8
source-local pods
One pod per exact HR-30 node avoids a shared remote box and its long unprotected tap conductors.
2 + 2
resistors per pair
Two separate 100 kΩ elements in HI and two in LO retain 100 kΩ after one resistor-short fault.
1.4204
nominal correction
Composite paper scale includes pod, measurement panel and nominal NI input. Every real channel still requires calibration.
0
authorized taps
Device-specific terminal accessories and the short upstream tail remain blocking physical selections.
Complete source-to-panel architecture
Eight-pod packaging candidate
What this fixes
No three-metre cable is directly attached to a robot power or safety node. Each long conductor begins after two source-local resistors.
What it cannot fix
The short conductor from each source terminal to JIN is upstream of the resistors. Exact terminal hardware, route and retention must be accepted before connection.
No safety function
The pods are diagnostic test equipment. They do not perform emergency stopping, power interruption or fault-tolerant monitoring.
Eight exact source nodes
| Channel Id | Pod Id | Signal | Planning V | Hi Net | Lo Net | Sheet | Hi Terminal | Lo Terminal | Location | Tap Boundary | Source Tail Max Mm | Source Tail State | Pod Input | Pod Output | Panel Input | Connection Released | Warning |
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| CH-AI-01 | DP-01 | ACT_MAIN_SOURCE_12V | 12.0 | RAW_12V_POS | RAW_0V | 01_external_source_panel.kicad_sch | PS1:+V | PS1:-V | external source enclosure; adjacent to PS1 output terminals | PS1 terminal accessory / approved parallel-conductor method SELECTION REQUIRED | 100 | EXACT LENGTH/TERMINATION NOT RELEASED | JIN.1 HI / JIN.2 LO | JOUT.1 HI / JOUT.2 LO | J1I.1 HI / J1I.2 LO | NO | PRELIMINARY - UNBUILT SOURCE-LOCAL DIAGNOSTIC PICKOFF PODS - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED TESTING, MOTION, WALKING OR ENERGIZATION |
| CH-AI-02 | DP-02 | ACT_MAIN_SAFE_12V | 12.0 | TETHER_POS_SWITCHED | RAW_0V | 04_touch_safe_tether.kicad_sch | XT1A:P1 | XT1A:P2 | pelvis rear tether inlet; adjacent to XT1A | dedicated sense breakout around high-current XT1A path SELECTION REQUIRED; no second conductor may be inferred at SBS contact | 100 | EXACT LENGTH/TERMINATION NOT RELEASED | JIN.1 HI / JIN.2 LO | JOUT.1 HI / JOUT.2 LO | J2I.1 HI / J2I.2 LO | NO | PRELIMINARY - UNBUILT SOURCE-LOCAL DIAGNOSTIC PICKOFF PODS - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED TESTING, MOTION, WALKING OR ENERGIZATION |
| CH-AI-03 | DP-03 | TTL_LDIST_SAFE_9V | 9.0 | TTL_LDIST_SAFE_9V | ACT_0V_CONTROLLED | 01_energy_precharge_conversion.kicad_sch | REG_TTL_L:LOG-OUT | REG_TTL_L:LOG-RET-OUT | pelvis power tray; adjacent to left-distal regulator output | physical regulator output terminal/test connector SELECTION REQUIRED | 100 | EXACT LENGTH/TERMINATION NOT RELEASED | JIN.1 HI / JIN.2 LO | JOUT.1 HI / JOUT.2 LO | J3I.1 HI / J3I.2 LO | NO | PRELIMINARY - UNBUILT SOURCE-LOCAL DIAGNOSTIC PICKOFF PODS - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED TESTING, MOTION, WALKING OR ENERGIZATION |
| CH-AI-04 | DP-04 | CTRL_5V | 5.0 | CTRL_5V | CTRL_GND | 04_motion_controller_carrier_connectors.kicad_sch | REG1:LOG-5V | REG1:LOG-GND | torso rear electronics tray; adjacent to motion-controller 5 V regulator | dedicated protected controller test connector is not present; board revision / tap implementation SELECTION REQUIRED | 100 | EXACT LENGTH/TERMINATION NOT RELEASED | JIN.1 HI / JIN.2 LO | JOUT.1 HI / JOUT.2 LO | J4I.1 HI / J4I.2 LO | NO | PRELIMINARY - UNBUILT SOURCE-LOCAL DIAGNOSTIC PICKOFF PODS - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED TESTING, MOTION, WALKING OR ENERGIZATION |
| CH-AI-05 | DP-05 | ESTOP_CH_A_24V | 24.0 | S12_CH1 | SAFE_0V | 02_estop_reset_safety_relay.kicad_sch | SR1:S12 | SR1:A2 | external safety enclosure; adjacent to SR1 | Pilz terminal parallel-conductor/accessory acceptance and safety-input loading review REQUIRED | 100 | EXACT LENGTH/TERMINATION NOT RELEASED | JIN.1 HI / JIN.2 LO | JOUT.1 HI / JOUT.2 LO | J5I.1 HI / J5I.2 LO | NO | PRELIMINARY - UNBUILT SOURCE-LOCAL DIAGNOSTIC PICKOFF PODS - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED TESTING, MOTION, WALKING OR ENERGIZATION |
| CH-AI-06 | DP-06 | HARDWIRED_PERMIT_24V | 24.0 | HARDWIRED_PERMIT | SAFE_0V | 02_estop_reset_safety_relay.kicad_sch | SR1:34 | SR1:A2 | external safety enclosure; adjacent to SR1 | Pilz terminal parallel-conductor/accessory acceptance and no-bypass fault review REQUIRED | 100 | EXACT LENGTH/TERMINATION NOT RELEASED | JIN.1 HI / JIN.2 LO | JOUT.1 HI / JOUT.2 LO | J6I.1 HI / J6I.2 LO | NO | PRELIMINARY - UNBUILT SOURCE-LOCAL DIAGNOSTIC PICKOFF PODS - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED TESTING, MOTION, WALKING OR ENERGIZATION |
| CH-AI-07 | DP-07 | K1_COIL_24V | 24.0 | K1_COIL_POS | SAFE_0V | 03_redundant_dc_interruption.kicad_sch | K1:A1 | K1:A2 | external contactor enclosure; adjacent to K1 coil terminals | Schneider coil-terminal accessory / approved parallel-conductor method SELECTION REQUIRED | 100 | EXACT LENGTH/TERMINATION NOT RELEASED | JIN.1 HI / JIN.2 LO | JOUT.1 HI / JOUT.2 LO | J7I.1 HI / J7I.2 LO | NO | PRELIMINARY - UNBUILT SOURCE-LOCAL DIAGNOSTIC PICKOFF PODS - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED TESTING, MOTION, WALKING OR ENERGIZATION |
| CH-AI-08 | DP-08 | K2_COIL_24V | 24.0 | K2_COIL_POS | SAFE_0V | 03_redundant_dc_interruption.kicad_sch | K2:A1 | K2:A2 | external contactor enclosure; adjacent to K2 coil terminals | Schneider coil-terminal accessory / approved parallel-conductor method SELECTION REQUIRED | 100 | EXACT LENGTH/TERMINATION NOT RELEASED | JIN.1 HI / JIN.2 LO | JOUT.1 HI / JOUT.2 LO | J8I.1 HI / J8I.2 LO | NO | PRELIMINARY - UNBUILT SOURCE-LOCAL DIAGNOSTIC PICKOFF PODS - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED TESTING, MOTION, WALKING OR ENERGIZATION |
End-to-end loading and scale
| Channel Id | Signal | Planning Source V Not Limit | Pickoff Series Each Lead Ohm | Panel Series Each Lead Ohm | Nominal Ni Differential Input Ohm | Nominal Ni Over Source Ratio | Nominal Scale Correction | Planning Ni Reading V | Planning Source Loading Ua | Calibration | Qualified Limit | Warning |
|---|---|---|---|---|---|---|---|---|---|---|---|---|
| CH-AI-01 | ACT_MAIN_SOURCE_12V | 12.000 | 200000 | 10200 | 1000000 | 0.704027035 | 1.420400 | 8.448324 | 8.448324 | REQUIRED WITH COMPLETE AS-BUILT CHAIN | NO | PRELIMINARY - UNBUILT SOURCE-LOCAL DIAGNOSTIC PICKOFF PODS - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED TESTING, MOTION, WALKING OR ENERGIZATION |
| CH-AI-02 | ACT_MAIN_SAFE_12V | 12.000 | 200000 | 10200 | 1000000 | 0.704027035 | 1.420400 | 8.448324 | 8.448324 | REQUIRED WITH COMPLETE AS-BUILT CHAIN | NO | PRELIMINARY - UNBUILT SOURCE-LOCAL DIAGNOSTIC PICKOFF PODS - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED TESTING, MOTION, WALKING OR ENERGIZATION |
| CH-AI-03 | TTL_LDIST_SAFE_9V | 9.000 | 200000 | 10200 | 1000000 | 0.704027035 | 1.420400 | 6.336243 | 6.336243 | REQUIRED WITH COMPLETE AS-BUILT CHAIN | NO | PRELIMINARY - UNBUILT SOURCE-LOCAL DIAGNOSTIC PICKOFF PODS - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED TESTING, MOTION, WALKING OR ENERGIZATION |
| CH-AI-04 | CTRL_5V | 5.000 | 200000 | 10200 | 1000000 | 0.704027035 | 1.420400 | 3.520135 | 3.520135 | REQUIRED WITH COMPLETE AS-BUILT CHAIN | NO | PRELIMINARY - UNBUILT SOURCE-LOCAL DIAGNOSTIC PICKOFF PODS - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED TESTING, MOTION, WALKING OR ENERGIZATION |
| CH-AI-05 | ESTOP_CH_A_24V | 24.000 | 200000 | 10200 | 1000000 | 0.704027035 | 1.420400 | 16.896649 | 16.896649 | REQUIRED WITH COMPLETE AS-BUILT CHAIN | NO | PRELIMINARY - UNBUILT SOURCE-LOCAL DIAGNOSTIC PICKOFF PODS - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED TESTING, MOTION, WALKING OR ENERGIZATION |
| CH-AI-06 | HARDWIRED_PERMIT_24V | 24.000 | 200000 | 10200 | 1000000 | 0.704027035 | 1.420400 | 16.896649 | 16.896649 | REQUIRED WITH COMPLETE AS-BUILT CHAIN | NO | PRELIMINARY - UNBUILT SOURCE-LOCAL DIAGNOSTIC PICKOFF PODS - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED TESTING, MOTION, WALKING OR ENERGIZATION |
| CH-AI-07 | K1_COIL_24V | 24.000 | 200000 | 10200 | 1000000 | 0.704027035 | 1.420400 | 16.896649 | 16.896649 | REQUIRED WITH COMPLETE AS-BUILT CHAIN | NO | PRELIMINARY - UNBUILT SOURCE-LOCAL DIAGNOSTIC PICKOFF PODS - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED TESTING, MOTION, WALKING OR ENERGIZATION |
| CH-AI-08 | K2_COIL_24V | 24.000 | 200000 | 10200 | 1000000 | 0.704027035 | 1.420400 | 16.896649 | 16.896649 | REQUIRED WITH COMPLETE AS-BUILT CHAIN | NO | PRELIMINARY - UNBUILT SOURCE-LOCAL DIAGNOSTIC PICKOFF PODS - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED TESTING, MOTION, WALKING OR ENERGIZATION |
Fault boundary
| Fault Id | Fault | Calculated Or Intended Response | Disposition | Safety Credit | Authority | Warning |
|---|---|---|---|---|---|---|
| DP-F01 | JOUT HI-to-LO short at 24 V planning screen | limited by 400 kOhm source-local series path; 60.000 uA ideal | PAPER SCREEN ONLY; PASS/FAIL NOT RELEASED | NONE | NO PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED-TEST, MOTION, WALKING OR ENERGIZATION AUTHORITY | PRELIMINARY - UNBUILT SOURCE-LOCAL DIAGNOSTIC PICKOFF PODS - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED TESTING, MOTION, WALKING OR ENERGIZATION |
| DP-F02 | one JOUT lead shorted to opposite source reference at 24 V | limited by 200 kOhm intact lead; 120.000 uA ideal | PAPER SCREEN ONLY; PASS/FAIL NOT RELEASED | NONE | NO PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED-TEST, MOTION, WALKING OR ENERGIZATION AUTHORITY | PRELIMINARY - UNBUILT SOURCE-LOCAL DIAGNOSTIC PICKOFF PODS - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED TESTING, MOTION, WALKING OR ENERGIZATION |
| DP-F03 | one of two same-lead resistors short | remaining 100 kOhm limits ideal 24 V current to 240.000 uA | SINGLE-FAULT INTENT; COMPONENT/PCB COMMON-CAUSE REVIEW OPEN | NONE | NO PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED-TEST, MOTION, WALKING OR ENERGIZATION AUTHORITY | PRELIMINARY - UNBUILT SOURCE-LOCAL DIAGNOSTIC PICKOFF PODS - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED TESTING, MOTION, WALKING OR ENERGIZATION |
| DP-F04 | one series resistor open | channel becomes invalid/high impedance; acquisition must flag implausible or missing signal | DETECTION/PROCEDURE OPEN | NONE | NO PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED-TEST, MOTION, WALKING OR ENERGIZATION AUTHORITY | PRELIMINARY - UNBUILT SOURCE-LOCAL DIAGNOSTIC PICKOFF PODS - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED TESTING, MOTION, WALKING OR ENERGIZATION |
| DP-F05 | both same-lead resistors short | dual/common-cause fault removes source-local limiting on that lead | UNCONTROLLED; QUALIFIED FAULT REVIEW REQUIRED | NONE | NO PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED-TEST, MOTION, WALKING OR ENERGIZATION AUTHORITY | PRELIMINARY - UNBUILT SOURCE-LOCAL DIAGNOSTIC PICKOFF PODS - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED TESTING, MOTION, WALKING OR ENERGIZATION |
| DP-F06 | source tail shorts before first resistor | fault is upstream of pod protection and may stress the measured circuit | BLOCKER: exact <=100 mm guarded route, tap accessory, retention and source protection review | NONE | NO PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED-TEST, MOTION, WALKING OR ENERGIZATION AUTHORITY | PRELIMINARY - UNBUILT SOURCE-LOCAL DIAGNOSTIC PICKOFF PODS - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED TESTING, MOTION, WALKING OR ENERGIZATION |
| DP-F07 | pod input/output reversed | long cable would be upstream of limiting resistors | BLOCKER: keyed labels, point-to-point inspection and connector-orientation control | NONE | NO PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED-TEST, MOTION, WALKING OR ENERGIZATION AUTHORITY | PRELIMINARY - UNBUILT SOURCE-LOCAL DIAGNOSTIC PICKOFF PODS - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED TESTING, MOTION, WALKING OR ENERGIZATION |
| DP-F08 | cross-channel cable short | each affected conductor remains behind its own two-resistor path if pods are correctly installed | PHYSICAL SEPARATION/BUILD TEST OPEN | NONE | NO PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED-TEST, MOTION, WALKING OR ENERGIZATION AUTHORITY | PRELIMINARY - UNBUILT SOURCE-LOCAL DIAGNOSTIC PICKOFF PODS - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED TESTING, MOTION, WALKING OR ENERGIZATION |
| DP-F09 | safety-circuit measurement loading | nominal 24 V source loading 16.897 uA through complete chain | PILZ APPLICATION/DIAGNOSTIC EFFECT AND QUALIFIED REVIEW OPEN | NONE | NO PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED-TEST, MOTION, WALKING OR ENERGIZATION AUTHORITY | PRELIMINARY - UNBUILT SOURCE-LOCAL DIAGNOSTIC PICKOFF PODS - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED TESTING, MOTION, WALKING OR ENERGIZATION |
| DP-F10 | pod enclosure or cable damage | ABS enclosure is not a safety-rated guard; exposed conductors or swapped cables possible | GUARDED CABINET LOCATION/STRAIN RELIEF/INSPECTION OPEN | NONE | NO PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED-TEST, MOTION, WALKING OR ENERGIZATION AUTHORITY | PRELIMINARY - UNBUILT SOURCE-LOCAL DIAGNOSTIC PICKOFF PODS - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED TESTING, MOTION, WALKING OR ENERGIZATION |
Candidate BOM
| Item | Manufacturer | Order Code | Quantity | Basis | Selection State | Procurement Released | Warning |
|---|---|---|---|---|---|---|---|
| one-channel diagnostic pickoff PCB | SELECTION REQUIRED | SELECTION REQUIRED | 8 | 74 x 34 x 1.6 mm two-layer native KiCad candidate | FABRICATOR/STACKUP/FINISH/DFM OPEN | NO | PRELIMINARY - UNBUILT SOURCE-LOCAL DIAGNOSTIC PICKOFF PODS - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED TESTING, MOTION, WALKING OR ENERGIZATION |
| 100 kOhm 0.1% 25 ppm/K 1206 resistor | Vishay | TNPW1206100KBEEA | 32 | four per pod; two in series per lead | EXACT CANDIDATE; RECEIVED LOT OPEN | NO | PRELIMINARY - UNBUILT SOURCE-LOCAL DIAGNOSTIC PICKOFF PODS - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED TESTING, MOTION, WALKING OR ENERGIZATION |
| 2-position 5.08 mm horizontal PCB header | Phoenix Contact | 1757242 | 16 | JIN/JOUT on eight pods | EXACT CANDIDATE | NO | PRELIMINARY - UNBUILT SOURCE-LOCAL DIAGNOSTIC PICKOFF PODS - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED TESTING, MOTION, WALKING OR ENERGIZATION |
| 2-position 5.08 mm screw plug | Phoenix Contact | 1757019 | 16 | source-tail pod end and pod-to-panel output end; panel-input plugs allocated separately | EXACT CANDIDATE; TERMINATION PROCESS OPEN | NO | PRELIMINARY - UNBUILT SOURCE-LOCAL DIAGNOSTIC PICKOFF PODS - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED TESTING, MOTION, WALKING OR ENERGIZATION |
| flanged ABS enclosure 80 x 40 x 20 mm | Hammond Manufacturing | 1551KFLBK | 8 | one enclosure per source-local pod | EXACT ENVELOPE CANDIDATE; CUTOUT/FAI/ENVIRONMENT OPEN | NO | PRELIMINARY - UNBUILT SOURCE-LOCAL DIAGNOSTIC PICKOFF PODS - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED TESTING, MOTION, WALKING OR ENERGIZATION |
| #2 x 3/16 PCB mounting screws | Hammond Manufacturing | 1551ATS100 | 1 | one 100-piece pack; four screws per pod | EXACT ACCESSORY CANDIDATE; FAI/TORQUE OPEN | NO | PRELIMINARY - UNBUILT SOURCE-LOCAL DIAGNOSTIC PICKOFF PODS - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED TESTING, MOTION, WALKING OR ENERGIZATION |
| one-pair shielded 22 AWG cable | Alpha Wire | 5610B2201 | 25 m minimum for eight 3.1 m cuts plus source tails | pod-to-panel and short source-tail candidates | EXACT CABLE FAMILY; ROUTE/BUILD/NOISE OPEN | NO | PRELIMINARY - UNBUILT SOURCE-LOCAL DIAGNOSTIC PICKOFF PODS - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED TESTING, MOTION, WALKING OR ENERGIZATION |
| 0.34 mm2 / 22 AWG 8 mm ferrule | Phoenix Contact | 3203066 | 48 | 32 pod-to-panel conductor ends plus 16 source-tail pod ends | EXACT CANDIDATE; CRIMP PROCESS OPEN | NO | PRELIMINARY - UNBUILT SOURCE-LOCAL DIAGNOSTIC PICKOFF PODS - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED TESTING, MOTION, WALKING OR ENERGIZATION |
| source-device terminal tap/accessory | SELECTION REQUIRED | SELECTION REQUIRED | 16 | HI and LO source boundary for eight pods | BLOCKING SELECTION; DEVICE-SPECIFIC | NO | PRELIMINARY - UNBUILT SOURCE-LOCAL DIAGNOSTIC PICKOFF PODS - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED TESTING, MOTION, WALKING OR ENERGIZATION |
Build and test traveler
| Test Id | Test | Acceptance | Result | Evidence | Authority | Warning |
|---|---|---|---|---|---|---|
| DP-T01 | Incoming identity | Record PCB revision, resistor lot/marking, connectors, enclosure, cable and ferrules against exact candidates. | NOT EXECUTED | REQUIRED | NO PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED-TEST, MOTION, WALKING OR ENERGIZATION AUTHORITY | PRELIMINARY - UNBUILT SOURCE-LOCAL DIAGNOSTIC PICKOFF PODS - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED TESTING, MOTION, WALKING OR ENERGIZATION |
| DP-T02 | Resistor measurement | Measure all 32 resistors before assembly and record each value; reject mismatch or mixed reels. | NOT EXECUTED | REQUIRED | NO PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED-TEST, MOTION, WALKING OR ENERGIZATION AUTHORITY | PRELIMINARY - UNBUILT SOURCE-LOCAL DIAGNOSTIC PICKOFF PODS - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED TESTING, MOTION, WALKING OR ENERGIZATION |
| DP-T03 | PCB inspection | AOI/visual and dimensional FAI; verify each lead contains two separate series footprints and no copper bypass. | NOT EXECUTED | REQUIRED | NO PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED-TEST, MOTION, WALKING OR ENERGIZATION AUTHORITY | PRELIMINARY - UNBUILT SOURCE-LOCAL DIAGNOSTIC PICKOFF PODS - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED TESTING, MOTION, WALKING OR ENERGIZATION |
| DP-T04 | Enclosure FAI | Verify board/standoffs, cutout clearance, lid closure, labels, strain relief and no exposed conductive parts. | NOT EXECUTED | REQUIRED | NO PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED-TEST, MOTION, WALKING OR ENERGIZATION AUTHORITY | PRELIMINARY - UNBUILT SOURCE-LOCAL DIAGNOSTIC PICKOFF PODS - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED TESTING, MOTION, WALKING OR ENERGIZATION |
| DP-T05 | Unpowered resistance | For each pod, measure JIN.1-JOUT.1 and JIN.2-JOUT.2; each must equal two series resistors within defined measurement uncertainty. | NOT EXECUTED | REQUIRED | NO PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED-TEST, MOTION, WALKING OR ENERGIZATION AUTHORITY | PRELIMINARY - UNBUILT SOURCE-LOCAL DIAGNOSTIC PICKOFF PODS - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED TESTING, MOTION, WALKING OR ENERGIZATION |
| DP-T06 | Isolation | Every pod lane remains open to enclosure, other pods, shield/drain, PE and synchronization slate at the approved test threshold. | NOT EXECUTED | REQUIRED | NO PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED-TEST, MOTION, WALKING OR ENERGIZATION AUTHORITY | PRELIMINARY - UNBUILT SOURCE-LOCAL DIAGNOSTIC PICKOFF PODS - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED TESTING, MOTION, WALKING OR ENERGIZATION |
| DP-T07 | Source-tail control | Qualified reviewer verifies exact source accessory, <=100 mm source-to-first-resistor path, abrasion protection, restraint and no protection/safety bypass. | NOT EXECUTED | REQUIRED | NO PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED-TEST, MOTION, WALKING OR ENERGIZATION AUTHORITY | PRELIMINARY - UNBUILT SOURCE-LOCAL DIAGNOSTIC PICKOFF PODS - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED TESTING, MOTION, WALKING OR ENERGIZATION |
| DP-T08 | Cable point-to-point | Verify DP-01..08 JOUT polarity to measurement-panel J1I..J8I; reversed input/output or channel identity is rejectable. | NOT EXECUTED | REQUIRED | NO PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED-TEST, MOTION, WALKING OR ENERGIZATION AUTHORITY | PRELIMINARY - UNBUILT SOURCE-LOCAL DIAGNOSTIC PICKOFF PODS - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED TESTING, MOTION, WALKING OR ENERGIZATION |
| DP-T09 | Low-voltage transfer | With source hardware absent, inject traceable low voltage and verify end-to-end ratio/polarity at the NI terminals. | NOT EXECUTED | REQUIRED | NO PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED-TEST, MOTION, WALKING OR ENERGIZATION AUTHORITY | PRELIMINARY - UNBUILT SOURCE-LOCAL DIAGNOSTIC PICKOFF PODS - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED TESTING, MOTION, WALKING OR ENERGIZATION |
| DP-T10 | Nominal transfer/calibration | Calibrate each complete pod+cables+panel+NI channel at relevant voltages; retain gain, offset, noise and crosstalk evidence. | NOT EXECUTED | REQUIRED | NO PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED-TEST, MOTION, WALKING OR ENERGIZATION AUTHORITY | PRELIMINARY - UNBUILT SOURCE-LOCAL DIAGNOSTIC PICKOFF PODS - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED TESTING, MOTION, WALKING OR ENERGIZATION |
| DP-T11 | Fault injection | Guarded test of output shorts, one resistor open/short simulation and cross-channel faults; compare measured current and detection to approved limits. | NOT EXECUTED | REQUIRED | NO PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED-TEST, MOTION, WALKING OR ENERGIZATION AUTHORITY | PRELIMINARY - UNBUILT SOURCE-LOCAL DIAGNOSTIC PICKOFF PODS - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED TESTING, MOTION, WALKING OR ENERGIZATION |
| DP-T12 | Qualified disposition | Electrical and functional-safety reviewers accept source loading, terminal taps, fault behavior and stage-specific use before any connection. | NOT EXECUTED | REQUIRED | NO PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED-TEST, MOTION, WALKING OR ENERGIZATION AUTHORITY | PRELIMINARY - UNBUILT SOURCE-LOCAL DIAGNOSTIC PICKOFF PODS - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED TESTING, MOTION, WALKING OR ENERGIZATION |
Open before connection
| Hold Id | Item | Closure Evidence | State | Authority | Warning |
|---|---|---|---|---|---|
| DP-H01 | device-specific source terminal taps | written manufacturer/application acceptance or engineered breakout for PS1, XT1A, both regulators, SR1 and K1/K2; exact conductors/ferrules/lugs/torques | OPEN | NO PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED-TEST, MOTION, WALKING OR ENERGIZATION AUTHORITY | PRELIMINARY - UNBUILT SOURCE-LOCAL DIAGNOSTIC PICKOFF PODS - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED TESTING, MOTION, WALKING OR ENERGIZATION |
| DP-H02 | source-tail physical route | as-installed <=100 mm source-to-first-resistor path, guarding, segregation, abrasion protection and strain relief for all eight pods | OPEN | NO PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED-TEST, MOTION, WALKING OR ENERGIZATION AUTHORITY | PRELIMINARY - UNBUILT SOURCE-LOCAL DIAGNOSTIC PICKOFF PODS - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED TESTING, MOTION, WALKING OR ENERGIZATION |
| DP-H03 | safety-circuit loading and fault review | Pilz/Schneider application review plus qualified analysis showing no masking, reset, permit or contactor-command effect | OPEN | NO PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED-TEST, MOTION, WALKING OR ENERGIZATION AUTHORITY | PRELIMINARY - UNBUILT SOURCE-LOCAL DIAGNOSTIC PICKOFF PODS - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED TESTING, MOTION, WALKING OR ENERGIZATION |
| DP-H04 | PCB and enclosure DFM/FAI | fabricator stackup/finish, resistor spacing, Hammond standoff fit, connector cutouts, retention, labels and cabinet environmental suitability | OPEN | NO PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED-TEST, MOTION, WALKING OR ENERGIZATION AUTHORITY | PRELIMINARY - UNBUILT SOURCE-LOCAL DIAGNOSTIC PICKOFF PODS - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED TESTING, MOTION, WALKING OR ENERGIZATION |
| DP-H05 | assembled pod and cable verification | all DP-T01 through DP-T11 results with calibrated equipment and retained evidence | OPEN | NO PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED-TEST, MOTION, WALKING OR ENERGIZATION AUTHORITY | PRELIMINARY - UNBUILT SOURCE-LOCAL DIAGNOSTIC PICKOFF PODS - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED TESTING, MOTION, WALKING OR ENERGIZATION |
| DP-H06 | end-to-end calibration/uncertainty | complete source simulator + pod + 3 m cable + measurement panel + NI chain calibration and timing/noise/crosstalk uncertainty | OPEN | NO PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED-TEST, MOTION, WALKING OR ENERGIZATION AUTHORITY | PRELIMINARY - UNBUILT SOURCE-LOCAL DIAGNOSTIC PICKOFF PODS - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED TESTING, MOTION, WALKING OR ENERGIZATION |
| DP-H07 | independent qualified review | electrical and functional-safety acceptance of exact as-built revision and stage-specific connection procedure | OPEN | NO PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED-TEST, MOTION, WALKING OR ENERGIZATION AUTHORITY | PRELIMINARY - UNBUILT SOURCE-LOCAL DIAGNOSTIC PICKOFF PODS - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED TESTING, MOTION, WALKING OR ENERGIZATION |
| DP-H08 | FER-G11 closure | installed protected pickoffs, current calibration, dry rehearsal, signed stage limits and complete records | OPEN | NO PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED-TEST, MOTION, WALKING OR ENERGIZATION AUTHORITY | PRELIMINARY - UNBUILT SOURCE-LOCAL DIAGNOSTIC PICKOFF PODS - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, CONNECTION, POWERED TESTING, MOTION, WALKING OR ENERGIZATION |
Engineering files
KiCad project · KiCad PCB · STEP · source nodes · contacts · cables · sources