Global Engineering Guideline
OEM Electrical & Control Guideline
OEM Electrical and Control Guideline
The OEM Electrical and Control Standard provides
standard design and implementation details for all
General Mills Incorporated (GMI) equipment
purchased from original equipment manufacturers
(OEMs). It communicates electrical expectations for
equipment and systems to both internal and external
resources and equipment manufacturers.
Table of Contents
1. Summary
2. Contacts
3. General Requirements
4. Definitions
5. Component, Control Panel, and
Construction Requirements
6. PLC and HMI Control Equipment and
Software
7. Safety
8. Documentation and Deliverables
9. Revision Summaries
1.
Summary
This document is a unified electrical specification for all OEM equipment
purchased for GMI. The document has several purposes:
•
Provide a guideline and communicates electrical expectations for OEM
equipment or systems to both internal and external resources and
equipment manufacturers.
•
Create a common machine specification that maximizes capital
efficiencies by conforming, wherever possible, to accepted industry
machinery standards.
•
Affirm GMI’s commitment to the safety and regulatory considerations of
electrical systems covered by this document.
•
Create a future framework for equipment redeployment by making the
equipment electrically compatible and similar at all locations.
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2.
Contacts
Document owner:
Daniel Migliori
Subject matter experts:
Daniel Migliori
David Otis
Mark Chatterton
Mark Daily
David Fulmer
763-764-2217
763-764-2217
763-764-2668
763-764-3490
615-849-1504
763-293-3659
3.
General Requirements
3.1
Scope
This document applies to:
•
New or remanufactured machinery, and/or multiple machines or
systems (unit of operations) that are purchased by GMI.
(Remanufacture does not include overhaul, repair, reconditioning, or
refurbishment to original specification.)
•
Other equipment or businesses deemed applicable by GMI.
•
Equipment intended for US sites.
Be aware that some details apply to specific functional areas (processing,
utilities, or packaging), and some apply specifically to area classifications
(such as outdoors, dusty, wet wash, and dry warehouse).
3.2
Approval Required for Variance
Consider all standards described in this document mandatory unless
otherwise identified as optional or preferred. Any variance from GMI
requirements or preferences requires prior GMI Engineering approval.
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Obtain approval from the engineer that issued this document (“GMI
engineer”) or has been designated as responsible for project deliverables.
GMI will provide and document specific project requirements and
approvals.
Always inform the GMI engineer of any mandated components or designs
that might compromise the equipment’s performance.
3.3
Project-Specific Requirements
Additional project-specific requirements will be included in the General
Mills purchase order and in GMI Global Engineering document
40_67_00.02 known as Schedule Z1. Schedule Z usually includes:
3.4
•
Conformance checklist
•
Project-specific electrical requirements and equipment
•
Device code identifiers, if specified
•
Control and other system requirements
•
Integration requirements
Panel Certification
All electrical control panels consisting of eight or more components,
whether supplied in a complete enclosure or as an open back plate, must
be built, certified, and labeled by a national recognized testing laboratory
(NRTL), such as Underwriters Laboratory (UL). An electrical control panel,
wiring, equipment or materials for which a NRTL certification does not
exist may be approved upon certification by an electrical engineer licensed
in the state for which the control panel will be installed. Such a certification
will not be valid unless based on a verification of the manufacturer’s
component safety and performance test data for the product. Variance
from this requires prior GMI Engineering approval.
1
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3.5
Hazard Identification, Risk Assessment, and Safety
Requirements
The vendor’s Risk Assessment and Safeguarding System for Process
Machinery must follow published ANSI, PMMI, ISO, IEC, and EN safety
guidelines for process equipment, unless conflicts exist with higher level
regulations.
3.6
Electrical and Safety Codes
3.6.1 General
All supplied equipment, wiring, and controls shall comply with the current
edition of the following electrical and safety codes and specifications at
the time of purchase. These codes and specifications are listed in order
of precedence. If a conflict exists, apply the code with the higher
precedence.
•
Local regulatory authority having jurisdiction.
•
NFPA 70 (National Electrical Code)
•
NFPA 79 (Electrical Standard for Industrial Machinery)
•
CIS_314_OEM Electrical and Control Standard. (This document)
•
General Mills Program for Control of Hazardous Energy (See Section
5 in this document)
•
OSHA 1910.Subpart S - Electrical (1910.301 to 1910.399)
•
OSHA 1910.147 - The Control of Hazardous Energy (Lockout/Tagout)
3.6.2 Packaging Machinery
The following codes apply to packaging machinery only.
•
ANSI/RIA R15.06 Safety Requirements for Industrial Robots and
Robot Systems
•
ISO/IEC/EN Published guidelines for hazard identification and risk
assessment of packaging equipment.
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•
ANSI/PMMI B155.1 for Packaging Machines
3.6.3 Utility Equipment
The following standards apply to utility equipment only.
3.7
•
NFPA 85 – Boilers
•
NFPA 86 – Ovens, Furnaces
Other GMI Standards and Guidelines
The following GMI Engineering standards and guidelines also apply.
•
CIS_301_Electric Motor Design Standard
•
CIS_302_Variable Frequency Drive Design Standard
•
CIS_303_Servo_Drive_Design_Standard
•
CIS_304_Safety_Controls_Standard
•
CIS_308_Portable Cord and Connector Standard
•
CIS_314_OEM Electrical and Control Standard (this document)
•
CIS_401_ControlLogix Programming Guidelines
•
CIS_402_Wonderware_Framework
•
CIS_403_HMI Application Standard
•
CIS_409_ControlLogix Configuration Guidelines
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4.
Definitions
Term
Definition
HMI (Human
Machine Interface)
Computer-based devices that communicate to the processor
through a network or over the computer backplane. Sometimes
called Operator Interface Terminal (OIT).
LOTO
(Lockout/Tagout)
The safety practice of locking out equipment with a padlock and
tag to render a piece of equipment safe at rest. Each plant has a
specific, detailed policy that meets OSHA requirements.
MQIS
Manufacturing Quality Information System. MQIS is GMI’s
proprietary MES layer of information systems. It includes various
computer- and network-based modules for processing and
storing plant floor manufacturing information.
NEC
National Electrical Code (NFPA-70)
Qualified person
General Mills employees or contractors who have been trained in
electrical safety. Personnel must also possess the correct tools
and PPE (personnel protection equipment) approved for the
voltage levels and arc flash hazard. (NFPA 70E)
Schedule Z
A companion MS Excel file to this document. Schedule Z is
found in GMI Global Engineering document 40_67_00.02 and
contains a checklist to ensure detailed compliance with this
standard. Additionally, Schedule Z contains specific
requirements for the designated plant, project, or machine.
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5.
Component, Control Panel, and Construction
Requirements
5.1
Products and Materials
5.1.1 Area Classification
Use the following table to determine minimum panel construction and
minimum rating for individual components on the equipment.
Area Classification
Packaging
Process & Utilities
Dry—warehouse
NEMA 12 (IP 54)
Painted white epoxy,
match equipment, or
STEELIT
NEMA 12 (IP 54)
Painted white epoxy or
match equipment
Dry clean, dusty
(possible wet splash)
NEMA 12 (IP 54)
Painted white epoxy,
match equipment, or
STEELIT
NEMA 12 (IP 54)
Painted white epoxy or
match equipment
Dry dusty with possible
wet wipe only
NEMA 12 (IP 65)
Stainless steel
NEMA 12 (IP 65)
Stainless steel
Wet wash
NEMA 4x (IP 66)
Stainless steel.
NEMA 4x (IP 66, IP67,
IP69K) Stainless steel.
Outdoors
Not applicable
NEMA 3, 3R, (IP 33) 4
or 4X (IP 66).
5.1.2 Preferred Components
Preferred electrical components are listed in Schedule Z.
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5.1.3 Device Selection
For equipment purchased for facilities in North America, use only devices
manufactured in North America or from manufacturers with a substantial
presence in North America, including substantial North American stock.
5.1.4 Disallowed Materials
Glass, mercury, wood, or asbestos shall not be used for any part of the
machine, including panels. Additionally, no material considered harmful
for food contact shall be permitted over or in the vicinity of an open food
area. Any variance, such as glass photoelectric devices, requires prior
GMI Engineering approval.
Exceptions:
•
GMI glass, fluorescent lighting bulbs in panels protected by a
shatterproof plastic lens shall be permitted.
•
Small, glass fuses shall be permitted.
5.1.5 Heat-ups
Where designated, equipment and electrical components must withstand,
in a non-powered state, occasional system heat-ups to a temperature of
150 degrees Fahrenheit for a 24-hour period.
5.2
Device Labels
5.2.1 Component Labels
Each component in the panel (such as terminal blocks and relays) as well
as each component on the machine (such as motors, solenoids, and
photoeyes) shall have an identification label. Provide white with black
letter, plastic laminate tags with a minimum 1/8-inch letter height. Tags
inside the panel may be attached with an adhesive and tags on the
machine components shall be attached to the machine frame
mechanically or with an adhesive. It is preferred that external machine
component device labels be metal detectable.
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5.2.2 Device Labels
All devices shall be labeled. The label shall include the device’s electrical
schematic identifier (e.g. XV13), common name, and I/O address (e.g.
01001) where applicable. Such labels shall not be fastened to a
removable panel or directly on the device.
The Vendor shall be permitted to use their standard device code identifier
system unless otherwise specified in Schedule Z.
Some plants may allow labels made with Brady HandiMark material. GMI
will specify the labeling method in Schedule Z.
5.3
Power Source
5.3.1 Main Power Source
The main power supply shall be nominal 480VAC, 3Ph, 60Hz. Alternate
voltages require prior GMI Engineering approval. The current and voltage
levels shall be indicated in the formal quotation.
Power for all devices other than PLCs, HMIs, servo control axis modules,
and network devices (see 5.3.2) shall be connected to the load side of
the main, lockable disconnect for this power source.
5.3.2 PLC, HMI, PC, Servos Axis Control Module, and Network
Devices
Power for PLC, HMI, PC, servo axis control modules, and network
devices shall be maintained at all times and supplied either from a
separate power source to the machine’s main control panel or derived
from the line side of the control panel’s 480VAC main supply. The choice
as to which option is used will be determined per project.
When derived from the line side of the control panel’s 480VAC main
supply, this power source shall have its own lockable disconnect.
Below is an illustration of an acceptable method for deriving the separate
power for the PLC, HMI, PC, servo axis control modules, and network
devices from the 480VAC supply.
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5.3.3 Derived Power for Other Voltages
Except where allowed in 5.3.2, all other required voltages shall be
derived from the main source.
Power supplies shall have a capacity of 25 percent over maximum inrush.
5.3.4 Device Voltages
5.3.4.1 Panel devices requiring a power source, such as PLC chassis and
HMIs, shall be 120VAC, 60Hz, if available; 24VDC is also acceptable.
5.3.4.2 Motor VFDs and servo amplifiers shall be 480VAC, 3Ph, 60Hz.
5.3.4.3 Field devices requiring a separate power connection from their signal
connection shall use 120VAC, 60Hz, if available; 24VDC is also
acceptable.
5.3.5 Disconnecting Means
5.3.5.1 Main disconnect
5.3.5.1.1 All electrical control panels greater than 50 Volts shall have
a lockable means—suitable as a LOTO point—for
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disconnecting all power to the machine. Control panels with
an integral lock and key are not acceptable. It is preferred
that auxiliary contacts indicating the status of the
disconnect be wired as a PLC input.
5.3.5.1.2 Panel doors shall be mechanically interlocked to the main
disconnect and include a defeater requiring only a common
electrician’s screwdriver to open the door while the panel is
energized.
5.3.5.1.3 For safety and reliability reasons, the mechanical
connection from the main disconnect operator/handle to
the disconnecting means shall be permanent. Throughthe-door style disconnects shall not be used.
Acceptable styles include but are not limited to:
•
Flange mounted disconnect
•
Cable operated disconnect
•
Side mounted disconnect
•
Remote mounted disconnect
5.3.5.2 Hot glue disconnect. For equipment that includes a hot-glue system,
include a separate disconnect for the glue system independent from
the main machine.
5.3.5.3 Other subsystem disconnects. Clearly labeled subsystem
disconnects shall be considered in situations where subsystem
lockout is desired with portions of the machine remaining energized.
Plant safety management approval shall be obtained for subsystem
disconnects.
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5.3.6 Short Circuit Current Rating (SCCR)
Equipment shall be designed and labeled with the SCCR rating. The NEC
requires that the SCCR rating of the industrial control panel must meet or
exceed the available fault current at the point of application. If the fault
current is unknown at the time of purchase, use the table provided below.
460V, 3ø
I, amp rating
30
60
100
150
200
300
400
500
600
SCCR, ka
5
10
14
18
22
26
32
34
42
230V, 200V, 3ø, 230V, 115V 1ø
I, amp rating
SCCR, ka
150
5
200
10
5.3.7 Loss of Power Toleration
The machine shall be designed to tolerate a sudden, random loss of
power (such as a power failure) at any time without damage to the
machine. Recovery procedures from such a power loss shall be provided.
5.4
Designs Requirements for Control and Power Panels
5.4.1 Enclosure Design
5.4.1.1 Panel access. Panels shall be designed to be accessible to qualified
personnel only. For panels with voltages greater than 50 volts, a
defeater/tool shall be required to allow access. The panel door shall
automatically re-latch when the door is closed.
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5.4.1.2 Door locks and latches. GMI prefers a single-handle latch
mechanism on each door in accordance with the enclosure rating.
Obtain GMI Engineering approval before using cabinet latching
systems that have more than one latch and/or requires a tool (i.e.
common screwdriver) to open or close. Do NOT fit control panel
latches with locks or keys.
5.4.1.3 Panel labeling. A NFPA 79 compliant machine nameplate including
the supplier’s name, model and/or serial number, rated volts, number
of phases and frequency, full load amps, nominal KVA load, SCCR
rating, and electrical diagram number(s) is required.
Panels or machines requiring more than one disconnecting means to
disconnect all power shall be marked to indicate that more than one
disconnecting means is required to de-energize the equipment.
Control panels and junction boxes not rated for washdown/hosedown
conditions shall be carry a label stating “Warning: No Wash Down.”
5.4.1.4 Finger-safe design. Finger-safe electrical components prevent
fingers from easily or inadvertently contacting live parts. Devices rated
IP20 are considered finger-safe.
Finger-safe components shall be used wherever possible.
Exposed, non-finger-safe parts operating at greater than 50 volts shall
be covered with clear Lexan labeled “Live Voltage Present.” The
Lexan covers shall be removable or hinged to allow access to
components when needed. Holes for test probes in compliance with
IP20 shall be permitted.
5.4.1.5 Light fixture
Panels 14-inches or deeper shall be provided with an LED light fixture
inside the panel with a door switch or IR motion sensor so the light
fixture will turn off when the panel door is closed.
5.4.1.6 NEC working clearance
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Electrical panels mounted on or near the equipment shall comply with
NEC working clearance requirements. Generally, the NEC requires
that electrical panels be positioned to provide a safe working space at
least 30-inches wide, 78-inches high, and with appropriate frontal
clearance based on the in-cabinet voltage. If the voltage in the cabinet
is 150 volts or less, the frontal clearance requirement is 36-inches
from the front plane of the cabinet to any object. For cabinet voltages
greater than 150 Volts, the NEC requires 42-inches from a grounded
surface, or 48-inches from the access point of another electrical panel
of any voltage.
5.4.1.7 Panel penetration
Control panels shall be designed with no top penetration and no
penetrations on the upper 1/3 of the sides. This requirement applies to
all area classifications.
Exception: Panel mounted devices, such as stack lights, may
penetrate the upper 1/3 of the sides upon GMI Engineering approval.
Top
No Enclosure
Penetration
Top 1/3
or Side
Top 1/3
of Side
Figure 1: Electrical Panel Penetrations
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5.4.1.8 Windows in enclosures. Windows in enclosures shall use clear
polycarbonate (Lexan) that maintains the rating classification of the
enclosure.
5.4.2 Component Mounting Requirements
5.4.2.1 Side and bottom. It is preferred that all components be mounted
ONLY on the back panel. Components shall not be mounted on the
bottom of the panel or on the lower 1/3 of the sides.
5.4.2.2 Penetration rating. All equipment that penetrates an enclosure shall
maintain the classification rating of that enclosure.
5.4.2.3 Terminal strips. All field wiring shall connect to terminal strips. It is
preferred that only a single level of terminal strips be used. Use of
multi-level terminal strips requires prior GMI Engineering approval.
Exception: Special-purpose, sensitive signals (such as thermocouple,
servo feedback, and load cells), which must be connected directly to a
PLC input card or instrument.
5.4.2.4 Component temperature and spacing
Component manufacturers’ recommendations on spacing
requirements and operational temperature range shall be followed.
The electrical panel shall be designed and built such that the
temperature inside the enclosure does not exceed the operating
temperatures of the components it contains—typically 40°C under
ambient operating conditions of 30°C (85°F).
Panels shall not be vented to achieve temperature ratings. If an air
conditioner is used, it shall be designed so that outside air does not
enter the enclosure. Additionally, air drawn into a heat exchange
section shall be filtered with an easily-maintained filter.
For systems with air conditioners, a method to prevent condensation
from spilling directly onto the floor shall be included
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For systems with panel cooling devices, such as an air conditioner or
heat exchanger, a method of de-energizing the cooling device when
one or more of the control panel doors are open shall be included.
5.4.2.5 Programming connections
All panels with voltages above 50 volts and which contain
programmable devices shall be provided with an exterior, 120VAC
duplex, GFI receptacle, protected at 5A, and labeled “For computer
use only.”
If the machine is connected to a plant Ethernet LAN, an Ethernet
outlet shall be included.
Programming plug receptacles needed to connect to any other
required device programming port without opening the panel shall be
provided.
Only NEMA 4X-rated receptacles shall be used regardless of the
panel rating. Refer to Schedule Z for specific plant requirements.
5.4.2.6 Plastic wiring duct. For interior wiring, plastic wiring duct shall be
used to maintain neat and workmanlike construction (such as
Panduit®). Note that GMI requires special, high-temperature rated
material for heat-ups.
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5.4.3 Spare and Space Requirements for Future
The following table lists space for future requirements. Variance requires
prior GMI Engineering approval. The proposal shall indicate the portion of
the space to be populated with spares.
Spare and Space Requirements
Category
5.5
Main Cabinet(s)
Machine Mounted
Enclosure
Back panel
15 to 30% area
10%
Terminal strip
25-40% I/O points
10%
PLC I/O
25% spare slots or space
10%
Power
Components
1 spare space for each similar
Starter, VFD or Axis Module
GMI Engineer’s discretion
Internal Components
5.5.1 FVNR Motor Starter
Full-Voltage Non-Reversing (FVNR) starters are the common across-theline starter. Allen Bradley IEC starters with Type II protection shall be
used for fixed-speed drives. NEMA type starters shall be accepted with
prior GMI Engineering approval.
5.5.2 Variable Frequency Drive Guidelines
Refer to CIS_302_Variable Frequency Drive Design Guidelines. Key
requirements:
•
Minimum VFD size is 1HP, 480VAC, 3 Ph.
•
Power line reactors shall be installed on the line side of ac drives (i.e.
PF525) that do not have built-in reactors.
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•
Configured range of the VFD shall not exceed the turndown
specification of the motor, gearbox of other drivetrain components.
Note: Typical VFD frequency range is 30Hz to 90Hz.
•
All VFD applications should utilize the “Safe Torque Off” safety feature
of the drives.
•
Provide full HIM with keypad and display.
•
Provide VFD parameters documented in the schematics.
5.5.3 Branch Circuit Protection
Individual branch circuit protection for all drives and starters shall be
provided. Circuit breakers shall be used unless otherwise prohibited.
5.5.4 Control Relays
DIN rail-mounted relays shall be used and shall have a means to indicate
when the relay is energized.
5.5.5 Solenoid-Operated Pneumatic Valves
Solenoid-operated pneumatic valves shall not be installed in the same
enclosure as other electrical components unless external exhausts are
provided.
GMI prefers solenoid-operated pneumatic valves be either free-standing
and rated for the area classification OR mounted in a separate, dedicated
panel.
For panel-mounted valves, a Hoffman Concept® or equivalent NEMA 4X
or 12 stainless steel enclosure shall be used. The number of enclosures
and valves per enclosure shall be dictated by the overall design,
geographic physical location, and concentration of pneumatic devices.
The panel shall be permitted to contain a remote I/O rack to support the
valves but shall contain no other electronic equipment.
Pneumatic tubing from a valve to its end device shall not exceed 10 feet
(3m).
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Compressed air requirements (PSI and CFM) for the system shall be
documented on the pneumatic schematic as well as labeled on the
equipment.
5.5.6 Power-Conditioning Filter
A power-conditioning filter (Islatrol® or equivalent) shall be used for all
computer-controlled electrical components, such as PLC processors and
servo-drive controllers.
5.5.7 LED Requirement
Panel indicators—pilot lights, illuminated pushbuttons, etc.—shall be of
the LED type.
5.6
PLC I/O
5.6.1 Prewired I/O Cables
With prior GMI Engineering approval, GMI will accept 1492 Series
prewired cables and interface modules cards with 16 or more point I/O.
5.6.2 Digital Input Modules
Digital input components connected to chassis-based I/O systems
located inside a control panel and connected to an input module shall be
fused with at least one fuse per 16 input points.
Digital input components connected to an on-machine I/O system shall
have a separate fuse or circuit breaker for each input module or block.
In either case, fusing inputs based on sub-groups determined by common
location or function is recommended. Variance requires prior GMI
Engineering approval.
5.6.3 Digital Output Modules
Individually fused outputs shall be used: either fused wiring arms or other
output fusing designs as approved by GMI Engineering. Blown fuse
indicators shall be provided for all applications.
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Digital outputs components connected to an on-machine I/O system shall
use a separate fuse or circuit breaker for each output module or block.
Exception: GMI permits electronically fused PLC output cards (such as
1756-OB16E and/or Point I/O) provided that the HMI indicates and resets
blown fuses.
5.6.4 Digital I/O and Field Device Voltage Requirements
Use the following table to determine voltage requirements.
Function
Process
Voltage Level
120VAC or 24VDC
Process where time critical
24VDC
Packaging
24VDC
Safety Circuits
24VDC
Utility
120VAC or 24VDC
5.6.5 24VDC Digital I/O Wiring
Use the following table to determine module and component wiring
requirements.
24 VDC I/O Module
Input
Output
Wiring
Field Component
Sinking
PNP
Sourcing
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5.6.6 Analog I/O
Function
Signal
Typical
100ohm Pt RTD
1756-IR6I,1769-IR6, 1734IR2
Hardy ControlLogix card using
C2
HI-1756-WS
Frequency
1756-CFM
4—20mA
1756-IF8H,1756-IF16 (Use
differential
configuration),1769-IF4I,
1734-IR4,
Temperature
Weight
Flow
Pressure, Level,
Conductivity,
Other
5.7
Fieldbus
GMI requires review and approval for all fieldbus use. A fieldbus is a
control network such as DeviceNet, Ethernet I/P, and CIPMotion that
connects the PLC or main processor to remote I/O, drives, and other field
devices.
5.8
Wiring Methods
5.8.1 Voltage Separation
Conductors shall be grouped and separated by voltage and insulation
class throughout the machine (for example, via wiring channels such as
Panduit® or rigid conduit). All conductors in a group shall have an
insulation voltage rating at least as great as the maximum voltage level of
the highest voltage conductor in that group. The following groupings shall
be observed:
•
Nominal 240 and 480 RMS voltage (includes 700VDC)
•
Nominal 120 RMS voltage (includes 90 and 180VDC)
•
50 volt RMS and less (includes 24VDC)
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•
TTL and Communications signals
5.8.2 Wire Size
For single conductors, stranded copper shall be used. Insulation type and
minimum size are specified below.
•
For panel wiring—18 Gauge TFFN or MTW (MTW is more flexible and
easier for the cabinet builder to route and connect).
•
For field control device wiring—16 Gauge TFFN.
•
For motor wiring—14 Gauge THHN and larger (sized for amperage).
Note: Use of conductors with an insulation class less than the maximum
circuit voltage applied to any other conductor within an enclosure is
discouraged. Doing so requires grouping and physical separation in
accordance with NFPA-79 and sec. 3.8.1 of this document.
GMI permits smaller size wires (no smaller than 20 AWG) when using
multi-conductor cable provided ampacity and voltage drop considerations
are satisfied.
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5.8.3 Wire Colors
Use the wire colors as described in the following table (refer to NFPA 79,
and IEC).
Wire Color
Use
Green or green with
yellow stripes
Grounding Conductor
Black
Ungrounded conductor at line voltage
Red
Ungrounded AC control conductor at less than line
voltage including PLC I/O
Blue
Ungrounded DC control conductor
Orange
Ungrounded control circuit conductors that remain
energized when the disconnect is off (such as external
interlocks) Note: this is a recent NFPA 79 change from
yellow
White
Grounded circuit conductor
White w/ blue stripe
Grounded (current-carrying) DC circuit conductors
White w/ orange stripe
to match the
ungrounded conductor.
Grounded (current-carrying) AC control circuit
conductors that remain energized when the disconnect
is off (such as external interlocks).
Striping and tracer
colors
Requires prior GMI Engineering approval if different
from above.
Pre-manufactured
wiring systems
Requires prior GMI Engineering approval
NOTE: For multi-conductor cables, GMI allows deviation from these color
requirements, providing that each conductor has its own unique identifier.
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5.8.4 Wire and Terminal Labeling
All terminal points and both ends of all wires shall be labeled with
machine-printed labels. Hand-written labels shall not be used.
For wires, A-B sleeve or Brady wrap-type wire markers shall be used.
Refer to CIS_401_ControlLogix Programming Frameworks for the
preferred labeling scheme for Logix processors. Other wire numbers are
derived from the page and line number or the number of the control
schematic drawing.
Terminal strip labels shall match the wire number. Wires connecting a
field device may include an additional label with the device tag number.
All spare wires shall be terminated and labeled as spare.
5.8.5 Shielded cables
5.8.5.1 Analog Signal Cables
Analog cables shall be shielded and the shield bonded to ground at
the I/O connection end only. The shield shall be trimmed and shrink
tubing applied to cover the exposed shield at both ends.
5.8.5.2 VFD Motor Leads
Motor lead shields shall be grounded at the motor junction box and on
the VFD ground terminal strip point as per the manufacturer’s
recommendation.
5.9
Raceway and Wiring Requirements
Raceway is an enclosed channel designed expressly for holding wire and
cable. It includes conduit and wireway. It does not include cable tray
utilized in the interior of control enclosures. The wiring of devices on the
machine to the control panel can be accomplished by various methods:
wire and cable in conduit, wires and cables in sealed wireway, exposed
cable in wire basket, and exposed cable supported on the machine. The
methods selected shall be determined by considering the ruggedness and
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duty for the environment and to meet the GMI sanitary requirements. All
raceway materials shall be NRTL approved. See Schedule Z for methods
allowed and forbidden for a particular application.
5.9.1 Conduit
Rigid conduit is allowed for all applications. Determination of the specific
type of conduit (aluminum, galvanized steel, PVC-coated) shall be based
on the application or plant requirements. Electrical metallic tubing (EMT)
shall not be used.
GMI requires sanitary construction for all conduit and supports.
Acceptable methods of conduit support include Mineralac® clamps with
spacers and inverted angle with U-bolts. GMI prohibits the use of allthread threaded rod and Unistrut®.
5.9.2 Wireway
Wireway or troughs require prior GMI Engineering approval. Typically,
GMI only accepts wireway when installing several multi-conductor preterminated cables (such as servo motor cables). Use Hoffman® or an
approved equivalent is preferred. GMI prefers that the wireway be rotated
45 degrees so there are no flat top surfaces. The wireway must maintain
separation of conductors by voltage and insulation class. The wireway
must have the access door mounted so that it opens upward with the
hinge at the highest part of the enclosure.
5.9.3 Flexible Connections
GMI permits flexible equipment connections only as follows.
•
Liquidtight Flexible Metal Conduit (LFMC) or Liquidtight Flexible
Nonmetallic Conduit (LFNC)
o
A properly sized equipment grounding conductor wire
shall be run with the phase conductors and used to
ground metallic parts of the equipment.
o
Flexible conduit length shall not exceed 36 inches.
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•
Power & Control Tray Cable (TC-ER)
•
SO or other flexible cord/cable listed in National Electrical Code
Article 400 is permitted only in the following cases:
o
Noise or vibration cannot be abated using flexible
conduit.
o
The connection is made to a moving part.
o
The motor is interchanged frequently—portable
equipment or equipment that must be frequently
interchanged for reasons other than breakdown.
o
On OEM equipment in accordance with Chapter 13 of
NFPA-79.
5.9.4 Exposed Cable
Exposed cable shall have a jacket rated for the application and
environment. Unsupported exposed cable shall not exceed 36 inches.
5.9.4.1 Wire Basket Construction
Where exposed cable is permitted, cables shall be rated as Power &
Control Tray Cable (TC-ER) and spaced with a minimum of ¼ inch
between cables and equipment framework. Wire basket construction
shall be permitted in order to achieve this spacing. When using wire
basket, cables are shall be secured with metal-impregnated wire ties
every 16 inches to 2 feet.
5.9.4.2 Quick Disconnect Connectors
GMI prefers quick disconnect connectors (such as Brad Harrison type)
for device connections when exposed cable (SO type) is used.
Any modular or quick-disconnect connectors on all field devices shall
be mounted facing down or otherwise positioned to avoid collecting
water or dust.
In wet locations, connectors shall have a rating of IP69K.
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5.9.4.3 Plug Connections Supplying Electric Power
For plug connections, load-breaking receptacles shall be used for
voltages greater than 50V AC or DC.
5.9.4.4 Long Cords
Long cords needed for portable equipment require GMI engineering
approval.
See CIS_308_Portable Cord and Connector Standard for additional
information.
5.9.5 Cable and Raceway Routing
Routing cable or raceways over open product areas shall not be
permitted.
5.10 Wire Ties
Only metal impregnated or metal wire ties are permitted, with the
exception of inside control panels and where the potential for open
product does not exist.
5.11 Motors Guidelines
Refer to CIS_301_Electric Motor Design Guidelines Key requirements:
•
NEMA Frame, 480VAC, Efficiency > 85.5%
•
Motors driven with inverters shall meet the requirements of NEMA
MG1 (Motors & Generators) part 31.4.4.2.
5.11.1 Field Disconnect
All induction and servo motors shall have a local, lockable field
disconnect close to the motor and in conformance to GMI LOTO
requirements. The field disconnect shall include an auxiliary contact that
provides an input to the PLC. It is preferred that the lockable field
disconnect be within 3 ft. of the device and within line of sight.
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Exception: With prior GMI Engineering approval, a motor within the
safety-guarded envelope of a machine does not require an individual
disconnect, if the motor is an integral part of the machine’s operation and
the main disconnect for the machine satisfies the requirement for locking
out the equipment.
5.12 Servo Motion
Refer to CIS_303_Servo_Drive_Design_Guidelines. Key requirements:
•
Allen Bradley Kinetix Motion Control or Bosch Rexroth Motion control
(req. approval)
•
Servo system 480VAC 3Ph
•
Servo motors sized with Motion Analyzer software.
•
Each axis homing to a switch or a hard stop, where applicable.
•
Homing initiated from HMI, where applicable.
•
Servo diagnostics displayed on HMI.
•
Absolute multi-turn encoders are preferred.
•
High-flex servo cables on axis requiring cable movement.
•
Use servo cables of the proper length to minimize excess and
eliminate coiling.
•
Disconnects are not permitted on the load side of the drive.
•
Wet Wash rated motors for use in wet wash areas (e.g. Allen Bradley
Food Grade MPF motors).
5.13 Field Devices
5.13.1 Quick disconnect
Use field devices with quick disconnect connection.
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5.13.2 Device Area Classification Rating
Select field devices for the area classification specified in the request for
proposal.
5.13.3 Solid State 24V DC Sensors
24VDC sensors must be PNP to supply a signal to a sinking input card.
6.
PLC and HMI Control Equipment and
Software
6.1
Processor
6.1.1 Rockwell PLC Systems
Rockwell ControlLogix or CompactLogix processor shall be used for new
machines. Use of non-Rockwell PLC machine controllers requires
approval by the Engineering Global Technical Services (GTS) Director.
Refer to CIS_409_ControlLogix Configuration Guidelines for more
information.
6.2
Control Network
6.2.1 PLC LAN Connection
All programmable controllers shall have a dedicated Ethernet connection
to the GMI PLC LAN. Programmable controllers with a single Ethernet
port (i.e. CompactLogix) will require a NAT (Network Address Translation)
device to provide its connection to the PLC LAN (figure 4.2). Only the
programmable controller or a single Ethernet module used by the
controller shall be connected directly to the PLC LAN. These
components shall not be connected to the PLC LAN: VFDs, HMIs,
instrumentation, vision systems, scanners, etc.
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6.2.2 HMI LAN Connection
HMI terminals requiring connection to GMI’s network shall be connected
to the plant’s HMI LAN. Such connections may be made directly to a GMI
HMI LAN switch or indirectly through an OEM-provided switch. (See
Figures 4.3A, B, or C below). The Ethernet addresses for HMI terminals
connected to the GMI HMI LAN shall be supplied by General Mills.
6.2.3 Fieldbus Network
HMI terminals not requiring connection to GMI’s network may be
connected to the Fieldbus network. Ethernet I/P is the standard Fieldbus
network, and all advanced components shall be connected to this
network (i.e. servos, VFD, flow meters, scanners, etc.). Fieldbus Ethernet
addressing must remain separate from all other networks. Use addresses
10.10.xx.xx or 192.168.1.X for this segment (figures 4.3A, B, or C). Other
industrial control networks, like DeviceNet and ControlNet, require GMI
approval.
6.2.4 Fieldbus Network Topologies
Star and Ring topologies are acceptable.
Ring topologies can be a mixture of technologies providing there are not
more than 25 devices on a segment. It is preferred to have the motion
control device level ring on a dedicated segment (figure 4.3C).
Linear topology is only acceptable on motion control systems with 4 or
less axes (figure 4.3B).
6.2.5 Motion Control Networks
Ethernet I/P CIP motion is the preferred motion control network. The
Logix Time Synchronization or CIP Sync GrandMaster clock owner shall
be contained within the motion control domain. The network design shall
have a non-PTP (Precision Time Protocol) device at the network
connection points to other networks. Non-PTP devices could be a 1783E-Tap, 9300-ENA (NAT) or non-PTP switch.
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6.3
Fieldbus Ethernet Switches
Ethernet switches that connect directly to the PLC LAN shall be of the
managed type. A switch separated from the PLC LAN by a NAT device
shall be permitted to be a non-managed type. Unmanaged switches shall
be limited to 8 ports or less. Reference Schedule Z for the preferred
managed and unmanaged switch selection.
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Figure 4.3A Controls Ethernet
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Figure 4.3B Controls Ethernet
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Figure 4.3C Controls Ethernet
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6.4
Software and Software Documentation
6.4.1 Ownership
All software developed for GMI becomes the property of GMI upon
completion of the project unless stated otherwise in the GMI-issued
purchase order.
6.4.2 Protected Code
Password protected or “locked down" source code that is unavailable to
GMI shall not be used. If the vendor refuses and is not willing to provide
unprotected code, then the OEM Vendor shall agree to provide lifetime
support for the protected code at their cost.
6.5
Allen-Bradley PLC Documentation
For ControlLogix applications, refer to CIS_401_ControlLogix
Programming Frameworks.
6.5.1 Language
Relay ladder logic shall be the language used exclusively. Structured text
and function block programming shall not be. Deviations must be
approved by a GMI Engineer.
6.6
Program Documentation
Use the following guidelines to ensure that the PLC and all programmable
devices are correctly documented:
6.6.1 Documented Source Code
Fully documented source code for all programmable systems shall be
provided in electronic format. All development software programming
packages and support licenses shall be provided. (Supplying the software
license is optional if the software already exists at the site.)
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Back-up and restore capability shall be provided. Step-by-step
instructions for backing up and restoring non-Rockwell software
controlled equipment shall be provided.
6.6.2 Documentation for PLC Ladder Logic
6.6.2.1 Rung Comments
GMI requires extensive use of rung comments and device descriptors.
At a minimum, a rung comment shall appear at the beginning of each
subroutine and each sub-grouping within a subroutine explaining the
control strategy for that program. Uncommon logic schemes also
require explanatory rung comments.
6.6.2.2 Device Descriptors
All I/O device descriptors shall be labeled with a common name and a
tag name included in the descriptor fields. The identical description
shall be used on the control schematics, device location drawings,
and labels on the devices.
6.6.3 ControlLogix Documentation
For Logix PLC applications, refer to CIS_401_ControlLogix Programming
Frameworks.
6.7
Operator Controls
The location, height, and identity of all operator controls (HMI and manual)
shall be provided in the vendor’s proposals. Plan to discuss these at
machine design review meetings.
6.7.1 Safety Controls
Refer to Section 7 (Safety) for detailed requirements on safety-related
controls including emergency stops, secondary safety devices, column
lights, and audible alarms.
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6.7.2 Human Machine Interface
This section covers HMI hardware that is software-based and includes a
graphical screen.
6.7.2.1 HMI Screen Height
The centerline of the screen shall be approximately 60-inches (152
cm) from the floor.
6.7.2.2 HMI Selection
GMI prefers Wonderware as the HMI software if the following
conditions apply:
•
Wonderware is already developed and offered as a standard
option.
•
Wonderware is needed for high level system control, as required
by the plant or project.
Stand-alone Wonderware applications shall use remote tag
referencing.
For all other applications, Rockwell HMIs with a 7” minimum screen
size shall be used. The specific sizes shall be dictated by the vendor,
machine, or project requirements.
6.7.2.3 HMI Communication Network
GMI prefers Ethernet for the communication network.
6.7.2.4 Functionality of a Graphical HMI
Indicate on the Schedule Z which of the following features is included
in the proposal:
•
Status of key machine elements
•
Guard door, emergency stop, and safety circuit status
•
Useful statistics for operator
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•
Abnormal machine conditions (including alarms)
•
Software adjustment parameters
•
Helpful diagnostics
•
Setup selection (recipes)
6.7.2.5 Keyboard, Touch screen Keypad, Size
Indicate on the Schedule Z which of the following features is included
in the proposal:
•
Terminal type: touch, keypad or both
•
Optional keyboard: keyboard, keyboard with pointing device or
none.
•
Screen size
•
Communication method
6.7.2.6 HMI Program Style
HMI software shall be written so that all machine logic and variables
are contained in the PLC processor memory and do not reside in the
HMI. Specifically, screen objects such as retained objects or initiated
variables shall not reside within the HMI software. An HMI shall be
able to shut down and restart while the machine is running without
affecting the machine’s behavior. Likewise, an HMI shall be able to
receive a new version of software while the machine is running
without the machine’s behavior being affected.
6.7.2.7 HMI Standards Documents
Refer to the following documents for additional information on HMI
configuration and Wonderware standards.
•
CIS_402_Wonderware_Framework
•
CIS_403_HMI Application Standard
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6.7.2.8 Standard Colors
The following table lists common machine functions and GMI’s
standard colors for HMI screens. Deviations must be pre-approved by
a GMI Engineer.
Color
Function
Red
Shutdown alarms
Amber
System alarms (up or down
stream)
Blue
Material shortages
Green
Normal or Start
White
Reset
White Text
Operator prompts
Yellow Text
Dynamic data
Green Text
Static information
Cyan Text
Display headings
Magenta Text
Communication messages
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6.7.3 Illuminated (LED) Devices, including Column Lights
If remote indicating lights are required, use full-size industrial
components, such as the Allen Bradley Bulletin 855T series for column
lights and 800T for pilot lights. All lighting elements must be LED. The
standard GMI light colors are:
Color
Function
Red
Emergency stop or system alarm condition
Amber
Warning condition (up or down stream)
Blue
Material shortages
Green
Normal or Start
White
Safety/Reset indicator
The order of the column lights from top to bottom shall be red, amber,
blue and green.
GMI discourages flashing indicators. Flashing indicators shall only be
used to:
•
Attract attention
•
Requires immediate action
•
Indicate a discrepancy between command and the actual states
•
Indicate a change in process (flashing during transition)
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6.7.4 Hard-Wired Manual Controls
Stop, cycle stop, emergency stop, reset, and start control devices shall
be hardwired (NOT HMI or key controlled). Deviations shall be preapproved by a GMI Engineer.
Use the following information to configure hard-wired control switches:
•
STOP Buttons—Use red, extended head pushbuttons with
momentary contacts. Choose between a STOP or CYCLE STOP
depending on the most desirable control strategy. Include both if the
control strategy warrants it.
•
EMERGENCY STOP Buttons—Use a safety-rated, lighted (LED), red,
mushroom-head, maintained pushbutton with a yellow background.
Section 7 (Safety).
•
RESET Buttons—Use white, flush-head pushbuttons with momentary
contacts. Reset buttons are required to reset all primary (emergency
stop) and secondary (guards) safety devices.
•
START Buttons—Use green, flush-head pushbuttons with momentary
contacts. A start button is any device that initiates machine motion
when actuated.
•
SAFETY Indicator Light—Use a white panel light (LED) to indicate
that the safety circuit is energized.
•
Combination devices—The above requirements can be satisfied by:
•
o
Combining the START and the RESET button or;
o
Combining the RESET button with the SAFETY
indicator light.
For all other hard-wired pushbuttons, use black, flush-head push
buttons with momentary contacts.
Label the pushbuttons appropriately to clearly identify the button’s
function.
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6.8
Control Integration Requirements
6.8.1 Standard Integration Requirements
All integration requirements listed in Schedule Z shall be met. These
typically include:
•
Upstream Shutdown Interlock Output — Hardwired, dry, normallyopen output contact (closed permissive to run upstream equipment) or
a software Ethernet I/P interlock.
•
Downstream Run Permissive Input — Hardwired, dry, normally-open
contact from downstream equipment (closed permissive to run this
equipment) or a software Ethernet I/P interlock. A protected method
(password or location for hardwired jumper) shall be provided to
bypass the Downstream Run Permissive for test purposes.
•
Machine speed signal — Analog signal representing a rate (such as
feet per minute or other unit per time) over software Ethernet I/P.
•
Emergency Stop — Means shall be included to integrate emergency
stop functions to support equipment furnished by others, including
emergency stop interlock circuit(s) and status monitoring. See Section
7 (Safety).
•
Emergency Stop for Others — Emergency stop logic interlocks (safety
circuit connection points and PLC inputs) for primary safety devices
furnished by others shall be provided. See Section 7 (Safety).
•
Emergency Stop by Others — Means to allow an emergency stop
zone furnished by others to control your equipment shall be provided.
See Section 7 (Safety).
Exception: Communication of the non-safety signals shall be permitted on
a peer-to-peer network as stipulated by the GMI engineer. Loss-ofcommunication logic shall be included when using networks.
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6.8.2 Sub-Unit Integration
Additional integration requirements for sub-units typically include:
•
Feeders
•
Level sensors
•
Metal Detector
•
Checkweigher
•
Date Coder
•
Motor Aux Contact (e.g. conveyors)
•
Line-Backup Sensor
•
Other Unit Operations
Sub-units shall be integrated with the main unit so the sub-unit stops,
starts, faults, and safely stops with the parent equipment. In addition,
controls shall be configured so the main unit’s HMI contains all operator
interaction (such as parameter adjustment and fault status) for the subunit.
6.9
Software Features
6.9.1 Interlock
For machines that have downstream and upstream interlocks, a means
for the operator to operate the machine with the interlocks overridden
shall be provided. Such an interlock override feature facilitates
maintenance, sanitation, and product changeover.
6.9.2 Cleanout Mode
For machines that have partial product or packages retained in the
machine, operator control features to easily clean out products and
packages shall be provided. Such a cleanout feature facilitates
changeover and production shutdown.
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6.9.3 Product Changeover Mode
For machines that require product changeover, features that allow for
quick and safe changeover procedures shall be provided.
6.9.4 Sanitation Mode
For machines requiring sanitation, operator controls and operational
modes to facilitate safe, thorough, and rapid sanitation of the equipment
shall be included.
6.9.5 RMT Information
Reliability Metrics Tracking is GMI’s proprietary module of MQIS that
tracks downtime for the production lines. The module tracks downtime for
each unit operation by cause. In addition, it measures time spent in each
major state, and counts the units produced or rejected. Exclusive
downtime assigns blame for each downtime event to the machine
causing the downtime. Additionally if a machine only accounts for a
fraction of the production, it assigns downtime proportionately. This data
is used to calculate the mean time to recover (MTTR) and mean time to
failure (MTBF) and system utilization (SU) for the machine and for the
combined system according to a companywide, unified methodology.
For machines designated as principal units of operation contributing to
the production line’s productivity, logic and data structures to indicate the
machine’s status as Running, Blocked, Starved, or Stopped condition
shall be provided along with the fault condition(s) that caused the
machine to stop. A separate proposal with specific requirements may be
requested for systems requiring this feature.
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7.
Safety
Safety controls may be implemented if reasonable means to design a
hazard out of the machine are inadequate. Safety controls are required to
monitor the access of a hazard area. Safety controls are not a
replacement for Lockout/Tagout.
Refer to CIS_304_Safety and Emergency Stop Circuit Design Guidelines
for more details.
7.1
Safety Design
A safety risk assessment shall be completed on each machine. A taskbased risk assessment is preferred over a hazard-based risk
assessment. Each task performed by an operator, sanitation worker, or
maintenance person shall be evaluated for hazards.
The preferred risk assessment standard is ANSI B11.TR3, Risk
Assessment and Safeguarding of Machinery Package. If a safety risk
assessment cannot be completed prior to the design of the control safety
system, a default ISO 13849-1 PLd (Performance Level) shall be used for
the safety design.
7.1.1 Safety Zones
Safety equipment in machines zones shall be designed to bring all
hazardous motion to a safe state within the zone. A machine might have
one or several zones. Equipment in upstream safety zones shall
automatically perform a cycle stop. Safety zones shall be designed so
operators can clearly and intuitively understand which controls apply to
each zone and can easily understand equipment behavior in every
situation.
7.1.2 Circuit Approval Required.
Safety circuits shall be submitted to GMI Engineering for approval
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7.1.3 Safety Interlock Sensors
Safety interlock sensors shall be used to safeguard any safety barrier that
provides easy access to a hazardous area. Only safety-rated sensors
with TÜV safety certification (or equivalent) shall be used.
If a guard is permanently mounted or requires a tool to access, no safety
interlock sensor is required.
In cases where hazardous motion may be present after the activation of
the safety circuit, latching-type devices designed so the latch is only
released when the machine is in a safe state shall be used. Delay
through a safety monitoring relay, a zero motion switch, or other means
consistent with the ISO 13949-1 PLd safety rating shall be used.
Safety interlock sensors that are most suitable for the need of the
application shall be selected. GMI prefers Rockwell Automation’s safety
sensors unless an application requires special form factors or
functionality.
Safety interlock sensors requiring separate interfacing devices or
converters shall be selected.
7.1.3.1 Safety Device Monitoring
The status of every safety input device shall be communicated to the
PLC and displayed on the operator interface.
7.1.4 Safety Controllers
Safety controllers shall be selected based upon the complexity of the
safety needs. For less complex safety systems (10 or fewer safety input
devices and one safety zone), a general safety controller (see 7.1.3.1)
shall be permitted. For complex safety applications (>10 input devices or
multiple safety zones), an advanced safety controller (see 7.1.3.2) shall
be used. All safety controllers shall be a product of Rockwell Automation.
Refer to CIS_304_Safety_Controls_Design_Standard for more safety
controller specification and safety circuit examples.
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7.1.4.1 General Safety Controllers
•
A Rockwell GuardMaster Safety Relay shall be permitted in single
zone applications with 10 or fewer safety input devices.
•
Utilize as many safety outputs as required.
•
Status of each channel of every safety device shall be
communicated via Ethernet I/P to the PLC for display on the
operation interface.
7.1.4.2 Advanced Safety Controllers
•
Programmable safety controllers shall be use for applications with
more than 10 safety devices or more than one safety zone.
•
Programmable safety controllers shall be Rockwell GuardLogix.
•
Safety programming shall be limited to the safety function blocks
available in the GuardLogix Safety controller.
•
Status of each channel of each safety device or component shall
be displayed on the operator interface.
•
GuardLogix processors shall have a Safety Signature generated,
and the safety processor must be locked prior to utilization of any
safety function of a system. Safety signatures shall be recorded in
the GMI Safety Signature Vault web portal.
7.1.5 Safety Power Outputs
Safety output devices shall be utilized whenever a safety function
requires power be removed from a motor or compressed air removed
from a pneumatic system. All safety power devices shall have a TÜV
safety certification (or equivalent). Power and pneumatic components
participating in safety functions shall be selected with safety features
integrated into the components themselves when available (i.e. safetorque off).
7.2
Safety Override and Bypassing
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Overriding, bypassing or defeating a safety system is prohibited.
7.3
Heat Seal Systems
With pre-approval by a GMI engineer, machine heat seal systems shall be
permitted to be left unaffected by safety circuits.
7.4
Startup Warning Audible Alarm Sequence
If a machine has hazards that are guarded using doors that can be
opened without a tool or guards that can be removed without a tool, a
startup warning sequence shall be implemented:
•
Operator pushes the start button for a specified prestart time
(generally a minimum of three seconds, per plant practice) during
which a startup warning alarm sounds. This gives other workers in the
area notification that the machine is about to start.
•
If the operator releases the start button before the end of the prestart
period, the equipment will not start and the prestart timer will reset.
•
If the operator keeps the start button pushed for the entire prestart
time, the machine starts, and the operator can release the start
button.
The start button shall be permitted to be used for both reset and start as
long as the safety circuit resets the safety devices and sounds the startup
warning alarm.
Exception: For equipment that is integrated as a subsystem to a larger
group, it shall be permitted that start of the larger group provides the start,
audible warning alarm, and delay (as well as emergency stop and normal
stop functions).
If the subsystem equipment has a start function independent of the start
for the larger group, this exception does not apply for the independent
start.
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7.5
Minor Servicing Exception (MSE)
Minor tasks which take place during normal production that are routine,
repetitive, and integral to the use of the equipment for production shall be
permitted to use the MSE (Minor Servicing Exception) instead of a full
Lockout Tagout provided the task meets the requirements of the MSE
Decision Tree listed below.
In general, minor servicing includes simple adjustments or inspections that
enable the equipment to continue to make good product, clearing jams
involving the product or packaging materials, and cleaning
product/material build-up during production. Minor servicing tasks would
commonly be completed by only one employee and would not require
component removal or equipment disassembly.
7.5.1 MSE Decision Tree
If a task is MSE eligible according to the MSE decision tree, control
safeties must be installed to protect the operator during the MSE task.
The performance level (PL) of these safeties shall be determined using
the MSE Performance Level Grid listed below.
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Are all the following true about the task?
 It is minor servicing. (see definitions)
 It will occur during normal production. (see definitions)
 It is routine. (see definitions)
 It is repetitive.”(see definitions)
 It is integral to normal production. (see definitions)
No
Yes
Are any of the following true about the task?
 Fastened-in-place guards will be removed.
 Tools will be used to add or replace components.
 There is potential to accidentally trigger a hazardous machine motion or action.
 There is potential contact with a moving part.
 Workers will be exposed to live electrical parts operating at 50 volts or higher.
Yes
No
Are all of the following true?
 The only source of energy is a single, cord & plug connected electrical cord.
 No stored or residual energy is present after unplugging the equipment
 The employee can maintain exclusive control of the electrical plug for the duration of
the task. (see definitions)
No
Yes
Complete a DesignSafe risk
assessment for the task.
Does the risk assessment place the
task in one of the red boxes on the
Risk Assessment Grid on the back of
this sheet?
MSE allowed under single electrical
energy source rules.
 The employee will maintain
exclusive control of the electrical
plug for the duration of the task.
Yes
No
MSE allowed.
All equipment:
 Worker can maintain exclusive control of at least one of the safety devices while
conducting the task. (see definitions)
 There is an equipment startup signaling system and startup delay OR multiple startup
steps sufficient to alert employees in time to vacate areas of hazard. (see definitions)
MSE not allowed.
Use LOTO.
New equipment:
 Electrical/controls safety components & circuits meet the Performance Level required
by the result of the DesignSafe risk assessment. (see MSE Performance Level grid)
 If the Performance Level of the controls design is less than PL-d, a maintained e-stop
button is provided.
Legacy equipment: Use of a maintained e-stop button plus an additional safety measure
(e-stop+1) is allowed. Except:
 Convert to LOTO if the assessed risk is catastrophic and likely or very likely.
 If upgrades are performed, bring MSE safeties up to current standards (above).
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MSE Performance Level Grid
7.5.2
MSE (Minor Servicing Exception) Procedure
Below is listed the required procedure to perform tasks eligible for the
minor servicing exception (as determined using the MSE decision tree)
and for which control safeties have been installed that need the
performance level (PL) specified in the MSE Performance Level Grid:
1. Actuate the cycle or system stop switch, if so equipped.
2. Verify that the machine has come to a complete stop.
3. Access the safeguarded area, by opening a guard door, breaking
a light-curtain beam or using a tool.
4. Perform the minor servicing or unjam the equipment.
5. When the work is complete, clear all obstructions, remove any
tools, and close all guard doors (or reset light curtains).
6. Press the RESET to reset the safety circuits. The SAFETY
indicator confirms that the reset is successful.
7. Press and hold the start button for the specified prestart time system enabled.
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8.
Documentation and Deliverables
8.1
Documentation Format
Both electronic and hard-copy versions of all documentation as specified
in the machine purchase order shall be provided. For engineering
drawings, both AutoCAD drawing (.dwg) and Adobe Acrobat (.pdf) files
shall be provided. A summary list of all the documentation provided shall
also be included.
8.2
Approval Documentation
Approval documentation, also referred as “shop drawings”, (bill of
materials, panel layout, and control schematics) shall be submitted prior to
fabrication. Any variance requires prior GMI Engineering approval.
8.3
Text in English
Text on drawings and all machine documentation (manuals, drawings,
procedures) shall be in English. Variance requires prior GMI Engineering
approval.
8.4
Electrical Symbols
GMI prefers the use of electrical symbols in accordance with IEEE 315.
Other symbols (such as pneumatic and hydraulic) shall follow IEC
standards. Variance requires prior GMI Engineering approval.
8.5
Deliverables
8.5.1 Bill of Materials Parts List
A parts list that includes functional descriptions, manufacturer’s name,
and part number, and quantities for each component shall be provided.
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8.5.2 Recommended Spare Parts List
When compiling a recommended spare parts list, it shall be assumed that
the equipment will operate 24 hours-per-day and 365 days-per-year.
Functional descriptions and OEM ordering information (such as functional
descriptions, manufacturer’s name, and part number, and quantities)
shall be included. A spare parts list shall be submitted in a specific format
to be provided by GMI. The spare parts list shall be submitted 60 days
prior to shipment.
8.5.3 Manufacturers’ Literature
At least one copy, in both electronic and hard-copy forms, of all relevant
literature for all major purchased components shall be provided.
8.5.4 Software and Software Documentation
The following software and software documentation shall be provided:
•
RSLogix programming and documentation in electronic format.
•
Fully-documented source code for all non-PLC and HMI
programmable systems in both electronic and hard-copy formats.
•
Rockwell HMI programs and documentation in electronic format.
•
Step-by-step back-up and recovery instructions to restore software for
each programmable device. An exception for equipment commonly
supported by the plant may be made by the plant engineer.
8.5.5 User and Service Manuals
User and service manuals for all equipment to support operator training
and ongoing equipment operation and maintenance shall be provided.
Service manuals shall include a sequence of operation, recommended
preventative maintenance schedule, and troubleshooting guide.
User and service manuals shall be provided in both printed and electronic
format.
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8.5.6 Field Installation Electrical Drawings
A preliminary drawing (labeled “Approved for Bidding”) shall be submitted
60 days prior to shipping that summarizes field electrical installation
requirements. The preliminary drawing shall contain conductor and
termination counts and enough detail to allow installation contractors to
accurately bid the installation. The Vendor shall inform GMI immediately
of any significant changes to these drawings once they have been
issued.
A fully developed field installation drawing (labeled “Approved for
Construction”) 30 days prior to shipment shall be submitted. The Approved
for Construction drawings shall include;
8.6
•
List of disconnect sizes and estimated FLA (Full Load Amps) for each
external power source
•
Details for wiring harnesses for re-termination between shipping splits
•
Detailed schedules for additional field conduit and wire quantities
listed by color and size required for installation
•
On the summary drawing, sufficient termination details to allow a
contractor to accurately bid the installation
Software Support after Installation
After installation, PLC software will be uploaded to the Plant PLC software
server. Manufacturer’s field support personal will then use either a GMI
plant terminal to access software through the system or have the client
application installed on their PC. Use of non-GMI PCs requires approval
by the plant I.S. department. Obtain current requirements and approval
from the plant before using. To be approved, PCs require an operating
system with current patches and the latest virus protection software.
When the PLC is in production, any PC support connections shall be
made through a programming port so that the PLC never loses connection
to the GMI network.
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8.7
Drawing Requirements
The following is a listing of drawing titles for specific functional areas. The
drawings can be separate or combined as separate layers of the same
drawing. All drawings are required. Variance requires prior GMI
Engineering approval. GMI prefers that the OEM vendor use the GMI
AutoCAD border.
•
Drawing Index or Table of Contents—List all drawings and
diagrams included in the electrical drawing set.
•
Legends Page—Include a separate drawing or a legends section on
a drawing where symbols are defined.
•
Equipment Layout and Footprint—Show equipment outline, belt
outline, main centerlines, control panels, operator stations, junction
boxes, utility connections, door swings, and guard door swings.
•
Panel Layout Drawings—Show internal and external electrical panel
layouts.
•
Device Location Drawings—Provide for packaging applications. Use
the assembly drawing as the background for this drawing.
•
Electrical Schematic Drawings—Show wiring (including all wire
numbers) for all devices. Include wiring diagrams for all controller I/O
and safety circuits.
•
Network Drawings—Show the wiring of any data communication,
fieldbus network, or other networks associated with the equipment.
•
Related diagrams—Where appropriate, provide the following
diagrams for reference: block diagram, electronic schematic,
lubrication diagram, pneumatic diagram, hydraulic diagram, and
coolant or refrigerant diagram.
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9.
Revision Summaries
Revision
Number
Revision
Date
Revision Owner
Revision Summary
(Brief description of major changes)
0
1
9-Feb-06
5-Sep-08
Jack Janzen
Jack Janzen
Original Development
Minor Error Correction
2
5-Nov-09
Jack Janzen
Major Revision and Update
3
20-Mar-15
David Otis
4
25-Sep-15
Mark Chatterton
Major Revision and Update
• Prohibit thru-the-door disconnects
• Renumber from old CIS_314 to MasterFormat
numbering scheme; change to document
format.
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9.1
Plant Customization Tracking
Enter information in these tables to track revisions to plant customized
documents.
NOTE: In the Entry column, enter your information between the dashes.
The entries automatically update document properties.
Document Property
Entry
Plant Code
-XXX-
Plant Owner
-Enter Name-
Plant Revision
Number
-0.0-
Plant Revision
Date
-xx/xx/xx-
Revision Revision
Number
Date
Revision
Owner
Use the following
format for the Plant
Revision Number:
<Master Revision
Number>.<Plant
Revision Number>
Revision Summary
(Brief description of major changes)
0
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