Text Section 4

Rev.
Date 1-31-13
SECTION 4
4.0 Electrical
4.1 General
4.1.2 Supplier Responsibilities

The Supplier is responsible for the adherence to Chrysler Group LLC, National Electric Code, Ontario
Electrical Inspection and O.S.H.A. design and construction standards. Preliminary review approval of
designs by Chrysler Group LLC Tool Engineering does not relieve the Supplier of this responsibility.
Deviation from these standards must not be acceptable without the signed approval of Chrysler Group
LLC Tool Design and/or a Chrysler Group LLC Tool Process Engineering representative.
4.1.3 Tryout of Machine and/or Automated Line

Tryout of machine and/or automated line must include:
A. A manual check of all electrical interlocks to the satisfaction of a Chrysler Group LLC Launch
Technician
B. A machine and/or automated line must run, in the weld mode, with parts and in the presence of a
Chrysler Group LLC Launch Technician.
4.1.4 Electrical Circuitry

All 120V AC electrical circuitry must be grounded.
4.1.5 Plug-In Relays

Plug in relays must NOT be used without prior WRITTEN permission from a Chrysler Group LLC AME
Controls Design Coordinator Supervisor.
4.1.6
4.1.7
4.1.7.1 Parts Loaded Light

Manual load stations with PLC controls must include a "Parts Loaded" light. This light must be white and it
must be ergonomically located to be visible by the operator during the manual load operation. For
operation description contact a Chrysler Group LLC AME Controls Design Coordinator.
4.1.7.2 Part-in-Position Light

Stations where parts are loaded or unloaded by automation must include a "Part in Position" light. This
light must be white located close to the tooling. For operation description contact a Chrysler Group LLC
AME Controls Design Coordinator.
4.1.7.3
4.1.8 Up-To-Date WD Before Shipping

Each machine, before shipping, must have an up-to-date WD in its control panel.
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Revision Date: 01/31/2013 Revision: 13.01
File name: DnD Sec 4 Electrical 1-31-2013.docx
4.1.9 Part Sensing in Load/Unload Stations
The Supplier must be responsible for the purchase, installation and wiring of sensors for detecting empty
or full conveyers, carriers, shuttles, etc., at all automatic and robotic load and unload stations. Installation
must be completed at the receiving plant when required.
4.1.10
4.1.11 Part Counters

Part counters must be provided on each line and/or machine. Part counters must not increment the count
until the automatic machine cycle has been completed with parts.
4.1.12 Operating Voltages

All equipment supplied must be suitable for operation at 480 Volts, 3-Phase 60 Hertz. Control voltages
other than 120 Volts AC and or 24 Volts DC require written approval from a Chrysler Group LLC AME
4.1.13 Nominal Voltage Supply Range

All equipment must operate at +10%/-15% of the nominal supply voltage without any detrimental effect to
material, equipment or performance.
4.1.14
4.1.15 Bi-metallic Type Thermal Overload Relays

Bimetallic type thermal overload relays will not be allowed on the Motor Starter.
4.1.16 Field Wiring for Control Circuits

Where field wiring (between control enclosures, installation of field devices) is not done through multi-
conductor cable, wire must be minimum 14AWG.
4.1.17 Low Energy Circuits

When low voltage circuits require the use of relays, the relays shall be equipped with contact assemblies
providing multiple parallel paths (bifurcated contacts at minimum).
4.1.18 I/O Devices

I/O devices must be 24VDC, unless prior written approval is obtained from a Chrysler Group LLC AME
4.1.19 PLC Processor Power Sources

All PLC processors must be provided with an isolated grounded power source. This power source must
be maintained in the event of the operation of the Power Distribution Panel disconnect.
4.1.19.1
4.1.20 PLC Systems - Manufacturers Recommendations

All PLC systems must be applied per the controller manufacturer's recommendations. This includes panel
layout, signal and power wire segregation, noise suppression, proper grounding techniques, etc.
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4.1.21
4.1.22 Lamp Test

All PLC controlled lights must have lamp test capabilities without affecting machine operation or causing
motion.
4.2 Design
4.2.1 Controls Design –Chrysler Group LLC Line-up Requirements

When Chrysler Group LLC is responsible for the controls design, the mechanical design source must
supply a complete detailed controls line-up, including but not limited to sequence of operation with
graphical timing representation, cylinder location with detailed information (bore and stroke, port sizes,
etc…), all applicable switches with part numbers, etc… for every piece of equipment being designed and
adequate information to permit the design of circuitry. If the information supplied is deemed inadequate,
design source must provide additional information or contact as required. This information must be
supplied immediately after 40% design review approval.
4.2.2 Controls Design - Supplier Requirements

When the Supplier is responsible for the controls design, the Supplier must contact the appropriate
Chrysler Group LLC Controls Design Coordinator for the latest design references, and standards. This
must be done BEFORE the start of design. Development of all circuit designs will be done with the
involvement of designated Chrysler Group LLC Controls Design Coordinator. Coordination is required to
permit maximum use of standards wherever possible. Review and approval of circuitry design (piping,
hard wire, I/O structure, panel layouts, logic etc.) are required prior to submission of "Approved For Build"
drawings (Reference 4.2.16).
4.2.3 Error-Free Designs

The design source is responsible to produce an error free design. All design errors must be corrected by
the design source without additional cost to Chrysler Group LLC.
4.2.4 Rework Design Requirements – Controls

On projects where it is necessary to rework existing equipment the supplier must request the most current
record of controls design (WD) from the appropriate Chrysler Group LLC Controls Design Coordinator. It
is the responsibility of the supplier to ensure that these designs are consistent with the equipment on the
plant floor. The supplier must provide a date to receive all potentially impacted software programs from
the plant i.e. PLC, HMI, etc. The date that the software programs are received must be used for tracking
updates. Any modified content shall be control reliable and comply with SMI-162.
4.2.5 Controls Design Identification Numbering

All controls designs must be identified with a unique WD number. This number must be obtained from a
Chrysler Group LLC AME Controls Design Coordinator. The controls design Supplier must provide a
separate control diagram for each fixture, including the logic specific to that fixture. All sheets must be
numbered as indicated below:
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A. Sheet numbers are to run in sequence starting with sheet #1 (1,2,3, etc......). Sheets added after
initial packages are approved must maintain the same flow as the initial design. Alpha numbered
sheets are allowed to be used, with the approval of a Chrysler Group LLC AME Controls Design
Coordinator. For example sheets added to the magnetic's will be placed at the end of the
magnetic circuits and utilize the next available line numbering.
B. Detail numbers are to run in sequence starting with detail #1 (1,2,3, etc......).
4.2.6
4.2.6.1 Wiring Diagram - Timing Chart

Each Wiring Diagram must include a detailed timing chart depicting the complete cycle of all processes
within that WD.
4.2.6.2 Wiring Diagram - Facility Chart

Each Wiring Diagram must include a detailed facility usage chart showing the continuous demand during
all points of the cycle for the following:
A. Hydraulic timing chart showing the peak hydraulic volume demands in G.P.M.
B. Pneumatic timing chart showing the peak pneumatic volume demands in CFM per plant drop.
C. Electrical timing chart showing the peak electrical demands in KVA per plant drop.
D. Water demand chart showing the peak water volume in G.P.M. per plant drop.
4.2.7 Random Skips

Each system must have the capability of running random skips.
4.2.8 Controls Design CAD File Guidelines
Files comprising the Controls Design must be named using the following guideline:
A. AutoCAD
12345001.DWG ---------------------- WD12345’s Sheet 1
[12345] [001] . [DWG] ------------ AutoCAD file extension.

| | ---------------------------- 3 digit sheet number.
| ------------------------------------- WD number for this design.
B. Human Machine Interface (HMI)

12345HMIxxRH.xxx --------------- Handed
12345HMIxx.xxx ------------------- Unhanded
[12345HMI] [xx] . [xxx] ---------- HMI file extension.

| | ----------------------- HMI number (1-9) in respect to its WD.
| -------------------------------------- WD number for this design.
C. Programmable Controllers
The FIS controller name plus the programming software’s extension.
12345ROOF1.xxx
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[12345][ROOF1] . [xxx] ------- Programming software’s extension.
| | ----------------------- FIS Controller name.
| ----------------------------------- WD number for this design.
D. Network Configuration and Calculations

12345ccss.xxx
[12345] [ccss] . [xxx] --------- Programming software’s extension.

| | ----------------------- cc = Chassis number – ss = slot location.
| --------------------------------- WD number for this design.
E. Safety Task Calculation

12345SafetyTask.xxx
[12345] Safety Task . [xxx] -- Programming software’s extension.

|---------------------------------- WD number for this design.
F. Ethernet/IP Performance Calculation

12345ENet.xxx
[12345] ENet . [xxx] -------- Programming software’s extension.

|------------------------------- WD number for this design.
4.2.9
4.2.10 Wire Color

The following is direction required for control and communication cable/wire color schemes within a
Chrysler Group LLC facility. Preferred cable manufacturer should be applied per the Chrysler Group LLC
Approved Source List. Application design considerations (Flex, Shielded, etc.) requirements should be
reviewed with the assigned Chrysler Group LLC AME Controls Design Coordinator. Wire size shall be
determined by the load requirements and shall not be smaller than the minimum allowance and proper
torque requirements by manufactured supplied component recommendations / UL listings.
Control Wiring
AC
o 480VAC (above the DP main disconnect) Black/Orange Tracer
o 480VAC (below the DP main disconnect) Black
o 120VAC Red
o 0VAC Common White
o 120VAC Interlock Orange
o 0VAC Interlock Common White/Orange Tracer
DC
o 24VDC Blue
o 0VDC Common White/Blue Tracers
o 24VDC Interlock Orange/Blue Tracer
o 0VDC Interlock Common White/Orange Tracer
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Ground Green
Process Control Network

o DH+ (9463 Belden) for Kitted Equipment Blue
o DCM (9463 Belden) for Kitted Equipment Blue
o DCM (9463 Belden) for New Equipment Teal Round Media
o RIO (9463 Belden) for Kitted Equipment Blue
o DeviceNet / DeviceNet Safe (Thick/Thin) Grey Round Media
o Fiber – For Process Applications (Peer-to-Peer/Drops) Grey Round Media
o Medlan (9463 Belden) for Kitted Equipment Brown
Network (ITI Plant Infrastructure)

o Cat 6e (OA & PA Network Drops) Blue
o Cat 6e Patch Cords (Plant) Grey
o Cat 6e Patch Cords (OEMs) Teal
o Cat 6e Patch Cords (Wireless) Yellow
o Cat 6e Crossover Cables Red
o Fiber –
 Backbone (Multi Mode) Orange (Existing)
 Backbone (Multi Mode, 50micron) Aqua (New Installs)
 Backbone (Single Mode) Yellow
 Network Drops (Multi Mode) Orange (Existing)
 Network Drops (Multi Mode, 50micron) Aqua (New Installs)
 Network Drops (Single Mode) Yellow
 Patch Cords (Multi Mode) Orange (Existing)
 Patch Cords (Multi Mode, 50micron) Aqua (New Installs)
 Patch Cords (Single Mode) Yellow
o Coax Black
o Phone Grey
4.2.11
4.2.12
4.2.13
4.2.14 Controls Design - AutoCAD

All controls designs must be done using AutoCAD software, reference Manufacturing CAD Requirements for
the authorized version. All designs must be updated before shipment and after launch.
4.2.14.1 AutoCAD Style and Format Guidelines

The following criteria must apply to AutoCAD designs.
A. AutoCAD Text Style must be set to Simplex, Font file: Simplex.shx

B. Data files must have the default menu set to ACAD. Under no circumstances must a full PATH
be set.
C. All text must be no smaller than 0.150".
D. Drawing limits must be set to "0.0" and "36, 24" in Model Space. ANSI Standard "D" size
drawing.
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E. Title block must be provided from a Chrysler Group LLC AME Controls Design Coordinator.
F. Drawing files must be AutoCAD format only. The inclusion of other application formats must
require approval of a Chrysler Group LLC AME Controls Design Coordinator.
G. No External references or Shape definitions are permitted. The preferred method is to utilize
AutoCAD Block definitions where various entity Shapes are required. All User Block definitions
must follow examples as shown in example files provided.
H. No "NESTING of BLOCKS" is permitted. It is the responsibility of the vendor to insure that no
Blocks are nested.
I. The area between the revision block and the title block must not be used for drawing related
geometry or text. This area is reserved for Program change information ONLY.
J. Line referencing must be placed on all, but not limited to, magnetic, robotic and I/O sheets
required for the design. The sheet number must make up the first digit(s) of the line reference. All
wires must align to and be identified as that reference number starting with (01) and numbered
consecutively. See reference for clarification.
XXXYYZZ
| | |----- ZZ = Wire number starting with 01 and numbered consecutively
| |--------- YY = Starting at 01 and numbered consecutively per sheet
|--------------- XXX = Sheet number
4.2.15 Programmable Controller Programming

The Supplier is responsible for entering the program into the programmable controller.
4.2.16 Controls Design - Document and CAD Data Requirements

This item outlines the documentation and CAD data requirements for Controls Designs, and the
associated timetables for submission.
A. Approvals (70% Complete)
Upon completion of each design, the supplier must provide Approval drawings and a copy of all
applicable calculation files for each WD to the assigned Chrysler Group LLC AME Controls
Design Coordinator from Assembly Manufacturing Engineering (AME) Controls Design in Auburn
Hills. This documentation must be clearly identified with "APPROVAL PRINT". Fourteen (14)
days must be scheduled for the Chrysler Group LLC AME Controls Design Coordinator
approval process.
a. (1) 11" x 17" copy of each WD Drawing Set

b. (1) electronic copy of each WD Drawing Set
c. (1) electronic copy of program files for every PLC
d. (1) electronic copy of program files for every Programmable Device (i.e. HMI, EDS etc., and all
applicable network configuration files.).
d. (1) electronic copy of the all applicable Calculations
Completed designs (hardwire, logic, peripherals, etc.) must be resubmitted within fourteen (14)
days after approval corrections or revisions have been returned to the Supplier (“Approved As
Marked” - 80% Complete). This documentation must be clearly identified with "APPROVED FOR
BUILD" (90% Complete).
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When the WD’s contain (FIS/AVI/PFS/PFCS) ITM content Hardware or connectivity, the supplier must
provide one (1) set of (PDF format only) Approval drawings for each WD to the assigned ITM Launch
Coordinator from Information Technologies Management (ITM) in Auburn Hills. The documentation must
be clearly identified with “APPROVAL PRINT”, in the exact format and content, for hardware and
software, as defined above for the Chrysler Group LLC AME Controls Design Coordinator. Fourteen 14
days must be scheduled for the ITM Launch Coordinator approval process.
B. As Shipped (98% Complete)
The following documentation is required at the time of tooling shipment or completion of

“Production Simulation (Formerly 20 Hour)” run if Plant Build tooling. All items listed are to be
delivered to the designated recipients no later than ten (10) days following shipment of tools from
the supplier or completion of “Production Simulation” run if Plant Build. CAD files and prints are to
be current and must have been updated to include ALL changes occurring through build and
tryout. All documentation must be clearly identified with "AS SHIPPED" to indicate design status.
These requirements are in addition to item 4.1.8.
1. The documentation outlined in this section must be delivered to the designated representative
of the Plant Manufacturing Engineering Department. The Chrysler Group LLC AME Controls
Design Coordinator will provide the name of this contact. The shipping document must be
adequately detailed to show that all of the deliverables per design have been included. The
shipper must be signed by the designated plant representative. The supplier must package and
deliver this documentation and provide a copy of the signed shipper to the Chrysler Group LLC
a. (1) 11" x 17" copy of each WD Drawing Set (for production floor)
b. (1) electronic copy of program files for every PLC (for office) (PDF format only).
c. (1) electronic copy of program files for every Programmable Device (i.e. HMIs, EDS, etc…and
all applicable network configuration files) (for office).
d. (1) electronic copy of all applicable Calculations.
e. (1) electronic copy of all applicable “Build” validation reports.
2. The documentation outlined in this section applies to ASME ONLY and must be delivered at
the installation site. The shipping document must be adequately detailed to show that all of the
deliverables per the design have been included. The shipper must be signed by the ASME
Launch Technician. The supplier must package and deliver the documentation and provide a
copy of the signed shipper to the Chrysler Group LLC AME Controls Design Coordinator.
a. (1) 11" x 17" copy of each WD Drawing Set (for Launch Technician).
b. (1) electronic copy of program files for every PLC
c. (1) electronic copy of program files for every Programmable Device (i.e. HMIs, EDS, etc… and
all applicable network configuration files).
d. (1) electronic copy of program files for every robot (for office)
e. (1) electronic copy of all applicable Calculations
f. (1) electronic copy of all applicable “Build” validation reports.
g. (1) hard copy of all applicable “Build” validation reports.
3. The documentation outlined in this section must be delivered to the Chrysler Group LLC AME
Controls Design Coordinator in Auburn Hills. The shipping document must be adequately
detailed to show that all deliverables per the design have been included. The supplier must
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package and deliver this documentation and provide the shipper for the Chrysler Group LLC AME
Controls Design Coordinator signature. The supplier must provide a copy of the shipper for the
Chrysler Group LLC AME Controls Design Coordinator.
a. (1) electronic copy of all AutoCAD files for all WD’s

c. (1) electronic copy of program files for every Programmable Device (i.e. HMIs, EDS, etc... and
all applicable network configuration files).
d. (1) electronic copy of all applicable Calculations
e. (1) electronic copy of all applicable “Build” validation reports.
f. (1) electronic copy of all signed Controls Process Review document(s)
g. (1) electronic copy of all validation reports pertaining to the WD
C. As Launched (100% Complete)
The following documentation is required after plant launch. All items listed are to be delivered to the
designated recipients no later than sixty (60) days following "Official" Launch date. All CAD files and
prints are to be current and must have been updated to include ALL changes occurring through launch.
All documentation must be clearly identified with "AS LAUNCHED".
1. The documentation outlined in this section must be delivered to the designated representative of the
Plant Manufacturing Engineering Department for signature. The Chrysler Group LLC AME Controls
Design Coordinator will provide the name of this contact. The shipping document must be adequately
detailed to show that all of the deliverables per design have been included. The shipper must be signed
by the designated plant representative. The supplier must package and deliver this documentation and
provide a copy of the signed shipper to the Chrysler Group LLC AME Controls Design Coordinator.
a. (1) 11" x 17" copy of each WD Drawing Set (for production floor)
b. (1) electronic copy of all AutoCAD files for all WD’s (for office)
c. (1) electronic copy of program files for every PLC (for office)
d. (1) electronic copy of program files for every Programmable Device (i.e. HMI's, EDS, Ethernet Switch
configuration, etc… and all applicable network configuration files) (for office)
e. (1) electronic copy of all applicable Calculations
f. (1) electronic copy of all applicable “In Plant” validation reports
2. The documentation outlined in this section must be delivered to the Chrysler Group LLC AME Controls
Design Coordinator in Auburn Hills. The shipping document must be adequately detailed to show that all
of the deliverables per design have been included. The supplier must package and deliver this
documentation and provide the shipper for the Chrysler Group LLC AME Controls Design Coordinator
signature. The supplier must provide a copy of the shipper for the Chrysler Group LLC AME Controls
Design Coordinator.
a. (1) electronic copy of all AutoCAD files for all WD’s

c. (1) electronic copy of program files for every Programmable Device (i.e. HMIs, EDS, Ethernet Switch
configuration, etc… and all applicable network configuration files)
d. (1) electronic copy of all applicable Calculations
e. (1) electronic copy of all applicable “In Plant” validation reports
f. (1) electronic copy of all updates and finalized Controls Process Review documents
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D. General Notes:
1. All documentation for Plant Floor and Technicians is required per machine/tool, not per WD design.
Where more than one tool is built to a common WD design, complete documentation is required for EACH
tool.
2. All plant floor 11x17 requirements must be bound.
3. All electronic documentation must be placed on a CD or DVD media. CD or DVD must be formatted to
be readable on any standard CD or DVD drive. Each CD or DVD must be provided in its own protective
case.
4. Consult Chrysler Group LLC AME Controls Design Coordinator for filename, disk organization, and
labeling requirements.
5. PLC Programs must be completely documented and annotated using project-specified Software.
6. All disks/data/software delivered to Chrysler Group LLC must be virus-free. It is the OEM's
responsibility to implement and police stringent procedures to assure this requirement.
4.2.17 PLC Monitoring of Safety Devices

All safety devices must have a contact run to the inputs of the PLC for monitoring.
4.2.18 Input Device Connection

Any input device must be connected to its own discrete input address.
4.2.19 PLC Controls System - Circuits Protection

In PLC control systems, the following circuits must have over current protection:
A. Programmable Logic Controller (PLC).
Note: Supplier must provide all over current protective devices through final buy-off at the plant.
4.2.20 Wire Designation - Output Designation

Where one controller output is wired to another controller input, the output designation must be used as
the wire designation.
4.2.21
4.2.21.1 Spare Terminals

In addition to the terminals required for the application there must be a minimum of twenty percent (20%)
spare terminals.
4.2.21.2 Pushbuttons and Pilot Lights Mounted on Enclosure Doors

Pushbuttons and pilot lights mounted on enclosure doors may be wired directly to I/O points within that
enclosure.
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4.2.23
4.2.24 WD Cell Layout

Cell layout is to be shown in the WD. The cell layout is to show all stations, robots, operators, run-bars,
emergency stop buttons, power distribution panels, interface panels, HMI panels, drive panels, junction
boxes, light screens, safety fence, safety gates, etc.
4.2.25 Cable Layout

A cable layout will be shown on each WD which will show how the components are connected together.
The layout will show the location of panels, run-bars, pendants, light screens, safety gates and pin
receptacle, etc. (floor or balcony) and how each component is connected.
4.2.26 Returning to a Full Automatic Mode After Emergency Stop

All systems must be able to return to a full automatic mode from an emergency stop within two (2)
minutes of initiating a restart sequence.
4.2.27
4.2.28
4.2.29
4.2.31
4.2.30 Part Sensing - Ensure Proper Loading of Parts

Supplier must provide part sensing to ensure that all parts have been properly loaded.
4.2.32 Part Sensing - Ensure Previously Loaded Parts Present

Supplier must provide part sensing to ensure that previously loaded parts are present when absence of
the parts creates an unacceptable repair condition.
4.2.33 OVER CYCLE Light - Manual Load/Unload Position

Supplier must provide an amber stack light at each manual load/unload position to indicate if an operator
has exceeded his/her load time when the line or system is in the automatic mode. If an operator is loading
to multiple load stations, the supplier must ensure that proper over cycle sequencing logic is provide to
prevent erroneous "Over cycle Time" faults. This light will be identified with a tag stating "OVER CYCLE".
Over cycle light must be ergonomically located to be visible by the operator during the manual load
operation.
4.2.34 Clear to Enter Light - Manual Load/Unload Position

Supplier must provide a green stack light at each manual load/unload position to indicate when the
machine is in a safe operating state to allow the operator to perform his/her function. This light will be
identified with a tag stating "CLEAR TO ENTER". The light must be ergonomically located to be visible by
the operator during the manual load operation, visible from outside of the guarded area within the
operator’s field of view and requires approval by a Chrysler Group LLC Launch Technician. For operation
description and or an example of approved tag format contact a Chrysler Group LLC AME Controls
Design Coordinator (reference WD_TAGS).
4.2.35 Position Indicating Sensors - Actuators

Position indicating sensors (limit or proximity switches) must be provided on ALL actuators. A UNIQUE
sensor signal must be provided to POSITIVELY indicate each extreme of motion and any intermediate
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positions necessary to the application. The exception to this requirement is weld guns which may be
sensed as a group by pressure switches.
4.2.36 Position Indicating Sensors - Applications

Sensing devices that read the position of a drive actuator (i.e. cylinder piston rod) are acceptable only on
simple clamping applications (i.e. ISI or DeStaCo type). All other applications must require sensing
devices (i.e. proximity or limit switches) that directly read the position of the driven member itself. This is
to preclude potential hazards that may arise if the driven member becomes disengaged from the drive
actuator and is especially important on large critical motions. Sufficient quantity of sensors must be
provided to ensure that the entire motion is positively at its intended position.
4.3 Identification
4.3.1 Cable Identification

Cable identification must be done within each wiring diagram (WD) package. Each interconnection cable
must be identified with a unique number within that WD. Numbers must begin with "1" and run
consecutively (no skips or reserved numbers).
All cables must have approved tags affixed at each end of the cable. These tags must carry the complete
cable identification. Mating receptacles must likewise be identified with the same information. i.e. "WD
12345 - Cable #1", "WD 12345 - Receptacle #1" All cable connections must be shown on WD drawings
and identified with cable and pin numbers. To simplify design, a cable name may be abbreviated within
its' own WD drawing package by omitting the WD number.
4.3.1.1 Receptacles
All receptacles must have conductors identified with the cable number and pin number. This tag will be in
addition to the tag with the wire number.
4.3.2 Standard Tag For Field Devices

Standard Tag for field devices must include:
A. Permanent identification utilizing either an approved engraved tag, mechanically attached to the
front of the enclosure or a Chrysler Group LLC approved oil and weld flash resistant polyester
label Polyester labels must meet the following requirements: Face stock: 2 mil white polyester.
Adhesive: 5 mil acrylic adhesive. Adhesion: min 2.5lbs/inch width on painted metal substrate.
Operating temperature: up to 350 F. Application temp: +45 F. Recommended label supplier:
Whitlam Label Company, Inc. 24800 Sherwood Ave. Center Line, MI 48015-1059 Ph: 586-
757-5100.
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B. Each tag must indicate the device PLC address and Description, function and direction of motion.
Characters must be a minimum 5/32" in height.
C. Tag must be readily visible from the service side of the line and must not be mounted on the
device it identifies or obscure the manufacturer’s label.
Note: For an example of approved tag format contact a Chrysler Group LLC AME Controls Design
Coordinator (reference WD_TAGS)
4.3.2.1 Devices Without a PLC Address

All devices without a PLC address for identification within a given WD must be numbered consecutively
and have a unique identification.
Example: Drawing
Identification
Station #1 Safety Gate #1 S01SG1

Station #1 Pendant #1 S01PD1
Station #1 Safety Pin #1 S01SP1
Station #2 Light Screen #1 S02LTS1
4.3.3 Cable/Receptacle Chart

All cables/receptacles must have a cable/receptacle chart. All cable charts must be located on a single
sheet in the hardwire drawings. These charts must show the relationship between the pin, and the wire
number. Spare wires in the cable chart are NOT to be labeled spare or sp. leave these lines open for
future use.
4.3.4 Identification Tags

All pilot lights, pushbuttons, illuminated pushbuttons, and selector switches must have an identification
tag. The tag must show the function and address number.
4.3.5 Engraved Pushbutton Tags

Engraved pushbutton tags must be sequential as they appear in the cycle. The devices must be arranged
in a logical order from left to right.
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4.3.6 WD Drawings
The WD drawings must identify all limit switches, proximity switches and solenoids with the address
number and function name. Example:
Example:
4.3.7 Devices with Horizontal Motions

Devices with horizontal motions such as shuttles, weld guns, dumps, pivots, and clamps must use only
the position name:
A. The EXTD (extended) is based on the position of the driven member and not the position
of the cylinder rod.
B. The RETD (retracted) is based on the position of the driven member and not the position
of the cylinder rod.
C. The color of, and the location of, the position indicator on the HMI is based on whether
the driven member is at the WORK (amber) or Home (green) position.
4.3.8 Devices with Vertical Motions

Devices with vertical motions such as presses and lifters must use only the position names RSD (raised)
or LWRD (lowered).
Note: Nomenclature for horizontal or vertical motions not covered by 4.3.7 or 4.3.8 must be approved by
a Chrysler Group LLC AME Controls Design Coordinator.
4.3.9 Pendants
Pendants must be identified with the WD number and the description as shown on the WD drawings.
4.3.10 Drives and Motors

All drives and motors must have an arrow indicating the direction of rotation. (See 4.3.2)
4.3.11 Function Naming

A function must be called by only one name. This name must be used consistently throughout the WD
and ladder logic.
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4.3.12 Wire and Electro-Mechanical Devices
Wires and electro-mechanical devices in systems which are connected to a programmable logic controller
must be designated per the I/O address.
4.3.13 Portable Hard Service Cords

All portable hard service cords (single ended, double ended, type STO, SOO etc.) that can be unplugged,
require identification on all plug ends to indicate the I/O address.
4.3.14 Panel / Buss Coordination

All electrical panels having power supplied directly from the plant buss system shall have the appropriate
buss/plug identifier physically located on the equipment identifying the source.
4.3.15 Enabling Pendant Placards

All electrical panels (Gate Pendant, HMI, Operator junction box, etc…) having enabling pendant
receptacles shall have a 8 ½” x 11” (minimum) laminated placard located on the fence in-close proximity,
which highlight all robots and or tooling within the gated area that have motion causing power conditioned
by said receptacle. The graphics on the placard shall be black and white and orientated specifically so
that visually it appears as the equipment is installed with the appropriate “YOU ARE HERE” text and
arrow at the bottom of the graphic. All robots and or tooling capable of moving in manual mode when the
enabling pendant is enabled and the specific panel in which the person is standing at (i.e. having an
enabling pendant receptacle), shall be highlighted / bolded with the remainder of the equipment in a
lighter shade of grey. For a sample, contact the assigned Chrysler Group AME Controls Design
Coordinator.
4.3.16 Lamination Requirements

Programmable devices that are not capable of being backed up/down loaded through software or other
means (i.e. Digi-dog, etc…) shall have the final device settings and or any settings that are different from
the default values reflected within the WD drawings prior to delivery of the As Launched
requirements. The supplier shall provide a laminated placard, per device, indicating the final settings
secured to the enclosure for reference and improved MTTR during replacement.
4.3.17 Control Panel Identifier Requirements

All control panels having lockout capabilities shall have the associated WD number identified on the
enclosure. This identifier will remove confusion within the Plant and support lockout / tag-out
identification placard requirements. For an example of approved tag format contact a Chrysler Group
LLC Controls Design Coordinator (reference WD_TAGS)
4.3.18 Equipment Operating Controls Requirements

All equipment operating controls, including but not limited to disconnect switches, ball valves, shutoff
valves, etc... shall be clearly marked with the function of operation and are permanently tagged and
identified.
Page 15 of 40
4.4 Construction/Installation
4.4.1 Switches and Solenoids

All limit switches, pressure switches, water flow switches, proximity switches and valve solenoids must be
purchased and pre-wired to Chrysler Group LLC Engineering Standards, and from an approved source.
4.4.1.1 Plug and Cord Grips

Plug and cord connectors with wire mesh grips must be provided for STO cord flexing applications.
4.4.1.2 90 Degree Adapter

A 90 degree adapter must be used when cord routing requires a bend into the device.
4.4.2 Terminal Boxes

Terminal boxes must be provided as required to insure that the exposed length of yellow STO cord, used
to connect the switches and valves, does not exceed (3) feet. Any deviation must be approved by a
Chrysler Group LLC Launch Technician.
4.4.2.1 20 Foot STO Cords

20' STO cords used only with Chrysler Group LLC Technician approval.
4.4.3 Portable Hard Service Cords - Conveyance Routed

Portable hard service cords (STO, SOO, etc.) that are routed through an approved conveyance i.e. wire
way, duct, conduit must have protection, at both ends to prevent damage to the cords.
4.4.4 Portable Hard Service Cords - Securing

Portable hard service cords (STO, SOO, etc.) must be secured in accordance to the manufacture
recommendation and in such a manner that the cord will not be damaged by normal equipment use with
an approved strap (Reference NFPA 79).
4.4.5 Part-In-Place Sensors

Part in Place sensors must be provided in each fixture. The quantity and location of sensors will be
determined by the Mechanical Design Coordinators during the 40% design reviews. Sensors must be
provided in a manner that will annunciate a mis-load and prevent damage to the equipment.
4.4.5.1
4.4.6 Supervisor Call

Supplier must provide a white stack light at each manual load/unload station to indicate when an operator
has called for a supervisor. Supplier must provide a selector switch at each manual load/unload station
mounted in an approve run bar / junction box located near the operator. The light must be located at the
aisle in proximity to the operator station and requires approval by a Chrysler Group LLC Launch
Technician. This light/selector switch will be identified with separate tags stating “SUPERVISOR CALL”.
For operation description and or an example of approved tag format contact a Chrysler Group LLC AME
Controls Design Coordinator (reference WD_TAGS).
Page 16 of 40
(Note: When KANBAN is functional within the receiving plant, in conjunction with PFCS, ONLY the stack
light shall be omitted and identified as a cost savings / credit to Chrysler.)
4.4.7 Low Material Call

Supplier must provide a yellow stack light at each manual load/unload station to indicate when an
operator has called for material. Supplier must provide a selector switch (or combination of selector
switches with an illuminated push-button, depending on the quantity of material) at each manual
load/unload station mounted in an approve run bar / junction box located near the operator. The light
must be located at the aisle in proximity to the operator station and requires approval by a Chrysler Group
LLC Launch Technician. This light/selector switch will be identified with separate tags stating “LOW
MATERIAL CALL”. For operation description and or an example of approved tag format contact a
Chrysler Group LLC AME Controls Design Coordinator (reference WD_TAGS).
(Note: When KANBAN is functional within the receiving plant, in conjunction with PFCS, ONLY the stack
light shall be omitted and identified as a cost savings / credit to Chrysler.)
4.4.8 Neutral Position Limit-Switches

Neutral-position limit switches must not be used in applications were actuator travel is (1) inch or less.
4.4.9 Open Wire Terminals

Open wire terminals exceeding 120 VAC on control transformers must be provided with a clear removable
insulator to prevent accidental contact.
4.4.10 Wiring Through Conduit

All wiring that runs through conduit must have Erickson type connectors at each break point that requires
disassembly for shipping. All conduit and associated fittings must be UL listed and installed in accordance
to the latest release of the National Electrical Code.
4.4.11 Multi-Conductor Cable Usage

Multi-conductor cables with plug-in connectors at both ends must be used to connect all components that
require disassembly for shipping.
4.4.12 Multi-Conductor Cables - Spares

All multi-conductor cables must have a minimum of 20% spare conductors.
4.4.13 Multi-Conductor Cables - Spare Wires

All spare wires in multi-conductor cables must be marked with the cable identification and pin number.
These spares must be secured together in an individual bundle.
4.4.14 Multi-Conductor Cable - Configurations

All multi-conductor cables must have a male connector on one end and a female connector on the other
end configured to ensure the absence of "Hot Pins".
4.4.15 Multi-Conductor Cable - Supplier Provided

Supplier must size and provide all required multi-conductor cables and related hardware.
Page 17 of 40
4.4.16 Multi-Conductor Cable - Guidelines
Multi-Conductor cables shall:
A. Be placed in and secured to a commercial cable tray.

B. Be supported and secured in accordance to the manufacture recommendation and in such
a manner that the cable will not be damaged by normal equipment use with an approved
strap (Reference NFPA 79).
C. Be run through the balcony floor when connecting to panels on the balcony.
D. Have its routing and method of support approved by a Chrysler Group LLC Launch
Technician.
E. Be designed to be stored on the balcony when feasible.
F. Be one piece per cable run. Extension cord and/or adapter applications may only be used
with Chrysler Group LLC Launch Technician approval.
G. Be selected from cable types appropriate to the application. All cable types must be
selected from the Chrysler Group LLC Manufacturing Approved Source List.
Applications requiring multi-conductor cable not listed in the Chrysler Group LLC
Manufacturing Approved Source List must require written authorization to deviate.
Proper application must be validated by the cable supplier.
H. Include strain relief and cord grips when applied to continuous/high flexing applications.
I. Be installed and dressed to minimize cable strain and wear when applied to
continuous/high flexing applications. Proper installation must be validated by the cable
supplier.
J. Have a designated ground wire sizes for the application.
K. The designated grounding conductor shall conform to the first make / last break connectivity as
defined within the National Electric Code.
4.4.17 Cable Trays - Commercial

Commercial cable trays must be provided by Suppliers for all cable runs. These cable trays and fastening
components must be UL Listed as equipment grounding conductors and installed in accordance with
Article 392 of the latest release of the National Electrical Code. (Reference Section 16.3.1.1.1 for
additional requirements)
4.4.17.1 Cable Trays - Floor Level

All floor level cable trays must be secured and covered. The cover must be substantial to withstand being
stepped on.
4.4.18 Equipment Grounding Conductors

Equipment grounding conductors must be stranded copper and sized in accordance with Table 250-122
of the latest release of the National Electrical Code. All electrical equipment with in an enclosure must
have a grounding conductor terminated to a listed common ground bar which is bonded to the unpainted
sub-plate. All non current carrying devices within an enclosure must be bonded, where necessary, to the
same ground bar by listed means. Contact a Chrysler Group LLC AME Controls Design Coordinator
for a copy of the latest Grounding/Bonding reference drawing and reference the Book Of
Implementation Guidelines (BOIG) AMS_0220.4.2.1 – Equipment Grounding.
Page 18 of 40
4.4.19 Crimp Feral
When stranded wire is used and the terminals / lugs are manufactured without pressure plates, crimp
feral(s) shall be installed prior to final wire termination to maintain connection integrity and the ability to
achieve proper torque requirements per the terminal / lug manufacture. When the terminals / lugs are
equipped with pressure plates, crimp feral(s) can be omitted.
4.4.20 Processes having Sealer / Adhesive

Purging is required to remove any aged material from the process flow. Secondary detection (Robot I/O)
shall be required to verify the carried nozzle’s physical presence (recorded encoder position) above the
purge bucket to allow any local or remote purging. In addition, purge bucket presence detection I/O shall
be utilized. The purge location shall be:
Robotic Carried Nozzle

The sealer nozzle shall be located 12" above the purge bucket. The purge bucket shall be mechanically
contained to prevent movement and resides below the robot sealer gun nozzle at the home location.
Robotic carried sealers shall only be able to purge at the purge position.
Pedestal Sealers
The material handling robot shall be able to purge from the home or "wait to drop" position. The purge
bucket shall be mechanically contained to prevent movement and resides no more than 48" below the
sealer nozzle. The pedestal sealer shall not be positioned more than 7’ from the floor. Nozzles positioned
higher than 7’ from the floor or purge buckets located further than 48" from the nozzle require approval
from the AME process manager.
4.4.21 Clear Protective covers

All field mounted electrical devices for tooling and or robotic applications (i.e. valves, i/o blocks, etc...)
shall be protected against damage with the addition of a removable clear plastic cover to keep dirt and
debris from accumulating on the block and wires though still visible and accessible for plant personal.
(The examples below represent acceptable solutions.)
4.4.22 Robot Connector Cover

All robots are to have the cable connector location covered to prevent damage to the connector / cable.
(The example below represent an acceptable solution.)
4.4.23 End of Travel Limit Switch for Bridge, Rail, Trolley and Carrier Switch Actuation Method
The placement of the End of Travel (EOT) limit switch and limit switch actuation cam, or trip dog, for the
process equipment supporting the product build is critical for the safety of the operator, the quality of the
product and prevents damage to the equipment and facility. As the equipment trolley and carrier is
moving with the product, within the design job station, the mechanical actuation cam or trip dog shall be
secured to the trolley in a fashion that will reliably trip the limit switch actuator independent of carrier
movement or carrier swing. The preferred location of the actuator cam, or trip dog, is mounted on the
trolley of the carrier. The preferred location of the EOT limit switch is mounted on the inside of the rail to
protect the limit and avoid Nycoil hose or other facility installation devices that will interfere with the limit
switch function. The supplier will show due diligence of the design and demonstrate the repeatability of
the process under normal and abnormal carrier conditions.
Page 19 of 40
Photo 4.4.23.a
Photo 4.4.23.b
Page 20 of 40
Photo 4.4.23.c
4.5 Circuitry Hardware
4.5.1 Motor Control Circuits

All motor control circuits must be hard wired and must meet the intent of Control Reliable (Reference SMI-
162).
4.5.2
4.5.3
4.5.4 Hydraulic Power Units

All hydraulic power units must include an energy conservation feature.
4.5.5 Sensors for Unique Assemblies

The Supplier must provide all sensors necessary to detect unique assemblies within an operation or
system.
4.5.6 Circuit Breakers

All circuit breakers must have visible trip indication and be UL489 branch circuit rated. The use of
supplementary over current protective devices (UL 1077) must comply with NEC requirements.
4.5.7
4.5.8 Motor Starter Overload Relay Contacts

Motor starter overload relay contacts must be wired in series with the motor starter coil. All motor starter
Page 21 of 40
relays and motor overload relays must include auxiliary contacts. A contact from each of these relays
must be wired to PLC inputs for monitoring.
4.5.9 Fusing Coordination

The build supplier must ensure that a fuse, whenever required, will be used for power and interface panel
short circuit/over current protection. The fuse installed in the upstream protective device, ahead of the
plant floor process equipment, must be the maximum amp rating of the switch. This fuse must not exceed
the 175% rating of the feeder. Class J fuses are preferred for plant floor applications. (except for welding
applications)
4.5.10 Buss Plug Fusing Guidelines

Buss plugs that are upstream of the typical control, weld and or power panel, must conform to the
following guidelines. These guidelines are only applicable to product launch, building construction and
equipment installation/relocation.
200 amp fusing and below

Bussmann RK5 class fuse
Dual Element Time Delay
FRS-R 600 Vac
FRN-R 250 Vac
225-600 amp fusing

Bussmann RK1 class fuse
Low Peak, Dual Element Time Delay
LPS-RK_SP 600 Vac
LPN-RK_SP 250 Vac
601 amp fusing and above

Bussmann Class L Fuse
Low Peak, Current Limiting
KRP-C_SP 600 Vac
4.5.11
4.5.12 Control Relay Monitoring

Control relays in Hardwire circuits that are necessary to be energized to permit normal operation must
have a contact wired to an input for monitoring.
4.5.13
4.5.14
4.6 Circuitry Software
4.6.1 PLC Ladder Diagram - Guidelines

PLC ladder diagram construction must conform to the following guidelines:
A. Spare output addresses must not be used for internal logic.

B. Program only one rung to energize an output instruction.
Page 22 of 40
C. Maximum rung size must be determined by display constraints.
D. All addresses must have complete annotation.
E. Rung comments must be utilized to fully document the use/purpose of the programmed rung.
F. Latest version of the Book of Implementations Guidelines.
4.6.2 Ladder Logic Program Organization

All ladder logic programs must be organized per Chrysler Group LLC Logic Standards. These standards
are available from a Chrysler Group LLC AME Controls Design Coordinator.
4.6.3 Timers and Counters

Timers and counters must be assigned with every effort to conserve memory.
4.6.4 Diagnostic Indicating Lights

Process and equipment diagnostics program must be developed to include the following:
A. All position, sequence, and event indicator lights on operator stations must be driven from PLC
outputs. Separate ladder logic rungs must be used to control these lights.
B. Diagnostic logic in the PLC must blink the position or event indicator light of the next event,
action, or sequence programmed, until the event, action, or sequence is complete. The light must
be held on until the device is no longer sensed by the detection switch (limit switch etc..), event,
action, or sequence begins.
C. The completion of the previous event, action or sequence must be used to blink the next event,
action, or sequence indicator light.
D. When the machine has completed the closing cycle, the indicator lights for all event, actions, or
sequences must be held on. As the opening cycle begins, the indicator light for the next event,
action or sequence must begin to blink. When the machine has completed the opening cycle the
functions listed in "B" through "D" must be repeated for the next cycle.
4.6.5 Logic Back-Checking Feature

A logic back-checking feature (using a normally closed contact of the opposing motion in conjunction with
the normally open indicator of the motion being sensed) must be provided on all motions.
4.6.6 Shift Register

PLC logic for all multi-station lines must include a shift register.
4.6.7 PLC Logic - Parity Checks

PLC logic must include parity checks between the PLC memory and the data detected by the sensors as
follows:
A. Wherever style sensitive parts are being introduced into a system. Comparison of shift register
and style sensors.
B. Wherever tooling must be shifted to accommodate a unique style before the part can be married
to the tooling. Comparison of style sensors, shift register, and tool position sensors.
C. Wherever Build System (VMS, AVI, or Manually input, etc.) data is downloaded to the tooling
PLC. Comparison of style sensor, Build System, and shift register data.
4.6.8 Switches - Deceleration

When switches are used to initiate deceleration, deceleration overrun timers must be programmed into
the PLC logic to safeguard against switch failure. Detection of a switch failure must stop the tooling and
generate a fault message or indication of the failure.
Page 23 of 40
4.6.9 Production Simulation Mode / Dry Cycle Mode (Formerly 20-Hour Run)
The supplier must provide a Production Simulation Mode / Dry Cycle Mode. This mode must simulate all
interlocks, part present sensors, etc., as required, in order to make use of the Production Logic for
Production Simulation. The intent is to have only one program, not a Production Simulation Program and
a Production Program, thus insuring that the Production Logic contains all of the corrections that occurred
during the Production Simulation/Dry Cycle. The Production Simulation Mode / Dry Cycle Mode logic will
remain in the system following launch. This feature is only active while in automatic mode. This
maintained pushbutton light is located on the system maintenance screen and can be enabled via a login
and password (see Secured Feature Login section within this document).
Features must include preventing a station from cycling if any production material is detected or
required external conditions are not met. This mode is utilized to simulate production. Equipment motion
is generated without the associated processes expulsing sealant, adhesive, or handling product. This
mode is useful for verifying process flow, robot dressing, cycle-time validation, and interference zones.
Dry cycle zones shall be groups of processes, exact areas to be defined during process verification, and
documented accordingly. To activate this mode, no part present can be detected within the zone (run-out
mode can be utilized to achieve this state). To deactivate this mode, it is required that all style registers
are clear within the zone (run-out mode can be utilized to achieve this state).
1. This mode cannot be enabled (and will drop automatic mode) if any product is detected within the
system (exceptions: any parts in enabled "hold-back" areas such as rack buffers and cross-
transfers).
2. If a part present switch is detected, the line shall stop and annunciate a "PART PRESENT
DETECTED IN DRY CYCLE MODE" diagnostic message shall be activated and displayed on the
HMI. Manual intervention will be required to clear this fault.
3. Robots will go to buffer racks and material rack stands. These must be empty or in bypass in
order to enable the mode.
4. The interaction with AVI must be deactivated in this mode (block build logic enabled).
5. Horizontal conveyors shall cycle with the unloading process.
6. While this mode is enabled, an indicator "DRY CYCLE MODE ENABLED" shall be displayed in
the left hand upper corner on all HMI screens (see example below).
7. The dry cycle mode logic shall not be removed from the code and available for usage at all times.
For detailed specifications, HMI screens and button functionality contact an Chrysler Group LLC Controls
Design Coordinator.
Two methods of dry cycle are available for palletized transfer processes:
"Dry Cycle Without Pallets" will cycle the processes without the presence of a pallet. Process flow
shall always be forward.
"Dry Cycle With Pallets" shall process pallet(s) to the end of the dry cycle zone. Once the zone is
blocked downstream, the process shall reverse the pallet(s) to the zone beginning and restart the
process. The pallet quantity must be identified in the pallet selection prior to selecting this option.
Pallet Quantity Selection

This feature determines the number of pallets in the dry cycle zone to be utilized for the with pallets
feature. The arrow up shall increment the quantity; the arrow down shall decrement the value. This
selection option is located on the system maintenance screen and can be enabled via a login and
password.
Dry Cycle with or without Pallets PBLT and Indicators
Page 24 of 40
These features are only active while in automatic mode. This maintained pushbutton light is located on
the system maintenance screen and can be enabled via a login and password.
4.7 Enclosures
4.7.1 Remote Programming Receptacle

All PLC enclosures must include an approved, remote programming receptacle and duplex outlet (with
cover). This receptacle must be externally accessible.
4.7.2 Panel Design - Knockouts

When an enclosure, junction box, etc… requires entry for communication, receptacles, bulkheads,
conduit fittings, etc..., all required knockout holes shall be made from the sides and or bottom (where
possible). Top entry shall only be permitted for power drop from the plant facilities and shall have the
appropriate listed fittings installed maintaining the NEMA rating of said panel. Any other top entry
requirement not listed above shall have approval from the assigned Chrysler Group LLC Controls Design
Coordinator prior to installation.
NOTE: Any piece of equipment within said panel requiring replacement, due to metal contamination, will
be the responsibility of the company performing the work.
4.7.3 Panel Designs - Cooling Devices

For all panel designs, the supplier must calculate and determine when cooling devices must be applied to
assure proper application of PLC and other electronic equipment. The calculations and any supporting
documentation must be provided to the Chrysler Group LLC AME Controls Design Coordinator for review
as requested. "Ambient Temperature" to be used in these calculations must be determined by the
receiving plant. When cooling devices are required, they are the responsibility of the supplier as a
component of the tooling system. Where an air conditioner is applied, a switch must be mounted inside of
the panel for "on-off" control.
Note: Where calculations indicate that enclosure conditions require the use of active cooling (air
conditioning) the panel lighting transformer must be sized to support the additional load. Individually
protected branch circuits, must be provided as required.
4.7.4 Air Conditioning Units – Stamping Exclusion

Air-conditioning units are NOT required on programmable controller enclosures used in Stamping
Plants.
4.7.5 Fixture Control Panels - Supplier Responsibilities

The build Supplier must furnish, install, and interconnect all fixture control panels.
4.7.6 Locations of Electrical Enclosures

Locations of all electrical enclosures will be determined with the approval of a Chrysler Group LLC
Launch Technician and shown on installation drawings. The location must comply with all National and
Local electric codes and must account for proper working space in front of the enclosure for Arc Flash
protection. (Reference SMI-164) (Reference Section 16 Item 16.4.3.16)
Page 25 of 40
4.7.7 I/O Rack Mounting
Each I/O rack must be installed in accordance to the manufacturers recommendation in a suitable
enclosure (NEMA-12 minimum).
4.7.8 Press Junction Boxes

On press applications provide NEMA-12 junction boxes for each lower fixture, each upper fixture, fixture
valves and press valves. (The press valve junction box is supplied with a Chrysler Group LLC standard
SA-WP-12)
4.7.9 Master Junction Box

A master junction box must be provided for each major component of a system, such as; each fixture,
station, or transfer. This must serve as the collection point for all wiring within that section that is to be
connected back to the power and interface panel. Supplemental enclosures must be provided, as
required, to minimize cord lengths to devices. Interconnections between these enclosures must be done
through hard pipe.
4.7.10 Mounting - Hinges

All enclosure, junction, and terminal boxes must be mounted with hinges in a vertical position. For
applications that require the enclosure to be mounted with the hinge placed horizontally, the hinge must
be located at the bottom of the enclosure to avoid the door closing on an operator. Approval is required
from a Chrysler Group LLC AME Controls Design Coordinator.
4.7.10.1 Enclosures - Identification

All major enclosures and junction boxes must be identified as follows:
A. Permanent identification utilizing an approved tag, mechanically attached to the front of the
enclosure.
B. Each tag must indicate the tool number/unit number, WD number, station and/or operation
number, description as noted in the wiring diagram (WD), and rack/chassis numbers (if
applicable).
Coordinator (reference WD_TAGS).
4.7.11 Conduit Entering Sheet Metal Enclosure

Conduit entering a sheet metal enclosure must:
A. Have listed fastening devices on both sides of the sheet metal.

B. Have an entrance bushing on the end of the conduit.
C. Adhere to National Electrical Code Liquid tight requirements.
D.A. Be UL listed and installed in accordance to the latest release of the National Electrical
Code.
4.7.12 Pushbutton Control Station

Each station that requires manual control must be provided with a pushbutton control station. The control
station must include pilot lights to monitor progress of the machine cycle. Start and finish of each function
must be indicated. Pushbutton enclosures and I/O panel assemblies with pushbuttons must have a
minimum of two (2) spare vertical rows of holes with hole covers installed.
Page 26 of 40
4.7.13
4.7.14 Windows- Stamping Exclusion

Provide a lexan window 1/4" thick in the door of the I/O enclosure to allow observation of I/O racks and
power supply.
- Stamping Exclusion
Lexan window 1/4" thick in the door of the I/O enclosure to allow observation of I/O racks and
power supply is NOT required in the door of the I/O enclosure used in Stamping Plants.
4.7.15 Separately Powered Lighting Transformer

A separately powered lighting transformer, properly sized for the number of light fixtures within the panel,
must be provided for panel deeper than 12". This power source must be maintained in the event of the
operation of the Power Distribution Panel disconnect.
Note: Where calculations indicate that enclosure conditions require the use of active cooling (air
conditioning) the panel lighting transformer must be sized to support the additional load. Individually
protected, branch circuit must be provided as required.
4.7.16 Junction Boxes at Balcony Break Points

The Supplier must provide junction boxes with terminal blocks at all balcony break points, with plug-in
connectors at one end, to facilitate tear down, shipping and reinstallation..
4.7.17 Power Factor Correction Capacitor Units

Power factor correction capacitor units must be provided for all drives but not limited to Servo, VFD’s,
etc., and motors 15 H.P. and larger which run continuously. Capacitor units must be (3)-phase, 480 volts,
completely metal enclosed with external discharge resistors, over current protection devices, and non
PCB filled. The capacitors must be installed in accordance to the drive manufacture or on the motor side
of the starter before the overloads. The capacitor KVAR rating must be sized in accordance with Chrysler
Group LLC Manufacturing Approved Source List. OEM supplied standard designs must include capacitor
units as part of there standard package.
4.7.18 Power and Interface Panel

Each fixture must be provided with a power and interface panel.
4.7.19 Back Panel Spare Capacity

All enclosures must include 20% spare white space capacity for future expansion.
4.7.20 Motor Off Pushbutton

Provide a motor off pushbutton for each fixture pushbutton box which has a motor on pushbutton.
4.7.21
4.7.22 Power Distribution for Weld Control Panels

480 Volt Distribution for weld control panels:
ALL PLANTS (EXCEPT WARREN AND STERLING STAMPING)
Page 27 of 40
Provide 480 volt power distribution boxes, sized to Article 312 (Table 312.6(B)) of the latest release of the
National Electrical Code for Top Entry ONLY, for all weld control panels with line connectors sized to
accept plant feeder cables. Plant feeder cables are to be sized for the thermal equivalent ampacity of the
weld control panel using a 50% duty cycle in the calculation multiplied by the number of load side
connections.
Each power distribution box must have load side connectors sized to support properly sized cables from
the distribution box to the weld controller. A maximum of three (3) AC or four (4) DC weld control panels
per power distribution box will be allowed.
4.7.23 Separation of Conductors for Welding Power

Conductors for welding power must not occupy the same raceway, Junction box, distribution box or
conduit as control, interlock and motor conductors. Exception: Weld power may be run in the same cable
tray using a divider if the equipment manufacturers documented requirements are achieved.
4.7.24 Pre-Hem and Hem Fixture Suppliers

All control components mounted to the fixture are supplied with the fixture. The control design source will
design the pre-hem and hem control systems to the architecture defined for the program and show which
components are fixture supplied or line build source supplied items.
4.7.25 Control Enclosures Raised

Control enclosures must not sit directly on the plant floor, a minimum 4 inch clearance must be
maintained between the bottom of the enclosure and the plant floor.
4.7.25.1 Floor Mounted Control Enclosures Anchoring

Floor mounted control enclosures must have accessible anchoring holes to allow securing while the
control enclosure is in its location.
4.7.26 Terminal Risers

All terminals must be mounted on 1 1/2" risers, where required.
4.7.27
4.7.28 Excess Wiring in Electrical Enclosures

Wires entering electrical enclosure should not exceed the distance from the point of entry to the farthest
terminal using the routing provided.
4.7.29 External Mounting of Control Transformers

External mounting of control transformers larger than 2 KVA is permitted with the approval of a
Chrysler Group LLC AME Controls Design Coordinator. Approval must be obtained prior to
submission of approval designs.
4.7.30 Lighting Panel

A separate 120 volt lighting panel for task / operator lights shall be designed in per zone,
minimum of one per WD package, controlled via the PLC and operated from an HMI
screen. The PLC code shall be flexible enough so that the receiving plant can adjust the shut
down times to fit their operation schedules and have the ability to override the PLC via manual
control from the controlling station HMI. This power source must be maintained in the event of the
Page 28 of 40
operation of the Power Distribution Panel disconnect. For operation description and panel drawings
contact a Chrysler Group LLC Controls Design Coordinator.
4.8
4.9
4.10
4.11 Programmable Controller
4.11.1 PLC Scan Time Requirements

The maximum scan time for all PLC’s shall not exceed 100 milliseconds with the FIS driver inhibited.
4.11.2 Chassis - Spare Capacity

All chassis must include 20% spare unassigned capacity.
4.11.3 Spare Memory

Supplier must provide an additional 20% spare memory to the amount required for the application.
4.11.3.1 Memory Usage Report

Supplier must provide a memory usage report for each PLC prior to delivery of equipment to Chrysler
Group LLC. The usage reported must be inclusive of all Chrysler Group LLC control and information
reporting requirements. The following example contains the minimum reporting requirements:
PLC Program Data Table

PLC Type Total Memory % Free Memory
Description Memory Memory
UB1_1 5/40 16384 words 5036 words 3234 words 50.4%
4.11.4 Solid State Input Devices

Electrical characteristics of all solid state input devices must be coordinated with the hardware (electronic
equipment) to which they are connected to insure reliable operation. In cases where additional devices
are required to condition signals, it is the OEM’s responsibility to provide them. If these devices generate
significant heat, they must not be installed in the same enclosure with the electronic equipment.
4.11.5
Page 29 of 40
4.11.6
4.11.7 Serial Communication Cables

Serial communication cables between the processor and all remote I/O racks must be routed in separate
metal raceways (3/4" minimum) and installed in accordance with the manufacturers installation and
grounding recommendations.
4.11.8 Complimentary I/O

Complimentary I/O is not permitted.
4.11.9 Tooling System Supplier Requirements

The tooling system supplier must be responsible for development, installation and debug of the ENTIRE
PLC program. This must include all logic necessary to cycle the equipment, provide specified level of
diagnostics, and interface to all required plant information networks.
4.11.10
4.11.11
4.11.12 PLC Components

For Processor components, consult the "Project Preferred Sourcing List" (PPSL) issued for each
respective project. When there is no PPSL, consult the Chrysler Group LLC Manufacturing Approved
Source List.
4.11.13
4.11.14 Purchasing Programmable Controller and Components

Programmable controller and components must be purchased new and after the order is received.
Component revision code must be brought up to the revision level as defined with in the program’s Block
Point Release document. For a copy of the program’s Block Point Release, contact Chrysler Group LLC
4.11.15 PLC Programming Requirements

All PLC's must have the ability to be programmed without opening the door of the enclosure.
4.11.16 Programming Equipment - Supplier Requirements

The Supplier is required to provide the following as it pertains to programming support equipment
(Chrysler approved computers and or laptops, Programming Work Stations (PWS), etc…):
o All software necessary for programming instructions, loading, editing, configuring, and
monitoring of controls programs, networks and integrated components.
o All cables and peripheral components necessary to utilize this equipment.
o A suitable industrial enclosure to mount and protect said equipment.
o Individual appropriately sized conduit runs and all listed fittings connecting to the PWS for
connectivity (i.e. 120V AC power, processor communication, Plant ITM/Maintenance
communication, etc…)
§ The conduit run dedicated for Plant ITM / Maintenance communications shall be installed
to the truss level, within the Plant, ending with a 90-degree sweep.
o Individual, appropriately sized over-current protected, branch circuit that will be maintained in
the event of the operation of the Distribution Panel disconnect.
Page 30 of 40
Programming support equipment must be provided for every system, (an authorized Chrysler Group LLC
representative will define the total quantity requirement for an entire program).
All programmable equipment, supplied by the equipment supplier, shall have the ability of being
connected to and backed up from a Programming Work Station (PWS).
Part numbers, insert drawings and software versions will be as specified for the program, contact the
assigned Chrysler Group LLC AME Controls Design Coordinator for information.
4.12 Programmable Message Displays
4.12.1 Programmable Message Display - PLC Utilization

All controls designs utilizing a PLC and HMI must include the functionality of a programmable local
message display. This display must present information and messages to assist in maintenance and
troubleshooting. The specific hardware and application methodology must be provided by the Chrysler
Group LLC AME Controls Design Coordinator as each project is defined.
4.12.2 Marquee Display

On systems larger than three (3) stations the supplier is responsible to provide and install a marquee to
provide event level information for the status of the system. The specific hardware and application
methodology must be provided by the Chrysler Group LLC ITM Department as each project is defined.
4.13 Control Functional Features
A Zone is defined as a physical and logical delineation of control scope. It may be identified by perimeter
barrier devices and / or presence sensing safety devices, placed such that no personal and or automation
can enter / exit without being sensed, in conjunction with other physical and logical process
requirements. Multiple zones can reside within a WD.
A System is defined as the start and finish of a defined process (i.e. S01 Elevator Lowered to S12
Elevator Raised). Multiple WD’s can reside within a system.
The assigned Chrysler Group LLC Control Design Coordinator and Launch Technician shall be
responsible for defining the various Zone(s) of Control, with the OEM, during Wiring Diagram assignment
activities. The resultant of these activities shall be outlined in detail within the Controls Process Review
document(s).
4.13.1 Return to Home Feature

A Return to Home feature shall be provided for each tool that is controlled by a PLC. This will be a
station-level feature selected at the HMI Station Manual screen. This feature shall be operational only in
manual mode with all guarding that restricts access to motions intact. The indicator for this feature ("At
Home") will function in automatic, manual or no mode. This feature will not reset "completes". This feature
will be required on all tooling regardless of the amount of sequences. For operation description contact
the assigned Chrysler Group LLC Controls Design Coordinator.
4.13.2 Run Out Feature

The purpose of run out mode is to completely clear the system of parts (as in preparation for dry cycle or
for weekend work). Run out zones are based on an auto zone and its supportive sub assembly zones.
The specific coverage shall be defined and documented during process verification. The zone coverage
Page 31 of 40
shall be annunciated above the PBLT depicting the affected zones. This feature shall be selectable in any
mode but operational only in automatic mode. This maintained pushbutton light resides on the system
maintenance HMI screen.
When the zone is enabled, all incoming product sources (material racks, conveyors, buffer racks,
etc.) shall be inhibited from bringing in new parts once the requirements are fulfilled for all existing
products within the zone (for instances where part mating is required).
This mode will utilize "hold-back" areas unless they are enabled.
4.13.3 Single Cycle Feature

This feature allows each applicable station to complete its process without transferring the product. Single
cycle zones are based on an auto zone and its supportive sub assembly zones. The specific coverage
shall be defined and documented during process verification. The zone coverage shall be annunciated
above the PBLT depicting the affected zones. This feature can only be activated while in automatic mode.
This maintained pushbutton light resides on the system maintenance HMI screen.
When enabled, each station in the system that has a part will complete one full cycle (achieves
cycle complete).
If only one part is in a zone, that part will only cycle once and will not continue cycling through
each station. The purpose of this mode is to cycle each part completely, not each station.
The control for single cycle will be at the HMIs within the zone. Cycle hold PBs will not activate
nor deactivate single cycle, but will take priority over single cycle.
Single cycle will not exist for overhead systems or cross transfers.
4.13.4 Clamp & Hold Feature

This mode is utilized to verify the material handling device(s) interaction with the product. This mode
applies to all devices within a station. Every station containing tooling and / or robots shall have a clamp
and hold feature. This feature shall be selectable in any mode but operational only in automatic mode.
This maintained pushbutton light resides on the station manual HMI screen.
Clamp and hold shall not apply to idle stations, cross transfers or any pallet return lines.
Clamp and hold shall inhibit all robots, with the exception of material handling robots, from
receiving a new style.
Clamp and hold shall hold all material handling docking robots at the docked position.
Page 32 of 40
Robotic Material Handling
This mode is utilized to verify the robot material handling device(s) interaction with the product. Every
material handling robot shall have a robot clamp and hold feature. This button initiates robot clamp and
hold. This maintained pushbutton light resides on the robot status HMI screen.
Robot clamp and hold shall be selectable in any mode.

Robot clamp and hold shall be operational only in Automatic mode.
Robot clamp and hold shall inhibit the robot from moving after its material handling device(s) have
extended on a pick up.
Robot clamp and hold shall inhibit the robot from opening its material handling device(s) at drop
off.
Robot clamp and hold shall hold Material handling robots that dock at the docked position. Station
clamp and hold also holds material handling robots at the docked position
4.13.5 Maintenance Robot Feature

This position is utilized to place the end of arm tooling into an easily accessible location for a
maintenance technician to service while in an upright, standing position. This position can only be
accessed from the home position. While in the maintenance position, the end of arm tooling shall be
orientated so that if a product was present within the end effector with the material handling devices
retracted, the product would remain in the end effector without falling out. For robots that utilize a
pedestal welder, the weld guns shall be closed to prevent potential cap change (all cap changes must be
performed via the cap change program). If an end effector is not present due to tool change capabilities,
the same position shall apply. Product must be able to transfer while a robot is at its maintenance position
(non-robot to robot hand-off processes). The maintenance position should be clear of all surrounding
robot programmed paths. If this is unobtainable, the use of interference zones is required. This feature
can only be activated while the machine is in automatic mode. This momentary pushbutton light resides
on the robot status and system maintenance HMI screens, however only the button on the robot status
screen applies to material handling robots. The specific robot to be sent to this position must be identified
via the "Robot Selection" prior to initiating this feature.
Maintenance With Part Position

This position is utilized to place the end of arm tooling with a product into an easily accessible location for
a maintenance technician to service while in an upright, standing position, with the material handling
device(s) extended. This position can only be accessed from the "wait to drop" position. While in the
maintenance with part position, the end effector shall be orientated so that if the material handling devices
were retracted, the product would remain in the end effector without falling out. Product must be able to
transfer while a robot is at its maintenance with part position (non-robot to robot hand-off processes). The
maintenance position should be clear of all surrounding robot programmed paths. If this is unobtainable,
the use of interference zones is required. This position can be requested while the machine is in
automatic mode. This momentary pushbutton light resides on the robot status HMI screen. The specific
robot to be sent to this position must be identified via the "Robot Selection" prior to initiating this feature
(see Robot Selection section within this document).
Maintenance Complete PBLT

This feature can only be activated while the machine is in automatic mode and while at the maintenance
position without parts. When activated, the selected robot shall return to its home position. While at the
maintenance with parts, when activated the selected robot shall return to its "wait to drop" position. This
momentary pushbutton light resides on the robot status and system service HMI screens, however only
the button on the robot status screen applies to material handling robots. Additionally, from the robot
Page 33 of 40
status screen, the specific robot must be identified via the "Robot Selection" prior to initiating this feature.
These indicators are available for each robot and reside on the robot status and system maintenance HMI
screens.
4.13.6 Return From Pounce Feature

A Return From Pounce feature shall be provided for each auto zone having robots that is controlled by a
PLC. This will be a station level feature selected at the HMI Robot Status screen. This feature will work
only in automatic mode with all guarding that restricts access to motions intact. This feature will return all
robots in a station to the home position. All robots will have a programmed pounce position. For operation
description contact a Chrysler Group LLC Controls Design Coordinator.
4.13.7 Tip Dress Feature

A Tip Dress feature shall be provided for each tool having robots that are controlled by a PLC. There will
be a global level feature selected at the HMI System Service / Maintenance Screen for that zone. There
will also be an individual / station level feature selected at the HMI Robot Status screen for that station.
This feature will work only in Automatic Mode with all guarding that restricts access to motions intact and
within the allowed cycle time of the machine. This feature will be required on all tooling having welding
robots. A HMI Tip Dress monitoring screen is required to monitor the torque values for the drive
controlling the cutters / motor for ware and damage. For operation description contact a Chrysler Group
LLC Controls Design Coordinator.
4.13.8 Wrong Program Loaded Feature

A "Wrong Program Loaded" logic feature shall be provided for every PLC application. This feature will
compare a manually programmed serial number of the processor to the actual processor system variable
defined in the processor. For operation description and standard logic contact a Chrysler Group LLC
Controls Design Coordinator.
4.13.9 Power On / Fault Reset Feature

A Power On/Fault Reset feature shall be provided for every MR Zone and identified according to the
stations within that zone. This button establishes power to a single MR zone and clears resettable faults.
This feature can only be activated when E-Stops are not enabled. This momentary pushbutton light
resides on a majority of HMI screens and pushbutton boxes.
Power On/Fault Reset shall function as described below:
[Flashing] When MR is active and a resettable fault is active.

[Solid] When MR is active and no resettable faults are active.
[Not Flashing nor Solid] MR not active.
4.13.10 Global Power On Feature

A Global Power On feature shall be provided for every System (i.e. elevator down to elevator up) and
identified according to the stations within that System. This button establishes power to several MR
zones. The global power on areas shall be large groups of processes, exact areas to be defined during
process verification and documented accordingly. This feature can only be activated when E-Stops are
not enabled. This momentary pushbutton light resides on the global system startup HMI screen.
Global Power On shall function as described below:
[Flashing] When at least one MR zone is able to achieve MR

[Solid] When all MR zones achieve MR
[Not Flashing nor Solid] MR zones are unable to achieve MR
Page 34 of 40
4.13.11 Global Automatic Feature
A Global Automatic feature shall be provided for every System (i.e. elevator down to elevator up) and
identified according to the stations within that System. This button establishes automatic mode on several
auto zones. The global automatic zone areas shall be large groups of processes, exact areas to be
defined during process verification, and documented accordingly. This feature can only be activated while
in no-mode. To activate global automatic, the button must be held for a pre-determined amount of time
(per Do’s and Don’ts). During this time, the automatic horn(s) are activated. This momentary pushbutton
light resides on the global system startup HMI screen.
Global Automatic shall function as described below:
[Flashing] When at least one auto zone is able to achieve automatic mode
[Solid] When all auto zones achieve automatic mode
[Not Flashing nor Solid] Auto zones are unable to achieve automatic mode
4.13.12 Abort Pick Feature

If the robot is having difficulty with a part pick-up, the robot can be manually commanded to abort the
pick-up process. This mode is activated from the HMI. If a robot has a part present or material handling
device fault at the part pick-up position, the PLC shall notify the robot that the part pick-up has been
aborted. "Abort Pick" can only be activated if a fault is present. Once activated, the robot shall return to its
home position without product. This feature can only be activated while the machine is in automatic
mode. This momentary pushbutton light resides on the robot status HMI screen. Additionally, the specific
robot must be identified via the "Robot Selection" prior to initiating this feature.
Double Pick Operations (Second Pick-Up)

This procedure is required for material handling applications that removes multiple components. If the
robot is having difficulty with the second part pickup and abort pick was selected, the robot shall move to
the "go to pick 2" position. At this time, the technician can select a re-pick. When "Abort Pick" is active
and the robot has returned home, one of the following process specific methods will cancel the feature:
Part Rack
The rack shall automatically be placed into bypass mode, sending the robot to another like style
position.
Vertical Conveyor
The conveyor will index to the next available style type, canceling the abort pick once the
conveyor has indexed.
Turn Table
The turn table shall index to the operator position with the clear to enter light disabled. The abort
pick shall be canceled once the turn table has indexed.
Abort Pick – Deactivation/User Initiated

When "Abort Pick" is active and the robot has returned home, the technician can select one of the
following methods to cancel the abort pick-up.
Selecting The Re-Pick Feature

This procedure is utilized to re-establish the pick process that was previously aborted. Re-pick selection
shall cancel the abort pick and initiate the "go to pick" program on the same part. This feature can only be
activated while the machine is in automatic mode and while the robot is at its home position. This
momentary pushbutton light resides on the robot status HMI screen. Additionally, the specific robot must
be identified via the "Robot Selection" prior to initiating this feature
Page 35 of 40
The re-pick option is available for the following processes:
Horizontal conveyors
Fixtures
Hand-off nests
Qualifying stands
Shuttles
Transfer pallets/carriers
CMM carts/turn tables
Remove The Product/Style
The technician can physically remove the product (deactivating the part present switches) and then
manually clear the style from the shift register edit screen.
4.13.13 Quality Hold

This mode is utilized to disable transferring of product for large areas. The quality hold areas shall be a
large group of processes. The specific coverage shall be defined and documented during process
verification. This mode activates all single cycle modes for the defined area. The zone coverage shall be
annunciated above the PBLT depicting the affected zones. Any quality hold button within the defined
zone can initiate or deactivate the mode. This feature can only be activated while in automatic mode. This
maintained pushbutton light resides on the system overview HMI screen.
Each single cycle zone can be deactivated individually, releasing product to the process.
If all single cycle zones for that affected quality hold area are off, this mode shall be deactivated.
4.13.14 Cycle Hold

This mode is utilized to hold the process in a known position. Cycle hold zones shall be identically
configured as auto zones. The zone coverage shall be annunciated above the indicators depicting the
affected zones. This feature can only be activated while in automatic mode. This maintained pushbutton
light resides on the system overview HMI screen.
Cycle hold will complete all current motions, then hold, allowing entry into the cell.
Examples of activities that will be affected by cycle hold are, but not limited to:
• Robot program calls will be inhibited if not yet initiated.
• Robots will not continue from pounce.
• Material handling robots will not go to pick-up, exit pick-up, go to drop-off and exit drop-off.
• Weld processes shall complete.
• Sealer/adhesive apply applications shall complete.
• Versa products will complete current motion.
• Tooling will complete current sequence (whether sequence in or sequence out), then stop.
Cycle hold will not affect each motion independently.
The control for cycle hold will come from the existing PBLTs on the pendant boxes and from the
HMI PB on the overview screen.
Cycle hold will take precedence to single cycle and inhibit the system when able.
Cycle hold will exist for overhead systems and cross transfers.
Versa product motion of the first two upstream stations and the first downstream station of the
adjacent auto zones must be held and/or completed prior to cycle being held. This is requested
so potential motion will not be interrupted.
Page 36 of 40
4.13.15 Secured Feature Login / Logout
Several features within this document require secured access. To validate feature activation by an
approved representative, it is possible to disable features until authorization is permitted. Specific login
names and passwords can grant different access to features. The secured area login prompt is activated
by selecting the "Log In" go to button.
Every screen that requires secured access shall have a "Log In" go to button. When selected, an
onscreen keyboard will be displayed for user input. Additionally, a five minute login active timer shall be
enabled. Every screen that requires secured access shall have a "Log Out" go to button. The user group
is displayed in the indicator above the button. When selected, or if the login active timer is done, the
secured feature selection device6s shall be disabled.
4.13.16 Pick Override

This procedure is utilized to retrieve faulty product from inaccessible locations such as a high conveyor,
transfer, or shuttle. If a robot part present or material handling device fault occurs at a pick position, this
feature shall ignore the part present detection and material handling device status. The robot shall be
sent to the "pick override inspection" position at a reduced speed. For robots that require a pick override
feature, the "Abort Pick" option shall not be available. This feature can only be activated while the
machine is in automatic mode and when the robot has a part present or material handling device fault.
The first time this button is selected, the material handling devices shall extend, and after an additional
selection, the robot shall move to the "pick override inspection" position. This momentary pushbutton light
resides on the robot status HMI screen. The specific robot to be sent to this position must be identified via
the "Robot Selection" prior to initiating this feature
Pick Override Inspection Position

This position is utilized to present the end effecter with product into an easily accessible location for a
maintenance technician to inspect while in an upright, standing position with the material handling
device(s) retracted. While in the inspection position, the end effector shall be orientated so that the
product will remain in the end effector without falling out. To exit the "pick override inspection" position,
the technician must select either the "Accept" or "Reject" feature:
Accept
This option can be utilized to exit the "pick override inspection" position and to re-establish the main
process. Once selected, the material handling devices will extend and the robot shall move to the "go to
drop" position. This feature can only be activated while the machine is in automatic mode and the robot is
at the "pick override inspection" position. This momentary pushbutton light resides on the robot status
HMI screen. Additionally, the specific robot must be identified via the "Robot Selection" prior to initiating
this feature
Reject
This option can be selected at anytime once the robot has acquired a part. This option is also utilized to
exit the "pick override inspection" position and cancel the "Abort Drop" feature. When this mode is
enabled, the robot will move to a pre-determined drop position where the suspect product will be
disposed of (floor, hook, etc.). Additionally, the robot shift register data will be automatically cleared, the
robot will verify all end effector part presents are off and return to the home position. In cases where the
reject was selected while an abort drop is active on the second drop, special automatic means may be
necessary to dispose of the first part that was dropped off. This feature can only be activated while the
machine is in automatic mode. This momentary pushbutton light resides on the robot status HMI screen.
Additionally, the specific robot must be identified via the "Robot Selection" prior to initiating this feature
Page 37 of 40
4.13.17 Abort Drop-Off
This feature is utilized in instances where the receiving process has an active part present or clamp fault
and product removal is advantageous to the recovery process. This feature can only be activated while
the machine is in automatic mode. This momentary pushbutton light resides on the robot status HMI
screen. Additionally, the specific robot must be identified via the "Robot selection" prior to initiating this
feature.
When this feature is enabled:
Receiving Processes Without Clamps
The robot shall move to the "wait to drop" position with the product.
Receiving Processes With Clamps
If the receiving process part presents are not activated, the robot shall move to the "wait to drop"
position with the product.
If the receiving process clamps fault while extending, the process clamps shall retract, the robot
material handling devices shall extend and then the robot shall move to the "wait to drop" position
with the product.
Receiving Processes Gravity Drop (Qualifying Stand)
The robot shall re-acquire the product and move to the "wait to drop" position. For stations that have weld
robots at the pounce position, the robots will be commanded to return home from pounce.
Double drop operations (abort second drop off)
This procedure is required for material handling applications that drop off multiple components. If the
robot is having difficulty with the second part drop off and abort drop was selected, the robot shall move
to the "wait for drop 2" position.
Abort Drop – Deactivation
When the abort drop is active and the robot has returned to the "wait to drop" position, the technician can
select one of the following methods to cancel the feature.
Selecting Reject
This option can be selected at anytime once the robot has acquired a part. This option is also utilized to
exit the "pick override inspection" position and cancel the "Abort Drop" feature. When this mode is
enabled, the robot will move to a pre-determined drop position where the suspect product will be
disposed of (floor, hook, etc.). Additionally, the robot shift register data will be automatically cleared, the
robot will verify all end effector part presents are off and return to the home position. In cases where the
reject was selected while an abort drop is active on the second drop, special automatic means may be
necessary to dispose of the first part that was dropped off. This feature can only be activated while the
machine is in automatic mode. This momentary pushbutton light resides on the robot status HMI screen.
Additionally, the specific robot must be identified via the "Robot Selection" prior to initiating this feature
Selecting Re-Drop
This feature is utilized to re-establish the drop process. When selected, it shall cancel the "Abort Drop"
feature and initiate the "go to drop" program. This feature can only be activated while the machine is in
automatic mode. This momentary pushbutton resides on the robot status HMI screen. Additionally, the
specific robot must be identified via the "Robot Selection" prior to initiating this feature
Page 38 of 40
4.14 Early Equipment Management (EEM)
4.14.1 Early Equipment Management

The purpose of the Early Equipment Management (EEM) step of the World Class Manufacturing (WCM)
method is to design equipment that is easy to operate, maintain and inspect and to reduce Life Cycle
Cost (LCC), resulting in fast and stable start-up of equipment in a reliable manner within a defined time
frame. Additional expected results of EEM methods also provide maintainable, accessible equipment
which is easy to operate, inspect and clean. The main activities include formal insertion of EEM in the
product development process through specific design reviews, the definition of quotes and specifications
of supply consistent with user’s needs (operation, maintenance, inspection and disposal) and co-design
initiatives. The OEM shall ensure all WCM and EEM requirements are met throughout the design,
fabrication and installation of the BIW Tooling and Facilities. The OEM shall ensure the following as it
pertains specifically to Controls equipment:
All gage faces shall have markings to indicate the proper operating set point and range. Gage
indication should be clearly visible verification of proper operating settings without having to read
the numbers on the gage face scale. Additionally, alternative means that allow for accurate
operating pressure to be displayed on an HMI, or acceptable display, the gage shall be omitted
from the designs.
All systems’ operating pressure range(s) are clearly identified on the sight gage glass. Each sight
glass shall include a color coded, semi-transparent label applied to outer surface of the gage
glass indicating correct, min/max (green) and incorrect, min/max (red) operating pressuresAll
digital displays are accompanied with labels mounted adjacent to the digital read out, indicating
correct and incorrect operating ranges.
All rotation and flow direction decals are installed where applicable.
All flow meters are installed where applicable.
All hydraulic system filters shall have an indicator to show when the filter element requires
replacement. Indicators should be visible from outside the cell. If possible, the equipment should
be designed for filter replacement while the equipment is running.
All systems have the ability to monitor and adjust key process parameters from outside the cell
(e.g. press tonnage, weld gun current, etc.) while the equipment continues to run.
All equipment operating controls are clearly marked with the function of operation and are
permanently tagged and identified.
Thermal - or other PdM indicators (where practical) are incorporated into equipment design (e.g.:
temperature sensitive labels on all critical components, tonnage monitoring, secondary current
modeling, vibration monitoring).
All equipment requiring air filters include a filter map and all openings shall be labeled with "air in
– do not restrict" and "air out – do not restrict" at the appropriate location, filter type including
NPM#, size, frequency of filter cleaning/change required, and a location to document date of last
filter change. All exhaust ports shall include air flow indicators or streamers to validate air flow
and all filters locations shall be easily accessible. External filters shall be installed on all external
motors.
Exploded assembly diagrams are provided and that they list all parts and detailed part numbers
on the equipment (not just recommended spare parts). Part numbers shall be stamped and
clearly identifiable on all parts. A "Bill of Material" with Chrysler NPM part numbers where
possible shall also be included.
Page 39 of 40
Spare parts lists include NPM codes compiled and readily available in accordance with the TMS
procedure. All recommended spare parts shall be locally available within North America.
All equipment is designed for quick program and machine cycle recovery.
All work instructions for start-up, shut down and fault recovery shall be documented and shipped
with the equipment. Include visual diagrams attached to the equipment. These work instructions
shall be part of the Training Deliverables.
All warning lights are properly labeled and in clear view of operator/operator station.
All shutoffs and controls are mounted outside the work cell in an easily accessible and
ergonomically compliant manner (e.g. solenoids, shutoff valves, motor controls, etc.).
All Automation can be easily put into manual mode of operation.
All Shutoffs block and discharge stored energy, have an internal bleed system. Lockouts shall
isolate material within the piping system.
Alarms are present (sound, lights, messages, pagers, etc.) for monitoring unsafe/dangerous
conditions, faults, running outside of process limits, equipment conditions, or other plant-
designated conditions.
Shutoffs and controls are "easy on and easy off", wherever possible, to enable "weekend" energy
savings.
Centralized access or display for diagnostic information (e.g. weld controllers).
Maintenance time-saving devices are used on the equipment where applicable (example: quick
disconnects, easily removable guards).
When using a hinged guard that is protecting from hazardous motion, it shall be electrically
interlocked and include captive fasteners.
All automatic operations be provided with guarding in accordance with SMI-145. All hinged,
sliding, or lift off guards that enclose hazardous motion and require routine (daily) access to the
industrial machinery shall be electrically interlocked. Automatic operations shall not operate
unless the interlocked guard is closed.
REVISION HISTORY
Revision
Date Number* NAME Description (include pages affected)
1-2-2013 13.01 M. Wesley 4.4.23 End of Travel Limit Switch for Bridge, Rail, Trolley and
Carrier Switch Actuation Method
Page 40 of 40

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Rev.

4.1.2 Supplier Responsibilities

4.1.3 Tryout of Machine and/or Automated Line

4.1.4 Electrical Circuitry

4.1.5 Plug-In Relays

4.1.7.1 Parts Loaded Light

4.1.7.2 Part-in-Position Light

4.1.8 Up-To-Date WD Before Shipping

4.1.11 Part Counters

4.1.12 Operating Voltages

4.1.13 Nominal Voltage Supply Range

4.1.15 Bi-metallic Type Thermal Overload Relays

4.1.16 Field Wiring for Control Circuits

4.1.17 Low Energy Circuits

4.1.18 I/O Devices

4.1.19 PLC Processor Power Sources

4.1.20 PLC Systems - Manufacturers Recommendations

4.1.22 Lamp Test

4.2.1 Controls Design –Chrysler Group LLC Line-up Requirements

4.2.2 Controls Design - Supplier Requirements

4.2.3 Error-Free Designs

4.2.4 Rework Design Requirements – Controls

4.2.5 Controls Design Identification Numbering

4.2.6.1 Wiring Diagram - Timing Chart

4.2.6.2 Wiring Diagram - Facility Chart

4.2.7 Random Skips

4.2.8 Controls Design CAD File Guidelines

[12345] [001] . [DWG] ------------ AutoCAD file extension.

B. Human Machine Interface (HMI)

12345HMIxx.xxx ------------------- Unhanded

[12345HMI] [xx] . [xxx] ---------- HMI file extension.

D. Network Configuration and Calculations

[12345] [ccss] . [xxx] --------- Programming software’s extension.

E. Safety Task Calculation

[12345] Safety Task . [xxx] -- Programming software’s extension.

F. Ethernet/IP Performance Calculation

[12345] ENet . [xxx] -------- Programming software’s extension.

4.2.10 Wire Color

Process Control Network

Network (ITI Plant Infrastructure)

4.2.14 Controls Design - AutoCAD

4.2.14.1 AutoCAD Style and Format Guidelines

A. AutoCAD Text Style must be set to Simplex, Font file: Simplex.shx

| | |----- ZZ = Wire number starting with 01 and numbered consecutively

| |--------- YY = Starting at 01 and numbered consecutively per sheet

|--------------- XXX = Sheet number

4.2.15 Programmable Controller Programming

4.2.16 Controls Design - Document and CAD Data Requirements

A. Approvals (70% Complete)

a. (1) 11" x 17" copy of each WD Drawing Set

B. As Shipped (98% Complete)

The following documentation is required at the time of tooling shipment or completion of

a. (1) electronic copy of all AutoCAD files for all WD’s

a. (1) electronic copy of all AutoCAD files for all WD’s

2. All plant floor 11x17 requirements must be bound.

4.2.17 PLC Monitoring of Safety Devices

4.2.18 Input Device Connection

4.2.19 PLC Controls System - Circuits Protection

A. Programmable Logic Controller (PLC).

4.2.20 Wire Designation - Output Designation

4.2.21.1 Spare Terminals

4.2.21.2 Pushbuttons and Pilot Lights Mounted on Enclosure Doors

4.2.24 WD Cell Layout