Drawing Packages

Module 2

Drawing Packages

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 Drawing Packages

Module Description
• This module covers Controls Drawing packages,
naming conventions and their relationship between
the physical component, the drawing package, and
ladder logic.
• It has a hands-on exercise to familiarize the students
with the training simulator.

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Module Objectives
• At the completion of this module, the participant will be able to:
– Describe the relationship between print naming conventions, equipment
naming convention, and logic naming conventions.
– Identify the categories of drawing packages and find the correct drawing
package for an identified station or cell.
– Identify the structure of the controls drawings
– Introduce controls drawing packages and GCCL item numbers.
– Locate and identify simulator components and correlate them to its
drawing package.
– Describe the purpose of the GRS-1 and GRS-4 robot standards.
– State the robot applications that require their own drawing package and
the number of processes that can be controlled from a single robot.
– Distinguish between IEC symbols and NFPA symbols.

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Module Performance Task List

MPTL
Task Description
Number
2 Identify the correct drawing package for a station or cell.
3 Identify types of drawing packages.
4 Locate and identify training simulator components.
5 Locate components on a supplied robot drawing package.
6 Select the correct IEC symbols given the NFPA symbols.

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CORPORATE STANDARDS
• New equipment will comply with the current version of
the controls architecture.
• Existing equipment is often upgraded to the current
version of controls architecture.
• CCRW group has produced corporate standards
which specify the components, installation practices,
and software related to new installations.

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HISTORY
• Committee was formed in 1997
• 1999 - Common Controls Hardware Design standard
(CCH-1)
• Common Controls Software for ControlLogix standard
(CCS-2) was also developed at about the same time.
• The committee consisted of:
– Truck Group Controls
– Small Car Group Controls
– Mid-Size Car Group Controls
– Large Size Car Group Controls
– MFD Assembly

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HISTORY
• The previous standards have evolved into a global
standard that will be followed at all GM facilities
around the world.
– Global Common Controls Hardware Design Standard
(GCCH-1)
– Global Common Controls Software Design Standard
(GCCS-1)

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Purpose
• The purpose of GCCH-1 is to provide a standard that
applies to the control system hardware designs for
GM’s Controls, Conveyors, Robotics, and Welding
(CCRW) group.
– Lean
– Flexible
– Cost effective
– Enhance productivity of the systems
– Enhance quality of the products produced

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Purpose
• The purpose of GCCS-1 is to provide a standard that
applies to the control system software designs for
CCRW.
– Reduced design and installation times
– Provides a set of PLC software routines that are
• Effective
• Robust
• Flexible

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GCCH-1 and GCCS-1 Benefits

• Assures safe operation of industrial equipment
• Increases productivity of systems
• Introduces common systems to all areas
• Reduces tool costs
• Leverages engineering resources
• Provides flexible designs to accommodate changes

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Other Technical Documents

• In addition to GCCH-1 and GCCS-1, GM has adopted
these technical documents:
– Occupational Safety and Health Administration (OSHA)
Federal Regulations
– Global Design for Health and Safety (G-DHS) Standard
– ANSI, NFPA, and IEC Industry Consensus Standards
– NA-CCRW Common Safety Guidelines (CCSG-1)
– Global Statement of Requirements (SOR)
– Global Common Controls Build Standards (GCCB-1)

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Organization

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Location
• Copies of corporate standards (including GCCH-1 and
GCCS-1) are available to GM personnel via the corporate
intranet. Point your browser to the following URL to access
these standards, and then browse the libraries:
– http://supplier.body.gm.com/crw/production/main/globalStandards/glob
alStandards.cfm

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NFPA TO IEC SYMBOL CONVERSION

• The ’06 Global Controls Architecture electrical
symbols have changed from NFPA style (North
America) to IEC style (used in the rest of the world).
• This change will help expand the design and build
process to become globally common within General
Motors.
• ECS-4000 shows the more commonly used symbols
within the hardware design packages. Both styles of
symbols are shown for reference.

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Interconnect Devices

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Pushbuttons, Lights & Switches

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Pushbuttons, Lights & Switches

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Circuit Protection

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Receptacle Pins

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Coils and Contacts

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Misc. Output Devices

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Side-By-Side Comparison

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CONTROL DRAWINGS
• Wiring diagram packages comply with the naming
conventions indicated in GCCH-1.
• Paint controls reference another GM document: GM
#34340 Electrical Controls General Requirements for
Drawing Naming Conventions.
• Drawing package categories:
– System/zone level
– Cell level
– Station/tool level.

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Drawing Package Categories

Zone (System) Level Dwg Pkg
Process
Flow

Cell 10
Cell 70
Cell 50
Sta Sta Sta
10 20 80
Sta Sta Sta
Sta
50 60 90
Sta Sta 70
30 40

Cell Level Dwg Pkg Station Level Dwg Pkg

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Zone / System Level

Zone / System Level

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Zone / System Examples

• Mechanical layout number = 9SL-12345
• System level wiring diagram = WD-9SL-12345

• Process Zone = BA_B01,

using plant = Fairfax, model year = 2004
• Zone level wiring diagram = WD-FA04BA_B01

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Cell Level
• The cell level is the middle level drawing package.
• The cell level shows the main control panel, cell layout
and its interconnections to the system and tools.
• The cell level contains:
– Cell power distribution
– Cabling and interconnection within the cell
– Processor and all associated network communications
• Cells are named with the same number as the first
process station controlled by the cell. The station
number comes from the mechanical drawing package.

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Simplified Cell Level Naming Example

CELL #10 CELL #30 CELL #50

STA #10 STA #20 STA #30 STA #40 STA #50 STA #60

STA
#15

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Complex Cell Level Naming Example

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Station Naming Examples

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Cell Level

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Station / Tool Level

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Tool Naming Example

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DRAWING PACKAGE COMPONENTS

• EC: Electrical Cabinet — Design of an electrical
enclosure
• ECS: Electrical Cabinet Standard — Standard
enclosure design intended to be frequently used.
Examples include:
– ECS 4011
– ECS 4026
– ECS 4050

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DRAWING PACKAGE COMPONENTS

• WD: Wiring Diagram — Electrical schematics and
layouts. Examples are:
– WD-FA05AB030_B01
– WD-MAA12345L
• WDS: Wiring Diagram Standard — Standard designs
intended to be frequently used. An example would be:
– WDS-G06-CARRY_SPOT_SGMDTD
• WDT: Wiring Diagram Template — The starting point
for designs where the majority of the documentation
has already been completed. An example would be:
– WDT-G06-BODY1CELL_MAIN
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DRAWING PACKAGE COMPONENTS

• GM-CCRW has established EPLAN electric P8 as its standard
for Computer Aided Engineering (CAE) of Control System
Designs.
• Every drawing package
Drawing package
is divided into lettered
sections that correspond
to specific functions. A 1 of 2

• Every lettered section is B 1 of 3

not necessarily part of every C 1 of 1

package. Only the sections

pertaining to a specific Z 1 of

application shall be included

in that drawing package.
However, Section A is always required.

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 Drawing Packages

DRAWING PACKAGE COMPONENTS

• A drawing package has several general items that
help the user.
– The title block provides useful information about the drawing
package
– The drawing status field allows the user to quickly identify
the state of the drawings and equipment in the design
process
– Date Stamp and File Name provide tracking information

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Title Block
LEFT-SIDE RIGHT-SIDE
GM group Drawing package description
GM engineer Drawing sheet description
Design source System/tool number
Design leader Release date
Programs Drawing number
Last Part Selected With: GCCL_x Revision letter and date
(Sheet A1 only)
Section letter
Sheet number
Reference used (Sheet A1 only)
Engineering manager (Sheet A1
only)
Drawing package revision level
(Sheet A1 only)

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Title Block

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Drawing Status
STATUS DESCRIPTION
PRELIMINARY Used when the design is in the preliminary stage
QUOTE Used when the design is submitted for quote
FOR APPROVAL Used when the supplier submits drawings for approval by
CCRW
RELEASED Used when the design has been approved
BUILD Used when the tools are in the process of construction
AS BUILT Used when construction is completed

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Date Stamp and File Name

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Content

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Section A
• Reference
• Table of Contents
• Master Change Sheet(s)

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Cell Sheet A1 Reference Information

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Cell Level Reference Drawing Packages
and Title Sheet

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Station Level Reference Drawing Packages
and Title Sheet

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Drawing Overview
Table of Contents

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Master Change Sheet

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Section B
• Zone (System): The zone (system) typically shows
an overview of the entire zone on the first sheet.
Supplemental sheets can be used to provide a closer,
more detailed view of a portion of the zone.
• Cell: The cell layout is typically shown as a detailed
section layout in the zone (system) layout package
and may not be required. If required, the layout must
be prepared as follows:
• Station (Tool): This diagram provides plant
maintenance personnel with a general location for all
switches and cylinders on the tool.
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System Layout

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Cell Layout

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Tool Layout

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Section C: Interconnections

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Zone EtherNet Connection

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Cell Bus Plug Drop

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Cell AC Voltage Distribution

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Cell DC Voltage Distribution

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Cell DeviceNet Interconnect

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Cell EtherNet Interconnect

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Tool DeviceNet Interconnect

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EC Panel & Cable Device ID

ALIAS EC PANEL TYPE ALIAS EC PANEL TYPE
Material Handling (AMS,
A MWS Maintenance Work Station
SKID) Panel
B Spare for user N Do Not Use
C Cell Main Panel O Do Not Use
D Display Panel Remote HMI P Power Distribution Panel
Operator Run Stand and
E other Equipment Control Q Do Not Use
Panels
Fixture Box, Valve Control
F Panel, DeviceNet Refresh R Robot Control Panel
Panel
G Entrance Gate Control Panel S Station to Station Interlocks
H Hydraulic Control Box TT Turntable
I Do Not Use U Do Not Use
Valve Manifold (DeviceNet)
J Junction Box V
Stack
K Spare for user W Weld Controller Panel
L Operator Display Box X Line Crossover Box
M Motor Controller, Drive Panel Y Do Not Use
Ethernet to DeviceNet
Z
Interface Box

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380 - 575VAC Cable Tagging

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Control Cable Labeling

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Section CD: DeviceNet

• The DeviceNet Interconnection is located in Section CD.
• DeviceNet is used for remote I/O communication from the PLC
to process equipment and tool level components. DeviceNet is
also used on robot end-of-arm tooling.
• By default, the modules are set at 125k bits/s at the OEM’s
factory. The GM standard states:
– 125K bits/s for conveyor systems
– 250K bits/s for tooling systems
– 500K bits/s for robot end-of-arm communications
• Rockwell states a maximum number of nodes communicating
on the network are 64 but GM’s standards dictate the
DeviceNet architecture as shown bellow.
– Maximum nodes per scanner at 250k baud = 20
– Maximum safety nodes per scanner at 250k baud = 10.
(A safety node counts as two towards the 20 maximum node limit.)
– Maximum number of safety nodes per PLC = 50
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Section CD: DeviceNet Node Allocation

NODE DESCRIPTION
0 DeviceNet Scanner Module
1-10 Safety I/O in Gate Boxes, Remote HMIs, Perimeter Guards
11-20 Robots and multi-axis controllers
21-29 Operator Panels (For example, Fixture Boxes, Run Stands, Light
Screens)
30-39 Tooling Inputs
40-49 Tooling Outputs
50-59 Other Panels (For example, VFDs, and Motor Panels)
60, 61 EPS Blocks (Four bytes maximum)
62 Do not use
63 Do not use (default setting of device from factory)

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Section CD: DeviceNet Device ID

• Device ID: All DeviceNet
nodes shall have a
lamicoid tag identifying the
network ID, device
designator and node
number (if applicable).

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Section CD: DeviceNet Cable Requirements

• Cable Requirements:
– Cable type: “Thick” and “thin”
are the two types of media
cable. “Thick” is used for trunk.
“Thin” is used for drops.
– Maximum cable length (thick) is
500m (1640 feet); maximum
drop length is 6m (20 feet).

COMMUNICATION RATE
125k bits/sec 250k bits/sec 500k bits/sec
Max “thick” trunk cable lengths 500 m (1640 ft) 250 m (820 ft) 100 m (328 ft)
Max “thin” trunk cable lengths 100 m (328 ft) 100 m (328 ft) 100 m (328 ft)
Max drop cable distance 6 m (20 ft) 6 m (20 ft) 6 m (20 ft)
Cumulative drop cable 156 m (512 ft) 78 m (256 ft) 39 m (128 ft)

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Section CD: DeviceNet Cable Labeling

• Cable Labeling: DeviceNet cable is labeled using
source/destination identifier associated with the cell
number as follows:
– D (for DeviceNet),
– Slot number of the residing scanner module
– Tee number of originating connection
– Tee number of destination connection or drop segment if
originating from a tee.

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Section CD: DeviceNet Cable Labeling

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Section CD: DeviceNet Grounding

• The DeviceNet cable system shall only be grounded at one location per
network.
• The DeviceNet network shall be grounded at the designated “SHLD”
terminal with a 10mm (#8 AWG) green w/yellow conductor.
• The “SHLD” terminal shall also be jumpered to the “V–” terminal.
• The neutral of the DeviceNet 24VDC power supply for the network is
connected to the V– terminal.
• To prevent ground loops, do not connect the DeviceNet power supply
24VDC neutral directly to ground. Connecting the neutral to the “V-“, which
in turn is connected to ground, creates one point of ground reference.
• For DeviceNet networks with more than one power supply, the grounding
terminals of additional PowerTaps or power supplies shall not be connected
to an earth ground.
•

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Section CD: DeviceNet Grounding

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Section CD: DeviceNet Auxiliary Power

• Output power for DeviceNet products is separate from
the DeviceNet 24VDC power.
• This “auxiliary” power shall be supplied through a
separate 4-pin mini interface.
• There are many types of configurations for a 4-pin
mini interface in the industry.
• The 4-pin mini interface selected is the
CENELEC EN 50 044 configuration
– pin 1 = +24VDC
– pin 4 = 0VDC
– pins 2 and 3 are spare.

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Section CD: Mini CENELEC EN 50 044

Auxiliary Power Cable Pin-Outs
Pin Mini (CENELEC) Standard
CENELEC EN 50 044
Pin 1 = +24vdc
Pin 2 = +24vdc (opt) ∗(2nd pwr supply)
Pin 3 = 0vdc (opt) ∗
0vdc 4 +24vdc +24vdc
Pin 4 = 0vdc 2 (2nd pwr supply) 2 4
0vdc

∗0vdc 3 1 +24vdc 3 0vdc∗

nd
+24vdc 1
(2 pwr supply) (2nd pwr supply)
Male Female
∗defined by CRW (front view) (front view)

• DeviceNet hardware and software will be discussed further in

Module 5 of this manual.

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Section CE: EtherNet

• EtherNet/IP is the communication network between PLCs, (real
time interlocks) HMIs and MWSs.
– PLC to PLC real time communication is based on User Datagram
Protocol/Internet Protocol (UDP/IP)
– PLC to HMI non critical traffic uses Transmission Control Protocol (TCP)
• Device ID: EtherNet/IP device addresses will be documented
on the cell level drawing package’s Interconnection pages.
• EtherNet/IP Features:
– 10 or 100 megabits per second data rate
– Cable lengths up to 100 meters
– Star topology
– Maximum number of nodes limited by number of available ports on a
switch

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Ethernet Cable Labeling

• Ethernet cables: Shall be
labeled with the (source)
switch number and port
number to the (destination)
enclosure number and
receptacle number.

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Section CE: EtherNet

• Ethernet networks provide connectivity to the plant
manufacturing information systems.
– Requires one EtherNet/IP module per MCP.
– MCP Ethernet network is connected to the zone switch
except for some stand-alone applications
– All MWSs shall be connected to the Ethernet Network
• Ethernet hardware and software will be discussed
further in Module 6 of this manual.

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EtherNet Interconnection – Section CE

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Section CG: Bonding & Grounding

• Grounding and bonding of equipment shall comply
with the NEC and IEC regulations. The grounding and
bonding section provides a guideline for developing an
effective grounding and bonding design for tooling
equipment.
• Grounding is a means to ensure electrical installations
are safe from electrical shock and fires by limiting
voltage imposed by line surges.
• Bonding is the intentional connection of metal parts to
form a low-impedance effective ground-fault current
path to remove dangerous voltage from metal parts
caused by a ground fault.
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Section CG: Bonding & Grounding

• System grounding is an intentional grounding of one
neutral conductor of the system to limit the maximum
potential value to ground due to normal operating
voltage.
• The benefits of system grounding are:
– Safety
– Lightning protection
– A system ground reference
– A ground fault return path
– A method for electromagnetic shielding

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Equipment Bonding – Section CG

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Section E – Magnetics
• This section illustrates system power distribution,
drives and motor wiring, transformer wiring, power
supplies, relays, I/O power distribution, and other
related items.
• There are two drawing level types:
– Cell Level — Power Distribution Panel schematics and Main
Control Panel schematics.
– Tool Level — ECS schematics and any other tool related
device schematics.

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Section E – Magnetics
• Over-current protection is provided by circuit breakers
in the enclosures.
• The drawing shall show the order from the highest to
lowest voltage (For example, 380 - 575VAC, 120VAC,
24VDC).

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380 - 575VAC PDP – Section E

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120VAC PDP – Section E

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24VDC MCP – Section E

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Wire Color / IEC 757 Code Chart

Color Color Code
Black BK
Brown BN
Red RD
Orange OG
Yellow YE
Green GN
Blue BU
Violet VT
Gray GY
White WH
Pink PK
Gold GD
Turquoise TQ
Silver SR
Green/Yellow Tracer GNYE
Black/Orange Tracer BKOG
Blue/Orange Tracer BUOG
White/Red Tracer WHRD
White/Orange Tracer WHOG

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Section E: Magnetics
• For the 120VAC distribution, there are two sources of
power:
– “Hot” power is supplied from the transformer which is
connected on the line side of the main disconnect. This
power is generally used for PLC Ethernet and DeviceNet.
– “Control” power is supplied from the transformer that is
connected on the load side of the main disconnect.

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Section F: Input / Output

• This drawing section provides a detailed explanation and
representation of the I/O distribution.
• Conductor numbers shall be designated by the chassis
number, module number, and bit number.

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I/O Conductor Numbering

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Cell MCP Chassis

• The cell Main Control Panel I/O requirements are detailed
below.
– There shall be a minimum of two spare slots per chassis.
– Isolated input modules shall be used to monitor inputs that are powered
from the DeviceNet power supply or other separately powered devices.
– The slot assignment shall be as shown below:

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Cell I/O Example

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Cell I/O Example

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Cell I/O Example

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Additional Tool I/O Requirements

• All enclosures with IP20 I/O shall have 20% spare space to
add additional modules.
• Hydraulic valves controlled by an output shall be fused
between the output and the valve.

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Additional Tool I/O Requirements

• All inputs shall be sinking.
• All outputs shall be sourcing.

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Cylinder Switch Requirements

• All switches from the same cylinder shall be on the same I/O block.
• Switch position shall be shown in the order of “Home”, “Work”.
• Integral switches (“world switch”) do not require “Y” connector.
• If three or more switches are used on the cylinder, additional work
positions shall be PX3, PX4, PX5, etc. starting from PX1 to PX2.
• If sensor cables are 1 meter or less, show one tag on the cable otherwise
show two tags (one at each end of the cable).

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Tool Level Inputs – Section F

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Section G – Pneumatics & Gas

• The pneumatic section of the wiring diagram is used to
illustrate how to design and draft the pneumatic systems.
• When air headers are required for an entire system, it shall
have a lockable self-relieving ball valve feeding the header.
• The header is to be sized according to the air requirements of
the system.
• A Pneumatic Sizing Design Aid is available on the CCRW
Global website.

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Section G – Pneumatics & Gas

• Cells
– All cells shall have an air prep
stand.
– The standard cell air prep stand’s
pipe sizes can be 1-1/2 inch or 2
inch. (Offline cells may only
require ¾ inch or 1 inch pipe.)
– This cell air stand shall feed a cell
header.
– The cell air stand shall consist of
the following:
• A Lockable self-relieving ball valve
• Water/contaminants trap
• 5 Micron particulate filter
• 0.3 Micron coalescent filter
• Regulator
• Slow-start shutoff

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Cell Level Air Stand

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Station Level Air Prep

• The standard station air prep stand’s
pipe size shall be one inch.
• The station air stand is fed from the
cell header with hose.
• Online station air stand shall consist of
the following in this order:
– A lockable self relieving ball valve
– 5 Micron particulate filter
– Pressure switch

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 Drawing Packages

Station Level Air Prep

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 Drawing Packages

Robot Air Prep

• Standard robot air prep stand
pipe size shall be ¾ inch.
• The robot air stand is fed
from the cell header.
• Robot air stand shall consist
of the following in this order:
– A lockable self relieving shutoff
– 5 Micron particulate filter

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 Drawing Packages

Robot Air Prep

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 Drawing Packages

Manifold
• Standard valve control shall be via DeviceNet
communication.
• Standard manifold are 4-station, 8-station and 12-
station configuration.
• Valve stations shall be in same order as tool sequence
where possible.
• All valve manifolds with eight or more positions shall
have dual air feeds (air feeds at top and bottom).
Manifolds with less then eight positions shall have
dual air feeds when required to satisfy liters per
minute (SLPM) or standard cubic feet per minute
(SCFM) tooling requirements.
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 Drawing Packages

Manifold
• Manifolds shall be fed with non-lubricated air except in
special application such as air drills.
• Pneumatic manifolds shall be numbered sequentially
starting with PM1.
• The sum of the CVs of all cylinders piped to the same
valve must not exceed the CV of that valve.
(Reference CCRW Pneumatic Sizing Design Aid.)

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 Drawing Packages

Pneumatic 8-Station Manifold & Valves

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 Drawing Packages

Pneumatic Manifold PM1

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 Drawing Packages

Air Logic Design Requirements

• Simple manual load/unload operations with four or
less sequence steps may be controlled by air logic
instead of PLC.
• Cycle time and ergonomic issues must be considered
before deciding to use air logic.
• Run Button designs shall include Anti-Tie-Down.

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 Drawing Packages

Air Logic Example – Section G

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 Drawing Packages

Section H: Hydraulic & Lube

• General Design Requirements
– More than one hydraulic system per cell shall require
approval.
– Hydraulic components shall be rated at 3000 PSI operating
pressure.
– Hydraulics schematics precede lubrication schematics.
• There are two types of hydraulic headers:
– Line header – Fed at one end by the hydraulic source and
limited to no more than 80 GPM (if more use loop header).
– Loop header – a circular header which allows two directional
flow to any given point in the system and can handle a
volume of 160 GPM or greater.

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 Drawing Packages

Section H: Hydraulic & Lube

• Cell Level Design Requirements
– Provide lockable ball valve between the hydraulic power unit
(HPU) and header manifold.
– Provide lockable ball valves for tank and drain when two or
more HPUs are used.
– Provide over-temperature and under-temperature switches if
oil must be maintained at a certain temperature for
operation.

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 Drawing Packages
Loop Header System
– Section H

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 Drawing Packages

Hydraulic Power Unit Design Requirements

• When designing the Hydraulic Power Unit (HPU),
select from the standard CRW designs (40 or 32
GPM) if applicable.
• HPU panel shall have a lockable disconnect.
• HPU panel shall monitor the following signals:
– Hydraulic oil pressure on.
– Hydraulic oil over-pressure.
– Hydraulic oil over-temp.
– Hydraulic oil low level.
– Filter dirty.
– Motor disconnect on.
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 Drawing Packages

Hydraulic Power Unit Design Requirements

• The following critical sensors shall de-energize the
HPU motor starter:
– Hydraulic oil over-temperature.
– Hydraulic oil low level.
– Motor disconnect off.
– All E Stops.

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 Drawing Packages

HPU – Section H

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 Drawing Packages

HPU Panel Design Example

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 Drawing Packages

Tool Level Design Requirements

• Isolation valves which are used to block flow and pressure shall
require approval.
• Pressure switch is required when using isolation valves.
• Accumulators are required based on flow rate and cycle time
calculations.
• Dump valve circuit is required when using accumulators.
• Relief valve pressure shall be set at 15% above system
pressure not to exceed 3000 PSI.
• Valve manifolds shall have a minimum of two stations not to
exceed six.
• Provide one spare station per manifold.
• Hydraulic manifolds shall be numbered sequentially starting
from HM1.

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 Drawing Packages

Tool Level Design Requirements

• There shall be a maximum of three sandwich-mounted
devices between the valve and the manifold (e.g., flow
control valve, pressure reducing valve, and pilot
operated check valve).
• Low-pressure drop check valves shall be used on the
tank and drain lines to prevent backflow.
• Provide lockable ball valves on the pressure line
feeding valve manifolds.
• All manifolds shall be externally drained.
• Pressure switch shall be provided upstream of each
valve manifold.

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 Drawing Packages
Tool Level Hydraulics – Section H

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 Drawing Packages

Air-Over-Oil Design Requirements

• There shall only be one cylinder per valve for all
pierces.
• Re-classifiers shall be provided.
• Intensifier unit shall be shown between the pneumatic
and hydraulic manifolds with the tank, P.O. checks and
switches.

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 Drawing Packages

Air-Over-Oil – Section H

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 Drawing Packages

Lubrication Design Requirements

• Provide lubrication chart listing each lube point.
• Provide low level and lube cycle switches.

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 Drawing Packages

Section I - Water
• Water piping and hosing schematics
– Cell Level
– Station Level

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 Drawing Packages

Section I - Water
• Cell Level Design Requirements
– The cell water stand shall provide
water feed and return lines to the
cell headers.
– Provide water shut off valves and
gauges on the supply and return
lines and a water strainer in the
feed line.
– Provide water headers for the cell.
– The cell water stand shall be
located to provide a “First in/Last
out” arrangement for hose drops
from the cell header.
– Hoses from the cell headers shall
supply water to the tooling.
– A pressure differential of 40 PSI
shall be maintained at the cell
water stand.

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 Drawing Packages

Cell Level – Section I

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 Drawing Packages

Section I: Water
• Tooling Level Design Requirements
– Flexible tubing shall be used for all conductors ½ inch or less.
– Ball valves shall be provided on the tool for the supply and return lines.
– A flow switch shall be provided on the water return line.
– Water hose color shall be green for supply and red for return.
– Flex tubing for transformers shall be 10mm (¼ inch).
– Flex tubing for weld guns shall be 12mm (⅜ inch).
– All jumper flex tubing shall be green 12mm (⅜ inch). The exception
would be robotic hip mounted applications with the transformer
connected in series after the weld gun shall use 12mm (⅜ inch) red flex
tube.
– Flex tubing for weld controllers shall be 10mm (¼ inch).
– Weld gun tips may be hosed in series on hard auto weld applications if
there are not more than two welds per job.
– A pressure differential of 20 PSI shall be maintained at the station water
stand.

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 Drawing Packages

Tool Level – Section I

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 Drawing Packages

Sections MA, MB & MC: Station Interconnection

• This section is provided to show cell level station
interconnection. Examples would be:
– An interconnection diagram between an operator fixture box
and the station light curtains
– A weld controller to transformer interconnection.

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 Drawing Packages

Station Interconnection Example #1

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 Drawing Packages

Station Interconnection Example #2

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 Drawing Packages

Weld Controller To Station Interconnection

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 Drawing Packages

Unassigned Sections
• Sections N through V are unassigned.

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 Drawing Packages

Section W – Welding (Station Level)

• This section of the drawing package contains a representation of the weld
circuit diagram for weld controllers, weld transformers, weld controller
junction boxes, if required, and weld guns.
– Design Requirements
– Show all weld controllers (singles, tri-packs, and 6 SCR packs).
– Show welding transformers with their associated weld controllers.
– Show weld gun assignments with their associated transformers.
– A weld controller junction box shall be provided when either of the following
apply:
• If the conductors between the weld controller and the transformer exceeds 12 meters
of 35mm² (40 feet of #2 AWG) conductor.
• If 3 or more transformers are connected to the same SCR.
– Provide regulator for each gun as shown in section G of the drawing package.
– No more than one gun may close on the same transformer per sequence.
– Provide weld sequence chart.
– 4-pin mini aux power shall be provided to each weld controller.

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 Drawing Packages

Welding Tool Level – Section W

Hard-Auto Weld: Unit-Pak

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 Drawing Packages

Welding Tool Level – Section W

Tri-Pak

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 Drawing Packages

Section X - Enclosure Layouts

• Section X shows the following information in this
order:
– Enclosure layout
– Enclosure push button and light layout
– Subplate layout
– Terminal rotation
– Receptacle pin chart

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 Drawing Packages

Section X - Enclosure Layouts

• The working space around enclosures shall comply with NEC
70, Article 110-26 for those regions affected per Global Design
for Health and Safety - Part 3 (G-DHS-3).
• The width of working space in front of the electric equipment
shall be the width of the equipment or 750mm (30 inches),
whichever is greater.
– This allows an individual to have at least shoulder width space in front of
the equipment.
• Step-back Distance will be as follows:
– 0 to 150 volts = 900mm (36 inches) minimum.
– 151 to 600 volts = 1100mm (42 inches) minimum.
• Exception: When two panels face each other, the minimum
distance shall be 1200mm (48 inches).
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 Drawing Packages

Enclosure Workspace Example

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 Drawing Packages

380 through 575VAC Power Distribution Panel (PDP)

• Main power distribution for cell components
• 380 through 575VAC components (for example circuit
breakers, drives, contactors, and distribution blocks)
• 120VAC “hot power” for PLC and lighting (branch
circuit breakers)
• 120VAC control power distribution (branch circuit
breakers)

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 Drawing Packages

380 – 575 VAC PDP

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 Drawing Packages

Cell Main Enclosure - Main Control Panel (MCP)

• 120VAC feed from PDP
• Main cell PLC and I/O chassis
• 24VDC power supplies
• Receptacles

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 Drawing Packages

MCP Enclosure

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 Drawing Packages

Combination 380 - 575VAC PDP/ MCP

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 Drawing Packages

Section X - Enclosure Layouts

• Perimeter and operator fixture boxes are required
when connecting light curtains within the cell. An
example of a fixture box design requirements is listed
below.
– 24VDC Power Supply
– Light Screens
– IP20 Safety I/O

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 Drawing Packages

Operator Fixture Junction Box

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 Drawing Packages

Operator Fixture J-Box Subplate

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 Drawing Packages

Operator Fixture Box Pin Chart

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 Drawing Packages

Receptacle Pin Orientation

• A receptacle will be mounted
and oriented as shown
below:

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 Drawing Packages

Receptacle Conductor Labeling

• Receptacle wires shall be labeled in accordance to the pin
chart in the drawing Section X. In addition to the wire
numbers at the termination end, the receptacle number will
also be provided.

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 Drawing Packages

Panel Grounding Design Requirements

• Each enclosure shall have a ground bar (or ground stud for
smaller enclosures) with all ground conductors terminating at
individual connections on the ground bar. If the ground bar is
rated accordingly, two conductors may be terminated on the
same connection point.
• The ground bar shall be permanently mounted and bonded to
the enclosure subplate. If the ground bar is mounted to the
enclosure off of the subplate, a suitable size conductor shall be
provided from the ground bar to the subplate.
• Dirt, oil, and paint shall be removed from the surface to which
the ground bar is mounted.

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 Drawing Packages

Panel Grounding Design Requirements

• A flexible, braided copper bonding jumper shall be provided
to bond the main enclosure panel to any enclosure door,
drawer units, and hinged subplates to ensure effective
grounding and compliance with IEC 60204 and NFPA 79
Chapter 17. This jumper shall have ring terminal connectors
at both ends and shall be bolted to the enclosure using a
locking type washer. The paint on the enclosure shall be
removed at the point of contact to ensure proper bonding.

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 Drawing Packages

Enclosure Tag ID Inside Enclosure

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 Drawing Packages

Section Y – Bill of Materials

• A detailed listing of parts is required to implement the
design defined by the drawing package.
• For designs documented with the ePlan engineering
tool, the BOM is a report that is generated at the
completion of the design.
• The BOM will reference the Global Common
Components List (GCCL). The GCCL is a list of all the
approved CCRW components. The latest GCCL file
must be obtained from the CCRW website.

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 Drawing Packages

Bill Of Materials (BOM)

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 Drawing Packages

Section Z – Standard/Reference Drawings

• Only reference diagrams and standard
drawings relevant to the WD level drawing
package should be included. For example,
DeviceNet dip switch settings are useful in the
cell level and station level drawing packages;
however, Ethernet information would be useful
in the system and cell level drawing packages.

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 Drawing Packages

Training Simulator (ECS-4009)

• The training simulator (ECS-4009) simulates two cells
with two different controllers.
• For ease of training and portability these controllers
are physically located in the same simulator cabinet.
• This would not be the case in an actual production
environment. They would actually be located in two
different main control panels.

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 Drawing Packages

Simulator Zone, Cell, Station Structure

First Cell
• The first cell simulates two
stations, AA110 and AA120.
Station AA110 simulates robots for
material handling. Station AA120
simulates a pedestal welding
station.
Second Cell
• There is only one station in this
cell, AA130. Physically station
AA130 merely controls the items
connected to the Siemens I/O
module, which simulate various
proximity switches.

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 Drawing Packages

Robot Drawing Packages

• General Requirements
– Robot Standards
• The GRS-1 (Global Robot Specification) and GRS-4 define the common
control interfaces and the functions of the robot circuits.

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 Drawing Packages

Functional Requirements: Stopping A Robot

• E-Stop — Terminates robot motion in the quickest
possible manner. Power to the robot output signals
shall cease upon the receipt of an emergency stop.
• General Stop — Shall stop the robot and be
functional in all robot modes.
• Auto Stop — Shall stop the robot and only be
functional with robot mode selector (on the robot) in
the AUTO position (AUTO/T1/T2).

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 Drawing Packages

Rules of Process
• A robot can control no more than two processes
excluding mechanical handling. This means a robot
can control the following processes:
– Carry Spot/MH & Pedestal Spot
– Carry Stud/MH & Pedestal Stud
– MH, Pedestal Dispense & Pedestal Stud
– 2 Carry Spots

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 Drawing Packages

Robot Applications / Drawing Packages

• Carried Stud Welder • Pedestal Sealer
• Carried Sealer • Material Handling (MH)
• Carried Spot Welder • Tool Changer
• Pedestal Spot Weld • Combination MH and Spot
• Pedestal Stud Weld Weld

• There are more applications.

• These are the most common.

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 Drawing Packages

Example Robot Applications

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 Drawing Packages

Robot Drawing Package Content

• Interconnection of control and network cables from
robot controller and associated equipment
• Robot Magnetics
• DeviceNet Interconnection
• Robot Safe I/O
• DeviceNet I/O Mapping to PLC as defined in GRS-4
• Panel layouts and receptacle pin charts
• Bill of Material

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 Drawing Packages

Header Sheet

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 Drawing Packages

Table of Contents

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 Drawing Packages

List of Changes

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 Drawing Packages

Interconnection

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 Drawing Packages

Magnetics #1

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 Drawing Packages

Magnetics #2

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 Drawing Packages

Redundant E-Stop Circuit

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 Drawing Packages

Magnetics #4

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 Drawing Packages

Magnetics #5

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 Drawing Packages

DeviceNet Interconnection

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 Drawing Packages

Chassis 01 Safe I/O

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 Drawing Packages

I/O Mapping

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 Drawing Packages

Cell/Robot Inputs #1

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 Drawing Packages

Cell/Robot Inputs #2

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 Drawing Packages

Cell/Robot Outputs #1

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 Drawing Packages

Cell/Robot Outputs #2

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 Drawing Packages

Enclosure Layout – Exterior

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 Drawing Packages

Enclosure Layout – Interior

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 Drawing Packages

Safe I/O Subplate Layout

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 Drawing Packages

Receptacle Pin Chart

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 Drawing Packages

BOM Sheet #1

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 Drawing Packages

BOM Sheet #2

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 Drawing Packages

MODULE PROGRESS CHECK

• Take 10 minutes to complete the Module Progress
check.
• We’ll review and discuss the answers.

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 Drawing Packages

MODULE PROGRESS CHECK

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 Drawing Packages

MODULE PROGRESS CHECK

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 Drawing Packages

MODULE PROGRESS CHECK

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 Drawing Packages

MODULE PROGRESS CHECK

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 Drawing Packages

MODULE PROGRESS CHECK

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 Drawing Packages

Lab Exercise: Drawing Package Level

• Objectives: After completing this Lab Exercise, the
participant will be able to:
– Identify the correct drawing package for an identified station
or cell.
• Instructor will review the answers upon completion.

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 Drawing Packages

Lab Exercise: Finding Components On Prints

• After completing this Lab Exercise, the participant will
be able to:
– Locate components in a print package.
• Instructor will review the answers upon completion.

Copyright 2008. General Motors Corporation. All Rights Reserved Mod 2 - 195
 Drawing Packages
Lab Exercise:
Finding Components On Robot Drawings
• Objectives: After completing this Lab Exercise, the
participant will be able to:
– Identify components using the supplied robot drawing
package WDS-G06-FANUC_R30IA.
• Instructor will review the answers upon completion.

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 Drawing Packages
Lab Exercise:
Trainer Familiarization
• Objectives: After completing this Lab Exercise, the
participant will be able to:
– Locate and identify major training simulator components
– Correlate major simulator components to their corresponding
cell
• Instructor will review the answers upon completion.

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 Drawing Packages
Lab Exercise:
NFAP to IEC Symbol Conversion
• Objectives: After completing this Lab Exercise, the
participant will be able to:
– Identify IEC symbols
• Instructor will review the answers upon completion.

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