WHITE PAPER A Condensed Guideto Control SystemInstallation: Specification,Design & White Paper, Title Page System Specification, DesignandInstallation A Condensed to Guide Automation Control AutomationDirect TomBy Elavsky The #1 Value inAutomation.™ www.automationdirect.com Save upto Controls: 50%onIndustrial WHITE PAPER A Condensed Guideto Automation Control SystemInstallation: Specification,Design & White Paper, pg. 2 can act asageneral guideto thespecification,can act design andinstallation ofautomated onControlThe following ofarticles System series isPart 1ofafour-part Design that system control design andconstruction, system installation, and finally control system could benefitfrom automation. We will then cover control device specification, control Part 1,weIn will cover thetopics ofSafety andIdentifying anoperation orprocess that referencestarting for automated control systems. covered are fullydetailed. Instead, thetopics are aimedat giving thereader agood dealing withautomation control systems orto even suggestthat thetopics being concept isnotourintent to completion. for It theguideto cover possibletopic every information, includingatypical “real world” application that canbefollowed from isourintent toIt produce thiswhitepaper asausableguide, withadditional responsibility for itsuseinyour application. information application, issuitablefor nordowe yourassumeany particular provided “as is” withoutaguarantee ofany kind. We donotguarantee that the personnel ordamageto equipment. The information provided inthiswhitepaper is install automation control to systems injury becausetheycanfailandcauseserious control systems. Persons orguidance shouldnotdesign and withoutsuchexpertise isrequired mostcases, toIn specialexpertise design automation andinstallindustrial that your communications withtheSystem Integrator gofaster andmore smoothly. much aspossibleaboutautomation control system devices andtheirterminology so youIf dodecideto useaSystem Integrator, itwould bebeneficial to understandas all together. Your firstoptionmay be to enlistthehelpofaqualified System Integrator. controlunderstanding ofelectrical devices, you may nothave theexperience to putit the appropriate equipment to makethishappen,andalthoughyou have abasic consistent results. You may have to develop themechanicalmeansandselect theskills the process willreduce theamount ofmanuallabor, improve throughput and produce have alsovisualized ways that would allow you to automate theoperation. Automating laborious, timeconsuming, isvery product andproduces inconsistent results. You may You may have come to realize that anoperation orprocess usedto produce your end utilitiesandmaterialmanufacturing, processing. processingtextile andmore andreliability inallareas hasincreased of productivity handling/conveyor systems, mixingprocesses, assemblymachines, metalprocessing, washes, to complex chemicalprocessing plants. Automation ofmachinetools, material controlElectrical systems from are simplepumpcontrols usedoneverything to car an automated control system. information presented shouldgive you achecklistto useinthesteps to implementing Whether control oranovice you at are electrical devices anexpert andsystems, the automating, to tipsonsettingupaprogram, to maintaining thecontrol system. will takeyou required from theskills to recognize anoperation orprocess suited for control systems. The information andreferences are presented inalogical order that

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www.automationdirect.com Save upto Controls: 50%onIndustrial WHITE PAPER A Condensed Guideto Automation Control SystemInstallation: Specification,Design : & White Paper, pg. 3 maintenance. The topics willbebroken down asfollows: operation of electrical controloperation ofelectrical equipment andsystems. help determine whichcodes andstandards for are thesafe necessary installation and Association (NEMA). There may orgovernment alsobelocalregulatory offices that can Association (NFPA) fire Manufacturer’scode, andthe codes oftheNational Electrical At aminimum,you shouldfollow oftheNational Fire allapplicablesections Protection instruments, suchasvoltmeters, ampmeters, current loopmeters, etc. clamp-on as well test andmeasurement asunderstandingoftheuse andoperation ofelectrical devices,of electronic suchastheoperation ofatransistor andothersolidstate devices, andPLCs.covering basicelectricity would bebeneficial It tohave someunderstanding when dealingwithautomated control systems. Also, many Web sites offer free tutorials even offer courses in Programmable Logic Controllers (PLCs), useful whichcanbe very technical colleges offer courses covering dealingwithbasicelectricity. Some subjects andsomelocal ofbasicelectricity onthesubject many goodpublications andarticles a longway inhelpingyou understandthevariouscodes andstandards. There are of basicelectricity, andpractice, Ohm’s includingDCandAC theory Law, etc. willgo equipment ingeneral. andelectrical Agoodunderstanding as possibleaboutelectricity even before you getto thisarea ofsafety, itwould bewiseto educate yourself asmuch organizations that provide applicablestandards andcodes are referenced below, but goal willbeto shock eliminateto personnel. offire therisk andelectrical The top likelyyourMost control energy, system willbedealingwithelectrical soyour first operation isin compliance with thelatest revision ofthesecodes. which codes shouldbefollowed andto verify that theequipment, installation, and by area andusuallychange overvary willbeyour time. responsibility to It determine trol system, alongwiththeequipment orprocess itisdesigned to control. These codes 1:SystemPart Identification andSafety •  • Part 4-INSTALL• Part andMAINTAIN 3-DESIGNandBUILD • Part •  Part 1 - SAFETY andIDENTIFICATION 1-SAFETY Part Part 2-SPECIFICATIONPart that regulate theinstallation andoperation ofyour con should follow allapplicablelocal, state andnational codes To minimize ofpotential therisk safety problems, you the equipment. automated equipment, aswell asto prevent damageto for withornearthe personnelwhomay beworking a simpleon/off control for apump, issafety, both attempting anautomated control system, oreven item to Theconsider before firstandmostimportant

The #1 Value inAutomation.™ - www.automationdirect.com Save upto Controls: 50%onIndustrial WHITE PAPER A Condensed Guideto Automation Control SystemInstallation: Specification,Design : & White Paper, pg. 4 is lockout/tagoutprocedures asspecified Occupationalby Safety andHealth Another area ofsafety that needs to beconsidered for automated control systems system orPLC program offthemotor can turn rotating asaw blade. However, since unexpectedly.occurring For thecontrolling example, ifthemachine hasajammedpart, devices shouldbeinstalledinamannerthat prevents any machineoperations from protection for ordamage. ofthesystem any that may part causepersonalinjury These tronic controlling devices, suchasasolidstate relay ora PLC outputmodule, to provide mechanical devices, suchasrelays orlimitswitches, that are independent ofany elec system aloneto provide asafe operating environment. You electro should useexternal or joggedto theproper position. resume. There may alsobemechanical positionsofequipment that have to bemoved established (ormaintained from thestate to prior theshutdown) before operations can For example, there may bespecific register values inthePLC that mustbe memory must bemetbefore thecontrol system orPLC control program canbe restarted. shutdown orany ofpower othertype interruption, there may berequirements that device orswitch labeled mustbeclearly nect Stop”.“Emergency After anEmergency allsystemdisconnecting power to themachinery, equipment orprocess. The discon control system: The following are othersafety points to consider inthedesign ofyour automated http://support.automationdirect.com/compliance.html Compliance to UL508Afor AutomationDirect canbefound products onour Web site at: found at: panel builderoruseanexistingUL508Abuilder. Additional information canbe built to UL508A,thenyou willneedto withULto contract directly become aUL508A trol systems isUL’s Standard for your Safety 508A.If control system panelrequires being Laboratories (UL).Oneofthemostapplicableareas ofinterestis Underwriters for con compliance purposes. Oneofthemostspecifiedandpremier safety testing laboratories failure that could leadto catastrophic results. Anotherreason might befor insurance or laboratory. Onereason isto ensure that thedevice meetsstandards that willprevent your automated control system shouldbelisted, approved orregistered withatesting There are many reasons devices why that you theelectrical willuseinthedesign of OSHA’s Web site at: initial design oftheautomated control system. Additional information canbefound on or mechanicalenergy storage device. The meansto dothisshouldbeconsidered inthe any energy source, feed, suchasthemainelectrical butalsoany pneumatic, hydraulic tagout procedure, to thedesign shutoff, shouldincludetheability neutralize, orisolate or maintenance order In to activities. have your control system makeuseofalockout/ andequipment, ortherelease ofhazardous energy ofmachinery service during startup safeguard operators andmaintenance personnelfrom energization theunexpected or Administration (OSHA). “Lockout/tagout” refers to andprocedures specificpractices to - Accidental Powering notrely ofOutputs - Do ontheautomation control Stop - - Emergency The control system mustprovide aquickmanualmethodof https://standardscatalog.ul.com/standards/en/standard_508a www.osha.gov/SLTC/controlhazardousenergy/

The #1 Value inAutomation.™ - - - - www.automationdirect.com Save upto Controls: 50%onIndustrial WHITE PAPER A Condensed Guideto Automation Control SystemInstallation: Specification,Design & White Paper, pg. 5 switch allsystem that disconnects power any timetheguard isopened. the operator mustopenaguard to remove you shouldalsoincludeabypass thepart, Identifying Process for Automation to personnelordamageto theequipment. not to causeinjury control system to ensure that ifthefeedback signal islost,thesystem shutsdown soas mounted onthemaincontrol panel. so that itrequires aswitch power to devices openit,disconnecting to theelectrical by theoperator, butthedeadfront interior doorwithadjustabledevices isinterlocked in front ofthemaincontrol panel. The outsideenclosure doormay stillrequire keyentry outside weather conditions. The deadfront aninterior isnormally door that ismounted etc., andthecontrols needto beinsidetheenclosure soasto protect themfrom make adjustments to devices, switches, suchasselector thumbwheels, potentiometers, frontsDead shouldbeusedoncontrol system enclosures where theoperator needsto authorized personnelto troubleshoot control ormakeadjustments to electrical devices. on control panelsthat have limited access, soitissafer for and maintenance electricians guarding. The useofprotective guards over live circuits shouldalsobeconsidered, even devices that have finger-safe terminal whichareconnections, surrounded by insulated without theproper tool, keyorotherauthorized means. energized circuits are secured to prevent unauthorized personnelfrom gainingaccess devices to continue to operate. allowing otherpoweredfaulted circuit willbeopened(de-energized), equipment and fusing, circuit breakers orotherinterrupting meanscoordinated suchthat onlythe control system circuitry, according to code, that ensures allcircuits are protected with devices.electronic canreducepractices electromagnetic andradiated noiseinterference to sensitive devices for faulted to conductors prevent fire, andalso realize that good grounding andinstallation inthedesign,practices ofyour construction system. Use protective equipment to stop itbefore personnelcancome withit. incontact damage, thenuseothermeansto dealwithit,suchasapplyingabrake to rotating damage. problem orequipment adetected would If result ofpersonalinjury inrisk cutting tools, binfull, orequipment etc. that ofpersonalinjury donotposearisk stopped. ofproblemsThese broken types are usuallythingssuchasjammedparts, position, etc., needsto bereturned to itsfail-safe positionandtheequipment/process be includedinyour afaultisdetected, design. thenany If mechanicalmotion,valve around relays andtimersoraPLC, anorderly system shutdown sequence should - Orderly Equipment Shutdown - Whether usingacontrol system designed - Closed-loopControl isyour responsibility inany ofclosed-loop -It type - Finger-Safe Fronts andDead -Anothersafety area to consider istheuseof - Unauthorized Access sure -Make allenclosures andcabinetsthat have - Control Power -Develop Distribution apower schemeinthe distribution - Grounding - To incorporate prevent shock, goodgrounding electrical a good understanding of basic electricity andsafety.a goodunderstandingofbasic electricity is to identify what canbeautomated. You needto have The firststep in anautomatedconfiguring control system

The #1 Value inAutomation.™ www.automationdirect.com Save upto Controls: 50%onIndustrial WHITE PAPER A Condensed Guideto Automation Control SystemInstallation: Specification,Design & White Paper, pg. 6 knowledge oftheoperation orprocessknowledge that you are goingto automate. mechanical operating mechanisms, , control sequences, etc. andasolid that you have isalsoimportant anunderstandingofbasichydraulics,It pneumatics, device, such as varying the speedofaconveyor,device, suchasvarying changing theamount avalve opens someinstances we thespeed,In may rate need to vary orposition ofourcontrolling position onascale. onaconveyor, product diverts orenergizing acontrol relay to signal that isin aproduct orapneumaticproduct, valve to control airpressure operating agate to acylinder that solenoidvalve toinclude anelectrical control water usedto wash residue from a nent adevice inoursystem, that could andselect control examples orsenseit.Some We would continue withthisanalysis,at eachpiece ofequipment orcompo looking sensors.) photoelectric selecting www.automationdirect.com/static/specs/peselection.pdf ontheconveyorthe positionofproduct beltmay vary. (Refer to our Web site at: an infrared beamoflight. approachThe may photoelectric bethebetter choice because by theproduct sensor that using candetect oraphotoelectric withtheproduct contact reached theconveyor. The sensorcanbealimitswitch witharoller that arm comes in Anotherapplication product. forthe next asensoristo indicate has whentheproduct controlstart/stop oftheconveyor isoutoftheway for that pushcylinder theproduct switch hasfullyretracted, to indicate whenthecylinder andprovide asignal to the valve that provided theairpressure to thepneumatic cylinder. We alsoneedalimit onto aconveyor. The cylinder “fully extended” thesolenoid signal isusedto de-energize isusedto pushourproduct isfullyextended, asinthecasewhencylinder cylinder step inouroperation. As anexample, we usuallyneedalimitswitch whena to detect completed. This isrequired soourcontrol system whento knows proceed to thenext sensors,photoelectric proximity sensors, etc. that willindicate whenanoperation is We willalsoneedto identify where to locate sensorssuchaslimitswitches, fujimcselection.pdf motor. (Refer to our Web site at: protection. We willneedto to size work themotorwithexistingconveyor starter controlled withanelectrically motor starter,starter circuit andoverload includingshort To automate theconveyor, we willneedto replace themanuallycontrolled motor theconveyorturn offonce has theproduct reached thedischarge end. the conveyor, andto theconveyor turn onto move theproduct. The operator mustalso operator to watch standingat themotor reaches starter astheproduct theentrance to for circuit and fireoverload protection, protection. bothshort The system requires an motor, offandon whichisturned by amanually controlled andincludes, motor starter moves from ourproduct point Ato point B. The conveyor ispowered by a3-phaseAC an operation iscomplete, etc. As asimpleexample, let’s say we have aconveyor that fluids, dispense when granular materials, inposition,detect senseproduct orientparts, You shouldunderstandhow to control motionandmovement, regulate theflow of for information onspecifyingandsizingmotor starters.) http://www.automationdirect.com/static/specs/

for information on The #1 Value inAutomation.™ - www.automationdirect.com Save upto Controls: 50%onIndustrial WHITE PAPER A Condensed Guideto Automation Control SystemInstallation: Specification,Design & White Paper, pg. 7 signal that corresponds to thereal value we have determined andcalibrated into the accomplished by usingananalogoutputsignal. Ananalogoutputsignal isavarying to control aflow rate, or remotely changing theset-point level for atank. This could be manufacturing equipment and processesmanufacturing canbeautomated. of automated control systems anddiscussed sometipsusedinidentifying which Part 1ofControlIn System Design, we covered involved safety aspects inthe use 2:ControlPart Device Specification Standard Machinery, forElectrical publication NFPA Industrial 79. publication NFPA Code (NEC), Electrical 70andalsoasagoodreference refer to the their Web site at: Further information for theNational Fire Protection Association (NFPA) canbefound at at their Web site at: Information for Manufacturer’s theNational Electrical Association (NEMA) canbefound www.automationdirectcom/videos https://forum.automationdirect.com You may also want to visittheAutomationDirect Customer Forums at: www.interconnectingautomation.com For information onPLCs andPLC programming fundamentals visit: References: Part 2willcover Control Device Specification. to aPCwithappropriateinterface software. system. ofthesecontrol Most systems would becomprised ofPLC-type I/Othat would ofa fallinto thecategory Control AndData Acquisition”“Supervisory (SCADA) trending, meetingregulations, etc., thenyou shouldlookat usingacontrol system that yourIf application requires keepingdata records for reference, traceability, history, likely needaPLC that caneasilycommunicate withthe HMIdevice. then theuseofanHMIisbestway to proceed. thesesituations, In you willmost your process requires changesto set-point values, making process time, flow rates, etc., use ofanoperator alsoreferred interface, (HMI).If to Interface asaHumanMachine You willalsowant to determine ifyour automated control system willbenefitfrom the can be “hard-wired” for simplerapplications. vices are identified, theycanbeusedasthe field devices ina PLC-based system, orthey basically identifying theI/O(inputsandoutputs)ofourcontrol system. Once thesede Identifying devices to control motion,flow, events, etc. andsensing completion is motor of 5 VDC would result inaconveyor speedof250feet perminute. 500 feet perminute. Ananalogsignal to thespeedcontrolling device for theconveyor device. For example, a0to 10 VDC signal could represent aconveyor speedof0to www.nfpa.org www.nema.org . Some ofthemore. Some useful publications are theNational .

or watch ourtutorial videosat

The #1 Value inAutomation.™ - www.automationdirect.com Save upto Controls: 50%onIndustrial WHITE PAPER A Condensed Guideto Automation Control SystemInstallation: Specification,Design & White Paper, pg. 8 the equipment inanautomated system. Your specifications need to includenotonly Part 2,weIn willcover how to specifythevariousdevices required for controlling equipment. We needto betheproverbial detective whowould askquestionssuchas; parameters andspecifications needed to specifythedevices required to control the Thewe need willbethe ofalltheequipment to develop firstskill gathering inthiseffort approvals required for safety andinsurance purposes, environmental conditions, etc. enclosure for thedevices, ofwire thetype required to meetthe variouscodes, agency the “controlling” devices for your application, butalsoitems suchasthehousingor input devices Figure 1: Typical wiring for andsourcing sinking Sourcing Input Sinking Input – – + + • Who willbeusingthecontrol system? • How willthesystem beused? • What cycle? istheduty • What are theminimummounting clearances? • What are themounting dimensions? • What istherelative range? humidity • What istheoperating temperature range? • How muchcurrent doesitdraw? • What isthepower rating? • What istheoperating voltage? Common Common Input Input Input DevicesInput devices, outputdevices andtheprocessing unit. will generally fallinto one ofthree categories; input The devices you needto specifyinyour control system Control System Devices PLC PLC Sensing Input Sensing Input

that whenthesensorseesob andstate anobstruction, to detect sensorused such asaphotoelectric can lookat aninputfrom adevice, generally inanONorOFFstate. We etc.terface, These inputsignals are proximity sensors, an operator in sensors,toelectric pushbuttons, may includelimitswitches, pho etc.an alarm, Typical inputdevices byintervention anoperator, detect point hasbeenreached, sense or position,indicate alimitorset movementa condition, detect devices areInput usedto sense words we have atruecondition. thesensorisON;inother struction, The #1 Value inAutomation.™ - - - www.automationdirect.com Save upto Controls: 50%onIndustrial WHITE PAPER A Condensed Guideto Automation Control SystemInstallation: Specification,Design & White Paper, pg. 9 of two states; ONorOFF. They canbewired into aPLC inputmoduleandthePLC can is false. ofsignalsThese are types calleddiscrete signals, meaningtheyare always one When thesensorisnotobstructed, thentheinputisOFF; orwe cansay thecondition station, we would theoperating needto voltage know ofthevalve andhow much For example, ifourprocess usesasolenoid valve to control water flow to a wash to ourspecifications are importance the ratings oftheseoutputdevices:Of hardwired relay logic. as “Bin Full”, etc. Outputsignals canalsobewired to directly acontrolling device using to control water flow, anoperator illuminating apilotlight to a to alert condition such module to control andstopping motors, thedevices, energizing suchasstarting avalve signals, are alsodiscrete; eitherONorOFF. The signals canbewired from aPLC output operator graphics display, andnumeric interface etc. These outputsignals, likeinput indications, etc. Typical outputdevices includerelays, pilotlights, motor starters, conveyors andpumps, on/off control of valves, operator status alerts/prompts, Output devices are ofequipment like usedto control suchasmotion,start/stop actions DevicesOutput operating distance. the air, orcoated, reducing thentheopticscaneasilybecomeand dirty theirsensitivity in and/ormist atmosphere Ifthere isalotofdust,dirt inwhichtheycanefficiently work. forability thesensorto bewashed down, etc. sensorsare Photoelectric sensitive to the temperature ranges, andhumidity butinsomecases, indoororoutdoor use, altitude, the environment inwhichthesensorwill operate. This shouldnotonlyinclude orsensetheendoftravel toof product consider important for amechanism, itisvery asensordevice,Also keepinmindthat whenselecting thepresence suchasto detect As anote, mostPLC orsourcing DCinputmodulescanbeconfigured assinking to ourspecifications are importance the ratings oftheseinputdevices:Of control relays are hardwired to create thesystem logic. automated system. Orthesesamesignals canbeusedina “relay logic” system, where be programmed to usethestatus ofthesignals to execute thelogic to control the • What are themounting dimensions? • What isthe operating temperature range? • What cycle? isthe duty • What isthe current draw? theyare• If rated for orsourcing? DC,are theysinking • What isthe operating voltage; 24,120or240 Volt AC orDC? • How muchcurrent dotheyrequire? • How muchforce canbeappliedto theactuator? • What distances cantheysense? theyare• If rated for orsourcing? DC,are theysinking • What istheoperating voltage; 24,120or240 Volt AC orDC?

The #1 Value inAutomation.™ 1 . www.automationdirect.com Save upto Controls: 50%onIndustrial WHITE PAPER A Condensed Guideto Automation Control SystemInstallation: Specification,Design & White Paper, pg. 10 we canproperly specifyaPLC output but alsotheinrushcurrent, sothat current itdraws. We notonly theon-state alsoneedto current know draw ofavalve, scanner, etc. asinputdevices would andthemonitor, serve printer, speakers, etc. would can belookedat inthesame mannerisapersonalcomputer (PC). The keyboard, mouse, status andthelogical conditions setinthe program (seefigure 3).Asimilardevice that processing unit(CPU) that useslogical programming to makedecisionsbasedoninput by aPLC,This element canbeperformed where we have inputs, outputs andacentral status oftheinputs. This usto brings ourthird category, the “decision making” element. goingoninbetween sothat theoutputsare controlleddecision making basedonthe All control systems bedefinedashaving inputs, cantypically outputsandsome of form The processing unit orsourcing type. output modulescanbesinking the ambient temperature andthenumberofoutputsenergized. Keepinmindthat DC mayloads suchaspilotlights. have outputtypes dependingon Certain derating curves valves between several outputmodules, usingtheremaining points to power smaller ing themallfrom beingenergized at thesametime. Anotheroptionisto splitupthe a highercurrent rating orto usetheladderprogram to sequence thevalves, prevent most likelywould blow thefuse. The anoutputmodulewith solution could beto select be 8times800mAor6.4amps, and time, thetotal inrushcurrent would for themallto energize at thesame output points andourprogram called lenoid valves to connected alleight fuse rated at 6amps. we If hadso and therefore hasacommon module hasatotal rating of6amps considerations, theentire output amp continuous duty, thermal after points andeachpoint israted for 1 anoutputmodulehaseight output If rush of800mAwhenfirstenergized. continuous current, itmay have anin a valve may berated to draw 250mA module oracontrol relay. Although Figure 3 sensor button signal photo alarm push Input Decision Making - -

output devices Figure 2: Typical wiringfor andsourcing sinking Sourcing Outpu Sinking Output

Switch Output Switch Output Output PLC PLC t starte motor Output Common Common Output valve light pilot r the application the application system, and the operating its memory, along with motherboard, used onthe microprocessor devices. The be theoutput Load Load The #1 Value inAutomation.™ – – + + - www.automationdirect.com Save upto Controls: 50%onIndustrial WHITE PAPER A Condensed Guideto Automation Control SystemInstallation: Specification,Design & White Paper, pg. 11 industrial inputandoutput(I/O)industrial modules. These PC-basedsystems rely onthecommu in someautomated control element, together systems with asthedecisionmaking element.program As PCsare amatter asthedecisionmaking used offact, would serve cooling, power, approvals. environment, andagency static electricity automated control system cycle, surge -duty suppression, enclosure type, heating and There are otherpoints to consider inthespecification ofdevices beingusedin your considerationsOther the motor. drive control foror possiblyavariable frequency eitherstart/stop orspeedcontrol of nameplate. thecaseofamotor, In you willneedtheratings to choosethemotor starter obtained from themanufacturer’s catalog, orwebsite, from ordirectly themotor RPM, aFLA(fullloadampere) of10.5 ampsat 460 VAC, etc. This information canbe motor may induction haveAn industrial ratings suchas230/460 VAC, 3-phase, 1725 • What ofenvironment type isitbeingusedin? • What isthemaximumcurrent draw? • What istheoperating voltage? ratings ofthe equipment: a conveyor, oravalve to control ahydraulic cylinder, you willneedto determine the adevice toWhen control selecting mover, aprime motor suchasanindustrial to power devicesInductive signal thatapumpto would raise orlower causeanoutputpoint to start thelevel. ladder program we could compare level to theactual asetpoint andproduce adiscrete 50 feet. The analogsignal could bewired into aPLC analoginputmodule, andinthe Analog signals are linear, typically soa5 VDC signal would tell usthetanklevel isat to 10volts DC,with0feet beingequalto 0 VDC and100feet beingequalto 10 VDC. can useasensorthat willproduce asignal that isrepresented by avoltage range of0 example, we may want to monitor thelevel ofaliquidintankthat is100feet tall. We system. Analogsignals are variableandcanrepresent arange ofvalues. As aquick Another area ofinputsandoutputsinvolves theuseofanalogsignals inacontrol deviceOther types expansion forget that aPLC thefact orPC-basedcontrol system allows easierchangesandfuture system witheitheraPLC, PC-basedcontrol, orsimplehardwired relay logic. Butdon’t system requires. Cost restraints may require you to compare implementing thecontrol ence, you how willlearn to determine how much “decision making” your ability control operator interaction withtheequipment orprocess. With someresearch andexperi allows typically aprogrammersoftware to develop that agraphical gives interface an to monitor connections orEthernet andcontrolnication theI/O. ports The application 2 .

The #1 Value inAutomation.™ - - www.automationdirect.com Save upto Controls: 50%onIndustrial WHITE PAPER A Condensed Guideto Automation Control SystemInstallation: Specification,Design & White Paper, pg. 12 When usingasolenoidvalve, you willwant itsoperating to voltage, know nominal CycleDuty save you agreat dealofredesign down theroad. automated control systems. Investing alittlethought thespecification during stagecan their temperature specifications. management Basicthermal isnotdifficult formost ofthesameenclosure. as part This willensure thedevices are always operating within require you to have both acooling system, suchasanA/Cunit,andasmallheating unit temperature operating range. Your control system, becauseofitsphysical location, may or ifinstalledinacolder climate, thedevices aren’t beingusedbelow thelisted low Ensure that thedevices usedinyour control system aren’t to overheating, subject Heating/Cooling Enclosures sion to eliminate thesevoltage spikes. isalwaysby equipment. electronic It recommended to usesomeform ofsurge suppres and thecoil canproduce highvoltage spikesthat candamageoutputdevices andnear valves,Solenoid etc. motor starters, coil makeuseofaninductive for theiroperation properly cool down. twooff timeofonly seconds. offtime wouldnot allow The short forthesolenoidto rated inacontinuous cycle modewithanontimeof10seconds at andan 50%duty valve’s We would not want (timeonvs. to operate cycle duty timeoff). asolenoid valve to havecontrol isalsoimportant anunderstandingofthesolenoid itsoperation. It current draw ofoutput device required andcurrent thetype inrushto helpselect to Surge Suppression SERIAL SF VOL POLES MODEL MAX. SAFE OHMS/PHASE 120 RPM Hz. 60 4 1.0 TS 4200 # 230/460 4 • Sufficient space for proper installation andmaintenance ofequipment access orrestricted (Reference• Security OSHA) • Access to theequipment (Reference OSHA) • Common ground reference (Reference NEC) 3 PHASEINVER ENC AV DUTY 7.6 7.5 .38 HP E213THFW7726AA BRG. S.E. TEFC .707 R1 309 CONT RPM CODE TER DUTY FL . 3530 1770 RPM 90 O.S.E. BRG. L 1770 .488 R2 KA 206 AMB. MAX. ACINDUCTIONMOT TO DES 11 22.3 22.3 RQUE ° C40 AMPS .2 2.39 FRAME FL X1 AMPS NL. 21.4/10.7 TYPE 13/6.5 VOL 460 460 ---- 3.21 213TC X2 TS SENSORS

TRF TEMP OR ROT INS . WK OR AMPS 2 10.6 10.5 10.5 NONE 41.4 XM H3 .75 NEMA) environmentindustrial (Reference • Protection from theelements inan dards (Reference NEC) • Conformance stan to electrical sures shouldinclude: minimum considerations for enclo operation ofyour equipment. The to ensure safeportant andproper aproper enclosureSelecting isim 4 3 The #1 Value inAutomation.™ - - - - - www.automationdirect.com Save upto Controls: 50%onIndustrial WHITE PAPER A Condensed Guideto Automation Control SystemInstallation: Specification,Design & White Paper, pg. 13 If usingDCvoltageIf from apower supplyinyour control system, consider usingapower DC Power required approvals are: applications requireSome approvals components. agency for ofthese Some particular ApprovalsAgency environments.humidity ground straps, anti-static floor coverings, etc. if you usetheequipment inlow- sure you take adequate precautions whenyou touch theequipment. Consider using problems occur muchmore frequentlyelectricity levels at humidity below 30%.Make equipment anddevicesMost willoperate down to 5%relative humidity. However, static Static Electricity specification designations for enclosures andequipment. generally applyto automation equipment. IECalsohasalistofcommon environmental The following tableisanexampleofNEMA’s common environmental specifications that power supplyto operate at alower temperature, thusincreasing itslife. quirements ifyou needto have your control system UL508approved andwillallow the supply rated for at thecalculated leasttwice load. This shouldsatisfy oneofthere Occasional prolonged submersion submersion Occasional temporary Corrosive agents Oil orcoolant spray andsplashing Oil andcoolant seepages Hose down andsplashingwater Dust, lint, fibers, andflyings Falling liquidsandlight splashing Falling dirt Incidental contact w/encl. contact Incidental equip. environmental conditions against thefollowing Provides adegree ofprotection Comparison non-hazardous ofspecific applications locations indoor

• • 1

• • • 2 • • • • • 4 4X • • • • • • Type ofenclosure • • • 5 • • • • • • 6 6P • • • • • • • • 11 • • • • The #1 Value inAutomation.™ 12 • • • • •

12K • • • • • - 13 • • • • • • www.automationdirect.com Save upto Controls: 50%onIndustrial WHITE PAPER A Condensed Guideto Automation Control SystemInstallation: Specification,Design & White Paper, pg. 14

programming, etc. document ourdesign, choices between usinghard-wired relays versus aPLC with output design layout, panellayout, diagrams, wiring billofmaterials, tools software to schematic withthedevices shown inahigh-voltage to low-voltage order, inputto design topics willincludeplanningby defining oursequence ofoperation, creating a Part 3, weIn willcover thesteps neededto design ourautomated control system. The system. andcontrolling equipmentfor in anautomated interfacing theelectrical control Part 2 ofControlIn System Design we covered specifyingthevariousdevices required 3:Design Part http://industries.ul.com/industrial-systems-and-components 5 Additional ULinformation canbefound at: www.osha.gov/SLTC/controlhazardousenergy 4 Additional information canbefound onOSHA’s Web site at: found at their Web site at: 3 Information forManufacturer’s theNational Electrical Association (NEMA) canbe http://support.automationdirect.com/docs/worksheet_guidelines.html 2 For “Considerations for ChoosingaPLC” refer to: 1 For andSourcing Concepts”“Sinking refer to: Footnotes: step isPart 3,ControlNext System Design products, refer to ifications. For industrial informationcontrol selection product for AutomationDirect Suppliers’ literature and Web sites are anexcellent resource for evaluating spec product Selection Product ment, calibration equipment, etc. nience receptacle insidethecontrol system enclosure to supplypower to test equip or cabinetto routine helpduring maintenance to thecontrol system. Provide aconve isalwaysIt agoodideato includeinterior lighting for your control system enclosure Enclosure Lighting andConvenience Receptacle ofmostyour controllingtion andwilldetermine theselection devices. The requirements for approvals ofyour any specifica oftheseagency needto bepart https://library.automationdirect.com/sinking-sourcing-concepts • CE(European Economic Union) • CUL(Canadian Underwriters’ Laboratories, Inc.) • UL(Underwriters’ Laboratories, Inc. https://www.automationdirect.com/adc/ProdInfo/ProdInfo http://www.nema.org

5 ) . The #1 Value inAutomation.™ - - - - www.automationdirect.com Save upto Controls: 50%onIndustrial WHITE PAPER A Condensed Guideto Automation Control SystemInstallation: Specification,Design & White Paper, pg. 15 Design making future making “logic” changes. wiring changeswithoutthe laborofmaking only ahalfdozen relays industrial of addstheflexibility andacouple timers. electronic It relay logic orcanbenefitfrom aPLC devices, we candetermine ifourautomated control system isbestsuited for hard-wired Once we have asequence ofoperation developed and alistofourinputandoutput should show orlisteachoperational step inourprocess. to takeplace,or actions by way ofa “sequence ofoperations” description. The sequence mostcases,In thefirststep indesigning our control system willbe to definethe process Sequence ofOperation control system. were developed the during “Identifying” and “Specifying” phasesofourautomated Figure 1 Useful to usat thisstep willbeany notes andliststhat the future andbeableto interpret theinformation. that anyone isimportant canlookat ourdocuments in It specifics down onpapersothat itcanbeeasilyunderstood. documenting task. The challengewillbeto getourdesign The design for ourcontrol system willbeintheform ofa 1 . APLC canbecost-effective whenusedinplace of

Figure 2. better suited to usingaflowchart application may be Our particular ship to eachother, asshown in event isgraphed inatimerelation inwhicheach condition and chart, be better suited to usingatiming somecases,In theapplication may symbols.with common flowchart have capabilities built-in flowchart as MicroSoft Visio®. These programs programapplication software such graph paperandapencil, oran canbedeveloped A flowchart with example ofaflowchart. take place. Figure 1shows apartial that needto steps andactions tion by meansofdecision-making that shows thesequence ofopera The #1 Value inAutomation.™

- - www.automationdirect.com Save upto Controls: 50%onIndustrial WHITE PAPER A Condensed Guideto Automation Control SystemInstallation: Specification,Design & White Paper, pg. 16 left, whilethesymbolforleft, themotor isshown to theright. for protective devices andoverload (fuses),contacts relay elements are shown to the side ofdrawings andoutputdevices ontheright-hand side. For example, thesymbols practice, isnormal asshown inFigureIt 3,to devices show ontheleft-hand inputtype wired relay control systems shown inaladderfashion. becausetheywereengineers andelectricians accustomedhard- to trouble-shooting madethetransition toladder logic PLC was basedupon.It ladderlogic easierfor ladder, showing conditions. thevariouswiring This analogyofaladderiswhat PLC automated control system. Acontrol schematicdrawn isnormally intheform ofa and defineaschematic asadrawing that shows thelogical ofan wiring stepThe inourdesign isto next develop designers aschematic. electrical Most Schematic

Figure 3 Figure 2 The #1 Value inAutomation.™ www.automationdirect.com Save upto Controls: 50%onIndustrial WHITE PAPER A Condensed Guideto Automation Control SystemInstallation: Specification,Design & White Paper, pg. 17 as circuit breakers and/orfuses. Ourdesign shouldshow oftheAC thedistribution withtheincoming power,The schematic shouldstart includingprotective devices such devices may includepower supplies, input/outputsignals from otherinstrumentation, surrounded devices ofelectronic by and wires.typically various types These electronic Why instrumentation Electronic isgrounding suchasPLCs important? andfieldI/Oare system that provides bothsafety andfunctionality. that needto begrounded, thebetter chance we have ofaproperly grounded control system design. The more detailswe canshow ontheschematic to allpoints reflect Proper thingsingoodautomated grounding control isoneofthemostimportant the control power to variousdevices, alongwithindividuallyfusingthesedevices. Figure 5alsoshows somegeneral suggestionsfor device grounding anddistributing filter provides isolation between the control power source devices. andthe electronic (control (highvoltage) andsecondary voltage) sides.between itsprimary Apowerline Using Figure 5asreference, we seeatransformer whichprovides magnetic isolation isolation providesElectrical safety, sothat afaultinonearea doesnotdamageanother. logic sidecircuitsconnect to any other. When aPLC, wiring that connections to avoid external important itis extremely making to provideand theinputoutputcircuits that useopto-couplers additionalisolation. in Figure 4. The PLC’s mainpower supplyincludesatransformer that provides isolation, isdividedinto threecircuitry mainregions separated by isolationasshown boundaries to lookat device isolation wiring strategies. PLCs provide idealisolation becauseits transformer inourautomated control system. At thispoint inourschematic, we need orcalculatedbased onourknown “load” ofdevices that willbepowered from the controlmany electrical devices. The control transformer needsto besized (VA rating) 115 VAC; for example, we could have acontrol voltage of24 VDC, whichiscommon for our system control voltage (115 VAC). Ourcontrol voltage canbesomethingotherthan show acontrol power transformer usedto step thehigherincoming voltage down to or 240 VAC equipment, etc. oftheschematic. we will inthisfirstsection Next, auxiliary to practice isnormal show anyIt high-voltage devices, suchas3-phasemotors, 480 Code® (NEC®) Electrical power andrequired andincludeallcircuitry devices for conformance to theNational 2 andany localcodes that might applyinourarea.

Figure 4 The #1 Value inAutomation.™ www.automationdirect.com Save upto Controls: 50%onIndustrial WHITE PAPER A Condensed Guideto Automation Control SystemInstallation: Specification,Design & White Paper, pg. 18 should beusednearequipment that produces excessive noise. electrical provide additionalsuppression ofEMIfrom otherequipment. Isolation transformers use ofanisolation transformer, for example115 VAC to 115 primary VAC secondary, can the AC source voltage could drop low enoughto causeinaccurate inputdata. Also, the tosensors connected thePLC inputsshoulduse thesamepower source. Otherwise, dips andbrownouts. When usingaconstant voltage transformer to power aPLC, the power source supplyingthePLC to minimize shutdowns dueto power surges, voltage cases, we may needto useaconstant voltage transformer to stabilize theincoming AC from theoutputtransients (spikes)from beinginduced into theinputcircuits. some In plies. circuits Input shouldbeutilized to isolate theoutputcircuits andprevent voltage We shouldconsider usingasecond transformer to source AC power to DCpower sup ence may causefailure orerratic operation ofthedevice. ofElectromagnetic (EMI)ortransient Interference risk interference. ofinterfer This type and even devices that are neartheinstrumentation enclosure. Allthesemay present a

Figure 5 The #1 Value inAutomation.™ - - www.automationdirect.com Save upto Controls: 50%onIndustrial WHITE PAPER A Condensed Guideto Automation Control SystemInstallation: Specification,Design & White Paper, pg. 19 want to show theanaloginputs, thentheanalogoutputs, andfinallyourdiscrete inputs of theinputmodulesfirst,then theoutputmodules.If wehave analogI/O, we would We would makeuseofreference and, linenumbering inmostcases, we would show all modules. Figure for 7isanexampleofthewiring aninputmodule. usingaPLC,If ofourschematic willshow theinputandoutput thefinalsection especially withaDCsupply. transient voltages generated are muchlarger inamplitudethanthesupplyvoltage, “bounces,” thecoil whichenergizes until the andde-energizes “bouncing” stops. The with arelayvoltages contact. whende-energized When arelay isclosedit contact considerable load devices damage. (devices withacoil) Inductive generate transient devices protectcomponents theelectronic from suddenpower surges that cancause component inachievingareliablean important power system. distribution These This isagoodpoint to mention surge suppression. Surge suppression devices are our schematic. devices,supplies, etc. auxiliary Figure exampleofthehard-wired of 6isapartial section 115 VAC powered devices, suchasDCpower supplies, 115 VAC power to PLC power this iswhere we would show thehard-wired connections, alongwiththenormal from ourcontrol voltage (115 VAC). ourcontrol If “logic” isbasedonhard-wired relays, ofourschematic willshow thehard-wired section The next devices that are powered Laboratories, Inc.®(UL) supply. ifourcontrolThis isespeciallyimportant system needsto meetUnderwriters’ isalsoagood ideato doublethecalculated oftheDCpowerIt amperage capacity for mostapplications involving DCpowered sensorswould be100mVpeak-to-peak. amplitude oftheAC component thatontheDCvoltage rides signal. rating Atypical aDCpowerselect supplythat canmeetthemoststringentrequirement. isthe Ripple also needto lookat theamount of “ripple” the devices beingpowered cantolerate and amperage draw (load)ofall thedevices that willbepowered from theDCsupply. We DCpowerIf isrequired inourcontrol system, we needto calculate theworst case 3 508A.

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www.automationdirect.com Save upto Controls: 50%onIndustrial WHITE PAPER A Condensed Guideto Automation Control SystemInstallation: Specification,Design & White Paper, pg. 20 safety. keeps thelower It voltage devices grouped together, allowing access to wiring cover allofthehigh-voltage safety shieldfor devices with anon-conductive personnel timers,electronic etc. Keepingthehigh-voltage devices toward thetop allows usto high-voltage devices andany devices, electronic suchasPLCs, DC power supplies, toward thetop ofthepanel, keepingasmuchdistance aspossiblebetween the The highervoltage devices (thosethat operate at 240/480 VAC) shouldbemounted Figure exampleofapanellayout drawing. 8isapartial need to follow themanufacturer-recommended mounting distances andclearances. components. Specialattention shouldbegiven to component location andspacing. We to scaleandincludedimensionsfor thepanelbuilderto follow when laying outthe subpanel inthecontrol system enclosure. The panellayout drawing shouldbedone to (thesubpanel),wire astructure allthecomponents, anddothisbefore mounting the panelisreferredcases, theactual to asasubpanel. We canmount allthecomponents Once we have ourschematic finalized, step isapanellayout thenext drawing. In most Panel Layout and outputs. Generallywe would useonesheetofourschematic to show eachmodule.

Figure 7 Figure 8 The #1 Value inAutomation.™ www.automationdirect.com Save upto Controls: 50%onIndustrial WHITE PAPER A Condensed Guideto Automation Control SystemInstallation: Specification,Design & White Paper, pg. 21 electronic devices can act asashieldfrom deviceselectronic any canact EMIgenerated by thehigh- between thehigh-voltage ofourcontrol section panelandanypartition sensitive terminals that willaidintroubleshooting ourcontrol system. somecases, In ametal easy indexingandfuture referencing. schematic andpanellayout. canalsobedoneasaspreadsheet, whichwould It allow The BOMcanbeintheform ofatabledrawn ononeofthesheetsalongwith built. Figure exampleofa bill ofmaterials. 9isashort what needstohelp thepanelbuilderknow bedonewhencontrol panelisbeing number.its part We alsohave comments orremarks aboutthecomponent that will easily identify thecomponent onourschematic, ofthecomponent, adescription and system, ofeachcomponent, thequantity any designations or “marks” that allow usto Materials(BOM)shouldlisteachcomponentThe inourautomated BillOf control Bill ofMaterials anenclosure.when selecting Manufacturer’sElectrical Association (NEMA) of thiswhitepaper for references to NFPA’s Code (NEC) National Electrical Outdoors? Indoors? Wash down required? Refer onenclosures to inPart 2 thesection system. We needto consider theenvironment where theenclosure willbelocated. oftheenclosureOur design that shouldincludetheselection willhouseourcontrol whenthe field wiring control enclosure isinstalled. blocks. The terminal blocksalsomakeitconvenient to for terminate theelectrician his blocks sotheyprovide thebestwire routing from thecomponents to theterminal voltage, red for inputs, violetfor outputs, etc. We to locate theterminal shouldtry signals that enter andleave ourcontrol panel. We may chooseto useblackfor high blocks canbesized, organized andeven to color-coded handlethedifferent types of well-organized look. We shouldalsomakeuseofterminal blocksinourdesign. Terminal keeps thewires inplace, withthewires easier, makesworking andgives thepanela components. The simplifiesthewire wire duct routing between components, ourpanellayoutIn design, we needto between thevarious include wire duct voltage devices.

Figure 9 4 , OSHA 5 , andalistofitems to consider 2 , the National , theNational

The #1 Value inAutomation.™ www.automationdirect.com Save upto Controls: 50%onIndustrial WHITE PAPER A Condensed Guideto Automation Control SystemInstallation: Specification,Design & White Paper, pg. 22 A wiring diagram,A wiring sometimesreferred to asaninterconnecting diagram, isusedmainly Wiring Diagram and Maintain. Discussion ofautomation control systems willcontinue inPart 4-Build, Launch terminaltor blocks, starters, etc. that canbedropped into your panellayout design. devices, etc. elements alsoincludescaledoutlinesofrelays,These pre-constructed mo This may includeschematics ofPLC I/Omodules, power supplies, communication elements ofdifferent manufacturers’ devices. electrical geared toward control electrical system design. These add-inscontain pre-constructed ortimingdiagram. areflowchart Add-ins packages software for thedrafting various Design Tools andlater forsystem locating startup wire routing anddevices troubleshooting. during sizes, colors, wire numbers, terminal blocks, etc. The diagram wiring isalsousefulfor usually includesconduit sizes, distances, between numberofconductors devices, wire into control enclosures, boxes, junction conduits, wireways, etc. The diagram wiring shouldincludeallcontrolIt enclosures orcabinets, any devices that are external wired diagram.wiring various devices andenclosures inthecontrol system. Figure 10isagoodexampleof for for installation by routing theelectrician andterminating between the thewiring ware canalsobeusedto create oursequence ofoperation, controlfuture electrical system designs. The soft drafting thework for diagrams toals andwiring re-use istheability program to create schematics, panellayouts, billofmateri software. The biggestadvantage drafting inusing asoftware utility,drafting suchasAutoDesk’s AutoCAD® orAutoCAD LT® and aruler, more itisnormally efficient touseasoftware withnothingmore thanapencil, paper can beperformed Although allofthetasksrelated to documenting thedesign

Figure 10

The #1 Value inAutomation.™ - - - www.automationdirect.com Save upto Controls: 50%onIndustrial WHITE PAPER A Condensed Guideto Automation Control SystemInstallation: Specification,Design & White Paper, pg. 23 1 For “Considerations for ChoosingaPLC” refer to: Footnotes: Build for developing aplanto maintain thecontrol system. that itisbrought onlineinasafe andlogical manner, andalsogive somesuggestions blocks, grounding, shieldedcable, etc. We willcover up the system thesteps so to start control system. willincludetipsontheuseofasubpanel,The terminal buildsection Part 4,weIn willcover up, thesteps neededto build, start andmaintain ourautomated the documents. how we would usethesedocuments, andfinallythe tools that canbeused to create documents that would for betypical anautomated control system design, why and ofdocumenting thedesign. and theimportance We of discussedthevarioustypes Part 3ofSystemIn Design, we covered how to design ourautomated control system 4:Build,Part &Maintain Launch www.osha.gov/SLTC/controlhazardousenergy 5 Additional information canbefound onOSHA’s Web site: found at 4 Information forManufacturer’s theNational Electrical Association (NEMA) canbe http://industries.ul.com/industrial-systems-and-components 3 Additional ULinformation canbefound at: Machinery, Standard publication NFPA Industrial Electrical 79. found at Code® (NEC®),publication NFPAElectrical 70.Further information canbe 2 The National Fire Protection Association® (NFPA®) produces theNational equipment. For PLC specificinformation aparticular onwiring ordevice refer to the The following guidelinesprovide general information onhow to wire mostautomation Wiring Recommendations plugged into mounted connectors onthepanel. to design ourcontrol panelwith mating sothat connectors thefieldwiring could be and terminate thefieldwires. Another is terminating methodthat hasaddedbenefits devices. to allexternal connect dress toThis quickly willallow theinstallingelectrician http://library.automationdirect.com/worksheet-choosing-controller www.nema.org www.nfpa.org . Anothergoodreference from theNFPA is . terminal blocksmounted to thesubpanelthat will also makeinstallation and maintenance easierby using any faileddevice orcomponent inthefuture. We can from thefront side. This willmakeiteasierto replace ing thesubpanel, itisbestto secure thecomponents the benefitsofusinga removable subpanel.Inbuild thedesignDuring ofourcontrol panel, we pointed out

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- www.automationdirect.com Save upto Controls: 50%onIndustrial WHITE PAPER A Condensed Guideto Automation Control SystemInstallation: Specification,Design & White Paper, pg. 24 • installation manualfor that device orPLC. • • include: control systems. You canorder thesepublications from directly NEMA. ofthese Some ington, D.C., publishesmany different documents that discussstandards for industrial following sources: established installation guidelines, you shouldobtainadditionalinformation from the youIf are notfamiliarwithsystem installation practices, oryour company doesnothave safety. ofthesystem to aspect determine whichareasExamine every are to critical operator or environment oftheplanningprocess. isto makepersonnelandequipment safety part As we have stressed inprevious thebestway sections, to provide asafe operating Plan for Safety ordamage.of thesystem that may causepersonalinjury that are independent oftheautomation equipment, to provide protection for any part environment. devices, suchasrelays electro-mechanical Use external orlimitswitches to equipment.notrely Do ontheautomation system aloneto provide asafe operating Important Wiring Recommendations Safety • • • • • • • • • exceed thisrecommended capacity. canacceptEach terminal connection one16AWG ortwo 18AWG size wires. not Do ICS 3: Industrial SystemsICS 3:Industrial StandardsICS 1:General Control for Industrial andSystems apowerlineInstall filter to reduce power surges andEMI/RFInoise. Avoid creating bendsinthewires. sharp Avoid incloseproximity running DCwiring to AC where wiring possible. multiple wires for thereturn line. To minimize voltage drops whenwires mustrunalongdistance, consider using Avoid closeto where running inputwiring outputwiring possible. Avoid running control wires nearhighenergy wiring. Use wire trays for routing where possible. possiblewire length. Use theshortest length. Always useacontinuous lengthofwire. notsplice Do wires to attain aneeded NEMA installation anduseofyour equipment. all National, State, andlocalgovernment requirements for theproper be specialrequirements application.sure for Be to your follow particular Warning: to personnelordamage result insituations that injury cancauseserious system planningandinstallation. Automation systems canfailandmay goalduring equipment isyour responsibility andshouldbeaprimary Warning: 1 : Association, Manufacturers locatedThe in National Electrical Wash Every automation Every application isdifferent. Therefore, there may Providing asafe operating environment for personneland

The #1 Value inAutomation.™ - www.automationdirect.com Save upto Controls: 50%onIndustrial WHITE PAPER A Condensed Guideto Automation Control SystemInstallation: Specification,Design & White Paper, pg. 25 installation and use of various types of electrical equipment. Copies oftheNEC ofelectrical installation anduseofvarious types • • • provides explanation ofeachtheseterms: abrief mounting, bonding, andgrounding ofthechassismay bestarted. The following list considerationsOnce mentioned above alltheimportant have beendetermined, the • • • • • • • • existing grounding standards that may beusedfor reference: may bethecauseofmostproblems power affecting quality. The following isalistof grounding system beimplemented. Poor grounding orimproper ordefective wiring system. thepanelandcontrol During system that areliable build, itisimportant torisk users. Grounding isthefoundation ofachievingareliable power distribution automation equipment anddevices from damage, serious failures, andeven potential limits thesevoltages andstabilizes interference. Grounding isamustto protect your damagetoserious theequipment. Grounding provides alow impedance path that voltage line. Apower failure, surge willcauseatemporary fuseburn-up, oreven very fromfluctuations apower supply, lightning, orunintentional withahigh contact linesurges.damaged by powerful These linesurges may come from common voltage additionto deviceIn interference, automation equipment anddevices could be interference may causeerratic operation ofcomponents andcausefailures. ent ofElectromagnetic (EMI)ortransient Interference arisk interference. of This type and even devices that are neartheinstrumentation enclosure. Allthesemay pres devices may includepower supplies, input/outputsignals from otherinstrumentation, surrounded devices ofelectronic by andwires.typically various types These electronic Why instrumentation Electronic isgrounding suchasPLCs important? andfieldI/Oare Grounding for information. orFire Inspector Checkwithyour office localElectrical Marshall Handbook. have additionalrequirements above andbeyond intheNEC thosedescribed your locallibrary. beobtainedfrom equipment Handbook canoften distributor or your localelectrical ICS 6:Enclosures Control for Industrial Systems assemblies andenclosures. Joiningorbondingthesecomponents properly reduces Bonding: component to equipment. either thesubpanelorotherconnected Mounting: Handbook-Grounding Equipment andShieldingofElectronic Bonding Military EquipmentElectronic EC&M -Practical Power Guideto Quality for onGrounding Book Soars Inspectors) IAEA 1996(InternationalAssociation ofElectrical RequirementsUL96A, Installation for Lightning Protection Systems IEEE Emerald (Standard Book 1100) IEEE Green (Standard Book 142) NEC Local andState Agencies: 2 : CodeThe provides National Electrical regulations concerning the refers ofachassissuchas;frames, shields, to thejoiningofmetallicparts refers physical to theactual installation ofeachdevice, instrument or Many localgovernments andstate governments

The #1 Value inAutomation.™ - www.automationdirect.com Save upto Controls: 50%onIndustrial WHITE PAPER A Condensed Guideto Automation Control SystemInstallation: Specification,Design & White Paper, pg. 26 • The shieldedcableslisted below are themostcommonly usedfor automation control the logic circuit. There are ofshieldedcableavailable varioustypes for different uses. cause aground loopthat willcausefailure onaprocessor orwould allow noiseinto manualmustbefollowed.manufacturer Improperinstallation ofshieldedcablesmay being installedrequires shieldedcables, thegrounding specifications provided by the cable willresult inerratic readings or signals from theproduct theinstrumentation. If verify whetherany requires connection ashieldedcable. Failure to usetheshielded the useofshieldedcablesfor specific connections. When installing instrumentation, used to reduce theinterference noise. instrumentation from Some requires electrical enclosed withametallicshieldunderneathjacketed sheath. Shieldedcablesare A shieldedcableisaninsulated cableconsisting ofstrands ofcopper orothermaterial Shielded Cables proper grounding. methodfora typical grounding thesubpanelto theenclosure cabinetto assure from power surges andreduces theeffectofEMIand ground noise. Figure 1shows As mentioned before, grounding protects theinstrumentation, devices, orcomponents and interference protection. Grounding: the interference from EMIandground noise. star washer andanothertightened nut. thesecond lug overwith anut.Install thenutoffirstlug followed a by stud, makesuretwo to installthefirstlugbetween star washers andtieit Note: noise interference. supplies are properly grounded to ensure elimination ofelectronic and bondingmethodsare permitted. Always makesure that power The installermustverify thelocalcodes to determine what grounding safety requirements by that are localcodes andregulations. mandatory Note: refers to to agrounding aconnection to conductor provide overload When usingground lugsandinstallingmore thanoneonthesame Please remember that bondingandgrounding are important

Figure 1 The #1 Value inAutomation.™

www.automationdirect.com Save upto Controls: 50%onIndustrial WHITE PAPER A Condensed Guideto Automation Control SystemInstallation: Specification,Design & White Paper, pg. 27 systems andinstrumentation: interference withyour equipment: or signals from otherdevices. Use theseguidelinesto prevent any of possibility devices orEMI. This interference causes static that may interrupt communications instrumentationElectronic canbeaffected by interference from otherelectronic layout, thefollowing specifications shouldbe considered: panel layout accommodates components. additionto thepanel allthenecessary In Therefore, theinstallation oftheinstrumentation musttake into consideration that the installedinsideanenclosure instrumentationElectronic istypically withotherdevices. InstrumentationMounting ofElectronic • Foil Shield: • Use components Approvals withAgency suchasUL,CE, etc. requirement guidelinesfor your specificpiece ofequipment. instrumentation always makesure to follow the manufacturer’s power • Power requirements are specific to eachpiece ofequipment. When installing vibration, noiseimmunity, etc. • Environmental specifications that cover theoperating temperature, humidity, themore ofshieldedcableintoday’s commonly usedtypes industry. thelow resistance ofbraid with100%coverage offoil shieldsandisoneof radiated emissionscoupling and electrostatic discharge (ESD.) combines It shielding. The combination shieldisusedto shieldagainsthighfrequency • Combination Shield: shieldingagainstdiffusionandcapacitive coupling at audiofrequencies only. spiral around theinnercablecore. The spiral shieldisusedfor functional • Spiral Shield: andto capacitive alesserextent, coupling. andinductive important, againstdiffusion coupling, performance superior where low DC resistance is Braided direction. shieldsprovide withanothersetinacounter-clockwise aluminumstrands. Onesetiswoven theninterwoven direction, inaclockwise • Braided Shield: thanlow DCresistance. field) coupling where capacitive shielded (electric coverage ismore important shieldedprotection. Foil shieldsare usedfor normally protection against insulation. The foil shieldprovides 100%cablecoverage for electrostatic orpolypropylene film. The film provides mechanicalstrength andadditional Figure 2 These cablesconsist ofaluminumfoil laminated to apolyester The spiral shieldconsists of wire (usuallycopper) wrapped ina These cablesconsist ofgroups oftinned, bare copper, or These cablesconsist ofmore thanonelayer of shields. a shieldedcablethat makesuseofcombination Figure 2shows area cross of atypical sectional

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from the mainsource. thecircuit turning breakers onorreplaceThen start thefusesone onthemaincircuitcan turn protector andcheckthevoltage at eachdevice that isfed iftheincoming powerto isthree -phaseandeachphase-to-ground, we phase. Next, ofourcontroldisconnect system. Then, measure thevoltage for proper values, phase- As afirststep, we may want to applypower to themaincircuit breaker orfused power, and basicallywork ourway through theentire schematic. commissioningduring istheschematic diagrams. We at theincoming willwant to start bywiring removing thefusesand/oropeningcircuit breakers. The besttool to use point, itisbestto ofourcontrol isolateAs thevarioussections astarting system power Up Start meter onanalogoutputs. to inputsandmonitors outputswiththeuseofanindicator ondiscrete outputsanda point tested andto simulate outputs, andtheotherpersonphysically appliesasignal team. to OnepersonusesaPCconnected thePLCtwo-person to viewthestatus ofeach 12 mA(middlevalue) and20mA(highvalue). testing requiresThe normally actual a example, ifusingacurrent inputmodule, you may want to simulate 4mA(low value), state. Analogpoints, bothinputandoutput,could becheckedat different values. For and outputpoints would belisted asnormally “off” andthenchecked for their “on” face. thetest for criteria Include eachpoint onthelist.As anexample, discrete input list that was created whendesigning your PLC ladderlogic orHMIoperator inter itistested.each point after thislistcanbecreated Normally from anI/Olistortagname is beingtested. isalsohelpfulto includeacheckbox It that canbeusedto checkoff To create alistwitheachI/Opoint start, shown andincludeany detailsofwhat criteria module terminals blockshasbeendone andthefieldwiring terminal correctly. complete I/Ocheckout. This willassure that thepoint-to-pointbetween theI/O wiring The lastitem to consider at thecompletion ofbuildingyour control system isto doa I/O Testing that thebasewasn’t grounded to thesubpanel. many casesofaPLC experiencing “noise” problems, whentheproblem isfound to be and components to closelyfollow themanufacturer’s recommendations. There are grounding, to critical theproper operation itisvery ofthePLC anditsrelated devices installingaPLCIf baseorchassiswhichconsists mainlyofmounting, bonding, and mounting clearances, heat dissipation andEMI. basedoncomponent enclosure• Make dimensions, selections recommended automated control system andrelated equipment/process. required testing. This process isalsocalled “commissioning” the equipment, terminated allfieldwiring,iary and completed we have installedourcontrol system enclosure andauxil ofourautomated controlThe startup system begins once

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www.automationdirect.com Save upto Controls: 50%onIndustrial WHITE PAPER A Condensed Guideto Automation Control SystemInstallation: Specification,Design & White Paper, pg. 29 may bepowered from thecircuit. circuit at atimeandmakeadditionalvoltage checksandtest equipment operation that Machinery, publication NFPA 79. www.nfpa.org publication NFPACode (NEC), 70.Further information canbefound at their Web site at 2 The National Fire Protection Association (NFPA) produces theNational Electrical found at their Web site at: 1 Information forManufacturer’s theNational Electrical Association (NEMA) can be Footnotes: may want to consider inyour maintenance schedule: period, dependingontheitem to bedone. The following are someoftheitems you eliminate future time problems. uptheschedulebasedonamonthly orquarterly Set the system willincrease ofthesystem thelongevity andmore importantly, itwill help system. Having aroutine components critical schedulefor anddevices in checking to develop aroutine isimportant maintenanceIt schedulefor your automated control Maintain ladder logic to makesure conditions, states, etc. are responding correctly. • Checkdiagnostics that may beprogrammed into theHMIoperator interface any• Review diagnostic history, includingevents andalarms • Measure device current to andcompare setabenchmark for changes • Checkequipment runtimesfor determining maintenance orreplacement • Checkandrecord power usage • CheckallI/Opoints onayearly basis • Perform andrecord calibrations • Checkandrecord any configuration settings • Test systems, allalarm horns, sirens, etc. • Checkto makesure are plug-inconnectors tight andsecured • Visually for inspect looseorfrayed wiring, moisture inenclosure, etc. lamptests • Checkindicators andperform batteries,• Checkbackup and/orreplace onaroutine schedule • Tighten (withpower allconnections removed) • Checkandrecord voltages at variouscircuits . Anothergoodreference from theNFPA Standard Industrial isElectrical as you go. usingaPLC, If aPCto itandmonitor connect the and usingLockout/Tagout (LOTO) procedures. Measure voltages from theirrespective loads, airpressure off, disabling hydraulics, the equipment onlinesafely. Consider having motors uncoupled Therefore, eachsystem willrequire adifferent strategy to bring controlKeep inmindthat every system willnotbethesame. www.nema.org.

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