Global Common

Controls Hardware Design Standards

GCCH-1

Rev 13 - Uncontrolled When Printed - December 12, 2023

Global Common Controls Hardware Design Standards (GCCH-1)
General Motors
Document Management Information
Owners
Greg Doppke (GM Common Architecture Group)
Approval
Jeremy Duvendeck (GM Common Architecture Manager)
Sponsoring Group
GM Manufacturing Engineering
Forward Questions and Comments to:
Greg Doppke
Email: gregory.doppke@gm.com

Online feedback is also available on GM Supply Power via the Hardware Forum.
Additional Copies of this Document may be obtained from:
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standards. Access to a controlled version is available through either method below:
• GM intra-net: navigate through the links on Socrates home page: (1) Search -> Vehicle
Systems (2) Supply Power (pull-down) -> Global Standards (internal), (4) Hardware, (5)
GCCH-1.
• Internet: GMSupplyPower.com, (1) Log-in, (2) Applications, (3) Manufacturing Engineering
Vehicle Systems, (4) Global Standards, Specifications and Procedures, (5) Hardware, (6)
GCCH-1.
Document Expiration Date
This document will expire December 31, 2026. It may be revised, reaffirmed, or withdrawn prior
to this date. Contact the organization listed above for the latest version.

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Global Common Controls Hardware Design Standards (GCCH-1)
General Motors
Revision History
Revision
Date By Revision History
Level
All Revised Chapters: Update standard to IEC symbols.
The rest of the chapters will be updated in the next
release.
Doc Management: Updated TOC and added revision
history and revision number by section.
CH3: Added rule for GA & Conveyor E-stop span of
control.
CH4: Updated Architecture section to match current
CCRW nomenclature. Span of control rules enhanced to
cover Paint, Press, GA, and Conveyors.
CH5 & CH6: Added Detail for Drawing Naming for
Conveyors, Paint, & Press. Removed duplicate entries
12/15/2008 Rev02 M. Schweiger from CH 6.
CH12: Updated I/O section to provide more detail on
CCRW pulse test strategy.
CH13: Updated air logic section. Revised requirements
for spare valves.
Annex C: Corrected metric values for Q. Added flow
calculation example from GCCH training class.
Annex E: Updated change form and added link to CCRW
Hardware Discussion forum. Please use the discussion
forum for questions or to provide feedback.
Annex G: Updated gate box function to match actual
operation. Removed outdated ECS-4011 drawing and
added reference to GM supply power.

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Global Common Controls Hardware Design Standards (GCCH-1)
General Motors
Revision
Date By Revision History
Level
All Revised Chapters: Removed references to CCRW.
CH1: Added Reference to NEC70-2008.
CH4: Added 2C Architecture.
Ch5: Removed requirement for Printed Ladder Listing.
Added regional EC panel naming guidelines. Updated
paint drawing naming guidelines.
Ch9: Updated Device ID table. Updated
Controller/System switch naming. Update source-
destination naming standard. Updated common
receptacle name table. Added DeviceNet setting for
conveyors and low automation architecture. Added
3/9/2010 Rev03 M. Schweiger additional constraints for Ethernet networks. Added PC
requirements.
CH13: Updated example pneumatic circuits and added
more explanatory information on their use.
CH15: Added equipment types to Table 15-1. Removed
flow tables for black pipe and stainless steel. Updated
example drawings.
CH30: Changed panel lighting requirements. Added
mode switch key codes. Updated panel tagging
requirements. Added reference to GCCB-1 for tag
material.
CH31: Updated with new purchase codes.
CH1: Removed EN954. Added ISO13849
CH3: Added references to ISO13849. Removed Safety
relay specific requirements. Added muting requirements.
Replaced references to HS1738 with NFPA79.
CH4: Added spare memory requirement. Added
architecture key elements chart. Added PC control
prohibition.
CH5: Added Naming Convention for Non-Unique WD
drawings. Added full file naming conventions for drawing
12/22/2011 Rev04 M. Schweiger
file deliverables.
CH9: Added Enet addressing requirements. Removed
“Separately Derived Source” grounding text. Updated PC
requirements. Updated DeviceNet Node Rules.
CH11: Replaced references to HS1738 with NFPA79.
Updated AWG metric wire conversion table. Updated
wire color chart. Updated some figures to IEC symbols.
Corrected 3 pin mini pin rotation.
CH30: Updated control panel tagging requirements.

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Global Common Controls Hardware Design Standards (GCCH-1)
General Motors
Revision
Date By Revision History
Level
CH3: Added additional information on MPS light
requirements. E-stop span of control changes.
Formatting changes.
CH4: Formatting changes. Corrected description of safety
IO. Added Plant Floor PC Requirements (Moved From
CH9). Updated Architecture Diagrams.
CH5: Added standard drawing naming section. Added
clarification of naming for mainline cells.
CH9: Removed PC Requirements. Added requirements
for private Enet networks. Added requirements for
12/21/2012 Rev05 M. Schweiger interlocking between PLCs on different system switches.
CH12: Updated Safety IO description. Clarified SBK and
BK numbering.
CH15: Updated water flow requirements chart (Thanks
John). Added water diagrams for LS style gun.
Consolidate many redundant water diagrams.
CH30: Added coordination study requirement for PDP
main breakers. Added PLC-in-a-Box example. Added
door width allowance for PDP panels.
CH31: Added information on regional item number
ranges.
All: Commonized formatting, document cleanup, added
allowance for EtherNet/IP for I/O in addition to
DeviceNet where applicable.
Doc Management: Updated contact information,
directions for online access, removed revision by section
and combined sections into one file.
CH4: Revised architecture slides, added powertrain
where applicable.
CH5: Added powertrain section, modified regional
language requirements, added status stamp sub-section,
2/1/2016 Rev06 G. Doppke revised deliverable requirements, updated paint system
abbreviations, corrected some example drawing names.
CH6: Changed device list to YZ section.
CH7: Revised to reflect current templates.
CH8: Removed requirement for system level layout,
revised content to reflect current templates.
CH9: Added content for linear power topology, extensive
revision to Ethernet section to clarify Ethernet I/O, other
minor cleanup.
CH10: Removed details for sequence of operations as it is
no longer required in hardware designs.

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Global Common Controls Hardware Design Standards (GCCH-1)
General Motors
Revision
Date By Revision History
Level
CH11: Corrected wire numbers, added clarification for
identified conductors as part of an assembly, replaced
CENELEC pinout with CIP physical layer pinout.
CH12: Clarified spare I/O requirements for IP67 devices,
added exception to requirement that all inputs for a
given cylinder are on the same I/O block.
CH13: Updated Table 13-1 (maximum flow rates) to
correlate with pneumatic sizing design aid.
CH15: Updated water flow requirements chart (Thanks
John).
2/1/2016 Rev06 G. Doppke CH29: Updated primary cable requirements for steel,
added primary cable requirements for aluminum (Thanks
John).
CH30: Clarified disconnect requirements, added
constructions exceptions, added clarification for circular
receptacle orientation.
CH31: Added ranges for functional (shop) specific parts.
CH33: Deleted.
Annex C: Deleted Table C-1, it was a duplicate of Table
13-1.
Annex G: Deleted.
All: Minor cleanup to formatting, spelling, etc.
throughout, removed GME/Europe.
Doc Management: Updated contact address, updated
document expiration date.
CH3: Changed ‘MPS’ to ‘SCS/MPS’ throughout, revised
3.9.4 to indicate safety PLC’s are preferred over safety
relays, removed exceptions from 3.10.4 related to
muting, revised 3.11.1.2 e-stop span of control based on
lessons learned, particularly with conveyors.
CH4: Changed ‘powertrain’ to ‘propulsion systems’
throughout, changed ‘maintenance workstation’ to
‘programming terminal’ throughout, revised diagrams in
12/14/2017 Rev07 G. Doppke 4.6 to show programming terminal connected to IECN,
removed PC hardware requirements in 4.9.3 and referred
instead to ME Cyber Security document with those
requirements, revised 4.14 bodyshop PLC, HMI, and PDP
span on control rules based on feedback from body team.
CH5: Clarified bodyshop system WD naming in 5.5.1.1,
added bodyshop unit drawing example for process
equipment without tool number in 5.5.1.3 add conveyor,
GA and paint system abbreviations in 5.5.2, 5.5.3 and
5.5.4, respectively, changed ‘powertrain’ to ‘propulsion
systems throughout, added arc flash calculation and
panel drawing hardcopy requirements in 5.8, added SCCR
rating requirements in 5.8.1.

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Global Common Controls Hardware Design Standards (GCCH-1)
General Motors
Revision
Date By Revision History
Level
CH9: Changed ‘maintenance workstation’ to
‘programming terminal’ throughout, added ‘CAM’ and
‘FMS’ designations to Table 9-1, added ‘ES’ and ‘CS’
designations to Table 9-2, revised 9.5.9 to limit drop
cable length to 4 m, changed ‘cascaded’ Ethernet
switches to ‘expanded’ Ethernet switches, relaxed
prohibition on interlocking over the backbone , revised
9.6.6.2 to indicate proper gateway for public device using
connected routing, removed prohibition on trunking,
added a note to Table 9-8 to indicate that it does not
apply to robots.
CH10: Revised 10.1 to indicate that a process to
document the equipment sequence is required.
CH11: Cleaned up sections 11.6 and 11.7 to divide up
identification and overcurrent protection, previously it
was mixed up, renumbered subsequent sections, added
new sections 11.7.2 and 11.7.3 for SCCR rating and arc
12/14/2017 Rev07 G. Doppke
flash requirements, respectively, replace ‘finger safe’ with
‘IP2X/IPXXB’.
CH13: Revised 13.4.2.5 item 2c to clarify short mechanical
motion and change length to 0.5 m to close gap between
0.1 m and 0.5 m.
CH15: Added note to 15.3 item 1 to verify transformer
type with aluminum welding.
CH29: Added section 29.15.1, weld PDP guidelines.
CH30: Change ‘maintenance workstation’ to
‘programming terminal’, revised 30.3 item 14 to use IP
ratings instead of ‘touchsafe’, added exception to 30.14
item 5 for orange paint for Brazil, 30.3 item 6 is a new
item that was previously part of item 5, also clarified to
indicated not painted, 30.14 item 7 revised to indicate
that default hole size is 22.5 mm, 30.14.3 revised to
clarify disconnect requirements, Figure 30-22 replaced
with picture of current warning label.
Doc Management: Updated document expiration date.
CH4: Revised Table 4-1 to add Compact GuardLogix to 3A
architecture and changed ‘maintenance workstation’ to
‘programming terminal’, revised section 4.5 and 4.7.1 to
clarify that control PDP is not for task lighting, removed
reference to PLC pair (PLC and safety partner) to allow for
12/14/2018 Rev08 G. Doppke
L8 PLC without partner, added general requirement that
selected PLC must meet required safety performance
level, added content for connection and node capacity in
addition to the memory requirements that were already
present.
CH5: Modified Table 5-4 for GA naming.

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Global Common Controls Hardware Design Standards (GCCH-1)
General Motors
Revision
Date By Revision History
Level
CH6: Minor cleanup to tables 6-1, 6-2, 6-3 and 6-4.
CH9: Revised Table9-1 to add VFD and Inverter to M
designation, changed programming terminal to PGT, add
TC for torque controller, revised 9.4.2 item 3 to ‘may’
instead of ‘shall’, added SEP to 9.5.3 item 2, added 9.5.3
item 3 for robot networks, added new 9.5.4 item 5 for
SEP, added new section 9.5.6.1 for SEP, added new items
in 9.5.7 to prohibit end to end cables and more than two
tees connected together, corrected 9.6.3 item 17 and
added exception for controller direct networks, deleted
Australian exception in 9.7.3 item 5.
CH11: Deleted item from 11.2 that required unit specific
magnetics (such as a motor) to be shown on the unit
drawing, added MOL and MSP to table 11-6, changed
11.9.1 item 1c from CPU to PLC.
CH12: Updated IO device naming and input/output
naming to clarify how to handle IP67 modular IO and
12/14/2018 Rev08 G. Doppke
similar IO and the controller and unit level.
CH13: Revised section 13.4.2.5 to indicate that dumps,
slides and lifters ‘typically’ use inching circuits instead of
‘shall’ use inching circuits.
CH30: Revised 30.3 item 14.a to remove “where
required” as this is implied in item 14, clarified 30.3 item
14.c, removed exception to 30.14 item 5, orange interior
is no longer required in Brazil, changed exception for
30.14.3 item 6 to a note and attempted to clarify that it
does not apply to isolation devices, revised 30.19.2 item 4
to more closely align with IEC 60204 and NFPA 79, revised
30.19.2 item 5 to indicate enclosures with local
disconnects, added new item 6 to 30.19.2 for new
warning sign for enclosures which remain energized with
the main disconnect off, item 7 was previously item 6.
CH31: Minor revision to 31.4 to revise ‘powertrain’ to
‘propulsion systems’.
Doc Management: Updated expiration date, updated
document approval contact.
CH3: Added clarification to section 3.11.1.2 item 4 in the
automation area to indicate that only the adjacent roll
bed shall be safety stopped, revised section 3.11.8 to
12/13/19 Rev09 G. Doppke indicate that opening a guard shall disable adjacent
hazardous motion that may enter the area.
CH4: Added note that DeviceNet is to be used by
exception only, removed DeviceNet and SmartGuard
from 3A architecture, update architecture figures 4-3, 4-
4, 4-5 and 4-9.

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Global Common Controls Hardware Design Standards (GCCH-1)
General Motors
Revision
Date By Revision History
Level
CH5: Added GA to section 5.3.3.1, added new GA system
abbreviations to table 5-4.
CH9: Revised section 9.6.2 item 6 in order to clarify that
the speed/duplex setting is dependent on switch type,
revised section 9.6.3 item 16 to a max of 20, revised
section 9.6.4 item 4 to indicate that DCDL is switch type
dependent, revised section 9.6.5 item 6 to indicate that
the programming port is DHCP, clarified the use of public
vs. private addresses in section 9.6.6, removed private
address switch from network isolation options in section
9.6.6.1 and indicated that connected routing is preferred,
added item to section 9.6.6.1 item 2 to limit public linear
networks and revised linear network max length to 25,
removed exception notes about connected routing,
removed duplicate information in section 9.7 and added
12/13/19 Rev09 G. Doppke
cross reference to section 30.18.
CH11: Added an item to section 11.2 to call for enclosures
to be designed to operate at 24 VDC.
CH12: Added an item to section 12.2 to clarify wire
number designations for the F section.
CH30: Clarified section 30.3 item 14b to indicate that
probe holes shall be provided if available, revised section
30.3 item 24 panel lighting requirement to those panels
with proper power available, removed redundancy in
section 30.14.1 item 5, corrected typo in section 30.14.2
and cleaned up section, added detail to section 30.18.3
item 3, revised section 30.18.3 item 13 to allow insulated
flexible wire, added new section 30.19.2 item 2 and
renumbered subsequent items accordingly, corrected
typo in section 30.19.2 item 5.
All: Minor typo correction throughout.
Doc Management: Updated expiration date.
CH1: Updated reference to G-DHS and NFPA 79.
CH3: Removed several sections that are now contained in
G-DHS, added references to G-DHS, corrected IEC
reference in section 3.7.3.1.
12/16/20 Rev10 G. Doppke CH4: Removed 2B architecture, added low/medium
architecture decision tree.
CH5: Added new GA system abbreviations to Table 5-4,
revised GA naming examples in sections 5.5.3.1 and
5.5.3.2, revised press naming examples in section 5.5.5,
deleted section 5.8.5 item 4e (2B architecture PLC
printout).

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Global Common Controls Hardware Design Standards (GCCH-1)
General Motors
Revision
Date By Revision History
Level
CH6: Replaced Figure 6-1 and revised section 6.2.1 to
replace ‘maintenance workstation’ with ‘programming
terminal’, revised tables 6-1 through 6-4 to change
‘master change sheet’ to ‘revision summary sheet’.
CH7: Replaced ‘master change sheet’ with ‘revision
summary sheet’ throughout.
CH9: Updated Table 9-5 based on feedback received,
corrected cross reference in section 9.5.10, corrected
Supply Power link in section 9.6.4, clarified section 9.6.3
item 15 and section 9.6.6.1 item 7, removed content
from section 9.7 that is now in G-DHS, added reference to
G-DHS.
CH11: Removed content for overcurrent protection, SCCR
rating and arcflash calculations that is duplicate with G-
12/16/20 Rev10 G. Doppke DHS, added references to G-DHS.
CH12: Rearranged section 12.2 to separate IP20 and IP67
IO requirements, added subsections to support specifics
of both, replaced Figure 12-12 with more current
representation, added item 12.6.1 to help explain where
style information should be present on multi-style tools.
CH13: Added bullet to 13.4.2.2 item 10 to indicated that
style information should be included based on new
section 12.6.1, removed references to 2B architecture,
corrected link to Table 13-4.
CH30: Removed details for working space, protection
from contact and disconnect operation and replaced with
references to G-DHS, added item 28 to section 30.3 for
AVT requirements per G-DHS, added reference to G-DHS
in section 30.18.
Doc Management: Updated expiration date, updated
document approval contact.
CH4: Added content to section 4.5 to clarify that 24 VDC
power is required where practical to minimize electrical
hazards, revised section 4.9.3 item 3 to clarify ME cyber
security requirements for PCs.
CH5: Added new items to Table 5-4, added new section
12/17/21 Rev11 G. Doppke 5.5.3.1 for GA system WD naming and renumbered
previous sections 5.5.3.1 and 5.5.3.2.
CH8: Added new section 8.4.1 for GA specific layout
section requirements.
CH9: Added items to table 9-1, added exception to
section 9.4.3 item 1 to clarify requirements for dual IP67
power supplies, minor cleanup throughout to improve
consistency and correct identified typos.

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Global Common Controls Hardware Design Standards (GCCH-1)
General Motors
Revision
Date By Revision History
Level
CH11: Added content to section 11.9.1 to reinforce
requirement for 24V utilization where possible to reduce
electrical hazards.
CH12: Relocated spare IO requirements from section 12.5
to 12.2.1 and 12.2.2 for IP20 and IP67 IO, respectively.
CH13: Revised section 13.6 to distinguish lift assisted
12/17/21 Rev11 G. Doppke
fixtured nut runners (LAFN) and floor mounted (FM).
CH30: Added exception to section 30.5 item 1 for typical
3, 4, or 5 pin receptacles, added content to 30.9 item 1
indicating 24 VDC for MCP feed, replaced figure 30-7 with
newer version, revised 30.19.2 item 4 to remove “or on
the inside of the enclosure door”.
Doc Management: Updated expiration date.
CH1: Updated a number of obsolete EN references with
current ISO standards, removed some European
requirements no longer applicable.
CH4: Minor change to 4.7.1 to add the wording “excepted
circuit”, revised 4.9.3 to be specific to programming
terminals, removed item 1 that was referring to an
obsolete SharePoint, revised item 2 (formally 3) to refer
to Cybersecurity requirements on Supply Power.
CH5: Revised 5.2.5 with current EPLAN training
information, revised 5.5.2 to break up conveyor tables
into shop specific tables, renumbered subsequent tables
accordingly, revised GA conveyor designations, added GA
example naming, revised 5.5.3 Table 5-5 (previously Table
5-4) to add and update GA system abbreviations, revised
5.8 to clarify engineering calculations required for both
approval and as built.
12/16/22 Rev12 G. Doppke
CH9: Revised 9.3 Table 9-1 with safety mat device
changes, revised 9.4.6 Table 9-2 to add the wording
“excepted circuit”, revised 9.6 throughout to add
information about gigabit Ethernet and 8 pin M12 X-
code, revised 9.6.3 item 5 to clarify 100 m between
devices, revised 9.6.5 to add new Figure 9-31 for public
Ethernet device tagging and renumbered subsequent
figures accordingly.
CH11: Revised 11.9.1 to add the wording “excepted
circuit”, revised 11.10- to add allowance for M12 L-code
connectors and rearranged section to indicate that 4 pin
mini is the preferred connection, added Figure 11-19.
CH13: Revised 13.3.2 according to current offline air
preps and updated Figure 13-3, revised 13.4.2.2 item 1
exception to be less than 4 valves, was 1 or 2, added item
9 for trapped air connection identification, added Figure
13-4, renumbered subsequent figures accordingly.

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Global Common Controls Hardware Design Standards (GCCH-1)
General Motors
Revision
Date By Revision History
Level
CH13 (cont.): Revised 13.4.2.2 item 11 to add exception
for blocked center valves to use yellow tags, clarified that
item 11 is for tooling valve tags, added new item 12 for
robot valve tags, add new Figure 13-6 for robot valve
tags, renumbered subsequent figures accordingly, revised
item 17 to update flow control note Figure 13-7, added
item 18 to clarify trapped air tagging, added item 19 to
require means to relieve trapped air, revised 13.4.2.3
item 4 to add caution note regarding trapped air and
meeting the requirements in G-DHS, revised 13.4.2.5
12/16/22 Rev12 G. Doppke
item 1 to clarify that approval is required for inching
circuits not found in published template applications,
revised 13.4.3 item 2 to remove the specific robot name
from the shut off tag, the shut off is local to the robot
controller and name is on the controller, revised 13.6.2
item 3 to update the reference tool number.
CH30: Revised 30.3 item 24 to clarify that lighting is
required based on panel size, not necessarily subplate
size, revised exception to indicate panels that do not
have excepted circuit power available.
Doc Management: Updated expiration date, removed
detail from “Forward Questions and Comments to”
section, including reference to Annex E which is being
deleted, retained name and email for feedback
submittals.
CH4: Revised section 4.6 to add item 1f to clarify that
public versus private addressing shall be according to
section 9.6 and to revise Figure 4-7 and 4-8 to indicate
typical network arrangements.
CH5: Multiple revisions to section 5.2 based on current
12/12/23 Rev13 G. Doppke
EPLAN requirements and deliverables, revised Table 5-4
and Table 5-5 with conveyor and GA naming updates,
revised section 5.6 to delete item 2 regarding AutoCAD
files, revised section 5.8 to remove AutoCAD content,
clarify EPLAN deliverables, and to limit the number of
hardcopies required.
CH6: Split section 6.2 into 6.2 and 6.3, renumbered
subsequent sections accordingly, added new subsection
6.2.1 and Figure 6-2 for combined controller/unit drawing
information.

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Global Common Controls Hardware Design Standards (GCCH-1)
General Motors
Revision
Date By Revision History
Level
CH9: Revised 9.3 Table 9-1 with new identifiers, revised
9.6.4 to indicate that public IP addresses shall be used
unless all requirements for private addresses are met,
revised 9.6.6 to clarify requirements to use private IP
addresses, added a note to 9.6.6.1 item 2 to remind
designers to consider the impact of using a linear
topology, added new subsection 9.6.6.3 for Ethernet I/O
into legacy cells, renumbered subsequent sections
accordingly.
CH11: Revised section 11.7.1 item 4c to clarify motor
overload requirements, added programming terminal to
11.9.1 item 1.
CH12: Added item 8 to section 12.2 to clarify splitter
cable design intent, revised Table 12-2 to delete limit
switch and add light curtain / light array.
CH13: Revised section 13.3.1 item 5e to remove “oil
filled” from (with gauge), refreshed diagram used in
12/12/23 Rev13 G. Doppke Figure 13-2, revised section 13.4.2.2 item 16 to specify
flow rate calculation instead of CV calculation.
CH30: Revised section 30.3 item 5 to indicate should
instead of shall because it is not always practical to show
all externally mounted devices in all views, revised
30.14.1 item 4 from 120 degrees to 90 degrees to better
align with commercially available enclosures.
CH31: Added new section 31.2 and subsections to explain
BOM sub sections, renumbered subsequent sections
accordingly, revised 31.3 item 5 to delete “BOM REV” and
“GCCL Reference Number”, these are not included in the
current BOM form, added a note to section 31.5 to clarify
that conflicting item numbers must be avoided, added
reserved range for PFS specific parts.
Annex C: Revised to use sonic conductance according to
ISO 6358 instead of Cv according to ANSI standards to
better align with newer component data.
Annex E: Deleted, email feedback is preferred.

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Global Common Controls Hardware Design Standards (GCCH-1)
General Motors
Table of Contents
Document Management Information ....................................................................................................... i
Owners ................................................................................................................................................. i
Approval ............................................................................................................................................... i
Sponsoring Group ................................................................................................................................. i
Forward Questions and Comments to: .................................................................................................. i
Additional Copies of this Document may be obtained from: ................................................................. i
Document Expiration Date .................................................................................................................... i
Revision History ................................................................................................................................... ii
Table of Contents .................................................................................................................................. xiii
1 General......................................................................................................................................... 1-1
1.1 Scope .................................................................................................................................... 1-1
1.2 Purpose................................................................................................................................. 1-1
1.3 Audience ............................................................................................................................... 1-1
1.4 Deviations ............................................................................................................................. 1-1
1.5 Normative Reference ............................................................................................................ 1-1
2 Reserved....................................................................................................................................... 2-1
3 Safety ........................................................................................................................................... 3-1
3.1 Scope and Purpose ................................................................................................................ 3-1
3.2 General Design Requirements ............................................................................................... 3-1
3.3 General Requirements for Hazardous Locations .................................................................... 3-1
3.4 Safety Control Systems (Monitored Power Systems) ............................................................. 3-2
3.5 Components and Implementation ......................................................................................... 3-2
3.5.1 Switch Contacts ............................................................................................................. 3-2
3.5.2 Control Relays and Contactors ....................................................................................... 3-2
3.5.3 Complex Safety Devices ................................................................................................. 3-3
3.5.4 Safety Relay Modules .................................................................................................... 3-3
3.6 Safety Circuit Requirements .................................................................................................. 3-4
3.6.1 Stop Circuit Classification and Usage.............................................................................. 3-4
3.6.2 Implementation of Safety Circuits.................................................................................. 3-4
3.6.3 Suspension of Safeguards .............................................................................................. 3-5
3.6.4 Muting .......................................................................................................................... 3-5
3.7 GM Safety Circuits ................................................................................................................. 3-6

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Global Common Controls Hardware Design Standards (GCCH-1)
General Motors
3.7.1 Emergency Stop............................................................................................................. 3-6
3.7.2 Logic OK Relay ............................................................................................................... 3-7
3.7.3 Point-of-Operation Guarding ......................................................................................... 3-7
3.7.4 Gating and Perimeter Guarding ..................................................................................... 3-9
3.7.5 Maintenance Entrance Gates ......................................................................................... 3-9
3.7.6 Perimeter Guards .......................................................................................................... 3-9
3.7.7 Material Entrances and Exits.......................................................................................... 3-9
3.7.8 Perimeter Guard Interlocking to Other Cells .................................................................. 3-9
3.7.9 SCS/MPS Circuits and Entrance Gate Control Panel Integration.................................... 3-10
3.7.10 Robot Interface ........................................................................................................... 3-11
4 Architecture.................................................................................................................................. 4-1
4.1 Purpose................................................................................................................................. 4-1
4.2 Scope .................................................................................................................................... 4-1
4.3 Common Controls Architecture ............................................................................................. 4-1
4.4 Automation Classifications (Architecture Definitions) ............................................................ 4-2
4.4.1 Architecture Key Elements............................................................................................. 4-3
4.5 Power Architecture ............................................................................................................... 4-4
4.5.1 Connectors and Cables .................................................................................................. 4-4
4.6 Network Architecture............................................................................................................ 4-7
4.7 Standard Industrial Control Panels ........................................................................................ 4-9
4.7.1 Power Distribution Panels (PDP) .................................................................................... 4-9
4.7.2 Main Control Panel (MCP) ........................................................................................... 4-10
4.7.3 Human Machine Interface (HMI) ................................................................................. 4-10
4.7.4 Entrance Gate Control Panel (Gate Box) ...................................................................... 4-10
4.7.5 Fixture Junction Box .................................................................................................... 4-10
4.7.6 Operator Interface Panel ............................................................................................. 4-11
4.7.7 Motor Control Panel .................................................................................................... 4-11
4.7.8 Safety Device Junction Boxes ....................................................................................... 4-11
4.8 Marquees............................................................................................................................ 4-11
4.9 Programming Terminal........................................................................................................ 4-11
4.9.1 Programming Terminal Location Requirements ........................................................... 4-12
4.9.2 Programming Terminal Integration Requirements ....................................................... 4-12
4.9.3 Programming Terminal Computer Requirements ......................................................... 4-12

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4.10 Press ................................................................................................................................... 4-13
4.10.1 Press Cell Span of Control ............................................................................................ 4-13
4.10.2 Press PLC and HMI Span of Control .............................................................................. 4-13
4.10.3 Press PDP Span of Control ........................................................................................... 4-13
4.11 Conveyors ........................................................................................................................... 4-13
4.11.1 Conveyor PLC and HMI Span of Control ....................................................................... 4-14
4.11.2 Conveyor PDP Span of Control ..................................................................................... 4-14
4.12 General Assembly ............................................................................................................... 4-14
4.12.1 General Assembly PLC and HMI Span of Control .......................................................... 4-14
4.12.2 General Assembly PDP Span of Control ........................................................................ 4-15
4.13 Paint ................................................................................................................................... 4-15
4.13.1 Paint PLC and HMI Span of Control .............................................................................. 4-15
4.13.2 Paint PDP Span of Control............................................................................................ 4-15
4.14 Bodyshop ............................................................................................................................ 4-15
4.14.1 Bodyshop PLC Span of Control ..................................................................................... 4-15
4.14.2 Bodyshop HMI Span of Control .................................................................................... 4-16
4.14.3 Bodyshop PDP Span of Control Rules ........................................................................... 4-17
4.14.4 Bodyshop High Automation Rules................................................................................ 4-21
4.14.5 Bodyshop Medium Automation (Offline Cell or Stand-Alone Station)........................... 4-21
4.14.6 Bodyshop Low Automation (Simple Manual Operation Stations) ................................. 4-22
4.15 Propulsion Systems ............................................................................................................. 4-22
4.15.1 Propulsion Systems PLC Span of Control ...................................................................... 4-22
4.15.2 Propulsion Systems HMI Span of Control ..................................................................... 4-22
4.15.3 Propulsion Systems PDP Span of Control ..................................................................... 4-22
4.16 Additional Requirements..................................................................................................... 4-22
5 Documentation and Naming ......................................................................................................... 5-1
5.1 CAE (Computer Aided Engineering) Tools .............................................................................. 5-1
5.2 EPLAN ................................................................................................................................... 5-1
5.2.1 GM EPLAN Library ......................................................................................................... 5-1
5.2.2 GM EPLAN User Manual ................................................................................................ 5-1
5.2.3 Installing EPLAN............................................................................................................. 5-1
5.2.4 EPLAN Training .............................................................................................................. 5-1
5.2.5 Converting AutoCAD to EPLAN....................................................................................... 5-2

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5.2.6 Delivering EPLAN Designs .............................................................................................. 5-2
5.2.7 GM Drawing Rules ......................................................................................................... 5-2
5.3 GM Title Block Format ........................................................................................................... 5-2
5.3.1 Title Block Field Definitions............................................................................................ 5-2
5.3.2 File Name and Date/Time Stamp ................................................................................... 5-4
5.3.3 Drawing Status Stamp ................................................................................................... 5-4
5.4 Kit Documentation Process ................................................................................................... 5-5
5.4.1 Types of Changes........................................................................................................... 5-5
5.5 Drawing Naming Convention ................................................................................................. 5-6
5.5.1 Bodyshop Naming Conventions ..................................................................................... 5-6
5.5.2 Conveyor Naming Convention Conventions ................................................................... 5-7
5.5.3 GA (General Assembly) WD Naming Convention.......................................................... 5-10
5.5.4 Paint Process WD Naming Convention ......................................................................... 5-16
5.5.5 Press WD Naming Convention ..................................................................................... 5-18
5.5.6 Propulsion Systems WD Naming Convention ............................................................... 5-19
5.5.7 Non Unique WD Naming Conventions (Regional or Project Specific) ............................ 5-20
5.5.8 EC Naming Conventions............................................................................................... 5-20
5.5.9 GM Standard Drawing Naming Conventions (Documentation Supplied by GM) ........... 5-21
5.6 File Naming ......................................................................................................................... 5-22
5.7 Action / Result (“Work” / “Load/Unload”) Naming Convention ........................................... 5-22
5.8 Deliverables ........................................................................................................................ 5-23
5.8.1 Documentation for Approval ....................................................................................... 5-24
5.8.2 Documentation for Construction ................................................................................. 5-25
5.8.3 Before Debug or Run-Off ............................................................................................. 5-25
5.8.4 Documentation As Shipped ......................................................................................... 5-25
5.8.5 Documentation As Built ............................................................................................... 5-25
6 Wiring Diagram (WD) Levels and Packages.................................................................................... 6-1
6.1 Purpose................................................................................................................................. 6-1
6.2 WD Levels ............................................................................................................................. 6-1
6.2.1 Single Tool or Self-Contained Machines ......................................................................... 6-2
6.3 Drawing Level Details ............................................................................................................ 6-2
6.3.1 System Level WD Drawing Package................................................................................ 6-2
6.3.2 Controller Level WD Drawing Package ........................................................................... 6-2

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6.3.3 Unit Level WD Drawing Package .................................................................................... 6-3
6.4 Drawing Section Format ........................................................................................................ 6-3
6.4.1 System Level WD Package Sections................................................................................ 6-5
6.4.2 Controller level WD Package Sections ............................................................................ 6-6
6.4.3 Unit Tool Level WD Package Sections............................................................................. 6-6
7 Drawing Section A: Reference Sheet(s), Table of Contents, and Revision Summary Sheet(s).......... 7-1
7.1 Purpose................................................................................................................................. 7-1
7.2 Title and Reference Sheet(s).................................................................................................. 7-1
7.3 Table of Contents .................................................................................................................. 7-2
7.4 Revision Summary Sheet(s) ................................................................................................... 7-3
8 Drawing Section B: Layout ............................................................................................................ 8-1
8.1 Purpose................................................................................................................................. 8-1
8.2 System (Zone) Layout ............................................................................................................ 8-1
8.3 Controller (Cell) Layout ......................................................................................................... 8-2
8.4 Unit (Station) Layout ............................................................................................................. 8-2
8.4.1 GA (General Assembly) Unit (Station) Layout ................................................................. 8-3
9 Drawing Section C: Interconnect ................................................................................................... 9-1
9.1 Purpose................................................................................................................................. 9-1
9.2 General Design Requirements ............................................................................................... 9-1
9.2.1 The Interconnect Shall Show: ........................................................................................ 9-1
9.2.2 Interconnect Line Types................................................................................................. 9-2
9.2.3 System (Zone) Interconnect ........................................................................................... 9-3
9.2.4 Controller (Cell) Interconnect ........................................................................................ 9-3
9.2.5 Unit (Station) Interconnect ............................................................................................ 9-3
9.3 Device ID (Subscript) Designations ........................................................................................ 9-4
9.4 Cable Labeling ....................................................................................................................... 9-6
9.4.1 Hardwired Cable Labeling .............................................................................................. 9-6
9.4.2 General Cable Labeling .................................................................................................. 9-7
9.4.3 Multi-Drop Power Cable Naming ................................................................................. 9-10
9.4.4 DeviceNet Cable Naming ............................................................................................. 9-12
9.4.5 Ethernet Cable Naming................................................................................................ 9-13
9.4.6 Receptacle Naming...................................................................................................... 9-15
9.5 DeviceNet Networks ........................................................................................................... 9-17

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9.5.1 Overview ..................................................................................................................... 9-17
9.5.2 DeviceNet Scanner ...................................................................................................... 9-17
9.5.3 DeviceNet Baud Rate ................................................................................................... 9-17
9.5.4 DeviceNet Node Requirements.................................................................................... 9-17
9.5.5 DeviceNet Component Requirements .......................................................................... 9-20
9.5.6 Device Identification Methods ..................................................................................... 9-20
9.5.7 DeviceNet Cable Requirements ................................................................................... 9-21
9.5.8 DeviceNet Cable Layout ............................................................................................... 9-22
9.5.9 DeviceNet Cable Length............................................................................................... 9-24
9.5.10 DeviceNet Network Cable Labeling .............................................................................. 9-25
9.5.11 DeviceNet Power Supply.............................................................................................. 9-25
9.5.12 DeviceNet System Grounding ...................................................................................... 9-26
9.5.13 DeviceNet Auxiliary Power........................................................................................... 9-27
9.6 Ethernet Networks .............................................................................................................. 9-28
9.6.1 Overview ..................................................................................................................... 9-28
9.6.2 Ethernet Communication Layer ................................................................................... 9-28
9.6.3 Ethernet Hardware ...................................................................................................... 9-28
9.6.4 Ethernet Configuration ................................................................................................ 9-34
9.6.5 Ethernet Interconnect ................................................................................................. 9-35
9.6.6 Ethernet I/O (Private Network Devices) ....................................................................... 9-37
9.7 Equipment Grounding (Protective Earthing) & Bonding ....................................................... 9-47
9.7.1 Grounding (Protective Earthing) .................................................................................. 9-47
9.7.2 Bonding ....................................................................................................................... 9-47
9.7.3 Electromagnetic compatibility (EMC) ........................................................................... 9-47
10 Drawing Section D: Sequence of Operations ........................................................................... 10-1
10.1 Purpose............................................................................................................................... 10-1
11 Drawing Section E: Magnetics ................................................................................................. 11-1
11.1 Purpose............................................................................................................................... 11-1
11.2 Drawing Section Design Requirements ................................................................................ 11-1
11.3 Wire Size ............................................................................................................................. 11-3
11.4 Voltage Drop Over Distance ................................................................................................ 11-4
11.5 Wire Colors ......................................................................................................................... 11-5
11.6 Identification....................................................................................................................... 11-8

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11.6.1 Device Identification.................................................................................................... 11-8
11.6.2 Wire Identification....................................................................................................... 11-9
11.7 Overcurrent Protection ..................................................................................................... 11-12
11.7.1 General Requirements............................................................................................... 11-12
11.7.2 Short Circuit Current Rating (SCCR) ............................................................................ 11-14
11.7.3 Arc Flash Incident Energy........................................................................................... 11-14
11.8 380 – 575 V Design Requirements ..................................................................................... 11-14
11.8.1 Main Disconnect ........................................................................................................ 11-14
11.8.2 Remote Disconnects .................................................................................................. 11-14
11.8.3 Enclosure Wiring on Line Side of Disconnect .............................................................. 11-14
11.8.4 Main Distribution Block and 380 – 575 V Wire Sizing ................................................. 11-14
11.8.5 Motor Starters and Overloads ................................................................................... 11-15
11.8.6 Power Factor Correction Capacitor (PFCC) ................................................................. 11-15
11.9 Design Requirements for Control Voltage (120 VAC) ......................................................... 11-16
11.9.1 Excepted Circuit (“Hot”) Power (not de-energized by the main disconnect) ............... 11-16
11.9.2 Control Power ........................................................................................................... 11-17
11.10 Design Requirements for Control Voltage (24 VDC) ....................................................... 11-17
11.11 VFD (Variable Frequency Drive) or ASD (Adjustable Speed Drive) Design Requirements 11-19
11.11.1 Proper VFD Design..................................................................................................... 11-19
11.11.2 General VFD Design Requirements ............................................................................ 11-19
11.11.3 VFD Enclosures .......................................................................................................... 11-21
11.12 Servo Systems – General Design Requirements ............................................................. 11-21
11.12.1 Servo Enclosure ......................................................................................................... 11-22
12 Drawing Section F: Input/Output (I/O) .................................................................................... 12-1
12.1 Purpose............................................................................................................................... 12-1
12.2 General I/O Design Requirements ....................................................................................... 12-1
12.2.1 IP20 I/O Requirements ................................................................................................ 12-2
12.2.2 IP67 I/O Requirements ................................................................................................ 12-3
12.3 Safety I/O Design Requirements .......................................................................................... 12-5
12.4 Processor Chassis I/O Design Requirements ........................................................................ 12-7
12.5 Tool I/O Design Requirements ............................................................................................. 12-8
12.6 Device Naming .................................................................................................................... 12-8
12.6.1 Style Designation ....................................................................................................... 12-11

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13 Drawing section G: Pneumatic (compressed air) ..................................................................... 13-1
13.1 Purpose............................................................................................................................... 13-1
13.2 Pneumatic design requirements .......................................................................................... 13-1
13.2.1 Pneumatic design order............................................................................................... 13-1
13.2.2 Pneumatic drawing section structure .......................................................................... 13-1
13.3 Air drops from plant supply ................................................................................................. 13-1
13.3.1 Cell (Controller) Air Prep.............................................................................................. 13-1
13.3.2 Offline Tool Air Prep (Tools Fed Directly From Plant Air) .............................................. 13-3
13.4 Air drops from cell supply.................................................................................................... 13-4
13.4.1 Cell Air Header ............................................................................................................ 13-4
13.4.2 Unit (Station) Air Drop ................................................................................................. 13-4
13.4.3 Robot air drop(s) ....................................................................................................... 13-13
13.4.4 Tipdress air drop (if applicable).................................................................................. 13-13
13.5 Other Pneumatic Device Requirements ............................................................................. 13-13
13.5.1 Automatic Pneumatic drills / vacuum cups ................................................................ 13-13
13.5.2 Surge tanks................................................................................................................ 13-14
13.5.3 Counterbalance system ............................................................................................. 13-16
13.6 Assist and Fixtured Nutrunners (LAFN/FM), Air Logic......................................................... 13-19
13.6.1 Definitions ................................................................................................................. 13-19
13.6.2 General ..................................................................................................................... 13-19
13.6.3 Design ....................................................................................................................... 13-19
13.6.4 Valves........................................................................................................................ 13-21
13.6.5 Enclosures for Pneumatic Components...................................................................... 13-21
13.6.6 Electrical Connections of Fixtured Nutrunners ........................................................... 13-22
14 Drawing Section H: Hydraulic and Lube ................................................................................... 14-1
14.1 Purpose............................................................................................................................... 14-1
14.2 Design Requirements .......................................................................................................... 14-1
14.2.1 Contents of the Controller (Cell) Level Drawing Package May Include: ......................... 14-1
14.2.2 Contents of the Unit (Station) Level Drawing Package May Include: ............................. 14-1
14.3 General Design Requirements ............................................................................................. 14-1
14.4 Controller (Cell) Level Design Requirements ........................................................................ 14-2
14.4.1 Header Design Requirements ...................................................................................... 14-2
14.4.2 Hydraulic Power Units (HPU) ....................................................................................... 14-3

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14.5 Unit (Station) Level Design Requirements............................................................................ 14-4
14.5.1 Isolation Valves and Accumulators............................................................................... 14-4
14.5.2 Dump Valve Circuits .................................................................................................... 14-5
14.5.3 Manifolds, Valves and Actuators .................................................................................. 14-5
14.5.4 Air Over Oil Systems .................................................................................................... 14-7
14.5.5 Lubrication Systems..................................................................................................... 14-8
14.5.6 Drills ............................................................................................................................ 14-8
15 Drawing Section I: Water ........................................................................................................ 15-1
15.1 Purpose............................................................................................................................... 15-1
15.2 Importance of Water to the Weld Equipment...................................................................... 15-1
15.3 Water Flow Requirements................................................................................................... 15-1
15.3.1 Flow Tables for Hose and Flex tube.............................................................................. 15-2
15.4 Drawing Package Level Definition for Section I .................................................................... 15-3
15.4.1 Component Symbols.................................................................................................... 15-3
15.5 Controller (Cell) Level (Water Preparation, Header, and Drops) Design Requirements ......... 15-3
15.5.1 Controller (Cell) Level Documentation ......................................................................... 15-4
15.6 Unit (Station) Level Design Requirements............................................................................ 15-6
15.7 Water Flow for Hard Automatic (Fixture) Welding Operations ............................................. 15-8
15.7.1 Kickless Cable Water Flow ........................................................................................... 15-8
15.8 Water Flow Diagrams for Robotic Operations ...................................................................... 15-8
15.8.1 AC Transgun Water Flow Diagrams .............................................................................. 15-8
15.8.2 Portable / Robotic Hip Mount Transformer Water Flow Diagram ................................. 15-9
15.8.3 MFDC Transgun ......................................................................................................... 15-10
15.8.4 High Capacity MFDC Transgun ................................................................................... 15-11
15.8.5 Robotic Single DC LS Transgun ................................................................................... 15-12
15.8.6 Robotic Dual DC LS Transguns .................................................................................... 15-13
16 Drawing Section J: Reserved.................................................................................................... 16-1
17 Drawing Section K: Reserved ................................................................................................... 17-1
18 Drawing Section L: Liquids (to be defined)............................................................................... 18-1
19 Drawing Section M: User Defined............................................................................................ 19-1
20 Drawing Section N: Reserved .................................................................................................. 20-1
21 Drawing Section O: Reserved .................................................................................................. 21-1
22 Drawing Section P: Reserved ................................................................................................... 22-1

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23 Drawing Section Q: Reserved .................................................................................................. 23-1
24 Drawing Section R: Reserved................................................................................................... 24-1
25 Drawing Section S: Reserved ................................................................................................... 25-1
26 Drawing Section T: Reserved ................................................................................................... 26-1
27 Drawing Section U: Reserved .................................................................................................. 27-1
28 Drawing Section V: Reserved................................................................................................... 28-1
29 Drawing Section W: Welding Applications Designs and Interface............................................. 29-1
29.1 Purpose............................................................................................................................... 29-1
29.2 Weld Controller Interface .................................................................................................... 29-1
29.3 AC (Alternating Current) Welding ........................................................................................ 29-1
29.4 MFDC (Medium Frequency Direct Current) Welding ............................................................ 29-1
29.5 Welding Section Layout ....................................................................................................... 29-2
29.6 Wire and Cable Designation ................................................................................................ 29-3
29.7 Welding Section Design Criteria........................................................................................... 29-4
29.8 MFDC Primary Cable Selection for Up To 24 kA (Steel) in GM North America....................... 29-6
29.8.1 Weld Controller to Transformer Cable Lengths for Up To 24 kA (Steel) in GM North
America 29-6
29.9 MFDC Primary Cable Selection for Up To 24 kA (Steel) in GM International (Metric) ............ 29-7
29.9.1 Weld Controller to Transformer Cable Lengths for Up To 24 kA (Steel) in GM International
(Metric) 29-7
29.10 MFDC Primary Cable Selection for Up To 50 kA (Aluminum) in GM North America .......... 29-7
29.11 MFDC Primary Cable Selection for Up To 50 kA (Aluminum) in GM International (Metric) 29-8
29.12 Welding Section Notes .................................................................................................. 29-10
29.13 Weld Sequence Chart .................................................................................................... 29-10
29.14 Weld Controller Junction Box ........................................................................................ 29-10
29.15 Weld Power Distribution Panel ...................................................................................... 29-11
29.15.1 Weld Power Distribution Panel Guidelines................................................................. 29-11
30 Drawing Section X: Enclosures ................................................................................................ 30-1
30.1 Purpose............................................................................................................................... 30-1
30.2 Overview............................................................................................................................. 30-1
30.3 General Design Requirements ............................................................................................. 30-1
30.4 Working Space (Footprint) About Enclosures....................................................................... 30-4
30.5 Cable and Receptacle Pin Charts.......................................................................................... 30-4
30.6 Standard Panels (ECS) ......................................................................................................... 30-4

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30.7 Custom Panels .................................................................................................................... 30-4
30.8 Power Distribution Panel (PDP) ........................................................................................... 30-5
30.9 Controller (Cell) Main Control Panel .................................................................................... 30-5
30.10 Fixture Junction Boxes ..................................................................................................... 30-6
30.11 Human Machine Interface (HMI) ..................................................................................... 30-7
30.11.1 Pushbutton Panels....................................................................................................... 30-7
30.12 Motor Starter Panels ....................................................................................................... 30-8
30.13 Programming Terminal .................................................................................................... 30-8
30.14 Construction Specifications ............................................................................................. 30-8
30.14.1 Doors .......................................................................................................................... 30-9
30.14.2 Door and Cover Fasteners ......................................................................................... 30-10
30.14.3 Disconnects ............................................................................................................... 30-10
30.15 Components and Installation ......................................................................................... 30-10
30.15.1 Inside Electrical Enclosures ........................................................................................ 30-10
30.15.2 Outside Electrical Enclosures ..................................................................................... 30-12
30.16 Wiring Methods ............................................................................................................ 30-12
30.16.1 General ..................................................................................................................... 30-12
30.17 Multiconductor Cables and Receptacles ........................................................................ 30-13
30.18 Panel/Enclosure Grounding (Earthing) ........................................................................... 30-14
30.18.1 Purpose ..................................................................................................................... 30-14
30.18.2 Proper Design ............................................................................................................ 30-14
30.18.3 General Design Requirements ................................................................................... 30-15
30.19 Labeling and Identification ............................................................................................ 30-16
30.19.1 Device Identification.................................................................................................. 30-16
30.19.2 Enclosure Identification and Labels............................................................................ 30-17
31 Drawing Section Y: Bill of Material (BOM) ............................................................................... 31-1
31.1 Design Requirements .......................................................................................................... 31-1
31.2 Bill of Material Sub-Sections ................................................................................................ 31-1
31.2.1 Main BOM (YA Section) ............................................................................................... 31-1
31.2.2 Variable BOMs (YB, YC, etc. Sections) .......................................................................... 31-1
31.2.3 Device List (YZ Section) ................................................................................................ 31-1
31.3 Required Information .......................................................................................................... 31-1
31.4 Purchase Codes ................................................................................................................... 31-2

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31.4.1 Spare Parts Designator ................................................................................................ 31-3
31.5 Item Number Ranges........................................................................................................... 31-4
32 Drawing Section Z: Standard and/or Reference Drawings ........................................................ 32-1
32.1 Purpose............................................................................................................................... 32-1
32.2 Design Requirements .......................................................................................................... 32-1
32.2.1 Section Sheet Order..................................................................................................... 32-1
32.2.2 Examples of Reference Types for Each WD Level Package ............................................ 32-1
Annex A Definitions.........................................................................................................................A-1
Annex B Engineering Design Reference ........................................................................................... B-1
Annex C Air Component Sizing ........................................................................................................ C-1
C1 Air Drop Sizing....................................................................................................................... C-1
C1.1 Air Drop Sizing Example ................................................................................................. C-1
C2 Valve and Component Sizing ................................................................................................. C-2
C2.1 Flow Characteristic Calculation ...................................................................................... C-2
Fitting Flow Characteristic Calculations ..................................................................................... C-4
C3 ..................................................................................................................................................... C-4
C4 Tube/Hose Flow Characteristic Calculations .......................................................................... C-4
C5 Example System Calculation .................................................................................................. C-5
Annex D Bibliography (informative) ................................................................................................ D-1
Annex E Reserved ........................................................................................................................... E-1
Annex F Heat Calculations for Control Enclosures ........................................................................... F-1
F1 Overview .................................................................................................................................. F-1
F2 Procedure ................................................................................................................................. F-1
F3 Results ...................................................................................................................................... F-2

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1 General
1.1 Scope
The provisions of this standard apply to the control system hardware designs for General
Motors Manufacturing Equipment. Additional specifications and standards may be provided for
a specific project; but the content of this standard shall take precedence in cases where another
document presents opposing direction. However, if another specification contains similar but
more stringent requirements, the contents of that document shall be used. Only national or
local codes and regulations (legal requirements) shall supersede this document for any GM
projects.
1.2 Purpose
The purpose of this standard is to provide clear and concise guidelines for designing the control
hardware for GM systems. The objective of these requirements is to provide lean, flexible and
cost-effective control systems that enhance both the productivity of the systems and the quality
of the products produced. The application of this standard shall result in common systems that:
1. Assure safe operation of industrial equipment.
2. Increase productivity of systems by increasing the mean time between failures (MTBF) and
decreasing the mean time to repair (MTTR).
3. Introduce common systems to all areas of the manufacturing facilities.
4. Reduce tool construction costs.
5. Leverage engineering resources.
6. Provide flexible designs to accommodate changes to the product or process.
1.3 Audience
This standard is primarily for use by controls design personnel. It shall be used by all personnel
(e.g., control engineers, machine tool builders, installation personnel and in-plant resources)
involved in the cycle of controls systems. This standard shall be used in all phases of the
equipment’s life:
1. Design
2. Debug
3. Buy-off
4. Installation
5. Production
1.4 Deviations
Any deviations from this specification require the advanced written approval of the GM Controls
Project Engineer responsible for the project in question. Any approved deviations shall only
apply to that specific instance, and it shall not be considered a change to the standard.
1.5 Normative Reference
The following normative references contain provisions that, through reference in this text,
constitute provisions of this standard. All normative references are subject to revision and the

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most recent editions of the normative standards indicated below shall apply. Reference the
applicable standards and norms for the region applied. Not all normative references listed apply
for all applications. Some normative references contain regional and not global requirements.
ANSI B11.19, for Machine Tools, Safeguarding When Referenced by the Other B11 Machine Tool
Safety Standards – Performance Criteria for the Design, Construction, Care, and Operation.
ANSI B11.20, Manufacturing Systems/Cells – Safety Requirements for Construction, Care, and
Use.
ANSI/RIA R15.06, for Industrial Robots and Robot Systems – Safety Requirements.
ISO 14118, Safety of machinery – Prevention of unexpected start-up.
ISO 14119, Safety of machinery – Interlocking devices associated with guards.
ISO 13854, Safety of machinery – Minimum gaps to avoid crushing of parts of the human body
IEC 60204, Safety of Machinery - Electrical equipment of machines.
IEC 60947 (parts 1, 2, and 3), Low-Voltage Switchgear and Controlgear.
ISO 13857, Safety of machinery – Safety distances to prevent danger zones being reached by the
lower limbs
ISO 14210, Safety of machinery – Guards – General requirements for the design and
construction of fixed and movable guards.
ISO 13849-1, Safety of machinery — Safety-related parts of control systems — Part 1: General
principles for design
ISO 13849-2, Safety of machinery — Safety-related parts of control systems — Part 2: Validation
ISO 4413, Hydraulic fluid power – General rules and safety requirements for systems and their
components.
ISO 4414, Pneumatic fluid power – General rules and safety requirements for systems and their
components.
ISO 13855, Safety of machinery – Positioning of safeguards with respect to the approach speeds
of parts of the human body.
EN ISO 12100-1, Safety of machinery. Basic terminology and methodology.
EN ISO 12100-2, Safety of machinery. Technical principles.
GM 1744, GM Global Hydraulic Standard for Industrial Equipment).
GM GCCB-1, GM Global Common Controls Build Specification.
GM G-DHS, Global Design for Health and Safety Specification.
GM GRS-1, GM Global Common Technical Specifications for Production Robots.
GM GRS-4 and related sections, GM Common Standard Robot Interfaces.
IEC 60529 (IEC529) Degrees of Protection Provided by Enclosures
IEC 61508 (all parts), Functional safety of electrical/electronic/programmable electronic safety-
related systems.

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IEC 61511 (all parts), Functional safety - Safety instrumented systems for the process industry
sector
IEC 62061, Safety of machinery - Functional safety of safety-related electrical, electronic and
programmable electronic control systems.
NFPA 70, NEC (National Electric Code).
NFPA 79, Electrical Standard for Industrial Machinery.
OESC, Ontario Electrical Safety Code.
OSHA 29 CFR 1910 Subpart O, Machinery and Machine Guarding.
Rockwell Publication DNET-UM072C-EN-P, DeviceNet Media Design and Installation Guide

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3 Safety
3.1 Scope and Purpose
The purpose of the safety section is to specify the functional characteristics, performance
expectations, use, general arrangement, and interconnections of the GM common safety
circuits. It shall be used by GM engineers, suppliers, and other designers as a guide for proper
implementation of GM common safety circuits. In addition, the reasoning behind the
functionality of the circuits will be outlined.

This section covers the controls aspects of the safety circuits for the GM common architecture.
However, it is not meant to be a complete safety design guide, nor does it address all the
available methods of achieving safe circuits. This section is not intended to limit new product
development or advances in technology or methodology. If the safety circuit design guidelines
outlined in this section are not appropriate for a particular application, then the responsible GM
Controls Project Engineer should be contacted for approved exceptions.
3.2 General Design Requirements

“Live Values that Return People Home Safely: Every Person, Every Site, Every Day.” –
GM Global Safety & Industrial Hygiene Vision

The goal of safety is to allow personnel to perform their tasks without risk of injury. Therefore,
adhering to the principles of design-in safety as outlined in the Global Design for Health and
Safety Specification (G-DHS), when a hazard cannot be eliminated it shall be controlled. If the
hazard cannot be controlled, then exposure to it shall be limited or other safeguards,
procedures, and protection shall be provided. In order to properly control hazards to personnel,
control reliability shall be employed to integrate safety features that stop the machine’s motion
and ensure it is in a safe state. It is required by national standards that all new equipment and
tools have control reliable safety circuits. The safety function of the circuits shall have the
highest priority, and the intentional defeat of a safety function for convenience purposes or to
enhance production shall be forbidden.

Common safety circuits shall be used throughout the tooling design process to allow consistency
and uniformity in design, application, and troubleshooting. All safety circuits described in this
section were designed to meet the requirements of the G-DHS specification. G-DHS outlines the
requirements for Safety Control Systems (SCS) or Monitored Power Systems (MPS), which can
be used as an alternative to lockout when personnel are performing routine minor maintenance
tasks during production. GM’s common architecture uses SCS (MPS) safety circuits.
Furthermore, the circuits in this common architecture were designed for flexibility and
modularity, which allows them to be adaptable to suit most safety circuit applications. The
methods and techniques described throughout this section shall be adhered to. Any exceptions
must have the approval of the responsible GM project controls engineer.
3.3 General Requirements for Hazardous Locations
Many hazardous areas require intrinsically safe and explosion-proof wiring and components. As
with all electrical designs the regional regulatory requirements (e.g., National Electric Code
(NFPA 70)), must be followed. For the definition of a hazardous or classified location, refer to
the NFPA 70 Article 500 as an example. The extent of a classified area is defined in accordance

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with NFPA 70 Article 514-2. The classification of specific liquids, gases, or vapors is found in
NFPA 79. All application specific questions about the acceptable wiring practices and
components should be directed to the responsible GM Controls Project Engineer.
3.4 Safety Control Systems (Monitored Power Systems)
Safety Control Systems (SCS) and all SCS/MPS circuits shall comply with the SCS/MPS key
elements and the circuit design requirements listed in the G-DHS specification. SCS/MPS circuits
meet all of the performance requirements of control reliability as set forth in the ANSI standards
and OSHA regulations. However, the SCS/MPS circuit design requirements in the G-DHS
specification outline key implementation details not found in either the ANSI standards or OSHA
regulations. Although a SCS/MPS is control reliable by design, not all control reliable systems
are SCS/MPS compliant.

When indicated by a risk assessment (g-Risk), safety circuits that are compliant with the
SCS/MPS requirements may be used as energy control in place of lockout. However, when the
task requires lockout, SCS/MPS shall not be used in place of lockout.
3.5 Components and Implementation
Simple reliability and safety may be achieved through careful selection and application of well-
tried components and methods. Circuits with a higher order of reliability depend more on the
construction of the circuit than components; however, proper component selection remains
important. All components shall be wired and used according to the manufacturers’
recommendations to ensure proper operation and a long service life. Components approved for
use in safety circuits shall be permitted to be used in non-safety applications.

Detailed component specifications and selections are beyond the scope of this document.
General requirements for safety components shall include but are not necessarily limited to
those listed in the sections below.
3.5.1 Switch Contacts
Where two contacts from a single safety device provide the redundant switches (e.g., gate
interlock switch, e-stop pushbutton) the contacts shall be normally closed and shall be “positive
opening” in accordance with IEC 60947-1 and 60947-5-1. The symbol shown in Figure 3-1 shall
appear on each normally closed contact block:
Figure 3-1 Positive Opening Contact Symbol

Safety switch devices with normally open contacts or normally closed contacts that are not
positive opening shall be redundant. Two or more independent devices shall be used in the
circuit.
3.5.2 Control Relays and Contactors
Control relays and contactors that are used in safety circuits shall be third party approved to the
applicable provisions of IEC 60947-1, 60947-4-1, and 60947-5-1. These relays are often called

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positive-guided relays and have mechanically linked contacts. This compliance ensures the
following:
1. If any N.O. contact on either the base unit or the auxiliary contact block fails to open, then
all N.C. contacts on either the base unit or the auxiliary contact block cannot close.
2. If any N.C. contact on either the base unit or the auxiliary contact block fails to open, then
all N.O. contacts on either the base unit or the auxiliary contact block cannot close.
3. The minimum opening of a N.O. or N.C. contact is 0.5 mm.
4. Open contacts can withstand a test voltage according to clause 8.3.3.4.1, 8.3.3.4.2, and
8.3.3.4.3 of IEC 60947-5-1.
If these control relays and contactors use an auxiliary contact block, then the block must meet
the requirements stated above and either be permanently mounted or screwed to the front of
the device. Figure 3-2 should appear on a positive-guided control relay or contactor:
Figure 3-2 Positive-Guided Contact Symbol

If positive-guided control relays or contactors cannot be used, the responsible GM Controls

Project Engineer must be contacted for approved exception.
3.5.3 Complex Safety Devices
Complex safety devices that are designed to be control reliable (e.g., light curtains, laser
scanners, and safety mats) shall be certified to the applicable standards by an independent
competent body or Nationally Recognized Testing Laboratory. In general, a single device cannot
be control reliable. Only a circuit or system comprising of a number of devices may be control
reliable. A list of GM approved complex safety devices can be obtained from the GM
engineering parts database.
3.5.4 Safety Relay Modules
Safety PLC’s and safety IO are the preference for safety systems. In the event a safety PLC or
product is not practical or available, then a safety relay module may be used. Safety relay
modules are designed to provide built-in redundancy and monitoring within a small, modular
package. These modules also reduce the possibility of wiring errors that may occur when
constructing the equivalent circuit from redundant, discrete, positive-guided control relays.
3.5.4.1 Selection
Safety relay modules vary in their input configurations, number and type of outputs, supply
voltage, physical size, and intended use. The selection of a particular module should be based
on the needs of the particular operating application. Typical safety circuit applications include
but are not limited to emergency stops, light curtains, safety mats, gate switches, robot axis
limit switches, and enabling devices. Modules with different quantities of immediate or delayed
output contacts for both basic stop modules and expansion modules are available. A list of GM
approved safety relay modules can be obtained from the GM engineering parts database.

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3.5.4.2 Power
Safety relay modules require control power to function. For GM common applications, all safety
relay modules shall use a 24 VDC supply voltage. For modules that can accept two different
supply voltages, only one of these shall be connected. Safety relay modules have a typical
operating voltage range between 22 to 26 VDC, not 18 to 30 VDC like most other control
components. A supply voltage outside of the manufacturer’s listed operating range has been
shown to cause unpredictable operation and/or component damage.

Upon the loss of power, all safety relay modules de-energize to a fail-to-safe condition with all
normally open contacts open.
3.6 Safety Circuit Requirements
All safety circuits shall conform to certain national and international standards. The following
sections will discuss the requirements of the standards as they apply to stop circuits, control
reliable circuits, and circuits that override safeguarding. A good understanding of these
requirements is needed to design capable safety circuits.
3.6.1 Stop Circuit Classification and Usage
Most safety circuits function as stop circuits that stop or inhibit machine motion. All stopping
functions shall override their related start functions and shall be initiated by de-energizing
rather than the energizing control devices. Removing the cause of a stop function or resetting
the stop circuitry shall not restart any part of the equipment.

NFPA 79 and IEC 60204 define three stop categories:

• Category 0: stopping by immediate removal of power to the machine actuators.
• Category 1: a controlled stop … with power to the machine actuators available to achieve
the stop and then removal of power when the stop is achieved.
• Category 2: a controlled stop with power left available to the machine actuators.
Most of safety circuits are Category 0 stopping circuits. Category 1 stops may be used where
demanded by safety and functional requirements (e.g., using dynamic braking to achieve a
faster stop). Category 2 stops are not safety stops and shall not be used within safety circuits.
3.6.2 Implementation of Safety Circuits
To achieve a high level of reliability, all safety circuits for power, control, and interlocks shall use
the following methods.
1. A single-channel circuit shall be interrupted in a control reliable manner by including at least
one of the following:
a. One normally open safety relay or expansion module contact.
b. Two normally open control relay or contactor contacts in series, each from a separate
monitored, positive-guided control relay or contactor.
c. One safety rated PLC output.
2. A dual-channel circuit shall be interrupted in a redundant manner by including at least one
of the following:

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a. One normally open safety relay or expansion module contact in each channel (from the
same safety relay module or its expansion module.)
b. Two normally open contacts, each from a separate monitored, positive-guided control
relay or contactor, with one contact in the first channel and the other contact in the
second channel.
c. Two safety rated PLC outputs or one Bi-polar safety output pair.
3.6.3 Suspension of Safeguards
The suspension of one or more safeguards shall comply with the requirements of IEC 60204 and
NFPA 79:

“Where it is necessary to suspend one or more safeguards, a mode selection device or

means capable of being secured (e.g., locked) in the desired mode shall be provided
to prevent automatic operation. In addition, one or more of the following measures
shall be provided:

- Initiation of motion by a hold-to-run or other control device.

- A portable control station (e.g., pendant) with an emergency stop

device, and, where appropriate, an enabling device. Where a
portable station is used, motion shall only be initiated from that
station.

- Limiting the speed or the power of motion.

- Limiting the range of motion.”

3.6.4 Muting
Safeguarding devices may be muted at times when no hazards exist to personnel. The muting of
safeguarding devices shall comply with local and international specifications (ISO 13849-1, ANSI
B11-19, IEC 62046, ANSI/RIA R15.06).

“Muting is the temporary automatic suspension of a safety function(s) by safety-

related parts of the control system.” (IEC 62046 3.1.23)

“Muting is the temporary automatically controlled deactivation of the function of a

safeguarding device during a portion of the robot, or robot system’s cycle. Muting
shall only be provided when it is necessary for the process being performed on the
machine. It shall be implemented such that a person cannot remain undetected in
the hazardous zone when muting is terminated. Muting may be used in conjunction
with any safeguarding device that electrically signals a stop.” (ANSI/RIA R15.06)

In addition to the above requirements for muting, the following additional requirements must
also be fulfilled:
1. Muting status indication shall be provided for all applications where switches are used to
mute the sensing field of a safety device (light curtain, laser scanner, safety mat, etc.).
a. The muting indicator will be on to indicate that the muting function is active.

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b. Yellow or Amber are the preferred colors for the muting status indicator.
c. The muting status indicator should be of sufficient brightness and be installed in a
location where it is visible by any person entering the hazard area.
d. The muting status indicator shall be powered from a muting output from either a safety
rated output or a muting module. The output must have the capability to detect a
failure (open circuit) of the muting indicator.
2. Where muting is provided for a safety device that also stops a transfer system, a mute
override function shall also be provided:
a. The muting override shall be a spring return hold-to-run actuator.
b. The muting override shall be key-operated.
c. Visible indication of the status of the mute override function (indicating light) shall be
provided.
d. The mute override shall be time limited to no more than 2 times the normal transfer
time of the equipment.
3.7 GM Safety Circuits
GM’s safety circuits are divided into five main functional categories:
1. Emergency stops
2. Point-of-operation guarding
3. Gating and perimeter guarding
4. SCS/MPS circuits and Entrance Gate Control Panel integration
5. Robot interface circuits
These circuit categories will be discussed in the following sections. Please refer to the most
recent sample drawing packages for the circuit schematics, which are available from the
responsible GM Controls Project Engineer. Applications or safety circuit configurations that are
not specifically listed are not necessarily prohibited. However, they shall require approval by
the responsible GM Controls Project Engineer.
3.7.1 Emergency Stop
The Reset circuit and its associated elements, which are described in the following sections, shall
provide the emergency stop function.
3.7.1.1 Definition and Requirements
All emergency stop devices shall comply with the requirements in Global Design for Health and
Safety (G-DHS) chapter 5 (safeguarding).
3.7.1.2 Span of Control
Emergency stop devices shall be provided and operate according to Global Design for Health
and Safety (G-DHS) chapter 5 (safeguarding).

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3.7.1.3 Local No E-stops Circuit
The Local No E-stops circuit module sums the contacts of the local emergency stop devices and
the “No E-stop” interlocks of the local equipment (e.g., robots.) Interlocks from this circuit may
be used in other cells per the span of control rules in G-DHS.
3.7.1.4 Reset Circuit
The Reset circuit shall function as the emergency stop circuit for the entire cell. This circuit shall
sum the status of, the Local No E-stops Circuit, and any external No E-stop interlocks from other
cells covered by the e-stop span of control. De-energizing this circuit shall stop all motion in the
cell.

The Reset circuit shall be configured for use with a monitored manual reset initiated by the
Reset pushbutton. Push and release shall be required to energize the Reset circuit.
3.7.1.5 Reset Pushbutton
The Reset pushbutton is the reset button for the Reset Circuit. The reset function shall be
implemented in a manner that prevents tie-down. It shall be blue, momentary, guarded, and
whenever possible illuminated.

All Reset pushbutton shall be located in proximity to an emergency stop button. The Reset and
E-stop buttons typically function as a pair and shall be located at the HMI. If no HMI is used,
these pushbuttons shall be located at the main control panel. The operator must have clear
view of the local cell from the Reset pushbutton location.
3.7.2 Logic OK Relay
For safety relay systems a Logic OK control relay shall be provided. This relay provides the
ability to de-energize motion power through the use of software. This relay is provided as a
supplemental feature, and the normal safety function shall not depend upon software. The
Logic OK control relay shall not cycle each time the Reset pushbutton is pressed. Contacts of
this relay shall be used in the inputs of the Reset safety relay module to achieve electrical
isolation between the Reset safety relay module and the PLC. The Logic OK control relay is not
part of the safeguarding and thus is not required to be redundant. This relay shall not be
interlocked to any other tool or cell.
3.7.3 Point-of-Operation Guarding
The guarding of machinery and equipment that is not contained inside a safeguarded cell shall
comply with ANSI B11.19 and IEC 62046. Point-of-operation safeguarding shall be located
wherever a machine operator may be exposed to a hazard.

Point-of-operation safeguarding devices and circuits shall adhere to the SCS/MPS key elements
listed in the G-DHS specification. These circuits shall be designed to stop and/or inhibit all
hazardous motion to which the operator is exposed. All machinery, equipment or associated
components that are accessible to the operator and may present a hazard shall not be capable
of any movement when the operator is present in the safeguarded area. If the operator is in the
safeguarded area and protected by a dynamic limiting device or alternative safeguarding, the
equipment is permitted to move.

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3.7.3.1 Operator Safety Devices Clear Circuit
The outputs of safeguarding devices that are used for operator safeguarding shall be used in a
circuit that reflects the condition “operator safety devices clear.” These safeguarding devices
may be presence-sensing devices (PSD’s) or interlocked barrier guards (e.g., automated safety
curtains, safety doors.) Where more than one functionally independent operator station exists,
individual, corresponding circuits shall be used.

All presence-sensing devices shall comply with the requirements in IEC 61496. When a
presence-sensing device(s) is used to guard an area, the outputs of the PSD controller(s) shall
drive independent circuit channels; this could be independent safety PLC inputs or separate
control relays.

Where the application and safeguarding require personnel to use a cycle start pushbutton to
initiate a tool cycle, the operator safety devices clear circuit shall be reset by the operator cycle
start pushbutton. The application must prevent tie-down of this pushbutton.

Presence-sensing Device Initiation (PSDI) is where a presence-sensing device is used to perform

both the safeguarding function and to initiate the machine cycle. Where PSDI is permitted, the
applications shall comply with IEC 61496 and ANSI B11.19.

For applications where it is necessary to allow motion while the operator safeguards are
interrupted, a selector switch may be provided that allows slow speed robotic teach
(<250mm/s) and tooling minor motion. This selector switch effectively bypasses the operator
safeguard for teaching tasks. Where this selector is provided, the following requirements must
be met:

1. The selector switch shall be keyed.

2. The selector switch shall be located in clear view of the device(s) being bypassed.
3. It shall not be possible to resume automatic operation while the selector switch is activated.
4. The selector switch controls shall be designed and installed consistent with the circuit
performance of the device being bypassed (generally redundant and monitored).
5. An indicator lamp shall be provided indicating when the bypass is active.
3.7.3.2 Robotic Applications
The Operator Safety Devices Clear circuit shall stop all robot motion for applications where a
robot workspace overlaps the workspace of an operator. When the operator is present, this
circuit shall stop the robot servo motion while maintaining the robot’s path (which enables a
fast recovery.)

A Dynamic Limiting Device (DLD) may be provided that allows the robot to operate independent
of the state of the operator safeguards during portions of its path when no operator hazard
exists. The DLD may be axis limit switches, a light curtain or another safety rated method. The
DLD should be positioned in a way that the robot interrupts it before it enters the operator area.
The DLD circuit shall be implemented such that the performance of the circuit is consistent with
the hazards (generally redundant and monitored). The DLD circuit shall stop the robot if it

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attempts to enter the shared workspace when the operator is present (operator safeguards
interrupted).
3.7.4 Gating and Perimeter Guarding
The purpose of perimeter guarding is to prevent unauthorized personnel from entering a
hazardous area or to stop hazardous motion if someone enters the safeguarded area. This
guarding may consist of mechanical fencing and/or presence-sensing devices.
3.7.5 Maintenance Entrance Gates
Each external maintenance entrance gate to the cell shall have a gate switch interlocked to the
safety circuit, typically an entrance gate control panel (gate box). Each gate switch provides
interlocks with redundant contacts that close when the gate is closed and reset. Opening the
gate shall open these contacts and automatically disable all motion within the cell that is not
safeguarded to prevent access to the hazard. One gate box may control multiple gates provided
all gates access the same safeguarded area, are on the same side of the line, and are within line
of sight of each other. Gatebox sharing applications must be approved by the responsible GM
controls project engineer. The usage of the Gate Reset and motion enabling interlocks is
described in the following sections.
3.7.6 Perimeter Guards
Only cell entrances designated as maintenance entrance gates shall have an Entrance Gate
Control Panel. Other openings in the cell perimeter, which allow personnel to reach hazardous
motion shall be protected by presence sensing devices or interlocked barrier guards (e.g.,
breakaway fences) serving as perimeter guards. Violation of a perimeter guard shall stop all
hazardous motion. Furthermore, the perimeter guarding safety circuit shall be reset at the point
of violation before the cell can resume automatic operation.

The perimeter guarding may be interlocked to other cells per section 3.7.8, Perimeter Guard
Interlocking to Other Cells.

Fencing and other fixed barrier guards that require a tool to remove shall not be interlocked
unless specifically required by a risk assessment.
3.7.7 Material Entrances and Exits
Material entrance and exit guarding shall conform to the requirements of the G-DHS
specification. Presence sensing devices at material entrances and exits may be muted to allow
passage of the material carrier into or out of the cell per section 3.6.4, Muting. Additional
safeguarding shall be provided to prevent or detect personnel intrusion.
3.7.8 Perimeter Guard Interlocking to Other Cells
Guarded areas that do not share common perimeter guarding and guarded areas that are
completely separated from adjacent guarded areas by fixed hard guarding, fencing or
equipment shall not have their perimeter guards interlocked to other cells.

Guarded areas that are separated from adjacent guarded areas by movable interlocked barrier
guards (e.g., break-away fences) shall have the guarding interlocked to the adjacent guarded
area as if it were an external perimeter guard of the adjacent guarded area (reference section
3.7.6, Perimeter Guards).

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Guarded areas that are separated from adjacent guarded areas by intercell light curtains or
other PSDs shall have their perimeter guards interlocked to the adjacent guarded areas.
Opening an external gate or perimeter guard in one guarded area shall disable only the
hazardous motion of material or equipment extending into the guarded area from any adjacent
areas. When the outside gates are open, violation of any intercell PSD shall stop all hazardous
motion in the adjacent guarded area. The intercell PSDs shall be ignored when all external
perimeter guards and gates are closed and reset.
3.7.9 SCS/MPS Circuits and Entrance Gate Control Panel Integration
There are four main motion enable interlocks from each entrance gate control panel:
1. Tool Minor Enable
2. Tool Major Enable
3. 1 Robot Teach Enable
4. All motions enabled (All robots teach enabled)
Interlocks are redundant and consist of safety inputs and safety outputs. Opening the gate shall
open these interlocks and automatically disable all motion within the cell, unless a selection is
made at the gate box deliberately enabling motion.

Corresponding interlocks from each Entrance Gate Control Panel within the cell shall be
connected in series. Opening multiple gates with motion enabled shall default to the enabled
motions common to all the Entrance Gate Control Panels. For example, if one Entrance Gate
Control Panel had “Tool Minor And/Or 1 Robot Teach” enabled and another had “Off/Auto”
enabled, the result shall be that no motion is enabled within the cell.
3.7.9.1 Tool Minor Enable
A Tool Minor Enable interlock consists of the Gate Reset signals, each bypassed by an Enabling
Pendant OK signal in series with the “Tool Minor And/Or 1 Robot Teach” and “All Motion
Enabled” selector switch positions.

The Tool Minor Enable function shall sum all of the Tool Minor Enable interlocks from each
Entrance Gate Control Panel.
3.7.9.2 Tool Major Enable
A Tool Major Enable interlock consists of a pair of Gate Reset signals, each bypassed by an
Enabling Pendant OK signal in series with the “All Motion Enabled” selector switch position. The
interlock is constructed to force the use of an enabling pendant to enable motion with the gate
open.

The Tool Major Enable function shall sum all of the Tool Major Enable interlocks from each
entrance gate control panel. If the cell has interlocked perimeter guard circuits as described in
3.7.8, Perimeter Guard Interlocking to Other Cells, then the Tool Major Enable safety function
shall include interlocks from this circuit. These interlocks may be bypassed by a control reliable
circuit to allow motion through the presence sensing device when the cell is under SCS/MPS
control.

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3.7.9.3 1 Robot Teach
A ‘1 Robot Teach’ interlock consists of a pair of Gate Reset signals, each bypassed by an Enabling
Pendant OK signal in series with the “Tool Minor And/Or 1 Robot Teach” and “All Motion
Enabled” selector switch positions.

The ‘1 Robot Teach’ interlock shall sum the ‘1 Robot Teach’ interlocks from each entrance gate
control panel.
3.7.9.4 All Robots Teach
An ‘All Robots Teach’ interlock consists of a pair of Gate Reset signals, each bypassed by an
Enabling Pendant OK signal in series with the “All Motion Enabled” selector switch position.

The ‘All Robots Teach’ interlock shall sum all of the ‘All Robots Teach’ interlocks from each
Entrance Gate Control Panel.
3.7.9.5 Cell SCS/MPS OK Circuit
The cell SCS/MPS OK circuit indicates that the cell is under SCS/MPS control and all hazardous
motion has been disabled.
3.7.9.6 Pendant Connectivity and Use
The entrance gate control panel design may provide the capability of connecting a single
enabling pendant per entrance gate control panel. If present and active, the enabling pendant
shall be held in the center position to enable any motion when the gate circuit is not reset.

For guarded area entry operations that do not require the use of an enabling pendant, the
connection of a pendant to the entrance gate control panel is optional. If a pendant is not
attached to the entrance gate control panel, the shorting plug shall be plugged into the pendant
receptacle on the entrance gate control panel in order to enable minor tool motion or robot
motion when the gate is not reset.
3.7.10 Robot Interface
3.7.10.1 Interlocks from the Robot to the Cell
There are two main safety interlocks from the Robot controller to the cell.
1. Robot E-stop Pushbuttons Not Pressed - The ‘Robot E-Stop Pushbuttons Not Pressed’
interlock shall be included in the cell controller’s No E-Stop circuit. Pressing a robot e-Stop
button shall stop the entire cell as well as any interlocked cells and equipment.
2. Robot Contactors Open - The ‘Robot Contactors Open’ interlock shall be used in the Cell
SCS/MPS OK circuit (reference section 3.7.9.5, Cell SCS/MPS OK Circuit). This interlock shall
consist of two normally closed contacts, one from each of the robot’s servo contactors,
which reflect that the robot servo contactors have de-energized.
Robots that are capable of communicating additional information related to position and speed
thru a safety rated network interface, may also have additional safety interlocks that can be
used as a DLD in lieu of an external safety device (e.g. light curtain).

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3.7.10.2 Interlocks from the Cell to the Robot
There are three main safety interlocks from the Cell to the Robot.
1. No External Emergency Stop - The ‘No External Emergency Stop’ interlock shall stop and/or
inhibit all robot motion and shall not be bypassed by any other circuit or function.
2. No External General Stop – The ‘No External General Stop’ interlock shall inhibit all robot
servo motion and shall not be bypassed by any other circuit or function.
3. No External Auto Stop - The ‘No External Auto Stop’ interlock circuit inhibits automatic robot
servo motions when the gates are open. It may be bypassed by switching the robot to
manual control at the individual robot controller. The conditions used shall be dependent
upon the arrangement of the cell, and they shall include all readily accessible means of
entrance including the entrance from another cell. In a Safety Processor System, the ‘No
External Auto Stop’ function also uses the ‘No External General Stop’ interlock.

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4 Architecture
4.1 Purpose
This section defines the current GM Common Controls Architecture and describes how it shall
be applied to plant production systems and equipment.
4.2 Scope
The GM Common Controls Architecture can be applied to Bodyshop, Conveyors, General
Assembly (GA), Paint, Plant Floor Systems (PFS), Propulsion Systems (GPS) and Press. Because of
the possible timing differences of executing projects and programs within the same
manufacturing facility between the different areas, there may be a mix of Common Controls
Architecture ‘vintages’. An all new Bodyshop would employ the latest Common Controls
Architecture, but, adding new tooling to existing equipment would most likely keep that existing
architecture. GA may install 5 new Fluid Fill machines in 5 different plants. Conveyors are
typically installed to be in place over many years and many programs. The use of the latest
Common Controls Architecture is determined by the Project Lead Engineers and Managers.
4.3 Common Controls Architecture
The Controls Architecture is the utilization of distributed programmable logic controllers (PLC’s)
and highly distributed inputs/outputs (I/O). Safety PLC’s (Rockwell GuardLogix) are provided on
high automation equipment (i.e., robotic cells) and where there are a significant number of e-
stop/safety guarding requirements. A Safety PLC may also centrally control a group of smaller
tools or conveyor system. Smaller safety PLC’s (Rockwell Compact GuardLogix) may control
smaller tools or equipment. Non-safety PLC’s (Rockwell ControlLogix, CompactLogix) are
provided on equipment which do not require many safety circuits (i.e., operator light curtains, e-
stops, perimeter guarding). The selected PLC shall meet the required safety performance level
for the application.

The GM common controls architecture is based around a philosophy of using PLCs with ladder
logic for control. PCs have reliability issues and can present security challenges for the plant
floor environment. The use of PCs for machine control is prohibited unless approved by the
responsible GM Controls Project Engineer.

Due to the highly distributed nature of the GM controls architecture and the significant usage of
safety PLCs, local (PLC Chassis) IO cards are rarely used. Plant floor control networks are the
primary mechanism for exchanging control interlocks. The 2 primary networks utilized are:
• EtherNet/IP for real-time control (safe and standard), messaging communication and I/O
communication (safe and standard).
• DeviceNet for I/O communication (safe and standard).
Note: The use of DeviceNet or EtherNet/IP for I/O varies based on the vintage of Common
Controls Architecture and is determined by the Project Lead Engineers and Managers. The use
of DeviceNet shall be by exception only and requires GM Controls Project Engineer approval.
The majority of the control circuits, relays, contactors, and field devices (switches and valves)
are powered with 24 VDC.

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The architecture structure is fundamentally similar between all the functional areas of the plant
(Body, Conveyor, General Assembly, Paint, Plant Floor Systems, Propulsion Systems and Press)
despite their unique processes. They all have a defined system, or area of control which in some
areas may be further defined by cells (guarded areas) and stations.

This architecture uses standard panels (Also known as ECS’s – Electrical Cabinet Standard) and
components coupled with standard industrial connectors to leverage the benefits of common
designs. These benefits include reducing design time, facilitating reuse, reducing component
cost, and improving final design quality. All designs shall use the Common Controls Architecture
standard panel designs (ECS’s) and standard templates where applicable.
4.4 Automation Classifications (Architecture Definitions)
The level of automation can be classified into 5 main groups. These groups are distinguished by
the type of control system used and the safety functions.
Table 4-1 Automation Classifications

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As a general guideline, low or medium automation architectures may be selected according to
Figure 4-1 below. Low or medium automation selections require GM Controls Project Engineer
approval.
Figure 4-1 Low/Medium Automation Architecture Decision Chart

4.4.1 Architecture Key Elements

The GM common controls architecture is made up of many standard components. The key
elements of the architecture are show in Figure 4-2 below.
Figure 4-2 Architecture Key Elements

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4.5 Power Architecture
The Power Architecture consists of a Power Distribution Panel (PDP) which has many branch
feeds of 380 – 575 V (region specific) for robots, motors, and other three phase loads. The PDP
also provides 120 V control power to remote panels, 24 VDC power supplies, and other various
components. Wherever practical, 24 VDC shall be used for control panel and end device power
to minimize electrical safety hazards and corresponding mitigation. PDP power shall be limited
to equipment required for the process only. Miscellaneous loads supplied with the equipment,
such as task lighting, shall be powered from an auxiliary power panel or the plant lighting bus.

In some facilities it is common for the weld controllers in the bodyshop to be powered from a
separate plant bus feed provided specifically for welding. Other facilities may only provide a
single bus feed for both electrical equipment and welding. A welding PDP may be used to
reduce the number of plant bus feeds to the equipment.
Exception: Where allowed regionally 220 V may be used in place of 120 V. The connector and
cable strategy for 220 V is identical to 120 V. Most standard panels (ECS) and components are
designed such that they can be used with either 120 V or 220 V.
4.5.1 Connectors and Cables
Cables and connections between control panels and equipment for 3 phase line voltage power
distribution (380 – 575 V) shall be either 4 Pole M35 connections or shall be hardwire.
All panel to panel control voltage (120 V and 24 VDC) connections shall use plug-in cables and
receptacles. Cables and connections for 120 V (and 220 V where allowed) power distribution
shall be 3 pin Mini. Cables and connectors for 24 VDC power distribution shall be 4 pin Mini. All
cable connections shall have external threads on the male end and internal threads on the
female end to facilitate the series connection of cables without special coupling nuts or devices.
The standard pin rotation for each connection is detailed in section 11 of this document.

Multi-conductor cables for low voltage (300 V or less) shall use the Harting Han EE Series
connector or equivalent. This does not apply to molded cord connectors for field devices (e.g.,
proximity switches, limit switches, pressure switches). The current rating of the multi-conductor
cables and connectors shall not exceed 10 A.

Exceptions:
-High mate and unmate frequency applications (i.e.: interchangeable tooling and dies) may use
connectors rated for that type of application.

-Electronic equipment which may use connectors rated for that application.

-Where “field” assembly is required (e.g., long cable runs for conveyors) the use of Harting Han
E-Series with screws or equivalent connectors is acceptable.
Other applications shall require GM Controls Project Engineer approval.

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Figure 4-3 Architecture Diagram Legend

Example Architecture Configurations for the various levels are shown in the following Figures.
These diagrams are provided for general concept information only. Templates which are posted
on GM Supply Power should be used as the starting point for any design.
Figure 4-4 4B & 3B Power Architecture (G12 and Prior)

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Figure 4-5 4B & 3B Power Architecture (Post G12)

Figure 4-6 3A Power Architecture

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4.6 Network Architecture
The (2) types of networks used are Ethernet (including EtherNet/IP) and DeviceNet.
1. Ethernet
a. EtherNet/IP is used for real-time control and interlocking from PLC to PLC (peer-to-
peer), PLC to process controllers (i.e., robots, weld controllers, fastening equipment,
dispensing) and robots to its process equipment (i.e., weld controllers, stud controllers,
sealer controllers). EtherNet/IP is also used for field inputs and outputs via an
EtherNet/IP I/O block or an EtherNet/IP intelligent device.
b. Safety interlocks can also be exchanged via EtherNet/IP provided both end devices
support the safety protocol. Safe and standard interlocks can communicate on the
same Ethernet network.
c. Ethernet is used to communicate PLC to HMI and PLC to vision systems.
Communications between host computer systems and PLC’s for build data, fault
messages, downtime data, and/or program archiving is over Ethernet.
d. All Ethernet devices at the controller (cell) level are connected to a Controller Ethernet
switch, either directly or via a linear network. Most manufacturing systems have many
Ethernet connections and may require multiple Ethernet switches. When multiple
Switches are needed at any level, all additional switches should be uplinked into the first
switch.
Exception: Single Ethernet devices or Ethernet devices in a linear network may not require a
Controller Ethernet switch.
e. When multiple controllers need to share interlock information an additional switch(es)
shall be provided to allow for these connections. These switches are called system
switches.
f. Ethernet device IP addresses and public (12x) versus private (192) addressing shall be
determined according to section 9.6.
2. DeviceNet
a. DeviceNet is used communicate PLC to field inputs and outputs which are external to
the main panel (e.g., sensors, valves) via a DeviceNet I/O block or DeviceNet intelligent
devices. The DeviceNet network shall be connected to DeviceNet scanner module in the
ControlLogix chassis. For robot controlled devices (e.g., end-of-arm tooling), the robot’s
DeviceNet network shall be connected to the robot scanner module inside the robot
controller.
b. DeviceNet-Safe is used to communicate the safety I/O to the safety PLC. Since the
safety traffic is given a higher priority, both safe and standard I/O can communicate on
the same DeviceNet network.

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Figure 4-7 4B & 3B Typical Network Architecture (G12 and Prior)

Figure 4-8 4B & 3B Typical Network Architecture (Post G12)

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Figure 4-9 3A Network Architecture

4.7 Standard Industrial Control Panels

GM has designed several categories of standard industrial control panels. Where an Off-the-
shelf industrial product will not serve the function a common panel design is created which can
be purchased and used by projects just as if it were any other industrial component. These
designs (also known as ECS panels) have been divided into several main categories detailed
below. A complete list of GM ECS panels can be found on the GM Supply Power site.
4.7.1 Power Distribution Panels (PDP)
A power distribution panel (PDP) provides electrical power to a tooling system or system of
industrial equipment. The purpose of the PDP is to simplify electrical safety lockout for the cell
or system and to reduce the number of plant drops for the system.

PDP’s are to provide 380 – 575 V (depending on the region) power to all of the equipment in the
system. PDPs also provide 120 V power for control. One transformer (lighting disconnect) in
the PDP panel provides “hot” 120 V power for excepted circuits (i.e., PLC, HMI) and enclosure
lighting (not task lighting). This power remains on when the PDP’s main disconnect is off. There
is a separate “lighting disconnect” to turn off the excepted circuit (“hot”) 120 V power. The
second transformer provides 120 V control power for 24 VDC power supplies used to power
inputs, motion outputs, lights, relays, and the remainder of the control system. The PDP
receives power directly from the plant control bus. The maximum disconnect size for a PDP
shall not exceed 400 A.

Exception: Where power in excess of 400 A is required, a manufacturer specific power

distribution panel (i.e. MCC) can be used. These applications shall require written pre-approval
of the responsible GM Controls Project Engineer.

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4.7.2 Main Control Panel (MCP)
The Main Control Panel is the focal point of the control system for a cell or tool. The Main
Control Panel contains:
1. The programmable logic controller (PLC)
2. All network interfaces needed to control the cell
The MCP receives 120 V power from the power distribution panel and may contain the 24 VDC
power supplies for network and control power. Industrially hardened 24 VDC power supplies
used in combination with industrially hardened PLC’s are typically used in place of the MCP with
integral power supplies. The characteristics of the MCP are similar for all applications.
4.7.3 Human Machine Interface (HMI)
The HMI is the point of control for the equipment by the maintenance personnel. It contains a
programmable display and the hardwired buttons necessary for the safety system. An HMI may
be mounted on the front door of a Main Control Panel or mounted remotely on a stand. A
remote HMI has a smaller footprint and may be placed closer to the equipment than the Main
Control Panel to facilitate maintenance activities An HMI is required if the tool is 6 sequence
steps or more and/or requires a diagnostic display. Implementation and placement of HMI’s
must be approved by the GM Controls Project Engineer.

A PHMI (Portable HMI) is an HMI that is small enough to carry and allows a person to get closer
to the equipment for manual operation (improved “line-of-sight”). The PHMI has a built-in
enabling pendant to enable/disable tool motion. The PHMI also requires a connectivity box for
the safe I/O and Ethernet interface. A small multi-conductor cable is provided between the
PHMI and connectivity box to carry the hardwired enable and stop signals to safe inputs. The
PHMI manually controls only tooling motion and is not a robot teach pendant.

The PHMI shall be used if 2 or more HMI’s are required for “line-of-sight” manual control of
tooling equipment.

A single PHMI may be used to control multiple offline tools (quantity of tools limited by span of
control rules and PHMI cable reach) in close proximity to each other.
NOTE: The use of a portable HMI requires GM Controls Project Engineer approval.
4.7.4 Entrance Gate Control Panel (Gate Box)
The entrance gate control panel is the control point of the SCS (MPS) system. This control panel
allows reduced mean-time-to-repair (MTTR) of the automated cells by providing a single point
of control to disable motion power and re-start of the cell.
4.7.5 Fixture Junction Box
The fixture junction box is the single point of connection for the safety signals associated with a
tooling fixture (e.g., valve manifold Output Power, light curtains and/or safety mats for operator
protection, and safety pins). These types of panels are typically replaced by industrially
hardened I/O blocks and power supplies.

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4.7.6 Operator Interface Panel
Operator interface panels are provided at any point in which the production operator needs to
interface with the automated equipment. These panels can be used for functions such as:
1. Safety Device Reset
2. Scheduling, sequencing, and routing.
3. Production Fault Annunciation.
Operator run stands are typically used at manual stations by the operator to signal the control
system to start the Automatic cycle.

At a minimum, operator run stands shall contain:

1. a single “Cycle Start” button (palm button)
2. an “Emergency Stop” button (mushroom)
3. a “Return To Start” button
4. a part(s) present light
5. a fault buzzer or light (to signal the operator that the part load has not completed)
An operator run stand shall be provided for each production operator. Items 3 thru 5 can be
omitted for certain simple applications at the discretion of the responsible GM Controls Project
Engineer.
4.7.7 Motor Control Panel
A motor control panel is used to provide disconnecting means and control of 380 – 575 V
motors for turntables, tip dressers, accumulator drive motors, pumps, fans, conveyors, etc. It
contains necessary over current protection, motor starters, overload elements, input/output
blocks, and terminations for the motor system. Motor control panels are typically replaced by
industrially hardened motor starters, drives, or combination starters.
4.7.8 Safety Device Junction Boxes
Safety device junction boxes are panels containing IO connected to safety devices (i.e. light
curtain, safety scanner, safety mat). These panels provide a means to connect and power safety
devices used for perimeter, intercell, and pedestrian guarding. These types of panels are
typically replaced by industrially hardened I/O blocks and power supplies.
4.8 Marquees
The marquee provides a highly visible method of annunciating the system’s general status. The
requirement and placement of marquees shall be determined for each system by the GM
Controls Project Engineer.
4.9 Programming Terminal
The programming terminals on the plant floor provide troubleshooting for technicians and allow
online access to PLC’s, HMI’s and DeviceNet, and/or Ethernet equipment.

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The programming terminal shall support Ethernet and DeviceNet connections to all PLCs, robots,
and process equipment (i.e., weld controllers, adhesive controllers, vision equipment)
associated to that programming terminal’s area of responsibility.
Exception: Completely isolated private Ethernet networks may not be accessible via the
programming terminal.
The programming terminals shall provide the following three areas of key functionality:
1. Electronic information transfer including:
a. Upload/download capability of the PLC programs
b. Human Machine Interface (HMI) screens
c. DeviceNet and/or Ethernet network configurations
2. Plant floor troubleshooting
3. Production system monitoring
4.9.1 Programming Terminal Location Requirements
1. Programming terminals should not span production systems (i.e., one terminal shall not be
allocated for both dash sub-assembly and main-line engine compartment tools).
2. One programming terminal shall be placed per every major sub-assembly system.
Exceptions and final location of the programming terminals shall be approved by the responsible
GM Controls Project Engineer.
4.9.2 Programming Terminal Integration Requirements
It is typically the supplier’s responsibility to successfully integrate the programming terminals for
the plant floor. The supplier shall successfully integrate the programming terminals in
establishing full communication (within the scope of the respective terminal) and not limited to
the following information:
1. to all PLC processors
2. to all HMIs
3. to all Robots
4. to all Process Controllers
4.9.3 Programming Terminal Computer Requirements
The Designer shall make every effort possible to use GM standard architecture components. In
the event a PC based mechanism is required, the following additional requirements must also be
met.
1. An enclosure that adequately protects the PC from the plant industrial environment is
required (Typically IP54 minimum). Reference ECS-4166 for an example enclosure.
2. The computer must meet the requirements listed in the Cyber Security and Plant Floor
Computing Devices SOR module found on GM Supply Power.

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a. Internal GM Supply Power link:
https://supplier.body.gm.com/crw/production/main/globalStandards/cyberSecuritySta
ndards.cfm
b. External GM Supply Power link:
https://www.gmsupplypower.com/apps/bodyext/crw/production/main/globalStandard
s/cyberSecurityStandards.cfm
4.10 Press
The Press Shop is where sheet metal body panels are stamped for the vehicle before they enter
the Bodyshop for assembly. The Press Shop is made up of Bays that contain press lines
(systems). Each press line is divided into workcells (cells). A cell defines the span of control for
the PLC’s, power distribution panels, and safety interlock systems.
4.10.1 Press Cell Span of Control
Each press shall have its own workcell. Typically, each cell shall have a Main Control Panel
(MCP), which will contain a PLC (Rockwell GuardLogix). When determining the span of the cell,
consideration must also be given to the PLC span of control.

Each cell shall have a remote color touch screen Human Machine Interface (HMI) with its
associated interface panel for manual controls and diagnostics.
4.10.2 Press PLC and HMI Span of Control
Since stamping systems can operate at a high line rate, the PLC span of control should be limited
so the control system performance can satisfy the demands of the equipment. A cell shall not
contain more equipment than can be controlled by a single Guardlogix PLC. Only one PLC is
allowed per cell.

Two cells can share an MCP or PLC if all of the following conditions are met:
• The cells are not separated by a buffer system
• The cells share a boundary or intercell safety device
• A detailed simulation analysis is performed documenting the capability of the proposed
control solution (i.e. single PLC has sufficient memory, connections, nodes and
processing power to satisfy the performance demands of the equipment)
• Each cell shall have its own HMI

Note: MUST GET APPROVAL from the responsible GM Controls Project Engineer to share
between multiple cells.
4.10.3 Press PDP Span of Control
Each cell shall have a PDP panel to supply 380 – 575 V power and 120 V control power. All
power to the equipment in a work cell shall be supplied from one PDP panel.
4.11 Conveyors
A conveyor is a horizontal, inclined or vertical device for moving or transporting bulk materials,
packages or objects in a path predetermined by the design. A conveyor system will typically
have predetermined points of loading or unloading. Conveyor systems are used to move parts
or subassemblies throughout our manufacturing facilities.

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4.11.1 Conveyor PLC and HMI Span of Control
Each conveyor system shall have a Main Control Panel. Large systems may require multiple
MCP panels. MCP panels can be shared across systems with the approval of the responsible GM
controls project engineer. Human Machine Interface (HMI) panels shall be provided as needed
for “line-of-sight” control and diagnostics.

A conveyor system can be controlled by one or many PLCs. When determining the PLC span of
control, consideration should be given to the performance of the PLC. The design target for a
completed system is a processor scan time of 100 ms or less. The individual scan time of all PLCs
on a completed system shall not exceed 125 ms.
4.11.2 Conveyor PDP Span of Control
Each MCP shall have a PDP panel to supply 380 – 500 V power and 120 V control power. For
facilities where the plant supplied voltage exceeds 500 V a step down transformer shall be
provided to reduce the voltage to 500 V. When a conveyor system exceeds the capacity of a
single standard PDP, multiple PDP panels can be used.
4.12 General Assembly
In General Assembly, the remaining components are installed in the empty painted vehicle
bodies. After assembly, each vehicle is tested before delivery to the customer. General
Assembly is divided into 3 main areas: Trim, Chassis, and Final. Each of these main areas is
further divided into process subsets, such as Glass Cell, Tire and Wheel, Lift Assists, Fastening,
Fluid Fills, Body Marriage, Dynamic Vehicle Test (DVT), Alignment, etc. The process subsets are
further divided into individual equipment.
4.12.1 General Assembly PLC and HMI Span of Control
Each piece of General Assembly Equipment shall have its own Main Control Panel (MCP), which
will contain a safety PLC. Each piece of equipment shall also have either a remote color touch
screen Human Machine Interface (HMI) panel or a portable HMI (PHMI) with its associated
interface panel for manual controls and diagnostics. Larger safety PLC’s (Rockwell GuardLogix)
are provided on high automation equipment and where there are a significant number of e-
stop/safety guarding requirements. A Safety PLC may also centrally control a group of smaller
tools or conveyor system. Smaller safety PLC’s (Rockwell Compact GuardLogix) may control
smaller tools or equipment.

Multiple pieces of equipment may share a PDP or PLC if all the following conditions are met:
• The equipment is located in the same manufacturing footprint.
• A detailed analysis is performed documenting the capability of the proposed controls
solution.
• The equipment is all part of the same process subset.

For guarded areas (cells) in General Assembly, the Bodyshop High Automation Span of Control
Rules shall be followed.

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4.12.2 General Assembly PDP Span of Control
Each MCP shall have one Power Distribution Panels to supply 380 – 575 V power and 120 V
control power to the MCP and the rest of the equipment in the system. A combo PDP/MCP can
be used to fulfill this requirement.
4.13 Paint
The Paint Shop is a series of complex operations that clean the sheet metal (PreTreatment),
apply an anti-corrosion layer (ELPO), apply primer (Prime Booth), apply basecoat , and apply
clearcoat (Topcoat Booth). In the Paint Shop, a system is defined as a large piece of equipment
that completes a specific task. Examples of systems are PreTreatment, ELPO and DC Rectifier,
Ovens, Air Supply Houses, Paint Mix and Sludge. The automation systems (Feather Duster,
Robotic Systems for painting and dispense, Overhead and Side Bells, etc.) are usually not
included as part of this definition since they are purchased systems and will have their own
individual control systems.
4.13.1 Paint PLC and HMI Span of Control
Typically, each major system will have a Main Control Panel (MCP) which will contain a
Programmable Logic Controller (PLC) and the network communication modules to support
reading and writing data to remote digital and analog input and output modules. For shared
systems (process and conveyors) the PLC shall be a Rockwell GuardLogix processor. For systems
that are not shared, a Rockwell ControlLogix processor may be used. Each system shall have
one or more touch screen Human Machine Interface (HMI) panels to provide status information,
manual controls and diagnostics to the operators. Up to six (6) HMIs can be controlled by the
same PLC.
4.13.2 Paint PDP Span of Control
Each system shall have one or more Power Distribution Panels to supply 380 – 575 V power and
120 V control power to the MCP and the rest of the equipment in the system. Nominal PDP
main sizes should be limited to 400 A maximum.
Note: MUST GET APPROVAL from the responsible GM Controls Project Engineer for PDP panels
that exceed 400 A.
4.14 Bodyshop
The Bodyshop is where the body of the vehicle which consists of many parts (i.e., underbody,
bodysides, roof, hood, doors, decklid) is assembled and joined by various processes (i.e., spot
welding, stud welding, and gluing). In the Bodyshop, a Zone (or System) is a group of assembly
operations linked by a common production process. There are many Zones within the
Bodyshop. Most Zones are subdivided into multiple cells and/or guarded areas.
4.14.1 Bodyshop PLC Span of Control
1. The design target for a completed system is a processor scan time of 100 ms or less. The
PLC scan time of a completed system shall not exceed 125 ms. It is the designer’s
responsibility to use the “Memory Estimator” before determining any PLC span of control.
2. For control of tooling stations, there shall be no more than one PLC per perimeter guarded
area. Perimeter guards include hard fencing, light curtains, and safety mats that are used to
delineate the scope of a cell.

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3. Both the tooling and transfer systems that are integrated within the perimeter-guarded area
shall be controlled by the same PLC where practical.
4. Small sections of transfer system located outside the guarded area that are used as idle
stations, operator stations, or queuing areas should be controlled by the PLC of the adjacent
guarded area.
5. Transfer systems (e.g., power-and-free conveyors, electrified monorail, powered rollers, and
skid systems) located outside of a guarded area that are intended to operate as
independent buffers or accumulators shall be controlled by their own PLC. They shall also
have independent power and magnetic circuits which allow them to operate while adjacent
systems are shut down. Cell-to-cell tooling conveyors may be controlled by the up-stream
or down-stream cell’s PLC; down-stream control is preferred.
6. Multiple cells or guarded areas (max of 3) may be controlled by one PLC if the memory,
connections, nodes and scan time requirements are met.
7. A stand-alone station may be combined with a cell if:
• The station is not likely to moved more than 6 m
• The combination of the station and the cell does not exceed the PLC span of control
rules. Otherwise, a stand-alone tooling station located outside the perimeter guarded
area may be controlled by its own PLC.

The responsible GM Controls Project Engineer shall approve all PLC spans of control.
4.14.2 Bodyshop HMI Span of Control
1. There are two general types of bodyshop HMI applications:
a. Maintenance (cell) HMI – This HMI allows full maintenance control for a cell, including
diagnostics, mode, manual motion, etc.
b. Operator HMI – This HMI provides limited functionality specific to an operator, including
limited diagnostics, limited maintenance functions or operator functions for their area
of responsibility.
2. Every cell, guarded area, or offline station (area requiring independent mode control) shall
have at least one maintenance HMI.
3. All content (stations, robots, etc.) in a cell shall have their diagnostics available on every
maintenance HMI for that cell, even if a particular HMI does not have manual control
capability of that content.
4. Operator HMIs should only get diagnostics from the station(s) associated with the operator.
Exception: Operator HMIs may receive diagnostics from other stations if the operator has
responsibilities for those other stations.
5. Manual control of a station is limited to a maximum of two maintenance HMIs, this is a
limitation of the standard PLC software.
6. Manual control should be allowed for all content in a cell from all HMIs for that cell.
Exception: Cells with more than two HMIs or cells with equipment damage or safety concerns.
7. Mainline cells with process equipment shall have 1 HMI on each side of the production line.

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Exception: Very simple cells, buffer only cells, overhead conveyance, cells immediately adjacent
to a crossover.
8. No more than 3 maintenance HMIs per cell.
9. No more than 6 HMIs per PLC (operator HMIs count as ½).
10. HMI arrangement shall meet the PLC performance requirements identified in section 4.14.1.
The responsible GM Controls Project Engineer shall approve all HMI spans of control.

4.14.3 Bodyshop PDP Span of Control Rules

1. Each offline tool without 380 – 575 V requirements (e.g., robots, drives) should obtain 120 V
from nearest cell’s PDP. A group of offline tools within the same area should share a PDP.
Note: Offline tools requiring only 120 V power may require a 120 V disconnect for lockout and
maintenance purposes.
2. Offline cells with robots (defined as manually loaded and manually unloaded):
a. Cells with one or two robots may obtain 380 – 575 V and 120 V from the nearest cell’s
PDP or have its own PDP. A group of offline one robot cells and tools (without robots)
may share a PDP.
b. Each cell that contains three or more robots shall have a separate PDP.
3. Each main line cell shall have a PDP.
Exception: A main line cell which contains only one robot, may obtain 380 – 575 V and 120 V
from the adjacent cell.

Note: Main-line cells are stations that utilize automatic load or unload (e.g., AMS, skid, geo
pallet, or robot passing) to transfer the part(s) from one cell to another.
4. Manually loaded or unloaded accumulators (e.g., part feed-up conveyors) integral to a cell
or accumulators within a cell shall obtain power from that cell’s PDP.
5. Accumulators between separated cells and/or systems may obtain power from the
upstream or downstream cell’s PDP.
Note: This is a change from previous architectures where the cell-to-cell accumulators where
fed separately from the plant bus. The previous architecture e-Stop circuit was powered above
the main PDP disconnect which allowed the accumulator to run while the upstream or
downstream cell’s PDP was locked out (main disconnect ‘Off’). The new architecture e-Stop
circuit is powered below the disconnect which causes an e-Stop condition when the cell’s PDP is
locked out. Since the cell-to-cell conveyor cannot run while the upstream or downstream cell is
‘Off’, the conveyor may be fed from the cell.
6. A cell should only have one Control PDP to maintain single point of lockout. Additional
PDP’s require approval of the responsible GM Controls Project Engineer.
7. Multiple cells may utilize the same PDP as permitted by power requirements.
The responsible GM Controls Project Engineer shall approve all PDP spans of control.

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4.14.3.1 Bodyshop PDP Span of Control Examples
Figure 4-10 PDP Example 1 – Offline (Only 120 V Required – No Gates)

Figure 4-11 PDP Example 2 – Shared Offline Tooling/Cells

Figure 4-12 PDP Example 3 – Mobile Offline Tooling (120VAC Only)

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Figure 4-13 PDP Example 4 – Offline Cells with Robots and Part Feed Accumulators

Figure 4-14 PDP Example 5 – Offline Tool Between Two Small Cells

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Figure 4-15 PDP Example 6 – Mobile Offline Cell

Figure 4-16 PDP Example 7 – Offline Cells with Robots and Accumulators

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Figure 4-17 PDP Example 9 – Main Line Cells

4.14.4 Bodyshop High Automation Rules

1. A Cell shall not contain more equipment than can be controlled by a single GuardLogix PLC.
Only one PLC is allowed per cell. The cell size shall remain practical based on cell content
rules below. When determining the cell span, all span rules must be observed, capability
does not dictate content.
2. A single cell shall not contain more than:
• 24 robots
• 30 stations
• 3 maintenance HMI’s (preferably not more than 2)

3. The content of the cell shall remain practical for maintenance. For example, a large number
of stations may be present with a material handling buffer area or with multiple fixture
turntables, but then the number of robots should be low. Or there may be several robots in
a few stations, such as welding respot. As a guideline, the combination of robots and
stations should adhere to the following formula:
(Robot Count) + (Station Count) ≤ 30
4. A cell shall have at least 1 SCS (MPS) gate box.
4.14.5 Bodyshop Medium Automation (Offline Cell or Stand-Alone Station)
Offline Cells or simple stand-alone stations which are manually loaded/unloaded and perform
an automatic operation on the part have the following requirements:
1. Each Offline Cell or stand-alone tool shall obtain power from either its own PDP or nearby
PDP.
2. Each Offline Cell or stand-alone tool shall have its own Main Control Panel. Multiple small
stand-alone tools or offline Cells can share a MCP as long as the PLC span of control rules
are followed.
3. Each Offline Cell shall have its own HMI. Multiple stand-alone tools may be controlled from
the same HMI.

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4. Each Offline Cell shall have at least 1 gate box.
4.14.6 Bodyshop Low Automation (Simple Manual Operation Stations)
Simple manual operation stations may not require logic control (PLC). If logic control is
required, due to ergonomic or cycle time reasons, simple manual load/unload operation stations
with four or less sequence steps shall be evaluated to be controlled by Air Logic.
Note: Air Logic shall not be used unless there is written approval from the responsible GM
Controls Project Engineer.
Reference air logic control design standards in Section 13.6.
4.15 Propulsion Systems
Propulsion Systems consists of the casting, machining and assembly systems associated with
typical powertrain systems (engine and transmission) and advance propulsion system
manufacturing.

Reference Propulsion Systems span of control requirements in GM SupplyPower:

• SP-E_xxxx or AN-E_xxx control documents (e.g. AN-E Assembly Controls Required
Practices)

or
• Propulsion System controls SOR

4.15.1 Propulsion Systems PLC Span of Control

Unless indicated in the appropriate SP-E documents, AN-E documents or the controls SOR, refer
to the bodyshop rules in Section 4.14.1.
4.15.2 Propulsion Systems HMI Span of Control
Unless indicated in the appropriate SP-E documents, AN-E documents or the controls SOR, refer
to the bodyshop rules in Section 4.14.2.
4.15.3 Propulsion Systems PDP Span of Control
Unless indicated in the appropriate SP-E documents, AN-E documents or the controls SOR, refer
to the bodyshop rules in Section 4.14.3.
4.16 Additional Requirements
The supplier shall design each system such that sufficient spare PLC memory, connections and
nodes are available. A minimum of 20% unused memory, connections and nodes shall be
provided for all applications after final integration of all functions including all plant floor
systems requirements.
Note: Additional spare memory shall be provided for applications where future styles or
equipment are planned.

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5 Documentation and Naming
Control system documentation and naming shall comply with the requirements indicated in this
section.
1. All documentation (i.e., drawings) shall be in the language defined by the using region.
Exception: The BOM portion of the EPLAN design is not translated and the part database is
maintained in English only. If a BOM in a regional language is required, then a corresponding
regional part database in that language would be required.
2. All tags and nameplates shall be in the language defined by the using region.
Note: It is recommended that tags and nameplates for the benefit of operators and other
production personnel be in the local language of the using region.
5.1 CAE (Computer Aided Engineering) Tools
GM has established EPLAN electric P8 as its standard for Computer Aided Engineering (CAE) of
Control System Designs. By automating the design process, EPLAN engineering tool, provides
the capability to produce high quality, comprehensive documentation, reporting, and design
analysis in substantially reduced time compared to prior systems.
5.2 EPLAN
EPLAN electric P8 software shall be used to generate a Controls Design package in accordance
with all other provisions of this Standard.
5.2.1 GM EPLAN Library
Designs created or modified in EPLAN shall use the GM EPLAN library as a source of sample
drawings, the GM EPLAN Symbol Library, GM EPLAN Macros, GM EPLAN Plot Frames, GM EPLAN
Toolbars, and GM EPLAN Parts Library. The latest version of the GM EPLAN Library can be
downloaded from the GM EPLAN page via GM Supply Power.
5.2.2 GM EPLAN User Manual
The document GCCH5A – GM EPLAN User’s Manual is also available for download by GM EPLAN
users. This document defines the standards that apply when designing GM Controls Systems in
EPLAN electric P8. All standards cited in GCCH5A shall be applied and enforced as a provision of
compliance to this standard.
5.2.3 Installing EPLAN
GM does not provide licensed copies of the EPLAN software to its suppliers. Each supplier will
be responsible for providing licensed software and support for EPLAN when an EPLAN design
package is required by GM. Suppliers can use the installation manual GCCH5I – GM EPLAN
Installation Guide, also found on GM Supply Power, as a reference to how GM is implementing
EPLAN licenses for its own users. Further support should be solicited directly from EPLAN
Software and Services LLC. (www.eplan.us)
5.2.4 EPLAN Training
Training for new GM EPLAN users is available from MTEC at Macomb Community College. Go to
https://wce.macomb.edu/info/landing/gm-training for a list of available training dates and
locations. Registration for this training is also provided via this site. EPLAN Basic Training,

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EPLAN Advanced Training, and EPLAN API Programming Training are available directly from
EPLAN Software and Services LLC.
5.2.5 Converting AutoCAD to EPLAN
There is limited capability to import and convert legacy AutoCAD information into EPLAN.
Guidelines for making this conversion can be found in GCCH5A – GM EPLAN User’s Manual -
Annex A. In no case does converting legacy design absolve GM Suppliers of the responsibility to
deliver documentation that is technically correct and compliant with this standard.
5.2.6 Delivering EPLAN Designs
Designs done in EPLAN provide for multiple, flexible output formats. In addition to a PDF output
of the drawing, various Excel, CSV, or other export files may be required. In all cases, a
complete EPLAN project backup zw1 file shall be delivered to GM in electronic format.
5.2.7 GM Drawing Rules
1. Sheet numbers shall be identified using only non-alpha whole numbers. Numbers such as
1.5, 4.5, 6A, 12B are prohibited.
Exception: Standard drawings (WDT or WDS) may use subpages such as 1A, 1B, etc. to present
multiple options or configurations for similar applications.
2. A minimum of 10% of the diagram area per sheet shall be left blank for future additions.
3. All schematic horizontal lines shall start on even line numbers.
Exceptions: (a) where lines are close together and part of a standard block, or (b) when adding
lines after the drawing has been released and there is insufficient space available.
5.3 GM Title Block Format
1. All controls drawings shall use the latest standard GM title block. See Figure 5-2 GM
Titleblock as an example.
2. The lower left corner of the title block shall start at 0, 0.
3. When printing drawings, allow room on one side of the sheet for a 3-hole punch.
Note: Single sided is preferred for drawings and is up to the discretion of the responsible GM
Controls Project Engineer.
5.3.1 Title Block Field Definitions
1. Titleblock Fields:
a. GM
b. GM ENGINEER. Controls Follow-up Engineer.
c. DESIGN SOURCE. Supplier of controls design.
d. DESIGN LEADER. Design leader of controls design supplier.
e. PROGRAMS. List of program(s) to apply design drawings (GMT-360, GMX320,…etc)
f. PACKAGE DESCRIPTION. Description of drawing package. (Same description on all
sheets).

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g. SHEET DESCRIPTION. Description of the particular sheet of the drawing package.
h. SYSTEM/ TOOL NO.: Reference system or tool layout number associated to the WD.
• For system and controller level drawings, use the SL number of the system.
• For unit (tool) level drawings use the tool number. If the tool number is already part
of the WD name, leave this field blank.

i. DRAWING NUMBER. Drawing package number.

j. RELEASE DATE (YYYY-MM-DD). The date when the drawing package was released for
quote or build. The international format (4 digit year, 2 digit month, 2 digit day) shall be
used for the date (e.g., 2006-03-12).
Note: After the release date, all changes shall be recorded as revisions.
k. REVISION LETTER. The last revision letter for the sheet.
l. DATE. The date of the last revision for the sheet. The international format (year,
month, day) shall be used for the date (e.g., 2006-05-26). (See item j above).
m. SECTION LETTER. The section letter of the drawing package (A – Z).
n. SHEET NUMBER. The sheet number of the current sheet. (Up to 3 digits, but, do not add
leading zeroes).
o. OF total sheets. List only the total number of sheets of the section on the 1st page of
each section. This is to avoid making a revision to every sheet in the package when
adding or inserting sheets. (Up to 3 digits, but, do not add leading zeroes).
p. REFERENCED USED. The drawing number from which the package was referenced (if
applicable). Only the 1st sheet of the drawing package shall have a “REFERENCE USED”.
Figure 5-1 “Reference Used” On Titleblock

q. ENG. MGR. Engineering manager of the follow-up GM engineer. Only the 1st sheet of
the drawing package shall have a “ENG MGR” box located above the “SHEET NUMBER”
box.
r. DRAWING PACKAGE REVISION LEVEL: Revision level of drawing package. This helps
illustrate total revision level of package without having to flip through pages. The
package revision level shall be above the titleblock in the lower right corner of the
drawing.

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Figure 5-2 GM Titleblock

5.3.2 File Name and Date/Time Stamp

All sheets shall be stamped with the file name and date/time.
5.3.3 Drawing Status Stamp
All sheets shall have the drawing status on the lower left of the drawing according to the
following package status:

Table 5-1 Drawing Status Descriptions

Status Description
(A)S BUILT Used when construction is completed.
(B)UILD Used when the tools are in the process of construction.
(F)OR
Used when the supplier submits drawings for approval or review by General
APPROVAL,
Motors.
REVIEW
(P)RELIMINARY Used when the design is in the preliminary stage.
(Q)UOTE Used when the design is submitted for quote.

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Status Description
Used when the design has been approved. Any future modification to the
(R)ELEASED drawings shall follow the standard change procedures for documentation,
approval, and distribution.

Note: (F)or approval is meant to be for “Review”. Suppliers are responsible for providing a
quality workable system in compliance to stated specifications and references. GM reviews the
design(s) to enable feedback and/or changes in a timely manner. Approval of the drawings does
not imply buy off of design or programming, or relieve the contractor of their responsibility to
furnish a quality workable system.
5.3.3.1 Bodyshop and General Assembly – Drawing Status Stamp
The business model in the Bodyshop and General Assembly generally allows for the use of just
two levels of drawing status:
1. Preliminary
2. Released
Anything prior to release is to be noted as Preliminary and it is not necessary to track changes.
Once “Released”, all changes must be tracked and maintained through all phases of the project
– from build through as-built. Deviations from this require GM Controls Project Engineer
approval.
5.4 Kit Documentation Process
After tooling is installed in the plants, it is sometimes necessary to install additional tooling,
mechanical components, and electrical components. It’s important to communicate these
changes properly to the installation contractors (if used), skilled trades, and plant engineers for
what is Added or Removed. Providing the final documentation which shows only the Added
components make it difficult for the person making the kit changes to understand the process.
Therefore, it is necessary to provide separate documentation packages for the kit installs which
show:
1. “Removed” components and wiring package
2. “Added” components and wiring package
3. “Final” package
5.4.1 Types of Changes
Kits may require the following changes:
1. Remove (Red) – components or wiring to remove on a sheet. Hatching will be used to
designate the items to be removed.
2. Add (Green) – components or wiring to add to a sheet. Clouds will be used to designate the
items to add.
3. Final – removes all components and hatching related to “Remove”, removes revision clouds
and converts all components from the ‘Add’ to normal.

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5.5 Drawing Naming Convention
The WD (Wiring Diagram) EC (Electrical Cabinet) packages shall comply with the naming
conventions indicated in this section. Many of the drawing names are derived from names of
mechanical equipment. In some cases, where underscores are used as separators in the
mechanical names they are dropped in the drawing names in the interest of brevity.
5.5.1 Bodyshop Naming Conventions
Cells (gated/fenced area) shall be numbered with the same number as the first station
controlled by the cell. For mainline cells, use the first mainline station in the cell.

Example: The cell that controls stations 12, 15, and 20 shall be CELL #15.

Figure 5-3 Cell Numbering Convention

5.5.1.1 Bodyshop System Level WD Naming Convention

Bodyshop systems are groups of cells referred to as Zones. These zones are designated by
letters (see GEP1, Global Engineering Process Standards). There are many zones within the
bodyshop. A system WD typically covers several zones or subzones. The system WD starts with
“WD-“, followed by the 2 letter code of using plant, year, and primary zone number. The year is
the intended start of regular production (SORP) of the equipment, not the model year. The
primary zone number is the main zone covered by the system drawing. Sub zones feeding the
main zone are not included in the system WD name.
Example Bodyshop System WD:
Covering Process Zones BA_B01, BB_B01, and BN_B01
Fairfax Plant (FA)
2008 start of Production (08)
System Zone level wiring diagram = WD-FA08BAB01
5.5.1.2 Bodyshop Controller Level WD Naming Convention
The control WD number shall be the 1st process station number in the cell or safety area
(specified by the Process Engineer in compliance with GEP1, Global Engineering Process
Standard) with a “WD-” prefix, 2 letter code of using plant, and SORP year.

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Figure 5-4 Process Cell Naming Convention From GEP1

Example Bodyshop Controller(Cell) WD:

Process Cell AB030_B01
Lansing Delta Township Plant (LD)
2009 start of Production (09)
Cell Level wiring diagram = WD-LD09AB030B01
5.5.1.3 Bodyshop Tool (Unit) Level WD Naming Convention
For Bodyshop tooling there is typically one WD drawing per tool. This drawing is commonly
referred to as the tool WD. The tool WD drawing number is created by adding a “WD-“ prefix
and a zone station number suffix to the mechanical tool number. The tool number is assigned
by the Process Engineer.
Example Bodyshop Tool (Unit) WD:
Tool number MAA13998S
Station number BA030B01
Tool level WD package = WD-MAA13988S-BA030B01
For process tooling with no tool number and no associated WDS (such as carried dispense
equipment), the WD drawing number will use the robot number.
Example Bodyshop Carried Dispense (Unit) WD:
Robot number BA020R02B01
WD package = WD-BA020R02B01
5.5.2 Conveyor Naming Convention Conventions
Conveyors are typically named by the Conveyor Type and Department in which the conveyor
system is located. The standard abbreviations for conveyor type and department are shown in
the tables below.
Table 5-2 Conveyor Type Abbreviations
Conveyor Type
AGV Automatic Guided Vehicle
ASR Automated Storage/Retrieval System
CHN Chain Conveyor
FTR Fork Transfer
EMS Electrified Monorail System
SKD Skid
SKL Skillet

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Conveyor Type
SRS Shipping/Receiving System
VAC Vertical Adjusting Carrier
VDL Vertical Drop Lift

Table 5-3 Paint Shop Department and Process Area Abbreviations

PAINT SHOP CONVEYORS
1 Char.
st
Department
P Paint
2nd Char. Area
B Body to Paint
E Elpo
F Finesse
G Paint to GA
L Panel Load / Unload
M Mix Bank / Resequencer
N New PTED to Old Paint
P Pretreatment
R Prime
S Sealer
T Topcoat
U Underbody
W Wet Sand / Washer
3rd Char. Function
B Booth
D Delivery
M Empty Carrier
P Production
R Repair
S Strip
T Transfer
V Oven

Note: For delivery to or from the paint shop, use PS as the feeding/destination zone.
Table 5-4 General Assembly Department and Process Area Abbreviations
GENERAL ASSEMBLY CONVEYORS
BCM Body Chassis Marriage AGV
GB RESS/Battery Delivery
GBFTT Flash Tool Delivery
GDR Door Build & Delivery
GEC Engine Build & Delivery
GF Final Build
GIP IP/Cockpit Build & Delivery

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GENERAL ASSEMBLY CONVEYORS
GMT Main Line Trim
GP Paint Delivery
GPT Pre-Trim Build & Delivery
GR Main Line Chassis
GRS Chassis Parts Delivery
GS Seat Delivery
GTG Tailgate / Liftgate
GTS Trim Parts Delivery
GW Tire & Wheel Delivery
RESS RESS/Battery Marriage AGV

Note: Bodyshop conveyors shall be named by zones. For zone to zone conveyors, use the
feeding zone and destination zone (e.g., “BAHA”).

5.5.2.1 Conveyor Controller Level WD Naming Convention

The controller WD name is created by a “WD-“ prefix, 2 letter code of the using plant, 3 letter
conveyor type, 2 or 3 letter process area, and 1 – 3 digit sequence (specified by the GM Controls
Project Engineer).
Exception: Paint conveyors will use a 3 letter process area per Table 5-3 and 2 digit sequence.
Example Paint Conveyor Controller Level WD:
Skid Conveyor System (SKD)
Lansing Grand River Plant (LG)
Paint Pretreatment System (PPP)
Sequence Number (01)
Controller Level wiring diagram = WD-LG-SKD-PPP01

Example Bodyshop Zone-Zone Conveyor Controller Level WD:

Skid Conveyor System (SKD)
Fort Wayne Plant (FW)
Feeding Zone (RA)
Destination ZONE (ZA)
Controller Level wiring diagram = WD-FW-SKD-RAZA1

Example GA Conveyor Controller Level WD:

Automated Guided Vehicle (AGV)
Orion Assembly (OR)
RESS Marriage (RESS)
Sequence Number (1)
Controller Level wiring diagram = WD-OR-AGV-RESS1
5.5.2.2 Conveyor Unit Level WD Naming Convention
The unit WD name is created by a “WD-“ prefix, 2 letter code of the using plant, 3 letter
conveyor type, 2 letter process area, 3 digit sequence, and 4 digit mechanical unit number.

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Exception: Paint conveyors will use a 5 digit unit number with the 1st digit identifying the floor
level.
Example Paint Conveyor Unit Level WD:
Skid Conveyor System (SKD)
Lansing Grand River Plant (LG)
Paint Pretreatment System (PPP)
Sequence Number (01)
Mechanical Unit Number (11245)
Unit Level wiring diagram = WD-LG-SKD-PPP01-11245

5.5.3 GA (General Assembly) WD Naming Convention

General Assembly WD drawing names are based on the systems they are associated with. Each
system in GA has an abbreviation that is use in the name.
Table 5-5 GA System Abbreviations
Abbreviations System Description
ABPT Air Brake Pressure Test
ACFL AC Fill
ACRC AC Reclaim
ADAT Advance Driver Assistance System Table
ADTS Automatic (tooling) Detail Set
AGCS Automatic Guided Cart System
AGVS Automatic Guided Vehicle System
AIRC Air Compressor
ALGN Alignment
APDT Air Pressure Decay Test
ASFL Air Suspension Fill
ASFR Air Suspension Fill And Read
ASVA Air Suspension Valve Actuation
ATST After Treatment System Table
AXBT Auxiliary Battery Sub Assembly Table
AXPT Aux Pump Sub Table
BCFS Body Chassis Fastening System
BCMS Body Chassis Marriage System
BKAP Brake Air Pressure Decay
BKDF Brake and DEF Combo
BKEF Brake Evac & Fill
BKFP Brake Fluid Processor
BKPB Brake Probe Tester
BKPS Brake Pump Station
BKPT Brake Pedal Test
BKTS Brake Tester
BSAR Bodyside Apply and Roll Down System
BSCA Bodyside Cladding Apply
BSDW Bodyside Dry Wipe

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Abbreviations System Description
BSFF Bodyside Front Flare
BSMA Bodyside Molding Apply
BSRD Bodyside Roll Down
BTLD Battery Load
CAPD Coolant Air Pressure Decay
CAST Caster Vision
CHTS Chassis Tester
CMDR Cam Drill
CMRH CRFM Rack Handler
CN Corners
CPIN Camber Pin
CPLU Cockpit Load/Unload
CPTS Charge Port Tester
CRFM Condenser Radiator Fan Module
CRLU Cradle Load/Unload
CS Console
CSCT Chassis Spring Compression Tool
CSLD Console Load Tool
CSLU Console Load/Unload
CSTS Console Tester
CSUL Console Unload Tool
DEFL Diesel Emission Fluid Fill
DFPS DEF Pump Station
DKRL Deck Lid Raise/Lower
DMIN Ditch Molding Install
Loading Dock Load/Unload (xx Denotes Dock
DOCKxx
Number)
DRAX Drive Axle
DRIN Door Re-Install
DRRM Door Removal
DRST Door Tester
DUMA Drive Unit Marriage AGC
DVTS Dynamic Vehicle Test (Roll Test)
ECMT Engine Control Module Sub Assembly Table
EGRT EGR Cooler Sub Table
ELTS Electrical Tester
EMBL Emblem Apply
EMBR Emblem Rack (Part Pick)
ENRH Engine Rack Handler
ETMC Engine Transmission Marriage Conveyor
ETMR Engine Transmission Marriage Revolver
EXLU Exhaust Load/Unload
FAFL Front Axle Fluid Fill
FAST Fastening
FLPA Fluid Fill Presentation Arm

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Abbreviations System Description
FMBH Foam Injection Bulk Handling
FMIN Foam Injection
FMLD Foam Module Load
FPIT Flex Plate Index Tool
FSTS Fascia Tester
FTRH Fuel Tank Rack Handler
FUFL Fuel Fill
FUTK Fuel Tank
FUWS Fuel and Windshield Fill System
GEPS Global Errorproofing System
GLAS Glass Install
GNF Gap and Flush (tunnel or fixed system)
HBNS Hub Nut Secure
HDRL Hood Raise/Lower
HEIN Headliner Install
HKRH Hub Knuckle Rack Handler
HLAM Headlamp Aim
HLTS Head Liner Tester
HOPR Scale Hopper
HTFL Heater Coolant Fill (Occupant Space)
HTRH (Retractable) Hard Top Rack Handler
HTTS Hot Drop Tester
IPTS IP Tester
ISRH Independent Rear Suspension Rack Handler
LG Liftgate
LGOF Liftgate Docking Station Off
LGON Liftgate Docking Station On
LGST Lift Gate Spoiler Table
LIDT LIDAR Module Assembly Table
LMSC LMS Chassis
LMSD LMS Doors
LMSE LMS Engine
LMSP LMS Cockpit
LMST LMS Trim
LRRT Long Range Radar Subassembly Table
MBTS MD Brake Tester
MBWH Main Body Wiring Harness
MDTS Manual Detail Set
MGLD MID Gate Load
MH Material Handler
OVT Manual Optional Vehicle Test
PABT Passenger Air Bag Tool
PBAT Pulley Bracket Sub Assembly Table
PBTA Park Brake Tensioning Adjust
PPLT People Platform Lift

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Abbreviations System Description
PRBT Primary Battery Sub Assembly Table
PRIN Prop Shaft Install
PSFL Power Steering Fill
PSPT Power Steering Pump Table
PTFL Power Steering & Transmission Fill
PTLU Powertrain Load/Unload
RAFL Radiator & AC Fill
RASC Robotic Active Safety Calibration
RDAP Radiator Fluid Fill & Brake APD Combo
RDDF Radiator & DEF Fluid Combo
RDFL Radiator Fill
RDPS Radiator & Power Steering Combo
RDRW Robotic Wet-Out of Door Water Deflector
RDTS Robotic Detail Set
REDC RESS Delivery Conveyor
Rechargeable Energy Storage System (RESS)
REFL
Coolant Fill
RELD RESS Load Tool
RELU Load/Unload of RESS Tool
REPS Radiator / RESS Pump Station
REMB Robotic Emblem Apply
RETS RESS Test Tool
REUL RESS Unload Tool
RFDT Roof Ditch Tool
RFLD Robotic Frame Load
RFMD Roof Module
RFSP Robotic Frame Spacer Removal
RFST Robotic Front Suspension Transfer
RFTN Robotic Frame Turnover
RGNF Robotic Gap and Flush
RGRI Robotic Glass Roof Install
RLTL Robotic Innovation Lab Tracking Line
RMWH Robotic Main Body Wire Harness
ROVT Robotic Optional Vehicle Test
RRFL Rear Axle Fluid Fill
RRST Robotic Rear Suspension Transfer
RSEC Robotic Secure
RSPS Robotic Shear Plate (install) Secure
RSRH Rear Suspension Rack Handler
RSRI Robotic Sunroof Install
RSTD Robotic Seat Delivery
RSTL Robotic Seat Load
RTHI Robotic Trailer Hitch Install
RTHL Robotic Trailer Hitch Load
RTSL Robotic Tire (Spare) Load

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Abbreviations System Description
RVNE Robotic Engine/Transmission VIN Marker
RVNP Robotic Primary VIN Marker
RVNS Robotic Secondary VIN Marker
RWTI Robotic Wheel & Tire Install
SBIN Serpentine Belt Install
SBRT Stab Bar Assembly Table
SP Suspension
SPC Shear Plate Conveyor
SQRS Squeak & Rattle System
SR Sunroof
SRVS Sunroof Vision System Error Proofing
STHV Seat Hook Verification Tool
STLU Seat Load/Unload
TG Tail Gate
TGGS Tail Gate (Multi Pro) Geo Set
TGLD Tail Gate Load
TGUL Tail Gate Unload
THI Trailer Hitch Install
THL Trailer Hitch Load
TIRD Tie Rods
TMFL Transmission Fill
TMRH Transmission Rack Handler
TMTO Transmission Top Off
TPMD Tire Pressure Monitor Data Extraction
TPMI Tire Pressure Monitor Installation
TPMV Tire Pressure Monitor Verification Station
TRAB Tire Room Audit Balancers
TRBC Tire Room Balance Area Conveyors
TRBS Tire Room Barcode Station
TRDC Tire Room Delivery Conveyor
TRMI Tire Room Mount & Inflate
TRPB Tire Room Primary Dynamic Balancers
TRSO Tire Room Soapers
TRST Tire Room Stemmer
TRTK Tire Room Tracker
TRTS Trim Tester
TRVS Tire Room Vision System
TRWA Tire Room Weight Apply/Turnover
UCAL Upper Control Arm Left Hand
UCAR Upper Control Arm Right Hand
VA Sonic Weld – Front Fascia Upper
VAST Vehicle Audio System Test
VB Sonic Weld – Front Fascia Lower
VC Sonic Weld – Rear Fascia Upper
VD Sonic Weld – Rear Fascia Lower

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Abbreviations System Description
VF Sonic Weld – Front Fascia Assembly
VINC Crash Cart VIN Marker
VINE Engine/Transmission VIN Marker
VINP Primary VIN Marker Under Windshield
VINS Secondary VIN Marker Frame/Body
VR Sonic Weld – Rear Fascia Assembly
VSEP Vision Error Proofing
Wheel Alignment Station Level (Contact or Non-
WALN
Contact)
WASP Waste Water Separator
WATR Water Test
Windshield Washer & Heater Coolant Fill
WHFL
(Occupant Space)
WHIN Wire Harness Install
WOVT Water Outlet Valve Sub Table
WPMD Wiper Module
WTLI Wheel & Tire Load/Install
WTMT Wheel & Tire Multiple
WWFL Windshield Washer Fluid Fill
XFER GA Transfers
ZHCT Z Height Compression Tool

5.5.3.1 GA System Level WD Naming Convention

General Assembly systems are often cell direct. When a number of systems are grouped
together, then a system level drawing is used to represent the overall system switch. A system
WD typically covers several systems that are closely associated (i.e., multiple Cam-drill or fluid
fill machines in close proximity). The system WD starts with “WD-“, followed by the 2 letter
code of using plant, 2 letter code of area, primary system abbreviation, suffixed with “-SYSTEM”.
The primary abbreviation name is from the primary system(s) covered by the system drawing.
Example GA System WD:
Plant: Flint (FT)
Area: GA
Covering Process Zones CAMD01, CAMD02, CAMD03, CAMD04 and CAMD05
System level wiring diagram = WD-FT-GA-CAMD-SYSTEM
5.5.3.2 GA Controller Level WD Naming Convention
The controller WD name is created by a “WD-“ prefix, 2 letter code of the using plant, 2
character department code,4 character (MAX) system code, and 2 digit sequence (specified by
the GM Controls Project Engineer).
Example GA Controller Level WD:
Orion Assembly Plant (OR)
General Assembly (GA)
AC Fill System (ACFL)
Sequence Number (03)

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Controller Level wiring diagram = WD-OR-GA-ACFL03
5.5.3.3 GA Station (Unit) Level WD Naming Convention
The unit WD name is created by a “WD-“ prefix, 2 letter code of the using plant, 2 character
department code, mechanical tool number, and 2 digit sequence (specified by the GM Controls
Project Engineer).
Example GA Station (Unit) Level WD:
Orion Assembly Plant (OR)
General Assembly (GA)
Mechanical Tool Number (MAA12345S)
Sequence Number (01)
Unit Level wiring diagram = WD-OR-GA-MAA12345S01
For process tooling with no unique tool number, the WD drawing number will use the station
name (based on cell name) and number.
Example GA Station (Unit) Level WD (No Unique Tool Number):
WD-OR-GA-ALGN10
WD-OR-GA-ALGN10R01 (When robot is part of station)
WD-OR-GA-ALGN01R01 (When robot is numbered after cell)
Note: In cases where the design of the mechanical unit prohibits conformity to these naming
conventions, the responsible GM Controls Project Engineer shall determine the alternate
naming convention to be used.
5.5.4 Paint Process WD Naming Convention
Paint WD drawing names are based on the department and system they are associated with.
The paint departments are identified as follows.
Table 5-6 Paint Department Abbreviations
Abbreviations Department Description
PP Paint Process
PD Paint Dispense
PS Paint Spray

Each system in each Paint department has an abbreviation that is used in the name.
Table 5-7 Paint Process Abbreviations
Abbreviations System Description
PT Pretreatment
ED Elpo
EO Elpo Oven
PO Prime Oven
PB Prime Booth
SO Sealer Oven
MA Misc. ASH
AB Abatement
SL Sludge

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Abbreviations System Description
PM Paint Mix
TB Topcoat Booth
TO Topcoat Oven
CW Chilled Water
HW Hot Water
RO RO Water

Table 5-8 Paint Dispense Abbreviations

Abbreviations System Description
IS Interior Seam Seal
SD Liquid Applied Sound Deadener
AC Anti Chip
UB Underbody Sealer
HS Hem Seal
RD Roof Ditch
BS Sealer Bulk Storage

Table 5-9 Paint Spray Abbreviations

Abbreviations System Description
PR Prime
BP Topcoat Base Coat Prime
BC Topcoat Base Coat
BK Blackout
TR Topcoat Tri Coat
CC Topcoat Clear Coat
BO High/Low Volume Blow Off
FD Feather Duster

5.5.4.1 Paint Process Controller Level WD Naming Convention

The controller (Main) WD name is created by a “WD-“ prefix, 2 letter code of the using plant, 2
character department code, 2 character system code, 1 digit system number, and a 2 digit stage
number (00 indicates the controller level drawing).
Example Paint Controller Level WD:
San Luis Potosi (SA)
Paint Process (PP)
Pretreatment System (PT)
First System (1)
Controller Level Drawing (00)
Controller Level wiring diagram = WD-SA-PP-PT100

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5.5.4.2 Paint Process Stage (Unit) Level WD Naming Convention
A unit drawing is the lowest level drawing. A unit drawing could be a phosphaste stage, oven
zone, or any part of a larger system. The unit WD name is created by a “WD-“ prefix, 2 letter
code of the using plant, 2 character department code, 2 character system code, 1 digit system
number, and a 2 digit stage number.
Example Paint Unit Level WD:
San Luis Potosi (SA)
Paint Process (PP)
Pretreatment System (PT)
First System (1)
Stage 1A Drawing (10)
Unit Level wiring diagram = WD-SA-PP-PT110
5.5.5 Press WD Naming Convention
Press WD drawing names are based on their location in the facility and the type of metal
forming equipment.
5.5.5.1 Press System Level WD Naming Convention
Each Press system shall have a system WD. The system WD name is created by a “WD-“ prefix, 2
character department code, 2 letter code of the using plant, system description and the
location.
Example Press System WD:
Metal Forming (MF)
San Luis Potosi (PS)
AA Transfer Press (AA3)
Location (AA1)
System Level wiring diagram = WD-MF-PS-AA3-AA1
5.5.5.2 Press Controller (Cell) Level WD Naming Convention
The controller WD name is created by a “WD-“ prefix, 2 letter code of the using plant, location,
and the 3 character description of the cell (press number).
Example Press System WD:
San Luis Potosi (PS)
Location (AA1)
Press Cell (PR1)
Controller Level wiring diagram = WD-PS-AA1-PR1
5.5.5.3 Press Unit (Station) Level WD Naming Convention
The Station WD name is created by a “WD-“ prefix, 2 letter code of the using plant, location, the
3 character description of the cell (press number), and the station name.
Example Press Station WD:
San Luis Potosi (PS)
Location (AA1)
Press Cell (PR3)
Station Name (SLD)
Unit Level wiring diagram = WD-PS-AA1-PR3-SLD

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5.5.5.4 Press Special EC Naming Convention
For common panel designs that are used on all presses in a location, the press cell may be
substituted with a generic placeholder in the EC name. For common panel designs that are used
in all presses in a plant the location may be substituted with a generic two digit placeholder.
Example Custom Press J-Box used on all presses in a location:
Station/Unit WD name (WD-PS-AA1-PR3-SLD)
Panel Subscript (M1)
Replace PR3 with PRx per rule above
EC Drawing Package = EC-PS-AA1-PRX-SLD-M1
5.5.6 Propulsion Systems WD Naming Convention
Propulsion systems facilities are typically by the department in which the equipment is located.
Refer to the GPSME_Naming_Convention.xlsm document for the complete department
abbreviation list and WD name generator tool.
5.5.6.1 Propulsion Systems System Level WD Naming Convention
The System WD name is created by a “WD-“ prefix, 2 letter code of the using plant, 2 number of
start of production, 2 letter Department and 2 digit module/loop.
Example Propulsion Systems System:
Romulus Plant (RO)
2016 start of Production (16)
Engine Assembly (EA)
Module/Loop (2)
System Zone level wiring diagram = WD-RO16EA2
5.5.6.2 Propulsion Systems Controller (OP) Level WD Naming Convention
The controller WD number shall be the 1st process station number in the cell or safety area
(specified by the Process Engineer) with a “WD-” prefix, system code, 3 digit operation code
(specified by the project controls engineer), 1 letter leg code (for parallel operation, if
applicable) and 1 letter duplicate machine code (if applicable).
Example Propulsion Systems Controller (OP) Level Drawing:
System (RO16EA2)
Operation Level+ Leg + Duplicate Machine (030+B+A)
Cell Level wiring diagram = WD-RO16EA2030BA
5.5.6.3 Propulsion Systems Unit (Station) Level WD Naming Convention
For Propulsion Systems there is typically one WD drawing per Unit (Station) if required. The unit
WD drawing number is created by adding a “WD-“ prefix and a station number is assigned by a
station identifier and then a station instance in a sequential fashion from load to unload or first
to last operation.
Example: Propulsion Systems Station (Unit) level WD:
Cell Level: WD-EA030
Station Identifier: (LK)
Station Instance: (01)
Station level WD package = WD-EA030-LK01

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5.5.7 Non Unique WD Naming Conventions (Regional or Project Specific)

Non unique WD drawings (i.e., drawings that can be used to build multiple pieces of identical
equipment) shall follow the individual special naming conventions for each area as defined
above or the general rules below.

The drawing name for non-unique regional WD drawings are created by a “WD-“ prefix, 3-4
letter code of the region (GMSA, GMNA, GMIO), year created and Application description. For
WD drawings based on WDS designs, the application description can be the WDS name with the
architecture (G06 or G08) designation removed. For other applications, the description could be
an abbreviation or combination of abbreviations. The year created may be substituted with the
two character digit for the compatible architecture (06 for G06 or 08 for G08).
Example Non unique WD Drawing based on WDS-G06-CARRY_SPOT_SGMD:
Region (GMNA)
Compatible Architecture (06)
Application description (CARRY_SPOT_SGMD)
WD Drawing Package = WD-GMNA06- CARRY_SPOT_SGMD
For non-unique WD drawings used on a single project in multiple instances, follow the naming
convention as described above replacing the “region” and” year created” with the 2 digit plant
code and SORP year.
Example Non unique WD Drawing based on WDS-G06-CARRY_SPOT_SGMD:
GM Lake Orion Plant (OR)
2011 start of Production (11) or Compatible Architecture (06)
Application description (CARRY_SPOT_SGMD)
WD Drawing Package = WD-OR11- CARRY_SPOT_SGMD
Or
WD-OR06- CARRY_SPOT_SGMD
5.5.8 EC Naming Conventions
Most applications can be designed to use standard ECS panel designs. Occasionally, a custom
panel design is required for some applications. Custom panel drawings are called EC drawings.
Custom panels shall follow one for the following conventions:

Panels that are unique and primarily of a controller level function (PDP, MCP, etc.) shall be
named by adding an “EC-“ prefix and a panel type subscript suffix to the controller level WD
name.
Example Custom Conveyor Power Distribution Panel Drawing:
Controller WD Name (WD-LG-SKD-PL01)
Panel Subscript (P1)
EC Drawing Package = EC-LG-SKD-PL01-P1
Panels that are unique and primarily of a tool or unit level function (Fixture J-Box, etc.) shall be
named by adding an “EC-“ prefix and a panel type subscript suffix to the unit level WD name.
The subscript is required in this instance as it is possible to have multiple custom panels
associated with a single WD drawing.
Example Custom Bodyshop Fixture J-Box Panel Drawing:

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Tool/Unit WD Name (WD-MAA13988S-BA030B01)
Panel Subscript (J1)
EC Drawing Package = EC-MAA13988S-BA030B01-J1
5.5.8.1 Non Unique EC Panel Naming Conventions (Regional or Project Specific)
Non unique EC panels (i.e., panels where one design can be used for multiple instances) shall
follow the individual special naming conventions for each area as defined above or the general
rules below.

The drawing name for non-unique regional EC panels (panels used across multiple projects in a
region) is created by a “EC-“ prefix, 3-4 letter code of the region (GMSA, GMNA, GMIO), year
created, panel description. For EC panels based on ECS designs, the panel description is the ECS
number of the panel. For other applications the description could be an abbreviation of the
panel function.
Example Non unique EC Panel Drawing based on ECS-4125:
Region (GMSA)
Year Created (10)
ECS Panel Referenced (4125)
EC Drawing Package = EC-GMSA10-4125

Example Non unique custom Panel Drawing:

Region (GMNA)
Year Created (10)
Description (Skid)
EC Drawing Package = EC-GMNA10-SKID
For non-unique EC panels used on a single project in multiple instances, follow the naming
convention as described above replacing the “region” and” year created” with the 2 digit plant
code and SORP year.
Example Non unique custom EC Panel Drawing based on ECS-4125:
Lansing Delta Township Plant (LD)
2011 start of Production (11)
ECS Panel Referenced (4125)
EC Drawing Package = EC-LD11-4125
5.5.9 GM Standard Drawing Naming Conventions (Documentation Supplied by GM)
In order to promote the deployment of common controls systems, GM will provide some
completed WD designs (referred to as WDS drawings) for some applications as well as template
drawings (referred to as WDT drawings) for typical applications requiring customization. The
WDS drawings are completed engineering and are designed to be used without modification.
The WDT drawings are starting points and must be renamed to application specific WD drawings
(per the rules in the previous sections) and modified to suit the particular application.

WDT and WDS drawings created for applications generally represent a specific controls
hardware solution set. Over time as technology and suppliers change, the standard solutions
sets will also change. Small changes will be handled as revisions to the drawings. Major
changes will require new drawings to be released.

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In order to ensure unique drawing naming, the architecture revision level or calendar year will
be incorporated into the drawing name. The drawing names for standard pipe & wire drawings
are created by adding an “WDT-“ or “WDS-“ prefix to the architecture revision level (e.g. G06,
G08, G12). For changes not tied directly to the architecture revision level, the calendar year
may be substituted for the architecture revision level. The calendar year should be preceded by
a “G” for globally acceptable designs or by the region code (GMSA, GMNA, GMIO) for regionally
acceptable designs.
Example New Controller Template Drawing for G12 Architecture Changes:
Region Global (G)
Compatible Architecture (12)
Application description (Body1CellMain)
WD Drawing Package = WDT-G12-Body1CellMain

Example New Skid Pipe & Wire Drawing incorporating a new drive technology:
Region Global (G)
Calendar Year Created (13)
Application description (SKD_001-2)
WD Drawing Package = WDS-G13-SKD_001-2
WDT and WDS drawings are typically published and maintained by GM. Before creating these
types of drawings the responsible GM Controls Project Engineer should be consulted.
5.6 File Naming
1. Drawing file names shall match the drawing name (WD or EC) with the inclusion of the
status, the date, and the language code (e.g., en, de, mx, es). The language code is generally
only required on drawings that are delivered in a language other than English.
Example File names for Drawing WD-TH-GA-ACFL03 Revision A
Eplan Backup file name: WD-TH-GA-ACFL03_RevA(2011_05_06).zw1
English PDF file name: WD-TH-GA-ACFL03_RevA(2011_05_06).pdf
Geman PDF file name: WD-TH-GA-ACFL03_RevA(2011_05_06)_de.pdf
Excel BOM file name: WD-TH-GA-ACFL03_RevA(2011_05_06).xls
Note: The Excel BOM (Bill of Material) is required as an input to the replacement part process.
The actual BOM documentation resides in the ePlan file and pdf deliverables.
5.7 Action / Result (“Work” / “Load/Unload”) Naming Convention
1. A consistent method of naming a mechanical function’s actions and results in schematic
drawings ensures the accuracy and clarity of the drawings. The following naming
conventions shall be applied. In cases where the design of the mechanical unit prohibits
conformity to these naming conventions, the responsible GM Controls Project Engineer shall
determine the alternate naming convention to be used.
2. The words “Extend” and “Retract” shall not be used except when describing the position of
a cylinder. The direction of movement of the cylinder operating a mechanical unit is not
relevant to the naming convention of the mechanical unit. For example, a cylinder on a slide
may retract to advance the slide and extend to return the slide.
3. Shot Pins shall “Engage” when the pin extends and “Disengage” when the pin retracts.

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4. “Home” position denotes when the fixture is ready to receive a part (load position).
5. Refer to Table 5-10 Action / Result Nomenclature
Table 5-10 Action / Result Nomenclature
Mech. Functions Pushbutton / Actuator Switch / Indicator
Work Load/Unload Work Load/Unload
Clamp CLOSE OPEN CLOSED OPENED
Contactor
Gate
Pierce
Stops
Weld Gun
Weld Gun
Backup
Dump ADVANCE RETURN ADVANCED RETURNED
Ejector
Index
Locator
Pivot
Pre-Loader
Slide
Transfer
Trunnion
Turnover
Wilker Slide ADV2 RETURN ADVANCED RETURNED
Shot Pin ENGAGE DISENGAGE ENGAGED DISENGAGED
Locating pin
Latch
Transfer Press RAISE LOWER RAISED LOWERED
Vertical Slide
Lifter
Lifter LOWER RAISE LOWERED RAISED
Turntable FORWARD REVERSE IN POSITION IN POSITION

Note: WORK and LOAD/UNLOAD nomenclature is not applicable to model specific positions
(e.g., COUPE POSITION, RHD POSITION, LUGGAGE RACK POSITION)
The position that the model specific tooling would be in the majority of the time should be
designated as HOME position.
5.8 Deliverables
1. Hardcopy drawings – (where required) shall be provided as follows:
a. Asia, and South America: on A4 white bond paper in a binder typical of the region.
b. North America: on 8.5 inch X 11 inch white bond paper in a 3 ring binder.

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2. Every control panel shall include a hardcopy of the respective EC or ECS drawing in the
enclosure.
3. Electronic copies of drawing files shall be provided in both CAD (.zw1) and .PDF formats to
the responsible GM Controls Project Engineer.
4. PLC program files shall be provided in .ACD format to the responsible GM Controls Project
Engineer.
5. HMI files shall be provided to the responsible GM Controls Project Engineer using the
application software’s archive (backup) feature to ensure all components of the application
are included.
6. All software (e.g., PLC, HMI, EDS (Electronic Data Sheets), VFD configuration, camera
configuration, etc.) shall be provided freely with no requirement of non-disclosure.
7. Engineering calculations – Electronic copies of the following:
a. All custom panels:
i. heat calculations
ii. SCCR ratings
b. Air/ hydraulic valve and header sizing (If required)
c. All control power related sizing including:
i. PDP transformer sizing
ii. 24 VDC power supply sizing
iii. Circuit Breaker sizing
d. Network
i. Network bandwidth
ii. Network power supply sizing (DeviceNet only)
iii. Trunk & drop cable budget (DeviceNet only)
e. PLC memory sizing
f. Weld water header sizing (If required)
g. Arc flash calculations – Complete GM IEEE1584 Excel file for all controls panels
operating at > 150 V.
Note: Complete arc flash calculation requires facilities and installation information. Verify
required workflow with GM Controls Project Engineer.
5.8.1 Documentation for Approval
For each approval submittal, the supplier shall provide, at a minimum, the following “For
Approval” documentation to the responsible GM Controls Project Engineer:
1. EPLAN zw1 file and exported PDF file, allow two weeks for approval.
2. One set of lockout placards, allow two weeks for approval.
3. One copy of the PLC program file, allow three weeks for approval.

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4. One copy of all HMI screens, allow three weeks for approval.
5. One set of engineering calculations per 5.8 item 6.
Note: “For approval” is meant to be for “Review”. Suppliers are responsible for providing a
quality workable system in compliance to stated specifications and references. GM reviews the
design(s) to enable feedback and/or changes in a timely manner. Approval of the drawings does
not imply buy off of design or programming, or relieve the contractor of their responsibility to
furnish a quality workable system.
5.8.2 Documentation for Construction
For construction, the supplier shall provide, drawings and BOM’s for the GM Controls Project
Engineer and for the build source. Documentation submitted to the build source for
construction should be translated and provided in the local language of the GM facility receiving
the equipment to ensure that the equipment is constructed with the proper tags.
5.8.3 Before Debug or Run-Off
For each tooling cell, the supplier shall provide one set of lockout placards documentation
before any debugging or run-off can begin as determined by the mechanical specification.
5.8.4 Documentation As Shipped
1. To the Plant Engineer - the supplier shall provide, at a minimum, the following “As Shipped”
documentation:
a. One set of drawings and BOMs.
b. One set of EPLAN zw1 files and exported PDF files.
c. One set of PLC program files for each PLC.
d. One set of HMI files for each HMI.
2. With the Main Control Panel - the supplier shall include, at a minimum, the following “As
Shipped” documentation:
a. One set of drawings and BOMs.
5.8.5 Documentation As Built
1. To the Plant Engineer - the supplier shall provide, at a minimum, the following “As Built”
documentation no later than two weeks after completion of start-up and debug:
a. One set of “As Built” EPLAN zw1 files and export PDF files.
b. One set of “As Built” lockout placards for installation on tooling cell.
c. One set of “As Built” lockout placards files.
d. One set of “As Built” PLC program files for each PLC.
e. One set of “As Built” HMI files for each HMI.
2. To the responsible GM Controls Project Engineer - the supplier shall provide, at a minimum,
the following “As Built” documentation no later than two (2) weeks after completion of
start-up and debug:
a. One set of “As Built” EPLAN zw1 files and export PDF files.

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b. One set of “As Built” lockout placard files.
c. One set of “As Built” HMI files for each HMI.
d. One set of engineering calculations per 5.8 item 6.
3. With each Main Control Panel - the supplier shall provide, at a minimum, the following “As
Built” documentation no later than two weeks after completion of start-up and debug:
a. One bound set of “As Built” drawings and BOM’s for placement in the control panel.

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6 Wiring Diagram (WD) Levels and Packages
6.1 Purpose
This section describes the design, structure, and naming convention of the electrical controls
wiring diagrams.
6.2 WD Levels
There are three levels of wiring diagram (WD) drawing packages. Figure 6-1 Wiring Diagram
Drawing Levels, illustrates the relationship between these packages.

Figure 6-1 Wiring Diagram Drawing Levels

System: A System is an area in which a process of interdependent operations takes place to

complete a finished product or sub-assembly (e.g., door, roof or dash zone, transfer press line).
The system level drawing may show the overall view of the multiple “control” areas or zones.
The main intent of a system drawing is to show the interconnections between multiple
controller level drawings.

Controller: The Controller (or Cell) level drawing shall include all the components controlled
within a single MCP span of control (i.e., Power Distribution Panel, Main Control Panel, Gate
Boxes, Station Boxes, Skid Contactor Panels, VFD Panels, Motor Starter Panels) and their
interconnection. Controller Drawings show the interconnection of multiple Unit drawings.
Reference EP-1 (Engineering Process Standard) for cell designations and naming.

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Unit: The Unit level drawing shall show a detailed schematic of the equipment. The equipment
could be a tool, station, conveyor section, or other unit of equipment.
6.2.1 Single Tool or Self-Contained Machines
For applications where an entire machine or tool is “self contained” and provided as a complete
assembly from the supplier, a single controller WD including all unit content may be utilized.
Consideration about the impact to build, bill of material, etc. must be taken into account when
combining drawing levels.
Figure 6-2 Combined Controller/Unit Drawing Example

6.3 Drawing Level Details

6.3.1 System Level WD Drawing Package
The highest drawing package level is a System Level WD, which shows the interconnections
between multiple controller level packages. There is typically one system level WD per system
(zone) level Ethernet switch.

The System Level WD shall contain a reference sheet that lists all the controller WD packages
and a description of their associated area of control within the system. The System level
package shall also show any interlocks (Network or Hardwire) between Main Control Panels.
Devices that can be purchased on a system basis (i.e., programming terminals, enabling
pendants, marquees, System Ethernet Switches) may also be included in the System WD
package.

If the system only contains one controller, then, the System Level WD is not required. The
Controller Level WD shall show all the necessary information.
6.3.2 Controller Level WD Drawing Package
The middle level drawing package is the Controller Level WD. The controller level WD shows the
interconnection for all equipment associated with a MCP. This should include: multi-conductor
cables, hardwired circuits, interlocks, and associated network communications. The cell or an
equipment layout may be shown in this package to provide an approximate location of the
components detailed in the package. The Controller Level WD shall also show the plant utility
drops required for the equipment (i.e., air, water, electrical bus feeds).

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Each electrical control panel (i.e., MCP, PDP, Operator Run Stand) typically is a separate drawing
package from the Controller level drawing package. This is to facilitate the use of the standard
panels (ECS’s).

Robots also have their own drawing package for their specific process application (i.e., welding,
sealing, hemming).
6.3.3 Unit Level WD Drawing Package
The lowest level drawing package is the Unit Level WD. A “unit”, commonly called a “tool”,
refers to a piece of equipment where an individual operation is performed (e.g., where two sub-
assembly parts are located on a fixture, clamped and welded together) or it may be an actual
tool on the end of a robot arm that performs welding, mechanical handling or adhesive apply.

The unit level WD shows the controls of all of the devices (e.g., sensors, valves, cords) associated
with that unit. This package shall show I/O device connections, pneumatic and hydraulic
connections, and any application-specific information (e.g., weld gun controller and weld gun
connections).

Specific examples of unit level WDs are the following:

• Bodyshop or GA tool WD drawings
• Paint Stage WD drawings
• Conveyor Module WD drawings
• Press Bed WD drawings
• Robot End-Effector Drawings

The unit level package shall also include the interconnection to the controller level package and
all necessary information for a unit to be piped and wired without the required use of other WD
drawing packages. The sequence of operation shall also be provided if it is not available in
another document (i.e., xRWD).
6.4 Drawing Section Format
Every drawing package is divided into lettered sections that correspond to specific functions.
(Refer to Figure 6-3 and Table 6-1, respectively.) This organizational structure permits quick
access to specific areas of a package and eases the revision process by allowing new sheets to be
incorporated without affecting other sheets.

Every lettered section is not necessarily part of every package. Only the sections pertaining to a
specific application shall be included in that drawing package. However, Section A is always
required.

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Figure 6-3 Naming Convention for Drawing Package Sections

There also may be sub-sections within the specific lettered section (i.e., CA, CB, CC). This is to
provide an even finer organization within that functional section. A typical example of this is to
show all the DeviceNet cabling in pages ‘CD’. ‘C’ is the main section for Interconnect and ‘D’ is a
sub-section reserved for DeviceNet.
Table 6-1 Section Titles of Drawing Package
Section Title Description
Reference, Table of Reference sheet(s) showing WD and tool numbers, table of
A Contents, and Revision contents with revision level, and revision summary sheet(s)
Summary Sheet(s) which detail changes.
B Layout Layout of zone, cell, or tool.
C Interconnection Electrical connections between panels.
CA Bus plug drops Cable drops from plant bus plug(s)
CB AC Power Interconnect Cables from PDP to other panels
CC DC Power Interconnect 24vdc cable interconnection
CD DeviceNet Interconnect DeviceNet cable interconnection from MCP to devices.
CE Ethernet Interconnect Ethernet cable interconnections
Grounding & Bonding
CG Grounding and bonding of equipment interconnection.
Interconnect
Miscellaneous All other electrical interconnections not covered in the previous
CM
Interconnect sub-sections.
D Sequence of operation Tool’s sequence of operation
E Magnetics Hardwired electrical circuits and power distribution.
Device input/ output wiring, cabling, power requirements, and
F I/O
addressing.
G Pneumatic and gas Air and gas circuits and devices (FRL, valve manifolds, cylinders)

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Section Title Description
H Hydraulic and lube Hydraulic and lube circuits and devices
I Water Water circuits and devices.
J reserved (do not use) Reserved for committee’s future use
K reserved (do not use) Reserved for committee’s future use
L Liquids Fluid fill (General Assembly)
M Miscellaneous. If not using for Cell Level Station Interconnection.
Cell Level: Used to show the cell level interconnection to
MA, Station Interconnects.
station panels (i.e., cable connections to operator light
MB, (Each station is a unique
curtains/fixture boxes/valves, weld controller to transformer
MC sub-letter)
connections).
N-V reserved (do not use) Reserved for committee’s future use
W Welding Welding circuits with welding charts.
X Enclosures Enclosure layout(s), receptacle wiring.
Bill of Materials for the applied drawing package (zone, cell,
Y BOMs tool, or panel). Listing of components accompanied by
description, manufacturer, sourcing, and quantities.
YA 1st BOM set Main material list for drawing set.
Secondary material list for unique applications where a 2nd
YB 2nd BOM set
equipment supplier exist.
Material list by device rather than item number, typical for EC
YZ Device List
or ECS drawings.
Reference Standard Standard drawings such as dip switch settings for various
Z
drawings components, pinout diagrams for the various field cords, etc.

6.4.1 System Level WD Package Sections

The drawing sections of the system level package shall include Section A, and may include, but
not be limited to, those identified in Table 6-2.

Table 6-2 Drawing Sections of the System Level WD Package

Section Title Content Description
Reference Sheet, Table of List of all WDs within control of this zone, table of
A Contents and Revision contents of drawing package, and revision summary
Summary Sheet sheet(s).
B Layout Graphical overview of Equipment.
C Interconnection The interconnection of utilities, networks and controls.
Bill of materials for zone components including
YA, YB, etc. BOMs
programming terminals and marquees, if required.
Reference Standard
Z Copy of standard controls drawings used in the System.
Drawings

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6.4.2 Controller level WD Package Sections
The drawing sections of the Controller Level WD shall include Section A and may include, but not
be limited to, the following:
Table 6-3 Drawing Sections of the Controller Level WD Package
Section Title Content Description
Reference sheet, table List of all WDs within the control of this package, table
A of contents and revision of contents of drawing package, and revision summary
summary sheet sheet(s)
General equipment layout. Location of Devices not
B Layout
specified on other documents.
C Interconnection Interconnection of utilities, networks, and controls
D Sequence of operation Controller sequence of operation
Main panel hardwired circuits and cell power
E Magnetics
distribution
F I/O Controller level Input/output wiring
G Pneumatic Air headers, shut-offs, accumulators, etc..
H Hydraulic Hydraulic headers
I Water Water headers and shut-offs.
M (and related Station cable interconnections. Weld controller cable
Station interconnect
subsections) connections to transformers
YA, YB, etc. BOMs Bill of materials for Cell components.
Standard controls drawings used in this control WD
Reference Standard
Z package. Note: Do not include these drawings here if
drawings
they are already in the parent zone level package.

6.4.3 Unit Tool Level WD Package Sections

The drawing sections of the Unit Level WD shall include Section A and may include, but not be
limited to, the following:
Table 6-4 Drawing Sections of the Unit Level WD Package
Section Title Content description
Reference sheet, table List of all WDs within control of this package, table of
A of contents and revision contents of drawing package, and revision summary
summary sheet sheet(s)
Graphical overview of equipment. General location of
B Tool layout
all associated control components.
C Interconnection Interconnection of networks and controls
D Sequence of operation Equipment Sequence of operation
F I/O Equipment input/output wiring and its power
G Pneumatic and gas Pneumatic and/or gas diagrams and connections
H Hydraulic and lube Hydraulic and /or lube diagrams and connection
I Water Water diagrams
Weld controller and weld transformer layout, weld
W Welding
schedule

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Section Title Content description
Bill of materials related to station panel and other
YA, YB, etc. BOMs
related components
Standard controls drawings used in this control WD
Reference Standard package. Note: Do not include these drawings here if
Z
drawings they are already in the System or Controller level
packages.

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7 Drawing Section A: Reference Sheet(s), Table of Contents, and Revision
Summary Sheet(s)

7.1 Purpose
The drawing Section A provides the pertinent information about the content of the drawing
package. Section A shall include the following:
1. Title of the drawing package.
2. List of all the reference tools and WD’s (Wiring Diagram).
3. Standard WDS’s and standard ECS’s (Electrical Control panel designs) used in the package.
4. TOC (Table of Contents).
5. Revision summary information.
7.2 Title and Reference Sheet(s)
Title and Reference sheet(s) shall provide the following information:
1. A simple box diagram where the design (system, controller, unit) is represented by a solid
line. If applicable, other designs associated are represented by a dashed line. In a cell WD,
for example, the controller (cell) is shown in a solid box in the center of the sheet. The
corresponding system (zone) is shown in a dashed box above and the corresponding units
(stations) are shown in dashed boxes below.
2. The boxes shall include the title description of the system, controller, or unit (e.g., DASH
ZONE, A ZONE – STA 10, or DASH CELL # 30, STA 1 - FRT BRKT WELDER).
3. Reference shall be made to all of the applicable station numbers, station descriptions, WD
numbers, EC numbers, tool numbers, standard ECS’s, and standard WDS’s.

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Figure 7-1 Sample Title and Reference Sheet

7.3 Table of Contents

The Table of Contents sheet in each drawing package shall provide a detailed list of each sheet
and their descriptions. See Table 6-1 for drawing section descriptions.

Table of Contents shall use the following headings and provide the following information:
1. SECTION
a. (1st column) shall show the section letter.
b. (2nd column) shall show section description
2. REV. (3rd column) shall show the revision level of each sheet.
3. SHEET (4th column) shall show the drawing sheet number.
4. DESCRIPTION (5th column) shall show the description of the sheet.
The Table of Contents shall list all of the sheets within the drawing package. With the proper
GM ePlan configuration, the table of contents can be created and updated automatically within
ePlan.

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Figure 7-2 Sample Table of Contents Sheet

7.4 Revision Summary Sheet(s)

The Revision Summary sheet(s) shall document all revisions to the drawing package and shall
provide a reference for all design or build changes for a particular tool.

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The Revision Summary table is used to provide a detailed list of the REVISION LETTER, SHEETS
AFFECTED, CHANGE DESCRIPTION, DATE OF CHANGE, CHANGE CODE, and CHANGED BY. See
Figure 7-4 for reference.
1. REV (1st column) shall show:
a. A revision letter used to identify a change(s) that occurs after a package has been
released.
b. The same revision letter shall appear on only the affected sheet(s) throughout the
package. Example: Revision “D” added another sequence step (e.g., valve, switches, and
cylinder). Therefore, the tool layout sheet, pneumatic sheet, tool I/O sheet, Bill of
Material sheet, and all other affected sheets would have the revision D.
c. Subsequent revision letters shall follow the last revision of the entire package - NOT the
last revision of the affected sheet.
d. The revision symbol (i.e., the revision letter placed inside a circle) shall appear near the
item(s) affected.
Figure 7-3 Revision Symbol Example

e. The first revision letter shall be identified as “A” and shall increment by one with each
new revision (B, C, D...). Do not skip letters (i.e., I, O, Q). Use 2 letters for revisions after
Z (i.e., AA thru AZ, BA thru BZ, CA thru CZ).
2. SHEET AFFECTED (2nd column) shall show the affected sheet number. Include the section
letter before the sheet number (e.g., A2, D1, Z4).
3. CHANGE DESCRIPTION (3rd column) shall show detailed descriptions of revision(s) and
include the following when applicable:

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a. Line # where change occurs.
b. Input and/or output numbers.
c. Specific description of change – vague comments such as “This sheet revised and
redrawn.” is unacceptable.
4. DATE (4th column) shall show the revision date.
5. CHANGE CODE (5th column) shall show one of the change codes listed in Table 7-2.
6. The sixth column (CHANGED BY) shall show the initials of the person making the revision.
Figure 7-4 Sample Revision Summary Sheet

7. Every revision summary sheet shall have the following Change Code Key located at the
lower right corner and above the titleblock. Reference Table 7-1.
Table 7-1 Revision Change Code Key
CHANGE CODE
PR PRODUCT CHANGE
R PLANT REQUEST
MECHANICAL
MP
PROCESS CHANGE
CONTROL PROCESS
CP
CHANGE
MECHANICAL DESIGN
M
CHANGE
CONTROL DESIGN
C
CHANGE
FLOOR AND BUILD
F
CHANGE

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Table 7-2 Change Code Definitions for Revision Summary Sheet
Code Definition Usage
a change to the tooling design driven by Product Engineering (e.g., a new
Product
PR weld spot is added that cannot be completed with the current tooling
Change
design, therefore, requiring the addition of a weld gun).
Plant the plant requests a design change (e.g., replace a light curtain with a safety
R
Request mat is requested by the plant for a particular application).
Mechanical a sequence change driven by the mechanical designers (e.g., a clamp that
MP Process originally closed with the 1st group of clamps shall now close with the 2nd
Change group of clamps).
Controls
a change in controls design intent (e.g., The addition of a “24 VDC Power
CP Process
On” light to the main control panel)
Change
Mechanical a change due to a mistake made by the mechanical design source (e.g., a
M Design cylinder for a unit has been undersized during design and will not function
Change correctly).
Controls
a change due to a mistake made by the controls design source. (e.g., an
C Design
item that is required for build has not been included in the BOM).
Change
prints are updated to show “as-built” changes made on the floor. These
Floor and
F changes do not affect the design intent (e.g., rearranging the order of the
Build Change
valves on a manifold block to reflect actual build).

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8 Drawing Section B: Layout

8.1 Purpose
The layout illustrates the relative position of controls components that are not typically included
on the system layout (e.g., DeviceNet tees, IP6X power supplies, power tees, I/O blocks,
Ethernet switches). The layout is the “overall map” of the components which are controlled by
the wiring diagram (WD) package.
Note: The controls layout included in WD designs is not a substitute for mechanical system
layout nor should it contain that level of detail. It is intended to supplement the system layout
by identifying the intended position of controls components that are not part of the mechanical
system layout.
Layouts may be provided by the mechanical process engineers (typically as .dwg or .dxf files).
These can then be imported into the controls drawing packages.
8.2 System (Zone) Layout
1. System (zone) layout shall show a basic overview of the entire system (zone) on the first
sheet. When needed, supplemental sheets shall be used to provide a closer, more detailed
view of a portion of the zone (system). System (zone) layout shall show relative position of
the cells, tools and their gating and fencing.
2. The system (zone) layout is not typical for system WD’s and is included only where required
by the GM Controls Project Engineer.
Figure 8-1 Sample System (Zone) Layout

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8.3 Controller (Cell) Layout
The controller (cell) layout is typically shown in the controller (cell) package and shall be
prepared as follows:
1. The controller (cell) layout shall show a plan view of the controller (cell) level components
(e.g., power supplies, power tees, safety I/O blocks, DeviceNet tees). The latest applicable
controller (cell) template includes the typical content for this layout.
2. Additional sheets may be added as needed to maintain clarity.
Figure 8-2 Sample Controller (Cell) Layout

8.4 Unit (Station) Layout

The unit (station) layout is typically shown in the unit (station) package and shall be prepared as
follows:
1. The unit (station) layout shall show the basic mechanical layout of the tool depicting the
cylinders, their respective sensors, and part present sensors. The latest applicable unit
(station) template includes the typical content for this layout.
2. The unit (station) layout shall show an outline of the processed part(s).
3. The unit (station) layout shall show operator(s) if applicable.
4. The cylinders and part present sensors shall be arranged in their relative position to the
part.
5. The cylinders shall show their description and number (i.e., CLAMP C05).
6. The cylinder’s controlling valve designation shall be shown next to cylinder (i.e., PM1.V1).

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7. The sensors shall show their designation (i.e., C05PX1, C05PX2).
8. Sensors shall show the IP67 I/O block for which it is connected (i.e., BK01).
9. The layout shall include a large arrow accompanied by the word FLOW, indicating the
direction of material flow (if applicable).
Figure 8-3 Sample Unit (Station) Layout

8.4.1 GA (General Assembly) Unit (Station) Layout

The following requirements for general assembly are in addition to (not in replace of) the
requirements above in section 8.4.
1. Pneumatic only tools require operator paddle buttons, cylinders, switches, logic elements
air prep, and valve board/plate location to be shown.

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Figure 8-4 GA Pneumatic Tool Layout

2. Tools with a PLC require tooling outline in addition to operator paddle buttons, cylinders
switches, I/O blocks, and valve elements.
Figure 8-5 GA PLC Tool Layout

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9 Drawing Section C: Interconnect

9.1 Purpose
The Interconnect Section shows all interconnections (e.g., between electrical control (EC)
panels, tools, robots, transfers, weld controllers, including cables, hardwiring, network wiring
and system grounding) required to construct, install, and assemble the control system. The
interconnect shall also show the connection between two or more systems (zones) that are
electrically interlocked.
9.2 General Design Requirements
9.2.1 The Interconnect Shall Show:
1. All EC panels relevant to the drawing package.
2. All panels and cables ordered on the drawing BOM. The EC panels shall be represented by a
box as shown in Figure 9-1.
Figure 9-1 Electrical Control Panel Representations

3. The Interconnect shall show number of cables and receptacles, as well as the number of
pins for the receptacles.
4. The Interconnect shall show number of conductors, the conductor size, and conductor color
for hardwired connections.
5. For hardwire connections other than power supply, information such as terminal numbers
and additional parts required shall also be shown.
6. If a hardwired cable is required, the Interconnect shall show appropriate balloons for the
cable referenced to the BOM. The BOM shall show the brand and part number (e.g., Belden
#9463).
7. The Interconnect shall show item numbers for devices that will be listed in the drawing
package Bill of Material (BOM).

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Figure 9-2 Show Item Balloons

8. Conduit interconnections shall show conduit size, conduit seals (if required), number of
conductors, conductor size, and conductor colors.
9.2.2 Interconnect Line Types
1. CONTINUOUS solid lines shall be used in the following instances:
a. Items which are purchased in the drawing package’s BOM (i.e., panels and cables.)
b. Interconnecting hardwire connections. Hardwire interconnections which are shown in
two or more drawing packages shall be drawn with continuous lines on the drawing
package from which the hardwire originates [and drawn with dashed lines (referenced)
on all other].
Note: An item shall only be drawn with continuous lines in one drawing package.
2. DASHED lines shall be used to indicate the following:
a. Items shown on the drawing package which are referenced (not purchased) in the BOM.
b. Items shown on the drawing package for clarity and are not listed in the BOM.
c. Interconnecting hardwire drawn with continuous lines on any other drawing package’s
interconnection sheet.

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3. PHANTOM lines shall be used to show a representative outline of the tool base or other
physical piece of equipment. This outline is used to show which items are mounted to the
tool base and which are not.
9.2.3 System (Zone) Interconnect
1. The system interconnect, more commonly referred to as the zone interconnect, shall show
wiring and communication between systems (or zones).
2. The system Interconnect shall show all applicable network interconnections (i.e., Ethernet
connections from system Ethernet switches to applicable controller (cell) Ethernet switches.
9.2.4 Controller (Cell) Interconnect
1. The controller interconnect shall show the wire and cable interconnections from the PDP
(Power Distribution Panel) to devices and other panels requiring power (i.e., main control
panel, robot controller, motor control panels, etc.).
Figure 9-3 Controller (Cell) Interconnect Example

2. The controller (cell) interconnect shall show the wire, cable, and network interconnections
from the Main Control Panel to the units (stations) main fixture box, operator display
panels, robots, weld controllers, remotely mounted HMI’s, and other Main Control Panels.
9.2.5 Unit (Station) Interconnect
1. The unit (station) interconnect shall show the power and network interconnections to all of
the field devices (e.g., proximity blocks and valve manifolds).

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Note: Individual sensors and actuators connected to input blocks and I/O modules are shown in
Drawing Section F.
Figure 9-4 Unit (Station) Interconnect Example (DeviceNet)

2. Connections to/from other drawing packages shall be shown as dashed and include the
drawing WD name of the referenced package.
9.3 Device ID (Subscript) Designations
1. All electrical devices (Electrical Control Panels, Valve Manifolds, IO Blocks, etc.) defined in a
WD shall have a unique identifier (in most cases this is the ePlan device tag).
2. The identifier shall be a unique 5 character letter number combination plus a suffix. The
first 5 characters will be defined by the WD drawing in which the device is initially defined.
Note: In cases where the 5 character letter number combination is not unique (i.e. R/L or
parallel systems), then an additional identifier may be required. For example, bodyshop systems
may use a B01/B02 designator per GEP-1 to uniquely identify multiple instances of the same 5
letter identifier.
3. The identifier suffix is a letter (or letters) that corresponds to the devices function (refer to
Table 9-1 Cable and Device ID Designations.) plus a unique number. The number, typically
starting from 1 to 9, uniquely identifying panels of similar function within the same system,
controller, or unit drawing (i.e. G1 = Gate Box 1, G2 = Gate Box 2, …etc.). EC panels are
typically numbered with a single digit, IP6x devices are typically numbered with two digits.
Example Power Distribution Panel: (Controller Level)
Defined in Cell Package WD-LD09AG010B01, Cell (AG010)
Device ID Designation for Power Distribution Panel from Table 9-1 (P)
First Panel in Drawing (1)
Device ID = AG010P1

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Example IP6X IO Block: (Unit Level)
Defined in Paint Pretreatment Stage 1A Package WD-SX01PT110, Stage (PT110)
Device ID Designation for IP6X IO blocks from Table 9-1 (BK)
First IO Block in Drawing (01)
Device ID = PT110BK01
Table 9-1 Cable and Device ID Designations
Letter Device/Panel Type
A Material Handling (AMS, SKID) panel
B Spare for user
BC Barcode Junction Box
BK IP6X Standard IO Block
C Main Control Panel (Industrial Hardened PLC)
CAM Camera
CH Chiller
D HMI Panel
Operator Panels (non-HMI), Other Equipment Control
E
Panels
ES Ethernet Switches
F Fixture Box
FMS Flexible Measurement System panel (e.g., Perceptron)
G Entrance Gate Control Panel
H Hydraulic Control Box
HM Hydraulic Manifold
I Do Not Use
IDC Integrated Drives (IP6x VFD or Motor Starter)
J Junction Box
K Spare for user
L Stack Lights
LC Light Curtain, Operator or Robot DLD
LCX Light Curtain, Inter-cell
LCG Light Curtain, Perimeter Guard
LCP Light Curtain, Pinch Point Guard
LSR Laser Interface Panel
M Motor Controller, VFD, Inverter
MC Marking Controller (e.g., SIC, Telesis, etc.)
MQ Marquee
N Nut Feeder J box
O Do Not Use
P Power Distribution Panel
Process PC (i.e., industrial PC, PC/monitor combination,
PC
etc.)
PGT Programming Terminal
PLS Programmable Laser Scanner
PM Pneumatic Manifold - Valve Manifold
PWS IP6X 24VDC Power Supply

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Letter Device/Panel Type
Q Do Not Use
R Robot Control Panel
S Station to Station Interlocks
SBK IP6X Safety IO Block
SM Operator Safety Mats or IP6X Modular IO Modules
SMG Perimeter Guard Safety Mats
SMJ Safety Mat Junction Box
T DeviceNet Tee, Power Tee, Control Transformer
TC Torque Controller
TR Welding Transformer
U Do Not Use
V Spare for user
W Weld Controller Panel
Y Robot Densification Pack Junction Box
Z VIN Controller

9.4 Cable Labeling

9.4.1 Hardwired Cable Labeling
1. The cable outside the panel shall be labeled at each end with source device designation and
destination device designation. A period may be used as a separator within either the
source or destination designation. The period separator is required (typically on the source
side) when multiple devices are available to terminate connections.
2. Line voltage (380 – 575 V) wires that terminate directly on fuse blocks or breakers inside the
PDP panel shall be labeled with the source device phase and destination device designation.
Example - Wires internal to the cabinet on E164CB from robot BA020R1:
E164L1-BA020R1
E164L2-BA020R1
E164L3-BA020R1
PE-BA020R1

Example – Cable External to the cabinet BA010P1 to robot BA020R1:

BA010P1.E164CB-
BA020R1

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Figure 9-5 Line Voltage Cable Tagging

9.4.2 General Cable Labeling

1. Control cables shall be labeled with source designation followed by the destination
designation. A period may be used as a separator within either the source designation or
the destination designation, or both. A period should be used as a separator to identify the
connection point of the cable for a particular device or panel.
Example:
SourceDevice(or Panel)Name.ReceptacleName –
DestinationDevice(or Panel)Name.ReceptacleName
Figure 9-6 Control Cable Example

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2. The format of the cable label shall be:
a. 1st line: Source designation separated by a period and followed by a dash (i.e.,
BA010P1.HAC1 -)
b. 2nd line: Destination designation separated by a period. (i.e., BA010C1.HAC)
3. The receptacle name and the period separator for the destination designation may be
suppressed under the following conditions.
a. There is only one unique location for the cable to connect on the panel/device.
b. The cable can connect to multiple locations on a device/panel with no change in
function. (i.e. DeviceNet Tap boxes, Power Tap boxes)
4. If a device name does not include the unit (station) identification, then a period separator
shall be used to precede the device name with the station/unit name. No more than one
period shall be used as a separator within any source designation or destination designation.
Devices that include the unit (station) number in their name do NOT require the unit
(station) name to be added to their designation a second time.

Example – Unit (Station) Included in both the source and destination:

Source (Unit (Station))Name.DeviceName –
Destination (Unit (Station))Name.DeviceName

(Cable between Units (Stations))

BA020.BK02 – (Station BA020 IO Block 2)
BA030.PM1 (Station BA030 Pneumatic Manifold 1)

Example – Unit (Station) Included in destination only:

SourceDeviceName.ReceptacleName –
Destination (Unit (Station))Name.DeviceName

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Figure 9-7 Cable Label Example

5. Auxiliary Power or Output Power connections on field devices such as valve manifolds,
input/output blocks, vacuum pumps, and water savers shall be designated as “PWR”. Cables
connecting to these devices shall NOT be labeled with this receptacle name, except where
multiple cables would be named identically if the receptacle name were not used.
6. Auxiliary Power or Output Power connections in a linear (pass through) topology shall be
designated as “PWRIN” and “PWROUT” for IP6x field devices or per the panel receptacles
(i.e. “DCIN” and “DCOUT”) for EC’s. Cables that are required to be labeled with these
receptacle names shall not include the “IN” or “OUT” suffix. See Figure 9-10 for example.
7. If the cable is shown only for reference purposes and not listed in the drawing package
BOM, it shall be shown as dashed lines.

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Figure 9-8 Showing Referenced Cables

8. For interlocking cables between cells or systems, the cable from the upstream (previous)
system or cell shall be shown with solid lines and listed on the system or cell’s drawing
package BOM. The cable to downstream (next) system or cell shall be shown with dashed
lines and not listed on the drawing package BOM. Ethernet cables from a controller
Ethernet switch to a system Ethernet switch are typically purchased on the system (zone)
drawing package.
9.4.3 Multi-Drop Power Cable Naming
Power cables installed in a trunk line drop line topology or a linear (pass through) topology shall
have a multiline tag in the following format:
1. The first line of the cable tag shall have the power source, either the originating panel
receptacle name or the IP6X Power Supply name; a period separator shall not be used in the
power source name.
Exception: Dual IP67 power supplies with multiple independent power outputs shall use a
period separator following by the specific source on device (e.g. DC1, DC11, etc.) in the power
source name.
2. After the power source name the label shall include the source device designation and
destination device designation. A period is not typical but may be used as a separator
within either the source or destination designation.
Example:
Power Source Name
SourceDeviceName – DestinationDeviceName

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Figure 9-9 Multi-Drop Power Label Example – Trunk/Drop Topology

Figure 9-10 Multi-Drop Power Label Example – Linear Topology

Note: The use of a linear power topology is intended to be used only in conjunction with a linear
network topology (i.e. linear EtherNet/IP network). Any other use of a linear power topology
requires GM Controls Project Engineer approval.

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3. If a device name does not include the unit (station) identification, then a period separator
shall be used to precede the device name with the station/unit name.
Figure 9-11 Multi-Drop Power Label Example – Unit Identification

9.4.4 DeviceNet Cable Naming

DeviceNet cables shall use a multiline tag format according to the following requirements:
1. The first line of the cable tag shall have the network name, typically the originating panel
receptacle name; a period separator shall not be used in the network name.
2. After the network name the label shall include the source device designation and
destination device designation. A period is not typical but may be used as a separator
within either the source or destination designation.
Example:
Network Name
SourceDeviceName – DestinationDeviceName
3. No more than one period shall be used as a separator within any source designation or
destination designation. Devices that include the station/unit number in their name do NOT
require the station/unit name to be added to their designation a second time.

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Figure 9-12 DeviceNet Example, Period Separator Not Required

4. DeviceNet Tees in the controller package that are uniquely numbered (i.e. T151, T152, T251,
etc.) do NOT require the station/unit name to be added to their designation.
5. If a panel has multiple locations to plug a DeviceNet cable connection then a period
separator shall be used to designate connection to that panel.
Figure 9-13 DeviceNet Cable Label Example

9.4.5 Ethernet Cable Naming

1. Ethernet cables in a star topology shall use a source-destination labeling.
2. For IP6X Ethernet switches the source shall be EthernetSwitchName.PortNumber, for IP20
Ethernet switches, the source shall be DeviceName.ReceptacleName

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3. Ethernet devices with only a single port do not require the port number / receptacle name
to be specified.
Example:
EthernetSwitchName.PortNumber-
DestinationDeviceName
Figure 9-14 Ethernet Cable Label Example – Star Topology

4. Ethernet cables in a linear topology shall have a multiline tag format. The first line of the tag
shall identify the switch name and port. The remainder of the tag shall include the source
designation and the destination designation.
Exception: Cables in linear networks with no Ethernet switch only require source and
destination designations.
Example:
EthernetSwitchName.PortNumber
SourceDeviceName.ReceptacleName-
DestinationDeviceName.ReceptacleName

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Figure 9-15 Ethernet Cable Label Example – Linear Topology

9.4.6 Receptacle Naming

For unique receptacle naming, use the letter designations specified in Table 9-1. For non-
specific generic receptacles which supply AC or DC voltage to devices use the following
designations:
Table 9-2 Standard Generic Receptacle Naming ID’s
ID Description Examples
AC AC voltage (i.e., 120 V) AC1, AC2, AC3
HAC “Hot” AC (120 V Excepted Circuit Power) HAC1, HAC2, HAC3
BRK Connection for Motor Brake BRK, BRK1, BRK2
CS Cycle Start PB connection CS1
DB Connection for VFD dynamic brake resistors DB
DC DC voltage (i.e., 24 V) (Powered on One Set of Pins) DC1, DC2, DC3
DD* DC voltage (i.e., 24 V) (Special Case, Dual Power) DD1, DD2
DN DeviceNet Connection (Non MCP Applications) DN1, DN2, DN3
D DeviceNet Connection (Connection to MCP) D01, D02, D03
EN Ethernet EN1,EN2, EN3
ES Emergency Stop PB connection ES1

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ID Description Examples
HDC “Hot” DC (24 V Excepted Circuit Power) HDC1, HDC2, HDC3
MJ* Major Motion. Output power to enable major motion. MJ1, MJ2, MJ3
MN* Minor Motion. Output power to enable minor motion. MN1, MN2, MN3
M Connection for Motor M, M1, M2
Single Channel Input. Panel receptacle used to connect single
P P1, P2
channel devices.
P 3 Phase Power Input or Output P, P1, P2
Safety Device: Safety device (can be used for light curtains, laser
SD* SDE1
scanners, or safety mats).
Dual Channel Safety Input. Panel receptacle used to connect Dual
S S1, S2
Channel Safety Devices.
Safety Input Connection. Receptacle Connection for Panels designed
SI SI, SI1, SI2
to be plugged directly into IP6X Safety IO modules.
Safety Output Connection. Receptacle Connection for Panels
SO SO, SO1, SO2
designed to be plugged directly into IP6X Safety IO modules.
Safeties Clear Minor: Output power after safety devices (light SCMN1, SCMN2,
SCMN*
curtain, laser scanner, safety mat) are clear for Tool Minor motions. SCMN3
Safeties Reset Minor: Output Power after safety devices (light
SRMN1, SRMN2,
SRMN* curtain, scanner, safety mat) are clear and reset for Tool Minor
SRMN3
motions.
Safeties Reset Major: Output Power after safety devices (light
SRMJ1, SRMJ2,
SRMJ* curtain, scanner, safety mat) are clear and reset for Tool Major
SRMJ3
motions.
User Motion: Output power configured as user requires (i.e., Tool
UM UM1, UM2, UM3
Minor or Major, with or without light curtains).

* Note: These receptacle ID’s are phasing out as the use of IP6X devices replaces the use of
fixture junction boxes.

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9.5 DeviceNet Networks
9.5.1 Overview
DeviceNet may be used for remote I/O communication networks. DeviceNet is also used for
DeviceNet-Safe communication over the same media when equipment is designed with the
Safety PLC. DeviceNet-Safe uses CIP Safety (Common Industrial Protocol) over DeviceNet which
includes the message arrival time assurance and data crosschecking functions. Both safe I/O
and standard I/O may share the same network. But, there are additional limitations that must
be realized on the shared DeviceNet network as indicated in the sub-sections below.
Note: The use of DeviceNet or EtherNet/IP for I/O varies based on the vintage of Common
Controls Architecture and is determined by the Project Lead Engineers and Managers.
All aspects regarding DeviceNet shall conform to the Open DeviceNet Vendors Association
(ODVA) guidelines and specifications, Rockwell DeviceNet Media Design and Installation Guide
(Pub. DNET-UM072C-EN-P) and any chosen manufacturers recommended wiring methods.

Strict attention shall be placed on each network segment for trunk/drop cable length and power
consumption. For each DeviceNet network, the responsible GM Controls Project Engineer shall
approve power consumption and cable length before DeviceNet construction may begin.
CAUTION: DeviceNet network is not rated for use in hazardous environments, such as Class 1,
Division 2 applications.
9.5.2 DeviceNet Scanner
When using DeviceNet, the Rockwell Allen-Bradley DeviceNet Scanner shall be used for the
remote I/O communications.
Exception: Robots have their own DeviceNet communication scanner for robot end-of-arm
devices (i.e., valves, switches).
9.5.3 DeviceNet Baud Rate
1. Safety PLC Architecture - The DeviceNet baud rate setting shall be 250 kbit/s. The
DeviceNet-Safe safety network requires the baud rate to be at least 250 kbit/s to satisfy the
required safety network response time requirements of the system. Both non-safety
(standard) I/O and safety I/O shall be set to 250 kbit/s to maintain standard baud rates.
2. Non Safety PLC Architecture (2C Architecture, SEP (Scalable Error Proofing)) - The DeviceNet
baud rate setting shall be 125 kbit/s. The maximum DeviceNet communication scan time
shall be 50 ms.
3. Robot Networks – The DeviceNet baud rate setting shall be 500 kbit/s for robot end of arm
tooling and robot controlled peripherals.
9.5.4 DeviceNet Node Requirements
1. It is recommended not to exceed 20 nodes per scanner (even though DeviceNet network
architecture allows for 64 nodes). Limiting to 20 nodes minimizes the possibility of
exceeding the maximum overall drop length of the network and keeps the network to a
manageable size for ease of maintenance and troubleshooting.

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a. The type of device and number of communication bytes required will also determine the
number of nodes on the network. A simple I/O block may only require 2 words (4 bytes)
of communication, whereas, a bar-code reader may require 8 words (32 bytes) of
communication.
b. DeviceNet scanner module(s) should be added if additional nodes are required.
Exceeding the limits on nodes per scanner module requires approval of the GM Controls
Project Engineer.
c. No more than 50 safety nodes shall be controlled by a single safety PLC.
2. For safety PLC architecture networks where the safety modules input RPI’s are 15 ms and
the output RPI’s are 30 ms (typical tooling settings).
a. Maximum of 10 safety nodes per network is allowed.
b. Maximum of 20 nodes (safety + standard) per network is allowed.
c. Exceeding these limits requires the approval of the GM Controls Project Engineer.
3. For safety PLC architecture networks where the safety modules input RPI’s are 30 ms and
the output RPI’s are 60 ms (typical conveyor settings).
a. Maximum of 15 safety nodes per network is allowed.
b. Maximum of 30 nodes (safety + standard) per network is allowed.
c. Exceeding these limits requires the approval of the GM Controls Project Engineer.
4. For standard PLC networks (2C Architecture)
a. Maximum of 30 nodes per network is allowed.
b. Exceeding these limits requires the approval of the GM Controls Project Engineer.
5. For standard PLC networks (SEP systems)
a. Maximum of 35 nodes per network is allowed.
b. Exceeding these limits require the approval of the GM Controls Project Engineer.
6. The following tables shall be used as a guideline to assign DeviceNet node numbers.
Table 9-3 General DeviceNet Node Allocation (Bodyshop and Press)
Node Primary Usage
0 DNet Scanner
1-2 DO NOT USE
3-4 HMI’s (Safety IO)
Other Controller/Cell Level Safety IO Devices (Gate Boxes,
5 - 10
Perimeter Guards, IP6X Safety IO, etc.)
11 - 20 Robot Controllers (Safety or Standard Connections)
Operator Interface Panel IO (Fixture Boxes, Run Stands, Light
21 - 29
Curtains)
30 - 39 Tooling inputs (Non-Safety) (BKx) (IP6X I/O blocks, etc.)
40 - 49 Tooling Outputs – (Non-Safety)(PMx) (valves, etc.)
Other Panels and Devices (VFD’s, Motor Panels, Integrated
50 - 59
Drives).

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Node Primary Usage
60 - 61 EPS Blocks (4 bytes max)
62 DO NOT USE
63 DO NOT USE

Table 9-4 DeviceNet Node Allocation (Paint)

Node Primary Usage
0 DNet Scanner
1-2 Spanner Modules for Interlocks
3-8 HMI’s (Process and Conveyor)
9 - 10 Spare
11 - 30 Motor Starters
31 - 40 Digital IP6X IO Blocks (BKx)
Analog IP6X IO Blocks (SMx) (Reserve < minimum 2 Nodes Space
41 - 50
for Each Block)
51 - 61 Other Panels (ECS and EC)
62 DO NOT USE
63 DO NOT USE

Table 9-5 DeviceNet Node Allocation (Conveyors)

Node Primary Usage
0 DNet Scanner
1-2 HMI’s (Safety IO)
3-4 Gate Boxes
5–8 Perimeter Guard
9 – 20 IP6X Safety IO (SBKx) (Estops, End Of Travel, Contactor Boxes)
21 – 39 Integrated Drives and Miscellaneous Associated Devices
40 - 49 IP6X IO Blocks (Non-Safety) (BKx)
50 - 60 Other Panels
61 DO NOT USE
62 DO NOT USE
63 DO NOT USE

Table 9-6 DeviceNet Node Allocation (Medium Automation 2C Architecture)

Node Primary Usage
0 DNet Scanner – Compact Logix
1-9 Spare
10 - 44 Tooling Nodes (Input Blocks and Output Devices)
45 - 63 DO NOT USE (Compactlogix Scanner Only Supports 90 Dints)

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9.5.5 DeviceNet Component Requirements
1. DeviceNet devices shall be connected to a drop line or directly to a “tee” or multi-port tap
box that is connected on the trunk line of the DeviceNet network. This will allow
replacement of the device without disturbing the trunk-line communication.
2. All tooling mounted devices shall be factory-wired, self-contained, pressurized waterproof,
and immune to the welding environment in compliance to IP6X rating (IP65 minimum for
tooling mounted devices).
3. Devices are typically configured for polled messaging. DeviceNet-Safe I/O modules are
configured for Cyclic messaging. COS (Change Of State) messaging may be used in only
approved applications. Reference the GCCS-2 for more information.
4. All DeviceNet products must be interoperable and approved by the ODVA (Open DeviceNet
Vendors Association).
5. Node addresses for DeviceNet devices shall be switch configurable with separate switches
or an auto-baud detection feature for setting the node baud rate.
Note: The use of non-switch node addressable devices shall require the approval of the
responsible GM Controls Project Engineer.
6. A 121 Ohm, ¼ W termination resistor (molded 5-pin connector with integrated resistor) shall
be provided at each end of the DeviceNet trunk. Wire resistors inside panels shall not be
used for network termination unless approved by the GM Controls Project Engineer.
7. Reference GCCB-1 Build Specification for all mounting, cabling and wiring specifications of
field components.
9.5.6 Device Identification Methods
The 1st network’s tees shall be designated series numbers between 100 and 199. (The 2nd
network’s tees shall be designated series numbers between 200 and 299 …etc.). When the MCP
is a drop from the trunk, it is recommended to designate the MCP tee as the middle number in
the series (i.e., T150). Then, designate the tees to the left of T150 starting with T149
decrementing down. Designate tees to the right of T150 starting with T151 incrementing up.
Tees added to an existing network may be identified with a subscript (i.e. T155A) or may be
numbered out of order (i.e. T155, T180, T156) to prevent having to renumber and retag all
devices on the network.

All DeviceNet nodes shall have a clearly visible identification tag (Reference GCCB-1 for
approved tag material) located adjacent to, but not on, the DeviceNet node and shall contain
the following information:
1. DeviceNet Node Labeling
a. Network I.D. xxxxxDyy
(xxxxx = Controller, yy = DeviceNet scanner slot location)
b. Device Designator (BK01, PM1)
c. Node #

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2. DeviceNet Tee Labeling
a. Network I.D. xxxxxDyy
(xxxxx = Controller, yy = DeviceNet scanner slot location)
b. Tee #
9.5.6.1 SEP Cable and Tag Identification
SEP networks shall have distinct color coded tape at every tee along with tagging to help
differentiate the networks. Every SEP trunk tee shall have a color coded placard (ideally
matching network color) indicating the network and number of the given tee. If that cannot be
achieved then use a consistent placard color for SEP networks. Minimum tag size is 120 mm
width and 70 mm height. Minimum font size is 12 mm height. Consult with conveyor group to
make sure colors are not duplicated.
Table 9-7 Example of SEP Multi-Network Color Designation
Network Background Color Text Color
D0 Orange Black
D1 Blue White
D2 Green Black
D3 Purple White
D4 White Black
D5 Red Black
D6 Yellow Black

Figure 9-16 Example of SEP Colored Tape and Colored Tag

9.5.7 DeviceNet Cable Requirements

1. Use the GCCL (Global Common Components List) for approved DeviceNet trunk cables, drop
cables, and associated tees and connectors.
2. “Thick” cable shall be used for Trunk cable. Exception: High flexing applications shall use
“thin” cable or an approved high flex equivalent to “thick” cable. If “thin” cable is used for
high flex applications on the trunk, it shall be the end of the trunk with a current draw not to
exceed that of the “thin” rating (3 A).

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3. Molded DeviceNet cable shall be used. Exceptions shall be approved by the responsible GM
Controls Project Engineer.
4. DeviceNet cables shall not be connected end to end, select the proper length cable for the
application.
5. No more than two tees shall be connected together. If more connections are required, then
a 4 or 8 multiport tap box shall be utilized.
6. DeviceNet receptacles should be used when entering/exiting control enclosures. The
NEMA/IP rating of the enclosure shall not be compromised.
7. Adequate space shall be provided between receptacles located on the enclosure to allow for
easy access of connecting/disconnecting the DeviceNet cable.
8. Unnecessary strain and extreme cable bends shall be avoided. The bend radius shall not be
less than 10 times the cable diameter.
9. A means to connect a diagnostic monitor to each network without breaking the network
shall be provided at the Main Control Panel. This is typically an unused port from a nearby
tee which is covered with a protective cap.
Note: It is unacceptable to connect a tee directly on a panel-mounted receptacle. Past practice
has shown this to be a source of a common failure point due to stresses imposed by the trunk
cable.
10. On very large networks (Trunk length > 200 m), a means shall be provided to connect a
diagnostic monitor to the network at the point on the network furthest from the Main
Control Panel.
9.5.8 DeviceNet Cable Layout
1. Trunk Topology: The trunk topology may incorporate direct drops to a device, a single drop
from a tee, or the use of a tap box which provides for multiple node connections from a
single tee. Nodes may also be daisy-chained on a drop. But, it is important to limit the total
drop length from the trunk to the end device to 6 m, including any length in enclosures.
Figure 9-17 DeviceNet Trunk Topology

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2. Calculating Network Length: When calculating the total network length, the maximum
distance would be between 2 terminating resistors as shown in the 1st illustration below.
However, most of the installations will probably have the terminators connected directly to
the end of the last tee or tap. In this case, the drop length of that last device must be used
instead of the distance between the tee and the terminating resistor.
Figure 9-18 Calculating DeviceNet Network Length

3. Calculating Cumulative Drop Length: The following example uses 4 DeviceNet tees on the
trunk and multi-port tap boxes on 2 of the tees. The cumulative drop length is 42 m. This
network would allow a data rate of 125 kbit/s (156 m max) or 250 kbit/s (78 m max) baud.
But, it would not support a data rate of 500 kbit/s (39 m max).

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Figure 9-19 Calculating DeviceNet Accumulative Drop Length

4. The DeviceNet cable rating is typically rated at 300 V. Both the trunk and drop lines shall be
kept at a minimum distance of 76 mm from power cables. Reference GCCB-1 Build
Specification for DeviceNet cable installation requirements.
9.5.9 DeviceNet Cable Length
Cable lengths shall strictly adhere to the ODVA specifications. The specifications are as follows:
Table 9-8 DeviceNet Cable Length
Communication Rate
Cable Type 125 kbit/s 250 kbit/s 500 kbit/s
Max “thick” trunk cable lengths. 500 m 250 m 100 m
Max “thin” trunk cable lengths. 100 m 100 m 100 m
Max drop distance 6m 6m 6m
Max drop cable distance 4m 4m 4m
Cumulative drop cable 156 m 78 m 39 m

1. Network trunk lengths shall not exceed the values indicated in the above table for the
applicable baud rate.
2. The maximum length for a drop shall be 6 m.
Note: This is the maximum length separating a device from the trunk line.
3. To account for any drop distance inside an enclosure, the maximum length for a drop cable
shall be 4 m.
4. The maximum cumulative drop cable length for the entire DeviceNet cable system shall not
exceed the values indicated in the above table for the applicable baud rate.

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9.5.10 DeviceNet Network Cable Labeling
The cable shall be labeled at each end with the network name and the source-destination device
destination. See Section 9.4.4 for examples.
9.5.11 DeviceNet Power Supply
1. The 24 VDC supply to the DeviceNet network shall be from a Class 2 (100 VA) rated power
supply or a larger power supply (i.e., 10 A) with a branch feed to the network which has a
circuit breaker rating no greater than 4 A. The 4 A circuit breaker must meet UL489
requirements (not just a supplementary over-current device).
Figure 9-20 DeviceNet Power Feed (Inside Panel Example)

Figure 9-21 DeviceNet Power Feed (100 VA IP6X Example)

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2. If connecting more than 1 power supply on a network (to compensate for voltage drop over
long distance), connect V- wires from both power supplies together, but, not the V+. Also,
do not jumper the 2nd power supplies V- to SHLD. It will already be grounded at the 1st
power supply’s SHLD connection.
Figure 9-22 More Than One Power Supply on a DeviceNet Network

3. Do not exceed the recommended network length for the rated current values provided by
Rockwell in their DeviceNet Media Design and Installation Guide DNET-UM072C-EN-P.
Example: For single power supply at the beginning of the network, thick cable: max length
is 140 m at 2.14 A or 80 m at 3.59 A.
9.5.12 DeviceNet System Grounding
1. The DeviceNet cable system shall only be grounded at one location per network.
2. The DeviceNet network shall be grounded at the designated “SHLD” terminal with a 10 mm2
(#8 AWG) green w/ yellow conductor.
Exception: The Rockwell IHPLC (PLC-in-a-Box) uses a 4 mm2 (#12 AWG) green w/ yellow
conductor from the PE terminal to the DeviceNet scanner.
3. The “SHLD” terminal shall also be jumpered to the “V-“ terminal. The neutral of the
DeviceNet 24 VDC power supply for the network is connected to the V- terminal. To prevent
ground loops, do not connect the DeviceNet power supply 24 VDC neutral directly to
ground. Connecting the neutral to the “V-“, which in turn is connected to ground, creates
one point of ground reference. (Refer to Figure 9-23 below.) For DeviceNet networks with
more than one power supply, the grounding terminals of additional PowerTaps or power
supplies shall not be connected to an earth ground.

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Figure 9-23 DeviceNet Grounding at the Scanner Module

4. Additional grounding shall not occur as a result of mounting or the installation of a

DeviceNet node. DeviceNet nodes shall never include (internally or externally) a direct
ground to the V- or shield connections.
Note: The provision of such a ground will cause ground loops and erratic operation.
9.5.13 DeviceNet Auxiliary Power
Output power for DeviceNet products is separate from the DeviceNet 24 VDC power. This
“auxiliary” power shall be supplied through a separate 4-pin mini interface per the CIP physical
layer specification described in section 11.10 and Figure 11-17.

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9.6 Ethernet Networks
9.6.1 Overview
EtherNet/IP shall be used for PLC to PLC, PLC to robot, and PLC to other process equipment.
EtherNet/IP is also typically used for PLC to RFID, barcode, and camera systems. EtherNet/IP
may also be used for remote I/O communication networks. Both standard I/O and safety I/O
(using CIP safety) may share the same network.
Note: The use of DeviceNet or EtherNet/IP for I/O varies based on the vintage of Common
Controls Architecture and is determined by the Project Lead Engineers and Managers.
9.6.2 Ethernet Communication Layer
1. Upper level systems (IT) is referred to as the PFCN-GPN (Plant Floor Control Network-
General Purpose Network).
2. The equipment level Ethernet networks are referred to as the PFCN-IECN (Plant Floor
Control Network-Industrial Ethernet Controls Network).
3. Ethernet/IP explicit messages utilize the Common Industrial Protocol (CIP) to communicate
from the PLC to the HMI and the PLC to upper-level systems for build data, fault messages,
down-time data, and program archiving (Upload-Download-Compare). Explicit messages
are also used to provide programming terminal access to PLC’s and HMI’s. This
communication is non-time critical (explicit messaging), it is point-to-point communication
using the TCP (Transmission Control Protocol), and it is sometimes referred to as “green”
path traffic.
Note: CIP was formerly known as ‘Control and Information Protocol’ and was later changed to
‘Common Industrial Protocol’.
4. EtherNet/IP control signal communication is based on UDP/IP (User Datagram
Protocol/Internet Protocol). It’s used for PLC-to-PLC peer-to-peer communication. This
communication is used for time critical (implicit messaging) real-time I/O control and
sometimes referred to as “red” path traffic. Exchange of this time critical messaging is
based on the producer/consumer model where a device is transmitting data (producing) on
the network with potentially many receiving devices consuming this data simultaneously.
EtherNet/IP implicit messaging is also used for PLC to robots, PLC to weld controllers, and
robot to its process equipment (i.e., weld controllers, sealers, vision systems).
5. UDP Unicast, when supported by the devices, shall be used for all implicit messages (real
time, red path traffic).
6. Speed and Duplex shall be 1 Gbit/s Full Duplex or 100 Mbit/s Full Duplex. The speed and
duplex shall be the same at both ends of all Ethernet Connections. This speed and duplex
setting may be hard set or may be set to auto negotiate, depending on the end device and
the industrial Ethernet switch. The setting shall be made according to the appropriate DCDL
template for the Ethernet switch utilized (see section 9.6.4).
9.6.3 Ethernet Hardware
1. All Ethernet switches connected to the plant floor infrastructure (PFCN) shall be managed
switches which have been interoperability tested and approved by IT. Private, isolated,
stand-alone Ethernet networks which are not connected to the PFCN either directly or

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indirectly (i.e., robot controller to private robot IO such as robot end of arm tooling) may not
require managed switches.
Note: Private, isolated Ethernet networks with unmanaged switches shall not be connected to
the PFCN. Consider this if future PFCN connectivity may be required.
2. A single brand of Managed Ethernet switches shall be used for each IECN network. A single
firmware block point shall be used for all switches on each IECN network.
Note: This may preclude mixing certain models of switches on the same network.
3. Industrially and environmentally hardened (IP65 minimum) switches shall be used for all
IECN networks. The use of panel mounted switches (IP2X) requires the approval of the GM
Controls Project Engineer.
4. The Ethernet cable connection from plant floor equipment to the upper-level systems (PFCN
IT Telecommunications Closet) is made through a punch-down box. This box is where the
transition from an 8 wire commercial drop cable to the 4 wire (100 Mbit/s) or the 8 wire (1
Gbit/s) industrial Ethernet cable occurs. This box is also where the transition from RJ45 to
M12 connector scheme is made. The box and any associated hardware required to make
the transition shall be provided as part of either the system package for system switches or
the controller package for directly connected controller switches.
Figure 9-24 Punch-Down Box (Redundant Uplink) – Individual Parts

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Figure 9-25 Punch-Down Box (Redundant Uplink) – Pre-Assembled Parts

5. Ethernet cable length shall not exceed 100 m between devices (receptacle length inside
control panels shall be included in the total length).
6. Only 1 uplink connection is required from the IECN to the PFCN-GPN if the uplink is not used
for ‘red path’ (real-time implicit messaging) traffic.
7. 2 uplink connections (redundant) from the IECN to the PFCN-GPN are required when ‘red
path’ traffic (real-time I/O) is sent over the PFCN-GPN.
8. Ethernet connections between equipment on the plant floor shall be made with 4-pin M12
D-code pre-molded CAT5e male-male cables for 100 Mbit/s or with 8 pin M12 X-code pre-
molded CAT5e male-male cables for 1 Gbit/s. These are available in various lengths listed
on the GM GCCL.
Figure 9-26 Industrial Hardened Ethernet Switch with Pre-Molded Cables

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9. A female 4-pin M12 D-code panel mount receptacle for 100 Mbit/s or a female 8-pin M12 X-
code panel mount receptacle for 1 Gbit/s to a RJ45 connector shall be provided to connect
cables to Ethernet devices that are on the inside of the panel. These are available in various
lengths listed on the GM GCCL.
Figure 9-27 4-Pin Ethernet Panel Mount Receptacle

10. Industrial Ethernet cable crossover cables shall not be used. The cable crossing feature of
IECN switches shall be used in combination with a straight-through, industrial Ethernet cable
when connecting two IECN switches together. The feature is disabled on the uplink port of
the lower IECN switch and enabled on the downlink port of the upper IECN switch. The
uplink to the PFCN should have this feature set to enable.
11. Two levels of Switches are used in GM IECN Ethernet Networks:
a. System (Zone) Switch – Managed switch uplinked to the plant infrastructure. System
switches are typically used to connect multiple controller level switches to allow
interlocking. End devices are not typically connected directly to system switches.
System expanded switches are not typical and shall require the approval of the
responsible GM Project Controls Engineer.
b. Controller (Cell) Switch – Managed switch typically uplinked to a system switch. If
interlocking between controller switches is not required, controller switches should be
uplinked directly to the plant infrastructure. Controller switches may be expanded.
• Controller switches connected directly to the plant infrastructure are commonly
referred to as Controller Direct Switches.
• Controller switches connected below other controller switches are commonly
referred to as controller expanded switches. These switches are used to expand the
capacity (number of ports and distance) of a single controller switch.

12. At least one spare (unused) port per switch should be provided for all controller and system
switches. IECN switches should not have more than 8 spare ports.
Exception: Additional spare may be provided to accommodate planned future equipment.
13. Ethernet switch levels from the PFCN shall be limited to no more than 3.

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Figure 9-28 Ethernet Switch Expanding Limit

14. The maximum number of end devices (IP addresses) in the public address space below a
system switch or controller direct switch is 250.
15. All industrial Ethernet controls networks shall be 12x.yyy.zzz.0/24 (subnet mask is
255.255.255.0).
16. The maximum number of controller switches below a system switch or a controller direct
switch is 20.
17. PLCs shall not be connected to controller expanded switches.
Exception: PLCs may be connected to controller expanded switches in the case of a controller
direct switch arrangement.
18. All controller expanded switches shall be connected to the main controller switch; do not
“Daisy Chain” controller expanded switches.
Exception: Controller direct switches may have up to two levels of controller expanded switches
for a total of 3 levels from the PFCN.
19. When interlocks need to be exchanged between two PLCs that are connected to separate
system switches an additional Ethernet interface card should be added to one of the PLC’s
chassis. The additional card is connected to one of the switches on the other system’s
network and assigned an address on that network.
Exception: Interlocking over the PFCN may be used with the approval of the responsible GM
Controls Project Engineer.

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Figure 9-29 Interlocks Between PLCs on Separate Systems

20. A controller switch that does not share interlocks with any other controller switches shall
not be connected to a system switch with other controller switches.
Exception: Controller switches or small groups of controller switches that do not share red-path
interlocks may be connected together under a system switch to minimize the number of uplinks
to IT (reduced cost). All of the following requirements must be met.

a. The controller switch is within 60 m of the system switch.

b. The system switch has enough open ports to accommodate the additional controller
switches.
c. The limits on the maximum number of controller switches and end devices are not
exceeded.
d. The controller switch is 8 ports or less.

This exception requires the approval of the GM Controls Project Engineer.

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9.6.4 Ethernet Configuration
1. All Ethernet switches and devices shall be configured to the latest specified blockpoint. This
will be provided for each project by the GM Controls Project Engineer.
2. Ethernet devices shall utilize public IP addresses unless all the requirements of section 9.6.6
are met.
Exception: Applications with addressing schemes defined in standard WDT or WDS template
shall adhere to the respective template.
3. Public IP addresses are assigned by Plant location. These are obtained from the Plant IT
Manager by the GM Controls Project Engineer. In general, the addresses follow the
convention listed below:
120.X.Y.Z – North America
121.X.Y.Z – Europe
122.X.Y.Z – Asia Pacific
123.X.Y.Z – China
124.X.Y.Z – LAAM

X = “odd” number octet for IECN networks, “even” number octet for GPN networks
Y = unique network assigned to a given TC
Z = unique value for each end device
4. All addresses in the public space meet the following requirements:
a. All subnet masks are 255.255.255.0
b. Switch IP addresses begin with .4 or higher
c. End device IP addresses begin with .30 or higher
d. IP addresses shall not use .255
5. The site needs to know in advance all public devices that will be connected to the PFCN. The
GM Controls Project Engineer is responsible for ensuring completion of the Ethernet DCDL
(Data Communications Device Listing). This document tracks the Device Name, location,
and MAC ID. I/O devices in the private address space are excluded from the DCDL and are
captured in the controls WD’s. The Ethernet DCDL templates are specific to switch type or
model and are accessible on the GM Website at:
https://supplier.body.gm.com/crw/production/main/globalStandards/csEtools.cfm

Figure 9-30 Example Ethernet DCDL

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9.6.5 Ethernet Interconnect
1. The Ethernet interconnect for the system (zone) shall be shown in the system level WD,
Section CE.
2. The Ethernet interconnect for the controller (cell) shall be shown in the controller level WD,
Section CE.
3. The Ethernet interconnect for the unit (station), if applicable, shall be shown in the unit level
WD, Section C.
4. The Ethernet interconnect shall show cable naming and balloon item numbers for the
associated cables and enclosures.
5. IP addresses, source switch ports, and Device DNS names shall be shown in the Interconnect
section of the WD Drawings. The DNS naming shall follow the format described in the “GM
Common Plant Floor Ethernet Device Naming Standard.”
Note: DNS names are required for devices in the public address space only. Devices in the
private address space may use standard device ID’s as defined in section 9.3.
Figure 9-31 Public Ethernet Device Tagging

6. At least one port per controller switch shall be designated as a programming port. A cable
shall be provided and the port shall be set to assign an IP address via DHCP using the
appropriate switch configuration eTool.

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Figure 9-32 Ethernet Interconnect Example

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9.6.6 Ethernet I/O (Private Network Devices)
Ethernet devices may utilize the private IP address space (192.168.1.xxx) only if all of the
following apply:
a. The device does not require setup, backup, restore, monitoring, and/or maintenance via
the programming terminal.
b. The device communicates only with the PLC under the local controller Ethernet switch.
c. The device does not require access to the upper-level plant network.
d. The device does not require any connection or access outside of the local controller
Ethernet switch.
Exception: Applications with addressing schemes defined in standard WDT or WDS template
shall adhere to the respective template.

Note: PLC communication cards installed to support private networks in legacy applications
without connected routing shall be privately addressed (see 9.6.6.3).
When EtherNet/IP is used for private I/O devices, the following requirements shall be observed.
9.6.6.1 Network Requirements
1. The network shall be isolated from the rest of the IECN by either:
a. A physical isolation. This is achieved by adding an additional Ethernet card to the
controller (chassis) and connecting all I/O directly to that card (Figure 9-33). This is not
preferred and may impact accessing private I/O from outside of the local chassis.
b. A logical isolation. This is achieved by either:
i. adding an additional Ethernet card to the controller (chassis) and connecting it and
all associated I/O to a logically segregated portion of a managed switch (not
preferred) (Figure 9-34) OR
ii. using a connected routing capable switch and logically routing the I/O in the private
address space to the Ethernet card in the public address space (Figure 9-35). This is
the preferred method of private network isolation.

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Figure 9-33 EtherNet/IP I/O Direct To Chassis

Figure 9-34 EtherNet/IP I/O to a Logically Isolated Managed Switch

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Figure 9-35 EtherNet/IP I/O to a Connected Routing Managed Switch

Note: Connected routing has very specific requirements that must be met before use. See
section 9.6.6.2 for details. The use of connected routing is the preferred method of private
network isolation, the use of other methods must be approved by the GM Controls Project
Engineer.
2. In order to reduce the number of managed switch ports required and to reduce the overall
cabling, a linear topology shall be used for EtherNet/IP I/O wherever possible.
NOTE: Be sure to consider the impact of disruption to downstream devices when using a linear
topology and device in the line is removed or powered down. Generally, this is acceptable since
most systems cannot operate without all devices communicating.
3. Do not use a ring topology. A ring topology is a linear network where a loop or ring is
formed by connecting the last device in the line to the first device. A ring is not allowed
because:
a. A closed ring introduces configuration challenges.
b. All devices may not be ‘DLR’ (see 9.6.6.5) even if they are two port devices.
c. There are logistical challenges with closing the ring on physically large (long run)
networks.
4. Do not mix devices in the public address space and devices in the private address space on
the same linear network.
5. Linear public networks are allowed only for like devices (e.g., multiple HMI’s) or for
preapproved combinations (e.g., SCA dispense controller).

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Figure 9-36 Linear Network Topology

6. A linear network shall not have more than 25 devices.

7. A switch used for both private and public devices should have the public devices at the
lowered number ports and the private devices at the higher number ports to maintain
consistent arrangement of public and private devices.
8. A diagnostic port shall be provided at the controller for connection to the private network
with a PC or other diagnostic device.
Note: A means to connect with a PC or diagnostic devices is required for every device on the
network. In the case of logical isolation as shown in Figure 9-34, two diagnostic ports would be
required, one in the public space and one in the private space.
9.6.6.2 Connected Routing
Connected routing is a function in the controller or system Ethernet switch where the
communication between public devices (12x IP address space) and private devices (192 IP
address space) is made possible. This function is subject to the following requirements and
limitations:
1. Connected routing is a hardware function of the switch. It is not possible in every switch.
This may limit the use of connected routing, especially in reuse situations.
2. All devices in the 192 address space MUST have their gateway address set to 192.168.1.1.
When hard setting IP addresses via switches (see 9.6.6.5), it is important to verify that the
gateway address is also set. Not all devices set the gateway when the IP address is hard set.
3. All devices in the 12x address space that need to communicate with devices in the 192
address space must have their gateway address set to the controller switch IP address,
regardless of whether the 12x device is on the controller or controller expanded switch.
4. The devices in the 192 space shall communicate only with 12x devices that are connected to
the same controller or controller expanded switch. The routing function shall not extend
beyond the controller switch. See Figure 9-37.

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Figure 9-37 Connected Routing Across Switches

9.6.6.3 Ethernet I/O Into Legacy Cells

As DeviceNet technology becomes obsolete, it may be necessary to utilize Ethernet I/O in legacy
cells (i.e., cells using Ethernet switches without connected routing). To minimize impact to
legacy cells, the following options may be utilized to implement private address Ethernet I/O
into legacy cells without connected routing availability.

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Figure 9-38 Option 1 - Direction Connection to Communication Module

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Figure 9-39 Option 2 - Private I/O Managed Switch

NOTE: Starting with option 1 is recommended where feasible. If I/O needs increase, it is
relatively simple to move from option 1 to option 2.
General requirements/considerations for Ethernet I/O into legacy cells:
1. Options above are intended to be minimally disruptive to existing Ethernet networks
without connected routing only, if connected routing is available, then the options above
are not required.
2. Additional privately addressed communication cards must be added to the chassis to
support the private I/O, communication to the private I/O from existing publicly addressed
communication cards will not be possible.
3. Node limit for an isolated private network is 100 nodes.
4. If a private I/O switch is required, then it shall be a managed switch.
5. Private I/O switches may be expanded to no more than a total of two layers.
6. Same linear network rules described in 9.6.6.1 apply.
9.6.6.4 Address Requirements
1. Private address requirements:
a. Private networks shall use the 192.168.1.x range for IP addresses.
b. Address 192.168.1.1 is reserved for the gateway address and shall not be used as IP
address.
c. Subnet mask shall be 255.255.255.0

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2. Each private network has 255 IP addresses (253 usable, 192.168.1.2 – 192.168.1.254). Limit
each address range to no more than 250 devices (IP addresses).
3. Where multiple private networks exist on the same controller (i.e., PLC, robot) they shall not
use duplicate private addresses even if the networks are isolated. Controllers requiring
duplicate addresses (more than 250 devices) require GM Controls Project Engineer
approval.
4. Addresses may be duplicated from controller to controller. (i.e., every material handling
robot may use the same addresses for I/O blocks).
Figure 9-40 IP Address Strategy

5. The following table shall be used as a guideline to assign private IP addresses:

Table 9-9 General Private IP Address Allocation Guideline
Address Primary Usage
0 DO NOT USE
1 DO NOT USE – Reserved for Gateway Address
2 - 10 Ethernet Switches (Private, Managed Switches)
11-20 Controller Ethernet Card (i.e. EN2T Card)
21-50 Reserved
Controller/Cell Level I/O Devices (Gate Boxes, Perimeter Guards, PB
51 - 100
Boxes, IP6X Safety IO, etc.)
101 - 140 Tooling inputs (Non-Safety) (BKx) (IP6X I/O blocks, etc.)
141 - 160 Tooling Outputs – (Non-Safety)(PMx) (valves, etc.)
161 - 200 Other Panels and Devices (VFD’s, Motor Panels, Integrated Drives)

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Note: Table above does not apply to robot level private networks.
9.6.6.5 Device Requirements
1. Only ODVA certified devices shall be used on GM networks.
2. IP6X (on machine) devices require dual 4 pin, M12, D-code or 8 pin, M12, X-code ports.
3. IP2X (panel mount) devices require dual RJ45 ports.
4. Devices shall support Device Level Ring (DLR) functionality.
5. Devices shall support unicast EtherNet/IP implicit message (real time) communication.
6. Devices shall support hard setting of the IP address in the 192.168.1.x range.
a. Switches (preferably rotary, see Figure 9-41) shall be used to set the 4th octet of the IP
address.
b. The subnet mask shall be set to 255.255.255.0 when using the switches to set the IP
address.
c. The gateway address shall be set:
i. to 192.168.1.1 when using the switches to set the IP address from 192.168.1.2 –
192.168.1.254.
ii. to 0.0.0.0 when using the switches to set the IP address to 192.168.1.1.
iii. programmatically when the switches are not used to hard set the IP address.
Figure 9-41 Preferred IP Address Switches – Example Set to 192.168.1.118

7. Devices shall comply with CIP specifications for power pin out described in section 11.10

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Note: GM Controls Project Engineer approval is required for the use of EtherNet/IP I/O devices
that deviate from the above specifications.
8. It is preferred that devices utilize mini (M22) power connectors and support “pass through”
power (Figure 9-42)
Figure 9-42 Preferred Power Connectors

9. It is preferred that devices include web browser based support for configuring, monitoring,
and troubleshooting.
9.6.6.6 Documentation Requirements
1. Document all private network in the CE section of the controller drawing package or the C
section of the unit drawing package (station robot, etc.).
2. Each private linear network should have at least one drawing sheet. It is not preferred to
include multiple linear networks on the same sheet.
3. Each device shall be tagged with the Device Name, Source Ethernet Switch and Port, and IP
Address.
Figure 9-43 Private Ethernet Device Tagging

Exception: Devices in linear networks with no Ethernet switch do not require source switch and
port.

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9.7 Equipment Grounding (Protective Earthing) & Bonding
Bonding and grounding are not the same; bonding is the connection of two or more conductive
objects to one another by means of a conductor such as a wire. Grounding, also referred to as
“earthing”, is a specific form of bonding wherein one or more conductive objects are connected
to the ground by means of a conductor such as a wire or rod. Thus, proper “grounding” of
objects (conductors) in the field will normally incorporate both bonds between objects and a
specific bond to the earth (ground).

Grounding and bonding of equipment shall comply with the NEC and IEC regulations. The
grounding and bonding section provides a guideline for developing an effective grounding and
bonding design for assembly tooling equipment. This section illustrates how to design and
layout an effective equipment grounding and bonding system for tooling stations and how to
connect the various components within the tooling cell. Regional and local regulations must
also be considered when designing a grounding system.

The following documentation is primarily intended for production assembly systems and does
not cover hazardous or classified locations. Grounding and bonding practices in hazardous or
classified locations shall be in accordance with all applicable local regulations (i.e., NEC articles
500, 501, 504 (intrinsically safe), 514 and other related articles).

9.7.1 Grounding (Protective Earthing)

Grounding is the intentional connection to earth through a ground connection or connections of
sufficiently low impedance and having sufficient current-carrying capacity to prevent the
buildup of voltages that may result in undue hazards to connected equipment or persons. All
grounding must be in accordance with local regulations and the requirements in G-DHS chapter
6 (electrical safety).
9.7.2 Bonding
Bonding is the continuous bonding together of non-current carrying conductive materials of an
electrical installation (i.e., enclosures, equipment frames, cable armor, conduit, portable electric
equipment, steel structures, and other non-current-carrying metal parts of the system) and to
the grounded conductor at the electrical supply source. The purpose of bonding is to establish
an effective path for fault current that will facilitate the operation of the overcurrent protective
device. All bonding must be in accordance with local regulations and the requirements in G-DHS
chapter 6 (electrical safety).
9.7.3 Electromagnetic compatibility (EMC)
9.7.3.1 General
The increasing use of electrical and electronic devices entails the following:
• Increasing density of components
• Increasing power electronics
• Increasing switching speed
• Lower power consumption of components

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This increases the risk of mutual influencing of individual electrical components. Electro-
Magnetic Compatibility (EMC) is understood to be the ability of an electrical or electronic device
to function without faults in an electromagnetic environment without influencing or disturbing
the environment beyond certain limits.
9.7.3.2 Propagation of a disturbance
Three components present in a system:
1. Source of the created disturbance.
2. Link between the possible source and the affected devices.
3. The affected devices.
Figure 9-44 Propagation of Disturbance

EMC measures take effect on all three components to prevent malfunctioning as the result of a
disturbance. When creating a system, the manufacturer shall take all possible measures to
prevent the occurrence of interference sources.
1. Only devices may be used in the system that conform to the limit class A of VDE0871.
2. All disturbed devices shall be interference-suppressed, including all coils and windings.
3. The control cabinet shall be structured such that mutual interference of individual
components is avoided or kept as low as possible.
4. Measures shall be taken to eliminate external interference.
9.7.3.3 Control Cabinet Structure
1. Fundamentally, the greater the distance between the interference source and the disturbed
device, the lower the interference is.
2. If space in the control cabinet is limited, it is possible to install additional plates for
screening. Housing plates in the cabinet shall be connected to one another in a good
conductive connection.
3. With regard to the structure of the control cabinet, interference effects can be avoided by
spatially separating power components (transformers, drive units and load power supply
units) from the control components.
4. Load cables and power cables shall be laid separately from signal cables (bus cables) with a
minimum clearance of 100 mm.
5. A highly conductive (large-area) connection shall be established between the screen bus and
the control cabinet housing and, this shall be as close as possible to the cable inlet. The
cables shall be stripped and clipped onto the screen bus or tied on with cable tie band.
Attention shall be paid to a highly conductive fit.

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6. External interference from the mains is avoided by installing line filters directly at the
control cabinet inlet.
7. Openings on the control cabinet towards the outside shall not be permissible because, as far
as high-frequency signals are concerned, they act like antennas into the interior of the
control cabinet.
8. All coils (relays and contactors) in the control cabinet shall be interference suppressed. This
shall also apply to valves and motor brakes.
9.7.3.4 Equipotential Bonding
1. If parts of the system are connected by signal lines (bus cables), equalizing currents may
flow via the screen. These equalizing currents may falsify signals, and this is why
equipotential bonding is necessary.
2. The equipotential bonding line shall possess an adequately large cross-section (at least 6
mm²).
3. The distance between the signal cable (bus cable) and the affiliated Equipotential bonding
line shall be as short as possible (antenna effect).
4. If equipotential bonding lines are connected to the central equipotential bonding bar, power
components (power supply units and drives) and non-power components (PLCs and ET200
modules) shall each be combined.
5. The better the equipotential bonding in a system is, the lower is the possibility of
interference resulting from potential fluctuations.
9.7.3.5 Screening of Cables
1. To suppress disturbance signal injections into signal cables (bus cables), these shall be
screened.
2. In the case of analog signals, the screen of the cable shall be connected on one side on the
receiving end.
3. In the case of digital signals, the screen shall be connected to the housing on both ends.
4. If screened tables have to be interrupted, the screen shall be continued through the
relevant connector housing.
5. Missing or incorrect connection results in an ineffective screening.

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10 Drawing Section D: Sequence of Operations

10.1 Purpose
The sequence of operation refers to the process sequence of the system or tool. Start-up and
shutdown procedures (referred to as sequences) are not included in the scope of this document;
however, it can be found in the system or tooling maintenance manuals.

The documentation of the sequence of operation in the wiring diagram is no longer typical.
However, a process shall be in place to document the delivery of required tooling (unit)
sequence from either the equipment supplier or processing engineers to the controls engineers.
An example of such a process is the xRWD delivery requirements described in section 2 of the
BIW Global Mechanical Design standard (GMD-1).

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11 Drawing Section E: Magnetics

11.1 Purpose
This section illustrates how to design and document the hardwire schematics for the system
power distribution, drives and motor wiring, transformer wiring, power supplies, I/O power
distribution, and other related items.

All design, installation, and wiring practices shall follow the latest revision of NFPA 79, IEC 60204
Safety of Machinery – Electrical Equipment of Machines, CSA Canadian Electric Code, Ontario
Hydro Electrical Specification for Industrial Machinery, and other pertinent local codes.
Note: Specific design requirements for hazardous areas (intrinsically safe systems) are not
covered in this document.
Use all ECS’s (Electrical Cabinet Standards) and Templates applicable to the Project or Program.
Consult the Lead GM Controls Project Engineer for the most recent designs and postings.
11.2 Drawing Section Design Requirements
1. All magnetic schematics shall be shown in the ‘E’ section of the drawing package.
2. It is preferred that electrical control cabinets (EC-xxxx) have their own drawing package
separate from, but, may also be included in the wire and piping drawing package. All
electrical cabinet standards (ECS-xxxx) shall have their own drawing package separate from
the wire and piping drawing package. In all cases, they will include the magnetic schematics
for the wiring of the control panel. Examples of electrical control cabinets are:
a. Power distribution panels
b. Main Control Panel
c. Entrance Gate Control Panel
d. Operator run stands
e. Drive and motor control panels
3. Each magnetics schematic sheet shall include even line numbers with equal spacing
beginning with 00 through 40 on the left side of the diagram and 50 through 90 centered
within the diagram. A leading digit for the schematics sheet number shall be placed in front
of these digits. For example, Sheet 3 of Section E shall start with line number 300 and end
with 390. Line numbers x50 -x90 may be omitted to allow room for large circuit diagrams
(e.g., safety relay circuits which span the entire sheet across).
4. Each Section E schematic sheet shall allow additional space in order to accommodate future
expansion of the drawing package, as necessary. As a general guideline, 25% additional
space, which is appropriately distributed, should be sufficient. This space requirement is at
the discretion of the GM Controls Project engineer, and they shall be consulted as the
drawings are being completed.

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Exception: ECS standard designs.
5. All wires that continue to another part of the schematic or a different sheet shall end at a
reference box containing the sheet letter and line number to which that wire continues.
The continuation of that wire shall start with a reference box containing the sheet letter and
line number from which it was referenced.
Figure 11-1 Reference Boxes in a Schematic

6. All items within Section E that are referenced from another drawing package shall be boxed
within a dashed line around the associated pins in order to clarify that these items do not
originate in the package. For troubleshooting purposes, this boxed in area shall reference
the WD or ECS where it originates and may show all of the necessary schematics associated
with the originating package including wire numbers.
Figure 11-2 Referencing Circuits from Other Panels

7. All Section E drawings shall be shown in order from the highest to lowest voltage (e.g., 380 –
575 V, 120 VAC, 24 VDC). If 380 – 575 V is supplied from another panel, the drawings shall
start with the 380 - 575 V feed followed by the 120 VAC and 24 VDC. If a 380 – 575 V
voltage does not exist and the 120 VAC is supplied from another panel, the drawings shall
start with the 120 VAC feed followed by the 24 VDC. If 24 VDC is the only voltage that is
supplied, the section shall start with this feed. The following order of appearance shall be
followed to assure continuity of designs:
a. Plant power drop to main disconnect
b. 380 – 575 V power distribution

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c. 120 VAC power distribution
d. 24 VDC power distribution
e. Magnetic (i.e., power supplies, relays) schematics
f. Interlock circuits to other panels or systems
8. Where practical, enclosures shall be designed to operate at 24 VDC in order to minimize
potential for exposure to hazardous voltage greater than 50 V and to eliminate electrical
PPE requirements.
11.3 Wire Size
1. Wire size shall be in compliance to NFPA 79, IEC 60204 and other local code requirements.
The calculation of current carrying capacity and conductor sizing methods are different
between North America and International Regions.
2. Conductors shall be compatible with the device terminals and shall not exceed the range
recommended by the device manufacturer.
3. Ambient temperature and number of current carrying conductors within a cable affect the
conductor ampacity. All electrical equipment is required to operate between air
temperatures of 5 °C and 40 °C. Reference de-rating tables in IEC 60204 and NFPA 79.
Table 11-1 Wire De-Rating for Ambient Temperature
Ambient Temp Factor
(°C) 60 °C 70 °C
26 – 30 1.0 1.0
31 – 35 .91 .94
36 – 40 .82 .88
41 – 45 .71 .82

Table 11-2 Wire De-Rating of Current Carrying Conductors in a Cable

# of Current Carrying
Factor
Conductors in a cable > 3
4-6 .8
7-9 .7
10 - 20 .5

4. The following table is a guide from AWG (American Wire Gage) to Metric conversion. Also
listed is the typical maximum current carrying capacity for the conductor sizes.

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Table 11-3 Wire Size (AWG to Metric Conversion) Guide
Metric
Conductor Conductor
Conversion NFPA Common Metric
Ampacity NFPA Ampacity IEC
AWG 79 Table 12.2.2 Conductor Size
79 Table 12.5.1 60204 Table 6
for Stranded Wire (mm2)
(A) (B2) (A)
(mm2)
30 0.5 0.05 0.05 Not Provided
28 0.8 0.08 0.08 Not Provided
26 1 0.13 0.14 Not Provided
24 2 0.20 0.25 Not Provided
22 3 0.32 0.34 Not Provided
20 5 0.52 0.5 7.5
18 7 0.82 1 10.1
16 10 1.31 1.5 13.1
14 15 2.08 2.5 17.4
12 20 3.31 4 23
10 30 5.26 6 30
8 50 8.37 10 40
6 65 13.30 16 54
4 85 21.15 25 70
3 100 26.67 35 86
2 115 33.62 35 86
1 130 42.41 50 103
1/0 150 53.49 50 103
2/0 175 67.43 70 130
3/0 200 85.01 95 156
4/0 230 107.20 120 179
250 255 126.68 120 179
300 285 152.01 150 Not Provided
350 310 177.35 185 Not Provided
400 335 202.68 240 Not Provided
500 380 253.35 240 Not Provided
600 420 304.02 300 Not Provided
700 460 354.69 400 Not Provided
750 475 380.03 400 Not Provided
800 490 405.37 500 Not Provided
900 520 456.04 500 Not Provided
1000 545 506.71 500 Not Provided

Note: For AWG sizes from 250 to 1000: metric (mm2) = AWG*1000/1973.53
11.4 Voltage Drop Over Distance
1. Another factor in determining wire size and ampacity is the length of the conductor. This is
especially important with 24 VDC control.

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2. The following is a chart of measured 24 VDC voltage drops in various lengths and current
draw (resistive load) for #16 AWG mini cord.
Figure 11-3 24 VDC Voltage Drop on #16AWG Mini Cable

11.5 Wire Colors

1. Panel wire colors shall be as described below in Table 11-4.
Exception: Multi-conductor hardwired cables (i.e., main bus drops, robot feeds, motor feeds).

Exception: Pre-manufactured receptacle wiring (i.e., 3 and 4 pin M12 mini, 5-pin DeviceNet,
light curtain receptacles).

Note: When pre-manufactured receptacles or multi-conductor cables are used in applications

where a conductor is required to be identified (e.g., grounded neutral), then care must be taken
to select the proper receptacle or multi-conductor cable OR to properly re-identify the
conductor based on its use.

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Table 11-4 Wire Color Chart

2. The wire color shall be shown on the schematics as a 2 or 4 letter designation according to
the following chart (IEC 757 Code for Color Identification):
Table 11-5 IEC 757 Code for Color Identification
Color Color Code
Black BK
Brown BN
Red RD
Orange OG
Yellow YE
Green GN
Blue BU
Violet VT
Gray GY
White WH
Pink PK
Gold GD

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Color Color Code
Turquoise TQ
Silver SR
Green with Yellow Trace GNYE
Black with Orange Trace BKOG
Blue with Orange Trace BUOG
White with Red Trace WHRD
White with Orange Trace WHOG

Figure 11-4 Example of Color Designation on Schematic

3. The 2 or 4 letter color designation shall be used for custom multi-conductor receptacles
shown on the pin charts. (See section 30.5).
Figure 11-5 Color Designation on Pincharts

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11.6 Identification
11.6.1 Device Identification
1. All devices in Section E shall include the section letter, originating line number, and a device
identifier. The list of GM device identifiers are defined within the GM ePlan configuration.
The following is just an example of some of the descriptions available:
Table 11-6 Device Identification Examples
Device Symbol Descriptor Examples
Circuit breakers CB E106CB, F102CB
Contactor C E226C
Fuse blocks FB E202FB
E104FU (single fuse block)
Fuses FU
E102FU1, E102FU2, E102FU3 (3-pole fuse block)
Light LT E305LT
Motor M E106M
Motor Forward MF E108MF
Motor Reverse MR E110MR
Motor High Speed MH E112MH
Motor Low Speed ML E114ML
Motor Overload MOL E116MOL
Motor Starter
MSP E116MSP
Protector
Pushbutton PB E216PB
Power supplies PWS E204PWS
Relay CR E220CR
Safety Relay SR E104SR
Timing Relay TR E2004TR
Transformers T E108T

2. In addition to the device identifier, there is a function code (suffix after line number)
included for devices such as relays and contactors which help to identify their unique
function.
Table 11-7 Device ID Function Code
Relay Name
Relay Description
xxx = line number
ExxxSRM (safety relay)
Master On
ExxxCRM (standard relay)
Local No E-Stop ExxxSRE
All Gates Reset ExxxSRG
Tool Major Enable ExxxSRTM
Tool Outputs Permissive ExxxSRTO
Robot Outputs Permissive ExxxSRRO
Robot No General Stop ExxxSRRG
Operator Safety Devices ExxxSROS

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Relay Name
Relay Description
xxx = line number
Next Cell OK ExxxSRN
Previous Cell OK ExxxSRP
Enabling Pendant OK ExxxSREP
Logic OK FxxxCRL

3. If a standard relay is used to compliment a safety relay, the relay name shall be the same as
the safety relay with the exception of replacing the “S” with a “C”. The complementing
standard relay shall also use its own associated line number.
Figure 11-6 Complementary Relay Naming

11.6.2 Wire Identification

1. All bus voltage (380 – 575 V) wires shall be designated by phase using L1, L2 and L3. The
wires shall change designations after each device thereafter with the prefix line number of
where the change occurs in addition to each phase designation. The prefix line number shall
increment by 1 if on the same line number.
Example A:
L1, L2, and L3 feed a disconnect on line 104. The wires directly after the disconnect
would be labeled 1041L1, 1041L2, 1041L3.

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Figure 11-7 Power Wire Designation After Disconnect

Example B:
If wires 1041L1, 1041L2, and 1041L3 are connected to a contactor on line 112, the wire
numbers after the that contactor would be 1121L1, 1121L2, and 1121L3. The wire
numbers after the 2nd contactor on the same line number would be 1122L1, 1122L2,
and 1122L3.
Figure 11-8 Power Wire Designation after Contactor

2. All other wire designations unless otherwise specified by this document, shall be numbered
with the line number from which it originates in the print package followed by a single digit.
For example, a wire starting on line 326 shall be labeled 3261, the second wire on line 326
shall be 3262, etc.
Exception: Neutral conductors shall be identified with a suffix of zero ‘0’ added to the line
number (i.e., if neutral originates at line 302, then, the wire is 3020).

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Figure 11-9 Neutral Wire Numbering

Exception: Small standard panels (ECS) may use generic wire numbering such as ‘V+’, ‘+24VDC’,
and ‘0VDC’ for the dc power commons to make it easier to identify the power conductors within
the panel.
Figure 11-10 Generic Wire Naming

Exception: I/O wires, etc. The rules for labeling these exceptions are documented in section
12.2.
3. Do not exceed nine wire designations per line. If additional wires are required, continue on
the next line.
4. Receptacle wires shall be labeled by the same rules as general conductors. For small
standard enclosures (ECS) where typically there is no internal wiring between devices, the
receptacle wire may be labeled to match the pin number.
Figure 11-11 Small ECS Wire Numbering

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11.7 Overcurrent Protection
Equipment and conductors shall have circuit breaker or fuse overcurrent protection in
compliance to NFPA 79, IEC-60204 and Global Design for Health and Safety (G-DHS) chapter 6
(electrical safety).
11.7.1 General Requirements
1. Main Disconnect – Overcurrent protection for the main disconnect shall be at minimum:
125% FLA of all heating loads
+ 125% FLA of highest rated motor
+ all other motors in simultaneous operation
+ 125% of the continuous non-motor loads
2. Conductors – Overcurrent protection of conductors shall not be larger than the rating listed
for the conductor in the ampacity tables listed in the NFPA 79 and IEC 60204 specifications.
3. Transformer Protection – Both the primary and secondary shall have overcurrent
protection. Circuit breakers are preferred. If providing fuses (for North America) use Class
RK5 (FRS) type for primary and FRN type on secondary. FLA = Full Load Amps
a. Primary (when secondary also has overcurrent protection) = max 250% FLA
b. Secondary (< 9 A) = 167% FLA
Secondary (≥ 9 A) = 125% FLA (if 125% is not standard rating, you may use next higher
standard size).
Figure 11-12 Transformer Overcurrent Protection

4. AC Motor Protection – The protective device for motor starters shall be selected to provide
Type 2 Protection. According to IEC 60204:
Type 1 protection: under short-circuit conditions, the contactor or starter may not be
suitable for further use without repair or replacement.
Type 2 protection: under short-circuit conditions, the contactor or starter shall be
suitable for further use.
AC Motor overcurrent protection shall be in compliance to NFPA 79 and IEC 60204.
a. A combination of a circuit breaker and motor overload can be used for AC motor
protection. If circuit breakers are used, the breaker shall be sized no larger than 250%
motor FLA.

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Figure 11-13 Motor Protection Using Circuit Breaker & Overload

b. A Motor Starter Protector (MSP) may also be used for short circuit and motor overload
protection.
Figure 11-14 Motor Protection Using MSP

c. Motor overload protection general requirements:

i. All motors shall have overload protection.
ii. Overload sizing shall follow motor controller manufacturer’s recommendation.
iii. When multiple overload devices have operating ranges overlapping the motor used
in the application, the overload with the higher range should be selected.
iv. Overload devices shall be set according to the manufacturer's documentation.
NOTE: Many overload devices already incorporate a % over the motor FLA and are intended to
be selected by and set to the motor FLA and not at a % higher. Verify selection and setting is
made per manufacturer’s documentation.

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5. ASD (Adjustable Speed Drive) or VFD (Variable Frequency Drive) Protection. Provide
overcurrent protection as recommended by the manufacturer.
6. 120 VAC and 24 VDC Branch Protection
a. Provide circuit breakers for 120 VAC and 24 VDC branch protection. Circuit breakers
rated only as supplementary shall not be used. (Must be UL 489 rated).
b. Class 2 power supplies do not require secondary protection.
c. For output module protection, use the manufacturer's recommended fuse.
11.7.2 Short Circuit Current Rating (SCCR)
Equipment must have a short circuit current rating equal to or greater than the RMS
symmetrical short circuit current available at the point of installation (typically 65 kA) and must
comply with the requirements in Global Design for Health and Safety (G-DHS) chapter 6
(electrical safety).
11.7.3 Arc Flash Incident Energy
Short circuit protection shall be designed to limit arc flash incident energy according to the
requirements in Global Design for Health and Safety (G-DHS) chapter 6 (electrical safety).
11.8 380 – 575 V Design Requirements
11.8.1 Main Disconnect
The main supply circuit disconnect is used as a central point of lockout for the equipment. The
main disconnect is normally located in the Power Distribution Panel (typically used for Bodyshop
cells) or the Main Control Panel.

The main supply circuit disconnect shall comply with the requirements in Global Design for
Health and Safety (G-DHS) chapter 6 (electrical safety).
11.8.2 Remote Disconnects
Where a “main” disconnecting means is required for a remote main accessible lockout:
1. Shall be wired to the load side of the control panel’s line disconnecting means.
2. Have the line and load side conductors installed in separate raceways.
11.8.3 Enclosure Wiring on Line Side of Disconnect
Line-side taps for excepted circuits (i.e., PLC and lighting disconnect) on the line side of the main
disconnect shall have their conductors routed in non-metallic conduit, inside the enclosure if
longer than 0.3 m. The conductor shall be stranded and rated for short-circuit proof. This does
not include the incoming power feed to the main disconnect.
11.8.4 Main Distribution Block and 380 – 575 V Wire Sizing
1. The main distribution block fed directly from the main disconnect shall be sized to match or
exceed the maximum capabilities of the system main disconnect. The wire from the system
main disconnect to the distribution block shall be sized to match the maximum capabilities
of the disconnect. Where electronic trip circuit breakers are used as the main disconnect
device, it is permitted to size the distribution block and the wire to the overload setting of
the main breaker.

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2. The wire between the distribution block and the branch circuit breaker or fuse block shall be
sized according to the maximum amperage capabilities of the circuit breaker or fuse block.
The wire after the circuit breaker or fuse block shall be sized in the same manner.
3. The 380 – 575 V multi-conductor cable shall be hardwired at both ends.
Exception: Conveyor applications and other applications using integrated drives may use a 4-pin
power (M35) trunk architecture. Other applications shall require approval by the responsible
GM Controls Project Engineer.
11.8.5 Motor Starters and Overloads
1. The motor starter shall be sized for the correct amperage, horsepower, and tooling life cycle
requirements.
2. Properly sized motor overloads shall be used to disable the motor starter in the event of a
thermal or current overload. These overloads shall be sized based on the motor nameplate
full load current.
11.8.6 Power Factor Correction Capacitor (PFCC)
1. Provide power factor correction capacitors for all AC single speed motors of 7.5 HP or
greater, except for the following applications:
a. Reversing, plugging, jogging, inching, or multi-speed operations.
b. Motors controlled by adjustable speed drives (VFD’s) or solid state (soft) starters.
Exception: Soft starters using a bypass contact may require a PFCC on the bypass circuit.
c. Applications using a clutch, brake, solid state rectifier, open transition wye-delta
reduced voltage starter, or DC injection braking.
2. If PFCC is required, first determine if the correction will be provided at the substation before
adding PFCC at the equipment. This determination is a joint decision made by the GM
Controls Project Engineer and the GM Plant Controls Engineer.
Note: Many GM plants have power factor correction banks installed at the substation and
therefore, do not require additional capacitance at the load(s). These banks of capacitors
automatically adjust to the varying load demands.
3. Typical installation for individual motors: Connect the capacitor leads between the starter
contactor and the overload device.

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Figure 11-15 Typical PFCC Wiring for Individual Motor

11.9 Design Requirements for Control Voltage (120 VAC)

1. Control voltage shall be 120 VAC to control devices (i.e., PLC power, panel lighting, primary
of dc power supplies, large contactors where 24 VDC is not practical).
Exception: In regions where 220 VAC is acceptable, it can be used in place of 120 VAC for power
to control devices. Use of 220 VAC requires the approval of the GM Controls Project Engineer.
2. Plug and cord connection for 120 VAC shall use the 3-pin mini configuration. Male
receptacles and cords shall have male (External) threads. Female receptacles and cords
shall have female (Internal) threads.
Figure 11-16 Standard 120 VAC Connection 3-Pin Receptacle

3. Wire numbering shall follow Section 11.6.2.

4. All transformers shall be labeled with the device number, voltage, and kVA rating.
5. All transformers shall show the internal terminal configurations.
6. All transformers shall have a grounded neutral.
The typical size wire for 120 VAC (≤ 10 A) shall be 1.5 mm2 (#16 AWG).
Note: Proper overcurrent protection must be provided for smaller wire size.
11.9.1 Excepted Circuit (“Hot”) Power (not de-energized by the main disconnect)
1. A transformer shall be powered above the system main disconnect. This transformer shall
be sized for a minimum of 125% of the total connected load. This transformer shall supply
power to the following:
a. Panel lighting (if used)

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b. Programming port
c. 24 VDC power supplies for PLCs, HMIs, and Ethernet switches
d. PLC power
e. Ethernet switch(es)
f. Programming terminal
NOTE: Where practical, excepted circuit (“hot” power) devices shall utilize 24 VDC to minimize
electrical hazards and reduce PPE requirements. Specifically, HMI and IHPLC (PLC-in-a-box)
enclosures requiring access to programming ports, memory cards, etc. shall utilize 24 VDC
power feeds unless approved otherwise by the GM Controls Project Engineer.
2. Secondary circuit protection for the transformer shall be required and conform to the
recommendation of the transformer supplier. If the transformer is provided with built-in
secondary protection, only branch circuit protection is necessary.
3. The PLC shall be individually branch circuit protected if it is not supplied with a protection
device that can be replaced or reset (internal fuses or soldered fuses shall be externally
protected). Check the manufacturer recommendation for external circuit protection.
4. All circuits sharing the same 120 VAC power feed as the PLC, shall be branch circuit
protected separate from the PLC. This will reduce the risk of a short circuit from an external
source tripping the circuit protection that feeds the system PLC.
11.9.2 Control Power
1. This transformer provides power to the 24 VDC power supplies for all magnetics, motion,
non-motion, and DeviceNet power.
2. The control transformer shall be powered below the main disconnect and disable all control
power when the main disconnect is ‘Off’.
3. The transformer shall be sized for a minimum of 125% of the total continuous load.
4. Indicator lights, for “AC Control Power On” shall be designed into the controls hardwire
circuit.
11.10 Design Requirements for Control Voltage (24 VDC)
1. All DC power supplies shall be sized for a minimum of 120% of the available load.
2. All power supplies shall be labeled with the device number, current capacity, and the
voltage.
3. All power supplies shall show internal terminal configurations.
4. All power supply secondary neutrals shall be grounded at the supply’s 0 V terminal.
Exception: Power supplies on a DeviceNet network shall not be connected to ground. The
network shall be grounded in one location per the recommended practices by ODVA.
5. The typical size wire for 24 VDC (≤ 10 A) shall be 1.5 mm2 (#16 AWG).
Note: Proper overcurrent protection must be provided for smaller wire size.
6. Plug and cord connection for 24 VDC control voltage shall be one of the following:

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a. A 4-pin mini configuration described in the physical layer chapter of the CIP specification
(preferred).
Figure 11-17 24 VDC Power 4 Pin Mini (per CIP Specification)

Note: Pins 1 and 4 may be used for unswitched power if there is no requirement for switching
the power (i.e., output power). When switched power (i.e., aux power or output power) is
required, pins 1 and 4 shall be used for this function.

Note: Pins 2 and 3 are not always connected in all devices. Confirm that the power pinout is
correct for the application.
b. A 4 pin A-code micro configuration described in the physical layer chapter of the CIP
specification.
Figure 11-18 24 VDC Power 4 Pin A-Code Micro (per CIP Specification)

c. A 4 or 5 pin L-code micro configuration described in IEC 61076-2-111.

Figure 11-19 24 VDC Power 4 or 5 Pin L-Code Micro (per IEC 61076-2-111)

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11.11 VFD (Variable Frequency Drive) or ASD (Adjustable Speed Drive) Design Requirements
This section describes design requirements for a motion control system and its interface with
the equipment controller.
11.11.1 Proper VFD Design
The selection of either a VFD or a servo drive for motion control should be based on the
mechanical load requirements of the system. Requirements for acceleration, speed, and
stopping accuracy should be reviewed before selecting a motion control package.
11.11.2 General VFD Design Requirements
1. In addition to the requirements below, all manufacturer's recommendations shall be
followed for the selected VFD. If the manufacturer's recommendations conflict with the
contents of this document, consult the responsible GM Controls Project Engineer for
direction.
2. The network connection to a VFD shall be EtherNet/IP or DeviceNet. The preferred network
is EtherNet/IP.
3. Standalone VFD drives shall be interlocked to the station by two separate methods.
• All motion command and diagnostic interlocks shall be communicated between the VFD
unit and the cell main panel via a network connection and controlled by the controller
PLC.
• All safety circuits (e.g. contactors, safe torque off (STO), etc.) shall be incorporated into
the controller’s SCS/MPS safety circuitry with via hardwire or safe network connection.

4. To avoid damage to some VFD units when using contactors between the VFD and the motor,
the contactors must open after the contacts in the enable circuit have been opened or the
drive is stopped. If required, this configuration shall be accomplished by using delayed
safety relay contacts or time delay safety software.
5. All software diagnostics for the VFD system shall be displayed on the station’s HMI and shall
be communicated over the network link.
6. All Manual Mode motion commands to the VFD unit shall be initiated from the station’s
HMI.
7. VFD systems should be designed to ensure drive and motor compatibility.
8. Definite-purpose inverter-fed motors (as specified in NEMA MG 1-1993, Part 31.40.4.2)
should be used.
Note: This requires motors to be capable of a 1600 V peak limit with a rise time of 0.1
microseconds or longer. For general-purpose motors, NEMA suggests limiting the voltage
overshoot to 1000 V peak with a rise time of 2 microseconds or longer.
9. The following steps shall be followed to ensure a correct match of the VFD and motor:
a. Define the operating profile of the load to which the VFD is to be applied.
b. Determine why the load operation speed needs to be changed. A “soft start” reduced
voltage starter may be all that is required.

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c. Size the VFD per the motor’s maximum current requirements under peak torque
demands. Do not size the VFD per the motor horsepower rating.
d. Evaluate the possibility of oversizing the VFD. Motor performance (i.e., breakaway
torque) is based on the chosen VFD’s capability and amount currently produced.
Depending on load type and expected duty cycle, it may be necessary to oversize.
10. The lead length from the drive to the motor should be as short as possible. Longer leads
create higher voltage spikes, thereby significantly affecting the longevity of the motor.
Table 11-8 Example Lead Lengths from the Drive Motors
Motor lead length (ft) Peak Voltage (V)
1 700
10 1000
50 1280
150 1310
300 1340

11. If lead length is excessive or if using a general-purpose motor, line reactors at the drive
output or motor input may be needed to reduce the voltage stress. Avoid the addition of a
reactor without a verified need. The additional impedance may reduce motor torque
available at low frequency.
12. Motor disconnects should not be placed directly between the drive unit and the motor.
Opening the circuit between the drive and the motor while under power can damage a VFD
unit. If a remote disconnect is required between the drive and the motor, use an auxiliary
contact (early break) from the disconnect to an interlocked relay to ensure the drive output
is “off” before the contact to the motor is opened. The remote disconnect shall also be
located within 9 m AND within sight of the motor.
13. Extended low-speed operation of the motor could cause overheating problems, these
applications may require a separate cooling fan motor. Temperature feedback of the motor
windings should be used to monitor over-temperature faults.
14. If the motion profile requires control at the lower part of the motor speed range or when
driving into a hard stop, the motor should be equipped with motor speed feedback by
utilizing an encoder.
15. A specific method shall be established to diagnose and clear all VFD unit faults.
16. The system shall have overtravel switches to ensure that overtravel motion disables the
drive unit. Appropriate diagnostics shall be provided at the station’s HMI panel.
17. A manual override for the overtravel switches shall allow the system to restart in the event
of an overtravel condition.
18. A safety pin or mechanical locking mechanism should be designed into the system if gravity
or stored energy hazards are present. If used, the pinning mechanism shall be interlocked
into the drive system to prevent damage due to the drive working against a pinned load.
19. Some applications may require the decel and in position switches to be connected directly
to the VFD for exact control of the unit. If PLC scan time may be a problem for decelerating
or positioning, the unit method of control should be used.

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20. A dynamic braking unit may be required for high inertial loads.
11.11.3 VFD Enclosures
1. The 380 – 575 V wiring that feeds the drive unit and the motor cable should be located apart
from the control and feedback wiring. Preferably, the drive unit and associated 380 – 575 V
wiring will be located high in the panel, near the entrance of the higher voltage, and
protected from inadvertent contact.
2. A dynamically resistive brake, if needed, should be located on the outside of the panel –
preferably on the top – to allow proper heat dissipation and to reduce the risk of
inadvertent contact with hot parts. The resistors shall be protected against contact by, at
minimum, an IP2X / IPXXB cover.
3. Correct grounding is necessary on VFD systems. It is imperative that the motor and drive
grounding methods of the manufacturer be followed correctly. Most systems will require
the following grounding:
a. Connection from the enclosure ground bus to the drive at the ground terminal provided
on the drive unit.
b. Connection from the enclosure ground bus to the station equipment ground as
described in the section 9.7.
c. Connection of the ground conductor of the motor cable (drive end) directly to the drive
unit’s ground terminal, not to the enclosure ground bus bar.
d. At the motor end, connection of the ground conductor to the motor case ground.
e. A shielded motor cable connection at the motor end to the motor case ground, and at
the drive end to the ground connection provided on the drive.
f. With an encoder, a shielded twisted-pair cable shall be used. Ground the encoder
connections. Ground the shield for the encoder cable at the drive end only on the
ground terminal provided on the drive unit.
11.12 Servo Systems – General Design Requirements
1. In addition to the requirements below, all manufacturers’ recommendations shall be
followed for the selected servo system. If the manufacturer's recommendations conflict
with the contents of this document, consult the responsible GM Controls Project Engineer
for direction.
2. The network connection to the servo drive shall be EtherNet/IP or DeviceNet. The preferred
network is EtherNet/IP.
3. Standalone servo drives shall be interlocked to the station by two separate methods.
a. All motion command and diagnostic interlocks shall communicate between the servo
unit and the station main panel via a network connection and controlled by the
controller PLC.
b. All safety circuits (e.g., contactors, safe torque off (STO), etc.) shall be incorporated into
the equipment’s SCS/MPS safety circuitry via hardwire or a safe network connection.
4. Motion commands shall be generated from the station PLC.

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5. The servo panel requires two power feeds from the station power distribution panel. One
control power supply for I/O and one (380 – 575) V supply for the servo drive unit.
6. All required software diagnostics for the servo system will be displayed on the station main
panel HMI.
7. All Manual Mode motion commands to the servo unit shall be initiated from the station
main panel HMI.
8. A specific method shall be established to diagnose and clear all servo unit faults.
9. The system shall have over-travel switches to ensure that any over-travel motion disables
the servo unit. These switches will be wired back to the servo unit inputs.
Exception: Software overtravels may be used in place of hardware with GM Project Controls
Engineer approval.
10. A specific method shall be established to manually override the over-travel switches to
restart the system in event of an over-travel condition.
11. A safety pin or mechanical locking mechanism should be designed into the system if gravity
or stored energy hazards are present. If used, the pinning mechanism shall be interlocked
into the drive system to prevent damage due to the drive working against a pinned load.
12. Cable shielding is important on all power wiring between the motor and the drive. The
cable shield and drain wires need to be carried through between the drive and motor. If the
cable is cut to wire in the contactor, ensure that the overall shield and drain wire are tied
together. A shielded cable from the contactor to the dynamic brake resistors shall also be
used to prevent electrical emissions into the electrical enclosure. The motor contactors
shall be isolated from low voltage signal wires, communication cables, and power supplies
because these devices as they will radiate high frequency emissions.
13. If used, the contactors in the motor cables shall be controlled and monitored to allow the
servo controller to stop the motor through software first. The motor shall only start when
the circuit is made. When stopping, the drive module must be disabled before the contactor
is de-energized. When starting, the contactor must be energized before the axis module is
enabled.
11.12.1 Servo Enclosure
1. The 380 – 575 V wiring that feeds the drive unit and the motor cable should be located apart
from the control and feedback wiring. Preferably, the drive unit and associated 380 – 575 V
wiring will be located high in the panel, near the entrance of the higher voltage, and
protected from inadvertent contact.
2. A dynamically resistive brake, if needed, should be located on the outside of the panel –
preferably on the top – to allow proper heat dissipation and to reduce the risk of
inadvertent contact with hot parts. The resistors shall be protected against contact by, at
minimum, an IP2X / IPXXB cover.
3. Proper grounding is critical on servo systems. It is imperative that the motor and drive
grounding methods of the manufacturer be followed correctly. This includes:
a. Connection from the enclosure ground bus to the servo unit at the ground terminal
provided on the servo unit.

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b. Connection from the enclosure ground bus to the station equipment ground, as
described in section 9.7.
c. Utilization of the ground stud provided on the servo unit for all grounding and shield
connections for the servo components, as specified by the manufacturer.

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12 Drawing Section F: Input/Output (I/O)

12.1 Purpose
This section provides a detailed explanation and representation of the I/O distribution.

The example drawings outline the proper format for presenting this unit within a controls
package. The details found within the example drawings are only included for reference
purposes. Although each control package is different, the illustrated format shall be followed.
12.2 General I/O Design Requirements
1. The section shall be denoted in the lower right corner of the title block (e.g., Section F) and
the sheet description shall also be listed (e.g., LOCAL I/O SLOTS 0 & 1).
2. All schematic components (i.e., relays, pushbuttons, lights, switches) shall have device ID’s.
The device ID shall appear next to or above the device.
3. Action/result tooling I/O shall use standard descriptions found in section 5.7.
4. Electronically fused (protected) output modules shall be used for all loads. Loads shall not
exceed the rating of the output device. If it is not possible to use electronically protected
modules, overcurrent protection per the manufacturer’s recommendations shall be
provided.
Figure 12-1 Electronically Protected Outputs (Module)

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5. When showing interlocks directly from other external I/O devices, the device shall be shown
with the address, description, and WD number of the external device. In addition, the
device shall be outlined with a dashed line.
6. All inputs shall be sinking.
Exceptions: Special electronic circuitry for which an isolated input module shall be used. The
use of sourcing inputs shall be approved by the responsible GM Controls/Project Engineer.
7. All outputs shall be sourcing.
Exception: The second output of a bipolar safety pair shall be a sinking output.
8. When utilizing splitter cables for multiple inputs or outputs to a single I/O point, place the
splitter such that the number of cable connections, cable combinations, and parallel cables
is minimized.
a. If sensors are located together (e.g., open/close sensors on a cylinder), then the splitter
should be located at the sensors with a single tool cord to the I/O point.
b. If the sensors are not located together (i.e., having the splitter at the sensors is not
practical without cable extensions), then the splitter should be located at the I/O point.
In this case, use the splitter with the male pigtail to make connecting to the port easier
because of the limited finger space around the I/O point connectors.
Reference Figure 12-2 for splitter cable design intent examples.
Figure 12-2 Splitter Cable Design Intent

NOTE: In situations where the splitter would be at the I/O point and unused ports exist, consider
removing the splitter and using multiple ports. This eliminates the cost of the splitter and
potentially provides additional diagnostic capability because many sensors have two signals
available (e.g., NO and NC inputs).
12.2.1 IP20 I/O Requirements
1. All enclosures with IP20 I/O should have 20% spare I/O and, if necessary, space to add
additional modules.
Exception: Standard ECS enclosures.

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2. Each I/O sheet shall have line numbers and the numbers shall begin with 00 through 40 in
the left column and 50 through 90 centered on the sheet. For example, Sheet "3" shall start
with line number "300" and end with "390" and Sheet “12” shall start with line number
“1200” and end with “1290”.
3. The maximum number of I/O points per sheet shall be limited to 32 for ease of readability.
Exception: I/O listed in table format.
4. The I/O shall progress through the section in numerical order according to both the chassis
and slot address.
5. A wire number consisting of the output designation followed by the letter “A”, “B’, etc. shall
be between device and output.
Figure 12-3 Output Wire Designation between Devices

6. Other wires designated by number shall be numbered according to section 11.6.2 item 2
with the addition of an “F” prefix on the front of the wire number so as not to be confused
with E section wire numbers.
7. I/O descriptions shall appear on the right-hand side of the module outside the common
wire.
12.2.2 IP67 I/O Requirements
1. Applications with IP67 I/O do not require 20% spare input or output points but there should
be provisions to add additional I/O if required (i.e., spare tap ports, spare node addresses,
etc.)
2. I/O descriptions shall be located next to the device.
3. I/O points shall be addressed as “DeviceID.IO Function.Port”.
4. Device ID shall be according to 12.6 item 4.
5. I/O function shall be as follows:
a. I – Input
b. O – Output
c. IOL – IO Link

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6. Port addressing and cable labeling shall match the physical device using the methodology
above. Matching the device supports field replacement, especially when drawings may not
be available, and helps tie software to hardware to support troubleshooting.
7. I/O naming examples:
a. Input/output block I/O points:
Example: BK01.I.D00 (IO block BK01, input, digital, input 00)
b. Input/output modular I/O points:
Example: SM01.I.S2A01 (Modular IO SM01, input, slot 2, analog, input 01)
c. Manifold valve outputs:
Example: PM1.O.V2S14 (pneumatic manifold PM1, output, valve 2, solenoid S14)
8. For typical, rectangular IO blocks (e.g., Turck TBEN or Rockwell 1732ES) and where practical,
the I/O block shall be arranged on the I/O sheet according to the physical device. See Figure
12-4.
Note: This is limited to IO blocks in a 1x4, 2x2, or 2x4 port arrangement.
Figure 12-4 Example Rockwell 1732ES I/O Block Representation

9. For other non-I/O block devices (e.g., Rockwell ArmorStart, Turck BL67), the I/O shall be
arranged schematically on the drawing in a simple, meaningful manner, but not necessarily
matching the physical device. This avoids drawing complexity associated with attempting to
match complex physical layouts. See Figure 12-5.

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Figure 12-5 Rockwell ArmorStart Representation

12.3 Safety I/O Design Requirements

Safety Input/Output (I/O) implements CIP-Safety protocol on DeviceNet or EtherNet/IP. Only
safety I/O approved by GM shall be used.
1. Safety I/O is used to monitor and control those signals used in safety and motion circuits
(i.e., E-Stops, safety gate switches, motion outputs).
2. Redundant circuits require (2) inputs to the safety I/O module.
3. If the safety signals are not opposing input pairs (complimentary dual channels of opposite
polarity) where the normal state of both inputs is opposite each other (i.e., Input 1 = ‘On’,
Input 2 = ‘Off’, or vice-versa), pulse testing is required. Pulse testing of at least one input
will detect the input short to +24VDC or to the 2nd redundant input.
Figure 12-6 Redundant Complimentary Inputs – No Pulse Testing Required

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4. Only (1) of the safety inputs is required to be pulse tested if any of the following conditions
are met; otherwise, dual pulse testing is required.
a. The safety I/O module and the device being monitored are in the same control
enclosure.
b. The safety I/O module and the device being monitored are separated by a multi-
conductor cable. The cable must meet one of the following requirements:
• 4 conductors only (Power, Pulse Test Output, Input 1, Input 2)
• 5 conductors only (Power, Pulse Test Output, Input 1, Input 2, 0VDC or PE)
• The cable does not contain any other 24 VDC signal or power conductors that could
be shorted to either safety input that could create an undetectable fault condition.
Additionally, the cable must not have any spare conductors that could be used as 24
VDC power or signal conductors.
• The non-pulse test signal input and its associated 24 VDC power are separated as a
shielded pair (shield connected to PE) inside the multi-conductor cable such that the
most likely failure mode would result in immediate detection.

c. Dual pulse testing would not raise the overall safety level of a device or enable detection
of any additional faults. GM approval is required for these applications.
d. The operation of the device is frequent enough that a failure would be detected on the
next machine cycle.
Figure 12-7 Redundant Inputs Where the Safety Device and I/O Module Are Located in the Same
Enclosure – Single Safety Pulse Test Required

Figure 12-8 Redundant Inputs Where the Safety Device and I/O Module Are Separated With a Single 4
Conductor Cable – Single Safety Pulse Test Required

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Figure 12-9 Redundant Inputs Where the Safety Device and I/O Module Are Separated With a Cable
Containing Many Power and 24VDC Signals – Dual Pulse Test Required

Figure 12-10 Safety Input Test Pulse Normal & Faulted Conditions

5. Relays or contactors controlled by the safety I/O shall have (1) NC contact monitored by the
safety I/O. This is to ensure the relay or contactor is “Off’ when safe output is ‘Off’.
12.4 Processor Chassis I/O Design Requirements
The processor chassis I/O sheets shall show all of the inputs and outputs that are wired to the
processor’s main control panel. For example, load side of fuses and circuit breakers, e-stop and
reset pushbutton auxiliary contacts, fault lights, horns, and relay inputs.
1. A source (Hot) and common wire that contains the line number reference shall be shown for
each I/O module. The chassis and slot number shall be shown above the respective module.
If two modules exist on the same side of the sheet (e.g., 4 pt. I/O module over another 4 pt.
I/O module) and they share the same common then only one set of commons with
references at the top and bottom are required.
2. The responsible GM Controls Project Engineer must approve the use of two or more
processors in a chassis.
3. The use of higher than 16 point I/O modules must be approved by the responsible GM
Controls Project Engineer.
4. There shall be a minimum of one spare slot per chassis.

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Exceptions: Standard ECS enclosures or industrially hardened PLC’s.
5. Use isolated input modules for monitoring inputs which are powered from the DeviceNet
power supply.
12.5 Tool I/O Design Requirements
The tool I/O sheets shall show all of the tooling inputs and outputs.
1. The I/O modules and tables shall be shown in order according to their network address or
node number.
2. When wiring to an external device, show the pin number of the cable or terminal with
subscript if hardwired and the wire number in the external location. In addition, the device
shall be outlined with a dashed line.
3. Group all switches associated to the same cylinder on the same I/O block. Do not place the
“Advanced” switch on one I/O block and the “Returned” switch of the same cylinder on
another I/O block.
Exception: If one position of the cylinder or motion is required to be monitored in safety, then
some switches may be on safety I/O and others may be on standard I/O.
4. All double solenoid valves shall be on the same I/O module shown consecutively. Do not
split up double solenoid valves with I/O points between the two-associated valve solenoids.
12.6 Device Naming
1. Cylinder Switch Naming:
a. Cylinders are designated as Cxx (where xx is the 2-digit cylinder number):
Home position (load position) = CxxPX1, (or CxxLS1 for limit switch)
Work position (operating) = CxxxPX2, (or CxxLS2 for limit switch)
Figure 12-11 Cylinder Naming – One Work Position

b. If 3 or more switches are used on a cylinder, additional work positions shall be PX3, PX4,
PX5, etc. starting from PX1 to PX2.
Note: PX2 to always be on the furthest work position.

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Figure 12-12 Cylinder Naming – Multiple Work Positions

c. Cylinder switch naming convention:

Table 12-1 Cylinder Switch Naming Example (Cylinder C08)
Switch Label Tag
“Home” C08PX1, C08LS1
“Work” C08PX2, C08LS2

2. Part Present Naming:

Table 12-2 Part Present Naming Example
Switch Type Label Tag
Proximity PPX1, PPX1
Photo eye PPE1, PPE1
Light Curtain / Light
PPS1
Array

3. Other Field Switch Naming:

The following switches shall use their function nomenclature for their Label Tag.
Table 12-3 Other Field Switch Naming
Switch Type Tag Alias and Label Tag
Pressure S10AirOK (sta 10), R1AirOK (robot 1)
Flow S50FlowOK, R5FlowOK
Float S20LevelOK,
Temperature S30OverTemp, S30UnderTemp

4. Industrial Hardened (IP67) Input/Output Device Naming:

a. Input block device tag naming: Input blocks shall be labeled sequentially with 2 digits
starting from 01.
Example: BK01 BK = block, 01 = 1st standard block on tool.
Example: SBK01 SBK = Safe I/O Block, 01 = 1st safety block in drawing package.

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b. Modular IO device tag naming: Modular I/O devices shall be named sequentially with 2
digits starting from 01.
Example: SM01 SM = Modular I/O, 01 = 1st modular IO assembly on tool.
Note: Both safety and standard I/O can start numbering at 01, however, care must be taken to
maintain unique device ID’s within a controller space. Controller based standard I/O should
start at 11 (i.e., BK11) so as not to interfere with unit level I/O and station based safety I/O
should started at 11 (i.e., SBK11) so as not to interfere with controller level I/O.
c. Manifold device tag naming: Manifolds shall be labeled sequentially with 1 digit starting
from 1.
Example: PM1 (PM = pneumatic manifold)
5. Sensor Cable tag naming:
a. The sensor cable shall be labeled at each end (“Y” cord has 3 ends).
b. The sensor cable end that connects at the sensor shall be labeled with the sensor tag
name and the input block destination identifier.
c. The sensor cable end at the “Y” intersection end shall be labeled with both sensor tag
names and the input block destination identifier.
d. The sensor cable which combines 2 sensors, shall be labeled with both sensor tag names
and the input block destination identifier.
Note: The “Y” cord is labeled “A” or “14” or both on one branch and “B” or “12” or both on the
other branch. The end marked “A, 14” is automatically (pre-configured in the cable) the 1st
input of the port on the sensor block and “B, 12” is the 2nd input of the port.
Figure 12-13 Input Block, Switch and Cable Tagging Example

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12.6.1 Style Designation
Where multi-style tooling exists, device tags shall include style information according to the
following:
1. Cylinder tags do not require style to be identified on the work/home position tags.
2. Valve tags at the valve manifold shall include style information when the valve action is for
particular styles only. Valve actions in a multi-style tool that are common to all styles in the
tool do not require style information to be present.
3. Part present tags at the sensors shall include style information when the part present sensor
is for particular styles only. Part present sensors in a multi-style tool that are common to all
styles in the tool do not require style information to be present.

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13 Drawing section G: Pneumatic (compressed air)

13.1 Purpose
Various gases are used in the manufacturing process with the most common being compressed
air (commonly referred to as pneumatics). Section G of the Controls Drawing Package contains
the various schematics required for each pneumatic system. This section describes how to
design these systems.
13.2 Pneumatic design requirements
This section describes and illustrates how to design a pneumatic system from the plant air
header drop down to the components mounted on the tool. The following sections and
diagrams explain how to properly design the pneumatic drawing section.
13.2.1 Pneumatic design order
1. Pneumatic distribution and preparation
2. Valve manifolds and cylinder piping
3. Pneumatic Drills / Vacuum cups
4. Special Components (e.g., Surge tanks, Counterbalance systems)
13.2.2 Pneumatic drawing section structure
1. The ‘Section Letter’ in the title block shall be "G".
2. Use as many sheets as required to cover each topic and avoid overcrowding; topics may be
combined on a sheet where space permits.
3. Each sheet shall include all applicable legends and charts.
4. Reference the Common Controls Build Specification GCCB-1 for all pneumatic build and
construction guidelines.
5. Operating pressure shall be 0.55 MPa (80 psi), unless otherwise specified.
13.3 Air drops from plant supply
13.3.1 Cell (Controller) Air Prep
1. The Sheet Description shall be “CELL PNEUMATIC AIR PREP DIAGRAM”
2. The following note shall appear in the lower right corner of the air prep drawing:

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Figure 13-1 Cell Level Drawing Notes

3. The cell air drop shall be shown starting in the upper left-hand corner of the drawing. It
shall be shown teed from the plant air header. A lockable (in the off position only), self-
relieving ball valve shall be shown near the plant header. The cell air drop shall be piped or
hosed to the cell air/water stand which is located outside the gated area.
4. The standard air/water stand design provides for a 50 mm (2 in) cell air header. Cells which
may require larger standard liters per minute (slpm) (or standard cubic foot per minute -
scfm) may need to be designed with custom air/water stands and/or surge tanks. The
typical maximum flow rates for each size are shown below.
Table 13-1 Maximum Flow Rates
ID SIZE (inch) ID Size (mm) Flow (SCFM) Flow (SLPM)
0.50 15.799 32.5 920
0.75 20.930 69.6 1970
1.00 26.645 133.5 3780
1.25 35.052 280.4 7940
1.50 40.894 424.3 12015
2.00 52.502 834.8 23640
2.50 62.713 1348.3 38180
3.00 77.927 2428.6 68770
Note: Table 13-1 assumes 12 m of SCH 40 pipe at 80 psi (0.552 MPa) with a max pressure drop
of 2 psi (0.014 MPa) at maximum flow.
5. The cell air/water stand shall be designed with the following pneumatic components:
a. A lockable, self-relieving ball valve with muffler. A tag stating “Air Feed Shutoff” shall be
mounted on or near the ball valve.
b. A pipe trap to collect sediment and water from the plant header shall be provided with a
ball valve at the bottom end for cleaning.
c. Teed (branch tee) from between the ball valve and the pipe trap shall be a particulate
filter, (5.0 micron).
d. A coalescent filter, (0.3 micron), shall be provided after the particulate filter.
e. A system pressure regulator (with gauge) shall be provided after the coalescent filter. A
single check valve may also be required in parallel to the coalescent filter and the
regulator if recommended by the component manufacturer. This is to prevent possible
damage to the filter and regulator due to the reverse flow of air when relieving air
upstream from these components.

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f. A slow start lockout valve with muffler shall be provided after the cell’s regulator which
will provide for a single cell air header for robots and tooling. A tag stating “AIR
LOCKOUT” or “AIR SHUT OFF” shall be mounted on or near the slow start valve.
g. A tee shall be provided between the coalescent filter and the cell regulator. This tee
shall be plugged at one end and is reserved for plant use (e.g., quick disconnect for
tools).
Figure 13-2 Typical Cell Air Stand Schematic

13.3.2 Offline Tool Air Prep (Tools Fed Directly From Plant Air)
1. The Sheet Description shall be “PNEUMATIC AIR PREP DIAGRAM”
2. Offline tools and Cell-to-Cell Conveyors piped or hosed from the plant header shall have air
prep designed with the following pneumatic components:
a. A lockable, self-relieving ball valve with muffler to provide an air feed shutoff for
downstream air.
b. A pipe trap to collect sediment and water from the plant header. It shall be provided
with a ball valve at the bottom end for cleaning.
c. Teed off (branch tee) from between the ball valve and trap shall be in order, a manual
shut-off valve with muffler, a particulate filter (5.0 micron), a pressure regulator with
inline check valve, a coalescent filter (0.3 micron), and a pressure switch. A tag stating
“AIR FEED SHUT OFF” or similar shall be mounted on or near the manual shut-off valve.
Note: Tools that are part of systems that do not have I/O or a diagnostic display do not require a
pressure switch. A pressure gauge may be used for visual indication of air pressure.

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Figure 13-3 Typical Offline Station Air Prep

3. Standard sizes air prep for offline tools are ½”, ¾”,or 1”. Deviation from the standard sizes
shall require the approval of the GM project engineer. In all cases the air prep shall be equal
to or larger than the minimum size calculated according to Annex C.
13.4 Air drops from cell supply
13.4.1 Cell Air Header
A single cell air header shall feed all of the robots and tooling within the cell. Reference GCCB-1
for the header build specifications.
13.4.2 Unit (Station) Air Drop
1. The unit (station) air drop(s) shall connect to the cell air header with hose.
2. Each unit (station) air drop shall have its own lockable (in the ‘off’ position only) self-
relieving ball valve or shutoff with muffler, an inline particulate filter (5.0 micron) and a
pressure switch. These shall be located on or near the unit base or located with the water
shutoffs on operator load station.
Note: Tools that are part of systems that do not have a diagnostic display (2A designs) do not
require a pressure switch.
3. Unit (station) air drop(s) shall be sized according to Annex C.
13.4.2.1 Unit (station) Level Drawing Package
1. The sheet order for the unit (station) Level ‘G’ sheets shall be:
a. PNEUMATIC AIR PREP DIAGRAM – illustrates shut-off and filter for the unit (station).
b. PNEUMATIC VALVE MANIFOLD AND CYLINDER PIPING – illustrates each valve manifold
and the associated cylinder piping

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c. PNEUMATIC DRILLS / VACUUM CUPS - illustrates pneumatic drills/vacuum cups and
their associated components and piping.
2. The notes in Figure 13-1 shall appear in the lower right corner of all unit (station) level
drawing showing air prep and distribution.
13.4.2.2 Unit (Station) Valves and Cylinder Air Circuits
1. Unit (station) valves shall be controlled via a network interface (DeviceNet or EtherNet/IP)
integrated into the valve manifold.
Exception: If controlling less than 4 valves on a station (tool), it is permissible to control valves
from a separate output device (i.e., IP6X IO Blocks, IP20 I/O in a box) with cord connection to
the valve(s).
2. The number of unit (station) valves and their functions shall be determined from the
sequence of operations.
3. Units (stations) with multiple cylinder functions (i.e., multiple parts, independent LH/RH
actions, etc.) shall have independent control of the cylinders with separate valves.
Combining multiple cylinder functions on the same valve shall require the approval of the
GM Controls Project Engineer.
4. Provide a minimum of one spare valve position per unit (station). For LH and RH units, one
spare position per side should be provided. For small tools this requirement may be
omitted with the approval of the GM Controls Project Engineer.
5. Ports on pneumatic valves and manifolds shall be identified as 1, 2, 3, 4, and 5.
6. When possible, unit (station) valves shall be mounted in sequential order starting at the
network interface end of the manifold (left to right on the drawing sheet).
7. Valves shall be shown in section ‘G’ of the Controls Drawing Package, on the sheet following
the station air drop for that manifold. Required valve tag information shall be shown below
each valve. All cylinders connected to a valve shall be shown directly above that valve. The
cylinders shall be shown in their home position with the cylinder description, cylinder
number, bore, and stroke.
8. Connections from the valve to the cylinder (tube or hose) shall be colored per the WD
design. Pressure to work position is typically blue and pressure to home position is typically
gray or white.
9. Connections in the pneumatic circuit (tube, hose, pipe, etc.) that contain stored pneumatic
energy (trapped air) shall be identified with a caution label as shown in Figure 13-4 at each
connection point.
Exception: Multiple connections at a common point, such as a distribution manifold, may be
identified with a single tag at the manifold.

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Figure 13-4 Trapped Air Identifier for Tubing Example

10. The valve manifolds shall be named ‘PMx’ for pneumatic (‘HMx’ for hydraulic) sequentially
within their respective valve type.
Table 13-2 Valve IO Address Naming Rules for Network Manifolds
PMx = Pneumatic manifold numbered sequentially as they are used within a tool
Designates output (to match software tag address) for network manifolds
.O. =
only
Vx = Valve location on a manifold or sub-base (numbered sequentially)
S = Solenoid
14 = Pressure from port 1 to 4 (formerly called “A” port)
12 = Pressure from port 1 to 2 (formerly called “B” port)

a. Network Manifold IO Address Examples:

Valve PM1V1, IO Addresses (PM1.O.V1S12, PM1.O.V1S14)
Valve PM1V2, IO Addresses (PM1.O.V2S12, PM1.O.V2S14)
Valve PM1V3, IO Addresses (PM1.O.V3S12, PM1.O.V3S14)
Valve PM1V4, IO Addresses (PM1.O.V4S12, PM1.O.V4S14)
b. For individual valves plugged directly into IP6x IO modules, the address is determined by
the IO block into which it is plugged. Manifold PM2 valve 1 plugged into IO block BK04
example:
Valve PM2V1, IO Addresses (BK04.O.D00, BK04.O.D01)
Exception: Robot valves shall be addressed with the appropriate DO[xxx] address per GRS-4.
11. Tooling Valve Label Tag
a. The valve tag shall be a one-piece tag divided into 3 sections (top, bottom left, and
bottom right) with black text on a white background.
Exception: Blocked center valves resulting in stored pneumatic energy (trapped air) shall use
valve tags with black text on a yellow background.
b. The top section shall have the name of the valve function (e.g. 1st CLAMPS) on the 1st
text line, with the list of the cylinders that are controlled by the valve on the 2nd text
line.
c. The valve function shall indicate applicable style for multi-style tooling per 12.6.1.
d. The bottom left section shall have the verb action towards the operating or work
position of the function (CLOSE) on the 1st text line and the valve designator
(PM1.O.V1S14) on the 2nd text line.

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e. The bottom right section shall have the verb action towards the non-operating or home
position of the function (OPEN) on the 1st text line and the valve designator
(PM1.O.V1S12) on the 2nd text line.
f. The following is an example of a tooling valve tag layout. See GCCB-1 (Build
Specification) for tag dimensions, tag material, text placement, and text height.
Figure 13-5 Example Tooling Valve Tags

12. Robot Valve Label Tag

a. The valve tag shall be a one-piece tag divided into 3 sections (center, left, and right) with
black text on a white background.
Exception: Blocked center valves resulting in stored pneumatic energy (trapped air) shall use
valve tags with black text on a yellow background.
b. The center section shall have the name of the valve function (e.g., GRIPPER) on the 1st
text line, with the list of the cylinders that are controlled by the valve on the 2nd and/or
3rd text lines.
c. The valve function shall indicate applicable style for multi-style tooling per 12.6.1.
d. The left section shall have the verb action towards the operating or work position of the
function (CLOSE) on the 1st text line, the valve designator (V1A) on the 2nd text line, and
the robot address (DO[801]) on the 3rd text line.
e. The right section shall have the verb action towards the non-operating or home position
of the function (OPEN) on the 1st text line and the valve designator (V1B) on the 2nd text
line, and the robot address (DO[802]) on the 3rd text line.
f. The following is an example of a robot valve tag layout. See GCCB-1 (Build Specification)
for tag dimensions, tag material, text placement, and text height.
Figure 13-6 Example Robot Valve Tag

13. All valve manifolds with 8 or more positions shall have dual air feeds (air feed to the top and
bottom). Manifolds with less than 8 positions shall have dual air feeds when required to
satisfy the maximum tooling flow requirements.
14. All valve manifolds shall be fed with non-lubricated air.

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Exception: A separate manifold shall be used for valves that control cylinders requiring
lubrication. The air feed to this manifold shall have an inline lubricator. The exhaust ports on
this manifold shall use reclassifiers.
15. All manifold exhaust ports shall be plugged or muffled. Adequate mufflers shall be used to
satisfy manifold flow requirements.
16. The maximum number of cylinders piped to a valve shall be determined by flow rate
calculation. The air consumed of all cylinders within the designated cycle time shall not
exceed the capacity of the valve. See Annex C.
17. Figure 13-7 shall appear on all unit (station) level drawings showing cylinders that require
flow controls.
Figure 13-7 Flow Control Note

18. For all circuits that utilize PO checks or blocking valves resulting in stored pneumatic energy
(trapped air), a caution tag shall be supplied close to the point of trapped air and at the
station air prep. Example tags are shown below. Reference the hardware design templates
for tag details.
Figure 13-8 Example Trapped Air Tag for Station Shutoff

Figure 13-9 Example Trapped Air Tag for PO Check

Figure 13-10 Example Trapped Air Tag for Blocked Center Valve

19. For all circuits that have stored pneumatic energy (trapped air), a means for manual
pressure relief shall be provided (e.g., PO check with integrated pressure relief, residual
pressure relief valve). The means shall not require disassembly of the equipment to relieve
the pressure (i.e., cracking a fitting shall not be required).

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13.4.2.3 Pneumatic Circuits

Various types of circuits are used to control motions on pneumatic equipment. Because each
application can have different constraints, no single circuit is ideal for all applications. Some of
the factors that can determine which circuit to use for a particular application can include the
following:
1. Length of Motion – Cylinders that cause motion greater than 0.5 m require some type of
inching circuit where the motion can be interrupted at any point during the stroke. Motions
greater than 0.5 m typically involve larger more hazardous pieces of equipment with
potentially more complicated setup and adjustment. For this type of application, the
inching circuits provide the maintenance personnel additional control over the equipment.
2. Stopping Performance – For non-operator tooling inside a gated area, stopping time is
typically not a critical issue due to the time required for personnel to open a gate and then
be exposed to equipment. In applications where there are operators or other personnel
interacting directly with the equipment, the stopping performance of a circuit is a critical
factor in the selection and placement of the operator safety devices (Safe Distance
Formula). Unless the motion is very short in duration (i.e. Locating Pins, Pin/Hook Clamps)
inching circuits should be considered for all operator stations.
3. Ability to Hold Position - With all inching circuits care must be taken during the design to
consider the effects of gravity and potential air leaks. With simple detented (2 position)
valve circuits constant air pressure is maintained in one direction minimizing the impact of
gravity and air leaks. With blocked center or P.O. check circuits constant pressure is not
continually applied to the circuit resulting in the possibility of air leaking out over time. This
can result in drifting of the load and sudden motion (slamming) upon restart.
4. Stored Energy – With blocked center valves and P.O check circuits stored energy in the form
of trapped air or gravity hazards can be present even when the air supply is switched off. All
circuits that contain trapped air must be tagged appropriately.
Caution: Circuits resulting in stored pneumatic energy (trapped air) are not preferred and may
be used only where required. Trapped air circuits shall meet the requirements in G-DHS chapter
3. Any stored energy circuit deviating from a published template application requires a
deviation per G-DHS chapter 3.
13.4.2.4 Typical 2 Position Detented Valve circuit
The 2 position detented valve circuit is the standard circuit for all non-operator stations. This
circuit should also be used on operator stations for short stroke motions where the stopping
performance is not critical to the placement of the operator safety devices (light curtains, two-
hand control, safety mat). This circuit does not trap air and maintains air pressure even when
valve power is removed.

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Figure 13-11 Typical 2 Position Detented Valve Circuit

13.4.2.5 Inching/Holding/Stopping circuits

An inching circuit shall be used for any cylinder that causes a mechanical motion of 0.5 m or
more. There may be some cases where an inching circuit is required on cylinders that cause
mechanical motion less than 0.5 m. The stopping time of the mechanical motion may also lead
to the use of an inching circuit based on safe distance calculations. A GM Controls Project
Engineer shall approve any inching circuit which deviates from a published template application.
Dumps, slides and lifters are examples of where inching circuits are typically used.
1. The provision of locking (brake) cylinders is preferred for inching applications. It is required
to provide a locking brake cylinder when the mass > 65 kg. Use a 3-position pressure center
valve with dual regulators and a single solenoid valve for the locking port. A regulator on
the brake release valve may be required for some manufacturers’ brakes.

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Figure 13-12 Inching Circuit with Brake

2. If a locking (brake) cylinder is not possible (except when mass > 65 kg):
a. For cylinders with shock absorbers on the end of travel or a significant vertical load
(such as a lifter), use a 2-position valve with pilot operated check valves and a single
solenoid valve for the pressure release on the PO check valves.
b. For other applications use a 3-position exhaust center valve with dual pilot operated
check valves.
Figure 13-13 Inching Circuit with and without Release Valve

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c. For short mechanical motions (<0.5 m) less than 65 kg (e.g., clamps in operator station
applications), where minimum stopping time is desired, use a 3-position blocked center
valve.
Figure 13-14 Typical Stopping Circuit for Short Stroke Motions

3. For rodless cylinders the following circuit shall be used. For non-horizontal applications the
regulators can be adjusted to accommodate an unbalanced load. This is a pressure center
circuit so drifting due to leaking will be minimized. An external mechanical brake to
minimize oscillation and drift is preferred for these applications.

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Figure 13-15 Inching Circuit for Rod-less Cylinders

13.4.3 Robot air drop(s)

Not all robots require air. For instance, robots may be using servo-weld-guns which do not use
air. The following is for those instances where air is required on a robot application:
1. The robot air drop(s) shall connect to the cell air header with hose.
2. Each robot shall have its own lockable (in the ‘off’ position only) self-relieving ball valve or
shutoff (with muffler) located outside the gated area next to the robot controller. A
particulate filter (5.0 micron) may also be provided after the ball valve or shutoff. There
shall also be a note on the drawing next to the ball valve or shutoff stating “Mount in an
easily accessible location not more than 2 m above the servicing level”. A tag stating
“ROBOT AIR SHUT-OFF” shall be mounted on or near the ball valve or shutoff. Reference
drawing templates and GCCB-1 for details.
13.4.4 Tipdress air drop (if applicable)
1. Robots without air drops:
The air supply for the tipdress shall be connected to the cell air header with hose.
2. Robots with air drops:
The air supply for the tipdress shall be connected after the robot’s air supply shut-off
with hose.
13.5 Other Pneumatic Device Requirements
13.5.1 Automatic Pneumatic drills / vacuum cups
1. The air feed line for the drills shall be tapped off of the station air drop after the slow-start
lockout valve. The air feed shall have the following components, in order: automatic dump

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valve to shut off the air supply and relieve any downstream pressure, pressure regulator,
and a pressure switch.
Note: Tools that are part of systems that do not have a diagnostic display (2A designs) do not
require a pressure switch.
2. The air feed line to the drills shall be sized according to the flow (SLPM or SCFM) demand.
Follow the manufacturer’s recommendation.
3. The air feed to each drill shall be lubricated using an injection lube system. Lubrication shall
enter the air feed line where it enters the drill. Each drill shall have its own adjustable
injector, which shall cycle each time the drill is initiated. Lube oil reservoir shall be sized to
provide lubrication for a minimum of one week of full production. Figure 13-16 Drill Lube
System Notes shall appear in the lower left corner of all tool level drawings showing drill
lube systems.
Figure 13-16 Drill Lube System Notes

4. Exhaust air from drills shall not be released to the atmosphere, but, instead be reclassified.
A reclassification system sized to handle the exhaust volume of the drills shall be provided.
The system shall have a drain line piped to an accessible area of the tool and the drain ball
valve should be no more than 1220 mm above the servicing level. The reclassifying tank
shall have a tag stating as shown in Figure 13-17 Reclassifier Tank Tag.
Figure 13-17 Reclassifier Tank Tag

5. The air feed line to the vacuum cups shall be sized according to the flow demand. Line sizes
are shown in Table 13-1.
13.5.2 Surge tanks
Surge tanks (also known as receivers or storage tanks) are used to minimize fluctuations in air
pressure when a large volume of air is required over a relatively short period of time (high slpm,
scfm).

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Surge tanks and safety pop-off valves shall be constructed, tested, stamped, and approved in
compliance to the local standards (i.e. ASME for US). Some states and countries (i.e. Canada)
require certification of all pressure vessels. Reference GCCB-1 (Build Specification) for surge
tank certification requirements. Surge tanks shall be installed in the station air drop. Air tanks
shall be assembled using the following appropriately sized devices as standard components:
1. Safety pop off valve
2. Pressure gauge
3. Pressure switch
4. Spare port (plugged)
5. Manual drain (auto drain optional) from lowest point of tank relative to mounting position.
6. Blow-off with two-way ball valve and muffler
7. Check valve on inlet
13.5.2.1 Tooling surge tank sizing
Tooling surge tanks shall be used when the station air drop is unable to meet the tool slpm
(scfm) requirements. Most tools do not need a surge tank but, tools with air drills, vacuum slug
removal, air assists, etc. should be scrutinized for surge tank requirement. Be sure to check the
slpm (scfm) rating for any filter, regulator, etc. that is used in the air drop as they may further
limit the slpm (scfm) available to the tool. When sizing a surge tank be sure to verify that the
tank will recharge before the next cycle of the tool, this may require that the tank be larger than
first calculated
Note: For counterbalance surge tank applications, reference 13.5.3.

Note: The operating pressure for air drills and vacuum cups is not necessarily 0.58 MPa (85 psi).
Follow the manufacturer’s specifications for proper operating pressure.

To determine the size of the surge tank use the following formula:
V = [t x (Qout – Qin) x Pa] / (P1-P2)
Where:
Description Metric English
V = volume of tank Liters cu ft
t = time to charge or discharge Minutes Minutes
Qout = flow rate out Slpm Scfm
Qin = flow rate in Slpm Scfm
Pa = atmospheric pressure 0.101325MPa 14.7psia
initial tank pressure (usually plant line
P1 = MPa Psig
pressure)
final tank pressure (usually the lowest
P2 = MPa Psig
pressure that the tool can operate at)

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Example (Metric):
Qin = 2831.685 slpm
Qout = 7079.212 slpm
t = 9 seconds = 0.15 minute
P1 = 0.620 MPa
P2 = 0.483 MPa

2. Determine size of surge tank required (Volume)

V = [t x (Qout – Qin) x Pa] / (P1 – P2) = [0.15 x (7079.212 – 2831.685) x 0.101325] /
(0.620 – 0.483) = 471.22 liter

3. Determine time to recharge the tank (recharge between cycles):

Qout = 0 slpm
t = [V x (P1 – P2)] / (Qin x Pa)
= [471.22 x (0.620 – 0.483)] / (2831.685x 0.101325)
= 0.23 min
= 13.8 s

The surge tank’s exhaust valve shall be sized to ensure that the bleed-off and drainage
can be completed within 20 seconds.
13.5.3 Counterbalance system
A counterbalance circuit is designed to offset the weight that a motor shall lift. The following
method shall be used to size counterbalance tanks and determine regulator settings.
Information regarding the bore, stroke and load the counterbalance cylinders shall overcome is
to be obtained from the mechanical design source.
13.5.3.1 Counterbalance air feed
1. Shall connect to the station air drop.
2. A lockable self-relieving ball valve (in the off position only) shall be shown mounted not
more than 2 m above the servicing level in an easily accessible location. A note stating
“MOUNT IN AN EASILY ACCESSIBLE LOCATION NOT MORE THAN 2 METERS ABOVE THE
SERVICING LEVEL” shall be provided next to the valve.
3. A tee shall be mounted after the ball valve for connection of the counterbalance surge
tank(s).
4. A pipe trap to collect sediment and water from the station drop shall be provided with a ball
valve at the bottom end for cleaning.
5. The following components are to be connected, in order, from the tee to the
counterbalance surge tank: filter, slow-start lockout valve, regulator with check valve in
parallel to prevent back-feeding through the regulator when dumping air with lockout and a
pressure switch.
6. Two-way ball valve leading to each counterbalance surge tank.
13.5.3.2 Counterbalance surge tank sizing
Determine the % cylinder load and cylinder volume to find the minimum counterbalance tank
volume. Use the counterbalance tank volume, cylinder volume, and balance pressure to

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determine the initial regulator setting. The final regulator setting shall be determined by
balancing the motor load while the cylinder is extending and retracting. The following
abbreviations are for calculating the size of the counterbalance tank.
Table 13-3 Counterbalance Surge Tank Variable Definition
Variable Definition
B = Bore
S = Stroke
Wm = Weight motor is designed to lift each cycle
Weight the counterbalance cylinders are designed to
Wcb =
lift each cycle
Wm + Wcb is the sum of all forces the total system shall
Wtotal = overcome (e.g., weight of tooling, body, inertia, and
friction)
Wcb / Wtotal = % cylinder load
Wm / Wtotal = % motor load

The sum of the equations above should be 100%.

Table 13-4 shall be used to determine the size of a counterbalance tank based on the percent
load the cylinders shall lift. Locate the correct percentage in the cylinder load chart and use the
multiplication factor seen to the right. The cylinder volume (Vcyl) is the total volume of all
counterbalance cylinders that will be connected to this tank.
Table 13-4 Counterbalance Surge Tank Sizing
MINIMUM COUNTERBALANCE
CYLINDER LOAD (%)
TANK VOLUME (Vtk)
97.5 40 x Vcyl
95 20 x Vcyl
90 10 x Vcyl
85 6.67 x Vcyl

13.5.3.3 Counterbalance regulator setting

P = Pressure required to balance load = Wtotal / Acyl

The following formula shall be used to determine the initial regulator pressure setting.
Where: Vtac = volume of actual surge tank used
Regulator setting (Metric) = [[(P + 0.101325) x (Vtac + (0.5 x Vcyl))] / (Vtac + Vcyl)] –
0.101325

Regulator setting (English) = [[(P + 14.7) x (Vtac + (0.5 x Vcyl))] / (Vtac + Vcyl)] – 14.7

Example (Metric): 2 counterbalance cylinders 25.4 cm bore x 182.88 cm stroke

Wm = 531 kg; Wcb = 4776 kg; Wtotal = 5307 kg

Determine: Regulator setting

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% cylinder load = Wcb / Wtotal = 4776 / 5307 = 0.9 (90%)

Acyl = pi x R2 = 3.14159 x (25.4/2)2 = 506.71 sq cm

For 2 cylinders: Acyls = 2 x 506.71 = 1013.42 sq cm

Vcyl = Acyl x S = 506.71 x 182.88 = 92667.12 cu cm

For 2 cylinders: Vcyls = 2 x 92667.12 = 185334.24 cu cm

From Table 13-4 – Counterbalance surge tank sizing:

Vtk = 10 x 185334.24 = 1853342.4 cu cm

From Figure x – Standard surge tank sizes:

Vtac = 2 x 984207.1 cu cm = 1968414.2 cu cm

P = Wtotal / Acyls = 5307 / 1013.42 = 0.524 MPa

Reg set = [[(P + 0.101325) (Vtac + (0.5 x Vcyl))] / (Vtac + Vcyl)] – 0.101325
= [[(0.524 + 0.101325) (1968414.2+ (0.5 x 185334.24))] / (1968414.2 + 185334.24)] –
0.101325
= 0.497 MPa
The pressure setting above shall be the line pressure downstream of the regulator and check
valve. The downstream pressure of the regulator drops due to the cracking pressure of the
check valve.

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13.6 Assist and Fixtured Nutrunners (LAFN/FM), Air Logic
13.6.1 Definitions
1. Lift Assist tooling (LAFN): is tooling that is suspended from a bridge and rail system and
provides an ergonomic assist to an operator in picking a part and placing it for assembly.
Another type of Lift Assist is a fixtured nut runner. A fixtured nut runner is a nut runner that
is not handheld, but placed in a fixture to provide an operator with an ergonomic assist.
These types of tooling may be electric or pneumatic or have a combination of the two
energy sources.
2. Floor mounted (FM): This tooling may be electric or pneumatic or a combination of the two.
Examples include, but are not limited to manual weld stations, lift tables, and sub assembly
tables.
13.6.2 General
1. The pneumatic logic shall be designed to minimize air consumption and maximize speed of
the tooling.
2. The design shall use air logic elements for logic, and power valves for actuation of the tool.
Any proposed deviations shall be approved in writing before start of final design by the
responsible GM Controls Project Engineer.
3. The GM Common Handle shall be used on all designs. (Reference GMME tool# MAA59363).
4. Similar sequence operations from tool to tool shall use a common design, (e.g., retract
locating pins, unclamp, remove part, and extend locating pins are quite common for several
tools).
5. Refer to GCCB-1 for more detailed information regarding tool build requirements.
13.6.3 Design
1. Tool pressure shall be regulated to a maximum of 0.55 MPa (5.5 bar, 80 psi) or less for
efficiency of air usage.
2. All logic and power valves shall be ISO certified and rated for dry service only.
3. Lubrication shall only be designed into the system on an exception basis as required by the
mechanical design (e.g. pneumatic nut runners). Multi-port injectors shall be used.
Lubrication shall enter the circuit only at the point of use. All effort shall be made to limit
lubrication to its specific device to avoid contamination. All necessary components shall be
utilized to recapture the lubricant - such as reclassifiers etc. Lubrication shall be confined to
only those components that require it. Exception shall be signed off and dated by the GM
engineer.
4. All LAFN/FM designs shall be drawn to show direct connection of piping and minimize the
use of corners and backtracking.
5. All equipment shall have an air prep circuit installed in the order outlined in GCCB-1.
6. All LAFN/FM drawings shall flow from left to right, then top to bottom.
7. Air power drawings shall show hose, piping, tubing, tees, power valves, cylinders, flow
controls and all circuit components.

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8. All notes are shown in the lower right hand column of the sheet.
9. Pushbuttons shall be labeled according to Ergonomics Engineering/Vendor Guidelines for
Assists & Specialized Tools. LAFN/FM push button color and naming convention shown
below, order of preference is left to right
Table 13-5 Pushbutton Color and Naming Convention
Control
Color Control Function
Location
Right White clamp up on high in Raise start faster
Left Black unclamp down off low out lower stop slower

10. All cylinders shall be shown in their home positions and all cylinder information shall be
supplied. (Bore & Stroke).
11. The following color code shall be utilized for tubes and hoses for LAFN/FM Tooling.
Table 13-6 Tube or Hose Color Coding
Color Function
Air to power valve pilots from controls, signal line; from push buttons or logic
Green
elements to power valve(s).
Blue Cylinder to work position, air supply to controls, power valves, and vacuum
White or Grey Cylinder to home position

12. The color code shall be located on each “G” page and placed in the upper right hand corner
of each page.
13. Tube, pipe and hose labeling shall be in numerical sequential order beginning with the
number one.
14. A note, showing which pipe, hose and tube numbers are not used and the last pipe, hose or
tube number used, shall be on the drawing on sheet G1.
15. All pipe, hose and tubing numbers and colors shall be appropriately identified on the piping
diagram.
16. Passive devices, such as bulkhead connectors shall have the same number entering as well
as exiting.
17. Shuttle valves shall have numbers at each of its ports.
18. All valves shall be shown mounted and numbered in the relative order that they are
activated in the normal sequence of operations.
19. Air logic sequencers, shift registers, and any other complex logic components shall not be
used.
20. All logic elements shall be mounted on a plate.
21. All detented memory elements shall have manual overrides.
22. All design efforts shall be made to avoid using amplifier valves.

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23. Timer elements shall only be used on exception basis and require GM Controls Project
Engineer approval.
24. Timers shall not be accepted as a method for confirmation of cylinder movement.
25. All vacuum circuits shall be designed to maintain the part(s) for at least 15 seconds after loss
of working air supply.
26. Control prints shall include suggested millimeter of mercury (mmHg) settings for vacuum
circuits.
27. Control prints shall include MPa (bar, psi) pressure settings for all regulators.
28. Meter in flow controls shall not be used.
29. Designs shall include flow controls for all cylinders to be used to adjust the speed of the
cylinder.
30. All flow controls and mufflers/silencers shall be shown and called out on the BOM.
31. All components, except pipe hose and tubing, shall be shown and called out on the BOM.
32. Ball valves shall not be used after the slow start.
13.6.4 Valves
1. All power valves shall be located on a plate; exceptions are made for valves that shall be in
close proximity to the cylinders which they actuate.
2. Limit valves shall be utilized to confirm cylinder location when required for equipment
safety and sequencing.
3. All electrically piloted valves (i.e., tool running signal from electric nut runners), shall have
LED indicators.
13.6.5 Enclosures for Pneumatic Components
1. Enclosures shall not be used. Pneumatic control components shall be mounted on a plate.
Deviations to use enclosures shall require GM Controls Project Engineer approval.
2. When an enclosure is required, the control enclosure shall be designed to contain all logic
components for all floor mounted equipment, equipment supported from balance cylinders,
torque tubes, articulating arms or similar rigid vertical mounts. The following shall apply:
a. Pneumatic control components shall be mounted on the sub-plate of the enclosure.
b. Mounting pneumatic control components on the enclosure walls is prohibited.
c. Each control enclosure shall have a breather vent located in the bottom of the right
hand side.
d. Hose and tubing entering/exiting an enclosure shall use individual or multiple port
bulkhead connectors.
e. When two or more run button assemblies are used, the run button assembly
commanding the most operations shall house the majority of components. This is to
keep the exterior air connections to a minimum and concentrate logic trouble shooting
to one main enclosure.
f. Provide at least 20% usable spare space.

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g. All items shall be mounted for ease of serviceability.
13.6.6 Electrical Connections of Fixtured Nutrunners
1. All electrical connections of fastening controllers shall be labeled and shown in detail in the
controls print. This includes, but is not limited to:
a. Ethernet connections and switches
b. DeviceNet connections
c. Receptacle wiring.
d. Terminal strip wiring
e. Phoenix connector wiring
2. All numbers and colors shall be identified on the controls print.
3. All hose and cabling and wiring shall have labels on both ends within 25 mm and on all
connectors, receptacles.
4. All wiring shall have numbers and the color of the wire and number shall be reflected in the
prints.

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14 Drawing Section H: Hydraulic and Lube

14.1 Purpose
Mechanical processes such as piercing, machining operations, metal forming (flanging), and
hydroforming will dictate the need for hydraulic and lubrication systems. Both of these systems
must be designed to provide proper flow to the required devices. Improper flow can result in
shortening the life of certain devices as well as improper function of devices.

The purpose of this section is to illustrate how to design hydraulic and lubrication systems. This
section will describe the hydraulic circuits and lubrication circuits, including the components,
valve packs, valve wiring and air circuits. This section shall also describe the interface to the
Hydraulic Power Unit (HPU) which delivers the hydraulic fluid to the tools.
14.2 Design Requirements
The design shall be in compliance with the GM Global Hydraulic Standard (GM1744) and the GM
Lubrication Standard LS1, unless the standards found in this document are more specific. The
hydraulic/lubrication piping and hosing diagrams may be shown in the controller (cell) level
and/or the unit (station) level drawing package.
14.2.1 Contents of the Controller (Cell) Level Drawing Package May Include:
1. headers
2. drops
3. system main ball valves
4. unions and tees
5. shared hydraulic power units (HPU’s)
14.2.2 Contents of the Unit (Station) Level Drawing Package May Include:
1. ball valves
2. manifolds and valves
3. accumulators
4. dump valve circuits
5. hydraulic power unit (HPU)
14.3 General Design Requirements
1. The SECTION LETTER “H” shall be shown in the lower right-hand corner of the title block.
2. The main design principle shall be one hydraulic system per cell. Sharing HPU’s between
different controllers (cells) requires GM Controls Project Engineer approval.
3. The hydraulic schematics shall precede the lubrication schematics in both the controller
(cell) level and the unit (station) level drawing packages. The unit (station) level drawing

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package shall place sheets of this section in the following order: hydraulic drops, hydraulic
manifolds and valves, followed by the lubrication system drawings, including all pneumatic
circuit connections (for air over oil systems and lubrication systems).
4. All components within the hydraulic system shall be rated at 206 Bar (20.6 Mpa, 3000 psi)
operating pressure, unless otherwise specified by the project equipment specifications.
5. Schematic hydraulic and lubrication lines shall be labeled on all drawings with their
corresponding size.
• The first sheet of the hydraulic portion of this section in the controller (cell) drawing
package only shall include the following legends and notes to be used for design and
build of all hydraulic schematics. If the unit (station) is stand-alone, then these legends
and notes shall appear on the first sheet of the unit (station) package as well (where
applicable).
• The note shown in Figure 14-1 shall appear near the bottom and to the right of the last
HPU shown for units (stations) requiring multiple HPU’s feeding the same hydraulic
system.

Figure 14-1 HPU Notes

• The note shown in Figure 14-2 shall appear in the lower left corner of the drawing. It
shall include the total hydraulic system requirements in terms of gallons per minute
(GPM) and the hydraulic header design pressure.

Figure 14-2 Hydraulic System Notes

14.4 Controller (Cell) Level Design Requirements

14.4.1 Header Design Requirements
1. The hydraulic header lines are to be labeled with tank (T), pressure (P), drain (D) and their
respective size.
2. A lockable ball valve shall be placed between the HPU and the header manifold. There shall
also be lockable ball valves for the tank and drain when 2 or more HPU’s are utilized.
3. All lockable ball valves shall be monitored.
4. Headers shall be sized to meet the requirements of the equipment specifications.

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5. Maximum header pressure shall be 206 Bar (20.6MPa, 3000 PSI), unless otherwise specified
by the project specifications. Special applications which require higher pressures require GM
Controls Project Engineer approval.
6. Over-temperature and under-temperature switches shall be provided if the mechanical
specifications of the equipment require the oil to be at a certain temperature for operation.
These switches and the appropriate heaters/coolers shall be shown on the first sheet of the
hydraulic portion of this section in the controller (cell) level package.
14.4.2 Hydraulic Power Units (HPU)
Note: HPU designs require GM Controls Project Engineer approval.
14.4.2.1 HPU Oil Supply Source
1. Hydraulic oil shall be supplied to the unit (station) from the hydraulic power unit (HPU). This
oil shall meet the GM Maintenance Lubricant Standard LS2 (GM1721).
2. Hydraulic oil shall be compatible with the system seals.
14.4.2.2 Hydraulic Power Unit Interface
1. Power, control, and communication cables for the standard Hydraulic Power Unit (HPU)
shall be routed in compliance to (GCCB-1).
2. A multi-conductor cable may be used to supply the high voltage motor power feed if the
HPU motor starter is remotely located. This multi-conductor cable must include a means to
de-energize the high voltage in the event the cable is disconnected under load (a second
motor start contact must be used if the pump is to be control reliable). The preferred
method to accomplish this is to use a 6-pin cable with 3 power conductors, ground, and two
conductors for a ‘cable connected/disconnect on’ signal. This ‘cable connected/disconnect
on’ signal is wired to an auxiliary contact on the disconnect switch through two shorter 4
mm2 (#12 AWG) pins in the 6-pin receptacle. If the disconnect is “off” or the cable is
disconnected under load, the shorter pins in the receptacle disable the signal to the motor
starter before the high voltage pins separate.
3. A means to disconnect and lockout motor power must always be provided on the HPU.
4. Network (DeviceNet or EtherNet/IP) compatible input module(s) shall be mounted on the
HPU to monitor all system status switches and faulted condition. These conditions shall
include but are not limited to the following signals:
a. Hydraulic oil pressure on - a normally open signal which closes when above the
operating set point.
b. Hydraulic oil over-pressure fault - a normally open signal which closes when above the
high set point.
c. Hydraulic oil over-temperature warning - a normally closed signal which opens when
above the normal operating temperature range setting.
d. Hydraulic oil over-temperature shutdown - a normally closed signal which opens when
above the maximum shutdown temperature setting.
e. Hydraulic oil low level warning - a normally closed held open signal which opens when
below the low level oil set point.

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f. Hydraulic oil low level shutdown - a normally closed held open signal which opens when
below the low oil level shutdown point.
g. Filter dirty sensors for each filter - a normally closed signal which opens when filter
requires replacement.
h. Motor disconnect on - a normally open held closed signal which opens if the disconnect
is in the “Off” position.
i. Hydraulic oil heater disconnect on - [if used] a normally open held closed signal which
opens if the disconnect is in the “Off” position.
5. Each HPU faulted condition shall be enunciated by one of the following methods mounted
on or near the HPU:
a. using pilot lights driven directly by the sensor.
b. using pilot lights driven by output modules.
c. using an alpha-numeric display.
6. The HPU I/O modules need not be distributed network modules if a dedicated PLC is used.
This PLC must however, be connected via Ethernet to the associated controller (cell) PLC.
This connection shall provide motor control and diagnostics to the cell HMI, as well as the
ability to upload/download the HPU PLC program.
7. Sensors shall be provided to de-energize the HPU motor starter if a faulted condition occurs,
which will damage equipment or endanger personnel. These conditions shall include but are
not limited to the following signals:
a. Hydraulic oil over-temperature shutdown - a normally closed signal
b. Hydraulic oil low level shutdown - a normally open held closed signal
c. Motor disconnect on, a normally open held closed signal
14.4.2.3 HPU E-Stop Requirements
All e-stops associated with a particular controller (cell) shall shut off the motor of the HPU and
discharge the accumulator to the tank (if accumulator is present in the system).
14.5 Unit (Station) Level Design Requirements
14.5.1 Isolation Valves and Accumulators
1. Isolation valves are devices that block flow and pressure of the hydraulic system. Isolation
valves shall be used as needed per project specifications and require GM Controls Project
Engineer approval.
2. A pressure switch shall be supplied with each isolation valve for monitoring pressure
downstream, or as project specifications require.
3. If the demand of the equipment is greater than the output of the designed hydraulic system
then either an accumulator or additional HPU’s will be necessary. An accumulator or
additional HPU requires GM Controls Project Engineer approval.
4. Accumulators shall be sized according to the chart located at the end of this section.
Accumulator sizing example:

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The hydraulic demand chart notes the greatest hydraulic demand is 120 GPM for a
period of 3 seconds. If the hydraulic system can deliver 80 GPM then the demand
exceeds the design flow by 40 GPM. Therefore, an accumulator capable of delivering 40
GPM in 3 seconds is needed. The following formula shall be used to determine the size
of the accumulator that is needed.
- Volume = GPM x TIME (minutes) x 3.85

For the application above a 10 gallon accumulator is required.

5. All accumulators shall be charged per the hydraulic system requirements.
6. If an accumulator is required, refer to section 14.5.2 for isolation and safety requirements.
14.5.2 Dump Valve Circuits
1. Set the relief valve pressure at 15% above the hydraulic system pressure.
2. A hydraulic dump valve circuit shall be included in the hydraulic system design when an
accumulator is required.
3. An accumulator must be dumped when used in conjunction with an isolation valve. The
isolation valve can dump the downstream accumulation at approximately 3 GPM. All
downstream accumulation must be dumped in 30 seconds. If the isolation valve cannot
dump the downstream accumulation within the required amount of time, a dump circuit is
required. The dump circuit valve must be sized to accomplish the complete dump in 30
seconds or less. The following formula shall be used to size a dump circuit valve.
4. GPM (Valve) = Accumulator Volume (cubic inches) / 115.3 Where the Accumulator Volume
(cubic inches) equals the available volume of the accumulator when the accumulator charge
pressure is 34.5 bar (3.45 Mpa, 500 psi) and the header pressure is 69 bar (6.9 MPa, 1000
psi) [these values are dependent upon the system requirements].
14.5.3 Manifolds, Valves and Actuators
1. Each manifold block for a specific unit (station) shall be numerically labeled in an increasing
sequence and shown in “SECTION H” in the sheet description of the tooling level drawing
package in that same order.
2. Valve manifolds shall have a minimum of two (2) stations, but no more than six (6) stations
with one spare station per valve manifold. (A station on a valve manifold is the location at
which the valve occupies.) The stations shall be labeled on the manifold as #1 at the top and
sequentially increasing moving down the manifold. The last station of the manifold shall be
labeled as the spare station, unless the manifold includes a dump valve, in which case the
spare station will be the next to last position.
3. There shall be a label centered directly above the valve detailing its respective operation
along with output designations.
4. The valve manifolds shall be labeled sequentially within their respective valve type. ‘P’ for
pneumatic and ‘H’ for hydraulic.
Note: Because hydraulic and pneumatic diagrams are in separate sections of the drawing
package, the valves must be designated uniquely with “H” and “P”. This will avoid confusion in
manifold numbering, especially when adding a manifold to an existing drawing package.

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HMx = Hydraulic manifolds or individual sub-bases numbered sequentially as

they are used within a tool
Vx = If manifold mounted, the valves are numbered sequentially according to
their position on the manifold. V1 is the 1st valve on the manifold, V2 is the 2nd
valve,..etc.
If sub-base mounted, number sequentially for each section (HV1, HV2, HV3…etc) within
a tool.
A = Pressure port when valve is actuated to “work” position.
B = Pressure port when valve is actuated to “load/unload” (home) position.

Example:
Tool with 1 hydraulic manifold (with 4 valves) and 2 separate hydraulic valves.
Manifold valves = H1V1A, H1V1B, H1V2A, H1V2B, H1V3A, H1V3B, H1V4A, H1V4B
H2V1A, H2V1B, H3V1A, H3V1B
5. The valve label shall be a one-piece white lamacoid tag etched into 3 sections. The top
section shall have the name of the valve function (e.g. 1st CLAMPS) on the 1st text line, with
the list of the cylinders that are controlled by the valve on the 2nd text line. The bottom
section is divided into 2 equal sections with 2 lines of text. The lower left side shall have the
verb action towards the operating or work position of the function (CLOSE) on the 1st text
line and the valve designator (H1V1A) on the 2nd text line. The lower right side shall have
the verb action towards the non-operating or home position of the function (OPEN) on the
1st text line and the valve designator (H1V1B) on the 2nd text line. Reference Figure 14-3.
Reference GCCB-1 for tag dimensions, text placement, and text height.
Figure 14-3 Example Valve Tags

6. Each valve and manifold shall be labeled with tank (T), pressure (P) lines, ports (A) and (B)
and test points (TPx).
7. Tube/hose size shall be shown between each cylinder and valve manifold group.
8. Each cylinder shall be shown below the valve with the cylinder number, bore, and stroke.
9. There shall be a maximum of three (3) sandwich mounted devices between the directional
valve and the manifold. For example:
a. Flow control valve
b. Pressure reducing valve
c. Pilot operated check valve

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10. ‘Low-pressure drop’ check valves or other suitable anti-siphon devices shall be used on the
tank and drain lines to prevent back-flow. Lockable ball valves, with monitored limit
switches, shall be used on the pressure line feeding valve packs for shut-off purposes.
11. Directional valves shall have respective pressure reducing valves (sandwich regulator), if
required by project specifications.
12. Tubing runs from the manifolds shall be taken to a bulkhead connection in close proximity
to the cylinder. Hose shall be used to complete the run from the bulkhead connection to
the cylinder.
13. Manifolds shall be externally drained, if required by the system specifications or
requirements.
14. A pressure switch shall be piped upstream of each valve manifold, opposite the side the
pressure line is fed. This switch is for individual manifold pressure indication.
15. Gage isolators shall have a port for each active station pressure and the manifold pressure.
16. Occasionally the volume of fluid in the lines between the valve and the cylinder is greater
than the volume of fluid in the cylinder. In this case, a flushing bypass circuit may be
required. If required, the circuit shall be located at or near as possible to the hydraulic
cylinder ports. A cylinder port will connect to the opposite cylinder port via an appropriately
sized ball valve. The circuit is designed to completely flush oil through hydraulic lines in a
maintenance situation. The flushing valve shall be labeled on the drawing and the tool:
“HYDRAULIC MAINTENANCE FLUSHING VALVE”
“OPEN TO FLUSH SYSTEM – CLOSE TO RUN TOOL”
14.5.4 Air Over Oil Systems
Note: Most air over oil systems are turnkey units. Examples are pierces by REO and BTM. The
turnkey vendor shall supply equipment specifications for these systems.
1. All components of the air over oil system shall be shown on one page in SECTION H.
2. There shall be only one cylinder per valve for all pierces.
3. If there is only a single pierce on a valve manifold then a regular hydraulic gage may be used
instead of a gage isolator.
4. Reclassifiers shall be used to maintain an exhaust atmospheric oil level acceptable to the
plant receiving the equipment. If a standard reclassifier is not sufficient to meet this
criterion then a central reclassifier system must be used.
5. The pneumatic manifold, valve, reclassifier, and connections to the intensifier unit shall be
shown to the left most area of the page. The hydraulic manifold, valve, cylinder(s),
switches, and connections to the tank shall be shown to the right most area of the page.
The intensifier unit shall be shown between the pneumatic and hydraulic manifolds with the
tank, required P.O. checks and switches.
6. There shall be a reference connection to the pneumatic manifold detailing the origination of
the feed line. The detail shall include a sheet description of section identification, sheet
number and drawing package identification if necessary, i.e., From G-XX, WD-XXXXX

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7. There shall be a note to the right of the hydraulic manifold and vertically parallel with the
pressure reducing valve that reads DO NOT ADJUST WITHOUT CONSULTING THE
MANUFACTURER FOR PROPER SETTINGS.
8. All labeling shall follow the conventions outlined in section 14.5.3.
14.5.5 Lubrication Systems
Note: For lube systems which are turnkey units, the turnkey vendor shall supply equipment
specifications.
1. All components of a lubrication system shall be shown in SECTION H.
2. There shall be a graphical representation of the lube injection unit with overall dimensions.
This representation shall also include any adjustment points, gage readouts as well as all
lube, pneumatic and electrical connections.
3. The following note shall appear in the upper left-hand corner of the drawing in section H.
Note: SET SYSTEM TO CYCLE EVERY xx CYCLES FOR xx SECONDS
ALL BEARING LINES TO BE 5 mm2 (0.1875 in) O.D. TUBE, MIN. SIZE
4. A chart similar to Table 14-1 that calls out each lube point shall be shown in the lower left
corner.
Table 14-1 Lube Chart
TOTAL SQ. IN. R=rear
LUBE TOTAL LUBE
AMOUNT OF PER M=mid
POINT SQ. IN. DESCRIPTION
POINTS POINT F=front
1 1 xx.x xxx.x PINION DRIVE M
2 1 xx.x xxx.x RACK/GEAR F
3 1 xx.x xxx.x STAR BRG. BLOCK F

5. There shall be a graphical representation of the lube block relating each lube point to a
description of its destination.
6. There shall be a schematic of all lube connection points and lines. This schematic shall also
include; the low level OK proximity switch, lube cycle proximity switch, the mechanical
device which moves the lube material, the cross-porting bars, any required pneumatic
solenoids and the direction of flow of the lube material. There shall be a reference
connection to the pneumatic solenoid detailing the destination of the feed line. The detail
shall include a sheet description of section identification, sheet number and drawing
package identification if necessary (i.e., FROM sheet G2 of WD-xxxxxxx).
14.5.6 Drills
Reference section 13.5.1.

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Table 14-2 Hydraulic Demand Chart

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Table 14-3 Accumulator Sizing

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15 Drawing Section I: Water

15.1 Purpose
This section describes and illustrates the proper method of designing water-cooling systems for
resistance welding equipment.

The example drawings outline the proper format, which shall be used for presenting this section
within a controls package. The details found within the example drawings are only for reference
purposes. Although each control package is different, this detailed format shall be followed.
15.2 Importance of Water to the Weld Equipment
High levels of heat are generated during the resistance spot welding process in both the parts
being welded and the components carrying the welding current. Water flow diagrams specified
in this standard have been designed to maintain the manufacturer’s specified operating
temperature.
15.3 Water Flow Requirements
1. Component water flow:
Table 15-1 Minimum Flow Requirements for Weld Components
Component Flow Req (LPM) Flow Req (GPM)
AC Transformer 3.8 1.0
DC Power Supply – TR231A, TR232A, TR233A, TR234A,
7.6 2.0
TR235A, TR236A
DC Power Supply – TR237A, TR238A, TR239A 15.2 4.0
DC Power Supply – TR262A, TR264A, TR265A 3.8 1.0
Global 1 Weld Gun Arm/ Electrode Cap 1.9 0.5
LS Series Weld Gun Arm/ Electrode Cap 3.8 1.0
Jumper Cable 3.8 1.0
Kickless Cable 7.6 2.0
Weld Gun Arm/ Electrode Cap 1.9 0.5
Bus Bar* 3.8 1.0
Shunt/ Cable Adaptor 3.8 1.0
Welder Control 3.8 1.0
DC Cable Used with Pogo Welding 3.8 1.0
Combined Global Robot Package – 1 LS Series Weld Gun, 1
11.4 3.0
MFDC Transformer (TR262A, TR264A, TR265A), 1 WC**
Combined Global Robot Package – 1 LS Series Weld Gun, 2
11.4 3.0
MFDC Transformers (TR262A, TR264A, TR265A), 1 WC**
Combined Global Robot Steel Welding Package – 1 Global 1
15.2 4.0
Weld Gun, 1 MFDC Transformer, 1 WC**

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Component Flow Req (LPM) Flow Req (GPM)
Combined Global Robot Aluminum Welding Package – 1
Global 1 Weld Gun, 1 MFDC Transformer (TR237A, TR238A, 22.8 6.0
TR239A), 1 WC**
LPM = Liters Per Minute GPM = Gallons Per Minute 1 GPM = 3.8LPM
* Bus Bars require water cooling when they exceed a length of 0.6 m or an ECTCsec of
2,000 A. (ECTC = Equivalent Continuous Thermal Current)
** These are the total flow requirements for the entire robot drop from the header.
The flow through the water saver portion of the circuit will be 3.8 LPM (1 GPM) less.
Refer to type of transformer used before finalizing aluminum welding flow
requirements.
2. Series Water Flow: When components are piped in series (e.g., kickless cables to water-
cooled jumpers or a transgun transformer to shunt adaptors), the component in the welding
circuit with the highest flow requirement determines the minimum water flow requirement
for that welding water circuit.
3. Parallel Water Flow: When components are piped in parallel (e.g., movable gun arm and
stationary gun arm), the sum of the individual components determines the minimum water
flow requirement for that welding water circuit.
15.3.1 Flow Tables for Hose and Flex tube
For proper design of controller (cell) and unit (station) water circuits, reference the following
tables for hose, and flex tube. For maximum flow capacities of Standard Black Iron Pipe,
reference the GM Worldwide Facilities Group’s MDG-7 specification. For other piping materials,
reference the appropriate manufacturers’ specifications for flow capacities.
Table 15-2 Smooth Bore Hose (I.D.)
Velocity Velocity Loss/m Loss/Ft.
Size (in) LPM GPM I.D. (in)
(m/s) (ft/s) kPa (psi)
5/8 19 5 0.625 1.61 5.27 0.18 0.0260
¾ 28.4 7.5 0.750 1.64 5.4 0.26 0.0385
1 53 14 1.000 1.69 5.55 0.23 0.0338
1¼ 94 25 1.250 1.95 6.4 0.17 0.0247
1½ 140 37 1.500 2.02 6.65 0.18 0.0260
2 268 71 2.000 2.19 7.20 0.22 0.0316
2½ 427 113 2.500 2.24 7.36 0.19 0.0286
3 617 163 3.000 2.24 7.36 0.16 0.0242

Table 15-3 Flex Tube

Velocity Velocity Loss/M Loss/ft
Size (mm) LPM GPM I.D. (mm)
(m/s) (ft/s) (kPa) (psi)
6 0.75 0.2 3 1.78 5.85 2.9 0.42
8 1.9 0.5 5 1.6 5.27 1.4 0.2
10 3.4 0.9 6.5 1.7 5.6 1.2 0.18
12 5.3 1.4 8 1.75 5.7 1.0 0.15
14 7.6 2.0 10 1.6 5.27 0.7 0.10

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Velocity Velocity Loss/M Loss/ft
Size (mm) LPM GPM I.D. (mm)
(m/s) (ft/s) (kPa) (psi)
16 11.0 3.0 12 1.6 5.5 0.6 0.09

15.4 Drawing Package Level Definition for Section I

1. The water piping and hosing schematics are divided into two distinct drawing packages,
controller (cell) Level and unit (station) Level.
a. The controller (cell) level drawing package shall include the controller (cell) air/water
stand (with main ball valves), headers, and drops to units (stations/robots). It does not
show the unit level detail.
b. The unit (station) level drawing package picks up where the controller level leaves off.
The unit level shall include the individual unit’s water feed and return ball valves,
gauges, water flow switch, manifolds, and tool welding equipment (e.g., weld guns,
water cooled cables, transformers). An offline unit (stand-alone station) may also
require its own air/water stand and be fed directly from the plant header.
2. In both the controller level and unit level packages, tables, legends, and notes shall be
shown on the diagram.
3. The SECTION LETTER “I” shall be shown in the lower right corner of the drawing title block.
15.4.1 Component Symbols
The following symbol legend shall appear at the bottom left corner of the water diagram.
Figure 15-1 Symbol Legend

15.5 Controller (Cell) Level (Water Preparation, Header, and Drops) Design Requirements

Note: Reference GCCB-1 for proper construction and assembly of water systems.
1. An approved air/water stand assembly shall be provided for each cell consisting of a shut-off
ball valve and gauges on the feed and return lines and a water strainer on the feed line.
2. The water system design assumes an optimum of 0.276 MPa (2.76 bar, 40 psi) differential
for the feed/return supply at the air/water stand.

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3. COLOR: Hoses and flex tube shall be green for water feed and red for water return.
Exception: Hoses > 25 mm (1 in) are not required to be color coded). Pipe headers shall be
identified with snap-on pipe markers which provide color and direction of flow. The pipe does
not need to be painted a specified color (i.e., standard stainless steel or black pipe is acceptable.
15.5.1 Controller (Cell) Level Documentation
1. The water preparation schematic shall begin at the top left side of the sheet and proceed
down in the following order:
a. Two way ball valves
b. Pressure gauges
c. Strainer on the feed line.
2. The schematic should then proceed from the left to the right of the page with successive
drops.
3. Both the header feed and return lines shall be shown as equal length runs and fed from the
air/water stand.
4. The feed and return ball valves shall have the appropriate label mounted nearby indicating
‘WATER FEED SHUT-OFF’ or ‘WATER RETURN SHUT-OFF’.
5. The following notes shall appear in the bottom right corner of all water schematics for both
the controller (cell) and unit (station) level drawings:
NOTES:

1. BEFORE BUILDING ANY WATER SYSTEMS, READ ALL CONSTRUCTION NOTES

CONTAINED IN GCCB-1 BUILD SPECIFICATION.
2. INSTALL UNIONS AS REQUIRED TO EASE REMOVAL OF COMPONENTS.
3. BALL VALVES SHALL BE MOUNTED A MAXIMUM OF 2 METERS ABOVE THE
SERVICING LEVEL.

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Figure 15-2 Example Controller (Cell) Level Water Diagram

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15.6 Unit (Station) Level Design Requirements
Note: Reference GCCB-1 for proper construction and assembly of water systems.
1. Each unit (station) with water shall have both a ‘feed’ and ‘return’ shut-off valve.
2. Each unit (station) with water shall have a flow switch in the ‘return’ line.
3. The feed/return pressure differential at the water shut-offs’ pressure gauges shall be 0.138
MPa (1.38 bar, 20 psi).
4. Water feed and return from headers to units (stations or robots) shall be hose.
5. Water hoses for the water “IN” (feed) lines shall be green.
6. Water hoses for the water “OUT” (return) lines shall be red.
7. Water return hose size from header to unit (station or robot) shall be same size as water
feed hose.
8. All jumpers (flex tube or hose) shall be green.
9. Flex tube for the welder control shall be 10 mm (0.25 in) I.D.. The smaller flex tube size is
used to restrict water flow, which would otherwise “rob” the proper water flow to other
components in the circuit. This also prevents erosion of the water passage within the SCR
package.
10. Weld guns that perform two welds or less per tooling cycle may have their tips piped in
series. Weld guns that perform more than two welds per tooling cycle shall have their tips
piped in parallel.
15.6.1.1 Unit (Station) Level Documentation
1. Each unit (station) level schematic shall show the water feed and return lines in the
following order:
a. Two way ball valve
b. Pressure gauge
c. Flow switch (water return only).
2. Manifold pairs shall be shown horizontally, and they shall be located near their respective
weld guns and transformers.
3. The following note shall appear in the bottom right corner of all water schematics for both
the controller (cell) and unit (station) level drawings:
NOTES:

1. BEFORE BUILDING ANY WATER SYSTEMS, READ ALL CONSTRUCTION NOTES

CONTAINED IN GCCB-1 BUILD SPECIFICATION.
2. INSTALL UNIONS AS REQUIRED TO EASE REMOVAL OF COMPONENTS.
3. BALL VALVES SHALL BE MOUNTED A MAXIMUM OF 2 METERS ABOVE THE
SERVICING LEVEL.

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Figure 15-3 Example Unit (Station) Level Water Diagram

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15.7 Water Flow for Hard Automatic (Fixture) Welding Operations
15.7.1 Kickless Cable Water Flow
Kickless cables typically require a minimum water flow of 7.57 LPM (2 GPM). However, the
water flow diagrams in the previous figure may limit the flow to the kickless cable to 3.78 LPM
(1 GPM). Therefore, the ECTC of the kickless cable is reduced. For maximum ECTC for kickless
cables with 3.78 LPM (1 GPM), see table below:
Table 15-4 Maximum ECTC for Kickless Cables at 3.78 LPM (1 GPM)
Length (ft) Cable Size (MCM) ECTC sec. (A)
5’ 300 MCM 6000 A
6’ 300 MCM 5400 A
5’ 500 MCM 7600 A
15.8 Water Flow Diagrams for Robotic Operations
15.8.1 AC Transgun Water Flow Diagrams
The water flow applies to transformers TR-74X, TR-77X, TR 78X, TR-80X, TR-81X and TR-82X.

Figure 15-4 AC Transgun

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15.8.2 Portable / Robotic Hip Mount Transformer Water Flow Diagram
The water flow diagram applies to transformer TR-70BX.

Figure 15-5 Portable / Robotic Hip Mount Transformer with Two Kickless Cables

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15.8.3 MFDC Transgun
The water flow diagram applies to DC power supply TR231A thru TR236A

Figure 15-6 MFDC Transgun

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15.8.4 High Capacity MFDC Transgun
The water flow diagram applies to DC power supply TR237A, TR238A, and TR239A.

Figure 15-7 High Capacity MFDC Transgun

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15.8.5 Robotic Single DC LS Transgun
The following water flow diagram applies to DC power supply TR262A. TR264A, & TR265A.

Figure 15-8 Robotic Single LS Transgun

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15.8.6 Robotic Dual DC LS Transguns
The following water flow diagram applies to DC power supply TR-264A & TR265A.

Figure 15-9 Robotic Dual LS Transguns

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16 Drawing Section J: Reserved

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18 Drawing Section L: Liquids (to be defined)

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19 Drawing Section M: User Defined

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20 Drawing Section N: Reserved

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22 Drawing Section P: Reserved

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23 Drawing Section Q: Reserved

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24 Drawing Section R: Reserved

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25 Drawing Section S: Reserved

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29 Drawing Section W: Welding Applications Designs and Interface

29.1 Purpose
This section of the drawing package contains a representation of the welding circuitry diagram
for weld controller(s), weld transformers, weld controller junction boxes (when required), and
weld gun(s).
29.2 Weld Controller Interface
The weld controller interface (including hardwire and Ethernet I/O mapping) is specified by GM
GRS4 Section B1 Specification.
29.3 AC (Alternating Current) Welding
Reference WS-2A specification for Alternating Current (AC) welding.

Spot welding (resistance welding) is achieved by the use of a 50/60Hz AC weld controller. The
weld controller utilizes an inversed parallel pair of Silicone Controlled Rectifiers (SCR) to control
the output. The pair of SCRs are turned on by pulsing a gate with a voltage signal which controls
the on time of the sine wave to the transformer.

Figure 29-1 AC Welding

29.4 MFDC (Medium Frequency Direct Current) Welding

Reference GWS-2D specification for Medium Frequency Direct Current (MFDC) Welding.

Medium frequency (1000 Hz) resistance welding is achieved by rectifying a three-phase 50/60
Hz AC voltage (which is further processed to smooth out the ripple) and supplying it to an
inverter. The inverter is comprised of IGBTs (Insulated Gate Bipolar Transistor) which are
switching transistors acting as gates controlling the voltage. The inverter then converts the DC
voltage to a square wave frequency of 1000 Hz and passes this through a transformer/rectifier
which rectifies the square wave 1000 Hz AC back to DC so that the welding is DC.

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The advantages of MFDC are:
• Higher Efficiency
• Lighter Transformers – Due to the higher operating efficiency, MF transformers are lighter
and more compact than AC types, especially where larger currents are required, making
them particularly suited to robotic applications. This means robots can be smaller so less
energy is expended in moving the welding gun.
Figure 29-2 MFDC (Medium Frequency) DC Welding

Figure 29-3 MFDC Weld Controller & Transformer

29.5 Welding Section Layout

1. The weld controller layout shall show the weld controller(s) and weld transformer(s). The
associated transformer wire numbers shall be shown inside the weld controllers.
2. A maximum of six SCRs or IGBTs shall be shown per page.
3. The welding transformers shall be shown below their corresponding weld controllers.
4. When weld controller junction boxes are required, they shall be shown between the weld
controller and the weld transformer(s).
5. The weld gun(s) shall be shown below their corresponding transformer.

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6. A Weld Sequence Chart shall be provided for each SCR or IGBT and shown on same sheet as
weld controller where space permitted. Weld Sequence Chart for ‘6-Packs’ (weld controller
with 6 SCR’s) may be shown on a separate sheet.
29.6 Wire and Cable Designation
1. For AC weld controllers, wires from the SCR shall be designated as ‘Sx’ where ‘x’ is the SCR
number in the welder control (e.g., S1 = SCR1 connection, S2 = SCR2 connection, S3 = SCR3
connection). The corresponding SCR common wire which is connected directly to the
contactor shall be designated as ‘Tx’ where ‘x’ is the corresponding phase conductor
number (e.g., T1 = L1 phase on load side of contactor, T2 = L2 phase on load side of
contactor, T3 = L3 phase on load side of contactor).
2. For MFDC weld controllers, transformer connections shall be designated as 1H1 and 1H2,
2H1 and 2H2, 3H1 and 3H2, etc. (Reference GWS-2, Section D).
3. 3. Transformer conductors inside the welder control shall be labeled with the ‘source –
destination’ scheme indicating SCR connection and transformer designation
a. AC welding with SCR’s example: S1-BC080TR01, T1-BC080TR01
b. MFDC welding with IGBT’s example: 1H1 – BC080TR01, 1H2 – BC080TR01
4. A tag shall be provided on both ends of the cable from weld controller to the transformer.
The tag shall be labeled using the ‘source-destination’ scheme where the ‘source’ is the
weld controller designation and ‘destination’ is the transformer designation (e.g., BC080W1-
BC080TR01).
Figure 29-4 Wire Designation within Weld Controller

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29.7 Welding Section Design Criteria
1. When showing multiple weld controllers, phase connections of conductors from the weld
bus plug to the weld controller shall alternate from one weld controller to the next. This is
to facilitate in balancing the load of the weld bus.
2. Weld transformers shall show the following:
a. Transformer number (**TRxx). Where ** = station designation, xx = consecutively
numbered transformer starting with 01 (per MD1 Specification).
Example: BC080TR01, BC080TR02
b. Transformer type (TR#). Where # = GM catalog number (e.g., TR231A, TR232A)
c. Transformer size (**kVA). Example: 90 kVA, 150 kVA.
Figure 29-5 Transformer Information

3. Conductor color coding for applications with specific polarity configuration such as “push-
pull welding shall be shown. Reference WS-1B “Over and Under Welding”.
4. Push/Pull welding polarity reversal shall occur at the weld controller or weld controller
junction box (when used) for the lower weld transformer.
5. Weld gun(s) shall be designated as **WGxx. Where ** = station number, xx = consecutively
numbered weld guns starting with 01 (per GMD1 Specification).

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Figure 29-6 Example Weld Page

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29.8 MFDC Primary Cable Selection for Up To 24 kA (Steel) in GM North America
This section addresses the process used to select the bus plug fuses, the primary cable used
between the bus plug and welder control and the primary cable between the inverter and
welding transformer or junction box. Reference the following table:
Table 29-1 MFDC Primary Cable Selection (Up To 24 kA) (GM North America Only)
From Weld
Bus From Weld Bus
Weld Controller to
Transformer Model Number Plug to Weld
Controller Transformer
Fuse (A) Controller (AWG)
(AWG)
TR231A,TR232A,TR233A,
Single Pack TR234A,TR235A,TR236A,
100 #2 (3 conductor) #2 (2 conductor)
Inverter DC TR251A,TR252A,TR253A,
TR262A,TR264A,TR265A
TR231A,TR232A,TR233A,
2-Pack TR234A,TR235A,TR236A,
200 2/0 (3 conductor) #2 (2 conductor)
Inverter DC TR251A,TR252A,TR253A,
TR262A,TR264A,TR265A

1. Cable lengths should be kept as short as possible, as any unnecessary length adds cost and
contributes to voltage drops.
2. The total length of cable from the bus plug to the weld controller should not exceed 140 ft.
3. The length of #2 AWG cable (when used) from the weld controller to the robot base or
tooling mounted transformer must not exceed the values in 29.8.1. If the length exceeds
the maximum allowable, a weld controller junction box and larger size cable is required.
Reference section 29.14 for weld controller junction box.
Note: Assume up to 25 ft. of minimum #2 AWG conductor included in the robot dress. The
actual type and size of cable is defined by the robot dense and dress specification.
29.8.1 Weld Controller to Transformer Cable Lengths for Up To 24 kA (Steel) in GM North America
1. Weld Controller to Robot Weld Junction Box at robot base (Carried W/G)
a. If cable length ≤ 120 ft, use (2) #2 AWG w/(1) #2 AWG GND.
b. If cable length > 120 ft, use (2) #4/0 AWG w/(1) #1/0 AWG GND.
2. Weld Controller to PED Weld Gun Transformer
a. If cable length ≤ 135 ft, use (2) #2 AWG w/(1) #2 AWG GND.
b. If cable length > 135 ft, use (2) #4/0 AWG w/(1) #1/0 AWG GND.

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29.9 MFDC Primary Cable Selection for Up To 24 kA (Steel) in GM International (Metric)
This section addresses the process used to select the bus plug fuses, the primary cable used
between the bus plug and welder control and the primary cable between the inverter and
welding transformer or junction box. Reference the following table:
Table 29-2 MFDC Primary Cable Selection (Up To 24 kA) (GM International – Metric)
From Weld
Bus From Weld Bus to
Weld Controller to
Transformer Model Number Plug Weld Controller
Controller Transformer
Fuse (A) (mm2)
(mm2)
TR231A,TR232A,TR233A,
Single Pack TR234A,TR235A,TR236A,
100 35 (3 conductor) 35 (2 conductor)
Inverter DC TR251A,TR252A,TR253A,
TR262A,TR264A,TR265A
TR231A,TR232A,TR233A,
2-Pack TR234A,TR235A,TR236A,
200 70 (3 conductor) 35 (2 conductor)
Inverter DC TR251A,TR252A,TR253A,
TR262A,TR264A,TR265A

1. Cable lengths should be kept as short as possible, as any unnecessary length adds cost and
contributes to voltage drops.
2. The total length of cable from the bus plug to the weld controller must not exceed 42 m.
3. The length of 35 mm2 cable (when used) from the weld controller to the robot base or
tooling mounted transformer must not exceed the values in 29.9.1. If the length exceeds
the maximum allowable, a weld controller junction box and larger size cable is required.
Reference section 29.14 for weld controller junction box.
Note: Assume up to 7.5 m of minimum 35 mm2 conductor included in the robot dress. The
actual type and size of cable is defined by the robot dense and dress specification.
29.9.1 Weld Controller to Transformer Cable Lengths for Up To 24 kA (Steel) in GM International
(Metric)
1. Weld Controller to Robot Weld Junction Box at robot base (Carried W/G)
a. If cable length ≤ 36 m, use (2) 35 mm2 w/(1) 35 mm2 GND.
b. If cable length > 36 m, use (2) 120 mm2 w/(1) 50 mm2 GND.
2. Weld Controller to PED Weld Gun Transformer
a. If cable length ≤ 41 m, use (2) 35 mm2 w/(1) 35 mm2 GND.
b. If cable length > 41 m, use (2) 120 mm2 w/(1) 50 mm2 GND.
29.10 MFDC Primary Cable Selection for Up To 50 kA (Aluminum) in GM North America
This section addresses the process used to select the bus plug fuses, the primary cable used
between the bus plug and welder control and the primary cable between the inverter and
welding transformer or junction box. Reference the following table:

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Table 29-3 MFDC Primary Cable Selection (Up To 50 kA) (GM North America Only)
From Weld
Bus From Weld Bus
Weld Controller to
Transformer Model Number Plug to Weld
Controller Transformer
Fuse (A) Controller (AWG)
(AWG)
Single Pack TR237A, TR238A, TR239A, Dual See Example See Example
300
Inverter DC TR264A, Dual 265A Below Below

1. Cable lengths should be kept as short as possible, as any unnecessary length adds cost and
contributes to voltage drops. Voltage drop is a major concern when welding at high
currents. It is recommended to keep the total voltage loss to no more than 4%.
2. The total length of cable from the bus plug to the weld controller should not exceed the
maximum recommended when using the cable sizing spreadsheet found on the BIW welding
page. Below is an example of the spreadsheet.
3. The use of a junction box at the base of the robot is required to adapt the 4/0 cable down to
#2 cable going into the robot weld power quick connect receptacle.
Note: Assume up to 25 ft. of minimum #2 AWG conductor included in the robot dress. The
actual type and size of cable is defined by the robot dense and dress specification.

Figure 29-7 Conductor Sizing Spreadsheet Example for GM North America

29.11 MFDC Primary Cable Selection for Up To 50 kA (Aluminum) in GM International (Metric)

This section addresses the process used to select the bus plug fuses, the primary cable used
between the bus plug and welder control and the primary cable between the inverter and
welding transformer or junction box. Reference the following table:

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Table 29-4 MFDC Primary Cable Selection (Up To 50 kA) (GM International – Metric)
From Weld
Bus From Weld Bus
Weld Controller to
Transformer Model Number Plug to Weld
Controller Transformer
Fuse (A) Controller (mm2)
(mm2)
Single Pack TR237A, TR238A, TR239A, Dual See Example See Example
300
Inverter DC TR264A, Dual 265A Below Below

1. Cable lengths should be kept as short as possible, as any unnecessary length adds cost and
contributes to voltage drops. Voltage drop is a major concern when welding at high
currents. It is recommended to keep the total voltage loss to no more than 4%.
2. The total length of cable from the bus plug to the weld controller should not exceed the
maximum recommended when using the cable sizing spreadsheet found on the BIW welding
page. Below is an example of the spreadsheet.
3. The use of a junction box at the base of the robot is required to adapt the 120 mm2 cable
down to 35 mm2 cable going into the robot weld power quick connect receptacle.
Note: Assume up to 7 m of minimum 35 mm2 conductor included in the robot dress. The actual
type and size of cable is defined by the robot dense and dress specification.

Figure 29-8 Conductor Sizing Spreadsheet Example for GM International (Metric)

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29.12 Welding Section Notes
The following notes shall appear on the weld diagram:
1. “WELD CONTROLLER JUNCTION BOXES SHALL BE BONDED TO TOOL BASE BY
CONSTRUCTION SOURCE TO PROVIDE AN ADEQUATE ELECTRICAL GROUND.”
29.13 Weld Sequence Chart
The Weld Sequence Chart is a table of the weld controller's sequence numbers and their
associated schedules, transformers, and weld guns. A completed Weld Sequence Chart shall be
shown with each of the weld controller's inverters.
Table 29-5 Weld Sequence Chart
Weld Sequence Chart for W/C: **Wx-Inverterx
WELD NO. WLD CNTRL SCHEDULE XFMR WELD GUN
1ST
2ND
3RD
4TH

29.14 Weld Controller Junction Box

The weld controller junction box is used to terminate the weld transformer primary cable
conductors on the tool to the cable conductors originating from the weld controller. The weld
controller junction box also allows for multiple transformers to be connected to the same weld
controller.
1. A welder control junction box shall be provided when either of the following apply:
a. The conductors between the welder control and the transformer exceeds the maximum
allowable of 35 mm2 (#2 AWG) conductor. Instead of 35 mm2 (#2 AWG), use 120 mm2
(#4/0 AWG) 2-conductor from the welder control to the welder control junction box
mounted on the tool base. Use 35 mm2 (#2 AWG) 2 conductor from the welder control
junction box to the transformer.
b. If 3 or more transformers are connected to the same inverter.
2. For lockout reasons sharing the same welder control junction box between multiple weld
controllers is prohibited.
3. Wires inside the weld controller junction box shall be labeled using ‘source-destination’
scheme accordingly:
Line side of distribution blocks - weld controller phase and weld controller designation.
Example: S1-BC080W1, T1-BC080W1, & GND-BC080W1
Load side of distribution blocks – welder control phase and transformer designation.
Example: S1-BC080TR01, T1-BC080TR01, & GND-BC080TR01.

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Figure 29-9 Weld Controller Junction Box

29.15 Weld Power Distribution Panel

A weld power distribution panel may be provided to feed power to the weld controllers within
the guarded area. Load calculations for the weld PDP must be completed to determine size of
the weld PDP and number of branch circuits.
29.15.1 Weld Power Distribution Panel Guidelines
1. A weld PDP should be used whenever more than one weld circuit is required.
2. Allowance should be made for future expansion if requirements are known.
3. Weld PDP and control PDP span of control should be identical.
4. Do not use more than one weld PDP per guarded area unless required per load calculations.
5. If weld power and control power are sourced from the same bus, then it may be possible to
use a single PDP for both.
Note: Combining control and weld power into a single PDP requires GM Controls Project
Engineer approval.

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30 Drawing Section X: Enclosures

30.1 Purpose
This section provides clear and concise guidelines for the controls design and tool construction
sources. However, where conflicts exist between this specification and other GM supplied
drawings or documentation, the supplied documentation shall have precedence over this
specification. Reference GCCB-1 for detailed designs and instructions for the construction,
mounting, and shipping of electrical enclosures.
30.2 Overview
A controls system design may include, but not be limited to, the following types of enclosures:
1. Power Distribution Panel (PDP)
2. Cell main enclosure
3. Human Machine Interface (HMI)
4. Fixture junction box
5. Programming terminal
6. Motor starter Panels
7. Standard panels (ECS)
a. Entrance Gate Control Panel
b. Remote HMI
c. Operator Runstand
The above panels may be combined at the discretion of the GM Controls Project Engineer.
30.3 General Design Requirements
The following rules shall apply to all enclosures. Additional requirements for specific enclosure
types shall be found in subsequent sections.
1. The section letter X shall be denoted in the lower right-hand corner.
2. The sheet order and description shall appear as follows (sheets may be combined at the
discretion of the GM Controls Project Engineer, sheets may be deleted if not required):
a. Enclosure Layout
b. Pushbutton And Light Layout
c. Tag Details
d. Subplate Layout
e. Terminal Rotation
f. Cable and Receptacle Pin Charts

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g. Mounting Details
h. Enclosure Footprint
3. All layouts shall be drawn full scale in reference to size and location of components.
Dimensioning should be done from only one side of a diagram.
Note: All dimensions shall be shown in metric.
4. All notes appearing in the standard drawings shall be included in all of the ‘X’ section
diagrams within the Controls package.
5. All devices shall be labeled and identified. The overall enclosure diagram should show all
externally mounted devices on all views of the enclosure.
6. All designs shall have 20% spare space appropriately distributed for additional components
and terminals.
Exception: ECS standard designs.
7. All components shall be selected from the latest GM eParts database where possible.
8. In order to improve visual control, electrical enclosures shall be no taller than 1500 mm.
The intent of this requirement is to have a better line of sight to the process equipment and
its operation unheeded by tall electrical control enclosures. There are exceptions to this
such as if a component inside the enclosure requires more height (e.g., large motor drive) or
if enclosures are designed to mount against walls, booths (e.g., Paint Area), or on a
mezzanine. It is desirable to maintain one standard panel design for all instances of the
same equipment throughout the plant.
9. Subplate mounted control components (e.g., relays, starters and contactors) should be
mounted in numerical order from left to right and top to bottom.
10. Terminals shall be a minimum of 200 mm from the servicing level. Controlgear (i.e.,
switching devices and associated control, measuring, protective, and regulated equipment,
assemblies and accessories) shall be a minimum of 400 mm from the servicing level. Ground
bars (PE Terminals) and transformers may be mounted below 200 mm.
11. Only devices for operating, indicating, measuring, and cooling shall be mounted on doors.
12. The need for air conditioners, heat exchangers, and fans shall be determined by the
enclosure heat calculations and the applicable ambient environment for the area (e.g., some
areas of plant such as the oven area, are hotter than others). All electrical equipment shall
correctly operate between +5 °C and +40 °C. Extra requirements may be necessary outside
this range. All GM standard Panels (ECS) are designed to operate up to 40 °C.
13. Windows in control enclosures require GM Controls Project Engineer approval.
14. Enclosures and components shall provide protection against electric shock due to direct
contact according to IEC-60204 and NFPA 79. In addition, the requirements in Global Design
for Health and Safety (G-DHS) chapter 6 (electrical safety) shall be met.
15. Use of wire duct less than 38 mm wide or 75 mm deep requires GM Controls Project
Engineer approval. Proper duct sizing and appropriate cable duct fill guidelines shall be
observed.
16. Cage clamp spring terminals shall be used where possible.

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17. Only 1 conductor per spring terminal.
18. On devices where screw terminals are provided, up to 2 conductors are allowed per screw
terminal (provided the terminal is rated for 2 conductors).
19. Wire end ferrules shall be used for conductors smaller than 0.75 mm2 (18 AWG). The
crimping device for end ferrules shall be the type that form a trapezoidal cam crimping
formation as shown below:
Figure 30-1 End Ferrule Crimping Formation

20. Terminal strips shall be shown numbered in sequential order from top to bottom and from
left to right.
21. The preferred method of routing communication wiring shall be outside the panel ductwork
away from line voltages, or in a separate duct. Communication cables should enter the
enclosure isolated from power feed(s) such as on the opposite corner of the enclosure.
22. 380 – 575 V power from the PDP to remote devices shall be hardwired multi-conductor
cable with strain relief at each end.
Exception: Per exception in 11.8.4, conveyor or other applications using integrated drives may
use plug in connectors.
23. Panel lighting shall be provided in multi-door free standing enclosures above 1828 mm.
24. Panel lighting shall be provided on all enclosures with a depth of 305 mm or greater and a
width x height of 1 m2 or greater. Lighting shall also be provided on enclosures with a width
x height of 2.3 m2 or greater regardless of depth.
Exception: Welding PDPs and other panels that do not have excepted circuit power available.
25. Panel lighting shall be shown and mounted inside the enclosure at the top above the
subplate. Panel Lighting shall be LED where possible.
26. Convenience receptacles on enclosures should not be required. In the case where a
convenience receptacle is provided, local codes and regulations must be followed. (e.g.
GFCI - Ground Fault Circuit Interrupter protection in the US)
27. When mounting auxiliary boxes such as a lighting transformer disconnect to the outside of
an enclosure, it is preferred to mount it front facing such that its door opens in the same
direction as the main panel door. This is to maintain the same affected minimum work-
space requirement around the main panel. If the auxiliary equipment is mounted side
facing, the overall footprint of the main panel is increased by the additional 1100 mm work-
space requirement (for 380 – 575 V) off to the side.
28. Panduit VeriSafe Absence of Voltage Testers (AVTs) shall be incorporated into the enclosure
design where required according to Global Design for Health and Safety (G-DHS) chapter 6
(electrical safety).

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30.4 Working Space (Footprint) About Enclosures
Working space around enclosures shall comply with the requirements in Global Design for
Health and Safety (G-DHS) chapter 6 (electrical safety) and NFPA 70, Article 110-26 for those
regions affected.
30.5 Cable and Receptacle Pin Charts
1. Multi-conductor cables/receptacles are provided between panels. The pin-out pin and wire
designations are shown in the Cable and Receptacle Pin Charts.
Exception: Typical 3, 4, or 5 pin receptacles (e.g., 3 pin mini power, 4 pin mini power, 5 pin
micro tool cord, etc.) do not require receptacle pin charts.
Figure 30-2 Receptacle Pin Chart

2. The Cable and Receptacle Pin Charts are typically shown at the end of the ‘X’ section.
3. Multi conductor cable/receptacle charts shall contain the following information:
Table 30-1 Receptacle Chart
Function Description
Receptacle number (see section 9.4.6 for receptacle cable
REC#
naming conventions.)
PNL Panel description of where the receptacle is mounted.
Panel number of where the receptacle is mounted (EC-xxxxx or
PNL#
ECS-xxxx)
RECP ITEM# Bill of material item number of receptacle.
RECP METER Length of receptacle wires.
Wire color of conductor. Use the standard IEC 757
WIRE COLOR
abbreviations (see Table 11-5 for abbreviation chart).
PIN # Pin number of receptacle.
WIRE # Wire designation of conductor.
30.6 Standard Panels (ECS)
To minimize design and construction costs, standard panels (ECS) and off the shelf industrially
hardened components (IP6X) shall be used where possible. Refer to the GM Controls Project
Engineer for ECS designs.
30.7 Custom Panels
Some applications require custom panel designs when an ECS panel is not available. When
custom designed panels (EC) are required, only 1 enclosure shall be shown per drawing package.

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30.8 Power Distribution Panel (PDP)
The Power Distribution Panel (PDP) supplies 380 – 575 V (depending on the region) power to all
robots, motors and other 380 – 575 V devices in a cell. Power for weld controllers is typically
supplied from a separate ‘weld’ bus and may be fed from a Weld PDP. The PDP also supplies
120 V power to various cell or system components (i.e., Cell Main Enclosure, IP6X Power
Supplies, Programming Terminal, Remote HMI). Power distribution panels are generally
supplied from the plant bus. If the GM recommended breakers and fuses are not used, a
coordination study is required to ensure selectivity between the bus plug fuse and the PDP main
breaker.
1. The PDP shall contain but not be limited to the following items:
a. Power disconnect and Lockout means
b. Overcurrent protection (circuit breakers). The use of fuses shall require GM Controls
Project Engineer approval.
c. Machine control transformer(s)
d. Control Power On Light
e. Processor Power On Light
f. Receptacles
g. Miscellaneous components (e.g., terminals, duct, distribution blocks, ground blocks,
tags)
30.9 Controller (Cell) Main Control Panel
1. The Cell Main Panel may contain but is not limited to the following items:
a. 120 V or 24 V feed from the PDP or power supply
NOTE: 24 VDC feed to MCP preferred to minimize electrical hazards and reduce PPE
requirements.
b. Processor
c. DeviceNet Scanner(s)
d. Ethernet module(s)
e. Miscellaneous components (e.g., terminals, duct, distribution blocks, ground blocks, and
tags)
For most applications the “PLC-in-a-Box” and IP6x components have replaced custom or ECS
main control panels.

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Figure 30-3 Typical “PLC-in-a-Box” Configuration

2. The main control panel may also contain:

a. HMI and related operators
b. Ethernet switch(es)
3. The main control panel enclosure subplate preferred layout (from top to bottom and left to
right) is the following:
a. Chassis with processor (Most commonly accessed components for diagnostics and
troubleshooting with visual indicators and alphanumeric codes. It is desired that this be
at a reasonable height).
b. DC power supplies
c. Terminal strips
4. The main processor shall reside in slot 0 (and safety partner, if needed, in slot 1 for safety
PLC applications). Additional processors may be located in any of the spare slots.
5. It is preferred that all terminal strips shall be located on the bottom half of the subplate.
30.10 Fixture Junction Boxes
1. The fixture junction box provides connectivity and interface requirements from the main
control panel to a station by picking up wiring for light curtains, safety mats, safety pins,
auxiliary power for valve manifolds, and receptacles for network connections.
2. Use the appropriate ECS for the fixture junction box where possible. If the fixture junction
box is a custom panel, it shall have its own drawing package separate from the wire and
piping diagram for the station.
3. For most applications, industrially hardened (IP6X) IO blocks and power supplies (which can
be mounted directly on the equipment or fence) may be used instead of a control panel.
4. Operator fixture junction boxes shall be mounted such that they are accessible from outside
the cell (typically on the fence). An accurate mounting location is required to determine the
proper cable lengths for all devices connected to the fixture junction box.

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30.11 Human Machine Interface (HMI)
1. The HMI is preferred to be mounted remotely from the main control panel to provide the
greatest flexibility in ‘line-of-sight’ access to the equipment. The other benefits are reduced
variability in the MCP (i.e., more common) and the separation of heat generating devices in
the MCP from the HMI.
2. Use the appropriate ECS for the remote HMI where possible.
3. The following pushbutton and light functions are required with all HMI’s whether mounted
on the cell enclosure or remotely. Additional devices may be required due to individual tool
designs.
Exception: HMI stations that control equipment without hazardous motion (i.e. some paint
systems) do not require the additional pushbutton functions.
Table 30-2 Pushbuttons and Light Functions for HMIs
Device Description
Red, Mushroom Head, illuminated, maintained
Emergency Stop
type
Reset Pushbutton/Blue pilot light
Auto Initiate Pushbutton/Green pilot light
Auto/ Manual 2 position maintained selector switch
Enable Black pushbutton, momentary
Do Black pushbutton, momentary
Undo Black pushbutton, momentary
Fault Red stack light

Note: The “Do” and “Undo” pushbuttons shall be used to manually initiate tool motion. The
“Enable” pushbutton shall be used with either the “Do” or “Undo” pushbuttons when the gate
entry system is not reset (i.e., gate open). Touch screen buttons are prohibited to initiate
manual motion.
4. A keyed selector (CES Key Blank, Key #SSG10 or #STGH10) shall be used for the Auto/Manual
mode selection.
Exception: Non-keyed selector switches may be used where the safety function of the system is
not altered by the selector switch. The use of non-keyed selector switches for auto/manual
mode selection requires GM Controls Project Engineer approval.
30.11.1 Pushbutton Panels
The following section describes Pushbutton/Light Enclosure for unit (station) control. The use of
pushbutton enclosures in place of programmable HMI’s requires GM Controls Project Engineer
approval.
1. An ‘E-STOP’ pushbutton shall be provided at all pushbutton panels from which motion can
be initiated. It is preferred that the ‘E-STOP’ pushbutton be located at the lower right side
of the pushbuttons and lights.
2. All ‘START’ pushbuttons shall be mounted above or to the left of the associated ‘STOP’
pushbuttons.

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3. Corresponding, opposing function lights and buttons shall be shown directly below each
other. These buttons and lights shall follow the machine sequence with lights directly above
the corresponding pushbuttons (when not using illuminated pushbuttons).
4. Selector switches and potentiometers (as well as any other device with a rotating member)
shall be mounted in such a way as to prevent rotation of the stationary member. Friction
alone shall not be sufficient.
5. The lowest button location shall be 915 mm from the servicing level and the highest button
location shall be 1676 mm from the servicing level (when mounted in enclosures taller than
1500 mm).
30.12 Motor Starter Panels
1. Independent motor starter panel(s) shall control all line start motors.
2. This panel shall be located near the drive unit and contain 380 – 575 V fuses or circuit
breaker, motor starters, control wiring, and a disconnect. The PDP enclosure shall supply
the 380 – 575 V power to the remote motor starter panels through the use of hardwired
multiconductor cable. The cable from the starter panel to the motor shall be protected by
properly sized circuit breaker or motor starter protector located in the motor starter
enclosure.
Exception: Paint motor starter panels can be connected directly to the plant power bus with the
approval of the GM Controls Project Engineer; a coordination study is required for these
applications.
3. The main disconnect in the PDP enclosure shall disable all power to all remote motor starter
panels controlled by that PDP enclosure.
30.13 Programming Terminal
The programming terminal is a standard control cabinet design (e.g. ECS-4166). The computer
terminal inside the enclosure is not furnished as part of the GM ECS. The requirements for this
PC can be found in section 4.9.3.
30.14 Construction Specifications
Reference GCCB-1 for complete enclosure construction standards. This section is intended for
design of panel layouts and content.
1. It is preferred to use standard metric size electrical enclosures (i.e., Rittal TS-8 for free
standing or Type AE for smaller boxes). Use of non-standard enclosures shall require the
prior approval of the GM Controls Project Engineer. Electrical enclosures and compartments
shall be of high quality construction (e.g. Hoffman or Rittal) in conformance with this
specification as well as both of the following:
a. ANSI/NEMA Standard ICS-1, Industrial Control.
b. ANSI/UL 508, Industrial Control Equipment.
2. Electrical equipment at a minimum shall be housed in non-ventilated IEC 60529 IP54 (NEMA
12) enclosures. The rating of the enclosure shall meet the requirements of the environment
in which it will be located.

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3. For custom panels, the height and width of the door opening shall be at least 25 mm greater
than the corresponding height and width of the subplate.
4. A permanent data pocket shall be attached to the inside or outside of the electrical
enclosure or compartment to accommodate the electrical documentation on A4 (8.5 x 11 in)
paper.
Exception: Panels too small to properly accept a data pocket do not require one.
5. All ferrous metal parts used in the enclosure shall be painted or plated to prevent rust. The
exterior and interior of all electrical enclosures shall be RAL 7035 light gray.
6. The subplate shall be galvanized (not painted).
7. Any holes specified in the documentation shall be through holes and sealed to IEC 60529 IP
54 (NEMA 12) specifications with a sealing plate. All holes shall be 22.5 mm diameter unless
required otherwise.
8. Mounting feet or other suitable features external to the enclosure shall be provided for
mounting. No holes in the enclosure body shall be present for mounting purposes. All free
standing enclosures shall be provided with 50 mm continuous angle iron welded at each
end. Each angle iron shall contain two 16 mm clearance holes for lagging to the floor (See
Figure 30-4). All other enclosures shall be provided with mounting straps, brackets or feet.
Mounting holes shall be provided in the external straps, which are welded to the enclosure
body for mounting purposes.
Figure 30-4 Angle Iron Feet

9. Hoisting capabilities shall be provided for all freestanding enclosures. All enclosures
weighing 70 kg or more shall have reinforced mounted eyebolts for lifting. The enclosure
shall be structurally reinforced to prevent warping or damage during its handling.
30.14.1 Doors
1. All electrical enclosures, compartments, control stations, and terminal and junction boxes
over 192 cm2 shall have vertical hinged doors. Covers that are not hinged shall be captive to
the box.
2. Doors shall be provided to allow access to all electrical connections and service points within
enclosures.
3. Door width shall not exceed 800 mm.
Exception: PDP panels are allowed a maximum door width of 1000 mm.

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4. The door swing shall be a minimum of 90° and shall not prevent ready access to the
disconnect handle.
5. All doors shall be bonded to the enclosure according to section 30.18.
30.14.2 Door and Cover Fasteners
1. Vault-type hardware (handle and internal mechanism) that latches simultaneously at the
top and bottom of the door shall be used on 1200 mm or taller enclosures.
2. The handle shall have a slotted head non-keyed entry mechanism and shall have no pinch
points.
3. Control enclosures without vault-type hardware shall have slotted head, captive-type
screws to secure the door closed.
4. Sealing materials shall consist of an oil resistant synthetic material and shall be held firmly
and permanently in place by an oil resistant adhesive. A sealing material at least 3 mm and
1.5 mm thick shall be used on doors and covers respectively.
30.14.3 Disconnects
Disconnects shall comply with the requirements in Global Design for Health and Safety (G-DHS)
chapter 6 (electrical safety) in addition to applicable requirements in NFPA 79 and/or IEC-60204.
30.15 Components and Installation
30.15.1 Inside Electrical Enclosures
1. Components shall be mounted to provide mechanical clearances sufficient for mounting,
wiring, adjustment, testing and replacement.
2. Each component shall be arranged and oriented in such a manner that identification may be
determined without moving the component or its wiring. Components shall be installed in
accordance with the manufacturer's installation drawings and specifications. The
manufacturer's standard mounting details shall not be modified or altered in any way.
3. Each component shall be mounted to provide heat dissipation consistent with the
temperature rating of the component, adjacent components and conductors. Safety relays
shall have a minimum of 18 mm spacing between it and other non-safety relays or
contactors on the same din rail (reduces heating effect on the lower wattage safety relay
from the higher wattage relays).
4. Equipment shall be mounted in a manner that allows any component or component part to
be replaced without removing the subplate. No components shall be mounted behind door
pillars unless adequate space is provided for replacement and servicing.
5. All control components shall be front mounted on a rigid metal subplate to allow the
removal of the complete subplate through the enclosure opening. The subplate metal shall
be a minimum of 2.6 mm (0.106 in, 12 gauge) nominal for mounting components with 6 mm
(0.25 in) screws or smaller. Where larger screws are required, additional reinforcement or
heavier gauge subplates shall be provided.
6. Any component(s) mounted on the subplate that carry line voltage or a combination of line
voltage and control voltage shall be grouped above or to the right side and segregated from

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devices that carry only the control voltage. This requirement does not apply where the line
voltage is 120 V.
7. Any component(s) mounted on the subplate that carry more than 600 V shall be mounted in
a separate enclosure or be physically isolated from the other control components.
8. Terminal blocks shall be mounted to provide an unobstructed access to the terminals and
their conductors. Terminal blocks shall not be stacked above each other. Terminal blocks
shall not be mounted in wire ways.
9. Separately grouped terminals shall be used for all power circuits, control circuits, remote
interlock wiring and signal circuits. The line and control voltage terminals shall be either on
separate din rails or separated by terminal end anchors and a minimum of 2 terminal
spaces. Wiring over 120 V shall not be routed through the same wire ducts with wiring 120
V or less.
Note: Motor leads are normally run directly to the individual motor starters.
10. Provide at minimum 10% spare terminals on each subplate of every electrical enclosure and
compartment. Control terminals shall have a minimum of (8) spare terminals. Common line
and neutral terminal numbers shall have a minimum of (2) spare terminals (in addition to
those required by the wiring diagram) mounted contiguously on terminal strips in main
control panels and terminal boxes.
Exception: ECS standard designs.
11. Only new components shall be used. Rebuilt or used components shall not be used unless
approved and/or supplied by the GM Controls Project Engineer.
12. Miscellaneous components not itemized on the Bill of Material (e.g., screws, fasteners, wire
duct, terminal strips, etc.) shall conform to the requirements of this specification.
13. Components of significant size and weight (e.g., CPUs, VFD’s, transformers) are to be
mounted on studs welded to the front of the subplate or bolts which are threaded through
and welded from the back of the subplate. Flat washers and lock washers shall be used in
securing such components to the subplate.
Exception: If different mounting requirements are provided by the device manufacturer, then
the manufacturer’s requirements shall be adhered to.
14. Screw-type terminals with captive saddle straps or equivalent means of retaining stranded
conductors shall be provided on control devices and terminal strips. If pressure plate is not
available, compression type ring lug connectors should be used.
15. All wire ducts shall be a minimum of 75 mm high, except for specially approved applications,
and be furnished with no-slip covers. All wiring duct within a panel on the same subplate
shall be the same height.
16. By definition, each terminal strip has a field side and a homerun or home side. Field wiring
starts with the left hand or bottom side of the first (leftmost or lower) terminal strip then
alternates with home wiring. The alternation of field/home/ home/field/field/home results
in the duct between terminal strips containing either field or home wiring, but not both.
17. Wires from door mounted devices that are not routed directly to I/O points shall be
terminated on the “field side” of terminal strips.

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18. Wires from multi–conductor receptacles that are not routed directly to I/O points shall be
terminated on the “field side” of terminal strips.
30.15.2 Outside Electrical Enclosures
The following are typical components mounted on the exterior of the control panel enclosure:
1. Sealed (typically IP54) Control transformers.
2. Line conditioning and regulating transformers of 500 VA or larger.
3. Other major heat generating devices suitable for exterior mounting.
4. Horns, Sirens, Warning Lights.
5. Door mounted HMI, push buttons and pilot lights shall be mounted so that no portion of the
equipment is immediately above the door opening and all devices are less than 2100 mm
from the servicing level. All door mounted devices shall not extend more than 150 mm
beyond the door frame. Attachments and fittings between these devices and the enclosure
shall be liquid tight.
30.16 Wiring Methods
30.16.1 General
1. Control wires within enclosures or inside jacketed, cable assemblies shall be type MTW with
0.8 mm wall insulation and not be smaller than 1.5 mm2 (#16 AWG). Wires outside
enclosures in raceways shall be type THHN with 0.8 mm wall insulation and no smaller than
1.5 mm2 (#16 AWG).
Exception: 0.75 mm2 (#18 AWG) may be used for 24 VDC or less when the current does not
exceed 7 A.
2. Wiring for door mounted components shall be secured with Panduit CPM87S-C cable tie
mounts or equivalent. The use of adhesive tie mounts is prohibited.
3. Communication cables and proprietary cables required by programmable controllers and
similar devices shall not be routed in wire ducts containing the control voltage wiring.
4. All conductors shall run continuously from one termination to another without splicing.
5. Control wires shall be numbered at both ends. Jumper wires connecting terminals shall be
routed through wire duct and be numbered on both ends.
6. Minimum spacing between devices and wiring duct shall be 20 mm.
7. Multiple wire runs shall be enclosed in wire ducts or be laced. Those that require bundling
shall be mechanically supported and secured. Where necessary, a bolt shall be stud welded
to the interior sheet metal for a bolt-down type tie-wrap securing strap or cable clamp.
8. Unfinished sheet metal edges shall be covered to prevent accidental damage to wire
insulation.
9. A maximum of two wires, of sufficient ampacity, can be connected to the control
transformer secondary X1 (hot) terminal. A maximum of three wires, of sufficient ampacity,
can be connected to the control transformer secondary X2 (common) terminal; one of these
being the grounding conductor.

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10. Devices with removable connectors shall have sufficient slack provided in the wiring to allow
easy removal or replacement of the device.
30.17 Multiconductor Cables and Receptacles
1. Spare receptacle wires shall be:
a. Long enough to reach the farthest terminal.
b. Identified with receptacle and pin number.
c. Grouped and bundled according to the receptacle number.
d. Bundled with reusable type tie wraps (not tape), individually coiled, and stored in the
bottom of the enclosure.
2. Receptacle wires shall be routed to the bottom of the enclosure before they reach their
termination point.
3. Receptacles shall contain either 20% spares or a minimum of four spares.
Exception: Cables with 10 or less conductors.
4. Receptacle spare termination shall be required. The number of spares terminated shall be
10% of the total wires used or a minimum of four, whichever is greater. One terminal shall
be provided for every two spare wires.
5. Top mounted receptacles shall be installed starting from the left rear of the enclosure
progressing towards the right. After the first row is filled, the next row shall be offset from
the first row for ease of cable installation.
6. For square and rectangular receptacles, top mounted receptacles shall have pin #1 oriented
to the rear of the enclosure. This orientation favors straight cable hoods. Side mounted
receptacles shall have pin #1 oriented towards the top of the enclosure.
Exception: Shallow enclosures may prohibit (not deep enough) orientation of pin #1 toward the
rear for top or bottom mounted receptacles. Therefore, the receptacle may be mounted
rotated 90° from the rear. Pin #1 orientation shall be opposite the cable in a 90° hood.
Figure 30-5 Receptacle Pin#1 Orientation

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7. For circular receptacles, the receptacle key shall be oriented to the top of the enclosure for
side mounted receptacles or the front of the enclosure for top or bottom mounted
receptacles. The note shown in Figure 30-6 shall be included on the enclosure layout sheet
in drawing section X.
Figure 30-6 Circular Receptacle Orientation

8. Receptacle wires shall be labeled in accordance to the pin chart in the drawing Section X. In
addition to the wire numbers at the termination end, the receptacle number and pin
number shall also be provided 25 mm from the wire number (will be concealed inside the
duct) and also provided 50 mm from the other (receptacle) end near the enclosure wall.
This is to facilitate in troubleshooting. The following note shall be provided on all pin chart
sheets.
Figure 30-7 Receptacle Wire Labeling

30.18 Panel/Enclosure Grounding (Earthing)

30.18.1 Purpose
This section provides the general guidelines for connection of the grounding conductors
(protective conductors) within control enclosures. All ground requirements that are external to
the enclosure should refer to the grounding requirements in Global Design for Health and Safety
(G-DHS) chapter 6 (electrical safety). For the purpose of this specification the terms grounding
and earthing are used interchangeably.
30.18.2 Proper Design
Proper grounding design is required for both safety and functional purposes. For safety
purposes, each enclosure must be designed to meet the requirements of the IEC 60204, NFPA
70, NFPA 79, G-DHS and all other local regulations. Additionally, sensitive electronic devices
require supplemental grounding techniques to reduce the effects of EMI. These additional
measures shall be included in the enclosure design to ensure correct operation of each device.

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30.18.3 General Design Requirements
1. Each enclosure shall have a group of PE terminals (ground bus) where all panel ground
connections are terminated.
2. All ground wires (protective conductors) shall have an individual connection to the ground
bus.
3. The ground bus shall be properly bonded to the subplate and enclosure. Where a bonding
conductor is used, it shall be an insulated green/yellow wire. The size of the bonding wire
shall be the same size or larger than the equipment grounding conductor.
4. The ground bus shall have a sufficient number of connections for the application plus an
additional 10% spare.
5. If the ground bus is mounted to the enclosure off of the sub-plate, a suitable size conductor
shall be provided from the ground bus to the sub-plate. In all cases, dirt, oil, and paint shall
be removed from the surface to which the ground bus is mounted to ensure proper
bonding. Preferably, it will be mounted on the lower right side of the panel, close to any
electronic devices, and separated from the incoming line voltage and power wiring.
6. The ground bus shall be connected to the cell supplemental equipment ground conductor as
specified in Global Design for Health and Safety (G-DHS) chapter 6 (electrical safety).
7. Each power supply ground conductor must terminate directly to the ground bus.
8. The ground conductor shall not be switched open with the operation of the enclosure
disconnect switch.
9. On grounded systems, the control transformer shall be grounded to the enclosure ground
bus with a single conductor, sized for the ampacity of the transformer. The ground
conductor shall be green with yellow tracer and shall have ground ring lugs at both ends.
10. Ground wires must run continuous from termination to termination. There shall be no
splices in the wiring duct, conduit, or junction box.
11. Ground wires should be kept as short as possible.
12. Only 1 conductor per ground terminal.
Exception: Terminals rated for multiple conductors may be used accordingly.
13. A flexible, braided copper or insulated flexible wire bonding jumper shall be provided to
bond the main enclosure panel to any enclosure doors, drawer-type units, hinged subplates,
etc., to ensure effective grounding and compliance with IEC 60204 and NFPA 79. This
jumper shall have ring terminal connectors at both ends and shall be bolted to the enclosure
using a locking-type washer. The paint on the enclosure shall be removed at the point of
contact to ensure proper bonding (does not apply to galvanized surfaces).
14. The PLC chassis and any VFD or servo chassis shall be bolted to the enclosure subplate. The
bolts shall be installed with locking washers, and the paint shall be removed at the point of
contact to ensure proper bonding with the subplate (does not apply to galvanized surfaces).
Exception: If different mounting requirements are provided by the device manufacturer, then
the manufacturer’s requirements shall be adhered to.

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15. Each ControlLogix chassis shall have two ground wires going to the enclosure ground bus.
The chassis functional ground shall be 10 mm2 (#8 AWG) green w/yellow trace wire and shall
be mounted to the ControlLogix chassis mounting tab with a grounding lug and washer. The
chassis power supply is grounded separately with a 1.5 mm2 (#16 AWG) green w/yellow
trace wire.
16. VFD and servo drive systems shall have one ground connection between the VFD or servo
control unit, and the enclosure ground bus. All other VFD or servo ground connections will
be terminated at the ground lugs provided on the VFD or servo control unit. The ground
wire that goes between the control unit and the enclosure ground bus shall be green
w/yellow trace and sized according to the manufacturer's equipment specifications.
30.19 Labeling and Identification
30.19.1 Device Identification
1. All control components shall be clearly and permanently identified, using the same
identification as shown on the documentation. Nameplates or identification tags shall be
mounted adjacent to the device, not on it. This requirement applies to devices mounted
inside enclosures and mounted on equipment. Characters shall not be smaller than 6 mm in
height.
2. All tags shall be white with black characters unless otherwise specified. Consult GCCB-1 for
acceptable tag material.
Exception: Warning tags described within this section shall be yellow with black letters.

Exception: Where environmental conditions require the use of other materials for tags, the
applicable material shall be provided.
3. Control panel devices shall be identified by tags that are mounted on the panel subplate and
Kroy labels or equivalent on the wireway cover. When the individual identification of
components is impractical (e.g., on electronic assemblies), group identification may be used.
Kroy labels shall be white with 20 point, Helvetica, black letters.
Figure 30-8 Subplate and Duct Labeling

4. Nameplates and device identification tags shall be held in place with metal drive screws.
Relays, breakers, fuses, and I/O chassis shall be identified with matching tags using the same

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identification as shown on the documentation. Characters shall not be smaller than 6 mm in
height. A mounting track is acceptable where many devices are located in close proximity to
each other.
Exception: Standard ring type nameplates are used for pushbuttons and pilot lights.
5. Receptacles shall be identified inside and outside of the enclosure with matching tags using
the same identification as shown on the documentation. Characters shall not be smaller
than 6 mm in height. All receptacles shall be identified by a tag adjacent to the receptacle.
A mounting track is acceptable where many receptacles are located in close proximity to
each other.
6. Where convenience receptacles are provided to support electronic devices or programming
panels, a nameplate shall be provided on or adjacent to the receptacle. The nameplate shall
read as follows: "Laptop Use Only. No Power Tools."
7. Where electrical equipment is removed from the original manufacturer's enclosure, or the
equipment is located where the manufacturer's nameplate is not readily visible, an
additional manufacturer's nameplate shall be permanently attached to the inside of the
control enclosure. A tag using the same identification as shown on the documentation shall
be located adjacent to the extra manufacturer's nameplate. Nameplates shall not be
removed from any electrical equipment or painted over.
8. Identification tags for fuses shall include the fuse number, fuse type, and fuse size.
30.19.2 Enclosure Identification and Labels
1. All enclosures shall have a permanent nameplate as shown below. The nameplate shall be
mounted in the upper right corner of the enclosure door. This nameplate shall provide the
following:
a. EC or ECS number – The enclosure drawing design drawing number
b. Description - Description of the panel
c. Date of manufacture – Date of panel construction completion.
Figure 30-9 Custom Enclosure Nameplate

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Figure 30-10 Example ECS Enclosure Nameplate

2. All enclosures shall have a permanent label to identify the panel manufacturer and to
uniquely identify each panel. The label shall be located directly below the ECS/EC tag. In
the event that the panel revision tag is below the ECS/EC tag, then the manufacturer
identifier label shall be directly below the revision tag. The manufacturer identifier shall
include the following:
a. Name of panel manufacturer. This may be a company logo if desired.
b. Unique panel identifier. This identifier shall be unique for every panel (i.e. serial
number) and it shall be within a consistent format within a manufacturer and it shall be
readily familiar to the panel manufacturer so that build history, quality data, etc. may be
provided by the panel manufacturer OR so that the panel manufacturer could provide
the identifier in the event that certain panels must be tracked down in the field.
Figure 30-11 Example Panel Manufacturer Identifier

3. All enclosures that connect to bus level voltages (380 – 575 V) shall also have the following
information on one or more permanent labels on the front of the enclosure. The label shall
be located the upper right corner of the enclosure, directly below the enclosure nameplate.
Where more than one incoming supply circuit is provided, information for each supply
circuit shall be provided.
a. Volts – The supply voltage of the panel.
b. Phase – Single or three phase as required.
c. Hz – Frequency of the supply.

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d. SCCR – The Short Circuit Current Rating (SCCR) of the panel (Figure 30-13).
e. Full Load Current – Shall not be less than the sum of the full load currents required for
all motors and other equipment that may be in operation at the same time under
normal conditions of use.
Note: This number is used to determine the ampacity requirements of the supply conductors.
This number shall also include ‘line-side’ loads such as the lighting transformer.
f. Maximum Ampere Rating - The maximum ampere rating of the short-circuit and ground
fault protective device (main circuit breaker or disconnect fuses). This information can
be included in the Description field in the enclosure nameplate.
Note: This number may be smaller than the Rated Full Load if the rated full load includes ‘line-
side’ powered equipment.
g. WD number - The wiring diagram number. Example: WD-12345.
Figure 30-12 Example Label

Figure 30-13 Example Short Circuit Label

4. All other enclosures (panels that do not require a SCCR tag) shall have the following
information on one or more permanent labels. This label shall be located on the front of the
enclosure. Where more than one incoming supply circuit is provided, information for each
supply circuit shall be provided.
a. Volts – The supply voltage of the panel.
b. Phase – Single or three phase as required.

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c. Hz – Frequency of the supply.
d. Full Load Current – Shall not be less than the sum of the full load currents required for
all motors and other equipment. Equipment that may be in operation at the same time
under normal conditions of use.
Figure 30-14 Example Label

5. The warning sign with a black lightning flash on a yellow background within in a black
triangle, shaped in accordance with a graphical symbol 60417-2-IEC-5036, the whole in
accordance with sign B.3.6 of ISO 3864 shall be provided on all electrical enclosures that do
not otherwise clearly show that they contain electrical equipment (i.e., no supply
disconnecting device, external lights, pushbuttons or selector switches). The warning sign
shall be plainly visible on the enclosure door or cover.
Exception: The warning sign may be placed on another side of the enclosure if there is not
sufficient space on the side with the door or cover.
Figure 30-15 Lightning Symbol for Electrical Panels

6. Enclosures with local supply disconnects and circuits that are still energized when the local
disconnect is ‘Off’ shall have a warning sign with black letters on a yellow background as
shown in Figure 30-16. The warning sign shall be plainly visible on the enclosure door or
cover.

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Figure 30-16 Energized Circuit Warning Sign

7. Enclosures sourced with greater than 50 V and which remain energized with the supply
circuit disconnect ‘Off’ (i.e., excepted circuits such as remote HMI’s and IHPLC’s supplied
with 120 V) shall have a warning sign with black letters on a yellow background as shown in
Figure 30-17. The warning sign shall be plainly visible on the enclosure door or cover.
Figure 30-17 Excepted Circuit Enclosure Warning Sign

8. After installation, PDP panels and any other panels directly connected to the plant power
bus shall also be tagged with the designation of the bus plug supplying the control panel.

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31 Drawing Section Y: Bill of Material (BOM)

31.1 Design Requirements

A detailed listing of parts is required to implement the design defined by the drawing package.
The Bill of Material (BOM) is documented in Section Y of the drawing package. For designs
documented with the EPLAN engineering tool, the BOM is a report that is generated at the
completion of the design. Details of this process are identified in GCCH5A.
31.2 Bill of Material Sub-Sections
31.2.1 Main BOM (YA Section)
The main bill of material shall be in the YA drawing section. This bill of material is used to show
all material always required for a given design. A YA section bill of material must exist in every
design that purchases material.
31.2.2 Variable BOMs (YB, YC, etc. Sections)
Variable bills of material may be used for design content that varies based on option content.
Typical examples include branch circuit breakers in PDP designs, type or color of pushbutton or
switch, PLC memory size, etc. Variable BOM sub sections may also be used for reference
content required for the design, but not purchased as part of the design. An example of this
includes motor start protector (MSP) devices for motor starter panels that are compatible with
the contactors in the panel, but purchased on the application WD.
31.2.3 Device List (YZ Section)
The device list BOM report is used to associated panel components with various device ID’s.
Examples include indicating the necessary circuit breaker, terminals, covers, etc. with a given CB
device or indicating the necessary holder, contact blocks, button, lights, etc. with a given PB
device. The device list is typical for EC or ECS enclosure designs. It should not be included with
WD wiring diagram designs.
31.3 Required Information
The Bill of Material must contain the following detailed information:
1. BOM name, matching the design electrical design name.
2. BOM description.
3. BOM revision level.
4. BOM revision notes, identifying what was added, removed, modified at each revision level.
5. Listing of parts including the following:
a. Item number.
b. Quantity – Total number of units required by the design. For quantities associated with
bulk items, (i.e., items supplied in lots greater than 1 unit), the identifier ‘A/R’ (e.g., As
Required) may be displayed.

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c. Description
d. Manufacturer
e. Part Number
f. Purchase Code
g. User Comment – Used to provide additional information not pertaining to the item
description.
31.4 Purchase Codes
The purchase code is identified with each part to assist the procurement group in identifying
how each part should be purchased. The following is a brief explanation of the purchase codes
listed in the BOM.
Figure 31-1 BOM Source Legend

• F - FURNISHED BY GM
• REF - PURCHASED BY OTHERS (NO SUBSTITUTION) Items marked REF are provided and
do not have to be purchased. They are listed in the BOM to aid in identifying
replacement parts. The items are typically provided through the purchase of an
assembly or are purchased on a different drawing BOM.
• M - CONSTRUCTION SOURCE MAKE ITEM Items marked M are typically custom items
such as stands or brackets. The construction source (either panel builder or integrator)
should make these items.
• B1 - PURCHASE ITEM OR EQUIVALENT ITEM (GM APPROVAL NOT REQUIRED) Purchase
the listed item or an equivalent. Substitution of an equivalent item is allowed without
approval.
• B2 - PURCHASE ITEM (SUBSTITUTION REQUIRES GM APPROVAL) -INTERCHANGEABLE
COMPONENT Purchase the listed item or an equivalent. The supplier must get approval
from the responsible GM project engineer before making the substitution. Either the
specified item or the substitution could be used as a replacement part without
engineering modification.
• B3 - PURCHASE ITEM (SUBSTITUTION REQUIRES GM APPROVAL) -NOT AN
INTERCHANGEABLE COMPONENT Purchase the listed item or an equivalent. The
supplier must get approval from the responsible GM project engineer before making the
substitution. These items have a higher potential impact and engineering risk (i.e.
potential software impact) than items classified as “B2”. These items are not
interchangeable; the exact part must be ordered for replacement parts.
• B4 - PURCHASE ITEM (NO SUBSTITUTION) Purchase the listed item. No substitution
allowed.

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31.4.1 Spare Parts Designator
A “-N” suffix is added to the purchase to assist the spare parts group in determining which
components are NOT required to be stocked as spare. This is typically panel construction
material such as sheet metal, wiring duct, DIN rail, etc.

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31.5 Item Number Ranges
Each part in the engineering parts database will be assigned an item number. Numbers 10,000
thru 79,999 are reserved for global parts. Items 80,000 thru 84,999 are user defined parts. In
addition to the global and user defined ranges there are also several ranges defined for regional
and/or functional parts databases. Please contact the responsible GM Controls Project Engineer
for information on regional database requirements.
NOTE: The published GM parts database contains some items that interfere with the intended
user defined range. It is also possible to have the same user defined items numbers in different
designs for different parts. Care must be taken to avoid conflicting item numbers when
selecting parts from multiple part databases.
• 90,000-90,999 Reserved
• 91,000-91,999 GME Regional Parts
• 91,000-92,999 Reserved
• 93,000-93,999 GMNA Regional Parts
• 94,000-94,999 Reserved
• 95,000-95,999 GMIO Regional Parts
• 96,000-96,999 Reserved
• 97,000-97,999 GMSA Regional Parts
• 100000-104999 Body shop Specific Parts
• 105000-109999 Conveyor Specific Parts
• 110000-114999 General Assembly (GA) Specific Parts
• 115000-119999 Paint Specific Parts
• 120000-124999 Propulsion Systems Specific Parts
• 125000-129999 Press Specific Parts
• 130000-134999 Plant Floor Systems Specific Parts

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Figure 31-2 Sample BOM

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32 Drawing Section Z: Standard and/or Reference Drawings

32.1 Purpose
This section references the diagrams and standard drawings used in a drawing package.
32.2 Design Requirements
Only reference diagrams and standard drawings relevant to the WD level drawing package
should be included. For example, network module dipswitch settings may be useful in the
controller (cell) level and unit (station) level drawing packages, however, Ethernet information
would be useful in the system (zone) level, the controller (cell) level, and the unit (station) level
drawing packages.
32.2.1 Section Sheet Order
1. The first sheet includes a table of contents that list all reference sheets and standard
drawings contained in this section.
2. The title block of the standard drawings shall not be changed to match the drawing level
package. The standard drawings shall be copied and placed into this section.
32.2.2 Examples of Reference Types for Each WD Level Package
1. System (zone) level drawing package
a. Ethernet information.
2. Controller (cell) level drawing package
a. Standard Labels format.
b. Ethernet information.
c. Dip-switch settings for scanner modules and I/O modules.
3. Unit (station) level drawing package
a. Ethernet Information
b. Dip-switch settings for valve manifolds, prox blocks, and field I/O modules.
c. Typical mini, micro, and euro plug pinout.

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Annex A Definitions
AC: Alternating current

Access gate: A doorway-like opening in a perimeter guard for entry into a hazardous area. The opening
is typically protected by a hinged gate that shall open outward from the cell. In some cases, the opening
may be protected by a light curtain without a hinged gate. When a gate is used, a tamper resistant
electrical switch shall detect if the gate is open.

Base limit switch: A positive acting switch that is operated by the movement of the robot base, or
rotational axis. This cam operated base limit switch shall be wired to safety relays in redundant pairs,
normally open (held closed) position. The base limit switch shall open when the robot’s position may be
hazardous to the machine operator. A base limit switch is an alternative to a robot light curtain.

Bus Bar: A solid copper conductor used to connect and distribute secondary welding current.

Captive contact control relay: A control relay designed to prevent any contacts of the relay to operate
when one contact fails. A captive contact control relay shall be monitored, and a control circuit shall
detect its failure.

C-type weldgun: This term refers to a straight acting weldgun.

Carried sealer: This term refers to the application process whereby the robot carries a dispense gun
mounted to its faceplate.

Carried spot welder: This term refers to the application process whereby the robot carries a spot
weldgun mounted to its faceplate.

Carried stud welder: This term refers to the application process whereby the robot carries a stud
weldgun mounted to its faceplate.

cfm (cubic feet per minute): Flow rate of air.

Control reliable: A control circuit designed so that the failure of a single component shall not prevent
the normal stopping action from taking place, but it shall prevent a new cycle from starting until the
component failure has been corrected.

Cv (“C-sub-v”): Flow coefficient. A common method of rating flow is by a Cv factor. The Cv factor is
derived from as expression which gives the number of gallons of water per minute that will pass through
the valve with a 1 psi differential between the valve’s inlet and outlet.

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DC: Direct current

Dense packs: This term refers to the combination of valves and associated components (e.g., water
savers) that are mounted to a plate which are normally controlled by a robot.

DC Welding Power Supply: A resistance welding power supply that consists of a welding transformer
and rectifier assembly (diode pack) used to produce DC welding current.

DeviceNet valve manifold: This term refers to a valve manifold with a DeviceNet interface. This
manifold may also have inputs for connection to external devices.

Diode Pack: The portion of a DC welding power supply that converts welding current from AC to DC.

Dual channel: A configuration characterized by two independent circuit paths operating together for the
same purpose.

Dynamic Limiting Device (DLD): A base limit switch or boom back limit switch that is used to mute the
output from a user point of operation guard during selected parts of robot motion. A light curtain may
also be used for muting the output.

ECTC: Equivalent Continuous Thermal Current.

Electro-Sensitive Protective Equipment (ESPE): An assembly of devices or components working

together for protective tripping or presence-sensing purposes and comprising at a minimum, a sensing
device; controlling/monitoring devices; and, output signal switching devices. (IEC 61496, 3.1)

Enabling device: A hand held device that must be continuously operated for motion to occur in a
hazardous area. Either a release or panic squeeze of the enabling device shall cause hazardous motion
to stop when this device is incorporated in the design.

End-effector: This term refers to a device or mechanism attached to a robot’s faceplate.

ESPE: See Electro-Sensitive Protective Equipment.

External device monitoring: A means by which the ESPE monitors the state of control devices which are
external to the ESPE, (IEC 61496, 3.6). This function is optional per 61496 document.

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Faceplate: This term refers to the mounting plate on the end of the sixth axis of the robot used to
mount the end-effector.

Fail-to-safe: A condition where the circuit defaults to a known, safe, de-energized state upon detection
of a fault.

Final Switching Device (FSD): The component of a machine’s safety related control system that
interrupts the circuit to the machine primary control element when the output signal switching device
(OSSD) goes to the OFF-state. (IEC 61496, 3.10)

Finite Simultaneity: Relating to operation of safety relays. Requires that when 1 of the channels
becomes “true”, the other channel must also become “true” within a specific time period or the relay
will become faulted. Infinite simultaneity indicates that there is no time constraint for the 2nd input
channel of a safety relay to become “true” after the other has become “true”.

Force-guided: See Positively Driven.

FSD: See Final Switching Device.

GPM: Gallons per minute. Measure of water flow.

Hard Automatic Welding: Welding performed by weld guns mounted in a fixture that clamp and locate
parts. This type of automation typically operates at a low welding rate (e.g., one weld per minute
typically). Weld guns and welder controls are initiated by the cell control.

Hardware circuit: A control circuit implemented only with electro-mechanical components (e.g., relays,
limit switches and push buttons) or solid state devices.

Hazardous area: A space that has been determined by risk assessment to have an immediate or
impending potential for causing harm to persons within the space.

Human Machine Interface (HMI): An interface to interact with a PLC system or any other controlled
equipment.

IEC: International Electrotechnical Committee.

IEV: International Electrotechnical Vocabulary. See IEC publication 50, which defines common technical
terms relating to electricity in French, English, and Russian.

ISO: International Organization for Standardization. ISO is not an acronym, "ISO" is a word, derived from
the Greek isos, meaning "equal". ISO is a worldwide federation of national standards bodies comprising
of 130 countries. ISO is a non-governmental organization established in 1947. The mission of ISO is to
promote the development of standardization and related activities in the world with a view to
facilitating the international exchange of goods and services, and to developing cooperation in the

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spheres of intellectual, scientific, technological and economic activity. ISO's work results in international
agreements which are published as International Standards.

Infinite Simultaneity: Relating to operation of safety relays. There is no time constraint for the 2nd
input channel of a safety relay to become “true” after the other has become “true”. Both channels do
not have to turn on at the same time (simultaneously). Finite simultaneity requires that when 1 of the
channels becomes “true”, the other channel must also become “true” within a specific time period or
the relay will become faulted.

Inverter Welder Control: A welder control that converts three-phase AC weld power to single-phase
square waves at a frequency of approximately 1000Hz. These square waves are then rectified into DC
welding current.

Jumper Cable: Flexible, single conductor copper cable typically used to connect a transformer or power
supply to the weld gun. These cables may or may not require water cooling. Often referred to as a
“jumper”.

Kickless Cable: Flexible, dual conductor copper cable typically used to connect a transformer or power
supply to the weld gun. These cables always require water cooling.

Links: A collection of nodes forming a segment or multiple segments that are connected via repeaters
is to be initiated or arrested, the MPCE is the last element (in time) to function. (IEC 61496, 3.14)

Manual Weld Guns: Portable welding guns that are manually positioned and initiated.

Material handling: This term refers to the application whereby the robot transfers a part using its end-
effector.

MFDC: Mid Frequency Direct Current. A welding system that uses an inverter welder control with the
primary advantage of being lightweight and compact, capable of producing welding currents
comparable to much larger AC (60Hz) equipment.

Monitored Power System (MPS): A systems design approach that removes all hazardous motion energy
from devices in a designated area (i.e. zone or cell). The MPS has four key characteristics as defined by
DHS-1.0: redundancy, monitored, fail-to-safe condition, and, implemented in hardware.

MPS: See Monitored Power Systems.

Multi-station line: Two or more stations linked by a common automatic transfer.

Muting: A means of bypassing the field of a presence sensing safeguarding device during the non-
hazardous portion of the cycle.

Network: The collection of nodes connected by repeaters and bridges.

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NFPA: National Fire Protection Association.

Non-motion power: Power to inputs and outputs that do not involve motion of any kind (e.g., inputs
from proximity sensors and outputs to lamps). Non-teacher: A person (e.g., supervisor, machine
operator and production personnel) who is not operating a robot teach pendant. Nodes: Physical device
on a DeviceNet network.

Off line sub assembly: A single station that performs sub assembly work and is independent of any
transfer mechanisms or other stations.

Operator light curtain: A light curtain positioned as a point of operation guard for the machine
operator.

Opposed polarity: A method of detecting short circuits between the channels of a redundant circuit by
switching +24VDC in one channel and 0VDC in the second channel. A short circuit between the channels
results in the loss of the voltage supply to the circuit, resulting in a fail-to-safe condition instead of an
undetected single channel operation.

OSSD: See Output Signal Switching Device.

Output motion power: Power to the outputs (e.g., valves, relays and starters) that control motion
devices.

Output signal switching device (OSSD): A component of the ESPE that is connected to the machine
control system. When a the sensing device is actuated during normal operation, this device responds by
going to the off state.

Ped: An abbreviation for Pedestal.

Pedestal sealer: This term refers to an application process in which the robot carries a part, using its
material handling end-effector, to a dispense gun that is mounted to the floor.

Pedestal spot welder: This term refers to an application process in which the robot carries a part, using
its material handling end-effector, to a spot weldgun that is mounted to the floor.

Pedestal stud welder: This term refers to an application process in which the robot carries the part,
using its material handling end-effector, to a stud weldgun that is mounted to the floor.

Pedestal Welding: A form of robotic welding that uses a stationary mounted pinch gun and a robot to
position the parts.

Perimeter guard: An arrangement of fencing and/or presence sensing devices placed at a safe distance
around the perimeter of a hazardous area to ensure the stopping and prevent the starting of a machine

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when a person is in a hazardous area. Perimeter guards are not normally operated on every machine
cycle.

Pinch Gun: A pinch gun is any self equalizing resistance spot welding gun, rocker (X type) or straight (C
type), that includes upper and lower electrodes and does not require solid backups or a fixture frame to
complete the welding circuit.

Point of operation guard: An arrangement of fencing and/or presence sensing devices, placed at a safe
distance from a hazard, at the point where persons perform interactive tasks with the machine. This
guard ensures the stopping and prevents the starting of a machine when a person is in the hazardous
area at an unsafe point in the cycle of the machine. The machine operator normally operated point-of-
operation guards on every machine cycle.

Pogo Weld Gun: A weld gun consisting of a cylinder and electrode holder assembly. The single point
gun is located on one side of the welding circuit, and it is used in conjunction with a pogo weld robot.

Pogo Welding: A special robot-carried operation that uses a single point, non self-contained weld gun.
The welding circuit is completed through stationary back-ups that are mounted in the fixture base.
Note: Pogo welders use LFDC power supplies and special robots capable of withstanding the applied
weld force.

Positive acting contacts: A mechanically operated contact that does not rely on spring pressure to open.

Positively driven operation: An operation which, in accordance with specified requirements, ensures
that auxiliary contacts of a mechanical switching device correspond to the open or closed position of the
main contacts. (IEV 441-16-12)

Positive-guided: See Positively Driven Operation.

Positive opening operation:

1. (of a mechanical switching device) An opening operation which, in accordance with specified
requirements, ensures that all of the main contacts are in the open position when the actuator
position corresponds to the open position of the device. (IEV 441-16-11)
2. (of a contact element) The achievement of contact separation as the direct result of a specified
movement of the switch actuator through non-resilient members (e.g. not dependent upon springs).
(IEC 947-5-1, Chapter 3: Special Requirements for Control Switches with Positive Opening
Operation, 2.2)
Every control switch with positive opening operation shall be indelibly and legibly marked on the outside
by the symbol: (IEC 947-5-1, Ch. 3, 5.2.7)

Presence sensing device (PSD): A device (e.g. light curtain, scanner, safety may) that creates a sensing
field, area, or plane that detects the presence of an individual or object.

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PSD: See Presence Sensing Device.

Redundant: An arrangement where two or more independent devices in parallel or series serve the
same function at the same time each providing a backup for the other.

Repeater: Device used to increase the physical capabilities (Either Trunk Length or Drop Budget) of a
DeviceNet network.

Retract: This term refers to the full open position of a three position weldgun cylinder.

Retract open switch: This term refers to the cylindicator on a weldgun cylinder that indicates when the
weldgun backup is open.

Risk assessment: A formalized means of evaluating the magnitude, frequency, likelihood and
avoidability of injury in a hazardous area.

Robot enabling device: A hand held device that shall be continuously operated in order for robot servo
motion to occur under user control. Either the release or the panic squeeze of the enabling device shall
cease robot servo motion to the robot to which this device is connected.

Robotic Hip Mount Transformer: A large transformer that is mounted on the first axis of the robot and
connected to the weld gun through a series of kickless cables and jumpers.

Robot light curtain: A DLD that will be interrupted by any movement of the robot into an area that may
be hazardous to the machine operator. A robot light curtain may be used as an alternative to a base
limit switch and/or boom back limit switch.

Safety relay: A commercial component that internally provides monitoring of dual input circuits to fulfill
the requirements of control reliable circuits. A safety relay shall have an IEC 947-15 rating.

Safety stop circuit: A control circuit designed to remove power from devices that control hazardous
motion. A safety stop circuit shall be a hardware, control reliable circuit.

scfm (standard cubic feet per minute): A standard cubic foot of air is defined as air at a barometric
pressure of 29.92 in Hg. (sea level pressure) with a temperature of 20 0C (68 0F) and a relative humidity
of 36%.

Secondary switching device (SSD): A device which, in a lock-out condition, performs a back-up safety
function by going to the OFF-state and initiating an appropriate machine control action (e.g. de-
energizing the MSCE). (IEC 61496, 3.24)

Servo disconnects: A servo disconnect mechanically breaks the electrical power to the servo drives. This
disconnection of power shall not interrupt the power supply to the robot processor or I/O power to the
arm.

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Shunt: A flexible, air-cooled, single secondary conductor that is made by stacking copper laminations or
“leafs” on top of one another.

Simultaneity: The timing constraint of one input needing to follow another within a fixed period of time.
In safety relays, the timing requirements are on the inputs.

Single channel: a circuit arrangement characterized by a single current path, usually in reference to
control signals or interlocks.

Smart input block (prox block): This term refers to a DeviceNet input device that can accommodate
multiple inputs.

SSD: See Secondary Switching Device.

Station: Where an individual operation (e.g., clamping, welding, piercing, drilling) is performed in order
to prepare the part(s) to be transferred to the next operation.

TABRA: See Task-Based Risk Assessment.

Task-Based Risk Assessment: A systematic process for evaluating all task and their associated hazards
and capturing recommended solutions to protect personnel from potential injury.

Teacher: A person (e.g., electrician, WEMR and technician) who is trained to operate and program a
robot with a teach pendant.

Transgun: A combination of a weld gun and weld transformer that are closely coupled thereby
minimizing the length and loop area of secondary conductors.

Trunk cable: The cable that is the bus, or central part of the DeviceNet coax cable system. The trunk
cable is composed of multiple sections of cable.

VFD: Variable Frequency Drive. A device which controls the speed of an AC motor by varying the
frequency and amplitude of its applied voltage.

Water Flow: The rate of water flow through a component(s) that is usually given in gallons per minute
(GPM) or liters per minute. (LPM).

Water saver: This term refers to the device that monitors the flow of water to the weldgun and shuts off
the water when “low flow” is detected.

WD: Wiring Diagram.

Weld: A number of “spots” made, where no indexing or movement of units takes place.

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Weld complete: A message that occurs when a group of welds takes place.

Weld position: The location of the tooling (e.g., indexes, slides or jaws) prior to the closing of weld guns.

Work cell: Individual sub-assemblies linked by transfer schemes (e.g., robotic or manual operator
transfers).

Zone: A group of assembly operations linked by a common production process, which produces a
finished part of the vehicle. This finished part is transferred to another zone for integration of the part
to the next series of assembly operations. A zone can consist of several stations within an assembly
process.

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Annex B Engineering Design Reference

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This document was reproduced with permission from Hoffman Engineering catalog. Hoffman is not
responsible for any errors or inaccuracies of this document. (Reference IEC 60529).

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Annex C Air Component Sizing
C1 Air Drop Sizing
The following formula shall be used for sizing air drops:

𝑉𝑉𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡 60 0.100 + 𝑁𝑁𝑁𝑁𝑁𝑁

𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆 = ∗ ∗
𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶 𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇 1000 0.100
𝑉𝑉𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡 60 14.504 + 𝑁𝑁𝑁𝑁𝑁𝑁
𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆 = ∗ ∗
𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶 𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇 1728 14.504
Where:
𝑉𝑉𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡 = total air volume consumed by all actuators and any auxiliary components (such as hoses
and tubes) on the tool within the total cycle time = ∑𝑖𝑖 𝑉𝑉𝑎𝑎𝑎𝑎𝑎𝑎,𝑖𝑖 + 𝑉𝑉𝑎𝑎𝑎𝑎𝑎𝑎
𝑉𝑉𝑎𝑎𝑎𝑎𝑎𝑎 = actuator volume in 𝑐𝑐𝑐𝑐 3(𝑖𝑖𝑖𝑖3 ) such as cylinders, grippers, etc.
𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶 𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇 is total cycle time in seconds (excluding dwell time).
Conversion factors: 60 seconds / 1 minute; liter / 1000 𝑐𝑐𝑐𝑐 3 (𝑓𝑓𝑓𝑓 3 / 1728 𝑖𝑖𝑖𝑖3 )
NTP is normal tool pressure. Typically, maximum tool pressure available = 0.552 MPa (80 PSIG)

Add a safety factor of 25% to the 𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆 (𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆) to obtain the total standard liter (cubic feet)
per minute 𝑇𝑇𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆 (𝑇𝑇𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆 ).
𝑇𝑇𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆 (𝑇𝑇𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆 ) = 𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆 (𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆) ∗ 1.25

Use the 𝑇𝑇𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆 (𝑇𝑇𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆 ) and Table 13-1 to determine the proper pipe size for the air drop.

Note: Standard liter per minute (SLPM) is a unit of volumetric flow rate of a gas at standard
temperature and pressure (STP). GCCH-1 uses standard conditions as defined by the
International Union of Pure and Applied Chemistry given as 273.15 K and 100 kPa.
Note: For non-cylindrical actuators (i.e., vacuum cups), the consumed volume may be added to
𝑉𝑉𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡 . Typically, air consumption values are provided in terms of a flow rate, hence must be
multiplied by the specific actuation time of the actuator.
C1.1 Air Drop Sizing Example
The following is an example of how to calculate 𝑇𝑇𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆 (𝑇𝑇𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆 ) and select the proper pipe size
for the air drop.

Given:

𝑉𝑉𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡 = 24580.6 𝑐𝑐𝑐𝑐 3 (1500 𝑖𝑖𝑖𝑖3 ); 𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶 𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇 = 6 𝑠𝑠𝑠𝑠𝑠𝑠; 𝑁𝑁𝑁𝑁𝑁𝑁 = 0.552 𝑀𝑀𝑀𝑀𝑀𝑀 (80 𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃)

𝑉𝑉𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡 60 0.100 + 𝑁𝑁𝑁𝑁𝑁𝑁

𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆 = ∗ ∗
𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶 𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇 1000 0.100
24580.6 60 0.100 + 0.552
= ∗ ∗
6 1000 0.100
= 1602.66 (56.56 𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆)

Add 25% safety factor:

1602.66 𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆 (56.56 𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆) ∗ 1.25 = 2003.33 𝑇𝑇𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆 (70.7 𝑇𝑇𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆 )
From Table 13-1: a 𝑇𝑇𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆 of 2003.33 (𝑇𝑇𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆 of 70.7) requires a pipe size of 25 mm (1 in)

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C2 Valve and Component Sizing
The following sections describe how to design a pneumatic circuit in accordance with ISO 6358-
3:2014 given the flow rate characteristics 𝐶𝐶 sonic conductance, 𝑏𝑏 critical pressure ratio, 𝑚𝑚
subsonic index, and ∆𝑝𝑝𝑐𝑐 cracking pressure of each pneumatic component. Components may be
connected in series or parallel. The purpose is to verify that the overall circuit can meet the air
consumption demand of the actuator. This section only considers cylinders, no other actuator
types are included.
C2.1 Flow Characteristic Calculation
This section describes how to accurately calculate the flow characteristics of the system, which
considers all of the pneumatic components inline with the actuator.

The following steps and formulae can be used to determine the overall capacity of an entire
circuit to supply an actuator with the volume of air it requires to function properly. Start by
determining the inlet pressure and temperature conditions, 𝑃𝑃𝑖𝑖𝑖𝑖 and 𝑇𝑇𝑖𝑖𝑖𝑖 respectively.

Typically, it is assumed 0.552 MPa (80 PSI) is available at the air prep and 0.014 MPa is the
pressure drop through any distribution manifold; thus 𝑃𝑃𝑖𝑖𝑖𝑖 = 0.538 𝑀𝑀𝑀𝑀𝑀𝑀 is the inlet pressure to
the first pneumatic component. Concurrently, it is assumed 𝑇𝑇𝑖𝑖𝑖𝑖 = 293 𝐾𝐾 is the inlet
temperature of air to the first pneumatic component. Alternate inlet conditions may be used if
appropriate.

Next, a good initial starting point for component size selection is to match up with the chosen
actuators’ port sizes. For example, given a cylinder with ¼” NPT ports, using a ¼” I.D. hose or 10
mm tube is appropriate. Component optimization may be done retroactively once a known
component set is deemed to have enough capacity.
Note: The information presented here does not consider actuator loads, transient behavior, or
devices and actuators not specifically mentioned.
Step 1: Determine the volume (𝑉𝑉𝑐𝑐𝑐𝑐𝑐𝑐 ) of the Cylinder or Pneumatic Actuator

Example: Double acting cylinder

𝐵𝐵𝐵𝐵𝐵𝐵𝐵𝐵 2 𝐵𝐵𝐵𝐵𝐵𝐵𝐵𝐵 2 − 𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃 2
𝑉𝑉𝑐𝑐𝑐𝑐𝑐𝑐 = �� � +� �� ∗ 𝜋𝜋 ∗ 𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆
2 4

Step 2: Determine the flow required for the Cylinder in SLPM or SCFM

𝑉𝑉𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡 60 0.100 + 𝑁𝑁𝑁𝑁𝑁𝑁

𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑟𝑟𝑟𝑟𝑟𝑟 = ∗ ∗
𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶 𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇 1000 0.100
𝑉𝑉𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡 60 14.504 + 𝑁𝑁𝑁𝑁𝑁𝑁
𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑟𝑟𝑟𝑟𝑟𝑟 = ∗ ∗
𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶 𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇 1728 14.504

Step 3: Determine individual Component Flow Characteristics

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Note: Most manufacturers provide sonic conductance and critical pressure ratio values per ISO
6358 (1989) only and not subsonic index and cracking pressure values. In these cases, values
subsonic index = 0.5 and cracking pressure = 0 may be assumed unless specified otherwise.
Acquire and/or calculate the flow characteristics of each component:

4. Valve & Manifold flow characteristics are provided by the manufacturer. These typically
represent flow from inlet port to outlet ports A/B of the combined assembly (valve with
manifold or subbase including any default fittings used).
5. Fittings. Flow characteristics may be provided indirectly by the manufacturer as effective
area and other relevant geometric dimensions of the fitting body. The flow characteristics
may then be calculated given this geometric data, refer to section C3 for details.
6. Tubes and Hoses. Flow characteristics may be determined one of two ways: using an
empirically derived model per ISO 6358-3 or a theoretical model based on first principles.
The length, diameter, and type of tube or hose must be known. Refer to section C4.
7. Manifolds and other types of flow splitting components may or may not have characteristics
provided by the manufacturer. Flow characteristics may need to be derived using either
method as described in section C3 or C4 as appropriate.
8. Flow controller flow characteristics are typically provided by the manufacturer. Note flow
controllers are variable orifice components and typical values given represent a fully open
needle valve in a meter out arrangement. Assume a fully open flow controller for the
purposes of sizing.

Step 4: Calculate the single set of flow rate characteristics of the system

Given pneumatic components 1, 2, … , n, their respective flow characteristics

(𝐶𝐶1 , 𝑏𝑏1 , 𝑚𝑚1 , ∆𝑝𝑝𝑐𝑐1 , ⋯ , 𝐶𝐶𝑛𝑛 , 𝑏𝑏𝑛𝑛 , 𝑚𝑚𝑛𝑛 , ∆𝑝𝑝𝑐𝑐𝑐𝑐 ), and the manner of their interconnectivity (series and/or
parallel), follow the methodology outlined in ISO 6358-3 section 6 and/or 7 to compute a single
set of flow characteristic parameters 𝐶𝐶𝑠𝑠𝑠𝑠𝑠𝑠 , 𝑏𝑏𝑠𝑠𝑠𝑠𝑠𝑠 , 𝑚𝑚𝑠𝑠𝑠𝑠𝑠𝑠 , ∆𝑝𝑝𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐 describing the inline components
of the assembly.

Note: The details of the calculation methodology described in ISO 6358 is excluded for brevity.

Step 5: Calculate the flow available (SCFM or SLPM) given the system arrangement including all
components.

Let the flow available be given by:

2 𝑚𝑚
𝑃𝑃𝑓𝑓
⎡ − 𝑏𝑏 ⎤
293 𝐾𝐾 ⎢ 𝑃𝑃𝑖𝑖𝑖𝑖
𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎 = 𝐶𝐶𝑃𝑃𝑖𝑖𝑖𝑖 ∙ � ∙ ⎢1 − � � ⎥⎥
𝑇𝑇𝑖𝑖𝑖𝑖 ⎢ ∆𝑝𝑝
1 − 𝑐𝑐 − 𝑏𝑏 ⎥
⎣ 𝑃𝑃𝑖𝑖𝑖𝑖 ⎦

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Where 𝑃𝑃𝑖𝑖𝑖𝑖 , 𝑇𝑇𝑖𝑖𝑖𝑖 are the inlet pressure and temperature respectively, and 𝑃𝑃𝑓𝑓 is the outlet pressure
of the pneumatic system, or conversely the required design pressure of the actuator. Note that
the flow characteristics are typically derived with respect to ANR conditions (Atmosphere
Normale de Reference) as defined in ISO 8778, thus in the above equation, the right-hand side
must be converted to reference IUPAC standard conditions.

Step 6: Check that the system design is sufficient

To be certain that the actuators will complete their actions in the designated cycle time, we
verify that the air flow rate available is greater than the flow rate required, i.e., 𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎 ≥
𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑟𝑟𝑟𝑟𝑟𝑟 .

If the available flow rate of the system is greater than the flow rate required, then the desired
cycle time will be met. Typically, the system will include flow controllers at the actuator allowing
for field adjustment of flow rate going into the actuator. This allows for tuning of the true cycle
time of the actuator. If the flow rate available is significantly larger than the required flow rate,
50 percent or more, the system may be oversized and some of the components could be
downsized to reduce component costs.
C3 Fitting Flow Characteristic Calculations
Flow characteristic calculations for fittings may use the following method.

Given the effective area 𝑎𝑎 (𝑚𝑚𝑚𝑚2 ), inner diameter 𝑑𝑑 (𝑚𝑚𝑚𝑚), let the flow characteristics be given
as:

100 ∙ 𝑎𝑎
𝐶𝐶 =
𝜌𝜌�𝑠𝑠𝑠𝑠𝑇𝑇0
1
𝑏𝑏 = 1 −
𝑠𝑠
𝑚𝑚 = 0.5
∆𝑝𝑝𝑐𝑐 = 0
𝛼𝛼 𝛼𝛼 2 4𝑎𝑎
Where the compressibility effect coefficient 𝑠𝑠 = 1 + + , flow coefficient 𝛼𝛼 = 𝜋𝜋𝑑𝑑2
, and
√1.68 3.36
3
universal constants are 𝜌𝜌 = 1.185 𝑘𝑘𝑘𝑘⁄𝑚𝑚 , 𝑅𝑅 = 287 𝐽𝐽⁄𝑘𝑘𝑘𝑘 ∙ 𝐾𝐾, 𝑇𝑇0 = 293.15 𝐾𝐾.
C4 Tube/Hose Flow Characteristic Calculations
Flow characteristic calculations for tube and hose must use one of the following two methods.

(1) Empirical model based on test results from ISO 6358-3:

Given a tube/hose of length 𝐿𝐿 (𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚), inner diameter 𝑑𝑑 (𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚), let flow characteristics be
given as:

𝜋𝜋𝑑𝑑2
𝐶𝐶 =
𝐿𝐿
2 ∙ 103 �𝑘𝑘 +1
𝑑𝑑
𝐶𝐶
𝑏𝑏 = 4.8 ∙ 102 2
𝑑𝑑

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Global Common Controls Hardware Design Standards (GCCH-1)
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𝑚𝑚 = 0.58 − 0.1𝑏𝑏
∆𝑝𝑝𝑐𝑐 = 0
−3 −0.31
Where 𝑘𝑘 = 2.35 ∙ 10 𝑑𝑑 for resin tubes such as polyurethane and 𝑘𝑘 = 3.61 ∙ 10−3 𝑑𝑑−0.31
for steel tubes. For other types of tubes/hoses, use secondary method below.

First principles model based on traditional fluid mechanics:

Given a tube/hose of length 𝐿𝐿 (𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚), inner diameter 𝑑𝑑 (𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚), let flow characteristics be
given as:

2.28 ∙ 10−3 𝑑𝑑2

𝐶𝐶 =
��1 + 𝜆𝜆𝜆𝜆� + 0.77�1 + 𝜆𝜆𝜆𝜆 + 0.3
𝑑𝑑 𝑑𝑑
1
𝑏𝑏 = 1 −
0.77 0.3
1+ + 𝜆𝜆𝜆𝜆
�1 + 𝜆𝜆𝜆𝜆 1 + 𝑑𝑑
𝑑𝑑
𝑚𝑚 = 0.5
Δ𝑝𝑝𝑐𝑐 = 0
1
Where 𝜆𝜆 = 4𝑞𝑞 2 is the Filonenko formula for the average Darcy friction factor,
�1.8 log10 � 𝑚𝑚�−1.64�
𝜋𝜋𝜋𝜋𝜋𝜋
𝑞𝑞𝑚𝑚 is the mass flow rate through the tube/hose, and 𝜇𝜇 is the dynamic viscosity in accordance
with the Sutherland law. Note other Darcy friction models may be used.
C5 Example System Calculation
The following example is for illustrative purpose only. It is the designer’s responsibility to verify
the capability of all pneumatic circuit designs.

For a particular station there are 4 clamp cylinders driven by a single valve. The cycle is a typical
extend & retract cylinder cycle. A 3 m section of 16 mm tubing will connect the valve manifold
to the distribution manifold and 4 m sections of 12 mm tubing will connect the distribution
manifold to each of the cylinders.

Given the following design variables:

Cycle Time = 0.6 seconds (Time to complete extend or retract motion)
Cylinder Size: 6.30 cm Bore x 1.5 cm Stroke
𝑃𝑃𝑖𝑖𝑖𝑖 = 0.538 𝑀𝑀𝑀𝑀𝑀𝑀
𝑇𝑇𝑖𝑖𝑖𝑖 = 293 𝐾𝐾

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Step 1: Determine the volume (𝑉𝑉𝑐𝑐𝑐𝑐𝑐𝑐 ) of the Cylinders

Note a typical double-acting cylinder of 63 mm bore has a piston diameter of 20 mm.

𝐵𝐵𝐵𝐵𝐵𝐵𝐵𝐵 2 𝐵𝐵𝐵𝐵𝐵𝐵𝐵𝐵 2 − 𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃 2

𝑉𝑉𝑐𝑐𝑐𝑐𝑐𝑐 = �� � +� �� ∗ 𝜋𝜋 ∗ 𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆
2 4
6.3 2 6.32 − 22
= �� � + � �� ∗ 𝜋𝜋 ∗ 1.5
2 4
= 88.8 𝑐𝑐𝑐𝑐 3

Including the volume of the associated tubes, an estimated volume for a typical 4-port
distribution manifold, and all four cylinders, the total volume is 𝑉𝑉𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡 = 2493 𝑐𝑐𝑐𝑐 3

Step 2: Determine the flow required in SLPM

Given the total volume above and the cycle time, the SLPM required is:

𝑉𝑉𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡 60 0.100 + 𝑁𝑁𝑁𝑁𝑁𝑁

𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑟𝑟𝑟𝑟𝑟𝑟 = ∗ ∗
𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶 𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇 1000 0.100
2493 60 0.100 + 0.538
𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑟𝑟𝑟𝑟𝑟𝑟 = ∗ ∗
(0.6 + 0.6) 1000 0.100
𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑟𝑟𝑟𝑟𝑟𝑟 = 795

Step 3: Determine individual Component Flow Characteristics

Let the flow characteristics be given as:

- Valve Manifold: {6.8, 0.31, 0.5, 0}
- 3 m tube, inner diameter 10 mm
- Manifold: {9, 0.35, 0.51,0}
- 4 m tube, inner diameter 8 mm

Note the tubes will use the empirical model based in ISO 6358.

Step 4: Calculate the single set of flow rate characteristics of the system

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Using ISO 6358-3 sections 6 and 7, the single set of flow characteristics of the system (of a single
series branch) is calculated as:

�𝐶𝐶𝑠𝑠𝑠𝑠𝑠𝑠 , 𝑏𝑏𝑠𝑠𝑠𝑠𝑠𝑠 , 𝑚𝑚𝑠𝑠𝑠𝑠𝑠𝑠 , ∆𝑝𝑝𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐 � = {5.05, 0.124, 0.51, 0}

Step 5 & 6: Calculate the flow available (SCFM or SLPM) and verify the flow capacity is sufficient.

Assuming the design pressure of the cylinder is 𝑃𝑃𝑓𝑓 = 0.483 𝑀𝑀𝑀𝑀𝑀𝑀, the available capacity of the
cumulative branches of the system is found to be:

2 𝑚𝑚
𝑃𝑃𝑓𝑓
⎡ − 𝑏𝑏 ⎤
293 𝐾𝐾 ⎢ 𝑃𝑃𝑖𝑖𝑖𝑖
𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎 �4 �
= ∙ 𝐶𝐶𝑠𝑠𝑠𝑠𝑠𝑠 ∙ 𝑃𝑃𝑖𝑖𝑖𝑖 ∙ � ∙ 1−� � ⎥⎥ = 3010
𝑇𝑇𝑖𝑖𝑖𝑖 ⎢⎢ 1−
∆𝑝𝑝𝑐𝑐
⎥
⎣ 𝑃𝑃𝑖𝑖𝑖𝑖 − 𝑏𝑏 ⎦

Since the available flow capacity is greater than the required capacity, we can conclude that the
component sizing and design is sufficient.

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Annex D Bibliography (informative)
Many European and international standards contain additional information concerning the safety of
equipment and machines as well as manufacturing and performance requirements of components. All
equipment certified by a notified body as conforming to applicable international standards shall be
acceptable where indicated by the specifying authority. These standards are referenced for
informational purposes only and do not represent a complete list.

IEC 50(441), International Electrotechnical Vocabulary (IEV) Chapter 441: Switchgear, Controlgear, and
Fuses.

IEC 947, Low Voltage Switchgear and Controlgear.

947-1, Part 1: General Rules.

947-4-1, Part 4: Contactors and Motor-Starters, Section 1: Electromechanical Contactors and Motor-
Starters.

947-5-1, Part 5: Control Circuit Devices and Switching Elements, Section 1: Electromechanical
Control Circuit Devices.
IEC 61496-1, Safety of Machinery – Electrosensitive Protective Equipment – Part 1: General
Requirements and Tests.

EN 1050, Safety of Machinery – Principles for Risk Assessment.

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Annex E Reserved

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Annex F Heat Calculations for Control Enclosures
F1 Overview
The following is a suggested method for determining the heat characteristics of control
enclosures. The equipment supplier is responsible for the accuracy of the calculations and any
assumptions made for the purpose of these heat calculations. The equipment supplier shall
state any assumptions, other than those documented by this section. The heat calculation
summary form shall be included with the related drawings when submitted for approval.
F2 Procedure
There are two values that the equipment supplier will have to determine in order to calculate
the heat characteristics of each control panel. The first is free surface area and the second is
heat load. All calculations shall use metric units.

Free surface area is the net surface area of the control panel that air can freely flow over.
Expressed in units of meters squared (m2).

Heat load is the cumulative amount of heat that is generated by all equipment in the control
panel. Expressed in units of Watts (W).
1. 1. Calculation of free surface area – calculate the area of each surface. Subtract any
surface that will be blocked from airflow after installation. Refer to the following examples.
a. floor mounted panel – all surface area can be used for the area calculation except for
the bottom of the enclosure
b. wall mounted panel – all surface area can be used for the area calculation except for the
back of the enclosure
c. other areas – areas used by push buttons, pilot lights, CRT’s, or other devices mounted
through the panel cannot be used for the area calculation
2. Defining ambient temperature – If the panel is on the plant floor, use 40 °C for the plant
ambient temperature. If the panel is located on the balcony, use 45 °C for the plant ambient
temperature.
3. Defining panel temperature – Interior panel temperature value used in the calculation shall
not exceed the lowest rated component within the panel. Refer to the equipment
manufacture’s ratings for all ambient temperatures and de-rating factors. Be sure to
consider de-rating factors when components are mounted on an angle or sideways which
may not allow for proper air flow required for adequate heat dissipation.
4. Calculating free heat dissipation
Calculate the following:

PV = (Tmax – Ta)X(5.5 A), in metric units where:

PV = total heat dissipated by the enclosure (Watts)

Tmax = maximum interior control panel temperature (°C)
Ta = maximum plant ambient air temperature (°C)
A = surface area of panel exposed to free air (meters squared)

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5.5 = this is the average heat transfer coefficient for painted sheet metal [W/(
m2 ° C)]
5. Metric conversions
Watt = 3.41 BTU/Hr
BTU/Hr = 0.293 Watt
m2 = 1550 in2
in2
= 6.45 X 10-4 m2
°C = (5/9) (°F-32)
°F = (9/5) °C +32
6. Calculation of total equipment heat load – Add the heat load of all devices that generate
heat. It is the responsibility of the equipment supplier to determine the heat generation
values. Refer to the equipment manufacturer’s data for all heat generation values. Since
heat varies with actual loading, the heat load of power supplies and transformers may be
figured at its actual load, plus 25% future capacity. You do not have to use the maximum,
full load rating of these devices.
F3 Results
Subtract the total equipment heat load (F2: Procedure, item 6) from the calculated free heat
dissipation (F2: Procedure, item 4.) If the result is negative, additional heat needs to be
dissipated from the panel. Appropriate steps shall be taken to reduce the heat loads inside the
enclosure and ensure that the maximum panel temperature will not be exceeded. If the
number is positive, that is the amount of additional heat that can be generated in the panel
before the interior will exceed its maximum internal temperature, when the ambient plant
temperature is at its maximum.

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