUM

SCREWING STATION SHEET NO

OP5060 180 OF 200

 200
RITTAL

DG
A0862 OP5060
8017667

OF
APR 2017
CHECKED BY

DRAWN BY

SHEET NO

182
JOB NO

DATE

PUSHBUTTON BOX
DWG NO A0862OP5060-182

DT ASSEMBLY LINE MID/PREMIUM

STACK LIGHT

DWG DESCRIPTION

SCREWING STATION
Q00.4 21161
G
BANNER 12 15

OP5060
K30LGRYPQ Q00.5 21161
R 15
13

BY
Q00.6 21161
A 15
14

REVISION

JOB DESCRIPTION
SS5034
FAULT RESET
FAULT
SS5034

DATE
RESET

35201 I00.3
**CBL5018 FROM STATION OP5060
CBL5018-4
MAIN PANEL TO PUSHBUTTON BOX
CBL PART# 1002018
CONTROL
PBLT5022 POWER ON
PBLT5022
POWER
ON Q01.0 21161
WH CBL5018-6
CBL5018-5

WH
35201 I00.2

CBL5018-3

PB5006
EMERGENCY STOP
EMERGENCY
STOP PB5006

50081 51061
CBL5132A-1 CBL5132A-3 **CBL5132A FROM ELEVATOR#1 MAIN PANEL
TO PUSHBUTTON BOX
50101 51101
CBL5132A-2 CBL5132A-4 CBL PART# 1001807
35201 I00.1
CBL5018-1 CBL5018-2
 SIEMENS
KTP700PN
CBL3604 FROM MAIN PANEL

RITTAL 1555.500
AH10332
TO HMI JBOX CBL PART# 1002007AWP

1
3

36041
Q00.7

HMI3604
AH10332

HMI POWER

2
4

GND
AUDIBLE ALARM

21161
21161

DWG NO A0862OP5060-187 JOB NO

A0862 OP5060
DWG DESCRIPTION DATE
APR 2017
HMI ENCLOSURE CHECKED BY
DATE REVISION BY
DRAWN BY
JOB DESCRIPTION
DG
DT ASSEMBLY LINE MID/PREMIUM

SCREWING STATION SHEET NO

OP5060 187 OF 200

 OF 200
DG
A0862 OP5060

APR 2017
CHECKED BY

DRAWN BY

SHEET NO

189
JOB NO

DATE

TERMINAL ROTATION
DWG NO A0862OP5060-189

DT ASSEMBLY LINE MID/PREMIUM

DWG DESCRIPTION

SCREWING STATION

OP5060
BY
REVISION

JOB DESCRIPTION
STRIP-ID WIRENO TB2 21161 TB2 35201
TB1 65343 TB2 21161 TB2 35201

DATE
TB1 40301 TB2 21161 TB2 35021
TB2 21161 TB2 21161 TB2 35141
TB2 21161 TB2 21161 TB2 80170
TB2 21161 TB2 21161 TB2 80170
TB2 21161 TB2 21161 TB2 80200
TB2 21161 TB2 21161 TB2 80200
TB2 21161 TB2 21161
TB2 21161 TB2 21161
TB2 21161 TB2 21161
TB2 21161 TB2 21161
TB2 21161 TB2 21161
 DWG NO A0862OP5060-190 JOB NO
A0862 OP5060
DWG DESCRIPTION DATE
APR 2017
BOM CHECKED BY
DATE REVISION BY
DRAWN BY
JOB DESCRIPTION
DG
DT ASSEMBLY LINE MID/PREMIUM

SCREWING STATION SHEET NO

OP5060 190 OF 200

 DWG NO A0862OP5060-191 JOB NO
A0862 OP5060
DWG DESCRIPTION DATE
APR 2017
BOM CHECKED BY
DATE REVISION BY
DRAWN BY
JOB DESCRIPTION
DG
DT ASSEMBLY LINE MID/PREMIUM

SCREWING STATION SHEET NO

OP5060 191 OF 200

 DWG NO A0862OP5060-192 JOB NO
A0862 OP5060
DWG DESCRIPTION DATE
APR 2017
BOM CHECKED BY
DATE REVISION BY
DRAWN BY
JOB DESCRIPTION
DG
DT ASSEMBLY LINE MID/PREMIUM

SCREWING STATION SHEET NO

OP5060 192 OF 200