E03.65.038.G - Ind.F - EN

PSA PEUGEOT - CITROËN
E03.65.038.G
Production Equipment Norms
ICS : 01.110,21.020,29.020
MACHINES AND INDUSTRIAL INSTALLATIONS
AUTOMATION
WRITING RULES OF THE FUNCTIONAL ANALYSIS, OF THE ORGANIC
ANALYSIS AND OF THE OPERATOR MANUAL
Page 1/55
No use restriction
This is a translation, the French original shall be used in all cases of litigation Date of translation: 29/08/2012
WARNING
This PSA norm has been translated by the PSA Technical Discipline proprietor of this norm.
This document is available on-line in "Normes" Intranet (normes.inetpsa.com) as well as on the B2B portal
(suppliers and industrial partners).
FOREWORD
This English version index F is technically equivalent to the French version index F of this standard. Only
the formalism differs.
This norm or technical specification provides methods and illustrations for the realization of a Detailed Functional
Analysis of the PSA Peugeot Citroën group to describe the automation of an industrial installation.
A glossary of the terms used in this standard is provided in the E03.65.015.G Norm.
A numerical tool for the writing assistance of the Detailed Functional Analysis is available.
The texts in blue and in italics are information whose aim is to accompany the rules.
1. The texts in black preceded by a number represent the rules. Each of them must be implemented and shelf
controlled by the integrator supplier.
2. The control of the correct application of this standard is to be performed with the control support of the guide
GE03-006G part 1 : control of the DFA, AT of the operator Manual.
Drafted by Checked by Approved by
Pascal GEHANT Frédéric TOURNUT Laurent MAUGUY

DRD/DISP/IMAI/AUT/ATA/SDO RT from the 03N/04N network DRD/DISP
DRD/DISP/IMAI/AUT/ATA/HRA
Date Signature Date Signature Date Signature
26/09/2014 - 26/09/2014 - 26/09/2014 -
OR: 27/03/2007 F: 21/08/2014 Network of competences : 03N INTERNAL USE

WRITING RULES AFD, AO, OPERATOR MANUAL E03.65.038.G 2/55
RECORDS
Index Date Nature des modifications
OR 27/03/2007 Creation of the Norm.
Addition of Top design with new numbering of the rules. Addition of the specific
A 08/12/2008 and degraded manual modes with new numbering of the rules and of the
experience feedback, evolution of the OPE charts and safeties of movements.
B 19/01/2012 Recasting of the document
C 27/04/2012 Maintained due to an error during conversion into pdf chapter 7.
D 27/05/2014 Alignment of the index D English to the index D French.
E 07/08/2014 Alignment of the index E English to the index E French.
F 21/08/2014 Alignment of the index F English to the index F French.
PARTICIPANTS
The following persons took part in the drafting and/or checking of this norm:
DRD/DISP/IMAI/AUT/ATA Arnaud BRIEND

DRD/DISP/IMAI/AUT/EMB Stéphane CALDAS, Jean-Louis BOURGEOIS
DRD/DISP/IMAI/AUT/FER Gérard GREMAUD
DRD/DISP/IMAI/AUT/MECA Bernard CHATEAU-JAUNE, Wilfried CARTON, Patrice CHIARUZZI,
Christian KACHEL, Jean-François TERNEL
DRD/DISP/IMAI/AUT/PEMO Olivier RONDET
DRD/DAPF/RHN/NCF Xavier de CARVALHO
CONTENTS
1. OBJECT AND FIELD OF APPLICATION 4
2. DOCUMENTARY REFERENTIAL 4
2.1. NORMS 4
2.2. REGULATION 4
2.3. OTHER DOCUMENTS 4
2.4. EXPRESSION ON DOCUMENTS 4
3. TERMINOLOGY 4
3.1. DEFINITIONS 4
3.2. ACRONYMS 4
4. INTRODUCTION: PRESENTATION / INSTRUCTION FOR USE 5
4.1. PRESENTATION OF THE DOCUMENTS 5
4.1.1. Transversal technical specifications 5
4.1.2. Safety 5
4.2. DFA WRITING 6

4.2.1. DFA summary structure 6

4.2.2. Description of the functional elements 6
4.2.3. Validation milestones of the dfa 7
4.2.4. Follow-up of the versions 8
4.2.5. PCT (procedure of conducting tests) DFA writing 8
4.2.6. DFA Summary 9
4.3. OPERATOR MANUAL 10
4.4. INSTALLATION FUNCTIONAL PCT (PROCEDURE OF CONDUCTING TESTS) 10
5. [M] GENERAL DESCRIPTION OF THE INSTALLATION (TD) 11
5.1. [M] PRESENTATION AND LOCATION (TD) 11
5.2. COORDINATES OF THE PEOPLE INVOLVED (TD) 11
5.3. STUDY DOCUMENTS OF REFERENCE (TD) 12
5.4. TECHNICAL CHARACTERISTICS (TD) 12
5.5. [M] LIST OF THE MECHANICAL FUNCTIONS (TD) 13
5.6. [M] SYNOPTIC (TD) 13
5.7. [M] BRIEF FUNCTIONAL DESCRIPTION (TD) 14
6. [M] INSTALLATION DESIGN (TD) 15
6.1. [M] FUNCTIONAL BREAKDOWN DESIGN (TD) 15
6.2. [M] DESIGN OF THE SAFETY GROUPS (TD) 19
6.3. [M] SAFETY INSTRUCTIONS WHEN IN OPERATION (TD) 21
6.4. [M] DESIGN OF THE ENERGY GROUPS (TD) 21
6.5. [M] DESIGN OF CABINETS AND CONTROL BOXES (TD) 23
6.6. [M] DESIGN OF THE EXPLOITATION MODES (TD) 24
6.7. AUTOMATION ARCHITECTURE (TD) 26
7. [M] FUNCTIONAL ELEMENTS PLC - CELL - RMG – ENTITY OR SEPARATE EQUIPMENT 28
7.1. [M] FUNCTIONAL DESCRIPTION 28
7.1.1. [M] Detailed functional synoptic table (TS) 28
7.1.2. [M] Description of the OPE (TS) 29
7.1.3. [M] Description of safeties (TS) 31
7.1.4. [M] Description of the energies (TS) 34
7.1.5. [M] Description of the cabinets and control boxes (TS) 35
7.2. [M] EXPLOITATION MODES 37
7.2.1. [M] Modes and procedures independent from the manu or auto mode auto (TR) 39
7.2.2. [M] Manu mode (TR) 40
7.2.3. [M] Auto mode (TR) 41
7.3. [M] EXPLOITATION INFORMATION 45
7.3.1. Interface description: [interface name] (TS) 45
7.3.2. [M] Operator terminal description: [identification mark: OT] (TR) 47
7.3.3. [M] Help control graph (TOT) 48
7.4. [M] DIAGNOSTIC 48
7.4.1. [M] Description of help control messages (TR) 48
7.4.2. [M] Description of the diagnostic messages (TR) 50
8. ORGANIC ANALYSIS (TR) 54
8.1. INSTANCIABLE BLOCKS USED (TR) 54
8.2. USER PROGRAM BLOCKS (TR) 54
8.3. MAPPING MEMORY (TR) 55

1.OBJECT AND FIELD OF APPLICATION

The object of this norm is to define the content of the Detailed Functional Analysis, of the Organic Analysis and of
the operator manual.
2.DOCUMENTARY REFERENTIAL
2.1.NORMS
E00.35.117.G MACHINES AND INDUSTRIAL INSTALLATIONS – REALIZATION GENERAL NORMATIVE
SPECIFICATIONS
E03.03.250.G MACHINES AND INDUSTRIAL INSTALLATIONS - AUTOMATION - REALIZATION RULES
OF THE ELECTRICAL FILES
E03.18.051.G MACHINES AND INDUSTRIAL INSTALLATIONS – AUTOMATION – ELECTRICAL
IMPLEMENTATION RULES AND SOFTWARE OF SAFETY FUNCTIONS.
E03.64.160.G MACHINES AND INDUSTRIAL INSTALLATIONS – AUTOMATION - REALIZATION RULES
OF THE OPERATOR TERMINALS
E03.65.015.G MACHINES AND INDUSTRIAL INSTALLATIONS – AUTOMATION - TRANSVERSAL
TECHNICAL SPECIFICATIONS
E03.65.036.G MACHINES AND INDUSTRIAL INSTALLATIONS – AUTOMATION – DESIGN AND
REALIZATION RULES OF THE PROGRAMS
GE03-006G ACCEPTANCE GUIDE OF THE ELECTRICAL EQUIPMENT OF THE MACHINE AND
INDUSTRIAL INSTALLATIONS
2.2.REGULATION
No object.
2.3.OTHER DOCUMENTS
ODIL Numerical tool of machine description and of generation of automation deliverables.
2.4.EXPRESSION ON DOCUMENTS
No object.
3.TERMINOLOGY
A dictionary (glossary) of the main terms and their definitions used in the domain of automation is provided in the
E03.65.015.G. Norm.
3.1.DEFINITIONS
No object.
3.2.ACRONYMS
For the requirements of this norm, the following acronyms are defined:
DFA Detailed Functional Analysis.

4.INTRODUCTION: PRESENTATION / INSTRUCTION FOR USE

 The information contained in the DFA must allow to have a common information source for the realization of the
electrical sketch, of the PLC program and of the MHI application.
 This introduction chapter presents the links between the different documents to be used as well as the structure
of the content of the DFA and the development of its validation phases.
 The rest of the document presents different methods and rules to write the chapters of the DFA in order to
describe in an exhaustive way the behaviour of the automation. .
 The writing of the DFA is based on the needs of the users defined in the specification books for the 4 functions
of help control.
 A single Detailed Functional Analysis document is developed by PLC. This document also contains the Organic
Analysis and the Operator Manual. Exceptionally, for a machine requiring several PLC for its control system, a
single file could be drawn up. In that case a validation of the AUT pilot is indispensable..
 In order to reduce the machine description time, the generation of the documentation (DFA, operator manual…)
and the generation of other deliverables, "ODIL" software has been created.
4.1.PRESENTATION OF THE DOCUMENTS
Transversal Technical Specifications

E03.65.015.G
Numerical tool DFA Norms
E03.65.038.G
Writing initial Detailed Functional Analysis

support of the DFA
Chapitres TOP CONCEPTION
On-line help for the
Chapters : TOP SCHEMATIC writing of the DFA
Chapters: TOP REALIZATION
Chapters TOP OPERATOR TERMINAL
=
Chapters TOP TRAINING [M]
Chapters TOP RECEPTION
DFA deliverables per milestones
Functional PEE
PEE - DFA writing Chapters [M] DFA extracts Installation
= = =
REE deliverable Operator Manual deliverable REE deliverable
4.1.1.TRANSVERSAL TECHNICAL SPECIFICATIONS

The PSA standard, referenced E03.65.015.G, defines the technical terms, the mnemonics and the diagnostic
messages required for the comprehension of the different automation documents.
A correct knowledge of this document is indispensable for the comprehension of the DFA specifications.
3. The mnemonics, the diagnostic and help control messages must comply with the rules defined in the PSA
E03.65.015.G norm.
4.1.2.SAFETY
4. Within the scope of the DFA, the safety rules must comply with the rules defined in the PSA E03.18.051.G.
standard

4.2.DFA WRITING
4.2.1.DFA SUMMARY STRUCTURE
The summary of the DFA proposed is broken down into 3 main parts.
1. GENERAL DESCRIPTION
2. DESIGN
3. PLC DESCRIPTION
4. DESCRIPTION of CELL 1
5. DESCRIPTION of RMG1
6. DESCRIPTION of OP10_01
7. DESCRIPTION of OP20_02 Development of each
8. DESCRIPTION of RMG2 element of the functional
9. DESCRIPTION of OP30_03 breakdown.
10. …
11. DESCRIPTION of CELLx
12. DESCIRPTION of RMGy
13. DESCRITPION of ENTITYz
14. …
15. ORGANIC ANALYSIS
The structure of the chapters for the description of each element of the functional breakdown is described below.
4.2.2.DESCRIPTION OF THE FUNCTIONAL ELEMENTS

5. The general structure of the DFA summary is based on the description of each element of the function
breakdown; PLC, cell, RMG and entities as well as of the separate equipment where each element and
equipment has an independent chapter. For each of them, specify its name (see the naming of the elements
and of the equipment of the E03.65.015.G norm) in the title of the chapter. This concerns the titles of the
chapter of row 1, 2 and 3.
Examples:
 CH5 DESCRIPTION OP10_01.
 CH5.1.1 Description of the safety group SG_01.
6. Each functional element and each equipment is described from the 4 major functions of the help control as
below :
§ n. DESCRIPTION OF THE FUNCTIONAL ELEMENT

§ n.1 FUNCTIONAL DESCRIPTION
§ n.2 OPERATING MODES
§ n.3 OPERATING INFORMATIONS
§ n.4 DIAGNOSTIC
This detailed description per element allows developing all the functionalities and the behavior of the installation.
All the information or functions of the installation are then described in the chapter of the functional element to which
they belong.

7. For readability reasons and to decrease the levels of chapters, all the functional breakdown elements are written
on the same chapter level (Level 1).
8. The progression order of the chapters must allow the visualization of the belonging of the elements between
themselves.
Examples:
 Structure of chapter to be applied : Cell1 / Rmg1 / Entity 01 / Entity 02 / Cell2 / RMG2 / Entity 03 / Screw
driver 1.
 Structure of chapter refused : Cell1 / Cell2 / Rmg1 / Rmg2 / Entity 01 / Entity 02 / Entity 03.
9. The summary will be limited to 4 levels of chapters. For the construction of the document, the level 4 is not
exceeded. The developing or additional rubrics according to the installation are preceded by bullet points in
order to limit the levels of chapters.
10. When the content of several chapters is identical for different functional breakdown elements, it must only be
described in the first of them. In that case, for the other chapters, there is a cross-reference that mentions in
which chapter is found the description.
Examples:
 RMG1 Auto Mode = RMG2 Auto Mode.
 Description in the RMG1 chapter of the auto mode.
 Description in the RMG2 chapter : Cross-reference to the RMG1.
4.2.3.VALIDATION MILESTONES OF THE DFA

11. In order that all the data required for the realization of the project is available at the right time, the DFA is
validated according to 6 distinct milestones defined below: .
12. Each highlighted colour of the titles of each chapter of the DFA represents the milestone of the project phase for
which it must be validated. The colors corresponding to each TOP are defined as below :
 Validation of the functional breakdown : TOP DESIGN
 Chapter required for the realization of the sketch : TOP SCHEMATIC
 Complement required for the realization : TOP REALIZATION
 Complement required to finalize the OT : TOP OPERATOR TERMINAL
 Complement required for the training : TOP TRAINING
 Final acceptance Report : TOP RECEPTION
13. Each TOP is also identified by a mark in the title of the chapter in order not to impose the color printing of the
document.
 Validation of the functional breakdown: Name of the chapter (TD).
 Chapters required for the realization of the sketch : Name of the chapter (TS).
 Complement required for the realization : Name of the chapter (TR).
 Complement required to finalize the OT : Name of the chapter (TOT).
 Complement required for the training : Name of the chapter.
 Final acceptance report : Name of the chapter.
The chapters of the DFA are not imperatively written in the order of the summary. Some information may not be
immediately available or be developed during the writing of the document involving “iterative” updates of the
chapters.
Example: Modification of the functional breakdown after implementation of the rules on Safety.

4.2.4.FOLLOW-UP OF THE VERSIONS

14. The versions of the DFA corresponding to the project validation steps must be subjected to a new index.
 V1.0 Version index TOP DESIGN.
 V2.0 Version index TOP SCHEMATIC.
 V3.0 Version index TOP REALIZATION.
 V4.0 Version index TOP OPERATOR TERMINAL.
 V5.0 Version index TOP TRAINING [M].
 V6.0 Version index TOP RECEPTION.
15. The important modifications performed and validated between 2 validation steps can be the object of an
intermediate index:
 V0.1, V0.2 …before the milestone of the TOP DESIGN validation.
 V1.1, V1.2 … before the milestone of the TOP SCHEMATIC validation.
16. The updating date of the document must be made manually and not automatically from the current date in order
to avoid the printing of the document with a mistaken date.
17. To take the minor intermediate modification into consideration, only the updating of the document can evolve.
18. The evolutions made during the study between 2 DFA versions are visualized by a color marker in order to
easily identify the modifications. These markers are deleted after each validation of the DFA. .
4.2.5.PCT (PROCEDURE OF CONDUCTING TESTS) DFA WRITING

The DFA writing Procedure of conducting tests consists in checking the correct implementation of the rules defined
in this DFA reference data.
19. The conformity of every chapter of the DFA must be recorded by the supplier in a Reprot of conducting tests
provided by PSA: GE03-006G Part 1, tab: control of the DFA, OA as well as operator manual and mentioned
for each validation milestone. The rules of the introduction chapter are to be controlled at each TOP validation.
A version of the RCT is stored at each TOP validation in compliance with the follow-up rule of the afore-mentioned
versions.
20. The chapters to be controlled of the guide GE03-006G Part 1, tab control of the DFA, OA as well as operator
manual must not be modified by the supplier.

4.2.6.DFA SUMMARY

4.3.OPERATOR MANUAL
21. The operator manual is a document obtained from the DFA. The ODIL tool allows to make the automatic
extraction of the operator manual from the DFA with the operations below:
 Update the DFA by deleting all the Non Applicable headings and chapters.
 Create an Operator Manual file by the duplication of the DFA file.
 Delete the chapters that do not contain « [M] » marker.
 Delete the « [M] » markers from the document.
 Delete the highlighting colours (Use the control: CTRL A).
22. No information must be added to the Operator Manual without having been previously integrated in the DFA.
If needed, specific instructions can be added in the DFA for the MO.
4.4.INSTALLATION FUNCTIONAL PCT (procedure of conducting tests)

The functional Procedure of conducting tests consists in checking that the working and behavior of the installation
are in compliance with all the information described in the DFA.
23. A functional RCT is written by the supplier from an Excel file provided by PSA GE03-006G Part 1, tab: functional
tests.
24. To guarantee the exhaustively of the controls this Reprot of conducting tests must be updated from the DFA
summary, previously built with 4 levels of chapters.
In compliance with the following operations:
Select the DFA summary then make a copy thanks to the « CTRL C » control:
Position yourself on the first cell of the control sheet in the Excel file and make a « Special Paste» to the « Text »
format of the summary of the DFA.
The document is then operational to write the functional RCT of the DFA.

25. The functional test tab must be duplicated in order that the Reprot of conducting tests contains the results of the
tests performed for the simulation phases of the tests at the supplier, and of the tests on the site.
For the PCT concerning the AUT standards and trade, use the sheet included in the standard.
5.[M] GENERAL DESCRIPTION OF THE INSTALLATION (TD)

This chapter « General Description of the Installation » allows providing the main general information on the
projects, its environment, its characteristics and the input data used.
26. All the chapters proposed for the general descriptions of the installation must be kept and filled in, whatever the
type of installation.
5.1.[M] PRESENTATION AND LOCATION (TD)

27. This chapter must specify the following points :
 Type of installation
Example: Assembly, preparation, rework …
 Location.
Example: Site of production, workshop, sector, vehicle reference…
 General location sketch of the installation in comparison with the production workshop.
This type of sketch is provided to obtain a global vision of the location and could be used as additional information
during the realization of the functional breakdown of the installation
If the format is compatible, this general sketch is integrated in the DFA, if needed a reference to the initial document
is indicated.
5.2.COORDINATES OF THE PEOPLE INVOLVED (TD)

28. This chapter must specify the coordinates of the people involved in a summary chart containing the information
below :
Name Company Department Function Phone number E-mail

PSA AUT PILOT  00 00 00 00 00 --.--@mpsa.com
Mechanician
Electrician
Automation
Expert

5.3.STUDY DOCUMENTS OF REFERENCE (TD)

29. This chapter must list in a summary chart all the study documents used.
The list and the reference of the standard programming modules used are defined in the Organic Analysis chapter.;
Wording Reference Version Date

Book of specifications/User needs
Project book
AUT Norms
AUT Standards
General functional analysis
Trade standards
External specifications of the Data Processing
System
Specific equipment DFA in interface.
Equipment technical documents in interface
Risk analysis
Mapping label document
Pneumatic files
Hydraulic files
Label detail diagram
chronograms
…
5.4.TECHNICAL CHARACTERISTICS (TD)

30. Define the technical characteristics: performances.
 Production rate.
 Availability.
 Cycle time.
 Manufacturing hours.
 …
31. Define the technical characteristics: energies used.
 Electric: type (light: LU, Motive Force network: FM, welding Force: FS, rescued network…), voltage, neutral point
(TN, TNS…), connection points, use…
 Pneumatic.
 Hydraulic.
 …

32. Define the technical characteristics: product.

 Type, diversity.
 Dimensions, weight.
 Support, login.
 …
33. Define the technical characteristics: environment.
 Temperatures.
 Specific surroundings (Paint, explosive, dusty …).
 Silicone prohibited in paint.
 …
5.5.[M] LIST OF THE MECHANICAL FUNCTIONS (TD)

34. All the mechanical functions are listed in a chart specifying their identification, their designation and their
possible particularities.
The “particularities” field more particularly allows to specify the dependence of a function towards another part of the
installation
Example:
Mechanical Link to the trade

Designation Particularities
identification
RET1 Blank press turnover machine Rotation direction on 180° only
Embarked on the turn-over
CHP1 Pressing trolley n°1
machine RET1
…
5.6.[M] SYNOPTIC (TD)

35. A simplified mechanical synoptic must allow the visualization of all the components of the installation and of its
environment , with their mechanical identifications:
 Elementary safety components.
Example: Gates, Curtains, Light Curtain …
 Elements of the Operative Part linked to automation.
Example: Stores, conveyors …
 Equipment interfaced with the logic controller.
Example: Robots, Torque cabinet…
 Operator stations.
 Sets of energy groups.
 Interfaced installations.

36. Visualise on this simplified sketch the flow of the parts of the installation.
Example:
5.7.[M] BRIEF FUNCTIONAL DESCRIPTION (TD)

37. Describe the main operations required to the realization of a part cycle. This description can be performed by a
writing description or in a graph. .
Example: Parts loading, curtain closing …
Example of flow chart:
Driving Station Carbody arrival

Arrival
CARBODY ARRIVAL
TO
SPECIFIC PLACING
WORKSTATION
PDC ARRIVAL TO ROBOT

INTERVENTION STATION READING OF THE TYPE
AND READING OF THE TYPE OF
VEHICLE
NO
CONCORDANCE DEGRADED
CARBODY/PDC FUNCTIONING
YES
TROLLEY ADVANCE
READING OF THE CARBODY
POSITION BY CAMERAS
PDC IS TAKEN BY THE

ROBOT TROLLEY BACKWARD MOTION

6.[M] INSTALLATION DESIGN (TD)

6.1.[M] FUNCTIONAL BREAKDOWN DESIGN (TD)
The functional breakdown consists in the structuring and regrouping of all the components of the installation into
different functional elements so called « functional breakdown Elements » to ensure the working of each part of the
installation. These are PLC/ Cell/ RMG/ Entity elements that comply with the arborescence below:
PLC
CELL
RMG
Entity
This breakdown is obtained by defining the elements of the lowest level to the highest level of the entity to the PLC.
If required, this construction can be reconsidered during the writing of the DFA, more particularly after the definition
of the Safety and Energy Groups.
38. Specify the specific criteria taken into consideration to perform the functional breakdown.
Example: Creation of 2 RMG in order to authorize a MANU mode on the Left side without perturbing the Right
side.
39. Visualize in a chart the arborescence of the functional elements including the name of the logic controller, the
mechanical name of each element and their designation. .
Example:
PLC CELL RMG Entity Designation

PLC3652
CELL1
RMG1
OP10_01 Loading of operator part
OP20_02 Fitting of robotized welding
RMG2
R1234_1R Placing robot
OP30_03 Turnover machine
OP40_04 Manual welding jig
Out of cell
RMG3
OP50_05 Unloading station
OP60_06 Removal conveyor
PA13_1U SEXTANT passage point
NTR11_1O Line PLC
SAPIA_2U Supervision of the means.
With this definition of the functional elements, it will be possible to copy them from this chart to be used again in
another chart during the writing of the DFA. .
40. In the chart, represent all the interfaced equipment as well as the flow points and locate them in comparison
with the functional elements of which they depend. Specify their name, their designation and distinguish the
corresponding cells by a light Brown background color.
The interfaced equipment for the entities is visualized on the Entity column.
If a separate equipment is interfaced with several functional elements, this separate equipment is then to be located
on the higher functional element – example: robot interfaced with 2 entities, the robot is located under the RMG.
A convention can impose a location for a type of separate equipment to make the breakdown homogeneous.

GENERAL RULES FOR THE OBTAINING OF THE FUNCTIONAL ELEMENTS

41. Each element can be present only one time in the functional breakdown of the installation.
Examples:
 Entity 1 cannot be defined with 2 different RMG.
 RMG1 cannot be defined in 2 different cells. …
42. The elements are to be numbered in the increasing number of the flow.
43. Each element cannot belong to another element of same level.
Example: a cell cannot contain a cell. …
44. All the elements of the breakdown must comply with the arborescence of the PLC / CELL / RMG / ENTITY
functional elements.
Example: An entity cannot contain a RMG.
45. When there is a closed grid zone, protected by an access controlled by the PLC, this area must necessarily
correspond to the one of the functional breakdown elements of the installation.
46. When a same installation is managed by several PLC, the numbers of the functional elements created in each
PLC must coincide if they share a common physical zone.
SPECIFIC RULES TO DEFINE THE « ENTITIES » ELEMENTS
47. An ENTITY is made up of Elements coming from Operative Part whose working is synchronized to perform a
function of the process, under the control of the PLC. It is a mechanical sub-assembly of the installation capable
of performing alone a function of the process of the installation.
Examples:
 Workstation or manufacturing operation.
 Regrouping of handling tables (Turn table + introduction table).
This first breakdown level into entities can then evolve in relation to the other rules defined below.
48. There is at least one ENTITY for a PLC, except when the later only manages a GC function.
49. The EPO depending on different working modes must be defined in different ENTITIES.
50. An ENTITY can have its own working modes under the dependence of RMG’s modes of higher level.
Example: Running-in mode of an Entity when the RMG is in AUTO mode.
51. The ENTITY level represents the lowest level in the functional breakdown.
52. The numbering of the ENTITIES must take into consideration the foreseeable evolutions of the installation and
have reserves if required.
SPECIFIC RULES TO DEFINE « RMG » element
53. An RMG Group of Working Mode is made up of one or several Entities whose working depends on a same
manu/auto selector.
Examples:
 RMG1 Entity 1.
 RMG2 Entity 2 / Entity 3.
54. An RMG cannot have manual mode, in that case there is no manual/auto selector.
55. A manual/auto selector of separate equipment is not considered as an RMG for the automation.
Examples: Manual/auto selector of Robot bay doesn’t constitute an RMG. .

56. The production and/or exploitation constraints can, alone, justify the addition of an additional RMG.
Examples:
 RMG1 = Left parts.
 RMG2 = Right parts.
 RMG1 in manu possible with RMG2 in auto mode and reciprocally.
57. An RMG contains at least one entity.
SPECIFIC RULES TO DEFINE THE « CELLS » ELEMENTS
58. A CELL can be made up of several RMG when they have common functionalities such as : safeties, energizing
functions, exploitation modes…
Examples:
 CELL1 RMG1 / RMG2 Common emergency stop.
 CELL2 RMG3 / RMG4 Common empty mode.
59. The CELL level is optional when it contains one or several independent RMG. The RMG are then directly linked
to the PLC element.
60. When the term “physical cell” is used to describe an automated part of the installation, a CELL must be created
in the functional breakdown so that both designations mention the same area.
Example: latticed cell controlled by the PLC = cell2.
61. The CELL level can contain only one RMG for choices of homogeneity with the other adjoining installations that
have the CELL level. If no constraint is imposed on the project, the cell level is deleted.
62. The scope defined by a functional CELL doesn’t necessarily correspond to a closed area with access controlled
by the PLC and can regroup the outer RMG in a latticed enclosure.
Example: Handling zone, aerial conveyor, vehicle assembly line….
63. A functional CELL contains at least one RMG.
SPECIFIC RULES TO DEFINE THE «PLC »ELEMENT
64. The PLC level is always present in the functional breakdown and represents the highest level in the breakdown.
65. The PLC element regroups all the functional elements of the installation and ensures a Field Command and/or
General Command function.
66. The PLC treats the global functions of the application and the system functions linked to the PLC.
Example: Global rotating light for the installation. PLC system faults,….
67. If the PLC manages a CT function, there is then at least one RMG and one entity
68. The functional synoptic is performed from the mechanical synoptic to which are added the elements below :
 Elements of the functional breakdown.
 Safety Groups/Energy Groups.
 Assisting elements (operator control box).
 Light curtain safety components, gates, ES, operator curtain…
 Connection point with data processing.
 Interfaced equipment.

69. The name of the different elements must appear

The name is made up of the functional name and of the belonging such as defined in E03.65.015.G.
Examples:
 API6_1O: Interfaced API6 PLC.
 CN12_2O: Interface numerical control 12
 EIFFEY_1U: Interfaced data processing machine n°1.
 SAPIA_2U: Interfaced data processing machine n°2.
 R5678_1R: Interfaced Robot R5678.
70. The zone of each functional element must be visualized on the synoptic.
71. The locations of the control boxes and of the operator terminals must comply with the final location on site in
order to correctly position the control units on the control boxes and synoptic tables on the terminals.
Examples:
 The disposition of the command buttons of 2 RMG on a same control box must correspond to the physical
location of the RMG
 Representation of the synoptic tables on the OT in compliance with the exploitation of the terminal.
72. The format of the synoptic table must be exploitable with the Word and Paint standard office automation tools.
Example:
PLC3652_1P (SG_1P, LG_1P) CELL2 (SG_2C, LG_2C)
OT2
CELL1 (SG_1C, LG_1C)

OB12I
RMG2
RMG1 RMG4
OB22C
CU15X
OB25X
OT1 LC12C
Interface WITH
RMG3
EIFFEL PA11
Interface with OB11C
API3651_1O
RMG5
LC15X
(SG_5X, LG_5X)
Interface with OT3
API3653_2O
OB15X

6.2.[M] DESIGN OF THE SAFETY GROUPS (TD)

The Safety Groups of the installation are defined to ensure the wired and scheduled disconnection of the OPE
commands via the energy groups according to the states of the different safety components of the installation.
73. The SG breakdown consists in making the inventory of the safety components then in defining and representing
the action scope of each safety components towards the functional elements. The synthesis is made in a chart
of the safeties obtained from the synthesis chart of the functional breakdown
This breakdown takes into consideration the recommendations defined in the risk analysis or in the technical
specifications managing the safety E03.18.051.G.
74. A SG is defined for one or several safety components having the same action area or impact on the OPE.
75. The action area of a SG compulsorily corresponds to one and single functional breakdown element.
76. The name of the SG depends on the functional element to which it depends.
Example: SG_1P (PLC), SG_2C (Cell 2), SG_4X (RMG4), SG_07 (Entity 7).
77. The OPE are secured by the SG of the elements to which they belong.
78. The construction of the SG must take the availability and production constraints into consideration.
Example: Ensure the access safety in the cell while ensuring the production on another one.
79. Several SG securing the same OPE with the same conditions are redundant. They must be combined to only
keep the SG of the functional element of highest level.
Example: If the installation has only one RMG, the SG is then of PLC level
80. If one safety is common to several functional elements but doesn’t correspond to the perimeter of highest level,
it is then required to define a SG for every elements.
Example: PLC1 = PLC1 + PLC2 +PLC3 with PB, Emergency Stop common to Cell/Cell 2. .
In that case, it is required to create 2 SG: SG_1C and SG_2C that use the same PB.
81. For every SG, it is required to present, out of the chart, the list of the safety components that make it up as well
as the logic equation if needed.
Example: SG_1C = Emergency Stop 1, Gates, Curtain Light, PLC watchdog relay.
82. Only the interfaced equipment concerned by a SG is kept in the chart. If the safeties sent to the separate
equipment are not the image of a SG, list the safety components sent to this interfaced equipment outside the
chart.
Example: ES, gate to the Robot.

83. When one of the construction rules cannot be implemented, the construction of the functional breakdown is
reconsidered.
Examples of breakdown in SG:
SG_1P
 PLC watchdog relay.
 Emergency stops.
 Emergency stops from upstream PLC.
SG_1C
 Access gate of cell1.
SG_1X
 Maintenance stop OB11X.
SG_01
 Operator curtain with safety edge.
SG_2X
SG_3X
 Access gate of the RMG3.
PLC Cell RMG Entity Designation

PLC3652
SG_1P
CELL1
SG_1C
RMG1
SG_1X
OP10_01 Operator part loading
SG_01
OP20_02 Robotized welding jig
RMG2
SG_2X
Out of cell
RMG3
SG_3X
OP60_06 Evacuation conveyor
Towards R1234_1R:
 Absence of Emergency Stops.
 Access door of cell1.
Towards PLC1 - line NTR11:
 Absence of Emergency Stops.

6.3.[M] SAFETY INSTRUCTIONS WHEN IN OPERATION (TD)

84. They describe all the safety instructions applicable on the installation.
85. These instructions concern the use of equipment or the implementation of procedures linked to safety.
Examples:
 Periodic controls.
 Compulsory wearing of glasses in the zone.
 Cleaning and control of the working of a Light beam safety device.
6.4.[M] DESIGN OF THE ENERGY GROUPS (TD)

The Energy Groups of the installation are defined to ensure the power supply functions of all the OPE.
86. The breakdown into Energy Groups allows to identify the different types of energies that supply the OPE of the
installation, their scope of action and the associated components. These energies can be of electrical,
pneumatic, hydraulic or auxiliary types, in a chart of the energies obtained from the synthesis chart of the
functional breakdown.
Examples of breakdown into Energy Groups:
 LG_1P: General electrical energy group.
 LG_1C: Electrical energy group – cell 1.
 PG_1C: Pneumatic energy group – cell 1.
 LG_1X: Electrical energy group RMG1.
 LG_01: Electrical energy group – entity 01.
 AG_03: Auxiliary energy Group for turnover machine lubrication– entity 03.
 LG_2X: Electrical energy group – RMG2.
 LG_3X: Electrical energy group - RMG3.
PLC Cell RMG Entity Designation

PLC3652
LG_1P
CELL1
LG_1C
PG_1C
RMG1
LG_1X
OP10_01 Operator part loading
LG_01
OP20_02 Robotized welding jig
RMG
LG_2X
AG_03
R1234_1R Deposing by robot
Out of cell
RMG3
LG_3X

87. An EG manages one and only one type of energy, but can manage several energies of same type.
Examples:
 Electrical 24V and 400V.
 Pneumatic 6b and 40b …
88. Each element of the functional breakdown can have one or several Energy Groups.
Examples:
 LG_1P = main cabinet electrical energy group.
 PG_1P = 6-bar pneumatic energy group.
 HG_1P = Hydraulic energy group.
89. The EG scope compulsorily corresponds to one and only one element of the same level of the functional
breakdown.
90. There is no « father » EG whose working is identical to a « father » EG.
91. For every EG, it is required to specify, out of the chart, the role of the energy group and the types of energy.
Example: PG_1P = 5-bar pneumatic energy group.
92. An AG energy group is created when an OPE assembly depends on a same source of energy called “auxiliary”.
An AG doesn’t depend on an RMG. These are energies whose type is mechanical movement (conveyor),
spraying, lubrication
93. A separate equipment that doesn’t depend on an energy group is not to be represented in the chart.
The separate equipment (s) that have their own power supply (independent from the PLC cabinet) can appear in
comment out of the chart.
94. The separate equipment (s) that depend on an EG are located at their belonging functional element and are
pointed out by a light brown background. They appear in the « bubble » of the EG to which they belong.
95. When one of the construction rules cannot be applied, the functional breakdown construction is reconsidered.

6.5.[M] DESIGN OF CABINETS AND CONTROL BOXES (TD)

Example :
Legend :
Locat :
Stationary operator terminals Visu & cmd control
PLC Cell RMG Entity or connection boxes of the and visualization
mobile terminals scope.
Manu Cmd.: scope of
manual commands
OT1 OT2 BT21B BT31B Designation
Visu & Visu & Visu &
PLC3652
cmd cmd cmd
EC11P Main cabinet
Cell 1
OB1OT11P Location. Driving panel
Control box for cell
OB1GT11C
access – gate 1
Access control box for
OB1GT21C
cell1 – gate 2
Manual
RMG1
cmd
OP10_01 Loading of operator part
Operator control box –
OB1OP_01
OP10_01
OP20_02 RobTOized welding jig.
Manu
RMG2
comd
Connection box for
Location.
BT21B mobile terminal – Gate
1
OP40_04 Manual welding jig.
OB1OP_04
OP40_04
ROBOT_1R Gluing robot
OB1OP_1R
glue presentation.
Out of cell
Visu &
RMG 3
cmd
Location.
OB1OT13X Driving panel
Connection box for
BT31B Location. mobile terminal – Gate
3
RMG access control box
OB1GT33X
– gate 3
Manu
cmd
OB1OP_05
OP50_05
Manu
cmd

96. This general presentation allows defining all the cabinets and control boxes including driving elements of the
installation, control and/or signalization. It allows defining the scope of each OT at the connection point of a
mobile terminal.
97. The name of the control boxes takes the physical mark of the element of the installation.
Example: OB1GT11C, AR11P …
98. Each cabinet and control box is necessarily linked to one element of the functional breakdown and must be
described opposite the chart. The functional elements that have neither cabinet nor control box are not
represented in the chart.
99. For each OT and each connection box of the mobile terminals, 3 criteria must be defined : the visualization
scope and diagnostic, the manual control scope and the physical location.
100. For the mobile terminals that can be disconnected, a matrix must make the link between the connection
points (and their scope) and the different mobile terminals that can be connected to them.
Example:
BT11B BT12B BT21B BT22B
OT3 x x
OT4 x x
101. For each cabinet and control box, the heading « Designation » allows to briefly specify their main function,
to add precisions on their location if required.
6.6.[M] DESIGN OF THE EXPLOITATION MODES (TD)

General presentation of the exploitation modes :
EXPLOITATION MODES
AUTO MODE MANU MODE
IN PRODUCTION OUT OF PRODUCTION OUT OF PRODUCTION
NORMAL DEGRADED MODES SPECIFIC RUNS  Manual mode of the OPE.
MODE Example : Example :
Normal cycles  Out of order equipment  Empty mode
 Mode without scheduling system  Running in mode
… …
PARTICULAR PROCEDURES BACK-UP PROCEDURES

Example : Example :
 Access request  Back movement
 Request for part removal  general opening
 Part presentation request for control  starting again of screwing
 Emptying request …
…

Example of design chart concerning the operating modes:
Operating and procedures independent from the manual mode or auto mode.
PLC Cell RMG Entity Mode Name Particular procedures Back-up procedures Control box
OB1GT11C
CELL1 Request for access
OB1GT21C
Operating and procedures in manual mode
Manual mode
Back-up
PLC Cell RMG Entity Name of the mode Particular procedures Control box
procedures
OB1OT11C
RMG1 MANU
(OT1)
OB1OT11C
OP10_01 Forcing of label reading
(OT1)
OB1OT11C
RAZ TE
(OT1)
OB1OT11C
General opening
(OT1)
Functions and procedures in automatic mode
Normal mode
Back-up
procedures
OB1OT11C
CELL1 Emptying request
(OT1)
OB1OT11C
RMG1 AUTO
(OT1)
OB1OT11C
OP10_01 Normal
(OT1)
OB1OT11C
Part stop request
(OT1)
OB1OT11C
Emptying
(OT1)
Back movement OB1OP_01
Screwing restart OB101
Degraded functions in automatic mode

Back-up
procedures
Robot placed out of production OB1OT11C
RMG1
1R (OT1)
OB1OT11C
OP10_01 Forced engagement mode
(OT1)
Movement back-
OB1OP_01
up
Specific functions in automatic mode
Back-up
procedures
OB1OT11C
OP10_01 Empty mode
(OT1)
Movement back-
OB1OP_01
up
102. For every functional elements, list in a design chart all the :
 Procedures independent from the exploitation modes.
 Functions and procedures in manual mode.
 Functions and procedures in automatic mode.
The working of each mode or procedure defined in the design chart is then detailed in the chapter : « Exploitation
modes » of every functional elements.

103. The breakdown elements having no exploitation mode are not represented in the chart.
104. For each exploitation mode and procedure, specify their name in the suitable column next to the element of
the functional breakdown concerned. .
Example: Empty mode, reading of the memory hub, declaration of part refused, general opening….
105. Each line of the chart must correspond to only one element of the functional breakdown and to only one
mode and/or procedure
The non filled-in cells of the chart are grey in order to emphasize the modes to be described.
106. The procedures that don’t depend on a mode are defined at the beginning of the chart in the heading:
“Procedures independent from the exploitation modes”.
107. In the heading: "Manual mode", define for each RMG a line corresponding to MANU (out of RMG without
manual mode).
108. In the heading: "Normal mode" define for each RMG a line corresponding to "AUTO" and for each entity a
line corresponding to "Normal mode" (to describe the associated operating cycle).
109. In the headings "Degraded functions in automatic mode" and "specific functions in automatic mode " list the
modes of each element concerned. .
110. The connection of a particular or back-up procedure to an exploitation mode must be emphasized in the
chart. .
Example :
Examples:
 If the mode is selected with a PB, specify "control box OB11X".
 If the mode is selected with the terminal, specify "control box OB11X (OT1)".
111. A back-up or particular procedure common to several modes of several functional elements is to be listed at
the beginning of the heading.
Example : Particular procedure "Empty mode of the entities and separate equipment of the cell1".
112. A back-up or particular procedure common to several modes of a same element is to be listed for each
case in the chart.
113. The column « Control box » specifies for each mode, the name of the control box and/or the Operator
Terminal allowing the selection of the mode. .
6.7.AUTOMATION ARCHITECTURE (TD)

114. The automation architecture must be presented with a schematic diagram in order to visualize the following
element :
 PLC (Type, configuration memory, PLC name …).
 Material configuration (Rack Cards, networks and connections used …).
 Field bus, types of I/O modules used (IP20, IP67), repeaters, switch…
 Communication bus (Ethernet with switch, series connections …).
 Interfaced equipment, connected to logic controller (Data processing systems, Robots, Bar Code reader…).
 MHI (Control boxes connected, Operator Terminals, production displays …).
115. Number of field bus and inter PLC networks, from 1 to n, in order to use again this numbering in the electric
file. Visualize the networks by different colours. .
116. Mention at least 1 element of each type of automation equipment present on the installation.

Example :

7. [M] FUNCTIONAL ELEMENTS PLC - CELL - RMG – ENTITY OR SEPARATE

EQUIPMENT
117. Risks of Quality of Product
 Mention that it concerns a workstation that includes risks of quality of the product.
 List the risks linked to electricity/automation.
 For each risk, mention the solution implemented or the chapter on which it is detailed.
7.1.[M] FUNCTIONAL DESCRIPTION

7.1.1.[M] DETAILED FUNCTIONAL SYNOPTIC TABLE (TS)
The detailed synoptic table allows locating, animating the sensors and representing the behavior of the mechanical
element to assist in the comprehension of the working of the installation.
This chapter is generally present in the chapters of entity level.
Example:
Niveau 6100 Niveau 0
Depuis TG223 Vers TG100
Repos AR Travail AR
(Evac) SQ1TG407 (Evac)
SQ2TG407 Mobile
en cours de
Sens Moteur
Sens Moteur
Mobile PL17Y
PL17Y
en cours de transfert SQ1PF13I

transfert vers ligne
dans la SE retouche SQ2PF13I
SQ3TG407
Travail Repos
(Intro) SQ4TG407 (Intro) TG224
AV TG224 AV
SQ1RI107 SQ1RI207
RIDEAU SUPERIEUR RIDEAU INFERIEUR
SQ1RI107 SQ2RI207
AV
SQ1TG508
SQ2TG508
Sens Moteur
PL18Y
SQ3TG508
SQ4TG508
AR TG225
BB1PP_08
SQ1PM_08
BI108

118. An entity must be represented in a « detailed functional synoptic table » to visualize the elements mentioned
below :
 Location of all the sensors :
 The sensors of the OPE..
 The sensors out of the OPE.
Example: Detection of presence of part, part presence Cell …
 Including the analogue or complex TOR sensors.
Example: multi position plates, handling manual system, multi-tracks, coder… …
 The interfaced equipment.
 The safety components.
Example: Location of Light Curtain, Bi manual…
119. These views must be developed to be reusable on a page of the Operator Terminal.
To keep a correct readability, the synoptic could be broken down into several pages.
The elements liable to be animated on the Operator Terminal are directly developed from the drawing tool
integrated to the Terminal and then integrated in DFA. This process will allow avoiding multiple data entries and the
elaboration of a synoptic that could not be exploited by the Terminal.
7.1.2.[M] DESCRIPTION OF THE OPE (TS)

120. This chapter is generally present in the chapters of entity level.
7.1.2.1.Synthesis of sensors and actuators (TS)

121. For each element of the functional breakdown, list all the OPE (Actuators/pre-actuators/associated
sensors) in a summarizing chart to describe the following data :
 Designation of the OPE and its mechanical name.
 In the development order of the cycle.
Examples: Tightening A, Swing unit B, PILOT C …
 Iin the order of the production flow.
Examples: RB221, RB222, RB223 …
 Identification of actuators.
 Type of pre-actuators controlling the OPE or detectors.
 Precise type of Rest/Work movements.
Examples: Up motion, opening, advance, back motion, stop, working….
 List and comment of the Sensors/pre-actuators.
 Mnemonic of the component.
 Safety treatment : allows to specify if the sensor is directly used in a wired safety chain or in a safety PLC.
Example: Over travel sensor.
 For the actuators, specify the stop category, in compliance with the EN60-204-1 Standard, considered in the risk
analysis. .
 Mention if the sensors (NO or NC) / pre-actuators are controlled in PLC I/O.
122. This synthesis chart is also used to describe the isolated sensors.
Examples: Presence of part, presence of tool…

123. Other charts can be added according to the needs to define and list the additional information on the OPE.
Examples: Power, motor reference ….

7.1.2.2.Specific OPE description [OPE Name] (TS)

124. This chapter allows to define the behavior of some specific or complex OPE. The OPE using intelligent pre-
actuators (that communicate on field bus) are also to be described in this chapter. .
Example: detailed cartography of the memory hubs,…
Examples: Speed voltage regulator, positioning, coder…
For the exchanges with the intelligent (example: speed voltage regulator), use the formalism of the description
chapter of the interfaces.
7.1.2.3.[M] Movement condition of the OPE (TR)

125. For each chapter that contains OPE, define the list of the mechanical and electrical safety conditions for the
“rest” and “work” movements in order to authorize the MANU and AUTO modes in the PLC program.
The mechanical safety conditions represent the inter-locking (s) to be performed in the PLC to proscribe some
movements and avoid mechanical collisions.
The safety conditions can be common to the MANU/AUTO modes, for the Rest/work or Specific to one or the other
of these modes.
7.1.3.[M] DESCRIPTION OF SAFETIES (TS)

126. For each SG, its detailed description is affected in the chapter of the element concerned, in a chart that lists
all the electrical and safety components required for its implementation. .

Example SG_1P (SG PLC) :

Safety group : SG_1P
PERMANENT CONDITIONS
Safety components Inhibition Acknowledgement Signaling
Designation Location Designation Location Designation Location location
Upper SG --
On the All the OT : Dedicated
Emergency PB 1 OB1GT11C NA NA Unlocking
button AU icon.
Unlocking On the All the OT : Dedicated
Emergency PB 2 OB1OP_01 NA NA
button AU icon.
Wire emergency Along the line OP10 Unlocking All the OT : Dedicated
NA NA OP10
stop to OP30 icon.
SG TREATMENT
Function SG component Acknowledgement Signaling
Designation Location Designation Location Location
Self control PLC validation relay KA1SV_1P Automatic NA NA
Safety PLC SG Relay KA1SG_1P Automatic NA NA
SIGNALING
Light SG_1P on White Presence of at least emergency stop.
OT
Green ES ok
Example SG_01 (SG of the entity 01) :
Safety group : SG_01
MHI Components
OB1OP_01 OB1OP_01
HL1LC_01
Operator HL2LC_01
validation
HL1LC_01
SB1VD_01
HL2LC_01
Validation Signaling
Safety components Inhibition Acknowledgement Signaling
Designation Location Designation Location Designation Location Location
Upper SG SG_1C
LC101 OP10_01 NA NA PB of validation OB1OP_01 NA
SG Treatment
Function SG component Acknowledgement Signaling
Designation Mnemonic Designation Location Location
Self control Relay of entity validation KA1SV_01 Automatic NA NA
Safety SG contactor KA1SG_01 Automatic NA NA
SIGNALING
Red light tower Stationary Armed light curtain – on-going process – do not cross the LC.
Flashing Incoherence of light curtain– waiting for acknowledgement
Green light tower Stationary Waiting for operator work
Flashing Waiting for operator validation
WORKING
Not protected OPE PILOT A not protected by the light curtain.
Description Operator safety : anti-intrusion light curtain

MHI COMPONENTS
127. Define the possible HMI components used for the signaling of the SG state. .
Permanent Conditions
128. The permanent conditions are described by :
 The reference of the higher SG (« SG father »).
 Each safety component linked to working and to the validation of the SG, is described on a distinct line by
specifying its location, the inhibition functions, acknowledgement and signaling.
Treatment of the SG, self-control heading, safety heading
129. A SG can be treated either in wired safety or in scheduled safety (safety PLC). A SG is characterized either
by a relay / contactor in wired safety or by a program object (SG bit) associated to a disconnecting component
(safety outlet…) in programmed safety.
130. In wired safety, each relay or SG contactor depends on a validation relay piloted by the PLC to ensure the
self control functions of the safeties, called KA.VS…, whose level is equal or higher to the element concerned.
Examples: Relays KA1SV_1C performs the self-control of the relays of the complete cell1, for the RMG SG 1 and
2.
The use of the self-control relay to SG level allows limiting the perturbations on the installation in case of
disconnection further to fault. The choice depends on the availability and of the safety level.
The self-control function is performed in compliance with the recommendations defined in the E03.18.051.G
standard.
131. The relay or SG contactor, in charge of the control of the power supply of the control of the OPE, is of KA,
KM or KT type depending on the type and the category of OPE stop to make safe.
132. All the OPE of the installation must be under the control of at least one SG.
133. In wired safety all the SG do not necessarily have relay or SG contactor. It is the case if all its OPE are
already under the control of a relay or SG contactor of lower level.
134. The SG functions are obtained starting from the entity level up to the PLC level, in compliance with the rules
below :
 If one OPE directly depends on a SG entity, there is a SG of the entity
The SG of entity level systematically has a SG relay or a SG function in the safety PLC.
 If an OPE directly depends on a RMG SG, without belonging to an Entity SG, there is a relay or RMG SG
contactor or a SG function in the safety PLC.
 If an OPE directly depends on a Cell SG, without belonging to an entity SG or RMG, there is a relay or cell SG
contactor or a SG function in the safety PLC. .
 If an OPE depends directly on a PLC SG, without belonging to an entity SG or RMG or cell, there is a relay or SG
contactor of the PLC or a SG function in the safety PLC.
Signaling
135. The heading « Signaling » allows to describe the behavior of the lights associated to the SG.
Working
136. The heading « OPE not protected » specifies if some OPE are not protected by the SG.
Examples : Suction cup, blocker …
137. The heading « Description » must allow to specify the working of the SG and the particularities linked to its
safety components or to its separate equipment. .
138. If some OPE of one functional element, depending on a safety group of higher level, require a particular
treatment, it is described in the description chapter of the safeties of this element.

Example: Stopping procedure of a voltage regulator in an entity further to a general emergency stop
ENT01 Particular treatments of the Safety systems
SG just above SG_1C
* the stop of the voltage regulator of the lifting Section must ensure a braked stop in
Description
case of loss of the Safety group SG_1C (stop of type 1)
139. The breakdown into SG and their detailed description allow performing the electrical sketch of the safety
relays or the sketch and the application of a safety PLC.
7.1.4.[M] DESCRIPTION OF THE ENERGIES (TS)

140. Each EG, defined in the graph of the energies, must be described in the chapter of its functional element, in
a chart that lists all the components required for the management of the group.
The description chart exploits the breakdown of the Energy Group to define the wired and scheduled treatment to
be implemented to pilot each EG.
Examples:
Electrical Energy Group

LG21P
MHI COMPONENTS
OB1OT11P OB1OT11P OB1OT11P
MISE EN MISE HORS
SERVICE SERVICE
IPB
validation and
BLANC ROUGE IPB stop
SB1EY_1P SB1EO_1P
HL1EY_1P HL1EO_1P
Validation Stop Signaling
INITIAL VALIDATION CONDITIONS
Safety KA1SG_1X & KA1SG_01
Energy NA
Operative part NA
Absence of events NA
Safety KA1SG_1P & KA1SV_1P
Energy NA
Operative part NA
Absence of events Refer to reactions described in the charts of the events.
EG TREATMENT
Function Component acknowledgment
Designation Mnemonic Designation Location
PB
Self control PLC validation relay KA1VL_1P Fault OB1OT11P
acknowledgment
Pre actuators Power contactor KM1LG21P NA NA
SIGNALING
POWER ON Stationary activated
flashing Authorization activated
POWER OFF stationary Out of operation
WORKING
Description PLC power supply, OT and input cards.

MHI Components
141. Visualizes the MHI components used for the power on/off and the signaling of the state of the group. The
components to be integrated correspond to those defined during the detailed description of the cabinets and
control boxes. Mention the name of the control box on which is found the component.
The models of the MHI components, or control units are available in the index of the writing model of the DFA. .
Initial conditions
142. Includes all the conditions that must be present to energize, but which are without effect when the request is
taken into consideration.
Permanent conditions
143. Includes all the conditions whose loss involves the power off of the group.
144. Each EG must depend on a validation relay piloted by the PLC to ensure the self control functions called
KA.LV…, KA.PV…, KA.HV… ou KA.AV… according to the type of energy of the EG, of the equal or higher level.
Example: Relay KA1VL_1C cell performs the self-control of the EG relays of the RMG 1 and 2.
The use of self-control relay at each level of EG allows to limit the disturbances on the installation in case of power
disconnection further to fault. The choice depends on the availability.
EG treatment, pre-actuator rubric
145. The "Pre-actuator" line mentions the pre-actuators used for the implementation of the pneumatic, hydraulic
and auxiliary energy groups.
Example : 6-bar disconnection electro valve and progressive pressurizing electro valve.
146. The pre-actuators of the EG must take into consideration the categories of stop of the OPE that it contains.
The stop categories are specified in the description chart of the OPE.
Examples :
 A motor is stopped in category1, the pre actuator of its EG is of KT type.
 Electro valves are disconnected in category 0, the type of pre actuator is of KA or KM type..
 If in a same EG, 2 motors must be stopped in category 1, one of which having to stop in 1 second and the other
one in 2 seconds, the KT will then have to be adjusted to 2sec.
Signaling
147. The heading « Signaling » allows to describe the behavior of the lights associated to the power on/off
components.
Working
148. The zone "Description" specifies the working of the energy group. If required, for the more complex working,
other shape of representation and of description such as Grafcet, flow charts, chronograms …will be provided.
This representation shape is developed out of the chart, in the same chapter.
If the functional elements belonging to an energy group require a particular treatment, it is described in the
description chapter of the energies of this element. The breakdown into EG and the detailed description of
each of them must allow to perform the electrical sketch of the energizing relays.
7.1.5.[M] DESCRIPTION OF THE CABINETS AND CONTROL BOXES (TS)

149. This chapter exists for each element of the breakdown including a cabinet or control box.
Each cabinet or control box is described in a sub chapter specifying its name.

7.1.5.1.[M] detailed description : [Name of cabinet or control box] (TS)
150. The detailed description of the control box of each functional element must indicate all its control and
signaling components (including the diagnostic or working light towers) in compliance with the final location. It
alone provides all the indications required on the control elements.
Example :
HL1FT11X
BOX
OB1OT11X INNER
PART
MANU AUTO
BLU YELLOW
W
OT1
HL1MN_1X HL1AT_1X
CELL START MANU AUTO INHIB.LC101

WITH WITHOUT
455
SB1ST_1I SA1MD_1X SB1ES_1I SA1IH_01
The behaviour of the components is defined in the exploitation running chapter in the description charts planned for
this purpose.
151. Represent the lock on the front face of the cabinet or of the control box in order to validate its location on
the installation as well as the type of key.
152. The possible components located inside an envelope are facing each other in a dotted line zone. .
Examples: switchover limit shunt, Light Curtain inhibition …
153. The representation of the components: PB, selectors, lights, operator terminals … must be in compliance
with the models proposed in appendix of the writing model of the DFA, in order to visualize and easily modify the
following elements :
 Type of component.
 Colour of the component.
 Reference of the keys used with key back recess position if required.
 Exact wording of the labels in compliance with the final location.
 Mnemonic (electrical sketch / schedule).
The models proposed can be modified or/and completed according to the needs of the installation.

154. The position of the control components must take into consideration the physical location of the functional
elements on the installation.
Example: RMG1 commands are on the left and RMG2 on the right if the RMG1 is located on the left of the control
box and the RMG2 on its right.
7.2.[M] EXPLOITATION MODES

155. Each exploitation mode (Normal, degraded, specific) and procedure (Particular, back-up) defined in the
design chart of the modes, must be developed in a detailed description chart. Description chart common to all
type of mode and procedure:
- [TYPE OF EXPLOITATION MODE] -
[Name of the
MODE : - [Name of MODE] -
functional
PARTICULAR PROCEDURE : - [Name of PROCEDURE] -
element]
BACK-UP PROCEDURE : - [Name of PROCEDURE] -
ROLE / SCOPE
MHI COMPONENTS
[Name-Control b. [Name-Control b. [Name-Control b. [Name-Control b.
[Name page] [Name page] [Name page] [Name page]
Component
specific
Component Component Component
MHI
HMI Validation HMI Stop HMI State
Required for
mode mode mode
the mode or
the procedure
[Mnemonic] [Mnemonic] [Mnemonic] [Mnemonic]
[Function] Validation Stop Signaling
VALIDATION INITIAL CONDITIONS
Safety
Energy
RMG/ENT state
Operative part
Absence of events
STOP INITIAL CONDITIONS
Safety
Energy
ENT/RMG state
Operative part
Absence of
events
Safety
Energy
RMG/ENT state
Operative part
Absence of
Refer to reactions described in the charts of events.
events
SIGNALISATION
[Wording of
Stationary
light 1]
Flashing
[Wording of
Stationary
light n]
Flashing
MODE
particularities
Description

Exploitation mode/Procedure
156. The title of the chart must indicate the type of the exploitation mode.
Examples: Procedure independent from the exploitation modes, manual mode, degraded mode in manual, normal
mode, degraded mode in automatic mode, specific mode in automatic mode.
157. A particular procedure or a back-up procedure can or cannot depend on a mode. The title of the description
chart must refer to the name of the procedure as well as to the mode (if required).
Role / Scope
158. The role allows to briefly defining the function performed by the mode or the procedure. The scope brings
precisions on the action field of the mode when it impacts other elements of the functional breakdown.
159. If several elements of the breakdown have the same mode or the same procedure, it is described in the
chapter of the first element, in the flow direction. For the other elements concerned, it must be mentioned to
refer to this chapter.
MHI components
160. This heading indicates what are the driving elements required for the implementation of the mode or
procedure. Additional functions might be added to the validation, the stop of signaling if required and are
presented in the order of the sequence of use.
Initial conditions
161. These are all the elements that must be present for the validation or the stop of the mode or the procedure,
but which have no effect when the request is taken into consideration.
Permanent conditions
162. These are all the elements whose absence prevents the validation and provokes the stop of the mode or
the procedure.
Initial Conditions / Permanent Conditions
163. The initial or permanent conditions controlled only in some cases must be specified.
Example: Control only if distant mode selected.
164. The « Operative Part » heading concerns the conditions linked to the process. .
Example: Degraded maintenance broach, tool in position….
165. The heading « Absence of events » within the initial conditions mentions what are the events that prohibit
the validation of the mode or of the procedure.
Example: Alert of cycle incoherence, Alarm of low level…
166. The heading « Absence of events » within the permanent conditions concerns the events that forbid the
validation and involve the stop of the mode or of the procedure. The reaction of these events towards the mode
or procedure is developed in the description chart of the diagnostic messages.
Example: immediate fault involving the loss of auto mode…
167. The different headings proposed to define the Initial and Permanent Conditions ensure the exhaustiveness
of the conditions to be taken into consideration. They are deleted during the Top training when they are without
object.
Signaling
168. This heading specifies, for every lights concerned by the mode or procedure the meaning of the stationary
or flashing state. This heading may be used to provide information on the animation of the state of the mode or
procedure on a view of the Operator Terminal.
Example:
 « Type of part: M10 » Flashing = waiting of loading – type: M10.
 « Type of part : M10 » Stationary = loading of type M10 Ok.
Working
169. The heading « Particularities » allows to synthesize the choices performed to ensure the working of the
mode or procedure and to provide additional information on the development of the mode or procedure.
Example: the procedure can be implemented for the « drums » and « Discs » diversities.

170. The development of the cycle and the behavior of the OPE during the mode or the procedure are described
in literal writing in the « description » heading. If required, for more complex cycles, there is a cross-reference to
other shapes of representation and description such as Grafcet, Organization Chart, Graphs of phases …
This representation shape is developed outside the chart, in the same chapter
7.2.1.[M] MODES AND PROCEDURES INDEPENDENT FROM THE MANU OR AUTO MODE
AUTO (TR)
7.2.1.1.[M] Independent particular procedures (TR)

171. The description of an independent particular procedure of a mode is to be added in this chapter of the
functional element concerned.
7.2.1.2.[M] Independent back-up procedure (TR)

172. The description of an independent back-up procedure of a mode is to be added in this chapter of the
Example:
Independent procedure of the exploitation modes
CELL1
Access request
ROLE / SCOPE
Allows to ask for a natural stop of the installation in order to go into the cell .
MHI COMPONENTS
OB1GT11C OB1GT11C OB1GT11C
OB1GT21C OB1GT21C OB1GT21C
ACCESS ACCESS ACCESS

REQUEST REQUEST REQUEST
SB1DA_1C SB1DA_1C HL1DA_1C

SB2DA_1C SB2DA_1C HL2DA_1C
Validation Stop Signaling
INITIAL CONDITIONS OF STOP
On-going request (flashing light) : the stop of the function « Access request »
Operative part
can only be done if the request is in progress (second push).
SIGNALING
Stationary Effective access request
Access request Lights
Flashing Access request in progress.
FONCTIONNEMENT
- During the natural stop phase, the push on the starting button of the cell has
no effect on the stop of the on-going cycle. .
- During the natural stop phase, a second push on the PB of the access
Particularities Request allows to cancel the request.
- An entity or separate equipment whose cycle is stopped by an event is
considered as natural stop during an access request so that the request can
be successful.
The access request involves the stop of the means in a state known of the
automatic cycle (the movements or elementary cycles are completed. Ex.
Description
gluing cycle, gate displacement…) and within mechanical and electrical
conditions authorizing an immediate restarting.

7.2.1.3.[M] Independent (TR)

173. The description of a degraded mode independent from a mode is to be mentioned in this chapter of the
7.2.2.[M] MANU MODE (TR)

Apply for this chapter the general rules defined for the exploitation modes.
174. The description of the MANU mode is to be defined in the RMG chapter.
Example:
RMG1 MANU MODE
MHI COMPONENTS
OB1OT11X OB1OT11X
MANU AUTO MARCHE

MANU
BLEU
SA1MN_1X HL1MN_1X
Selection Validation Stop Signaling
Safety SG_1X
Energy LG21P
SIGNALING
Manu mode Stationary Manu mode validated
Description The movements are authorized only with the gates closed.
175. The description of a particular procedure linked to a manu mode is to be added in this chapter of the
176. The description of a back-up procedure linked to a manu mode is to be added in this chapter of the
7.2.2.1.[M] Manual controls (TR)

177. This chapter only exists in the description of the Entity element.
178. The manual controls are to be listed in a chart for each control box. These movements can be piloted either
from an Operator Terminal or directly with a PB.
Example:
[Name of the
[Name of the control box]
entity]
OPE name Wording of the Type of Controls
Controls OT / PB
TIGHTENING A Opening OT
Closing OT
RB224 Forward motion PB
Backward motion PB
RB225 Forward motion PB
Backward motion PB
RB224  RB225 Forward motion PB
NA NA

7.2.3.[M] AUTO MODE (TR)

For this chapter, apply the general rules defined for the exploitation modes.
179. The description of a particular procedure linked to a mode is to be added in the chapter of the mode.
180. The description of a back-up procedure linked to a mode is to be added in the chapter of the mode.
181. The description of the AUTO mode is to be defined in the RMG chapter.
Example:
RMG1 - AUTO MODE -
MHI COMPONENTS
OB1OT11X OB1OT11X OB1OT11X
OB1GT11X
OB1GT21X
MANU AUTO CYCLE AUTO MODE

START
yellow
SA1AO_1X SBnDC_1X HL1AO_1X

Selection Validation Stop Signaling
INITIAL CONDITIONS OF VALIDATION
Absence of events No incoherence of cycle.
Safety SG_1X
Energy LG21P, GP_1X
SIGNALING
Stationary On-going auto mode.
Auto mode light Auto mode not validated but all the initial and permanent
Flashing
conditions are present.
WORKING
Particularities * see particular procedure : « stop cycle ».
7.2.3.1.[M] Normal mode (TR)

Apply for this chapter the general rules defined for the exploitation modes.
182. The description of the normal mode only concerns the functional element of entity level.
183. In addition to the chart, more particularly for the complex cycles, another shape of description can be used
in addition such as : chronogram, Grafcet, Organization charts, Graphs of phases …
SIMPLIFIED GRAPH OF PHASES (EQUIVALENT G7 LEVEL 1).
The representation in a graph of phases is proposed in the remainder of the document to describe any type of
process in a graph. This method allows to easily and rapidly write or modify the description of a complex cycle with
no consideration of the programming language used.
This representation is useful more particularly to describe combinatory programmed cycles (Ladder language) and
for which the writing in G7 language is not suitable.

This description of the cycles in graph allows to :

 Define and visualize precisely the behavior of the Entities in engineering phase.
 Have an identical representation applicable for all type of process .
 Prepare and provide the elements required for the programming.
 Have a document exploitable in commissioning and adjustment phase.
 Visualize on the Operator Terminal the evolutions of the cycle and the state of the memories.
If this method is used, the rules below must be respected.

184. The graph of simplified phase must allow visualizing the working of the entity and the development of the
different operations, in working phases.
For a continuous process, the graph allows describing the switching in/off phases of the installation.
185. A phase represents a development of cycled actions whose function is to place the installation in condition
before a work is started, whose type can be :
 Operator Work.
Example: Part loading, Manual welding, Bar code reading, Conformity control …
 Work of an interfaced equipment.
Example: Robot, screw driver, stuffing press …
 Data processing dialogues
Example: Answer to a Mission request …
186. Each phase has at least one memory of end of Work Carried out.
187. The symbolic used in case of divergence or convergence is similar to the one used on the GRAFCET.
Example: Divergence in ET, or OU …
PHASE 1
Rôle TE1PH01_01
PHASE 10 PHASE 20
Rôle … TE1PH10_01 Rôle … TE1PH20_01
A background color is attributed to the phases in order to improve the readability of the graph, to emphasize the
divergences…
188. The global role of the phase must be briefly described to represent the main operation performed. This
piece of information is used again in the PLC program to describe and structure the development of the cycle.
Example: Phase 1 Loading of lining, Phase 2 skin welding …
189. A number must be attributed to each phase in order to visualize the development order in the cycle. They
are not necessarily consecutive, more particularly when several phase are carried out simultaneously.
Example: Phases 10,11… and Phases 20,21 … symmetric or simultaneous …
In compliance with the E03.65.036.G Standard, the number of the phase is not used to perform the sequence of the
cycle in the program.

GRAPH OF DETAIL PHASES (EQUIVALENT G7 LEVEL 2)

190. Each phase has a detailed phase that allows visualizing the development of the operations, or steps, inside
each phases.
Example:
PHASE N : ROLE …
CONDITIONS ACTIONS / SIGNALISATIONS
… Conditions  …
… Initiales  …  Etape 1
…  …
…  …
 Etape 2
…  …
 … Actions finales  Etape 3
 …
PHASE N+1 : ROLE …

CONDITIONS ACTIONS / SIGNALISATIONS
 …  …
 …  …
 Etape 1
 …  …
 …  …  Etape 2
 …  …
 …  Etape 3
191. Each line in a phase corresponds to a step during which are performed the operations or actions. These
actions are only performed when the corresponding conditions are validated. .
192. The « conditions » are states of the physical and/or logic process that allow starting the actions of the
corresponding step and to ensure their progression. .
193. The conditions of the first step of the phase represent the initial conditions of the phase. They are
emphasized by a white color background.
Example: Installation in Rear safety, Memories TE to 0.
194. The « actions » of a step correspond to the controls to be performed in cycle when the corresponding
conditions are validated. A mark is associated to every actions performed in the steps in order to specify and
distinguish its type.
Examples:
  = Simple action  Tightening opening, mission request …
  = Conditional action  Writing of report Good if blowing Ok
  = Signaling  Light tower – waiting for operator loading
  Operator Assisting messages  Waiting for connection of flexible G
195. The actions of a step allowing to leave the phase are called the final actions of the phase. They define the
actions required for the development towards the next phase (s) and necessarily contain 1 or several working
memories. They are distinguished by a white background.
Example: Memory of end of work carried out, end of welding memory…
196. Each phase can possibly have intermediate working memories to memorize a work during a phase.
Example: Forcing-in, screwing in several steps in a same phase.

197. The graph proposed can be completed by an organic description of the cycle so that it can be used in
adjustment and commissioning phase.
Examples: Number of label, symbols of memories, symbols of the bits of auto request…
Example:
PHASE 10 PHASE 20
Sequency control of skid TG219 TE1PH10_ 01 Sequency control of skid TG766 TE1PH20_ 01
PHASE 11 PHASE 21
Removal of skid TG219 Removal of skid TG766
PHASE 30
Removal of skid TG221
PHASE 10 : SEQUENCY CONTROL OF SKID TG219

CONDITIONS ACTIONS / SIGNALING
 Presence of skid at the station on TG219  Balogh reading : Order Number

 No memory TG219 to be engaged
 No skid memory TG219 waiting process
 Reading Ok  Request for EIFFEL parameters

 Control of answer ENV_PARA
 Cr_Para NOk  Memory of skid TG219 out of list to be
engaged
 Control of answer ENV_PARA  Request for EIFFEL Mission
 Cr_Para Ok
 Control of Order N° received
 EIFFEL order N° <> Order N° read  Memory of skid TG219 in waiting process
 No skid memory TG219 off list
 Order Number control received
 Order N° EIFFEL = Order N° read  Memory of skid TG219 on the list to be engaged
198. When a normal mode is identical for several entities, only the heading of the chart is required to identify the
existence of the mode and to indicate a cross-reference to the entity where the complete description is found.
Example:
OP7_07
- NORMAL MODE -
Idem OP6_06
199. The description of the particular procedures in normal mode is to be declined in a chart containing the
information according to the example developed in the MANUAL mode chapter. .
Examples: request for the presentation of part, part input/output request….
200. The description of the back-up procedures in normal mode is to be declined in a chart in which appear the
information, in accordance with the example developed in the MANUAL mode chapter.
Examples: Request for a screwing restart, request for a back movement.…
7.2.3.2.[M] Degraded modes linked to the auto mode (TR)

201. The description of a degraded mode linked to an auto mode is to be introduced in this chapter of the
7.2.3.3.M] Specific modes linked to auto mode (TR)

202. The description of a specific mode linked to the auto mode is to be introduced in this chapter of the
7.3.[M] EXPLOITATION INFORMATION

7.3.1.INTERFACE DESCRIPTION: [INTERFACE NAME] (TS)
7.3.1.1.Description of exchanges and states (TS)

203. This chapter precisely defines all the information received or sent between an element of the functional
breakdown and an interface of type :
 Another element of the functional breakdown of the PLC (cell, RMG, Entities).
 Data processing systems (Supervision, traceability, flow …).
The memory labels, the voltage regulators are not defined as interfaces but as OPE.
204. For the separate equipment, this chapter defines the exchanges between the separate equipment and the
element of the functional breakdown with which it is interfaced. .
205. The information is classified into 2 categories : safety and working :
 The information linked to safety is defined in the "SG breakdown " chapter .
 The information linked to working allows to make the cycle evolve or to inform the interface of the states of the
installation. .
206. For the 2 categories; safety and working, the information is classified according to 2 types of information :
 "State" = information available without solicitation and periodic updating by the automation..
Examples: Wired emergency stop, Conveyor motor is operating …
 "Exchange" = information started on the initiative of one of the partner of the exchange on the occurrence of an
event. These are solicited, wired and/or programmed exchanges.
Examples:
 The types of the mechanisms used can be different.
 Question / Answer.
 Work / Report.
 Date reading, data writing request.
 Mission, passage report request, …
 Loading authorization …
207. The description of the exchanges and states with an interface is to be performed with a chart that includes
the information below :
 Name of the interface: of the interfaced equipment or another functional element. .
 The direction of the information specifies if the information comes from the interface of the PLC.
 The accurate comment specifies the role of the exchange or the state. .
 The mnemonic mentions the identification of the component on which is cabled the information or the PLC
mnemonic. .
 The data represent the format of the information.
 The communication support specifies how are exchanged the data between the programmed, wired equipment,
network …

The charts are used again to visualize the state of the states and exchanges on the Operator Terminal. The
communication support column is deleted during the integration on the Terminal. .
Example of working and safety state and exchanges:

PLC3652 INTERFACE : API3653_1A

Communication
Comment Mnemonic Format
support
SAFETY STATES
 Relay of safety Group PLC3652 KA1SG_1P Binary, 1 bit TOR Wiring
 Relay of Emergency stop PLC3653 KA1AU_1A Binary, 1 bit TOR Wiring
SAFETY EXCHANGES


WORKING STATES
 Presence of part on store SQ1PP_01 Binary, 1 bit Profibus output
 Auto mode RMG1 KA1AO_1X Binary, 1 bit Profibus output
WORKING EXCHANGES
 Unloading authorization request - robot 1 DMDCGT1R1P Binary, 1 bit Profibus output
 Unloading authorization - robot 1 OKDCGT1R1A Binary, 1 bit Profibus input
 Cycle code - robot 1 NRCYC1R1P Decimal, 4 bits Profibus output
Example :exchanges of frames with SAIG :

 INTERFACE : EIFFEY_01
PLC3652
 Understructure removal PAA1
Communication
Comment Mnemonic Data
support
ECHANGES DE FONCTIONNEMENT : DDE_PARA
Word state Mission Hexadecimal Inner variable
Heading Decimal 102
Length of emission table Inner variable
oct
 Type of mission DDE_PARA
 Transmitter API_ARMA
 Addressee EIFFEY_1
Modules
07
TCP/IP  Request Log-in
Ascii
01
 Quantity of occurrences
Ascii Ethernet SAIG
 Flow point PAA1
 Type of mission DEMINF
 Part report x8
Data
EFER010000002
 Order number
3
 Complement  x 42
208. A same piece of information sent to several communication supports is to be defined on distinct lines.
209. The column « Format » allows defining the format of the data. Its type can be binary, decimal, ascii, hexa…
specify the quantity of bits, octets, words….
This column is used on the TO to visualize the dynamic state of the variable.

7.3.1.2.Functional description (TR)

210. This chapter defines the working to be implemented to communicate with the interfaced equipment.
Depending on the case, this description can be the parameter setting of the interface, a chronogram of the
exchanges. ….
Example : Parameter setting of the SAIG connection module.
211. For the exchanges of more than 2 information (s) , it is required to establish a chronogram to visualize the
behavior of the exchanges.
7.3.2.[M] OPERATOR TERMINAL DESCRIPTION: [IDENTIFICATION MARK: OT] (TR)
7.3.2.1.[M] General description (TR)

212. Present the structure of the OT application obtained from the programming software workshop, in the
chapter of the functional element of the Operator Terminal scope. .
213. The arborescence of the pages must be performed in compliance with the rules defined in the document
E03.64.160.G. If the software workshop doesn’t allow to correctly visualizing the pages, this arborescence is
presented in a chart.
Example:
Functional Arborescence of the
Title of the page Comments
element Pages
Lev. 0 Lev. 1 Lev. 2 Lev. 3
APIDT8 1 APIDT8 station OP65
10 Diagnostic messages
History of the diagnostic
20
messages
100 Maintenance
Follow-up of application
110 versions
OT
150 Material diagnostic (1/2) PLC diagnostic – main Rack
160 Network diagnostic
151 Material diagnostic (2/2) PLC diagnostic – auxiliary Rack
200 Production follow-up
The information present on the page
CELLc 1000 CELLc : Robot
depends on the robot selected
CELL1 1100 CELL1 Main page of CELL1
CELL2 1200 CELL2 Main Page of CELL2
RMG1 3100 RMG1 (1/2) Main Page of RMG1
3101 RMG1 (2/2)
3150 RMG1 : Degraded mode
3155 RMG1 : without stirrup blowing Declaration of HS stirrup blowing
RMG1 : Support declaration Declaration of one of the HS pallet
3156
HS supports
RMG2 3200 RMG2 RMG2 main page
The manual control present on the
ENT 5000 ENT: Manual controls
page depends on the entity selected.
ENT01 5100 ENT01 : OP1 Main page of Entity 1
5150 ENT01 : Inductel
5160 ENT01 : Balogh
5165 ENT01 : List of robot code Example of detail pages
ENT02 5200 ENT02 : OP2 Main page of entity 2.
5250 ENT02 : Inductel
5260 ENT02 : Stirrup screw driver
The AUT or trade standard page numbers are emphasized in bold characters.

214. In a chart, define the role of each permanent key defined on the Operator Terminal. For the non tactile
terminals, specify the reference of the associated key.
7.3.2.2.[M] Detailed description of the pages (TOT)

215. For each Operator Terminal, define the pages dedicated to each functional element non defined in a PSA
standard or specific to the installation, such as :
 Welcome page with the synoptic of the installation.
 Pages including a synoptic.
 Specific page with interfaced equipment.
 Working page of the interfaces.
 Degraded mode page.
 Pages of production counter.
 Page of production messages.
 Page of working cycle.
 Any page of a PSA standard on which are shown action or control dynamic keys.
 …
This detail description must allow to represent on the OT all the states and exchanges required for the user.
When the OT controls several functional elements, the detailed description is performed in each of them.
7.3.3.[M] HELP CONTROL GRAPH (TOT)

216. This chapter allows to show the possible graphs controlling the installation destined to the Operator Manual.
The graphs can be made available on a view of the Operator Terminal.
Examples: Starting sequence, Commissioning graph …
7.4.[M] DIAGNOSTIC
7.4.1.[M] DESCRIPTION OF HELP CONTROL MESSAGES (TR)
These messages are intended to help the user to perform the starting or to put back the installation in cycle.
They involve no reaction on the process or the installation.
217. Each help message to control the installation must be described in the DFA, the definition of each message
must be in compliance with the rules listed in the E03.65.015.G standard.


7.4.2.[M] DESCRIPTION OF THE DIAGNOSTIC MESSAGES (TR)

218. The chapter « DIAGNOSTIC » of each functional element of the installation must include a description of all
its events in a chart to the Word format. This exhaustive list is obtained after treatment and analyzes of the
criteria described below.
219. Each event of the installation must be described in the DFA to introduce the information below :
Message of the event, to be defined in compliance with the rules listed in the E03.65.015.G standard,
 The identification mark of the Operator Terminal (s) (OT) on which the message must be displayed.
 The description of the cause at the origin of the starting of the event.
 The reaction to be provoked on the installation further to an event of Manufacturing Stop, Immediate Fault, or
Deferred Fault types.
Example: Stop of the auto mode, power disconnection of the pneumatic group.…
 If needed, the description of the procedure to be performed and the display of the messages of help control
specifying the missing conditions, for the breakdown and the installation cycle restarting. .


220. The classification of the events in the different categories proposed must be in compliance with the criteria
and with the algorithm proposed below:
Expected Message of
The event Example
action diagnostic
Source outside Causes a Requires a
Following
Event scope of PLC reaction of aknowledge-
action by
Category disturbs the (excluding the control ment after Signification
the
functioning separate part of the disappearance
operator
equipment) process of the event
Indicates the
AE : alert appearance of
an event that
Low level of glue
does not
on a drum
interfere, but
AL : alarm  that requires
intervention
WT : waiting
WO : waiting for
Signals the
operator Waiting part
external
WU : waiting for   panel in
condition
upstream upstream
missing
WD : waiting for
downstream
Indicates the
controller
MP : Immediat
causing the off Request of input
manufacturing   fault or 
(Except into cell
stop delayed fault
Emergency
Stop)
Indicates the
PS : process missing

stop condition for
the cycle
Indicates the
Late sensor
missing
AK :
condition for
acknowledge  
the cycle until
process stop
acknowledgm
ent
Indicates the
Delayed Electrode end of
DF : delayed fault   default
fault life
installation
Only for
Indicates the
IF : immediat triggering a Immediat
  default energy loss
fault safety fault
installation
component

Does the event

disturb the state
or working of
CATEGORIZATION
one of its OF THE EVENTS
element or of its
OPE?
An event arises on the

installation ? No
Yes
Does the event disturb
the working? No
Yes Is an acknowledgement
required to confirm the AE :
end of the cause of the Alert
event ? No
Yes AL :
Alarm
Origin beyond the PLC
scope (upstream, WA/AO/AM/AV :
downstream or operator) Waiting
Yes
No
Is the operator at the

origin of the event?
Yes
By a safety SP : Stop Production
No component ? No
Yes
Does the event involve an
immediate stop in addition ID :
to the condition missing in Immediate defect
the cycle? Yes
No
Does the event involve a

differed stop in addition to DD :
the condition missing in the Differed Defect
cycle? Yes
No
Is an acknowledgement
required to confirm the
SP :
end of the cause of the
No Stop Process
event ?
Yes AK :
Stop Process
acknowledged

221. PLC inputs: all the PLC physical inputs must be diagnosed, in compliance with the rules defined in the
E03.03.250.G standard.
The inputs diagnosed by the functional modules, PSA or integrators do not appear in the description of the DFA
EVENTS. These events are described in the documentations associated to the programming modules.
222. An input belonging to an input group whose combination corresponds to a numerical value is not diagnosed
individually. The events are then associated to this value and not individually to each of the inputs.
Example: n TOR Inputs defining a cycle code: Incoherence of cycle code/cycle code unknown
223. EXPLOITATION INFORMATION: all the exploitation information, exchanges and state with an interface
must be diagnosed.
Examples: Communication fault, Dialogue fault, poor Report, …
The exploitation information diagnosed by the functional modules, PSA or integrators, do not appear in the
description of the events of the DFA. These events are described in the documentations associated to the
programming modules.
224. Each separate equipment is the object of at least one diagnostic message signaling the presence of events.
The detailed diagnostic is displayed on the separate equipment. .
225. CYCLE: any abnormal behavior that may occur during the installation must be subjected to a suitable
diagnostic message. .
Examples: Fault of part destination, bad support Number, working Waiting Performed…
226. SYSTEM: the events linked to the system and not treated automatically by the manufacturer must be
diagnosed specifically by the PLC application.
Examples: Fault of configuration, coupling fault, field bus fault… …
8.ORGANIC ANALYSIS (TR)

8.1.INSTANCIABLE BLOCKS USED (TR)
227. List all the instanciable blocks used, PSA standard OR SPECIFIC Integrator. Specify for each of them the
name of the module, the version used, the description and the reference of the documentation.
Example:
Initial Documentation reference
Instanciable block Description
version PSA INTEGRATOR
8.2.USER PROGRAM BLOCKS (TR)

228. List in a chart each program block out of instanciable blocks. .
The PLC program structure must be in compliance with the specifications defined in the PSA E03.65.036.G norm.
229. The user blocks must be the object of a description.

8.3.MAPPING MEMORY (TR)

230. Describe the data zones associated to each element of the functional breakdown and specify the address
ranges, the data blocks, the data structures,… in a chart as described below : :
Zone Constant Saved Mnemonic

data / + value value Description
PLC Cell RMG Entity
Blocks / Comment
Structure
231. For the constants, specify the value, the mnemonic and the comment. .
232. For the saved data, specify (at each cycle for restoration on cold back-up) the zones, words or bit of word
with the mnemonic and the comment.

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PSA PEUGEOT - CITROËN

Drafted by Checked by Approved by

Pascal GEHANT Frédéric TOURNUT Laurent MAUGUY

Date Signature Date Signature Date Signature

26/09/2014 - 26/09/2014 - 26/09/2014 -

OR: 27/03/2007 F: 21/08/2014 Network of competences : 03N INTERNAL USE

Index Date Nature des modifications

OR 27/03/2007 Creation of the Norm.

B 19/01/2012 Recasting of the document

C 27/04/2012 Maintained due to an error during conversion into pdf chapter 7.

D 27/05/2014 Alignment of the index D English to the index D French.

E 07/08/2014 Alignment of the index E English to the index E French.

F 21/08/2014 Alignment of the index F English to the index F French.

DRD/DISP/IMAI/AUT/ATA Arnaud BRIEND

OR: 27/03/2007 F: 21/08/2014 Network of competences : 03N INTERNAL USE

4.2.1. DFA summary structure 6

OR: 27/03/2007 F: 21/08/2014 Network of competences : 03N INTERNAL USE

1.OBJECT AND FIELD OF APPLICATION

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4.INTRODUCTION: PRESENTATION / INSTRUCTION FOR USE

4.1.PRESENTATION OF THE DOCUMENTS

Transversal Technical Specifications

Writing initial Detailed Functional Analysis

Chapters TOP OPERATOR TERMINAL

DFA deliverables per milestones

4.1.1.TRANSVERSAL TECHNICAL SPECIFICATIONS

OR: 27/03/2007 F: 21/08/2014 Network of competences : 03N INTERNAL USE

15. ORGANIC ANALYSIS

4.2.2.DESCRIPTION OF THE FUNCTIONAL ELEMENTS

§ n. DESCRIPTION OF THE FUNCTIONAL ELEMENT

OR: 27/03/2007 F: 21/08/2014 Network of competences : 03N INTERNAL USE

4.2.3.VALIDATION MILESTONES OF THE DFA

OR: 27/03/2007 F: 21/08/2014 Network of competences : 03N INTERNAL USE

4.2.4.FOLLOW-UP OF THE VERSIONS

4.2.5.PCT (PROCEDURE OF CONDUCTING TESTS) DFA WRITING

OR: 27/03/2007 F: 21/08/2014 Network of competences : 03N INTERNAL USE

OR: 27/03/2007 F: 21/08/2014 Network of competences : 03N INTERNAL USE

4.4.INSTALLATION FUNCTIONAL PCT (procedure of conducting tests)

OR: 27/03/2007 F: 21/08/2014 Network of competences : 03N INTERNAL USE

5.[M] GENERAL DESCRIPTION OF THE INSTALLATION (TD)

5.1.[M] PRESENTATION AND LOCATION (TD)

5.2.COORDINATES OF THE PEOPLE INVOLVED (TD)

Name Company Department Function Phone number E-mail

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5.3.STUDY DOCUMENTS OF REFERENCE (TD)

Wording Reference Version Date

5.4.TECHNICAL CHARACTERISTICS (TD)

OR: 27/03/2007 F: 21/08/2014 Network of competences : 03N INTERNAL USE

32. Define the technical characteristics: product.

5.5.[M] LIST OF THE MECHANICAL FUNCTIONS (TD)

Mechanical Link to the trade

5.6.[M] SYNOPTIC (TD)

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5.7.[M] BRIEF FUNCTIONAL DESCRIPTION (TD)

Driving Station Carbody arrival

PDC ARRIVAL TO ROBOT

PDC IS TAKEN BY THE

OR: 27/03/2007 F: 21/08/2014 Network of competences : 03N INTERNAL USE

6.[M] INSTALLATION DESIGN (TD)