A Condensed Guide to Automation Control System Specification, Design & Installation: White Paper, Title Page

WHITE PAPER
A Condensed Guide to Automation Control
System Specification, Design and Installation
By Tom Elavsky
AutomationDirect

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 A Condensed Guide to Automation Control System Specification, Design & Installation: White Paper, pg. 2

The following is Part 1 of a four-part series of articles on Control System Design that
can act as a general guide to the specification, design and installation of automated
control systems. The information and references are presented in a logical order that
will take you from the skills required to recognize an operation or process suited for
automating, to tips on setting up a program, to maintaining the control system.
Whether you are an expert or a novice at electrical control devices and systems, the
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information presented should give you a check list to use in the steps to implementing
an automated control system.

Electrical control systems are used on everything from simple pump controls to car
washes, to complex chemical processing plants. Automation of machine tools, material
handling/conveyor systems, mixing processes, assembly machines, metal processing,
textile processing and more has increased productivity and reliability in all areas of
manufacturing, utilities and material processing.

You may have come to realize that an operation or process used to produce your end
product is very laborious, time consuming, and produces inconsistent results. You may
have also visualized ways that would allow you to automate the operation. Automating
the process will reduce the amount of manual labor, improve throughput and produce
consistent results. You may have the skills to develop the mechanical means and select
the appropriate equipment to make this happen, and although you have a basic
understanding of electrical control devices, you may not have the experience to put it
all together. Your first option may be to enlist the help of a qualified System Integrator.
If you do decide to use a System Integrator, it would be beneficial to understand as
much as possible about automation control system devices and their terminology so
that your communications with the System Integrator go faster and more smoothly.

In most cases, special expertise is required to design and install industrial automation
control systems. Persons without such expertise or guidance should not design and
install automation control systems because they can fail and cause serious injury to
personnel or damage to equipment. The information provided in this whitepaper is
provided “as is” without a guarantee of any kind. We do not guarantee that the
information is suitable for your particular application, nor do we assume any
responsibility for its use in your application.

It is our intent to produce this whitepaper as a usable guide, with additional

information, including a typical “real world” application that can be followed from
concept to completion. It is not our intent for the guide to cover every possible topic
dealing with automation control systems or to even suggest that the topics being
covered are fully detailed. Instead, the topics are aimed at giving the reader a good
starting reference for automated control systems.

In Part 1, we will cover the topics of Safety and Identifying an operation or process that
could benefit from automation. We will then cover control device specification, control
system design and construction, control system installation, and finally control system

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 A Condensed Guide to Automation Control System Specification, Design & Installation: : White Paper, pg. 3

maintenance. The topics will be broken down as follows:

• Part 1 - SAFETY and IDENTIFICATION
• Part 2 - SPECIFICATION
• Part 3 - DESIGN and BUILD
• Part 4 - INSTALL and MAINTAIN

Part 1: System Identification and Safety

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The first and most important item to consider before
attempting an automated control system, or even
a simple on/off control for a pump, is safety, both
for personnel who may be working with or near the
automated equipment, as well as to prevent damage to
the equipment.

To minimize the risk of potential safety problems, you

should follow all applicable local, state and national codes
that regulate the installation and operation of your con-
trol system, along with the equipment or process it is designed to control. These codes
vary by area and usually change over time. It will be your responsibility to determine
which codes should be followed and to verify that the equipment, installation, and
operation is in compliance with the latest revision of these codes.

Most likely your control system will be dealing with electrical energy, so your first
goal will be to eliminate the risk of fire and electrical shock to personnel. The top
organizations that provide applicable standards and codes are referenced below, but
even before you get to this area of safety, it would be wise to educate yourself as much
as possible about electricity and electrical equipment in general. A good understanding
of basic electricity, including DC and AC theory and practice, Ohm’s Law, etc. will go
a long way in helping you understand the various codes and standards. There are
many good publications and articles on the subject of basic electricity and some local
technical colleges offer courses covering subjects dealing with basic electricity. Some
even offer courses in Programmable Logic Controllers (PLCs), which can be very useful
when dealing with automated control systems. Also, many Web sites offer free tutorials
covering basic electricity and PLCs. It would be beneficial to have some understanding
of electronic devices, such as the operation of a transistor and other solid state devices,
as well as understanding of the use and operation of electrical test and measurement
instruments, such as voltmeters, current loop meters, clamp-on amp meters, etc.

At a minimum, you should follow all applicable sections of the National Fire Protection
Association (NFPA) fire code, and the codes of the National Electrical Manufacturer’s
Association (NEMA). There may also be local regulatory or government offices that can
help determine which codes and standards are necessary for the safe installation and
operation of electrical control equipment and systems.

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Another area of safety that needs to be considered for automated control systems
is lockout/tagout procedures as specified by Occupational Safety and Health
Administration (OSHA). “Lockout/tagout” refers to specific practices and procedures to
safeguard operators and maintenance personnel from the unexpected energization or
startup of machinery and equipment, or the release of hazardous energy during service
or maintenance activities. In order to have your control system make use of a lockout/
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tagout procedure, the design should include the ability to shut off, neutralize, or isolate
any energy source, such as the main electrical feed, but also any pneumatic, hydraulic
or mechanical energy storage device. The means to do this should be considered in the
initial design of the automated control system. Additional information can be found on
OSHA’s Web site at: www.osha.gov/SLTC/controlhazardousenergy/

There are many reasons why the electrical devices that you will use in the design of
your automated control system should be listed, approved or registered with a testing
laboratory. One reason is to ensure that the device meets standards that will prevent
failure that could lead to catastrophic results. Another reason might be for insurance or
compliance purposes. One of the most specified and premier safety testing laboratories
is Underwriters Laboratories (UL). One of the most applicable areas of interest for con-
trol systems is UL’s Standard for Safety 508A. If your control system panel requires being
built to UL508A, then you will need to contract directly with UL to become a UL508A
panel builder or use an existing UL508A panel builder. Additional information can be
found at: https://standardscatalog.ul.com/standards/en/standard_508a

Compliance to UL508A for AutomationDirect products can be found on our Web site at:
http://support.automationdirect.com/compliance.html

The following are other safety points to consider in the design of your automated
control system:
- Emergency Stop - The control system must provide a quick manual method of
disconnecting all system power to the machinery, equipment or process. The discon-
nect device or switch must be clearly labeled “Emergency Stop”. After an Emergency
shutdown or any other type of power interruption, there may be requirements that
must be met before the control system or PLC control program can be restarted.
For example, there may be specific register values in the PLC memory that must be
established (or maintained from the state prior to the shutdown) before operations can
resume. There may also be mechanical positions of equipment that have to be moved
or jogged to the proper position.
- Accidental Powering of Outputs - Do not rely on the automation control
system alone to provide a safe operating environment. You should use external electro-
mechanical devices, such as relays or limit switches, that are independent of any elec-
tronic controlling devices, such as a solid state relay or a PLC output module, to provide
protection for any part of the system that may cause personal injury or damage. These
devices should be installed in a manner that prevents any machine operations from
occurring unexpectedly. For example, if the machine has a jammed part, the controlling
system or PLC program can turn off the motor rotating a saw blade. However, since

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the operator must open a guard to remove the part, you should also include a bypass
switch that disconnects all system power any time the guard is opened.
- Orderly Equipment Shutdown - Whether using a control system designed
around relays and timers or a PLC, an orderly system shutdown sequence should
be included in your design. If a fault is detected, then any mechanical motion, valve
position, etc., needs to be returned to its fail-safe position and the equipment/process
stopped. These types of problems are usually things such as jammed parts, broken
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cutting tools, bin full, etc. that do not pose a risk of personal injury or equipment
damage. If a detected problem would result in risk of personal injury or equipment
damage, then use other means to deal with it, such as applying a brake to rotating
equipment to stop it before personnel can come in contact with it.
- Grounding - To prevent electrical shock, incorporate good grounding
practices in the design, construction and installation of your system. Use protective
devices for faulted conductors to prevent fire, and also realize that good grounding
practices can reduce electromagnetic and radiated noise interference to sensitive
electronic devices.
- Control Power Distribution - Develop a power distribution scheme in the
control system circuitry, according to code, that ensures all circuits are protected with
fusing, circuit breakers or other interrupting means coordinated such that only the
faulted circuit will be opened (de-energized), allowing other powered equipment and
devices to continue to operate.
- Unauthorized Access - Make sure all enclosures and cabinets that have
energized circuits are secured to prevent unauthorized personnel from gaining access
without the proper tool, key or other authorized means.
- Finger-Safe and Dead Fronts - Another safety area to consider is the use of
devices that have finger-safe terminal connections, which are surrounded by insulated
guarding. The use of protective guards over live circuits should also be considered, even
on control panels that have limited access, so it is safer for maintenance electricians and
authorized personnel to troubleshoot or make adjustments to electrical control devices.
Dead fronts should be used on control system enclosures where the operator needs to
make adjustments to devices, such as selector switches, thumbwheels, potentiometers,
etc., and the controls need to be inside the enclosure so as to protect them from
outside weather conditions. The dead front is normally an interior door that is mounted
in front of the main control panel. The outside enclosure door may still require key entry
by the operator, but the dead front interior door with adjustable devices is interlocked
so that it requires a switch to open it, disconnecting power to the electrical devices
mounted on the main control panel.
- Closed-loop Control - It is your responsibility in any type of closed-loop
control system to ensure that if the feedback signal is lost, the system shuts down so as
not to cause injury to personnel or damage to the equipment.

Identifying Process for Automation

The first step in configuring an automated control system

is to identify what can be automated. You need to have
a good understanding of basic electricity and safety.

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It is also important that you have an understanding of basic hydraulics, pneumatics,

mechanical operating mechanisms, electronics, control sequences, etc. and a solid
knowledge of the operation or process that you are going to automate.

You should understand how to control motion and movement, regulate the flow of
fluids, dispense granular materials, orient parts, sense product in position, detect when
an operation is complete, etc. As a simple example, let’s say we have a conveyor that
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moves our product from point A to point B. The conveyor is powered by a 3-phase AC
motor, which is turned off and on by a manually controlled motor starter and includes,
for fire protection, both short circuit and overload protection. The system requires an
operator standing at the motor starter to watch as the product reaches the entrance to
the conveyor, and to turn the conveyor on to move the product. The operator must also
turn the conveyor off once the product has reached the discharge end.

To automate the conveyor, we will need to replace the manually controlled motor
starter with an electrically controlled motor starter, including short circuit and overload
protection. We will need to size the motor starter to work with the existing conveyor
motor. (Refer to our Web site at: http://www.automationdirect.com/static/specs/
fujimcselection.pdf for information on specifying and sizing motor starters.)

We will also need to identify where to locate sensors such as limit switches,
photoelectric sensors, proximity sensors, etc. that will indicate when an operation is
completed. This is required so our control system knows when to proceed to the next
step in our operation. As an example, we usually need a limit switch to detect when a
cylinder is fully extended, as in the case when the cylinder is used to push our product
onto a conveyor. The cylinder “fully extended” signal is used to de-energize the solenoid
valve that provided the air pressure to the pneumatic cylinder. We also need a limit
switch to indicate when the cylinder has fully retracted, and provide a signal to the
start/stop control of the conveyor that the product push cylinder is out of the way for
the next product. Another application for a sensor is to indicate when the product has
reached the conveyor. The sensor can be a limit switch with a roller arm that comes in
contact with the product or a photoelectric sensor that can detect the product by using
an infrared beam of light. The photoelectric approach may be the better choice because
the position of the product on the conveyor belt may vary. (Refer to our Web site at:
www.automationdirect.com/static/specs/peselection.pdf for information on
selecting photoelectric sensors.)

We would continue with this analysis, looking at each piece of equipment or compo-
nent in our system, and select a device that could control or sense it. Some examples
include an electrical solenoid valve to control water used to wash residue from a
product, or a pneumatic valve to control air pressure to a cylinder operating a gate that
diverts product on a conveyor, or energizing a control relay to signal that a product is in
position on a scale.

In some instances we may need to vary the speed, rate or position of our controlling
device, such as varying the speed of a conveyor, changing the amount a valve opens

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to control a flow rate, or remotely changing the set-point level for a tank. This could be
accomplished by using an analog output signal. An analog output signal is a varying
signal that corresponds to the real value we have determined and calibrated into the
device. For example, a 0 to 10 VDC signal could represent a conveyor speed of 0 to
500 feet per minute. An analog signal to the speed controlling device for the conveyor
motor of 5 VDC would result in a conveyor speed of 250 feet per minute.
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Identifying devices to control motion, flow, events, etc. and sensing completion is
basically identifying the I/O (inputs and outputs) of our control system. Once these de-
vices are identified, they can be used as the field devices in a PLC-based system, or they
can be “hard-wired” for simpler applications.

You will also want to determine if your automated control system will benefit from the
use of an operator interface, also referred to as a Human Machine Interface (HMI). If
your process requires making changes to set-point values, process time, flow rates, etc.,
then the use of an HMI is the best way to proceed. In these situations, you will most
likely need a PLC that can easily communicate with the HMI device.

If your application requires keeping data records for reference, traceability, history,
trending, meeting regulations, etc., then you should look at using a control system that
would fall into the category of a “Supervisory Control And Data Acquisition” (SCADA)
system. Most of these control systems would be comprised of PLC-type I/O that
interface to a PC with appropriate software.

Part 2 will cover Control Device Specification.

References:
For information on PLCs and PLC programming fundamentals visit:
www.interconnectingautomation.com

You may also want to visit the AutomationDirect Customer Forums at:
https://forum.automationdirect.com or watch our tutorial videos at
www.automationdirectcom/videos

Information for the National Electrical Manufacturer’s Association (NEMA) can be found
at their Web site at: www.nema.org.

Further information for the National Fire Protection Association (NFPA) can be found at
their Web site at: www.nfpa.org. Some of the more useful publications are the National
Electrical Code (NEC), publication NFPA 70 and also as a good reference refer to the
Electrical Standard for Industrial Machinery, publication NFPA 79.

Part 2: Control Device Specification

In Part 1 of Control System Design, we covered safety aspects involved in the use
of automated control systems and discussed some tips used in identifying which
manufacturing equipment and processes can be automated.

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In Part 2, we will cover how to specify the various devices required for controlling
the equipment in an automated system. Your specifications need to include not only
the “controlling” devices for your application, but also items such as the housing or
enclosure for the devices, the type of wire required to meet the various codes, agency
approvals required for safety and insurance purposes, environmental conditions, etc.
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The first skill we need to develop in this effort will be the gathering of all the equipment
parameters and specifications needed to specify the devices required to control the
equipment. We need to be the proverbial detective who would ask questions such as;
• What is the operating voltage?
• What is the power rating?
• How much current does it draw?
• What is the operating temperature range?

• What is the relative humidity range?

• What are the mounting dimensions?
• What are the minimum mounting clearances?
• What is the duty cycle?
• How will the system be used?
• Who will be using the control system?

Control System Devices

The devices you need to specify in your control system
will generally fall into one of three categories; input
devices, output devices and the processing unit.

Input Devices
Sinking Input Input devices are used to sense
PLC a condition, detect movement
Input
or position, indicate a limit or set
+ point has been reached, sense
Input intervention by an operator, detect
– Common Sensing an alarm, etc. Typical input devices
may include limit switches, pho-
toelectric sensors, pushbuttons,
Sourcing Input proximity sensors, an operator in-
PLC terface, etc. These input signals are
Common
generally in an ON or OFF state. We
+ Input can look at an input from a device,
Sensing such as a photoelectric sensor used
– Input
to detect an obstruction, and state
that when the sensor sees the ob-
Figure 1: Typical wiring for sinking and sourcing struction, the sensor is ON; in other
input devices words we have a true condition.

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When the sensor is not obstructed, then the input is OFF; or we can say the condition
is false. These types of signals are called discrete signals, meaning they are always one
of two states; ON or OFF. They can be wired into a PLC input module and the PLC can
be programmed to use the status of the signals to execute the logic to control the
automated system. Or these same signals can be used in a “relay logic” system, where
control relays are hardwired to create the system logic.
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Of importance to our specifications are the ratings of these input devices:
• What is the operating voltage; 24, 120 or 240 Volt AC or DC?
• If they are rated for DC, are they sinking or sourcing?
• What distances can they sense?
• How much force can be applied to the actuator?
• How much current do they require?

As a note, most PLC DC input modules can be configured as sinking or sourcing1.

Also keep in mind that when selecting a sensor device, such as to detect the presence
of product or sense the end of travel for a mechanism, it is very important to consider
the environment in which the sensor will operate. This should not only include
temperature and humidity ranges, but in some cases, indoor or outdoor use, altitude,
ability for the sensor to be washed down, etc. Photoelectric sensors are sensitive to the
atmosphere in which they can efficiently work. If there is a lot of dust, dirt and/or mist in
the air, then the optics can easily become dirty or coated, reducing their sensitivity and
operating distance.

Output Devices
Output devices are used to control actions such as motion, start/stop of equipment like
conveyors and pumps, on/off control of valves, operator alerts/prompts, status
indications, etc. Typical output devices include relays, motor starters, pilot lights,
operator interface graphics and numeric display, etc. These output signals, like input
signals, are also discrete; either ON or OFF. The signals can be wired from a PLC output
module to control the devices, such as starting and stopping motors, energizing a valve
to control water flow, illuminating a pilot light to alert an operator to a condition such
as “Bin Full”, etc. Output signals can also be wired directly to a controlling device using
hardwired relay logic.

Of importance to our specifications are the ratings of these output devices:

• What is the operating voltage; 24, 120 or 240 Volt AC or DC?
• If they are rated for DC, are they sinking or sourcing?
• What is the current draw?
• What is the duty cycle?
• What is the operating temperature range?
• What are the mounting dimensions?

For example, if our process uses a solenoid valve to control water flow to a wash
station, we would need to know the operating voltage of the valve and how much

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current it draws. We also need to know not only the on-state current draw of a valve,
but also the inrush current, so that Sinking Output
we can properly specify a PLC output PLC
Output
module or a control relay. Although Load
a valve may be rated to draw 250 mA +
continuous current, it may have an in- Output
Switch Common –
rush of 800 mA when first energized.
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If an output module has eight output
points and each point is rated for 1
amp continuous duty, after thermal Sourcing Output
PLC
considerations, the entire output Common
module has a total rating of 6 amps
+
and therefore has a common
Output
fuse rated at 6 amps. If we had so- Switch Output –
lenoid valves connected to all eight Load
output points and our program called
for them all to energize at the same Figure 2: Typical wiring for sinking and sourcing
time, the total inrush current would output devices
be 8 times 800mA or 6.4 amps, and
most likely would blow the fuse. The solution could be to select an output module with
a higher current rating or to use the ladder program to sequence the valves, prevent-
ing them all from being energized at the same time. Another option is to split up the
valves between several output modules, using the remaining points to power smaller
loads such as pilot lights. Certain output types may have derating curves depending on
the ambient temperature and the number of outputs energized. Keep in mind that DC
output modules can be sinking or sourcing type.

The processing unit

All control systems can typically be defined as having inputs, outputs and some form of
decision making going on in between so that the outputs are controlled based on the
status of the inputs. This brings us to our third category, the “decision making” element.
This element can be performed by a PLC, where we have inputs, outputs and a central
processing unit (CPU) that uses logical programming to make decisions based on input
status and the logical conditions set in the program (see figure 3). A similar device that
can be looked at in the same manner is a personal computer (PC). The keyboard, mouse,
scanner, etc. would serve as input devices and the monitor, printer, speakers, etc. would
be the output
push motor devices. The
button starter
microprocessor
used on the
photo Decision valve
sensor Input Output motherboard,
Making
along with
alarm pilot its memory,
signal light the operating
system, and
Figure 3 the application

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program would serve as the decision making element. As a matter of fact, PCs are used
in some automated control systems as the decision making element, together with
industrial input and output (I/O) modules. These PC-based systems rely on the commu-
nication ports or Ethernet connections to monitor and control the I/O. The application
software typically allows a programmer to develop a graphical interface that gives an
operator interaction with the equipment or process. With some research and experi-
ence, you will learn how to determine how much “decision making” ability your control
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system requires. Cost restraints may require you to compare implementing the control
system with either a PLC, PC-based control, or simple hardwired relay logic. But don’t
forget the fact that a PLC or PC-based control system allows easier changes and future
expansion2.

Other device types

Another area of inputs and outputs involves the use of analog signals in a control
system. Analog signals are variable and can represent a range of values. As a quick
example, we may want to monitor the level of a liquid in a tank that is 100 feet tall. We
can use a sensor that will produce a signal that is represented by a voltage range of 0
to 10 volts DC, with 0 feet being equal to 0 VDC and 100 feet being equal to 10 VDC.
Analog signals are typically linear, so a 5 VDC signal would tell us the tank level is at
50 feet. The analog signal could be wired into a PLC analog input module, and in the
ladder program we could compare the actual level to a set point and produce a discrete
signal that would cause an output point to start a pump to raise or lower the level.

Inductive devices
When selecting a device to control a prime mover, such as an industrial motor to power
a conveyor, or a valve to control a hydraulic cylinder, you will need to determine the
ratings of the equipment:
• What is the operating voltage?
• What is the maximum current draw?
• What type of environment is it being used in?

An industrial induction motor may have ratings such as 230/460 VAC, 3-phase, 1725
RPM, a FLA (full load ampere) of 10.5 amps at 460 VAC, etc. This information can be
obtained from the manufacturer’s catalog, or website, or directly from the motor
nameplate. In the case of a motor, you will need the ratings to choose the motor starter
or possibly a variable frequency drive for either start/stop control or speed control of
the motor.

Other considerations
There are other points to consider in the specification of devices being used in your
automated control system - duty cycle, surge suppression, enclosure type, heating and
cooling, power, environment, static electricity and agency approvals.

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Duty Cycle
When using a solenoid valve, you will want to know its operating voltage, nominal
current draw and current inrush to help select the type of output device required to
control its operation. It is also important to have an understanding of the solenoid
valve’s duty cycle (time on vs. time off). We would not want to operate a solenoid valve
rated at 50% duty cycle in a continuous mode with an on time of 10 seconds and an
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off time of only two seconds. The short off time would not allow for the solenoid to
properly cool down.

Surge Suppression
Solenoid valves, motor starters, etc. make use of an inductive coil for their operation
and the coil can produce high voltage spikes that can damage output devices and near-
by electronic equipment. It is always recommended to use some form of surge suppres-
sion to eliminate these voltage spikes.

Enclosures
Selecting a proper enclosure is im-
MODEL # AVE213THFW7726AA L FRAME 213TC
portant to ensure safe and proper
POLES 4 ENC TEFC CODE K DES A TYPE TRF INS H3
FL 1770 FL
operation of your equipment. The
VOLTS 230/460 RPM AMPS 21.4/10.7
SF 1.0 DUTY CONT.
TEMP.
SENSORS
NONE minimum considerations for enclo-
MAX.
SERIAL AMB. ° C 40
sures should include:
MAX. SAFE S.E. O.S.E. NL. ROTOR
RPM 4200 BRG. 309 BRG. 206
AMPS 13/6.5
WK2 .75
Hz. HP RPM TORQUE VOLTS AMPS
• Conformance to electrical stan-
4 .38 90 22.3 ---- 10.5
dards (Reference NEC)
60 7.5 1770 22.3 460 10.5

120 7.6 3530 11.2 460 10.6 • Protection from the elements in an
R1 R2 X1 X2 XM
OHMS/PHASE .707 .488 2.39 3.21 41.4 industrial environment (Reference
3 PHASE INVERTER DUTY AC INDUCTION MOTOR
NEMA)3
• Common ground reference (Reference NEC)
• Access to the equipment (Reference OSHA)4
• Security or restricted access (Reference OSHA)
• Sufficient space for proper installation and maintenance of equipment

Heating/Cooling
Ensure that the devices used in your control system aren’t subject to overheating,
or if installed in a colder climate, the devices aren’t being used below the listed low
temperature operating range. Your control system, because of its physical location, may
require you to have both a cooling system, such as an A/C unit, and a small heating unit
as part of the same enclosure. This will ensure the devices are always operating within
their temperature specifications. Basic thermal management is not difficult for most
automated control systems. Investing a little thought during the specification stage can
save you a great deal of redesign down the road.

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DC Power
If using DC voltage from a power supply in your control system, consider using a power
supply rated for at least twice the calculated load. This should satisfy one of the re-
quirements if you need to have your control system UL 508 approved and will allow the
power supply to operate at a lower temperature, thus increasing its life.
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The following table is an example of NEMA’s common environmental specifications that
generally apply to automation equipment. IEC also has a list of common environmental
specification designations for enclosures and equipment.

Comparison of specific non-hazardous applications indoor locations

Provides a degree of protection Type of enclosure

against the following
environmental conditions 1 2 4 4X 5 6 6P 11 12 12K 13

Incidental contact w/ encl. equip. • • • • • • • • • • •

Falling dirt • • • • • • • • • • •
Falling liquids and light splashing • • • • • • • • •
Dust, lint, fibers, and flyings • • • • • • • •
Hose down and splashing water • • • •
Oil and coolant seepages • • •
Oil or coolant spray and splashing •
Corrosive agents • • •
Occasional temporary
submersion • •
Occasional prolonged submersion •

Static Electricity
Most equipment and devices will operate down to 5% relative humidity. However, static
electricity problems occur much more frequently at humidity levels below 30%. Make
sure you take adequate precautions when you touch the equipment. Consider using
ground straps, anti-static floor coverings, etc. if you use the equipment in low-
humidity environments.

Agency Approvals
Some applications require agency approvals for particular components. Some of these
required approvals are:

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• UL (Underwriters’ Laboratories, Inc.5)

• CUL (Canadian Underwriters’ Laboratories, Inc.)
• CE (European Economic Union)

The requirements for any of these agency approvals need to be part of your specifica-
tion and will determine the selection of most of your controlling devices.

Enclosure Lighting and Convenience Receptacle

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It is always a good idea to include interior lighting for your control system enclosure
or cabinet to help during routine maintenance to the control system. Provide a conve-
nience receptacle inside the control system enclosure to supply power to test equip-
ment, calibration equipment, etc.

Product Selection
Suppliers’ literature and Web sites are an excellent resource for evaluating product spec-
ifications. For industrial control product selection information for AutomationDirect
products, refer to https://www.automationdirect.com/adc/ProdInfo/ProdInfo

Next step is Part 3, Control System Design

Footnotes:
1 For “Sinking and Sourcing Concepts” refer to:
https://library.automationdirect.com/sinking-sourcing-concepts
2 For “Considerations for Choosing a PLC” refer to:
http://support.automationdirect.com/docs/worksheet_guidelines.html
3 Information for the National Electrical Manufacturer’s Association (NEMA) can be
found at their Web site at: http://www.nema.org.
4 Additional information can be found on OSHA’s Web site at:
www.osha.gov/SLTC/controlhazardousenergy
5 Additional UL information can be found at:
http://industries.ul.com/industrial-systems-and-components

Part 3: Design
In Part 2 of Control System Design we covered specifying the various devices required
for interfacing and controlling the electrical equipment in an automated control
system.

In Part 3, we will cover the steps needed to design our automated control system. The
design topics will include planning by defining our sequence of operation, creating a
schematic with the devices shown in a high-voltage to low-voltage order, input to
output design layout, panel layout, wiring diagrams, bill of materials, software tools to
document our design, choices between using hard-wired relays versus a PLC with
programming, etc.

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Design
The design for our control system will be in the form of a
documenting task. The challenge will be to get our design
specifics down on paper so that it can be easily understood.
It is important that anyone can look at our documents in
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the future and be able to interpret the information.
Useful to us at this step will be any notes and lists that
were developed during the “Identifying” and “Specifying” phases of our automated
control system.

Sequence of Operation
In most cases, the first step in designing our control system will be to define the process
or actions to take place, by way of a “sequence of operations” description. The sequence
should show or list each operational step in our process.

Our particular application may be

better suited to using a flowchart
that shows the sequence of opera-
tion by means of decision-making
steps and actions that need to
take place. Figure 1 shows a partial
example of a flowchart.

A flowchart can be developed with

graph paper and a pencil, or an
application software program such
as MicroSoft Visio®. These programs
have built-in flowchart capabilities
with common flowchart symbols.

In some cases, the application may

be better suited to using a timing
chart, in which each condition and
event is graphed in a time relation-
Figure 1 ship to each other, as shown in
Figure 2.

Once we have a sequence of operation developed and a list of our input and output
devices, we can determine if our automated control system is best suited for hard-wired
relay logic or can benefit from a PLC1. A PLC can be cost-effective when used in place of
only a half dozen industrial relays and a couple electronic timers. It adds the flexibility of
making future “logic” changes without the labor of making wiring changes.

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Figure 2

Schematic
The next step in our design is to develop a schematic. Most electrical designers
and engineers define a schematic as a drawing that shows the logical wiring of an
automated control system. A control schematic is normally drawn in the form of a
ladder, showing the various wiring conditions. This analogy of a ladder is what PLC
ladder logic was based upon. It made the transition to PLC ladder logic easier for
engineers and electricians because they were accustomed to trouble-shooting hard-
wired relay control systems shown in a ladder fashion.

Figure 3

It is normal practice, as shown in Figure 3, to show input type devices on the left-hand
side of drawings and output devices on the right-hand side. For example, the symbols
for protective devices (fuses), contacts and overload relay elements are shown to the
left, while the symbol for the motor is shown to the right.

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The schematic should start with the incoming power, including protective devices such
as circuit breakers and/or fuses. Our design should show the distribution of the AC
power and include all circuitry and required devices for conformance to the National
Electrical Code® (NEC®)2 and any local codes that might apply in our area.

It is normal practice to show any high-voltage devices, such as 3-phase motors, 480
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or 240 VAC auxiliary equipment, etc. in this first section of the schematic. Next, we will
show a control power transformer used to step the higher incoming voltage down to
our system control voltage (115 VAC). Our control voltage can be something other than
115 VAC; for example, we could have a control voltage of 24 VDC, which is common for
many electrical control devices. The control transformer needs to be sized (VA rating)
based on our known or calculated “load” of devices that will be powered from the
transformer in our automated control system. At this point in our schematic, we need
to look at device wiring isolation strategies. PLCs provide ideal isolation because its
circuitry is divided into three main regions separated by isolation boundaries as shown
in Figure 4. The PLC’s main power supply includes a transformer that provides isolation,
and the input and output circuits that use opto-couplers to provide additional isolation.
When wiring a PLC, it is extremely important to avoid making external connections that
connect logic side circuits to any other.

Figure 4

Electrical isolation provides safety, so that a fault in one area does not damage another.
Using Figure 5 as reference, we see a transformer which provides magnetic isolation
between its primary (high voltage) and secondary (control voltage) sides. A powerline
filter provides isolation between the control power source and the electronic devices.

Figure 5 also shows some general suggestions for device grounding and distributing
the control power to various devices, along with individually fusing these devices.

Proper grounding is one of the most important things in good automated control
system design. The more details we can show on the schematic to reflect all points
that need to be grounded, the better chance we have of a properly grounded control
system that provides both safety and functionality.

Why is grounding important? Electronic instrumentation such as PLCs and field I/O are
typically surrounded by various types of electronic devices and wires. These electronic
devices may include power supplies, input/output signals from other instrumentation,

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Figure 5
and even devices that are near the instrumentation enclosure. All these may present a
risk of Electromagnetic Interference (EMI) or transient interference. This type of interfer-
ence may cause failure or erratic operation of the device.

We should consider using a second transformer to source AC power to DC power sup-

plies. Input circuits should be utilized to isolate the output circuits and prevent voltage
from the output transients (spikes) from being induced into the input circuits. In some
cases, we may need to use a constant voltage transformer to stabilize the incoming AC
power source supplying the PLC to minimize shutdowns due to power surges, voltage
dips and brownouts. When using a constant voltage transformer to power a PLC, the
sensors connected to the PLC inputs should use the same power source. Otherwise,
the AC source voltage could drop low enough to cause inaccurate input data. Also, the
use of an isolation transformer, for example 115 VAC primary to 115 VAC secondary, can
provide additional suppression of EMI from other equipment. Isolation transformers
should be used near equipment that produces excessive electrical noise.

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Figure 6

If DC power is required in our control system, we need to calculate the worst case
amperage draw (load) of all the devices that will be powered from the DC supply. We
also need to look at the amount of “ripple” the devices being powered can tolerate and
select a DC power supply that can meet the most stringent requirement. Ripple is the
amplitude of the AC component that rides on the DC voltage signal. A typical rating
for most applications involving DC powered sensors would be 100 mV peak-to-peak.
It is also a good idea to double the calculated amperage capacity of the DC power
supply. This is especially important if our control system needs to meet Underwriters’
Laboratories, Inc.® (UL)3 508A.

The next section of our schematic will show the hard-wired devices that are powered
from our control voltage (115 VAC). If our control “logic” is based on hard-wired relays,
this is where we would show the hard-wired connections, along with the normal
115 VAC powered devices, such as DC power supplies, 115 VAC power to PLC power
supplies, auxiliary devices, etc. Figure 6 is a partial example of the hard-wired section of
our schematic.

This is a good point to mention surge suppression. Surge suppression devices are
an important component in achieving a reliable power distribution system. These
devices protect the electronic components from sudden power surges that can cause
considerable damage. Inductive load devices (devices with a coil) generate transient
voltages when de-energized with a relay contact. When a relay contact is closed it
“bounces,” which energizes and de-energizes the coil until the “bouncing” stops. The
transient voltages generated are much larger in amplitude than the supply voltage,
especially with a DC supply.

If using a PLC, the final section of our schematic will show the input and output
modules. Figure 7 is an example of the wiring for an input module.

We would make use of reference line numbering and, in most cases, we would show all
of the input modules first, then the output modules. If we have analog I/O, we would
want to show the analog inputs, then the analog outputs, and finally our discrete inputs

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Figure 7
and outputs. Generally we would use one sheet of our schematic to show each module.

Panel Layout
Once we have our schematic finalized, the next step is a panel layout drawing. In most
cases, the actual panel is referred to as a subpanel. We can mount all the components
to a structure (the subpanel), wire all the components, and do this before mounting the
subpanel in the control system enclosure. The panel layout drawing should be done
to scale and include dimensions for the panel builder to follow when laying out the
components. Special attention should be given to component location and spacing. We
need to follow the manufacturer-recommended mounting distances and clearances.
Figure 8 is a partial example of a panel layout drawing.

Figure 8

The higher voltage devices (those that operate at 240/480 VAC) should be mounted
toward the top of the panel, keeping as much distance as possible between the
high-voltage devices and any electronic devices, such as PLCs, DC power supplies,
electronic timers, etc. Keeping the high-voltage devices toward the top allows us to
cover all of the high-voltage devices with a non-conductive safety shield for personnel
safety. It keeps the lower voltage devices grouped together, allowing access to wiring

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terminals that will aid in troubleshooting our control system. In some cases, a metal
partition between the high-voltage section of our control panel and any sensitive
electronic devices can act as a shield from any EMI generated by the high-
voltage devices.

In our panel layout design, we need to include wire duct between the various
components. The wire duct simplifies the wire routing between components,
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keeps the wires in place, makes working with the wires easier, and gives the panel a
well-organized look. We should also make use of terminal blocks in our design. Terminal
blocks can be sized, organized and even color-coded to handle the different types of
signals that enter and leave our control panel. We may choose to use black for high
voltage, red for inputs, violet for outputs, etc. We should try to locate the terminal
blocks so they provide the best wire routing from the components to the terminal
blocks. The terminal blocks also make it convenient for the electrician to terminate his
field wiring when the control enclosure is installed.

Our design should include the selection of the enclosure that will house our control
system. We need to consider the environment where the enclosure will be located.
Outdoors? Indoors? Wash down required? Refer to the section on enclosures in Part 2
of this whitepaper for references to NFPA’s National Electrical Code (NEC)2, the National
Electrical Manufacturer’s Association (NEMA)4, OSHA5, and a list of items to consider
when selecting an enclosure.

Bill of Materials
The Bill Of Materials (BOM) should list each component in our automated control
system, the quantity of each component, any designations or “marks” that allow us to
easily identify the component on our schematic, a description of the component, and
its part number. We also have comments or remarks about the component that will
help the panel builder know what needs to be done when the control panel is being
built. Figure 9 is a short example of a bill of materials.

The BOM can be in the form of a table drawn on one of the sheets along with the
schematic and panel layout. It can also be done as a spreadsheet, which would allow
easy indexing and future referencing.

Figure 9

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Wiring Diagram
A wiring diagram, sometimes referred to as an interconnecting diagram, is used mainly
for installation by the electrician for routing and terminating the wiring between the
various devices and enclosures in the control system. Figure 10 is a good example of a
wiring diagram.
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It should include all control enclosures or cabinets, any external devices that are wired
into control enclosures, junction boxes, conduits, wireways, etc. The wiring diagram
usually includes conduit sizes, distances, number of conductors between devices, wire
sizes, colors, wire numbers, terminal blocks, etc. The wiring diagram is also useful for
system startup and later for locating wire routing and devices during troubleshooting.

Figure 10

Design Tools
Although all of the tasks related to documenting the design
can be performed with nothing more than a pencil, paper
and a ruler, it is normally more efficient to use a software
drafting utility, such as AutoDesk’s AutoCAD® or AutoCAD LT®
software. The biggest advantage in using a software drafting
program to create schematics, panel layouts, bill of materi-
als and wiring diagrams is the ability to re-use the work for
future electrical control system designs. The drafting soft-
ware can also be used to create our sequence of operation,
flowchart or timing diagram. Add-ins for the various drafting software packages are
geared toward electrical control system design. These add-ins contain pre-constructed
elements of different manufacturers’ electrical devices.

This may include schematics of PLC I/O modules, power supplies, communication
devices, etc. These pre-constructed elements also include scaled outlines of relays, mo-
tor starters, terminal blocks, etc. that can be dropped into your panel layout design.

Discussion of automation control systems will continue in Part 4 - Build, Launch

and Maintain.

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Footnotes:
1 For “Considerations for Choosing a PLC” refer to:
http://library.automationdirect.com/worksheet-choosing-controller
2 The National Fire Protection Association® (NFPA®) produces the National
Electrical Code® (NEC®), publication NFPA 70. Further information can be
found at www.nfpa.org. Another good reference from the NFPA is
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Electrical Standard Industrial Machinery, publication NFPA 79.
3 Additional UL information can be found at:
http://industries.ul.com/industrial-systems-and-components
4 Information for the National Electrical Manufacturer’s Association (NEMA) can be
found at www.nema.org.
5 Additional information can be found on OSHA’s Web site:
www.osha.gov/SLTC/controlhazardousenergy

Part 4: Build, Launch & Maintain

In Part 3 of System Design, we covered how to design our automated control system
and the importance of documenting the design. We discussed the various types of
documents that would be typical for an automated control system design, why and
how we would use these documents, and finally the tools that can be used to create
the documents.

In Part 4, we will cover the steps needed to build, start up, and maintain our automated
control system. The build section will include tips on the use of a subpanel, terminal
blocks, grounding, shielded cable, etc. We will cover the steps to start up the system so
that it is brought online in a safe and logical manner, and also give some suggestions
for developing a plan to maintain the control system.

Build
During the design of our control panel, we pointed out
the benefits of using a removable subpanel. In build-
ing the subpanel, it is best to secure the components
from the front side. This will make it easier to replace
any failed device or component in the future. We can
also make installation and maintenance easier by using
terminal blocks mounted to the subpanel that will
connect to all external devices. This will allow the installing electrician to quickly dress
and terminate the field wires. Another terminating method that has added benefits is
to design our control panel with mating connectors so that the field wiring could be
plugged into connectors mounted on the panel.

Wiring Recommendations
The following guidelines provide general information on how to wire most automation
equipment. For specific information on wiring a particular PLC or device refer to the

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installation manual for that device or PLC.

• Each terminal connection can accept one 16 AWG or two 18 AWG size wires. Do not
exceed this recommended capacity.
• Always use a continuous length of wire. Do not splice wires to attain a needed
length.
• Use the shortest possible wire length.
• Use wire trays for routing where possible.
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• Avoid running control wires near high energy wiring.
• Avoid running input wiring close to output wiring where possible.
• To minimize voltage drops when wires must run a long distance, consider using
multiple wires for the return line.
• Avoid running DC wiring in close proximity to AC wiring where possible.
• Avoid creating sharp bends in the wires.
• Install a powerline filter to reduce power surges and EMI/RFI noise.

Important Wiring Safety Recommendations

Warning: Providing a safe operating environment for personnel and
equipment is your responsibility and should be a primary goal during
system planning and installation. Automation systems can fail and may
result in situations that can cause serious injury to personnel or damage
to equipment. Do not rely on the automation system alone to provide a safe operating
environment. Use external electro-mechanical devices, such as relays or limit switches
that are independent of the automation equipment, to provide protection for any part
of the system that may cause personal injury or damage.

Warning: Every automation application is different. Therefore, there may

be special requirements for your particular application. Be sure to follow
all National, State, and local government requirements for the proper
installation and use of your equipment.

Plan for Safety

As we have stressed in previous sections, the best way to provide a safe operating
environment is to make personnel and equipment safety part of the planning process.
Examine every aspect of the system to determine which areas are critical to operator or
machine safety.

If you are not familiar with system installation practices, or your company does not have
established installation guidelines, you should obtain additional information from the
following sources:
NEMA1: The National Electrical Manufacturers Association, located in Wash-
ington, D.C., publishes many different documents that discuss standards for industrial
control systems. You can order these publications directly from NEMA. Some of these
include:
• ICS 1: General Standards for Industrial Control and Systems
• ICS 3: Industrial Systems

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• ICS 6: Enclosures for Industrial Control Systems

NEC2: The National Electrical Code provides regulations concerning the
installation and use of various types of electrical equipment. Copies of the NEC
Handbook can often be obtained from your local electrical equipment distributor or
your local library.
Local and State Agencies: Many local governments and state governments
have additional requirements above and beyond those described in the NEC
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Handbook. Check with your local Electrical Inspector or Fire Marshall office
for information.

Grounding
Why is grounding important? Electronic instrumentation such as PLCs and field I/O are
typically surrounded by various types of electronic devices and wires. These electronic
devices may include power supplies, input/output signals from other instrumentation,
and even devices that are near the instrumentation enclosure. All these may pres-
ent a risk of Electromagnetic Interference (EMI) or transient interference. This type of
interference may cause erratic operation of components and cause failures.

In addition to device interference, automation equipment and devices could be

damaged by powerful line surges. These line surges may come from common voltage
fluctuations from a power supply, lightning, or unintentional contact with a high
voltage line. A power surge will cause a temporary failure, fuse burn-up, or even very
serious damage to the equipment. Grounding provides a low impedance path that
limits these voltages and stabilizes interference. Grounding is a must to protect your
automation equipment and devices from serious damage, failures, and even potential
risk to users. Grounding is the foundation of achieving a reliable power distribution
system. During the panel and control system build, it is important that a reliable
grounding system be implemented. Poor grounding or improper or defective wiring
may be the cause of most problems affecting power quality. The following is a list of
existing grounding standards that may be used for reference:
• IEEE Green Book (Standard 142)
• IEEE Emerald Book (Standard 1100)
• UL96A, Installation Requirements for Lightning Protection Systems
• IAEA 1996 (International Association of Electrical
• Inspectors) Soars Book on Grounding
• EC&M - Practical Guide to Quality Power for
• Electronic Equipment
• Military Handbook - Grounding Bonding and Shielding of Electronic Equipment

Once all the important considerations mentioned above have been determined, the
mounting, bonding, and grounding of the chassis may be started. The following list
provides a brief explanation of each of these terms:
• Mounting: refers to the actual physical installation of each device, instrument or
component to either the subpanel or other connected equipment.
• Bonding: refers to the joining of metallic parts of a chassis such as; frames, shields,
assemblies and enclosures. Joining or bonding these components properly reduces

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the interference from EMI and ground noise.

• Grounding: refers to a connection to a grounding conductor to provide overload
and interference protection.

As mentioned before, grounding protects the instrumentation, devices, or components

from power surges and reduces the effect of EMI and ground noise. Figure 1 shows
a typical method for grounding the subpanel to the enclosure cabinet to assure
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proper grounding.

Figure 1

Note: Please remember that bonding and grounding are important

safety requirements that are mandatory by local codes and regulations.
The installer must verify the local codes to determine what grounding
and bonding methods are permitted. Always make sure that power
supplies are properly grounded to ensure elimination of electronic
noise interference.

Note: When using ground lugs and installing more than one on the same
stud, make sure to install the first lug between two star washers and tie it
with a nut. Install the second lug over the nut of the first lug followed by a
star washer and another tightened nut.

Shielded Cables
A shielded cable is an insulated cable consisting of strands of copper or other material
enclosed with a metallic shield underneath a jacketed sheath. Shielded cables are
used to reduce the interference from electrical noise. Some instrumentation requires
the use of shielded cables for specific connections. When installing instrumentation,
verify whether any connection requires a shielded cable. Failure to use the shielded
cable will result in erratic readings or signals from the instrumentation. If the product
being installed requires shielded cables, the grounding specifications provided by the
manufacturer manual must be followed. Improper installation of shielded cables may
cause a ground loop that will cause failure on a processor or would allow noise into
the logic circuit. There are various types of shielded cable available for different uses.
The shielded cables listed below are the most commonly used for automation control

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systems and instrumentation:

• Foil Shield: These cables consist of aluminum foil laminated to a polyester

or polypropylene film. The film provides mechanical strength and additional
insulation. The foil shield provides 100% cable coverage for electrostatic
shielded protection. Foil shields are normally used for protection against
capacitive (electric field) coupling where shielded coverage is more important
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than low DC resistance.
• Braided Shield: These cables consist of groups of tinned, bare copper, or
aluminum strands. One set is woven in a clockwise direction, then interwoven
with another set in a counter-clockwise direction. Braided shields provide
superior performance against diffusion coupling, where low DC resistance is
important, and to a lesser extent, capacitive and inductive coupling.
• Spiral Shield: The spiral shield consists of wire (usually copper) wrapped in a
spiral around the inner cable core. The spiral shield is used for functional
shielding against diffusion and capacitive coupling at audio frequencies only.
• Combination Shield: These cables consist of more than one layer of
shielding. The combination shield is used to shield against high frequency
radiated emissions coupling and electrostatic discharge (ESD.) It combines
the low resistance of braid with 100% coverage of foil shields and is one of
the more commonly used types of shielded cable in today’s industry.

Figure 2 shows a typical cross sectional area of

a shielded cable that makes use of combination
shields.

Figure 2

Mounting of Electronic Instrumentation

Electronic instrumentation is typically installed inside an enclosure with other devices.
Therefore, the installation of the instrumentation must take into consideration that the
panel layout accommodates all the necessary components. In addition to the panel
layout, the following specifications should be considered:

Electronic instrumentation can be affected by interference from other electronic

devices or EMI. This interference causes static that may interrupt communications
or signals from other devices. Use these guidelines to prevent any possibility of
interference with your equipment:
• Environmental specifications that cover the operating temperature, humidity,
vibration, noise immunity, etc.
• Power requirements are specific to each piece of equipment. When installing
instrumentation always make sure to follow the manufacturer’s power
requirement guidelines for your specific piece of equipment.
• Use components with Agency Approvals such as UL, CE, etc.

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• Make enclosure selections based on component dimensions, recommended

mounting clearances, heat dissipation and EMI.

If installing a PLC base or chassis which consists mainly of mounting, bonding, and
grounding, it is very critical to the proper operation of the PLC and its related devices
and components to closely follow the manufacturer’s recommendations. There are
many cases of a PLC experiencing “noise” problems, when the problem is found to be
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that the base wasn’t grounded to the subpanel.

I/O Testing
The last item to consider at the completion of building your control system is to do a
complete I/O checkout. This will assure that the point-to-point wiring between the I/O
module terminals and the field wiring terminal blocks has been done correctly.

To start, create a list with each I/O point shown and include any details of what criteria
is being tested. It is also helpful to include a check box that can be used to check off
each point after it is tested. Normally this list can be created from an I/O list or tag name
list that was created when designing your PLC ladder logic or HMI operator inter-
face. Include the test criteria for each point on the list. As an example, discrete input
and output points would be listed as normally “off” and then checked for their “on”
state. Analog points, both input and output, could be checked at different values. For
example, if using a current input module, you may want to simulate 4 mA (low value),
12 mA (middle value) and 20 mA (high value). The actual testing normally requires a
two-person team. One person uses a PC connected to the PLC to view the status of each
point tested and to simulate outputs, and the other person physically applies a signal
to inputs and monitors outputs with the use of an indicator on discrete outputs and a
meter on analog outputs.

Start Up
The startup of our automated control system begins once
we have installed our control system enclosure and auxil-
iary equipment, terminated all field wiring, and completed
required testing. This process is also called “commissioning” the
automated control system and related equipment/process.

As a starting point, it is best to isolate the various sections of our control system power
wiring by removing the fuses and/or opening circuit breakers. The best tool to use
during commissioning is the schematic diagrams. We will want to start at the incoming
power, and basically work our way through the entire schematic.

As a first step, we may want to apply power to the main circuit breaker or fused
disconnect of our control system. Then, measure the voltage for proper values, phase-
to -phase and each phase-to-ground, if the incoming power is three phase. Next, we
can turn on the main circuit protector and check the voltage at each device that is fed
from the main source. Then start turning the circuit breakers on or replace the fuses one

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 A Condensed Guide to Automation Control System Specification, Design & Installation: White Paper, pg. 29

circuit at a time and make additional voltage checks and test equipment operation that
may be powered from the circuit.

Keep in mind that every control system will not be the same.
Therefore, each system will require a different strategy to bring
the equipment online safely. Consider having motors uncoupled
from their respective loads, air pressure off, disabling hydraulics,
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and using Lockout/Tagout (LOTO) procedures. Measure voltages
as you go. If using a PLC, connect a PC to it and monitor the
ladder logic to make sure conditions, states, etc. are responding correctly.

Maintain
It is important to develop a routine maintenance schedule for your automated control
system. Having a routine schedule for checking critical components and devices in
the system will increase the longevity of the system and more importantly, it will help
eliminate future problems. Set up the schedule based on a monthly or quarterly time
period, depending on the item to be done. The following are some of the items you
may want to consider in your maintenance schedule:
• Check and record voltages at various circuits
• Tighten all connections (with power removed)
• Check backup batteries, and/or replace on a routine schedule
• Check indicators and perform lamp tests
• Visually inspect for loose or frayed wiring, moisture in enclosure, etc.
• Check to make sure plug-in connectors are tight and secured
• Test all alarm systems, horns, sirens, etc.
• Check and record any configuration settings
• Perform and record calibrations
• Check all I/O points on a yearly basis
• Check and record power usage
• Check equipment run times for determining maintenance or replacement
• Measure device current to set a benchmark and compare for changes
• Review any diagnostic history, including events and alarms
• Check diagnostics that may be programmed into the HMI operator interface

Footnotes:
1 Information for the National Electrical Manufacturer’s Association (NEMA) can be
found at their Web site at: www.nema.org.
2 The National Fire Protection Association (NFPA) produces the National Electrical
Code (NEC), publication NFPA 70. Further information can be found at their Web site at
www.nfpa.org. Another good reference from the NFPA is Electrical Standard Industrial
Machinery, publication NFPA 79.

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