Map every Aux I/O point on paper during design, before the panel is built. Work the mapping exercise, then the release-mode check, then start the Riverside setpoints list.
Here's the layout: an accumulation line feeds a sorter induction, three divert lanes each end at a pack station, and one lane has a footswitch at the operator position. For each point, mark whether an Aux I/O is required and write the one reason it is or isn't.
| Point in the layout | Aux I/O? | The one reason |
|---|---|---|
| End-of-line accumulation zone feeding the sorter induction | Y N | |
| A zone the PLC has to hold pending a scan result | Y N | |
| A merge-entry zone the PLC sequences | Y N | |
| A zone whose product presence the PLC needs to make a routing call | Y N | |
| The pack-station lane with a footswitch at the operator position | Y N |
Now the footswitch point specifically: does it need a PLC in the loop, or can it be configured locally in the zone controller? Write your answer in one line.
A maintenance tech unplugs one Aux I/O to trace a fault, on a zone holding four cartons. Mark the safe default and say what happens under each mode.
What happens on the disconnect under each mode, and why the default matters more than the exception: