7
assemblies
Source, normal, reverse, HI-open, LO-open, short and reference-DMM pairs.
10
Phoenix plugs
Each contact is mapped; intentional opens are physically empty.
0.50-0.60
N m
Phoenix terminal torque; actual values and tool identity must be recorded.
0
built
Parts, crimp coupons, insulation limit and qualified review remain open.
Visual kit map
Editable physical layout
Normal path
CK-02 is blue and straight-through. It is the only transfer cable used for ordinary point calibration.
Fault tools
CK-03 through CK-06 are red, orange or black/yellow, kept in a separate compartment and removed after each controlled case.
Output off to change
No plug, adapter or meter lead is fitted, removed or rerouted with the source output enabled.
Seven controlled assemblies
| Assembly Id | Name | Function | Construction | Finished Length Mm | End A | End B | Label Color | Maximum Use | State | Warning |
|---|---|---|---|---|---|---|---|---|---|---|
| CK-01 | isolated source lead pair | Keysight output 2 or 3 to fixture JPS | two manufacturer-assembled Mueller 18 AWG silicone leads; factory tin-dipped ends removed and re-terminated | 975 target; record actual; 950 minimum | BU-0061-M-39-2 red and -0 black shrouded 4 mm bananas | one Phoenix 1757019, contact 1 red HI and contact 2 black LO | WHITE body / RED HI / BLACK LO | 24 V DC candidate, 10 mA source-current-limit candidate | UNBUILT | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
| CK-02 | normal transfer cable | fixture JDUT to selected pod JIN | Alpha 5610B2201, both conductors populated straight through; shield and drain isolated at both ends | 300 +/-5 jacket span | Phoenix 1757019 JDUT | Phoenix 1757019 POD JIN | BLUE - NORMAL ONLY | 24 V DC candidate, one disconnected chain | UNBUILT | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
| CK-03 | reversed-polarity adapter | controlled negative-response characterization | Alpha 5610B2201, contacts crossed; shield and drain isolated at both ends | 300 +/-5 jacket span | Phoenix 1757019 JDUT | Phoenix 1757019 POD JIN | RED - REVERSE POLARITY | 24 V DC candidate only under CF-P10 | UNBUILT | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
| CK-04 | HI-open adapter | controlled CAL_HI open characterization | Alpha 5610B2201; black LO conductor only; white conductor and shield/drain cut back and insulated | 300 +/-5 jacket span | Phoenix 1757019 JDUT; contact 1 physically empty | Phoenix 1757019 POD JIN; contact 1 physically empty | ORANGE - HI OPEN | 24 V DC candidate only under CF-P11 | UNBUILT | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
| CK-05 | LO-open adapter | controlled CAL_LO open characterization | Alpha 5610B2201; white HI conductor only; black conductor and shield/drain cut back and insulated | 300 +/-5 jacket span | Phoenix 1757019 JDUT; contact 2 physically empty | Phoenix 1757019 POD JIN; contact 2 physically empty | ORANGE - LO OPEN | 24 V DC candidate only under CF-P11 | UNBUILT | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
| CK-06 | current-limit shorting adapter | controlled CAL_HI-to-CAL_LO short at JDUT | one Phoenix 1757019 with an 80 +/-5 mm 22 AWG insulated loop; two ferrules | 80 +/-5 conductor before termination | Phoenix 1757019 contact 1 to contact 2 | NONE - capped single-ended adapter | BLACK/YELLOW - SHORT; OUTPUT OFF TO FIT/REMOVE | candidate 10 mA current-limit characterization only | UNBUILT | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
| CK-07 | reference-DMM patch pair | fixture JHI/JLO to Fluke V/ohm and COM | unaltered manufacturer-assembled Fluke TL930 red/black pair | 610 manufacturer nominal | red/black multi-stacking 4 mm plugs to JHI/JLO | red to V/ohm, black to COM; both current jacks empty | GREEN - REFERENCE DMM ONLY | 30 V RMS / 60 V DC, 8 A manufacturer rating; fixture candidate <=24 V DC | UNBUILT / RECEIVE AND INSPECT | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
Contact-by-contact wiring
| Assembly Id | Circuit | From Connector | From Contact | To Connector | To Contact | Signal Or Fault | Conductor | Shield Or Drain | Continuity Target | State | Warning |
|---|---|---|---|---|---|---|---|---|---|---|---|
| CK-01 | 1 | KEYSIGHT + RED | 4 mm plug | JPS | 1 | CAL_HI | red 18 AWG | NOT PRESENT | <1 ohm after lead-null; actual recorded | NOT EXECUTED | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
| CK-01 | 2 | KEYSIGHT - BLACK | 4 mm plug | JPS | 2 | CAL_LO | black 18 AWG | NOT PRESENT | <1 ohm after lead-null; actual recorded | NOT EXECUTED | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
| CK-02 | 1 | JDUT | 1 | POD JIN | 1 | CAL_HI | white 22 AWG | CUT BACK AND INSULATED BOTH ENDS | <1 ohm after lead-null; actual recorded | NOT EXECUTED | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
| CK-02 | 2 | JDUT | 2 | POD JIN | 2 | CAL_LO | black 22 AWG | CUT BACK AND INSULATED BOTH ENDS | <1 ohm after lead-null; actual recorded | NOT EXECUTED | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
| CK-03 | 1 | JDUT | 1 | POD JIN | 2 | CROSSED HI TO LO | white 22 AWG | CUT BACK AND INSULATED BOTH ENDS | <1 ohm after lead-null; actual recorded | NOT EXECUTED | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
| CK-03 | 2 | JDUT | 2 | POD JIN | 1 | CROSSED LO TO HI | black 22 AWG | CUT BACK AND INSULATED BOTH ENDS | <1 ohm after lead-null; actual recorded | NOT EXECUTED | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
| CK-04 | 1 | JDUT | 1 EMPTY | POD JIN | 1 EMPTY | CONTROLLED HI OPEN | NO CONDUCTOR | CUT BACK AND INSULATED BOTH ENDS | >10 Mohm; actual recorded | NOT EXECUTED | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
| CK-04 | 2 | JDUT | 2 | POD JIN | 2 | CAL_LO | black 22 AWG | CUT BACK AND INSULATED BOTH ENDS | <1 ohm after lead-null; actual recorded | NOT EXECUTED | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
| CK-05 | 1 | JDUT | 1 | POD JIN | 1 | CAL_HI | white 22 AWG | CUT BACK AND INSULATED BOTH ENDS | <1 ohm after lead-null; actual recorded | NOT EXECUTED | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
| CK-05 | 2 | JDUT | 2 EMPTY | POD JIN | 2 EMPTY | CONTROLLED LO OPEN | NO CONDUCTOR | CUT BACK AND INSULATED BOTH ENDS | >10 Mohm; actual recorded | NOT EXECUTED | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
| CK-06 | 1 | JDUT | 1 | JDUT | 2 | CONTROLLED HI-LO SHORT | 22 AWG offcut loop | NOT PRESENT | <1 ohm after lead-null; actual recorded | NOT EXECUTED | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
| CK-07 | 1 | JHI RED | 4 mm jack | FLUKE | V/OHM | CAL_HI REFERENCE | red TL930 | NOT PRESENT | <1 ohm after lead-null; actual recorded | NOT EXECUTED | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
| CK-07 | 2 | JLO BLACK | 4 mm jack | FLUKE | COM | CAL_LO REFERENCE | black TL930 | NOT PRESENT | <1 ohm after lead-null; actual recorded | NOT EXECUTED | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
Cut, strip and ferrule definition
| Cut Id | Assembly Id | Material | Quantity | Raw Length Mm | Finished Length Mm | End Preparation | Tolerance Or Gate | Warning |
|---|---|---|---|---|---|---|---|---|
| CUT-01 | CK-01 | Mueller BU-0061-M-39-2 red | 1 | 990.6 nominal manufacturer assembly | 975 target; 950 minimum | retain banana end; remove complete tin-dipped segment; strip 9 mm; crimp 3200742 | record actual; reject below 950 mm or with insulation damage | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
| CUT-02 | CK-01 | Mueller BU-0061-M-39-0 black | 1 | 990.6 nominal manufacturer assembly | 975 target; 950 minimum | retain banana end; remove complete tin-dipped segment; strip 9 mm; crimp 3200742 | record actual; reject below 950 mm or with insulation damage | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
| CUT-03 | CK-02 | Alpha Wire 5610B2201 | 1 | 360 | 300 +/-5 jacket span | remove 30 +/-1 mm jacket each end; cut foil/drain flush; sleeve 20 +/-2 mm FIT-221-1/4; strip populated conductors 10 mm; crimp 3203066 | no shield strand, nicked conductor or exposed copper; empty contacts physically unpopulated | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
| CUT-04 | CK-03 | Alpha Wire 5610B2201 | 1 | 360 | 300 +/-5 jacket span | remove 30 +/-1 mm jacket each end; cut foil/drain flush; sleeve 20 +/-2 mm FIT-221-1/4; strip populated conductors 10 mm; crimp 3203066 | no shield strand, nicked conductor or exposed copper; empty contacts physically unpopulated | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
| CUT-05 | CK-04 | Alpha Wire 5610B2201 | 1 | 360 | 300 +/-5 jacket span | remove 30 +/-1 mm jacket each end; cut foil/drain flush; sleeve 20 +/-2 mm FIT-221-1/4; strip populated conductors 10 mm; crimp 3203066 | no shield strand, nicked conductor or exposed copper; empty contacts physically unpopulated | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
| CUT-06 | CK-05 | Alpha Wire 5610B2201 | 1 | 360 | 300 +/-5 jacket span | remove 30 +/-1 mm jacket each end; cut foil/drain flush; sleeve 20 +/-2 mm FIT-221-1/4; strip populated conductors 10 mm; crimp 3203066 | no shield strand, nicked conductor or exposed copper; empty contacts physically unpopulated | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
| CUT-07 | CK-06 | one insulated 22 AWG conductor from 5610B2201 controlled offcut | 1 | 100 | 80 +/-5 before termination | strip 10 mm each end; crimp one 3203066 per end; form loop without sharp bend | minimum inside bend radius 10 mm; no exposed copper | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
| CUT-08 | CK-07 | Fluke TL930 part 1616671 | 1 | 610 nominal | DO NOT CUT OR MODIFY | receive, inspect, label only | reject damaged insulation, loose plug, wrong colors or failed continuity | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
Fabrication traveler
| Step Id | Operation | Instruction | Required Record | Stop Rule | Result | Authority | Warning |
|---|---|---|---|---|---|---|---|
| TR-01 | kit segregation | Clear bench; no robot, battery, safety circuit, actuator, USB-grounded equipment or live source connected. | Photograph empty bench and fixture isolation | STOP on any robot or energized circuit connection | NOT EXECUTED | NO PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED-ROBOT-TEST, MOTION, WALKING OR ENERGIZATION AUTHORITY | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
| TR-02 | incoming inspection | Record manufacturer, order code, lot and quantity for every cable, connector, ferrule, shrink and tool. | Incoming record and photographs | STOP on substitution or damage | NOT EXECUTED | NO PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED-ROBOT-TEST, MOTION, WALKING OR ENERGIZATION AUTHORITY | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
| TR-03 | cut and strip | Process one assembly at a time from wire-cut-list.csv; use calibrated length and stripping gauges. | Actual lengths and strip measurements | STOP on nicked strands or tolerance failure | NOT EXECUTED | NO PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED-ROBOT-TEST, MOTION, WALKING OR ENERGIZATION AUTHORITY | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
| TR-04 | shield isolation | For CK-02..05 cut foil/drain flush at both ends and cover with 20 +/-2 mm FIT-221-1/4 sleeve. | No shield/drain continuity to any contact | STOP on exposed shield strand | NOT EXECUTED | NO PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED-ROBOT-TEST, MOTION, WALKING OR ENERGIZATION AUTHORITY | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
| TR-05 | ferrule crimp | Use CRIMPFOX CENTRUS 10S: 3200742 on 18 AWG source leads; 3203066 on 22 AWG conductors. | Lot/tool ID, visual crimp inspection and coupon pull record | STOP on wrong ferrule/tool or incomplete insertion | NOT EXECUTED | NO PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED-ROBOT-TEST, MOTION, WALKING OR ENERGIZATION AUTHORITY | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
| TR-06 | plug termination | Insert to contact map; tighten every Phoenix 1757019 screw to 0.50-0.60 N m with in-calibration torque driver. | Contact, torque value, driver serial/date | STOP on loose strand, exposed copper or torque miss | NOT EXECUTED | NO PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED-ROBOT-TEST, MOTION, WALKING OR ENERGIZATION AUTHORITY | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
| TR-07 | labels | Apply both-end assembly ID, role, direction and fault label; orange open adapters name the open conductor; short adapter states OUTPUT OFF TO FIT/REMOVE. | Two-person label-to-map check | STOP on ambiguity or unreadable text | NOT EXECUTED | NO PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED-ROBOT-TEST, MOTION, WALKING OR ENERGIZATION AUTHORITY | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
| TR-08 | continuity and isolation | Four-wire/lead-null continuity per populated path; >10 Mohm between open contacts, shield/drain and populated circuits at a qualified test voltage not yet released. | Raw readings and instrument identities | STOP until insulation test voltage is selected | NOT EXECUTED | NO PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED-ROBOT-TEST, MOTION, WALKING OR ENERGIZATION AUTHORITY | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
| TR-09 | polarity fixture | With no source connected, use continuity to verify CK-02 straight, CK-03 crossed, CK-04 HI open, CK-05 LO open and CK-06 short. | Signed connector/contact matrix | STOP on any mismatch | NOT EXECUTED | NO PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED-ROBOT-TEST, MOTION, WALKING OR ENERGIZATION AUTHORITY | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
| TR-10 | retention and bend | Perform qualified axial retention coupon/test and verify minimum 49 mm cable bend radius for 5610B2201 assemblies. | Force, duration, displacement and post-test continuity | STOP because numeric retention limit remains open | NOT EXECUTED | NO PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED-ROBOT-TEST, MOTION, WALKING OR ENERGIZATION AUTHORITY | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
| TR-11 | DMM pair | Verify CK-07 red JHI-to-V/ohm and black JLO-to-COM; meter current jacks remain visibly empty. | Photograph and continuity readings | STOP on current-jack use | NOT EXECUTED | NO PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED-ROBOT-TEST, MOTION, WALKING OR ENERGIZATION AUTHORITY | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
| TR-12 | bag and control | Cap contacts; bag each assembly separately; store CK-03..06 in FAULT ADAPTER compartment physically separated from CK-02. | Inventory, seal and custodian | No adapter may be left attached | NOT EXECUTED | NO PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED-ROBOT-TEST, MOTION, WALKING OR ENERGIZATION AUTHORITY | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
Inspection and test record
| Test Id | Test | Acceptance Or Evidence | Result | Review | Warning |
|---|---|---|---|---|---|
| CK-T01 | identity and count | all seven assemblies present; order codes and lots recorded | NOT EXECUTED | REQUIRED | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
| CK-T02 | contact population | every populated and intentionally empty contact matches connector-contact-map.csv | NOT EXECUTED | REQUIRED | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
| CK-T03 | continuity | every populated path <1 ohm after lead-null; actual readings retained; final numeric limit qualified | NOT EXECUTED | REQUIRED | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
| CK-T04 | open isolation | intended opens and shield/drain >10 Mohm at qualified test voltage; voltage selection remains open | NOT EXECUTED | REQUIRED | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
| CK-T05 | polarity | CK-01/02/07 straight; CK-03 crossed; CK-04/05 single-conductor; CK-06 short only | NOT EXECUTED | REQUIRED | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
| CK-T06 | screw torque | every 1757019 terminal 0.50-0.60 N m with in-calibration driver; actual value recorded | NOT EXECUTED | REQUIRED | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
| CK-T07 | crimp coupons | 18 AWG/3200742 and 22 AWG/3203066 visual and pull coupons accepted to a released numeric limit | NOT EXECUTED | REQUIRED | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
| CK-T08 | strain and bend | no conductor load at terminal; 5610B2201 bend radius >=49 mm in use | NOT EXECUTED | REQUIRED | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
| CK-T09 | labels | fault adapters recognizable from either end and segregated from blue normal cable | NOT EXECUTED | REQUIRED | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
| CK-T10 | low-energy dry rehearsal | source absent; correct cable selected from procedure and returned after each simulated step | NOT EXECUTED | REQUIRED | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
Candidate BOM
| Item Id | Quantity | Unit | Manufacturer | Order Code | Description | Selection State | Procurement Released | Warning |
|---|---|---|---|---|---|---|---|---|
| CK-B01 | 1 | each | Mueller Electric | BU-0061-M-39-2 | red 39 inch 18 AWG silicone shrouded-banana lead | EXACT CANDIDATE | NO | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
| CK-B02 | 1 | each | Mueller Electric | BU-0061-M-39-0 | black 39 inch 18 AWG silicone shrouded-banana lead | EXACT CANDIDATE | NO | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
| CK-B03 | 2 | m | Alpha Wire | 5610B2201 | one-pair shielded 22 AWG cable | EXACT CANDIDATE; includes process scrap | NO | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
| CK-B04 | 10 | each | Phoenix Contact | 1757019 | two-position 5.08 mm screw plug | EXACT CANDIDATE | NO | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
| CK-B05 | 4 | each | Phoenix Contact | 3200742 | AI 1-6 RD ferrule for 18 AWG source leads plus two coupons/spares | EXACT CANDIDATE | NO | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
| CK-B06 | 20 | each | Phoenix Contact | 3203066 | AI 0.34-8 TQ ferrule for 22 AWG assemblies plus coupons/spares | EXACT CANDIDATE | NO | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
| CK-B07 | 1 | each | Phoenix Contact | 1213154 | CRIMPFOX CENTRUS 10S hand crimper | EXACT TOOL CANDIDATE; calibration/inspection open | NO | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
| CK-B08 | 1 | each | Alpha Wire | FIT-KIT-221BK | black FIT-221 heat-shrink kit containing 1/4 inch tubing | EXACT MATERIAL CANDIDATE; shrink process open | NO | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
| CK-B09 | 1 | each | Fluke | TL930 / part 1616671 | 61 cm red/black 4 mm patch-cord pair | EXACT CANDIDATE; do not modify | NO | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
| CK-B10 | 1 | each | SELECTION REQUIRED | SELECTION REQUIRED | calibrated 0.50-0.60 N m torque driver and bit | SELECTION REQUIRED | NO | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
| CK-B11 | 1 | each | PROJECT PRINT | CK-LABEL-P0.1 | water-resistant two-ended cable and fault labels | MATERIAL/ADHESION SELECTION REQUIRED | NO | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
| CK-B12 | 1 | each | SELECTION REQUIRED | SELECTION REQUIRED | latching divided storage case with normal/fault physical segregation | SELECTION REQUIRED | NO | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
Open before fabrication or use
| Hold Id | Open Item | Closure Evidence | State | Authority | Warning |
|---|---|---|---|---|---|
| CK-H01 | received parts and lots | supplier records, identity and incoming inspection | OPEN | NO PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED-ROBOT-TEST, MOTION, WALKING OR ENERGIZATION AUTHORITY | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
| CK-H02 | source-lead tin removal and final length | released work instruction plus actual lengths >=950 mm | OPEN | NO PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED-ROBOT-TEST, MOTION, WALKING OR ENERGIZATION AUTHORITY | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
| CK-H03 | crimp pull limits | qualified 18 AWG and 22 AWG coupon values, sample count and results | OPEN | NO PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED-ROBOT-TEST, MOTION, WALKING OR ENERGIZATION AUTHORITY | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
| CK-H04 | insulation test voltage and limit | qualified low-energy test method compatible with connected components | OPEN | NO PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED-ROBOT-TEST, MOTION, WALKING OR ENERGIZATION AUTHORITY | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
| CK-H05 | torque tool | exact calibrated driver/bit selection and in-date certificate | OPEN | NO PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED-ROBOT-TEST, MOTION, WALKING OR ENERGIZATION AUTHORITY | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
| CK-H06 | label and storage materials | durability/adhesion and physical fault-adapter segregation | OPEN | NO PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED-ROBOT-TEST, MOTION, WALKING OR ENERGIZATION AUTHORITY | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
| CK-H07 | fixture and received-mating FAI | 73099/TL930 fit, 1757019 mating, enclosure access and bend clearance | OPEN | NO PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED-ROBOT-TEST, MOTION, WALKING OR ENERGIZATION AUTHORITY | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
| CK-H08 | fabrication and inspection | signed traveler and all CK-T01..10 evidence | OPEN | NO PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED-ROBOT-TEST, MOTION, WALKING OR ENERGIZATION AUTHORITY | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
| CK-H09 | qualified electrical/metrology review | accept contact maps, tests and calibration-procedure use | OPEN | NO PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED-ROBOT-TEST, MOTION, WALKING OR ENERGIZATION AUTHORITY | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
| CK-H10 | FER-G11 and work authority | separate signed staged authorization; this kit cannot grant it | OPEN | NO PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED-ROBOT-TEST, MOTION, WALKING OR ENERGIZATION AUTHORITY | PRELIMINARY - UNBUILT OFF-ROBOT CALIBRATION CABLE AND FAULT-ADAPTER KIT - ZERO SAFETY CREDIT - NOT APPROVED FOR PROCUREMENT, FABRICATION, ASSEMBLY, ROBOT CONNECTION, POWERED ROBOT TESTING, MOTION, WALKING OR ENERGIZATION |
Engineering files
contact map · cut list · traveler · STEP · primary sources