AC and DC Power and Ground Wiring

AC and DC Power and Ground Wiring
AC and DC Power and Ground
Wiring
Installation Manual
D3P00661202
PN1:003
Revision B — October 1995
This manual supercedes the issue dated May 1995.
See CE Statement in Section 1
microPROVOX and PROVOX are marks of one or more of the Fisher-Rosemount group of companies.
All other marks are the property of their respective owners.
ã Fisher-Rosemount Systems, Inc. 1989, 1995. All rights reserved.
Printed in USA
The contents of this publication are presented for informational purposes only, and while every effort
has been made to ensure their accuracy, they are not to be construed as warranties or guarantees,
express or implied, regarding the products or services described herein or their use or applicability. We
reserve the right to modify or improve the designs or specifications of such products at any time without
notice.
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Fisher-Rosemount Systems, Inc.
Technical Documentation Editor
8301 Cameron Road, MD#12
Austin, TX 78753
FAX Number: (512) 834-7200
Attention: Technical Documentation Editor
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Project File
Documentation Map
Documentation Map
AC and DC Power and Ground Wiring
This map shows manuals used to plan the installation of a PROVOXr Process
Management System. The number, title, and binder location are shown for each
document, identifying where specific information is located. See the descriptions
on the back of this map for more information.
PROVOX
Instrumentation
YOU ARE HERE
Installation
Manual
PN1:003
AC and DC Power and Ground Wiring
PN1:002
Planning and Installation
PN1:004
Signal Wiring and Highway System
Guidelines
PN1:005
Preventing Electrostatic Discharge
PN1:006
Environmental Considerations for
Instrumentation systems
PN4:007
Lightning Protection Guidelines for
Instrumentation Systems
PN1:008
Site Evaluation
Revision B — October 1995
PN1:003
iii
Documentation Map
PROVOX documentation supports each stage of system development.
System Development Stages
System Design
Document Type & Contents
Configuration Engineering Manuals
Configuration data-entry help for a
product, including theory of
operation for improved product
use.
Installation and User Manuals for
Configuration Products
Installation procedures, and
operating methods and procedures
for using the configuration
software.
Technical Reference Manuals
Advanced user information for
expanding the capability of the
PROVOX system.
System Manager’s Guide
Expert users information for
managing operating systems.
System Planning and
Installation
Installation Manuals
Site preparation, including the
environment, power, and
grounding. Also, product signal
wiring, cable connections, and
hardware installation.
System Startup and
Operation
User Manuals
Maintenance
Maintenance Manuals
Operating methods and
procedures for a product, and
software installation.
Tutorials
Structured training for operators.
Preventative maintenance,
calibration, troubleshooting, and
repair procedures.
Ordering Information — To order additional manuals, contact your local
sales representative, specifying the number, title, and quantity of each
document required.
iv
Revision B — October 1995
PN1:003
AC and DC Power and Ground Wiring
Contents
Section/Title
1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
2
2.1
2.2
2.3
3
3.1
3.2
3.2.1
3.2.2
3.3
3.4
4
4.1
4.2
4.3
4.4
4.5
5
5.1
5.2
5.3
Revision B — October 1995
PN1:003
Page
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1
Intended Audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CE Statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Structure of this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warnings, Cautions, and Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Related Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reference Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Excellence in Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1
1-2
1-2
1-3
1-3
1-4
1-4
1-5
AC Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1
AC Power Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AC Source Voltage and Frequency . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Wire Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1
2-2
2-3
AC Power Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1
System-Level Power Distribution . . . . . . . . . . . . . . . . . . . . . . . . . .
System Cabinets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Using Type CP6101 and CP6102 Power Supplies . . . . . . . . .
Using Type CP6103 Power Supply Units . . . . . . . . . . . . . . . . .
Consoles and Computers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Peripheral Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1
3-12
3-12
3-12
3-15
3-20
DC Power Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1
DC Voltage Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DC Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DC Power Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DC Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Field Transmitter Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1
4-1
4-2
4-4
4-4
Cabinet Alarm Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1
System Using Types CP6101 and CP6102 Power Supply Units
System using Type CP6103 Power Supply Units . . . . . . . . . . . .
Device Alarm Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1
5-2
5-2
v
Contents
Section/Title
6
System Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1
Guidelines for Effective Grounding . . . . . . . . . . . . . . . . . . . . . . . . .
Separating AC and DC Grounds . . . . . . . . . . . . . . . . . . . . . . . . . . .
AC Ground System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DC Ground System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cabinet Ground Considerations . . . . . . . . . . . . . . . . . . . . . . . . .
Ground Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Master and Local Ground Buses . . . . . . . . . . . . . . . . . . . . . . . .
Single-Point Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Supply Common (PSC) Wiring . . . . . . . . . . . . . . . . . . . .
Marking Grounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ground Impedance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
File and Shield Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
For PROVOX Cabinets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
For OEM Cabinets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
For Remote Termination Panels . . . . . . . . . . . . . . . . . . . . . . . . .
Intrinsic Safety Barrier Grounding . . . . . . . . . . . . . . . . . . . . . . . . . .
Consoles and Computers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Peripheral Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1
6-2
6-2
6-2
6-2
6-4
6-5
6-9
6-9
6-9
6-10
6-10
6-10
6-10
6-11
6-11
6-14
6-14
Earth Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1
Designing an Earth Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing an Earth Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1
7-7
Lightning Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1
6.1
6.2
6.2.1
6.2.2
6.2.3
6.3
6.3.1
6.3.2
6.3.3
6.3.4
6.3.5
6.4
6.4.1
6.4.2
6.4.3
6.5
6.6
6.7
7
7.1
7.2
8
Page
Glossary
Index
Figures
3-1
3-2
3-3
3-4
3-5
3-6
3-7
3-8
3-9
vi
AC Power Distribution System . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AC, DC and Signal Grounding System . . . . . . . . . . . . . . . . . . . . .
AC Distribution System Grounding (Continued).
DC Grounding also Shown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Three Phase AC Power Input System . . . . . . . . . . . . . . . . . . . . . .
Reverse Transfer Uninterruptible Power Supply (UPS)
with a Manual Transfer Switch (Three Phase) . . . . . . . . . . . . . .
Single Phase AC Power Input System . . . . . . . . . . . . . . . . . . . . . .
Reverse Transfer Uninterruptible Power Supply (UPS)
with a Manual Transfer Switch (Single Phase) . . . . . . . . . . . . . .
Multiple Circuit Breaker Panel Wiring . . . . . . . . . . . . . . . . . . . . . . .
Single Circuit Breaker Panel Wiring . . . . . . . . . . . . . . . . . . . . . . . .
3-3
3-4
3-5
3-6
3-7
3-8
3-9
3-10
3-11
Revision B — October 1995
PN1:003
Contents
Section/Title
3-10
3-11
3-12
3-13
3-14
3-15
3-16
3-17
3-18
4-1
4-2
4-3
4-4
4-5
4-6
4-7
4-8
4-9
4-10
4-11
4-12
4-13
4-14
5-1
5-2
5-3
5-4
5-5
6-1
6-2
6-3
6-4
6-5
6-6
6-7
Revision B — October 1995
PN1:003
System Cabinet AC Power Connections for
Type CP6101 and Type CP6102 Power Supplies . . . . . . . . . . .
System Cabinet AC Power Connections for
Type CP6103 Power Supply Units . . . . . . . . . . . . . . . . . . . . . . . .
Console AC Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cabinet AC Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . .
Type CP9411 System Cabinet Power Distribution . . . . . . . . . . . .
DC9410-Series Control Room Furniture Power Distribution . . .
Electronics Enclosure Power Distribution . . . . . . . . . . . . . . . . . . .
Custom Computer AC Power Connections . . . . . . . . . . . . . . . . . .
Isolated Ground Receptacle Details . . . . . . . . . . . . . . . . . . . . . . . .
Typical DC Power System —CP6101/CP6102 . . . . . . . . . . . . . .
Typical DC Power System and Ground Connections
for Cabinets with Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . .
Simplex DC Power Distribution with Redundant
Type CP6101 and Type CP6102 Power Supplies . . . . . . . . . . .
Dual Simplex DC Power Distribution with a
Type CP6103 Power Supply Unit . . . . . . . . . . . . . . . . . . . . . . . . .
Redundant DC Power Distribution with a
Type CP6103 Power Supply Unit . . . . . . . . . . . . . . . . . . . . . . . . .
Fully Redundant DC Power Distribution with
Type CP6101 and Type CP6102 Power Supplies . . . . . . . . . . .
Typical DC Power System and Ground Connections
for Cabinets with a Type CP6103 Power Supply Unit. . . . . . . .
DC Distribution Assembly and Type CP6103 Power Supply Unit.
Terminal Block Details for a Type CP6103 System
Power Supply Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control I/O Remote Termination Power . . . . . . . . . . . . . . . . . . . . .
Control I/O Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control I/O Power Connections (Continued) . . . . . . . . . . . . . . . . .
Control I/O Power Connections (Continued) . . . . . . . . . . . . . . . . .
Highway Device Power Connections . . . . . . . . . . . . . . . . . . . . . . .
Types CP6101 and CP6102 Power Supply Alarm
Wiring Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Type CP6103 Power Supply Unit Alarm Wring Example . . . . . .
Features of Control I/O Card File Alarm Wiring . . . . . . . . . . . . . .
Highway Device Alarm Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Redundant Highway Device Alarm Wiring . . . . . . . . . . . . . . . . . . .
AC and DC Multiple Cabinet Ground System . . . . . . . . . . . . . . . .
Details of AC and DC Ground System with NEC/CSA
Code Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Details of Local and Master Ground Buses . . . . . . . . . . . . . . . . .
DC/Cabinet Grounding System . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Multiple Cabinet System Grounding . . . . . . . . . . . . . . . . . . . . . . . .
Typical System Cabinet Ground Bus Assembly . . . . . . . . . . . . . .
Typical OWP Wall Frame Grounding . . . . . . . . . . . . . . . . . . . . . . .
Page
3-13
3-14
3-16
3-16
3-17
3-18
3-19
3-19
3-20
4-5
4-6
4-7
4-7
4-8
4-8
4-9
4-10
4-10
4-11
4-12
4-13
4-14
4-15
5-3
5-4
5-4
5-5
5-6
6-3
6-4
6-5
6-6
6-6
6-7
6-8
vii
Contents
Section/Title
Page
6-8
6-9
6-10
Shield Ground Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Typical Ground Connections for Intrinsic Safety Barriers . . . . . .
Typical Ground Connections for Active , Galvanic Isolated,
Intrinsic Safety Barriers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Example of Plant Ground Grid System . . . . . . . . . . . . . . . . . . . . .
Grounding Example (UFR Ground System) . . . . . . . . . . . . . . . . .
Grounding Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grounding Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grounding Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grounding Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grounding Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Typical Test Setup and Connection for Testing an
Earth Ground System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-11
6-12
Voltage and Frequency Requirements . . . . . . . . . . . . . . . . . . . . . .
Recommended Wire Sizes for 120 Volts . . . . . . . . . . . . . . . . . . .
Recommended Wire Sizes for 240 Volts . . . . . . . . . . . . . . . . . . .
Copper Conductor Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Class 2 Stranded Conductors for Single-core and
Multi-core Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ground Wire Sizing Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2
2-3
2-4
2-5
7-1
7-2
7-3
7-4
7-5
7-6
7-7
7-8
6-13
7-2
7-3
7-4
7-5
7-5
7-6
7-6
7-7
Tables
2-1
2-2
2-3
2-4
2-5
6-1
viii
2-7
6-8
Revision B — October 1995
PN1:003
Section Tab Guide
Introduction
1
AC Power Requirements
2
AC Power Distribution
3
DC Power Distribution
4
Cabinet Alarm Wiring
5
System Grounding
6
Earth Grounding
7
Lightning Protection
8
9
Glossary
Glossary
10
Index
Revision B — October 1995
PN1:003
Index
ix
This page intentionally left blank.
x
Revision B — October 1995
PN1:003
1-1
Introduction
Figure 1-Table 1
1
1
Introduction
This installation planning manual provides system-level
recommendations and guidelines for AC and DC power and ground
wiring of PROVOXr and microPROVOXt Process Management
Systems. Product-level instructions for power and ground wiring is
described in product installation manuals.
Note
Proper power and ground wiring are of prime
importance for operator safety, signal integrity,
and reliable operation of an instrumentation
system. Following the recommendations in this
installation planning manual to the maximum
extent possible can help you achieve these goals.
All power and ground wiring practices must conform to applicable local
codes and regulations. It is believed that the recommendations and
guidelines given in this installation planning manual meet or exceed the
codes and regulations.
The recommendations and wiring diagrams in this installation planning
manual are typical examples rather than specific requirements. Primary
emphasis is on safety and proper equipment operation.
While these recommendations and guidelines attempt to cover most
situations, there will no-doubt be peculiar installations that may deviate
from the norm. In these situations, contact your Fisher-Rosemount
Systems representative or sales office for assistance.
1.1
Intended Audience
This installation planning manual is intended for use by plant engineering
personnel who are planning and designing the power and ground
facilities for a PROVOX or microPROVOX system.
Revision B — October 1995
PN1:003
1-2
Introduction
1.2
CE Statement
If you intend to have your PROVOX system certified for compliance to
appropriate European Union directives, the following CE statement is
extremely important to your ability to achieve that compliance.
1
This manual describes installation and
maintenance procedures for products
which have been tested to be in
compliance with appropriate CE
directives. To maintain compliance,
these products must be installed and
maintained according to the
procedures described in this manual.
Failure to follow the procedures may
compromise compliance.
1.3
Structure of this Manual
This manual contains the following sections:
Section 1 — Introduction: includes an overview of this manual, the
intended audience, the stylistic and typographical conventions used, and
lists of documents where additional information is available.
Section 2— AC Power Requirements: describes the quality and the
specifications for the ac power required for the instrumentation system.
Section 3 — AC Power Distribution: describes the required distribution
of ac power to system cabinets, operator consoles and other equipment.
Section 4 — DC Power Distribution: describes the required distribution
of dc power in system cabinets used by the controllers, I/O systems, and
other cabinet-mounted equipment.
Section 5 — Cabinet Alarm Wiring: describes cabinet alarm circuits used
to detect loss of power supply output, loss of battery backup, and cabinet
over-temperature.
Section 6 — System Grounding: describes techniques used to assure
proper system grounding for optimum instrumentation system operation.
Section 7 — Earth Grounds: describes how to design and test earth
ground systems.
Section 8 — Lightning Protection: briefly describes lightning protection
principles and references for further reading.
PN1:003
Revision B — October 1995
1-3
Introduction
1.4
Manual Conventions
This manual uses the following conventions:
J
J
J
1.5
Acronyms and Abbreviations — Terms are spelled out the first time
they appear in text. Thereafter, only the acronym or abbreviation is
used. In addition, the glossary defines the acronyms and
abbreviations.
Revision Control — The title page lists the revision level and the
printing date of this manual. When the manual is revised, the revision
level and the printing date are changed.
References — References to other documents include the name
and catalog number for Fisher-Rosemount Systems manuals.
Warnings, Cautions, and Notes
Warnings, Cautions, and Notes attract attention to essential or critical
information in this manual. The types of information included in each are
explained in the following:
Warning
All warnings have this form and symbol.
Do not disregard warnings. They are
installation, operation, or maintenance
procedures, practices, conditions,
statements, and so forth, which if not
strictly observed, may result in personal
injury or loss of life.
Caution
All cautions have this form and symbol. Do
not disregard cautions. They are
installation, operation, or maintenance
procedures, practices, conditions,
statements, and so forth, which if not
strictly observed, may result in damage to,
or destruction of, equipment or may cause
a long term health hazard.
Revision B — October 1995
PN1:003
1
1-4
Introduction
Note
1
Notes have this form and symbol. Notes contain
installation, operation, or maintenance
procedures, practices, conditions, statements,
and so forth, that alert you to important
information which may make your task easier or
increase your understanding.
1.6
Related Documents
The planning manuals listed below provide further information for system
installation planning:
J
PN1:002, Planning the Installation
J
PN1:004, Signal Wiring and Highway System Guidelines
J
PN1:005, Preventing Electrostatic Damage
J
PN1:006 Environmental Conditions for Instrumentation Systems
J
J
1.7
PN4:007, Lightning Protection Guidelines for Instrumentation
Systems
PN1:008, Site Evaluation
Reference Documents
The reference documents listed below are industry standard reference
material where further information about power and grounding can be
found:
1. Getting Down to Earth, 4th ed., Blue Bell, Pennsylvania; Biddle
Instruments. Copies of this publication are available from Biddle
Instruments, 510 Township Lane Road, Blue Bell, Pennsylvania,
19422, USA.
2. NFPA, NFPA-70 National Electrical Code, Boston; National Fire
Protection Association.
3. CSA, C22.1 Canadian Electrical Code, Part 1, Rexdale, Ontario;
Canadian Standards Association.
4. ISA,RP60.08 Electrical Guide for Control Centers, Pittsburgh;
Instrument Society of America.
PN1:003
Revision B — October 1995
1-5
Introduction
5. API, RP-550 Installation of Refinery Instruments and Control
Systems, 3rd ed., Washington DC; American Petroleum Institute.
1.8
1
Excellence in Documentation
Our goal is to provide documents that meet your needs. Through
surveys and interviews, we continually evaluate our documents as part
of the broad Fisher-Rosemount Systems customer-support program.
Various manuals are produced for different purposes and for readers
with varying backgrounds and experience.
Please assist us in the evaluation of this manual by completing the
reader evaluation form located at the front of the document. In addition, if
you have any suggestions for specific pages, return a marked-up copy
along with your survey.
Revision B — October 1995
PN1:003
1-6
Introduction
1
This page intentionally left blank.
PN1:003
Revision B — October 1995
2-1
AC Power Requirements
Figure 2-Table 2
2
AC Power Requirements
Commercial ac power utilities normally provide power that meets the
voltage and frequency requirements of the instrumentation system.
However, plant distribution networks may drop 5 percent or more of the
input ac power between the service entrance point to the plant and the
final power connection to the various portions of the instrumentation
system. Furthermore, starting transients from large motors and other
loads connected to the distribution system can cause additional
momentary line-voltage reductions as well as possible waveshape
distortions. Therefore, accessing ac power requirements and then
designing a plant ac distribution system that meets them is critical to
reliable, efficient control system operation. This section describes
considerations to help you design a good plant ac distribution system.
2.1
AC Power Quality
To maintain good ac power quality, such problems as power loss,
intermittent noise, low voltage, or transients and surges on power lines
must be controlled or designed around. To suppress electrical noise, a
dedicated feeder between the main distribution panel and the
instrumentation system branch panel is recommended. If low voltage
from the commercial power source or objectionable transients and
surges exist, or if noise is a problem even with a dedicated feeder, a
device such as a noise filter or voltage regulating power source which
reduces input power noise may be required.
Devices which can be used include:
J
Isolation transformer
J
Noise filters
J
Line conditioner
J
Voltage regulating power source
J
Motor-generator set
J
uninterruptible power supply (UPS)
Note
It is strongly recommended that isolation
transformers be used because they inherently
provide good line regulation and transient filtering.
Revision B — October 1995
PN1:003
2
2-2
AC Power Requirements
If loss of power from a commercial power source is a probability, a
backup power source such as an uninterruptible power supply for critical
portions of the control system is recommended.
The instrumentation system should have an ac power source that is
isolated from lighting and all other power loads, and each building or site
containing instrumentation should have a separate power source or
backup power source. These conditions are particularly important for the
instrumentation system control center, which generally contains the
console or computer and associated equipment.
2
When an isolation transformer is used, the primary power source should
be supplied from the highest line voltage available from the commercial
source, and then through a step-down transformer to the required lower
voltage for the instrumentation system. Only the instrumentation system
should be connected to this step-down transformer; no other ac loads
should be connected. The reason for using the highest voltage is to take
advantage of the natural noise attenuation which occurs when the
voltage and any noise is stepped down.
2.2
AC Source Voltage and Frequency
The ac power source should have sufficient capacity to handle
equipment inrush overcurrents or surge currents (lasting about ten
cycles), and still regulate its output voltage within the nominally rated
voltage tolerances for the equipment. This tolerance is measured at the
power input to the equipment when the equipment is energized.
Table 2-1 lists the voltage and frequency requirements for the dc power
supplies which provide dc power to cabinet-mounted PROVOXr
instruments, such as SR90 and SRx controllers and the Control I/O
subsystem.
Table 2-1
Voltage and Frequency Requirements
Type CP6101
Nominal
Range
Type CP6102
Hz
Nominal
Range
97--127
Type CP6103
Hz
Nominal
Range
Hz
48--52
120/240
85--264
47--63
100
86--113
58--62
110/115
117
102--132
58--62
120/127 107--140
48--52
200
172--226
58--62
220
187--242
48--52
230/240 204--264
58--62
230/240 204--264
48--52
Power requirements for PROVOX operator consoles and peripheral
equipment are listed in their product bulletins. For other equipment using
switching power supplies, use only low impedance output power
sources. Then use normal transformer load recommendations.
PN1:003
Revision B — October 1995
2-3
AC Power Requirements
2.3
Recommended Wire Sizes
Wiring from the power source to equipment should be large enough to
maintain the voltage at the equipment input terminals within the specified
tolerances when all equipment is energized. The wiring must, at a
minimum, conform to applicable local, state, and federal codes to ensure
that it can conduct the current load safely without overheating.
Recommended wire sizes for various load currents and run lengths are
listed in Table 2-2 for 120 volts input power and Table 2-3 for 240 volts
input power. Figures in the tables represent one-way distances. Each run
length indicates the maximum distance in feet (meters) which each wire
size can be to carry the current (listed in the left column) with no more
than a 2% voltage drop. If a 4% drop is acceptable, double the distances
shown. For a 5% drop, multiply all distances by 2.5.
Table 2-4 presents properties and data for various wire sizes. For
countries incorporating metric standards, use the equivalent or larger
standard metric wire size from Table 2-5.
Table 2-2
Recommended Wire Sizes for 120 Volts
Wire size — AWG (mm2)
Load
Current
(A)
Power
(Watts)
12
(3.31)
10
(5.28)
8
(8.37)
6
(13.30)
4
(21.15)
2
(33.63)
1/0
(53.46)
2/0
(67.44)
3/0
(85.02)
Run Length — Feet (Meters)
1
120
622
(189.6
)
992
(302.4)
1570
(478.5)
2444
(744.9)
3896
(1187.5)
6185
(1885.2
)
2
240
311
(94.8)
496
(151.2)
785
(239.3)
1222
(372.5)
1948
(593.7)
3093
(942.7)
3
360
207
(63.1)
330
(100.6)
523
(159.4)
814
(248.1)
1299
(395.9)
2062
(682.5)
3278
(999.1)
5
600
124
(37.8)
198
(60.3)
314
(95.7)
489
(149.0)
779
(237.4)
1237
(377.0)
1967
(599.5)
2482
(756.5)
10
1200
62
(18.9)
99
(30.2)
157
(47.8)
244
(74.4)
389
(118.6)
618
(188.4)
983
(299.6)
1240
(377.9)
1566
(477.3)
15
1800
41
(12.5)
66
(20.1)
105
(32.0)
163
(49.7)
260
(79.2)
412
(125.6)
656
(199.9)
827
(252.1)
1044
(318.2)
20
2400
31
(9.4)
49
(14.9)
78
(23.8)
122
(37.2)
195
(59.4)
309
(94.2)
492
(149.9)
620
(189.0)
783
(238.7)
25
3000
25
(7.6)
39
(11.9)
63
(19.2)
98
(29.9)
156
(47.5)
247
(75.3)
393
(119.8)
496
(151.2)
626
(190.8)
30
3600
21
(6.4)
33
(10.1)
52
(15.8)
81
(24.7)
130
(39.6)
206
(62.8)
328
(100.0)
413
(125.9)
522
(159.1)
35
4200
18
(5.5)
28
(8.5)
45
(13.7)
70
(21.3)
111
(33.8)
177
(53.9)
281
(85.6)
354
(107.9)
447
(136.2)
40
4800
15
(4.6)
25
(7.6)
39
(11.9)
61
(18.6)
97
(29.6)
154
(46.9)
246
(75.0)
310
(94.5)
391
(119.2)
Revision B — October 1995
PN1:003
2
2-4
AC Power Requirements
Table 2-2
Recommended Wire Sizes for 120 Volts
Wire size — AWG (mm2)
2
Load
Current
(A)
Power
(Watts)
12
(3.31)
10
(5.28)
8
(8.37)
6
(13.30)
4
(21.15)
2
(33.63)
1/0
(53.46)
2/0
(67.44)
3/0
(85.02)
Run Length — Feet (Meters)
45
5400
22
(6.7)
35
(10.7)
54
(16.5)
86
(26.2)
137
(41.8)
218
(66.4)
276
(84.1)
348
(106.1)
50
6000
20
(6.1)
31
(9.4)
49
(14.9)
78
(23.8)
124
(37.8)
197
(60.0)
248
(75.6)
313
(95.4)
Table 2-3
Recommended Wire Sizes for 240 Volts
Wire Size — AWG (mm2)
Load
Power
Current (Watts)
(A)
12
(3.31)
10
(5.28)
8
(8.37)
6
(13.30)
4
(21.15)
2
(33.63)
1/0
(53.46)
2/0
(67.44)
3/0
(85.02)
Run Length — Feet (Meters)
1
240
1243
1983
(378.9) (604.4)
3141
(957.4)
4888
7792
(1489.9) (2375.0)
2
480
622
992
(189.6) (302.4)
1570
(478.5)
2444
(744.9)
3896
(1187.5)
6185
(1885.2)
3
720
414
661
(126.2) (201.5)
1047
(319.1)
1629
(496.5)
2597
(791.6)
4124
6557
(1257.0) (1998.6)
4
960
311
(94.8)
496
(151.2)
785
(239.3)
1222
(372.5)
1948
(593.7)
3093
(942.7)
4918
6205
(1499.0) (1891.3)
5
1200
249
(75.9)
396
(120.7)
628
(191.4)
977
(297.8)
1558
(474.9)
2474
(754.1)
3934
(1199.1)
4964
6266
(1513.0) (1909.8)
10
2400
124
(37.8)
198
(60.3)
314
(95.7)
489
(149.0)
779
(237.4)
1237
(377.0)
1976
(599.5)
2482
(756.5)
3133
(954.9)
15
3600
83
(25.3)
132
(40.2)
209
(63.7)
326
(99.4)
519
(158.2)
825
(251.5)
1311
(399.6)
1654
(504.1)
2089
(636.7)
20
4800
62
(18.9)
99
(30.2)
157
(47.8)
244
(74.4)
389
(118.6)
618
(188.4)
983
(299.6)
1240
(377.9)
1566
(477.3)
25
6000
50
(15.2)
79
(24.1)
125
(38.1)
195
(59.4)
311
(94.8)
495
(150.9)
787
(239.9)
993
(302.7)
1253
(381.9)
30
7200
41
(12.5)
66
(20.1)
105
(32.0)
163
(49.7)
260
(79.2)
412
(125.6)
656
(199.9)
827
(252.1)
1044
(318.2)
35
8400
35
(10.7)
56
(17.1)
90
(27.4)
139
(42.4)
222
(67.7)
353
(107.6)
562
(171.3)
709
(216.1)
895
(272.8)
40
9600
31
(9.4)
49
(14.9)
78
(23.8)
122
(37.2)
195
(59.4)
309
(94.2)
492
(149.9)
620
(189.0)
783
(238.7)
45
10,800
44
(13.4)
70
(21.3)
108
(32.9)
173
(52.7)
275
(83.8)
437
(133.2)
551
(167.9)
696
(212.1)
50
12,000
39
(11.9)
63
(19.2)
98
(29.9)
156
(47.5)
247
(75.3)
393
(119.8)
496
(151.2)
626
(190.8)
PN1:003
Revision B — October 1995
2-5
AC Power Requirements
Table 2-3
Recommended Wire Sizes for 240 Volts
Wire Size — AWG (mm2)
Load
Power
Current (Watts)
(A)
12
(3.31)
10
(5.28)
8
(8.37)
6
(13.30)
4
(21.15)
2
(33.63)
1/0
(53.46)
2/0
(67.44)
3/0
(85.02)
2
Run Length — Feet (Meters)
60
14,400
52
(15.8)
81
(24.7)
130
(39.6)
206
(62.8)
328
(100.0)
413
(125.9)
522
(159.1)
70
16,800
45
(13.7)
70
(21.3)
111
(33.8)
177
(53.9)
281
(85.6)
354
(107.9)
447
(136.2)
80
19,200
61
(18.6)
97
(29.6)
154
(46.9)
246
(74.9)
310
(94.5)
391
(119.2)
90
21,600
54
(16.5)
86
(26.2)
137
(41.8)
218
(66.4)
276
(84.1)
348
(106.1)
100
24,000
49
(14.9)
78
(23.8)
124
(37.8)
197
(60.0)
248
(75.6)
313
(95.4)
125
30,000
62
(18.9)
99
(30.2)
157
(47.8)
198
(60.3)
250
(76.2)
150
36,000
52
(18.1)
82
(25.0)
131
(39.9)
165
(50.3)
209
(63.7)
200
48,000
39
(11.9)
62
(18.9)
98
(29.9)
124
(37.8)
156
(47.5)
Table 2-4
Copper Conductor Properties
Size
Area
*Area
AWG/
Cir
mm2
Conductors
Stranding
MCM
Mils
18
1620
18
1620
16
2580
16
2580
14
4110
14
4110
12
6530
12
6530
10
10380
10
10380
8
16510
8.35
1
8
16510
8.35
7
6
26240
13.27
4
41740
21.15
Revision B — October 1995
Qty
0.82
1
Uncoated
Coated
8.08
0.046
0.002
7.95
8.45
0.051
0.002
4.89
5.08
0.058
0.003
4.99
5.29
0.064
0.003
3.07
3.19
0.073
0.004
3.14
3.26
0.081
0.005
1.93
2.01
0.092
0.006
1.98
2.05
0.102
0.008
1.21
1.26
0.116
0.011
1.24
1.29
0.128
0.013
0.764
0.786
0.049
0.146
0.017
0.778
0.809
7
0.061
0.184
0.027
0.491
0.510
7
0.077
0.232
0.042
0.308
0.321
0.015
1
0.019
1
0.024
1
7
5.27
Area
7.77
7
3.30
Dia. In.
Ohms/kFT
In.2
0.001
7
2.08
Overall
0.040
7
1.31
Dia. In.
DC Resistance at 75° C, 167° F
0.030
1
7
0.038
PN1:003
2-6
AC Power Requirements
Table 2-4
2
Copper Conductor Properties (Continued)
Size
Area
*Area
AWG/
Cir
mm2
MCM
Mils
3
52620
2
Conductors
Stranding
DC Resistance at 75° C, 167° F
Overall
Qty
Dia. In.
Dia. In.
26.69
7
0.087
0.260
66360
33.59
7
0.097
1
83690
42.43
19
1/0
105600
53.46
2/0
133100
3/0
4/0
Uncoated
Coated
0.053
0.245
0.254
0.292
0.067
0.194
0.201
0.066
0.332
0.087
0.154
0.160
19
0.074
0.373
0.109
0.122
0.127
67.49
19
0.084
0.419
0.138
0.967
0.101
167800
84.95
19
0.094
0.470
0.173
0.0766
0.0797
211600
107.16
19
0.106
0.528
0.219
0.0608
0.0626
250
37
0.082
0.575
0.260
0.0515
0.0535
300
37
0.090
0.630
0.312
0.0429
0.0446
350
37
0.097
0.681
0.364
0.0367
0.0382
400
37
0.104
0.728
0.416
0.0321
0.0331
500
37
0.116
0.813
0.519
0.0258
0.0265
600
61
0.992
0.893
0.626
0.0214
0.0223
700
61
0.107
0.964
0.730
0.0184
0.0189
750
61
0.111
0.998
0.782
0.0171
0.0176
800
61
0.114
1.03
0.834
0.0161
0.0166
900
61
0.122
1.09
0.940
0.0143
0.0147
1000
61
0.128
1.15
1.04
0.0129
0.0132
1250
91
0.117
1.29
1.30
0.0103
0.0106
1500
91
0.128
1.41
1.57
0.00858
0.00883
1750
127
0.117
1.52
1.83
0.00735
0.00756
127
0.126
1.63
2.09
0.00643
0.00662
2000
Area
Ohms/kFT
In.2
Note:
These resistance values are valid only for the parameters as given. Using conductors having coated strands,
different strand types, and especially different temperatures will change the resistance.
Note:
The formula for the temperature change is: R2 -- R1 (1 + a (T1 -- 20) acu = 0.00393
Note:
Class B stranding is listed as well as solid for some sizes. Its overall diameter and area is that of its circumscribing
circle. The construction information is per NEMA Standard WC8--1976 (Rev 5--1980). The resistance is calculated
per National Bureau of Standards Handbook 100, dated 1966 and Handbook 109, dated 1972.
Note:
Conductors with compact and compressed stranding have about 9 percent and 3 percent, respectively, smaller bare
conductor diameters than those shown.
Note:
The IACS conductivities used bare copper = 100%.
Note:
Reprinted with permission of NFPA 70-1984, National Electrical Code, Copyright 1984, National Fire Protection
Association, Quincy, MA 02269. This reprinted material is not the complete and official position of the NFPA on the
referenced subject.
* This column has been added and is not part of the table in the National Electrical Code.
PN1:003
Revision B — October 1995
2-7
AC Power Requirements
Table 2-5
Class 2 Stranded Conductors for Single-core and Multi-core Cables
Nominal
Cross Section
Area (mm2)
Minimum Number of Wires In Copper
Conductor
Circular
Conductor
Compacted
Conductor
Shaped
Conductor
Maximum resistance of
Annealed Copper Conductor at
20°C (Ohms/km)
Plain Wires
Metal-Coated
Wires
0.5
7
36.0
36.7
0.75
7
24.5
24.8
1
7
18.1
18.2
1.5
7
6
12.1
12.2
2.5
7
6
7.41
7.56
4
7
6
4.61
4.70
6
7
6
3.08
3.11
10
7
6
1.83
1.84
16
7
6
1.15
1.16
25
7
6
6
0.727
0.734
35
7
6
6
0.524
0.529
50
19
6
6
0.387
0.391
70
19
12
12
0.268
0.270
95
19
15
15
0.193
0.195
120
37
18
18
0.153
0.154
150
37
18
18
0.124
0.126
185
37
30
30
0.0991
0.100
240
61
34
34
0.0754
0.0762
300
61
34
34
0.0601
0.0607
400
61
53
53
0.0470
0.0475
500
61
53
53
0.0366
0.0369
630
91
53
53
0.0283
0.0286
800
91
53
0.0221
0.0224
960 (4x240)
1000
Number of wires not specified
91
53
0.0189
0.0176
0.0177
1200
Number of wires
0.0151
1600
not specified
0.0113
2000
0.0090
Note:
Extracts from BS63601981 are reproduced by permission of the British Standards Institution. Copies may be
obtained from BSIat Linford Wood, Milton Keyes ,MK146LE.
Note:
To obtain the maximum resistance of hard-drawn conductors, the values in columns 5 and 6 should be divided by
0.97.
Revision B — October 1995
PN1:003
2
2-8
AC Power Requirements
2
This page intentionally left blank.
PN1:003
Revision B — October 1995
3-1
AC Power Distribution
Figure 3-Table 3
3
AC Power Distribution
The ac power supplied to a PROVOXr Process Management System
should be taken from an ac power distribution system which is isolated
from the power supplied to all other functions in a process control
system. In addition, a separate distribution system is recommended for
each building containing control system equipment. This isolation can be
provided by either an isolation transformer or by an uninterruptible power
supply.
Note
To maintain ac power quality, isolation of power
supplied to the instrumentation from power
supplied to all other functions and the importance
of using a different distribution system for each
building containing instrumentation cannot be
overemphasized,
PROVOX system cabinets and consoles require single-phase power.
Commercial computer systems usually require a 120/240 volt circuit, two
120 volt circuits, a 208Y/120 volt circuit, or European 230/240 Vac 50 Hz
single phase circuit, depending on computer configuration. If a
three-phase distribution system is used, exercise care to balance the
load between phases at each power panel, minimizing any voltage
differentials between the ac neutral and the grounding conductors.
3.1
System-Level Power Distribution
Figure 3-1 shows a typical system-level power distribution system.
Figure 3-2 and Figure 3-3 shows further details of typical ac power
distribution and a plant ground system. Input ac power is supplied
through an isolation transformer or UPS, with the ac ground point for the
instrumentation system established at or near the transformer or UPS.
The ac circuit conductors are routed through the main distribution panel
(containing the main disconnect switch) into the circuit breaker panel or
panels. This system meets or exceeds the requirements of Article 250 of
the National Electrical Code. The isolated grounding system is used for
signal reference.
Revision B — October 1995
PN1:003
3
3-2
AC Power Distribution
Figure 3-4 provides additional detail for three-phase wiring between an
isolation transformer and the main distribution panel.
Figure 3-5 shows an uninterruptible power supply (UPS) used in a
three-phase system with an isolation transformer.
Figure 3-6 provides additional detail for single-phase wiring between an
isolation transformer and the main distribution panel.
3
Figure 3-7 shows an uninterruptible power supply (UPS) used in a
single-phase system with an isolation transformer.
For large systems, multiple circuit breaker panels should be used.
Separate panels are dedicated to system cabinets and to consoles and
computers, as shown in Figure 3-1.
Figure 3-8 provides wiring details for a multiple circuit breaker panel
installation.
Figure 3-9 provides wiring details for a small system to a single circuit
breaker panel.
Both Figure 3-8 and Figure 3-9 show the neutral and ground conductors
bonded to separate bus bars inside the circuit breaker panel. The bus
bars are electrically isolated from the panel and from each other.
Throughout the system, all ac circuit conductors (line, neutral, and
ground) are electrically isolated from their conduits and circuit breaker
panels.
This conductor isolation is maintained from the isolation transformer or
UPS to the point of final connection at the instrumentation equipment.
The only connection between neutral, isolated ground, and earth ground
is at the main bonding jumper. The insulated grounding conductor should
be the same size or larger than the phase and neutral conductors.
PN1:003
Revision B — October 1995
3-3
AC Power Distribution
Console &
Computer
Breaker Panel
System Cabinet
Breaker Panel
Main
Distribution
Panel
Plant
Power
Grid
1
3
Insolation
Transformer
DC6961
Logging
Unit
System
Cabinet
#1
Computer
Logging
Unit
System
Cabinet
#2
Console
Bay #1
System
Cabinet
#3
Console
Bay #2
Computer
Console
Bay #1
System
Cabinet
#4
Console
Bay #3
Computer
Console
Bay #2
System
Cabinet
#5
Console
Bay #4
Console
Bay #5
System
Cabinet
#6
System
Cabinet
#7
Logging
Unit
Computer
Logging
Unit
Computer
Cabinet
#1
Computer
Cabinet
#2
System
Cabinet
#8
System System System
Cabinet Cabinet Cabinet
#9
#10
#11
Legend
-- Utility box for cabinet power connections
-- Utility box for isolated ground receptacles
1
-- a single breaker panel may be used for small systems.
Figure 3-1
AC Power Distribution System
Revision B — October 1995
PN1:003
Figure 3-2
PN1:003
Plant Ground GND
DC/Cab GND
DO NOT ENCLOSE Grounding
Conductors in Metalic Conduit.
4/0 AWG
Insulated
Cable
C
B
A
Main
Distribution
Panel
Figure 3-2 AC Distribution System Grounding
Grounded
Steel
Column
per Code
PROVOX
Instrumentation
Ground (PIG)
Alternate
AC Supply
N
AC
Supply
N
Transfer
Switch
Single Phase
Shown
Power Cord
Existing Building
G
N
L
Isolate N and G
terminals from box
Power Cord
For Multi--Cabinet Grouping, Refer to Figure 3-3.
Computer
Isolated Gnd
Twist Lock
Receptical PROVUE
Power Cord
OWP Wall Unit
Bond Conduit Both Ends
3
Branch Circuit
Distribution
HOST
COMPUTER
Power
Distribution
3-4
AC Power Distribution
AC, DC and Signal Grounding System
Revision B — October 1995
3-5
AC Power Distribution
Single
Cabinet
L
Circuit for each
Cabinet Supply
N
G
2
Notes:
1
2
PSC
Cabinets are grouped in a maximum of eight so a
cabinet ground and local ground bus (LGB)
connection will come to the master ground bus
(MGB) for each group
Typical ac input for a dc power supply
CP6103
3
2
Cab GND
To PROVOX instrumentation Ground (PIG)
Example of Multiple Cabinets and Power Supplies
2
PSC
CP6103
PSC
PSC
CP6103
PSC
CP6103
PSC
PSC
PSC
CP6103
PSC
LGB
DC GND
To PROVOX instrumentation Ground (PIG)
Cab GND
MGB
1
Cab GND
Tie
To Additional
Cabinet Grounds
To Additional
LGB’s
PSC
PSC
PSC
PSC
--
--
LGB
To MGB
Figure 3-3
AC Distribution System Grounding (Continued). DC Grounding also Shown
Revision B — October 1995
PN1:003
3-6
AC Power Distribution
AC Input from
Commercial
Power Source
Isolation Transformer
2
ÆA
C
B
ÆB
3
A
ÆC
C
3
Main
Distribution
Panel
2
1
A
ÆA
ÆB
ÆC
N
GND
B
4
To Circuit
Breaker
Panel(s)
Grounded
Steel Column
DC/CAB GND
PROVOXr Instrumentation Ground (PIG)
Dedicated Plant Ground Grid Point
Notes:
1
Circuit breaker, as required by local codes and
regulations
3
2
Conduit provides a safety ground connection
for individual panels.
4
Figure 3-4
PN1:003
The isolation transformer secondary can be a
208Y/120 Volt, 120 Volt, 120/240 Volt output or
European 230/240 Volt.
The conductor between the neutral and ground
leads and the dedicated AC ground should be as
short as physically possible.
Three Phase AC Power Input System
Revision B — October 1995
3-7
AC Power Distribution
AC Input
from
Commercial
Power
Source A
Isolation Transformer
C
A
B
B
C
C
Main Transfer Switch
A
A
B
B
C
N
To Circuit
Breaker
Panel(s)
G
3
Backup
Input
Rectifier
Inverter
1
AC Input
from
Commercial
Power
Source
A
B
C
N
2
Static
Switch
Battery
Bank
DC/CAB GND
Grounded
Steel Column
Notes:
1
Conduit provides a safety ground connection
for individual panels.
2
The conductor between the neutral and ground
leads and the dedicated AC ground should be as
short as physically possible.
Figure 3-5
PROVOXr Instrumentation Ground
Dedicated Plant Ground Grid Point
Reverse Transfer Uninterruptible Power Supply (UPS) with a Manual
Transfer Switch (Three Phase)
Revision B — October 1995
PN1:003
3-8
AC Power Distribution
AC Input from
Commercial
Power Source
Isolation Transformer
2
Main
Distribution
Panel
Lin
e
1
Main Disconnect
Switch
2
Lin
e
Neut
GND
Neut
3
3
Backup
Input
Grounded
Steel Column
DC/CAB GND
To Circuit
Breaker
Panel(s)
PROVOXr Instrumentation Ground
Dedicated Plant Ground Grid Point
Notes:
1
Circuit breaker, as required by national codes and regulations
2
Conduit provides a safety ground connection for individual panels.
3
The conductor between the neutral and ground leads and the dedicated AC ground should be as short as physically possible.
Figure 3-6
PN1:003
Single Phase AC Power Input System
Revision B — October 1995
3-9
AC Power Distribution
AC Input
from
Commercial
Power
Source
L
Isolation Transformer
Main Transfer Switch
2
L
N
N
To Circuit
Breaker
Panel(s)
G
3
Backup
Input
Rectifier
Inverter
1
AC Input
from
Commercial
Power
Source
L
N
3
Battery
Bank
DC/CAB GND
Grounded
Steel Column
PROVOXr Instrumentation Ground
Notes:
Dedicated Plant Ground Grid Point
1
Conduit provides a safety ground connection
for individual panels.
2
This output can be substituted for the isolation
transformer in Figure 3-1.
Figure 3-7
Static
Switch
3
The conductor between the neutral and ground
leads and the dedicated AC ground should be as
short as physically possible.
Reverse Transfer Uninterruptible Power Supply (UPS) with a Manual
Transfer Switch (Single Phase)
Revision B — October 1995
PN1:003
Figure 3-8
PN1:003
A
Circuit breaker as required by national codes
and regulations.
2
N
A
B
C
1
N
Neutral Bus (Isolated
from Breaker Panel)
G
Ground Bus (Isolated
from Breaker Panel)
G
G
C
N
B
A
G
N
C
B
A
Figure 3-8. Multiple Circuit Breaker Panel Wiring
Conduit provides a safety ground connection
for individual panels.
Ground Bus (Isolated
from Breaker Panel)
G
2
2
Main Power Circuit
Breaker Panel
Emergency Disconnect Switch
Neutral Bus (Isolated
from Breaker Panel)
C
N
B
From Main Power
Distribution Panel
2
Circuit Breaker
Panel
System
Cabinet
Power
System
Cabinet
Power
System
Cabinet
Power
System
Cabinet
Power
N
A
B
C
Ground Bus (Isolated
from Breaker Panel)
G
N
Neutral Bus (Isolated
from Breaker Panel)
G
2
Circuit Breaker
Panel
3
1
Notes:
N
G
Isolated
Ground
Receptical
Computer
Power
Console
Power
Console
Power
3-10
AC Power Distribution
Multiple Circuit Breaker Panel Wiring
Revision B — October 1995
AC Power Distribution
3-11
From Main
Distribution Panel
ÆA
N
ÆC
ÆB
1
Circuit Breaker Panel
B
C
2
3
1
Twist Lock,
PROVUE
2
3
PROVUE
and OWP
2
CP6103
Power
Supply
2
OWP
Neutral Bus (Isolated
from Breaker Panel)
Isolated
Ground
Receptacle
N
Ground Bus (Isolated
from Breaker Panel)
Notes:
1
Conduit provides a safety ground connection for individual panels.
2
Circuit breaker as required by national codes and regulations.
3
Second phase required if console has dual circuit power utility strip.
Figure 3-9
Revision B — October 1995
Single Circuit Breaker Panel Wiring
PN1:003
3-12
AC Power Distribution
3.2
System Cabinets
All ac power for the system cabinets is routed from a circuit breaker
panel, as shown in Figure 3-8 and Figure 3-9, and is connected to the
Type CP7101 Power Distribution Panel assembly located in a system
cabinet when Type CP6101 or CP6102 Power Supplies are used, or
directly to the power supply when a Type CP6103 Power Supply is used.
3
3.2.1
Using Type CP6101 and CP6102 Power Supplies
Each Type CP7101 Power Distribution Panel assembly contains one or
two separate ac circuits. as shown in Figure 3-10. These circuits supply
power to the two twistlock receptacles and the duplex receptacle in the
panel. One twistlock receptacle is dedicated to the primary power. The
second twistlock receptacle is dedicated to the backup power supply, if
supply redundancy is selected. The duplex receptacle, with its own
circuit breaker, is used for the cooling fans within the cabinet.
Each twistlock receptacle in power distribution panels used in nominal
100 or 120 volt ac systems must be supplied from a separate 20 ampere
circuit breaker. Each twistlock receptacle in nominal 200, 220, or 240 volt
ac systems must be supplied from a 15 ampere circuit breaker. The
duplex receptacle is connected in parallel with the primary twistlock
receptacle through a 15 ampere (120 Vac) or 7.5 ampere (240 Vac)
circuit breaker internal to the power distribution panel.
All ac power cords between the conduit utility box and the power
distribution panel should be connected to the utility box as shown in
Figure 3-10. All ac power supplied to a single cabinet grouping must be
tied to the same ground system at the power source neutral to ground
point.
3.2.2
Using Type CP6103 Power Supply Units
Each Type CP6103 Power Supply Unit contains one or two power
supplies, as shown in Figure 3-11. Terminal blocks are provided for two
ac input sources which allows each power supply to be connected to a
separate ac source. Separate dc output terminals are provided on the
front of the housing for each power supply. The chassis of the power
supply unit is internally bonded to the ground terminal of each ac input
terminal block.
PN1:003
Revision B — October 1995
3-13
AC Power Distribution
Cable
Clamp
Utility Box
System Cabinet Assembly
ÆA
N
1
Power Input
from Circuit
Breaker
Panel
2
To Primary
Power
Supply
5
N
4
ÆA
Top View
3
Primary
Power
Cable
To
Cabinet
Fans
3
6
Front View
N
N
ÆB
ÆA = Phase A
ÆB = Phase B
N = Neutral
= Ground
ÆA
To Back-up
Power
Supply
5
Top View
Secondary
Power Cable
Notes:
(if Selected)
Ground Stud on
Distribution Panel
1
Connections inside of utility box may be to a terminal block or wire nut connections.
2
Conduit provides a safety ground connection for the utility box.
3
Pushbutton reset circuit breaker rated at 7.5 (240 Vdc) or 15 (120 Vdc) Amperes.
4
Power cable connections to the power distribution panel are factory wired.
5
Example shows NEMA L5--20R receptacle.
6
Example shows NEMA 5--15R receptacles.
Figure 3-10 System Cabinet AC Power Connections for Type CP6101 and Type
CP6102 Power Supplies
Inputs from each terminal block are routed through a 1 pole 15 ampere
circuit breaker to an auxiliary terminal block for use by auxiliary
equipment. The type of equipment normally connected to the auxiliary
terminals are cabinet fans, modems, and other light loads. Since the
terminal block is tied to the power supply source, you do not want any
power problems in the auxiliary to cause the main breaker to trip.
Therefore, use a 20 A breaker for 600 W power supply and a 30 A
breaker for a 1200 W power supply. In no case, use higher than a 30 A
breaker per branch circuit.
Revision B — October 1995
PN1:003
3-14
AC Power Distribution
3
AC Input 1
L
+
26Vdc (PS1 Output)
--
3
N
1
AUX
Output 1
2
AUX
Output 2
+
26Vdc (PS2 Output)
--
L
N
Type CP6103 System Power Supply Unit
Notes:
2
Rocker ON/OFF switch/circuit breaker for auxiliary ac outputs
Two wires can be connected to each terminal
3
Input 1 and Input 2 shall be supplied from separate dedicated circuit breakers
1
3
AC Input 2
Figure 3-11 System Cabinet AC Power Connections for Type CP6103 Power Supply
Units
PN1:003
Revision B — October 1995
3-15
AC Power Distribution
3.3
Consoles and Computers
All ac power for the console or computer equipment is routed from a
circuit breaker panel (this can be the same panel as the cabinet
equipment), as shown in Figure 3-8 and Figure 3-9. The ac power
requirements for the console or computer must be provided at the point
of connection to the console or computer equipment. For voltage and
frequency requirements, refer to the product bulletin for the equipment.
Power for console components is supplied from a utility power strip
located inside each console bay unit or auxiliary console bay assembly
as shown in Figure 3-12. All utility power strips in a console grouping
must receive power from the same circuit breaker panel. Consoles with a
single-circuit utility power strip are supplied single-phase power from
separate circuit breakers. A 15 ampere breaker is used for nominal 120
volt ac systems, and a 10 ampere breaker is used for 220 or 240 volt ac
systems.
Power for components installed in Type CP9411 System Cabinets and
DC9410-Series Control Room Furniture (OWP wall units) is supplied
from utility strips (located inside the cabinet or wall unit) as shown in
Figure 3-13, Figure 3-14, and Figure 3-15. Figure 3-16 shows the power
distribution in the electronics enclosures available for wall units.
For the system cabinets, input power from a breaker is connected to a
terminal block inside the cabinet. For wall units, connection to the utility
power strip is provided by an IEC input power cord (country specific). All
utility power strips in a cabinet grouping must receive power from the
same circuit breaker panel. Wall units with single circuit utility power
strips are supplied power from separate circuit breakers.
As shown in Figure 3-17, computer cabinets are normally supplied power
from a utility box through power cords to a power distribution unit inside
the cabinet. For a 120 volt ac, 60 hertz single bay computer, the
computer power distribution unit must be supplied either from two
single-phase 120 volt power circuits with neutrals connected together, or
from a 120/240 volt ac circuit. For a multibay computer, the computer
power distribution unit can be supplied from three-phase 208Y/120 volt
ac power circuits. Each phase conductor can be supplied through a
separate 20 A circuit breaker which is part of a ganged circuit breaker.
For a 220 or 240 volt, 60 hertz, single bay computer, the computer power
distribution unit must be supplied from a 20 A circuit breaker, 220 or 240
volt, single-phase branch circuit. For a multibay computer, the computer
power distribution unit must be supplied from a 30 A circuit breaker, 220
or 240 volt, single-phase branch circuit.
Revision B — October 1995
PN1:003
3
3-16
AC Power Distribution
Console Bay Unit or Auxiliary Console Bay Assembly
Utility Box
Power
Input from
Circuit
Breaker
Panel
Utility Power Strip
N
4
N
G
G
2
3
1
Top View
Ground
Stud
N
G
= Neutral
= Ground
To Console
Components
(as required)
Notes:
1
AC power cable and plug connections to
the utility strip are factory wired.
2
For installations which include an isolated
ground receptacle, a three-wire, isolated
ground receptacle, is supplied with
consoles that have a single-circuit utility
strip. Installations that do not include an
isolated ground receptacle should be
connected as shown in Figure 3-18.
Example shows NEMA L5--15R
receptacle.
3
Power cable connections to the utility power strip are factory wired.
Figure 3-12 Console AC Power Connections
Power Strip
Circuit
Breaker
Green
L
To Ground
White
Black
G
N
Power Input From Circuit
Breaker Panel
Figure 3-13 Cabinet AC Power Connections
PN1:003
Revision B — October 1995
3-17
AC Power Distribution
Cabinet
Power Strip 1
10 AMP
Breaker 1
HUB Group 1
1
1 AMP
HDL Group 1
1
1 AMP
WS Group 1
1
6.2 AMP
Total: 8.2 AMPS
3
4
Breaker 2
Circuit Breaker Box
Power Strip 2
3
10 AMP
Fan
Notes:
1
2
3
4
1 AMP
HDL Group 2
1
1 AMP
WS Group 2
1
6.2 AMP
Fan
0.4 AMP
2
4
10 AMP
Fan
3
1
Total: 8.6 AMPS
Power Strip 3
Breaker 3
HUB Group 2
Cabinet
Bus Bar
4
HUB Group 3
1
1 AMP
HDL Group 3
1
1 AMP
WS Group 3
1
6.2 AMP
Fan
To
Chassis
0.4 AMP
2
1 AMP
VT Terminal
Local
Ground
(External)
Total: 9.6 AMPS
Auto ranging input voltage
Fixed 115 or 230 input voltage
Customer supplied breaker and power cord
Terminal block (inside cabinet)
Figure 3-14 Type CP9411 System Cabinet Power Distribution
Revision B — October 1995
PN1:003
3
3-18
AC Power Distribution
Power Strip 4
1
0.2 AMP
Logic Module
1
2.5 AMP
Monitor
1
2.4 AMP
Monitor
1
2.4 AMP
AIU
10 AMP
Wall Unit
Breaker 4
3
5
3
Total: 7.50 AMPS
Breaker 5
Breaker 6
Power Strip 7
1
0.2 AMP
Logic Module
1
2.5 AMP
Monitor
1
2.4 AMP
Monitor
1
2.4 AMP
AIU
10 AMP
Wall Unit
Breaker 7
5
Power Strip 8
10 AMP
Wall Unit
Breaker 8
Circuit Breaker Box
Total: 7.03 AMPS
4
3.2 AMP
Adapter
1
0.32 AMP
Logging Printer
6
1.6 AMP
Color Printer
5
Total: 5.12 AMPS
2
Note:
1
2
3
4
5
6
Auto ranging input voltage
Removable IEC input cord (country specific)
Customer supplied breaker
Switch select voltage
Receptacle
Fixed 120, 220 or 240 input voltage
Figure 3-15 DC9410-Series Control Room Furniture Power Distribution
PN1:003
Revision B — October 1995
3-19
AC Power Distribution
Electronics
Enclosure Rack
Electronics
Enclosure
Power Strip
10 AMP
HUB Group
1
1 AMP
HDL Group
1
1 AMP
WS Group
1
6.2 AMP
Fan
3
0.4 AMP
2
Total: 8.6 AMPS
Black
Green
3
White
Notes:
1
2
3
Auto ranging input voltage
Fixed 115 or 230 input voltage
To external ac input
Figure 3-16 Electronics Enclosure Power Distribution
Power Cord
Utility Box
2
Power
Input from
Circuit
Breaker
Panel
Computer Cabinet
ÆC
4
Power Strip
3
1
ÆC
ÆC
ÆB
ÆA
ÆB
ÆB
ÆA
ÆA
Neutral
N
N
Chassis
Ground
ÆA = Phase A
ÆB = Phase B
ÆC = Phase B
N = Neutral
= Ground
Cable
Clamp
Notes:
1
For 3Æ operation remove jumper and add third phase as shown.
2
Conduit provides a safety ground connection for the utility box.
3
Wire nut connections inside of utility box.
4
An isolated ground receptacle and twist lock connector can also be used.
5. Connections shown are applicable to Hewlett-Packard system only.
Consult DEC manual for power input connections diagram.
Figure 3-17 Custom Computer AC Power Connections
Revision B — October 1995
PN1:003
3-20
AC Power Distribution
3.4
Peripheral Equipment
All peripheral equipment used with consoles and computers is powered
either from the utility power strips inside the console or computer cabinet,
or from remote isolated ground receptacles. These receptacles are
shown in Figure 3-8 and Figure 3-9 and detailed in Figure 3-18. Isolated
ground receptacles must be constructed and installed in such a way that
the ground terminal is electrically isolated from the conduit and the box in
which the receptacle is mounted.
3
If non-isolated communications or signal wiring is used, each peripheral
unit must receive ac power from the same circuit breaker panel as the
electronics unit or computer with which it interfaces. The load imposed
on the utility power strips by the peripherals and the electronics units
should be balanced between the utility power strips as much as possible.
However, if possible, connect the power cable for a console printer unit
or a console disk unit (hard) to a utility strip which is not supplying power
to a console electronics unit or a video display unit.
1
Line
Power Input
from Circuit
Breaker Panel
Neutral
Ground
Note:
1
Isolated ground receptacle for console and
computer remote peripherals is a 15 Amp, 120
Volt, 2-pole, 3-wire duplex receptacle, NEMA
type 5-15R, Orange in color or with orange
triangle.
Figure 3-18 Isolated Ground Receptacle Details
PN1:003
Revision B — October 1995
4-1
DC Power Distribution
Figure 4-Table 4
4
DC Power Distribution
All controller, I/O, multiplexer, or communications devices contained in a
system cabinet are powered by a nominal 24 volt dc power distribution
system. The system cabinets are available with a laminated bus bar
which distributes dc power to the devices in the cabinet. Power to this
bus bar can be obtained from system power supply units or from a
user-supplied dc source within the processing plant.
4.1
DC Voltage Nomenclature
As you look at PROVOXr equipment dc voltage markings and read the
PROVOX manuals, you will find small variations in the dc voltage
nomenclature. These variations follow the PROVOX system marking
conventions.
The system nominal dc voltage is +24 volts, and cabinet bus bars are
marked for the nominal voltage. The dc power supplies produce a range
of 24 to 26 Vdc, and the power supplies are marked for their nominal
output voltage. For example, the output terminals on the Type CP6103
System Power Supply Unit are marked as +26 Vdc and --26 Vdc. These
variations fall within the operating range of dc-powered PROVOX
equipment, which is 21 to 29 Vdc.
In this manual and other PROVOX manuals, dc voltages are indicated as
24 Vdc nominal where no particular device is referenced. If, however, a
specific device, such as a power supply, is being considered, then the
voltage indicated will be the voltage of the device.
4.2
DC Power Supplies
Type CP6101 and CP6102 System Power Supply units mount on EIA
rails at the bottom of a PROVOX system cabinet and are provided with
ac power through a Type CP7107 Power Distribution Panel. A second
power supply unit can be used for backup with both units connected
through the power distribution panel. Details for wiring the power supply
units are found in the appropriate power supply and power distribution
panel installation planning notes. For additional backup and power
outage protection, a user-supplied dc power source (either batteries or
dc power supplies) can be connected to the power distribution panel.
The Type CP6103 System Power Supply Unit mounts on EIA rails at the
bottom of a cabinet and are provided with ac power directly to the ac
Revision B — October 1995
PN1:003
4
4-2
DC Power Distribution
input terminal blocks on the power supply unit housing. The unit can
house two power supplies, one of which can be used to backup the
other. Details for wiring the power supply units are found in Installing and
Maintaining Type CP6103 System Power Supply Unit Manual,
PN2.1:CP6103.
In a multi-cabinet distribution using Type CP6103 System Power Supply
Units, a DC Distribution Assembly should be mounted in the central
cabinet and used for distributing dc power to the cabinets. The power
supply units should be mounted in the central cabinet with the DC
Distribution Assembly.
4
The voltage at the bus bars mounted in the cabinets is nominally 24 volts
dc. However, the different voltages available from backup batteries and
power supplies, plus the varying voltage drops that occur in the
connecting wiring, can cause the voltage at each device to be higher or
lower. Be sure that the voltage at the device terminal connections is
within the tolerance specified for each individual product (see the
appropriate product bulletin for these specifications).
4.3
DC Power Recommendations
When designing the dc power distribution system, the overall process
strategy needs to be reviewed to make sure that the system can provide
the reliability to the process management system as required by the
process.
Note
Process management system availability can be
an overlooked aspect of dc power distribution
system design. Availability is more than simply
redundant controllers, I/O cards, and
communications. It may also require redundant dc
power distribution.
A good review reveals what level of redundancy is needed. Redundancy
can mean simple backup of power supplies, or can mean two separate
dc power systems supplying power to separate, but redundant, I/O and
controller files in separate cabinets.
Figure 4-1 shows the typical terminations for the Type CP6101 and Type
CP6102 System Power Supply units, the Type CP7101 Power
Distribution Panel (PDP), and bus bars in system cabinets. Cabinets 1
through 3 show a typical system with three cabinets, three primary
supplies, and one backup supply. The backup supply is normally load
PN1:003
Revision B — October 1995
4-3
DC Power Distribution
sharing with the three primary supplies, so all four supplies are in use.
Therefore, should one of the primary supplies or the backup supply fail,
there is no power loss at the load.
The backup supply must be connected to the same Local Ground Bus
(LGB) as the associated primary supplies. A backup supply can back up
a primary supply in a separate cabinet if the total length of multistrand,
8-AWG (8.35 mm2), wire between the backup supply, primary supply,
and the local ground bus (LGB) does not exceed 21 feet (6.4m). The
length is from the supply to the PDP to the bus bar and back to the
power supply common (PSC).
An alternate redundant bus method is also shown in Figure 4-1 at
cabinets 4 and 5. This method can be used when two or three adjacent
cabinets require a total input current of less than 35 amperes. The bus
bars can be connected together and receive power from the redundant
power supply unit.
Figure 4-3 illustrates simplex dc power distribution with redundant Type
CP6101 and Type CP6102 power supplies and Figure 4-6 illustrates fully
redundant dc power distribution with Type CP6101 and Type CP6102
power supplies.
Figure 4-2 shows the typical termination for the Type CP6103 System
Power Supply Units and bus bars in system cabinets. Cabinets 1 through
3 show a typical system with three cabinets, three primary supplies, and
three secondary supplies. The secondary power supplies are normally
load sharing with the primary supplies. If either the primary or secondary
supply fails, there is no power loss at the load.
An alternate method is also shown in Figure 4-2 at cabinets 4 and 5.
This method can be used when two adjacent cabinets require a total
input power of less than one 600 Watt (23 A) or 1200 Watt (46 A) power
supply. Both sets of bus bars can be connected to one power supply
unit. The bus bars can be installed in separate cabinets or in a front and
rear access cabinet.
Figure 4-4 illustrates a dual simplex dc power distribution configuration,
with two power supplies in a single Type CP6103 Power Supply Unit.
Figure 4-5 illustrates a redundant dc power distribution configuration with
two power supplies in a single Type CP6103 Power Supply Unit.
Figure 4-7 illustrates an alternate dc power distribution with two power
supplies in a single Type CP6103 Power Supply Unit, providing power for
three cabinets. The terminal blocks (TR1 +/-- and TR2 +/--) are installed
on a DC Distribution Assembly, and are used to organize and simplify
connections. Use No. 8 AWG insulated wire: red for all +24 V wiring and
black for all --24 V wiring.
Figure 4-8 shows the general wiring to a DC Distribution Assembly. The
terminations on the assembly are arranged similarly to those on a Type
Revision B — October 1995
PN1:003
4
4-4
DC Power Distribution
CP6103 Power Supply Unit. The assembly is capable of supplying eight
bus bars. It should be mounted below the power supply unit for easy
access and organization of dc power wiring.
Figure 4-9 shows the details of the power and alarm connection terminal
block on a Type CP6103 Power Supply Unit.
4.4
DC Power Connections
All dc power to the devices located in the system cabinets is obtained
from the cabinet laminated bus bar. Terminations of typical products are
shown in Figure 4-12 through Figure 4-14 and are detailed in the
installation planning manual for each product. Each product requires
nominal +24 Vdc and power supply common (PSC) connections. The
terminations are made to the laminated bus bar by using stranded wire
with a minimum size of 12 AWG (3.30 mm2). Use red wire for +24 Vdc
and black for PSC (--24 Vdc).
4
Connect the PSC circuits at a common point beyond which no additional
power supply return currents flow. The connection point can be at the
local ground bus (LGB) or master ground bus (MGB) for systems using
Type CP6101 and Type CP6102 Power Supplies, at the local ground bus
(LGB) for systems using Type CP6103 Power Supply Units.
If dc power for remotely located Control I/O termination panels is
obtained from the same source as the Control I/O card files, as shown in
Figure 4-10, there must be less than 1 volt drop across the power leads
to the termination panels. The distance between the card files and the
remote termination panels must not exceed 200 cable feet (61 m). If dc
power is applied from a separate source, the ground and returns must be
referenced to the same point. Also, ac power must be obtained from the
same ac power distribution system.
4.5
Field Transmitter Power
DC power for field transmitters should not be obtained directly from the
24V bus bar, but should be obtained from the fused terminations on the
individual card files or termination panels that are designed exclusively
for powering the transmitters. AC Power for ac-powered field devices
(such as relays, solenoids, and transmitters) must not be the same ac
power used to power the process management system. The two ac
power sources must be isolated to prevent ground loops.
PN1:003
Revision B — October 1995
Figure 4-1
Revision B — October 1995
3
PIG
4
+24V
SEC
+24
PRI
+24
PSC
2
COM
SEC
+24
PRI
+24
PSC
Cab Gnd
Master
Ground
Bus
+24V
PSC
4
4
3
Cabinet ground should be at least 0.5 in. (12.7 mm) braid wire.
Wiring from master ground bus to single-point DC ground should be at
least No. 4/0 AWG (107.16 mm 2) insulated wire.
Notes:
Breaker for +24V
1
Master ground should be located in center cabinet or area of grouping.
2
PSC
COM
System Power
Supply
Cabinet
Bus
Bar
7
6
5
SEC
+24
PRI
+24
PSC
Optional
Rear
7
Bus Bar
SEC
+24
PRI
+24
PSC
6
Local
Ground
Bus
+24V
System Power
Supply
COM
Power Distribution
Panel
1
PWR
BTRY
PS 1
PS 2
+24V
System Power
Supply
COM
Power Distribution
Panel
1
PWR
BTRY
PS 1
PS 2
System Cabinet 5
Wiring to local ground bus should be at least No.
8 AWG (8.35 mm2) insulated wire.
Optional rear bus bar (typical)
Wiring from local ground bus to master ground bus
should be at least No. 1/0 AWG (53.46 mm2)
insulated wire.
5
System Cabinet 4
Figure 4-1. Typical DC Power System and Ground Connections for System Cabinets
with Type CP6101 and CP6102 Power Supplies
Dedicated Plant Ground
Grid Point
Grounded
Steel Column
Isolation
Transformer
4
Legend:
PSC = Power Supply Common
+24V = Normal 24 Volts
SEC
+24
SEC
+24
PSC
PRI
+24
+24V
PSC
PWR
BTRY
PS 1
PS 2
PWR
BTRY
PS 1
PS 2
System Power
Supply
Power Distribution
Panel
1
+24V
System Cabinet 3
Power Distribution
Panel 1
COM
System Power
Supply
System Cabinet 2
PRI
+24
PSC
COM
System Power
Supply
PWR
BTRY
PS 1
PS 2
Power Distribution
Panel
1
System Cabinet 1
DC Power Distribution
4-5
4
Typical DC Power System —CP6101/CP6102
PN1:003
Figure 4-2
PN1:003
Figure 4-2.
2
PIG
2
1
SEC
+24
PRI
+24
PSC
Cab Gnd
Master
Ground
Bus
+ 26V (PS1)
-+ 26V (PS2)
--
System Power
Supply Unit
SEC
+24
PRI
+24
PSC
3
Cabinet
Bus
Bar
3
2
Cabinet ground should be at least 0.5 in. (12.7 mm) braided wire.
Wiring from master ground bus to single-point dc ground should be at
least No. 4/0 AWG (107.16 mm 2) insulated wire.
6
5
4
3
SEC
+24
PRI
+24
PSC
Optional
6
Rear
Bus Bar
SEC
+24
PRI
+24
PSC
5
System Cabinet 5
Local
Ground
Bus
System
Power
Supply
Unit
+
-- 26V (PS1)
+
-- 26V (PS2)
Optional rear bus bar (typical)
Wiring to local ground bus should be at least
No. 8 AWG (8.35mm2) insulated wire.
Wiring from local ground bus to master ground bus
should be at least No. 1/0 AWG (53.46 mm 2)
insulated wire.
4
Top
System Cabinet 4
Notes:
Master ground should be located in center cabinet or area of grouping.
1
3
SEC
+24
SEC
+24
Local
Ground
Bus
PRI
+24
PSC
PRI
+24
PSC
+
-- 26V (PS1)
+ 26V (PS2)
--
System Cabinet 3
Typical DC Power System and Ground Connections for Cabinets with Type CP6103 Power Supply Units
Dedicated Plant Ground
Grid Point
Grounded
Steel Column
Isolation
Transformer
3
Legend:
PSC = Power Supply Common
+24V = Normal 24 volts
SEC
+24
PRI
+24
PSC
+
-- 26V (PS1)
+
-- 26V (PS2)
System Power
Supply Unit
System Cabinet 2
4
System Power
Supply Unit
System Cabinet 1
4-6
DC Power Distribution
Typical DC Power System and Ground Connections for Cabinets with Power
Supplies
Revision B — October 1995
4-7
DC Power Distribution
Optional
Rear Bus Bar
Cabinet
Bus Bar
COM
PSC
PSC
+24V
PRI +24
PRI +24
SEC+24
SEC+24
+24V Breaker
PWR Out
BTRY Backup
PS 1
PS 2
PSC
PSC
Optional Backup
System Power Supply
Power Distribution
Panel
PSC
4
PSC
COM
PRI +24
PRI +24
SEC+24
SEC+24
+
+24V
System Power Supply
--
Optional
Battery Backup
Figure 4-3
Local Ground Bus
Simplex DC Power Distribution with Redundant Type CP6101 and
Type CP6102 Power Supplies
Optional
Rear Bus Bar
Cabinet
Bus Bar
Optional
Rear Bus Bar
Cabinet
Bus Bar
Connections
at Top of Bar
Connections
at Top of Bar
PSC
PSC
PSC
PSC
PRI +24
PRI +24 PRI +24
PRI +24
SEC+24
SEC+24 SEC+24
SEC+24
Cab #2
Cab #1
PSC
PSC
PSC
PSC
PRI +24
PRI +24
PRI +24
PRI +24
SEC+24
SEC+24
SEC+24
SEC+24
Local Ground Bus
Figure 4-4
+
26V (PS1)
-+
26V (PS2)
--
System Power
Supply Unit
Note: One power supply housing can
handle two power supplies in a simplex or redundant mode of operation.
The power supply is mounted in the
central cabinet of a three or more
cabinet system
Dual Simplex DC Power Distribution with a Type CP6103 Power Supply
Unit
Revision B — October 1995
PN1:003
4-8
DC Power Distribution
Optional
Rear Bus Bar
Cabinet
Bus Bar
Connections
at Top of Bar
PSC
PSC
PRI +24
PRI +24
SEC+24
SEC+24
Note: One power supply housing can handle two power supplies in a simplex or redundant mode of operation.
4
PSC
PSC
PRI +24
PRI +24
SEC+24
SEC+24
+
26V (PS1)
-+
26V (PS2)
--
System Power
Supply Unit
Local Ground Bus
Figure 4-5
Redundant DC Power Distribution with a Type CP6103 Power Supply
Unit
Optional
Rear Bus Bar
Cabinet
Bus Bar
PSC
PSC
PRI +24
PRI +24
SEC+24
+24V Breaker
PWR Out
BTRY Backup
PS 1
PS 2
SEC+24
+24V
PSC
PSC
PRI +24
PRI +24
SEC+24
SEC+24
PSC
PSC
PRI +24
PRI +24
SEC+24
SEC+24
+24V Breaker
PWR Out
BTRY Backup
PS 1
PS 2
COM
PN1:003
+24V
Optional Backup
System Power Supply
Primary Power
Distribution Panel
PSC
System Power Supply
--
Optional
Battery Backup
Figure 4-6
PSC
Connections
at Top of Bar
COM
+
Secondary Power
Distribution Panel
Local Ground Bus
Fully Redundant DC Power Distribution with Type CP6101 and Type
CP6102 Power Supplies
Revision B — October 1995
4-9
DC Power Distribution
System Cabinet 1
Cabinet
Bus Bar
System Cabinet 2
4
Optional
Rear
Bus Bar
System Cabinet 3
PRi
PS1
Cabinet
Bus Bar
SEC
PS2
PSC
PSC
PRI
+24
PRI
+24
SEC
+24
SEC
+24
Connections
at Top of Bar
E
B
5
A
L
H
D
G
PSC
K
D
PRI
+24
A
SEC
+24
PSC
PSC
PRI
+24
PRI
+24
SEC
+24
K
TR1 TR1 TR2 TR2
+
—
+
—
Optional
Rear
Bus Bar
Cabinet
Bus Bar
Connections
at Top of Bar
SEC
+24
6
4
Type CP6103
Power Supply
Unit
+
-- 26V (PS1)
+ 26V (PS2)
--
PSC
PRI
+24
5
SEC
+24
G
3
1
2
7
PSC
L
E
PRI
+24
B
SEC
+24
H
5
Local
Ground
Bus
Cab Gnd
2
Isolation
Transformer
Notes:
Grounded
Steel Column
Dedicated Plant Ground
Grid Point
Figure 4-7
PIG
1
Local ground and power supply must be located in center cabinet or area of grouping.
2
Wiring from master ground bus to single-point DC ground should be at least No. 4/0
AWG (107.16 mm2) insulated wire.
3
Cabinet ground should be at least 0.5 in. (12.7 mm) braided wire.
4
Optional rear bus bar (typical)
5
Letters indicate wiring from the terminal blocks to the
corresponding letters on bus bars: i.e. A to A, B to B, etc.
6
Terminal blocks on the DC Distribution Assembly. The assembly should
be installed under the Type CP6103 Power Supply Unit.
7
The bus bar in the cabinet with the power supply must be connected
directly to the terminal block on the Type CP6103 Power Supply Unit.
Typical DC Power System and Ground Connections for Cabinets with
a Type CP6103 Power Supply Unit.
Revision B — October 1995
PN1:003
4-10
DC Power Distribution
+
-- 26V (PS1)
+ 26V (PS2)
--
Type CP6103 System
Power Supply Unit
DC Distribution Assembly
26 VDC PS2 (Sec)
+
+
--
IN
OUT
+
26 VDC PS1 (PRI)
+
--
--
IN
OUT
--
Note: the DC Distribution Assembly should be installed under the power supply unit
4
Figure 4-8
DC Distribution Assembly and Type CP6103 Power
Supply Unit.
PS1
(RIGHT)
+
26 VDC
OUTPUT
--
dc output block
+
26 VDC
OUTPUT
-PS2
(LEFT)
ALARM
INTL.
Alarm connections
PS2
Figure 4-9
PN1:003
PS1
N.O.
COM.
N.C.
Terminal Block Details for a Type CP6103 System
Power Supply Unit
Revision B — October 1995
DC Power Distribution
I/O File Cabinet
Remote Termination Panels
PSC
PSC
PRI
+24
SEC
+24
Control
I/O File
PSC
PRI
+24
SEC
+24
Control
I/O File
PRI
+24
SEC
+24
PSC
PRI
+24
SEC
+24
+
-- 26V (PS1)
+ 26V (PS2)
--
1
PRI
+24
Termination
Panel
200 Feet Maximum
Wiring Distance
Type CP6103
Power Supply Unit
PSC
4-11
A
C
SEC
+24
E
D
PSC
1
PRI
+24
5
F
B
SEC
+24
4
4
Termination
Panel
D
C
F
5
E
To Termination
Cabinet Bus Bars
LGB/MGB
To PIG
TRI
+
TR1
--
TR2
+
To Power
supply
TR2
--
2
Cabinet
Ground
3
Notes:
1
Wire must be sized such that the PRI to PSC voltage measured at bus B does not vary more than 1 volt maximum
from the PRI to PSC voltage measured at bu A (without the secondary power supply on.
2
For two or more termination cabinets per supply, use a DC Distribution Assembly arrangement in the central cabinet
for busing the power.
3
Cabinets grounds are tied together and brought back to the MGB or PIG. In the case were no MGB is used, only an
LGB is tied to the PIG.
C, D, E, and F power supply to remote termination bus.
The connection may be made from a DC Distribution Assembly instead of a power supply unit.
4
5
Figure 4-10 Control I/O Remote Termination Power
Revision B — October 1995
PN1:003
4-12
DC Power Distribution
Secondary
+24V
Primary
+24V
Simplex Power Connect
PSC
TB!
2
PSC
Pri +24V
Sec +24V
Redundant Power
Connection
1
Shield
4
Control I/O
Card File
Panel Mounting Screw
Discrete I/O
Cable Interface
Panel
TB!
PSC
Pri +24V
Sec +24V
Simplex Power
Connection
Redundant Power
Connection
Panel Mounting Screw
Shield
Redundant
Discrete I/O
Termination
Panel
TB2
TB!
PSC
Pri +24V
Sec +24V
Redundant Power
Connection
Simplex Power
Connection
Shield
Redundant
Pulse Count
Input
Termination
Panel
TB2
Panel Mounting Screw
TB!
PSC
Pri +24V
Sec +24V
Simplex Power
Connection
Redundant Power
Connection
Panel Mounting Screw
Shield
Redundant
5 Amp Relay
Output
Termination
Panel
TB2
Notes:
1
Dashed lines indicate connection when using redundant power. When simplex power is used, jumper termination
primary +24V and secondary +24V together.
2
Wires from +24V and PSC buses to cardfiles should be insulated and stranded of size 12 AWG (3.3 mm2).
Figure 4-11 Control I/O Power Connections
PN1:003
Revision B — October 1995
4-13
DC Power Distribution
Secondary
+24V
Primary
+24V
PSC
Shield
Panel Mounting Screw
2
Analog Input
Cable Interface
Panel
TB!
PSC
Pri +24V
Sec +24V
Simplex Power Connection
Redundant Power
1
Connection
Panel Mounting Screw
Shield
Single-ended
Analog Input
Termination
Panel
4
TB2
TB!
PSC
Pri +24V
Sec +24V
Simplex Power Connection
Redundant Power
Connection
Shield
Isolated
Analog Input
Termination
Panel
TB2
Panel Mounting Screw
Shield
Analog Output
Cable Interface
Panel
Shield
Analog Output
Termination
Panel
Panel Mounting Screws
A
B
RTN
J13
Type CL6922
Intelligent Device
Interface and
Type CP7801 I/O
Bus Interface
Type CL6923
Intelligent Device
Interface
Notes:
1
Dashed lines indicate connections when using redundant power. When simplex power is used, jumper termination
primary +24V and secondary +24V together
2
Wires from +24V and PSC buses to cardfiles should be insulated and stranded of size 12 AWG (3.3 mm2).
Figure 4-12 Control I/O Power Connections (Continued)
Revision B — October 1995
PN1:003
4-14
DC Power Distribution
Secondary
+24V
Primary
+24V
PSC
Shield
Panel Mounting Screw
2
TB!
PSC
Pri +24V
Sec +24V
1
4
Analog Input
Cable Interface
Panel
Shield
Redundant
Single-ended
Analog Input
Termination
Panel
TB2
Panel Mounting Screw
TB!
PSC
Pri +24V
Sec +24V
Shield
Redundant
Isolated
Analog Input
Termination
Panel
TB2
Panel Mounting Screw
Shield
Analog Output
Cable Interface
Panel
Panel Mounting Screw
TB!
PSC
Pri +24V
Sec +24V
Redundant
Analog Output
Termination
Panel
Shield
Panel Mounting Screw
TB2
Notes:
1
When redundant terminations are needed, the use of redundant power is recommended.
2
Wires from +24V and PSC buses to cardfiles should be insulated and stranded of size 12 AWG (3.3 mm2).
Figure 4-13 Control I/O Power Connections (Continued)
PN1:003
Revision B — October 1995
DC Power Distribution
Primary
+24V
Secondary
+24V
4-15
PSC
SRx Controller
(20 Series)
UOC/IFC
1 2 3 4 5 6 7
PSC
+24V PRI
+24V SEC
FAN
PSC
1
To +-terminal
on fan Tray
+ --
TB3
+24V PSC
4
SR90 Controller
Highway II Bridge
+ --
Highway II Fiber
Optic Extender
PSC
PSC
+24V
PSC
PSC
+24V
PSC
PSC
+24V
PSC
PSC
+24V
Local Traffic Director,
Network Traffic
Director, Highway
Interface Unit
Serial Interface
Unit
Virtual I/O Coupler
Card File
Programmable
Controller
Interface Unit
Notes:
1
Wires from +24V and PSC buses to cardfiles should be insulated and stranded of size 12 AWG (3.3 mm2).
Figure 4-14 Highway Device Power Connections
Revision B — October 1995
PN1:003
4-16
DC Power Distribution
4
This page intentionally left blank.
PN1:003
Revision B — October 1995
5-1
Cabinet Alarm Wiring
Figure 5-Table 5
5
Cabinet Alarm Wiring
PROVOXr system cabinets can be equipped with alarm circuits to detect
loss of output from a power supply unit, loss of battery backup, cabinet
over-temperature, and loss of power to an installed PROVOX device. As
shown in Figure 5-1, Figure 5-2, and Figure 5-4, the outputs of the
device alarm circuits are connected in series to operate an alarm relay.
When you use Types CP6101 and CP6102 System Power Supplies, the
alarm relay is included in the Type CP7101 Power Distribution Panel
(PDP). When you use Type CP6103 System Power Supply Unit, the
alarm relay is included in the unit.
The alarm relay provides a dry contact closure to a user-supplied
external alarm annunciator. If a controller card file, a local traffic director,
or a network traffic director has two power converter cards installed in a
single card file, the two alarm circuit outputs are connected in series to
indicate a low voltage or loss of output from either power converter card.
The alarm circuits are flexible for any application. Although the alarm
circuits for a single cabinet are typically connected in series to provide a
single cabinet alarm, as shown in Figure 5-1, Figure 5-2, and Figure 5-4,
each individual circuit or any combination of circuits in a device can be
connected to produce individual alarm indications.
5.1
System Using Types CP6101 and CP6102
Power Supply Units
Figure 5-1 shows the alarm connections for a system using a Type
CP6101 or Type CP6102 Power Supply Unit, using one or two Type
CP7101 Power Distribution Panels (PDP). A fuse pigtail is connected to
the PRI 24 Vdc connection at the top of the power bus. This fuse is then
connected to the cabinet thermal switch. From the switch, the alarm
wiring is routed to any file alarm connections, as shown in Figure 5-4
through Figure 5-3, and to the controller alarm outputs as included in the
alarm configuration.
One system alarm can be used, or several, depending on the alarm
configuration and the number of PDPs in the system. Alarm wiring can
go from cabinet to cabinet in a serial link. As you go from one cabinet to
another, you will need to put the thermal switch in the link. The PDP
must get 24 V into the alarm input terminals (INTLK) on the PDP. The
PSC terminal must be connected to the bus bar. Refer to Figure 5-1 for
an illustration of redundant power source alarming.
Revision B — October 1995
PN1:003
5
5-2
Cabinet Alarm Wiring
5.2
System using Type CP6103 Power Supply
Units
Figure 5-2 shows the alarm connections for the Type CP6103 System
Power Supply Unit. The type CP6103 Power Supply Unit provides a
26 Vdc power source and protection for the alarm circuit. Connect to the
cabinet thermal switch from the power supply, then route through the file
and alarm circuits back to the supply.
The power supply unit contains separate alarm connections for each
power supply. The alarm and interlock terminal blocks connect to alarm
relay contacts and interlocks in the power supplies. The alarm terminal
blocks do not require wire terminating lugs.
5
To cause either power supply relay to function as a combined alarm
relay, connect any number of external alarm contacts that are closed
during normal equipment operation in series and wire them across the
interlock terminal connection of the power supply. If the interlock
connections of an installed power supply are not connected to external
alarm contacts, jumper the connections to enable the power supply
alarm relay to operate properly.
To use only one combined alarm for a cabinet, wire the output alarm
contacts for one power supply into the interlock circuit of the other power
supply. The alarm chain starts and ends at the power supply alarm
interlock (INTLK) connections. Use PS1 and route to the cabinet thermal
switch, then to chain, and back to PS1 interlock. This completes the
serial alarm chain. If you are not using an alarm chain, jumper the
interlock connections. For example, for a redundant system, the PS2
interlock (INTLK) should be jumpered. For two simplex systems which
are not using the alarm chain, both interlock circuits would be jumpered.
5.3
Device Alarm Wiring
Figure 5-4 through Figure 5-3 illustrate typical alarm wiring to PROVOX
devices installed in a PROVOX system cabinet. All devices being
powered from a Type CP6101, CP6102, or CP6103 power supply unit
must be referenced to the same LGB or MGB. Devices connected only
by a Control I/O bus or PROVOX highway cable do not require the same
ground reference since both communication systems provide isolation
between the devices.
PN1:003
Revision B — October 1995
Cabinet Alarm Wiring
5-3
Cabinet Thermal Switch
PSC
Control I/O
Card File
TB!
PRI
+24
SEC
+24
4 A Fuse
PSC
Pri +24V
Sec +24V
Alarm Contact 1
Alarm Contact 2
Alarm Common
Power Bus
Bar
1
Control I/O
Card File
TB!
PSC
Pri +24V
Sec +24V
Alarm Contact 1
Alarm Contact 2
Alarm Common
5
SR90 Controller
Alarm
Contact(s)
PSC
PRI
+24
SEC
+24
2
N.C.
COM Alarm Out
N.O.
INTLK (Alarm In)
PSC
Power Bus
Bar
Power Distribution
Panel
Alarm Wiring
3
PSC
SEC
+24
PSC
N.C.
COM Alarm Out
N.O.
INTLK (Alarm In)
PSC
Power Distribution
Panel (PRI)
Details of Redundant
PDP Alarm Wiring
N.C.
COM Alarm Out
N.O.
INTLK (Alarm In)
PSC
Power Distribution
Panel (SEC)
1
For simplex operation, use the common terminal and connect to the Alarm 1 terminal. Install the
Power/Communications card in Slot 1.
2
For SR90 controller, connect alarm wiring in series to the alarm contacts for each controller in the file.
3
For a single alarm output, make the dotted line connection.
Figure 5-1
Types CP6101 and CP6102 Power Supply Alarm Wiring Example
Revision B — October 1995
PN1:003
5-4
Cabinet Alarm Wiring
To Files
From Files
Control I/O
Card File
TB!
PSC
Alarm
Intl.
Pri +24V
Sec +24V
Alarm Contact 1
Alarm Contact 2
Alarm Common
N.O.
COM
External
Alarms
PSC
PS1
PS2
Wiring Detail for One External
Alarm Relay Output
5
Control I/O
Card File
TB!
N.C.
1
Pri +24V
Sec +24V
Alarm Contact 1
Alarm Contact 2
Alarm Common
From Files
To Files
Alarm
Contacts
Alarm
Intl.
SR90 Controller
2
N.O.
COM
External
Alarms
N.C.
PS2
External
Alarms
Alarm
Intl.
N.O.
COM
N.C.
PS1
Wiring Detail for Two External
Alarm Relay Outputs
1
2
PS2
Type CP6103
System Power
Supply Unit
PS1
For simplex operation, use the common terminal and connect to the Alarm 1 terminal. Install the
Power/Communications card in slot 1.
For an SR90 controller, connect alarm wiring in series to the alarm contacts for each controller in the file.
Figure 5-2
Type CP6103 Power Supply Unit Alarm Wring Example
1
TB!
PSC
Control I/O
Card File
Pri +24V
Sec +24V
Alarm Contact 1
2
Alarm Contact 2
Alarm Common
Notes:
1
For systems using Types CP6101 and CP6102 System Power Supply Units for see
Figure 5-1 for connections. For systems using a Type CP6103 System Power Supply Unit,
see Figure 5-2 for connections.
2
Alarm contact 2 path used when secondary power converter card installed. Alarm
common path is used instead of alarm contact 2 path for single power converter card.
Figure 5-3
PN1:003
Features of Control I/O Card File Alarm Wiring
Revision B — October 1995
5-5
Cabinet Alarm Wiring
Cabinet Thermal Switch
1
Alarm
SRx Controller
Alarm Wiring
TB1
N.O.
Common
N.C.
I/O Driver
Card
UOC/IFC
(20 Series)
SR90 Controller
5
Alarm
Alarm
Highway II Bridge
Alarm
Alarm
PSC
PSC
+24V
Alarm
PSC
PSC
+24V
Highway II Fiber
Optic Extender
Highway Interface
Unit
Serial Interface
Unit
Notes:
For systems using Types
CP6101 and CP6102 System
Power Supply Units for see
Figure 5-1 for connections. For
systems using a Type CP6103
System Power Supply Unit, see
Figure 5-2 for connections.
1
2.
When redundant devices are
installed, you may wire their
alarm contacts in series with the
primary units or you may wire
them separately as shown in
Figure 5-5.
Figure 5-4
Alarm
PSC
PSC
+24V
Alarm
PSC
PSC
+24V
Virtual I/O Coupler
Card File
Programmable
Controller
Interface Unit
Highway Device Alarm Wiring
Revision B — October 1995
PN1:003
5-6
Cabinet Alarm Wiring
1
TB1
UOC/IFC
(20 Series)
[Redundant Unit]
N.O.A
Common
N.C.A
PSC
PSC
PSC
PSC
PSC
+24V
Redundant
Manual
Card File
Alarm Common
Alarm 1 N.O.
Alarm 2 N.O.
5
PSC
PSC
PSC
PSC
Pri +24V
Sec +24V
Alarm Common
Alarm 1 N.O.
Alarm 2 N.O.
Alarm
Highway Interface
Unit
[Redundant Unit]
Alarm
Serial Interface
Unit
[Redundant Unit]
Alarm
Virtual I/O Coupler
Card File
[Redundant Unit]
PSC
PSC
+24V
PSC
PSC
+24V
PSC
PSC
+24V
Alarm
PSC
PSC
+24V
Redundant
Controller
Card File
Programmable
Controller
Interface Unit
[Redundant Unit]
Notes:
1
Figure 5-5
PN1:003
For systems using Types CP6101 and CP6102 System Power Supply Units for
see Figure 5-1 for connections. For systems using a Type CP6103 System
Power Supply Unit, see Figure 5-2 for connections.
Redundant Highway Device Alarm Wiring
Revision B — October 1995
6-1
System Grounding
Figure 6-Table 6
6
System Grounding
The ground network for an instrumentation system is a very critical
consideration since this network affects the operation of the entire
control system. Thus, the extra time and effort spent in laying out a good
ground system will be rewarded by easier startup and more reliable
operation.
Poor or faulty grounds are among the most common causes of
instrumentation system problems. With the installation of a new
instrumentation system, an effective ground network can be installed at
the beginning. The expansion of an older system however, may use
grounding as it now exists. Depending upon the degree of expansion
and the types of ground network deficiencies in the older system, it may
be more cost effective to install a new ground network to ensure efficient
operation.
6.1
Guidelines for Effective Grounding
Following the guidelines listed below will provide effective grounding for
the instrumentation system. Explanations of the guidelines are included
in the following subsections.
J
J
J
J
J
J
Revision B — October 1995
Provide a ground network dedicated to the instrumentation system.
Do not share a ground network with other plant systems.
Design the ground network so that is is accessible for testing.
Isolate console and computer electronics enclosures from metal
conduits and building steel. Enclosures should be grounded only by
the grounding conductor which is included in their ac power circuits.
Connect all cabinets within a grouping to the same ground system.
Provide a single-point ground for all cabinets interconnected by
non-isolated signals. Also, provide a single-point ground for all
cabinets sharing a backup power supply.
Provide a low impedance, high integrity, ground path between all
instrumentation and the PROVOXr or microPROVOXt
instrumentation plant ground connection.
PN1:003
6
6-2
System Grounding
6.2
Separating AC and DC Grounds
Two separate ground terminations are used for the instrumentation
system, as shown in Figure 6-1. One termination is used for the ac
ground system and one is used for the dc and cabinet ground system.
The systems shown provide a safety return path to earth for faults in the
system and provide noise isolation between ac and dc circuits.
6.2.1
AC Ground System
The single-point termination shown in Figure 6-2 and Figure 6-3 provides
the ac ground for ac-powered devices in the instrumentation system. The
ac ground must conform to all applicable local, state, and federal
electrical code requirements for a ground system.
6
6.2.2
DC Ground System
The single-point termination shown in Figure 6-4 and Figure 6-5,
provides the reference for all of the dc power and analog signals of the
system cabinet equipment. The dc ground serves as the final termination
point for all signal common and power supply common wiring. The power
supply common (PSC) is the power return for all 24 volt dc power
connections in the system.
6.2.3
Cabinet Ground Considerations
The cabinet ground must remain separate from all other dc ground
connections until it is terminated at the single dc and cabinet ground
point, as shown in Figure 6-4 and Figure 6-5. The cabinet ground is
connected to the same point as the system ac ground at the PROVOX
Instrumentation Ground (PIG).
The cabinet ground provides protection to both equipment and personnel
from accidental shock hazards. It also provides a direct drain line for any
electromagnetic interference (EMI) to which the components of the
cabinet may be subjected. This ground must meet all code requirements
for a ground system.
The cabinet ground is connected directly to the system cabinet, usually
at one of the four mounting studs on the bottom corners of the cabinet.
Cabinet grounds are always routed to the center cabinet in a group of
cabinets. The console bay unit and console bay assembly do not
connect to the cabinet ground. These units are grounded through the ac
power wiring.
PN1:003
Revision B — October 1995
6-3
System Grounding
Plant Power Grid
Isolation
Transformer
System Cabinet
Breaker Panel
Console &
Computer
Breaker Panel
Main
Distribution
Panel
PIG
Grounded Steel
Column
AC Ground
(MGB)
1
System
Cabinet
#1
DC and Cabinet Ground
2
3
Logging
Unit
1
1
Computer
Logging
Unit
System
Cabinet
#2
Console
Bay #1
System
Cabinet
LGB
#3
Console
Bay #2
Computer
Console
Bay #1
System
Cabinet
#4
Console
Bay #3
Computer
Console
Bay #2
System
Cabinet
#5
Console
Bay #1
System
Cabinet
#6
Console
Bay #2
System
Cabinet
LGB
#7
Logging
Unit
Computer
Cabinet
#1
Computer
Logging
Unit
Computer
Cabinet
#2
System
Cabinet
#8
System System System
Cabinet Cabinet Cabinet
#9
#10
#11
LGB
Notes:
1
Wiring from LGB to MGB should be No. 1/0 AWG (53.46mm2) to 4/0 AWG (107.16mm2) insulated wire.
2
Wiring from MGB to ground grid should be at least No. 4/0 AWG (107.16mm2) insulated wire.
3
DC grounds from cabinet LGBs should be connected on one side of the MGB and cabinet grounds to the other side.
Figure 6-1
AC and DC Multiple Cabinet Ground System
Revision B — October 1995
PN1:003
6
6-4
System Grounding
Isolation
Transformer
Equipment Cabinets
Equipment Cabinets
Line
Neutral
Ground
LGB
LGB
1
Grounded
Steel Column
AC Ground
PIG
2
4
MGB
DC and Cabinet Ground
6
3
2
2
Cab GND
Dedicated Plant
Ground Grid Point
Notes:
1
1/0 — 4/0 AWG cable. Conductor used to connect the grounding electrode to the neutral ground bond at the
source of a separately derived instrumentation power system. (per NEC 250.26 Parts a and b)(CSA C22.1
Section 10)
2
1/0 — 4/0 AWG cable. The conductors used to provide a low impedance ground reference for the DC power
system (Logic, Transmitter, Output) and/or a cabinet ground for EMI/RFI noise protection of the instrumentation
cabinets, file, and field wiring shields.
3
Supplemental conductor used to connect the grounding electrode for the source of a separately derived instrumentation power system directly to the plat ground grid system. This is used to provide low impedance ground
reference to EMI/RFI noise. (per NEC 250.81/250.83)(CSA C22.1 Section 10)
4
If the PIG is not tied to an electrical ground steel column, the grounded conductor must be a continuous wire
from the neutral-ground bond point to the ground grid point. The wire insulation must be stripped at the PIG and
the wire clamped to the PIG to maintain the continuous ground. If the column is grounded, then terminations
may be made at the PIG.
Figure 6-2
Details of AC and DC Ground System with NEC/CSA Code Reference
Note
Devices connected by only a PROVOX highway
system (Data Highway or Highway II) do not
require connection to the same ground system
because the system provides isolation between
devices. Systems so isolated may also have
separate power sources.
6.3
Ground Wiring
Proper connections, wire sizing, ground impedance, and so forth are
extremely important to effective grounding. The following subsections
describe these requirements for a PROVOX system.
PN1:003
Revision B — October 1995
6-5
System Grounding
Instrumentation
Transformer
PSC Connections (16 Terminals)
Line
1
Neutral
Ground
Grounded
Steel Column
Local Ground Bus (LGB)
1
PROVOXr Instrumentation
Ground (PIG)
Recommended DC
Side (3 Terminals)
DC/Cab GND
Dedicated Plant
Ground Grid Point
Recommended Cabinet
Side (3 Terminals)
1
6
Master Ground Bus (MGB)
Notes:
1
1/0 -- 4/0 AWG cable.
Figure 6-3
6.3.1
Details of Local and Master Ground Buses
Master and Local Ground Buses
Master ground bus (MGB) assemblies and local ground bus (LGB)
assemblies facilitate ground wiring and provide single-point terminations
within cabinets or cabinet groupings. The buses can be installed at the
factory or can be installed in the field after the instrumentation system is
delivered. Both assemblies mount on isolated brackets at either the
bottom or top front of the system cabinet. An LGB assembly provides a
central termination point for all power supply common (PSC) connections
within a cabinet group of eight bays or less. The cabinets can be in
either an in-line or back-to-back configuration.
The LGB assembly has one lug in the middle for connection to an MGB
assembly. This lug accepts wire sizes of AWG 1/0 to 4/0 (53.46 to
107.16 mm2). For a single grouping of cabinets, a connection can be
made directly from the LGB assembly to the instrumentation system dc
ground. For more than one cabinet grouping, an MGB assembly should
be used to connect the several cabinet groupings together before being
connected to the dc ground.
Figure 6-6 shows the details for mounting MGB and LGB assemblies in a
system cabinet, and the dimensions of the factory-supplied assemblies.
Figure 6-7 shows details for grounding wall frames in OWP consoles.
Revision B — October 1995
PN1:003
6-6
System Grounding
Power Bus
Bar
Power Bus
Bar
Optional
Rear Power
Bus Bar
Single
Cabinet
2 to 8 Cabinet Grouping
Optional
Rear Power
Bus Bar
PSC
LGB
CAB GND
6
DC GND
CAB GND
AC GND
MGB
PROVOXr Instrument
Ground (PIG) 1
Figure 6-4
The PIG can also be sued as an MGB if it is located in the same room.
LGB
LGB
DC MGB
Notes:
A LGB will be required for each
cabinet grouping of 2--8.
A cabinet ground will be required
for each grouping of 8 or more or
one large MGB can be used.
PN1:003
1
DC/Cabinet Grounding System
LGB
Figure 6-5
Note:
LGB
CAB. MGB
MGB
To PIG
Multiple Cabinet System Grounding
Revision B — October 1995
6-7
System Grounding
Ground Bus
Assembly
Mounting
Bracket (2)
Grommet (2)
1
Notes:
1
Isolate the assembly from
the mounting bracket.
2
Ground bus assemblies are
mounted in the bottom front
of PROVOXr cabinets.
Cabinet
Kick Plate
System
Cabinet
2
Typical Bus Assemblies
Local Ground Bus Assembly
Battery Backup
Return Connection
MGB Connection
INCH
(mm)
Master Ground Bus Assembly
1.75
(44.5)
15 (380)
Figure 6-6
0.375
(9.53)
Typical System Cabinet Ground Bus Assembly
Revision B — October 1995
PN1:003
6
6-8
System Grounding
Ground strap through wall
connects to next wall
6
Ground connection
point
Wall frame ground should be at
least 0.5 in (12.7 mm) braided wire.
Figure 6-7
Typical OWP Wall Frame Grounding
Users can fabricate their own master ground bus, but should ensure that
the following conditions are met:
J
Copper/copper clad steel or hard brass (B16)
J
Minimum of 3/8 inch (9.5 mm) thick and 1-3/4 (44.5 mm) inch wide
J
Holes for lugs
J
Double bolted lugs
J
Bus isolated from mounting bracket with standoffs.
Table 6-1 lists the wire sizes which should be used for LGB to MGB,
MGB to PIG, and PIG to plant ground wiring.
Table 6-1
Ground Wire Sizing Chart
Wire Length
PN1:003
Wire Size
Up to 25 feet
1/0
Up to 50 feet
2/0
Up to 200 feet
4/0
Revision B — October 1995
6-9
System Grounding
6.3.2
Single-Point Grounding
In some situations, a single-point ground may not be practical or
feasible. For example, cabinets that are connected only by the data
highway need not be returned to the same single-point ground.
However, the same single-point ground should be used in the following
cases:
J
J
J
Cabinets are located in the same local area.
Cabinets are bolted together to form one continuous assembly or
unit.
Cabinets share the same single-ended signal.
This case occurs if one field transmitter is connected to two points in
separate cabinets or if an output from a device is used as an input for
a device in another cabinet.
J
6.3.3
Cabinets are located in separate buildings or in distant separate
areas, but the ac power to the cabinets is taken from the same power
source without transformer isolation.
Power Supply Common (PSC) Wiring
The power supply common (PSC) should be carried on separate wires
from each power supply unit or power distribution panel to their
respective cabinet power bus bar. One PSC ground reference is used
per power supply unit and is tied from one cabinet power bus bar to the
LGB or MGB, as shown in Section 4. The recommended wiring size for
these ground points is No. 8 AWG (8.35 mm2) multistrand, with the
lengths being as short as possible. PSC wiring should be insulated to
avoid unintentional ground loops that can occur if bare wires touch the
metal cabinet or each other.
6.3.4
Marking Grounds
Use insulated or jacketed copper wire cable (the use of welding cable is
recommended) for the dc ground, ac ground, and cabinet ground
connections. To aid in ground identification, identifiable insulation colors
(green or green with a yellow stripe) or some labeling method should be
used.
All system ground points should be labeled as follows:
FOR INSTRUMENTATION SYSTEM GROUND ONLY. DO
NOT USE FOR ELECTRIC ARC WELDER CONNECTION.
Revision B — October 1995
PN1:003
6
6-10
System Grounding
6.3.5
Ground Impedance
A high quality instrumentation system ground should provide a ground
point that measures one ohm or less to true earth. In some cases, three
ohms may be acceptable. In an unfavorable area, it may be necessary to
select the best ground impedance available. There are several methods
that can be used to obtain a high quality earth ground system, and these
methods vary depending upon the soil type and moisture content at the
individual location. See section 7 for information about soils and earth
grounds.
6.4
6
File and Shield Grounding
Proper shield and file grounding ensures proper system operation by
reducing electromagnetic and radio frequency interference.
6.4.1
For PROVOX Cabinets
PROVOX cabinets supplied by Fisher-Rosemount Systems have welded
frames that provide good ground connections between frame members.
The EIA rails installed in the cabinets provide proper ground paths for
files installed in the cabinets.
To provide a positive ground path for field wiring shields, connect shield
wires to the cabinet frame or EIA rails. For large amounts of field wiring,
it is suggested that a cable tie panel be installed in the horizontal cable
trays. Then, connect the tie panel to the drilled and tapped holes in the
EIA rails or cabinet frame, using a short 0.5 inch (13 mm) wide copper
braid strap. Use external tooth lockwashers to ensure good
metal-to-metal contact. Field wiring and cable shields are described in
detail in the installation planning manual, Wiring and Data Highway
Guidelines, PN1:004.
6.4.2
For OEM Cabinets
For OEM cabinets, drill and tap the frame members and mounting rails to
ensure good metal-to-metal contact. Use 0.5 inch (13 mm) wide copper
braid to interconnect frame members and mounting rails. Make a 24 inch
(610 mm) ground strap for each file, using 12 AWG (3.31 mm2) stranded
copper wire. Attach a number 6 ring terminal to one end and a number
10 ring terminal to the other end of each strap. Connect the number 6
terminal to the back of the file using one of the number 6 screws,
securing the back plate to the file assembly. Connect the other end of
the strap to the mounting rail with a number 10 screw.
PN1:003
Revision B — October 1995
System Grounding
Cabinet 1
Cabinet 2
Cabinet 3
Cabinet 4
6-11
Cabinet 5
2
Cable Tie
Panel
EIA Rail
3
MGB
1
1
1
1
To AC Power System
6
Grounded
Steel Column
Notes:
Dedicated Plant
Ground Grid Point
Figure 6-8
PROVOXr
Instrumentation
Ground (PIG)
1
Cabinet ground should be at least
0.5 in. (12.7mm) wide braided wire.
2
Cable tie panel grounded to the cabinet
frame.
3
Shields grounded to EIA rails.
Shield Ground Wiring
For grounding shields in other enclosures, drill and tap the rail and
connect 0.5 inch (13 mm) wide copper braid between the mounting rail
and each cable tie panel. Make sure that the mounting rails are strapped
to the local ground bus with 0.5 inch (13 mm) copper braid. Use external
tooth lockwashers to ensure good metal-to-metal contact. See Figure 6-8
for an illustration of shield grounding.
6.4.3
For Remote Termination Panels
If Control I/O termination panels are remotely mounted on a wall or
similar mounting, the panels must be grounded to the PROVOX
Instrumentation Ground (PIG).
6.5
Intrinsic Safety Barrier Grounding
In some applications where hazardous gases are present, special
handling or special wiring practices must be used. Conformity with local
codes and regulations is essential. Several documents present the
requirements for hazardous area instrumentation use or code guidelines;
contact local authorities for copies of the applicable documents.
Revision B — October 1995
PN1:003
PN1:003
Figure 6-9
1
5
PIG
G
N
O
2
System
Power
Supply
5
4
LGP
MGB
3
SC
CO
MV
Optional connection direct to PIG.
5
I/P Transducer
or Positioner
--
+
Transmitter
+
--
Hazardous Area
Intrinsic Safety
Barriers
Terminals shown are for controller I/O unit installation
planning note for I/O unit terminal designations.
SC
PSC
+24V
Controller 4
Card File
Multiplexer
I/O File
+24V
Typical Ground Connections for Passive Intrinsic Safety Barriers
Master ground bus (MGB), if required. If not, connect local ground
bus (LGB) directly to instrumentation system DC ground.
Main power panel connections to circuit breaker panel; one phase
shown for clarity.
Figure 6-9
3
2
G
N
O
DC/Cab GND
Ground Bus
Neutral Bus
Breaker
Panel
6
Notes:
Isolation transformer or UPS connected to main power.
1
Dedicated Plant Ground
Grid Point
Grounded
Steel Column
Isolation
Transformer
System Cabinet
Safe Area
6-12
System Grounding
Typical Ground Connections for Intrinsic Safety Barriers
Revision B — October 1995
Revision B — October 1995
1
PIG
G
N
O
2
DC/Cab GND
Ground Bus
Neutral Bus
Breaker
Panel
G
N
O
System
Power
Supply
LGP
PSC
5
4
SC
+24V
OV
--
+
+V
OV
--
+
+V
Fuse protects input/output circuits. Size large enough to
accommodate power consumption of barriers and load.
--
+
--
+
Transmitter
or Sensor
I/P Transducer
or Positioner
+
mA
AT
+
mA
AT
Intrinsic Safety
Barriers
Hazardous Area
Terminals shown are for controller card file. Consult
appropriate multiplexer I/O unit installation planning note
for I/O terminal designations.
MGB
3
SC
CO
SC
MV
Controller 4
Card File
Multiplexer+24V
I/O File
5
Typical Ground Connections for Active, Galvanic Isolated, Intrinsic Safety Barriers
Master ground bus (MGB), if required. If not, connect local ground
bus (LGB) directly to instrumentation system DC ground.
Main power panel connections to circuit breaker panel; one phase
shown for clarity.
Figure 6-10
3
2
Notes:
Isolation transformer or UPS connected to main power.
1
Dedicated Plant Ground
Grid Point
Grounded
Steel Column
Isolation
Transformer
System Cabinet
Safe Area
System Grounding
6-13
6
Figure 6-10 Typical Ground Connections for Active , Galvanic Isolated, Intrinsic Safety
Barriers
PN1:003
6-14
System Grounding
The ground for passive intrinsic safety barriers should be connected to
the same point as the system ground, as shown in Figure 6-9. Ground
connections for active, galvanic isolated, intrinsic safety barriers are
shown in Figure 6-10. For additional information on intrinsic safety
barriers supplied by Fisher-Rosemount Systems, refer to installation
manual, Installing CL6340 and CL6350-Series Intrinsic Safety Products,
PN2.1:CL6340.
6.6
Consoles and Computers
Consoles and computers are grounded only to the instrumentation
system ac ground, as shown in Figure 3-8, Figure 3-9, Figure 3-12 and
Figure 3-13. The conduit carrying the circuit conductors is electrically
isolated from the console or computer cabinets. The ac ground to the
consoles or computers should be the same size or a size larger than the
current-carrying conductors. For example, the line and neutral wires
should be No. 12 AWG (3.30 mm2) stranded wire, and the ac ground
should be No. 10 AWG (5.27 mm2) stranded wire. To minimize the effect
of noise, use wire made of a large number of small conductors for the ac
ground. For example, use No. 8 AWG (8.35 mm2) wire composed of 168
strands of No. 30 AWG (0.05 mm2).
6
6.7
Peripheral Devices
Peripheral devices and systems for the PROVOX and microPROVOX
instrumentation systems can include such equipment as a high-speed
printer, a mass software storage device such as a disk unit, a secondary
computer, or even a PROVOX or microPROVOX console. Although
physically separated, a common grounding system should exist.
For any area of the instrumentation system where more than one
grouping of equipment exists, the common grounding system must be
designed so that it does not create excessive current paths. Regardless
of the ground types used, the interconnecting wiring must be large
enough to safely and adequately handle the currents involved. When
other vendor equipment or other types of Fisher-Rosemount Systems
equipment are used with PROVOX or microPROVOX I/O or data links,
the other equipment should be powered from the same ac power
distribution system as the one that powers the PROVOX or
microPROVOX instrumentation system. Finally, all of the ground systems
need to be tied together.
PN1:003
Revision B — October 1995
7-1
Earth Grounding
Figure 7-Table 7
7
Earth Grounding
Proper earth grounding is extremely important to user safety and efficient
operation of an instrumentation system. A good earth ground safely
conducts electrical currents, caused by faults, to ground, and a good
earth ground can considerably reduce electrical noise. Such noise can
cause erroneous control signals in the system. The information in this
section provides guidelines for constructing a good earth ground. In all
cases, construction of and connection to earth grounds must be in
accordance with local, state, and federal codes.
7.1
Designing an Earth Ground
7
For digital switching circuits, several process instrument industry sources
recommend a ground system that ideally has a resistance of one ohm or
less between the instrumentation ground system and true earth—with a
maximum resistance of no more than three ohms. A resistance of one
ohm or less minimizes the phantom errors caused by voltage drops in
the ground system.
The ground system for the instrumentation system must be at least as
good as any ground associated with any other system. If a ground used
with a radio communication system has a one-ohm resistance to true
earth, then the ground system used with the instrumentation system
must also have one ohm or less resistance to true earth. Both ground
systems should be referenced to the plant grid.
For a plant grid, multiple ground rods provide the most effective ground
system because:
J
J
The individual rod-to-earth contact resistances are effectively placed
in parallel. Adding rods to the system reduces the ground-systemto-earth resistance.
An element of safety is provided over the single rod system. All
ground contact does not depend upon a single rod.
The distance between rods in a multiple rod system must be greater than
the immersion depths of the rods. For more information on installing and
testing of ground systems, refer to the publication, Getting Down to Earth
from Biddle Instruments. See subsection 1.7, Reference Documents, for
more information.
Figure 7-1 shows an example of a plant grid system. If en existing plant
grid is accessible, and if the ground-grid-to-true-earth resistance meets
Revision B — October 1995
PN1:003
7-2
Earth Grounding
the requirements, the existing grid can be used for the instrumentation
system ground.
A dedicated point close to the instrumentation system (preferably a
ground rod location) is used for the system ground point. The ground rod
is connected to one of the plant ground grid rods with 4/0 AWG copper
wire. The ends of the wires are thermally welded to the rods. If either the
existing grid is not accessible or the resistance is not within
specifications, a new grid is required.
Figure 7-2 through Figure 7-7 illustrate various examples of grounding
that may be used.
Plant
Ground
Grid
7
Power
Substation
Ground
Plant Ground Grid Connection
1
Notes:
= Ground Rod
Dedicated
Instrumentation
System Ground
All connecting lines should be at least No. 4/0 AWG (107 16 mm3)
copper wire thermal welded to the rods
1
Ground connection can be a single rod or one of the configurations
shown in the following figures.
Figure 7-1
PN1:003
Example of Plant Ground Grid System
Revision B — October 1995
Earth Grounding
7-3
Weld nut to bolt and base
plate or use double nut.
H-Column
Optional Pigtail to
PIG (4/0 AWG)
Column Base Plate
To PIG 4/0 AWG
Weld tie bar to rebar
and anchor bolt.
Rebar-Grade Bar
Pier or Pedestal
Grade Beam
Vertical Rebar
(4 or More)
3 to 12 Ft
or more
7
Spacer Loop
Spread
Footing
Steel Wire Ties
Horizontal
Rebar
3 to 6 Ft.
Figure 7-2
Revision B — October 1995
Grounding Example (UFR Ground System)
PN1:003
7-4
Earth Grounding
Existing Ground Rods
AC PWR GND
DC/Cabinet Ground
from Master Ground
Bus
PROVOXr Instrumentation
Ground (PIG)
Dedicated Ground Point
for Instrumentation
7
Existing
Rod
Figure 7-3
PN1:003
New Rod
Grounding Example
Revision B — October 1995
Earth Grounding
7-5
Existing Counterpoise System
AC PWR GND
DC/Cabinet Ground
from Master Ground
Bus
PROVOXr Instrumentation
Ground (PIG)
Existing Cable
Existing Buried
Copper Cable
7
New Rod
Figure 7-4
Dedicated Ground Point
for Instrumentation
Grounding Example
Existing Ground Grid System
AC PWR GND
DC/Cabinet Ground
from Master Ground
Bus
PROVOXr Instrumentation
Ground (PIG)
Existing Cable
Dedicated Ground Point
for Instrumentation
Figure 7-5
Revision B — October 1995
Existing Ground
Grid
Grounding Example
PN1:003
7-6
Earth Grounding
UFER Ground Connections
AC PWR GND
DC/Cabinet Ground
from Master Ground
Bus
PROVOXr Instrumentation
Ground (PIG)
Dedicated Ground Point
for Instrumentation
Refer to Figure 48 for UFER
Ground System
7
Figure 7-6
Grounding Example
Existing Grounding
AC PWR GND
DC/Cabinet Ground
from Master Ground
Bus
PROVOXr Instrumentation
Ground (PIG)
Dedicated Ground Point
for Instrumentation
Buried Steel Plate
Existing
Figure 7-7
PN1:003
Minimum
5’ x 5’
Grounding Example
Revision B — October 1995
7-7
Earth Grounding
7.2
Testing an Earth Ground
An earth ground tester, illustrated in Figure 7-8, is used for testing the
ground system. The tester measures the resistance between the ground
system and the earth. The tester consists of a voltage source, an
ammeter, and switches to select the resistance ranges.
Earth Ground Tester
C1
Earth Ground
Under Test
P1
A
V
C2
P2
1
P
Earth Electrode
C
7
60% D
D
Auxiliary
Electrodes
2
Notes:
1
Disconnect ground cable from system while test is being made.
2
Auxiliary electrodes must be placed in a straight line from the earth
ground under test.
Figure 7-8
Typical Test Setup and Connection for Testing an Earth
Ground System
The preferred test method is to gather sufficient data to plot the actual
curve of resistance versus distance. If plotting is impossible, a simplified
Fall-of-Potential Test may be used with a compromise on accuracy. Refer
to the publication, Getting Down to Earth from Biddle Instruments. See
subsection 1.7, Reference Documents, for more information. This book
also contains information about using a two-point method of testing for
verification.
As a preventive maintenance item, each connection on the grounding
system, from the PSC connections through the LGB, MGB, PIG and
earth ground connections, needs to be checked annually. This check will
ensure that connections are tight, that ground wires are in good
condition, and that no contamination exists which can otherwise
compromise ground integrity. During the check, the power system
connections from power supply units to cabinet bus bars should also be
checked.
Revision B — October 1995
PN1:003
7-8
Earth Grounding
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7
PN1:003
Revision B — October 1995
8-1
Lightning Protection
Figure 8-Table 8
8
Lightning Protection
In areas where damage from electrical storms may occur, a lightning
protection system should be installed to protect both equipment and
personnel. This protection should include protection for the building, the
power distribution system, the PROVOXr highway system, and any
cables that run outdoors to other locations. Refer to installation planning
manual, Lightning Protection Guidelines for Instrumentation Systems,
PN4:007, for detailed information.
The following documents also contain information and guidelines for
installing lightning protection.
J
J
Revision B — October 1995
National Fire Protection Association Inc. (NFPA) Lightning Protection
Code NFPA-78
IEEE Recommended Practices for Grounding of Industrial and
Commercial Power Systems IEEE Std. 142
PN1:003
8
8-2
Lightning Protection
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8
PN1:003
Revision B — October 1995
Glossary-1
Glossary
A/D
Acronym: Analog-to-Digital, or Analog to
Digital Converter
AC or ac
Acronym: alternating current
American Wire Gauge (AWG)
The usual system of wire size
measurement in the United States. A
14 AWG wire has a cross-sectional area
of 2.08 mm; a 000 AWG wire has a
cross-sectional area of 85.02 mm. Note
that the smaller the AWG value, the
larger the wire.
analog
ACIA
Acronym: Asynchronous
Communications Interface Adapter
Continuously variable over a given range.
A process control system senses a
physical variable such as voltage,
current, or resistance as an analog value.
Glossary
ADC
Acronym: Analog to Digital Converter
AI
Acronym: Analog Input
AIO
Acronym: Analog Input/Output
analog to digital converter (A/D or
ADC)
An integrated circuit device that converts
analog signals into a digital form. This
enables a digital computer to operate on
such signals.
assembly (ASSY)
In PROVOXr systems, a collection of
hardware and/or PWB modules, or a
single PWB module that is built up from
individual components.
ASSY
ALM
Abbreviation: Alarm
Abbreviation: Assembly
attenuation
The reduction of signal strength as it
travels on a cable.
alternating current (AC or ac)
A flow of electricity which cycles to
maximum in one direction, decreases to
zero, then reverses itself and reaches
maximum in the opposite direction, then
increases again to zero.
Revision B — October 1995
AWG
Acronym: American Wire Gauge
Baby N Connector
Obsolete variation of BNC.
PN1:003
Glossary-2
Bayonet Neil-Councelman
Connector
carrier band
backplane
CCITT
BNC
CHIP
Obsolete variation of BNC.
A printed circuit board at the rear of the
DC6460-Series Console Electronics Unit
which, by means of its attached
connectors, mates with the modular
cards and assemblies installed in the
card file.
An industry-standard term and acronym
for a type of connector for coaxial cable
that is frequently used for a variety of
applications in PROVOXâ systems.
bridge
Glossary
1. A highway communications device
used to configure a network of devices by
linking together highways that require
extensive intercommunications.
2. A device used to interconnect local
PROVOX Highway IIs and to separate
the traffic on them from the traffic on the
network PROVOX Highway II.
Bridge Highway II
A highway that is used to interconnect
bridges where there is a high volume of
intercommunication.
bus
A general term for a group of signal lines
to be considered together, as in a data
bus or address bus. The data highway of
a PROVOXr system is such a bus.
cable tap
A device for connecting the highway
device to the highway cable. (Commonly
referred to as a tap.)
PN1:003
A type of base-band network used in a
process control environment.
Acronym: Comite Consultatif International
pour Telephonie et Telegraphie, or
International Consultative Committee for
Telephony and Telegraphy. [See
International Consultative Committee for
Telephony and Telegraphy]
Acronym: Computer/Highway Interface
Package
CIA
Acronym: Communications Interface
Assembly
CIU
Acronym: Computer Interface Unit
CMOS
Acronym: Complimentary Metal Oxide
Semiconductor
Communications Interface Assembly
(CIA)
A printed circuit card that links files of
PROVOXr devices and the data
highway. The CIA provides the timing and
data conversion necessary for
communications.
complimentary metal oxide
semiconductor (CMOS)
A family of digital integrated circuits that
use transistors operating in a push-pull
mode to carry out logic functions. A
CMOS usually is capable of low-powered
operation.
Revision B — October 1995
Glossary-3
Computer/Highway Interface
Package (CHIP)
A PROVOXr software product that allows
user-written programs to interact with the
PROVOX system. There are different
CHIP versions, so that any of several
types of computers can be the host
computer.
data highway
A data communications network for a
limited area that functions as a logical
token bus. In a PROVOX Highway II
communications system, there are three
types of highways: Network Highway II,
Bridge Highway II, and Local Highway II.
dB
console
Generic term for the terminal or device an
operator uses to monitor and control a
process.
control room instrumentation (CRI)
Process control equipment designed for
installation and operation in a control
room environment.
controller
A PROVOXr Integrated Function
Controller (IFC) or Unit Operations
Controller (UOC) or multiplexer controller
(MUX).
current to pneumatic transducer (I/P)
An electro--mechanical device that
converts a DC signal (typically 4- to
20-milliamps) to a proportional pneumatic
output signal.
cyclic redundancy check (CRC)
A method of error detection in data
transmission and data storage. The
check evaluates both the number of ones
and zeroes in a block (parity) and the
position of the values in the block.
D/A
Acronym: Digital to Analog, or Digital to
Analog Converter
DAC
Acronym: Digital to Analog Converter
Revision B — October 1995
Acronym: Decibel
dBmV
Acronym: Decibel millivolt
dc
Acronym: direct current
DC
Acronym: direct current
decibel
The relative difference between two
signal levels expressed logarithmically.
decibel millivolt
A measure of signal strength that is
calculated by using the following formula:
dBmV = 20 log (signal voltage÷1 millivolt)
device
A piece of electronic hardware that
performs one or more prescribed
functions.
DI
Acronym: Discrete Input
digital to analog converter (DAC or
D/A)
An electronic circuit (usually an IC) that
converts a digital signal ( digital data) into
an analog signal of corresponding value.
digital volt meter (DVM)
A test instrument that measures voltage,
current, or resistance, and gives
numerical readings.
PN1:003
Glossary
Glossary-4
DIO
Acronym: Discrete Input/Output
discrete
Having either of two states, for example,
on or off, or 1 or 0.
electrostatic damage (ESD)
Deterioration of integrated circuits due to
high levels of static electricity. Symptoms
of ESD include degradation of
performance, device malfunction, and
complete failure.
EMI
Acronym: Electromagnetic Interference
discrete input/output (DIO)
The reception and transmission of
discrete signals. In PROVOXr systems,
DIO usually refers to a discrete
input/output card in a controller.
DO
Acronym: Discrete Output
drop cable
Glossary
The cable that connects a highway
device and the cable tap.
DVM
Acronym: Digital Volt Meter
EMX
Acronym: Expanded MUX Controller
full duplex communication
Simultaneous transmission in both
directions over a communications
channel.
ground
1. A voltage reference point in a system
that has a zero voltage potential.
2. A conducting connection between an
electrical circuit or equipment and either
the earth or some conducting body that
serves in place of the earth.
highway
See data highway.
IDI
EIA
Acronym: Electronic Industries
Association
Electronic Industries Association
(EIA)
A group of electronic manufacturers that
creates industry standards for
communication between electronic
devices. Among these standards are
RS-232 and RS-449.
electromagnetic interference (EMI)
The general category of electrical noise
induced by radio frequency and
magnetic, electrostatic, or capacitive
coupling.
PN1:003
Acronym: Intelligent Device Interface
IEC
Acronym: International Electrotechnical
Commission
IEEE
Acronym: Institute of Electrical and
Electronics Engineers
IFC
Acronym: Integrated Function Controller
Input/Output (IO or I/O)
Signal reception and transmission, or
signal interfacing. Input, for a process
control device, involves accepting and
processing signals from field devices.
Output, for a process control device,
involves converting commands into
electrical signals to field devices.
Revision B — October 1995
Glossary-5
Institute of Electrical and Electronic
Engineers (IEEE)
An independent technical organization
that defines standards for the electrical,
electronic, and computer industries.
light-emitting diode (LED)
An electronic component that generates
a small focused beam of light, in
response to a current passing through.
LEDs are available in several colors,
depending on the type of crystal they
contain.
interface
An electronic circuit that governs the
connection between two devices and
helps them exchange data reliably.
International Consultative
Committee for Telephony and
Telegraphy (CCITT)
A technical organization that develops
compatibility and other recommendations
for telecommunication, including data
communication. (The acronym comes
from the organization’s French name.)
International Electrotechnical
Commission (IEC)
An international group developing
standards and certification in electronics
and electrical engineering.
IO or I/O
Acronym: Input/Output
I/O channels
Input/output channels: communications
paths from a device to a communications
link or other device.
jumper
An electrical connector used to select a
particular signal path and bypass
alternates on a printed circuit board. The
jumper contains a connecting wire,
usually within a small plastic rectangle
with two receptacles that can be pushed
down on a pair of pins sticking up from
the board’s surface.
Revision B — October 1995
local device (LD)
Any PROVOXr device that resides on a
local highway and can communicate
directly with a local traffic director.
local ground point (LGP)
A central termination point for all signal
common and power supply common
circuits within a cabinet group of eight or
fewer bays.
Local Highway II
A highway that is used to connect as
many as 30 PROVOX devices together
into a logical token bus.
local traffic director (LTD)
A communications device that controls
the data flow on a local data highway. As
many as 30 devices can be on the
highway. An LTD also stores and
forwards messages to other local areas.
logical ring
See logical token ring.
logical token
A frame that is passed between highway
devices giving permission to
communicate on the highway.
logical token bus
A communications protocol in which one
device on a highway transmits a frame
(logical token) while all other devices on
the highway receive the token
sequentially, but only keep it if it is
addressed to them.
PN1:003
Glossary
Glossary-6
logical token ring
1. A group of highway devices that pass
a token to each other.
2. A communications protocol in which all
devices on a highway can transmit and
receive frames (logical tokens)
simultaneously in a
predecessor-successor arrangement.
LTD
Acronym: Local Traffic Director
master ground point (MGP)
A common termination point for as many
as six local ground point (LGP)
assemblies.
MGP
Acronym: Master Ground Point
Glossary
microPROVOXt
A mark of Fisher Controls International,
Inc. Fisher-Rosemount Systems’ line of
self-contained process control systems.
modem
Modulator/demodulator: a device that
allows a computer to transmit and receive
data via a telephone or other
communications network.
MUX
Abbreviation: Multiplexer
network device (ND)
A PROVOXr device that communicates
directly with a network traffic director. An
network device can be any device, but
usually is one that collects information
from several local highways. Local traffic
directors, consoles, multiplexers,
programmable controller interface units
(PCIUs), data concentrator units (DCUs),
unit operations controllers (UOCs), and
trend units are common network devices.
PN1:003
Network Highway II
A highway that is used to connect Local
Highway IIs and Bridge Highway IIs.
network traffic director (NTD)
A PROVOXr device that controls the
data flow for the network data highway.
The NTD links network devices and local
data highways via the local traffic
directors.
NIU
Acronym: Network Interface Unit
noise
Unwanted and typically random signal
components that obscure the genuine
signal information being sought.
normally closed (NC)
Said of a contact pair closed (conducting)
when its device or relay coil is not
energized. Such a contact pair also is
called a break contact.
normally open (NO)
Said of a contact pair open (not
conducting) when its device or relay coil
is not energized.
NTD
Acronym: Network Traffic Director
operational amplifier (OP AMP)
A high-gain, linear, DC amplifier, typically
an integrated circuit, used in a wide
variety of applications.
optical isolation
The technique of electrically isolating two
circuits by converting an electrical signal
to an optical signal and back again.
Optical isolators commonly consist of an
LED and a phototransistor mounted in
a DIP.
Revision B — October 1995
Glossary-7
original equipment manufacturer
(OEM)
The firm that makes a product sold by
another firm. For example, Hewlett
Packard is the OEM for some products
sold by Fisher-Rosemount Systems.
PCI
Acronym: Pulse Count Input
PCIU
Acronym: Programmable Controller
Interface Unit
plant area
The collection of equipment in a plant
that has common manufacturing
strategies and alarm strategies.
plant management area (PMA)
A collection of plant process areas
(PPAs). A PMA controls the console point
reporting load, and indirectly, central
processing unit (CPU) loading.
printed circuit (PC)
A conduction path of metal on a
substrate material which is used to carry
signals between electronic components.
printed wiring board (PWB)
A board containing printed circuits
(printed wiring) which serves as the
mounting base for integrated circuits and
other electronic components.
Programmable Controller (PC)
A control machine, built of computer
subsystems, that takes the place of
electro-mechanical relay panels.
Programmable controllers make use of
solid-state digital logic.
programmable controller interface
unit (PCIU)
A PROVOXr highway device that permits
programmable controllers to receive and
respond to commands from other
PROVOX devices such as consoles,
trend units, and UOCs, via the data
highway.
programmable logic controller (PLC)
plant process area (PPA)
Within a process-control system, a
collection of equipment that uses a
common alarm strategy.
PMA
Acronym: Plant Management Area
power supply common (PSC)
The negative terminal of the 24- volt
system power supply: a reference for
digital signals.
power supply unit (PSU)
In a PROVOXr system, a device or
component that converts standard
alternating current to the direct current
voltage that other system devices need.
Revision B — October 1995
A microprocessor or mini-computer
system able to perform simple analog
and discrete control. PLCs were
developed as replacements for relay
control panels, and are typically used for
motor control. The acronym PLC is
trademarked by Allen-Bradley Company,
Inc.
PROVOXr
A mark of Fisher Controls International,
Inc. A Fisher-Rosemount Systems’
product line of distributed process control
equipment.
PSC
Acronym: Power Supply Common
PWB
Acronym: Printed Wiring Board
PN1:003
Glossary
Glossary-8
PWR
RS-232C
Radio, Electronic, and Television
Manufacturers’ Association (RETMA)
RTD
Abbreviation: Power
Formerly, a group of electronic
manufacturers who developed a standard
for rack mounting of electronic
equipment. Replaced by EIA.
radio frequency interference (RFI)
Inadvertently transmitted energy that falls
in the frequency band of radio signals. If
this energy is sufficiently strong, it can
influence the operation of electronic
equipment.
recipe management
Glossary
A structured method used to develop,
store, retrieve, and maintain batch control
recipes.
recipe procedure
[See procedure.]
resistance temperature detector
(RTD)
A device or element that measures
process temperature very accurately.
RTDs sense temperature changes by
measuring the resistance of a coiled
metal wire, typically platinum.
RETMA
Acronym: Radio, Electronic, and
Television Manufacturers’ Association
return loss
The relative difference between the level
of a signal on a cable and the signal
reflected back from an impedance
mismatch.
RFI
Acronym: Radio Frequency Interference
PN1:003
An EIA standard for transmitting data
serially through a cable 50 feet or less in
length.
Acronym: Resistance Temperature
Detector
rule inference
In fuzzy logic control, the process of
evaluating if-then rules based on fuzzy
variables to determine the logical sum of
the individual rules.
rule table
In fuzzy logic control, a matrix of output
membership function labels (control
actions) based on input membership
function labels (conditions).
RWM
Acronym: Read/Write Memory
serial
Sequential: said of data transmitted one
bit after another.
serial batch structure
A number of sequential processes. The
simplest batch structure.
serial interface
A data transmission device through which
bits are sent sequentially.
serial interface unit
A device that lets a computer
communicate with other devices of a
PROVOXr instrumentation system, via
the data highway.
SGP
Acronym: Shield Ground Point
shield ground point (SGP)
A copper bus bar that fits in horizontal
cable trays in a system cabinet. This bar
is a convenient place to ground signal
cable shields.
Revision B — October 1995
Glossary-9
signal common (SC)
Transceiver Cable
synchronous data link
communication (SDLC)
uninterruptible power supply (UPS)
A ground point that provides a reference
for analog input and analog output
signals in a PROVOXr system. System
installers should reference all other DC
wiring to power supply common (PSC).
A protocol for communications between
synchronized devices. The protocol
features bit-level message frames with
error checking.
TCP/IP
Acronym: transmission control
protocol/internet protocol
A two-part communications protocol
(transmission control protocol and
internet protocol) that provides reliable
and guaranteed transfer of data between
two computer programs or networks.
terminal
A point of connection for two or more
conductors in an electrical circuit.
token
See logical token.
token bus
A logically independent network of
devices that are physically linked
together through a specially shielded
coaxial trunk cable using cable taps, drop
cables, and communication interfaces.
Revision B — October 1995
Ethernet/IEEE 802.3 transceiver cable
provides the link between your system or
server and the Ethernet Transceiver or
DELNI.
A backup device for the AC power
source. A UPS connects between the AC
power source and computer equipment.
Should there be a failure of or
interruption in the AC power source, the
UPS supplies continuous power to the
computer.
Unit Operations Controller+ (UOC+)
A unit operations controller (UOC) with
advanced control capability, including
function sequence table (FST) and logic
control point (LCP) functionality, an
expanded database, and faster
processing.
Universal Asynchronous
Receiver/Transmitter (UART)
A device that connects a word-parallel
controller or data terminal to a bit-serial
communications network.
UOC
Acronym: Unit Operations Controller
PN1:003
Glossary
Glossary-10
VME Communications Interface
Assembly (VCIA)
An interface card and adapter assembly
that connects the DC6460-Series
Console Electronics Unit (VME-bus) to
the PROVOX data highway. The VCIA
card provides the timing and data
conversion necessary for
communications. The VCIA adapter
assembly mounted on the backplane
connects two internal coaxial cables to
two BNC connectors on the data highway
connection panel.
VME Redundant Communications
Interface Assembly II (VRCIA II)
Glossary
voltage output (VO)
A terminal, available on a PROVOXr
controller or multiplexer, that produces a
1- to 5-volt analog output signal.
VRCIA II
Acronym: VME Redundant
Communications Interface Assembly
X.25
A CCITT protocol for connecting data
terminal equipment to public packet
switched
An interface adapter assembly that
connects the DC6460-Series Console
Electronics Unit (VME-bus) to the
PROVOX Highway II token passing bus.
The VRCIA II adapter provides the timing
and data conversion necessary for
communications. The VRCIA II has
coaxial connectors for the primary and
secondary highway cables. Right-angle
adapters are required for the coaxial
connectors.
PN1:003
Revision B — October 1995
Index-1
Index
A
equipment voltage markings, 4-1
alarm relays
alternate connections, 5-1, 5-2
location, 5-1, 5-2
G
alarm wiring, purpose, 5-1
alarms, power supply, 5-2
B
backup power, 4-1, 4-2
C
circuit breakers
multiple, 3-2
panels, 3-1, 3-15
ratings
consoles, computers, 3-15
peripheral equipment, 3-20
Type CP6101, CP6102
supplies, 3-12
Type CP6103 supply, 3-13
common grounding, 6-14
compliance, European, 1-2
D
DCDA, (dc power distribution
assembly), 4-1
ground points
local, 4-4
master, 4-4
ground rods, 7-1
ground system testing, 7-7
grounds
braided wire size, 6-10
conformance to codes, 6-2
console, computer wire size, 6-14
earth, 7-1
effective grounding, 6-4
faulty, 6-1
highway isolation, 6-4
intrinsic safety barriers, 6-11
labeling, 6-9
network, 6-1
power supply common (PSC)
wire size, 6-9
proper impedance, 6-10
PROVOX instrumentation ground
(PIG), 6-2
termination point, 6-2
tying together, 6-14
wire color coding, 6-9
wire shields, 6-10
wire sizing, 6-5
H
highway isolation of grounds, 6-4
E
I
earth grounds, maximum
resistance, 7-1
installation, power supplies, 4-1
equipment dc voltage range, 4-1
Revision B — October 1995
isolation
bus bar, 3-2
PN1:003
Index
Index-2
power, 3-1
L
R
labeling ground points, 6-9
local ground bus (LGB), 3-2, 4-4,
6-5
redundancy
alternate methods, 4-2, 4-4
need for power, 4-2
M
S
master ground bus (MGB), 3-2, 4-4,
6-5
shield grounding, 6-10
mutli-cabinet power distribution, 4-1
P
PDP, (power distribution panel), 4-1
PIG, (PROVOX instrumentation
ground), 6-2
plant grid, 7-1
plotting earth ground resistance,
7-7
Index
power, need for redundancy, 4-2
single phase power, 3-1
T
three phase power, 3-1
U
uninterruptable power, 3-2
V
power distribution
assembly, 4-1
multi-cabinet, 4-1
voltage markings, equipment, 4-1
power loss, 2-2
voltage ratings
consoles, computers, 3-15
dc power, 4-4
system power supplies, 3-12
power strips, utility, 3-15
power supply common (PSC), wire
sizing, 6-9
power supply units, 3-12
power utilities, 2-1
PROVOX instrumentation ground
(PIG), 6-2
PSC connections, 6-5
Q
quality
helpful devices, 2-1
PN1:003
problems, 2-1
voltage ranges, 2-2
W
wire braids for grounds, 6-10
wire sizing
for load currents, 2-3
for voltage drop, 2-3
ground vs. phase and neutral
conductors, 3-2
grounds, 6-5
power supply common (PSC),
6-9
Revision B — October 1995
Notes
Notes
Revision B — October 1995
PN1:003
Notes
Notes
PN1:003
Revision B — October 1995
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For more information, FAX (612) 895-2244
PN1:003
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