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Fisher CbnSrois
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PR5V0X Insthimdntation
Planning Guide
,.n ,.*ii - >
September 1981
Publ, No. PN4:003
AC and DC Power & Grounding
INTRODUCTION
Tills installation planning note provides system-level recommendations and
guidelines for the ac and dc power and ground wiring in your PROVOX instru-
mentation system. Specific instructions for wiring and grounding of indivi-
dual products are given In the installation planning notes for each product.
Proper wiring and grounding are of prime importance for operator safety,
signal Integrity, and electrical protection of the instrumentation system.
Note
All power and ground wiring practices must conform to
the current National Electric Code and to current
state and local codes and regulations, as recommended
in the latest National Electrical Code Handbook from
the National Fire Protection Association (NFPA 81).
Syotum ac power problems can arise from two sources: (1) the commercial power
network and (2) the plant distribution system. Generally, the only cure for
commercial power problems Is a backup power source for the critical portions
of the process. However, plant distribution problems can be minimized by
following the recommendations in this installation planning note to the max-
imum extent possible. Major topics to be discussed are:
o AC, DC, and Signal Grounding Requirements
o Input AC Power Transformation
o AC Power Wiring and Distribution
o DC Power Wiring and Distribution
o Power Alarm Wiring
o System Grounds
o Ground Wiring
o Common Crounding Between PROVOX Instrumentation and Other Peripheral
Devices and Systems
o Earth Ground Systems
o Ground System Testing
o Lightning Protection
Fisher Controls Company 1981; All Rights Reserved
/ ' ^ /
AC, DC, AND SIGNAL GROUNDING RKquiKEMENTS li v i j 5
Certain basic cri teri a, established as requirements for the ac power, signal,
n n d ^ l r supply c o ^ n grounds, are l i st ed below. Ail PROVOX instrumentation
syntcas oust confora to these requirements.
AC power ground systems must exhibit :
o A dedicated, private ground for the PROVOX instrumentation system
alone. . . . .
o Less than 5-volt, peak-to-peak, measurement between the ac neutral
and grounding conductor at t hei r points of connection to the console
or computer.
o Consoles and computers that are isolated from the conduits through
which their interconnecting ac power is routed.
o Consoles or computers and their associated peripherals that are
connected to the same power distribution and ground system.
o A cabinet connection to only one local circuit-breaker panel.
o An earth ground connection that is made in accordance with local,
state, and national electrical codes.
o An isolated ground that, at a minimum, satisfies safety require-
ments.
DC power ground systems must exhibit:
o A dedicated, private ground for the PROVOX instrumentation system
alone,
o Resistance measurements of 3 ohms or less from the cabinet laminated
bus bar terminal lugs to the earth ground.
o A potential difference of no more than 200 millivolts dc between the
signal common (SC) and power supply common (PSC) at all points
within the system, with all units powered.
o A redundant power supply that is connected to the same local ground
point as the main power supplies that it Is backing up.
o A common connection between the PSC and SC circuits only at a point
where no additional power supply return currents flow beyond that
point (i.e., between that point and ground); the connection point
can be, at the local ground point (LGP) or master ground point (MGP).
o A single-point ground for (1) all cabinets using common analog
signals and (2) all cabinets sharing a redundant power supply (the
data highway is isolated and does not require a single-point
ground).
INPUT AC POWER TRANSFORMATION
Commercial ac'power utilities normally provide power that meets the voltage
and frequency requirements of the PROVOX instrumentation system. However,
plant distribution networks may drop up to 5 percent or more of the Input ac
power between the service entrance point to the plant and the final power
connection to the various portions of the instrumentation system. Furthcr-
-2
more, starting transients from large motors and other loads tied to the dis-
tribution system can cause additional momentary line-voltage reductions as
well as possible waveshape distortions.
To minimize these problems, the PROVOX Instrumentation system must be provided
with a separate ac power transformation system that is Isolated from all other
loads; each building or site containing PROVOX instrumentation should have a
separate power transformer. This is particularly important for the instru-
mentation system control center, which generally contains the operator console
with Its computer and mass storage devices. The power transformer primary
should be supplied from the highest line voltage available from the commercial
source, and only PROVOX equipment should be connected to the secondary. The .
powor transformer should have sufficient capacity to handle Initial surge
currents (lasting about ten cycles with overcurrent inrush as shown in figure
I ) , and still regulate Its output voltage within the equipment tolerances for
the steady-state line-to-neutral nominal-rated voltage, as measured at the
input power side of the system when the system is energized (see table 1 ) .
Wiring from the power transformer to the PROVOX Product power terminals should
be of sufficient size to maintain these specified tolerances at the input
terminals when all equipment Is energized. The wiring must also conform to
local, state, and national electrical codes to ensure that it can handle the
current load safely without overheating. The ac voltage and frequency re-
quirements and tolerances for each PROVOX product can be found In the appli-
cable product bulletin,
AC POWER WIRING AND DISTRIBUTION
The ac power wiring for a PROVOX instrumentation system is, for the most part,
the responsibility of the user, but standards are available for this wiring as
exemplified by the recommendations of this section. Furthermore, all local,
state, and national electrical codes and regulations for such wiring must be
followed. Therefore, the recommendations and wiring diagrams of this section
are necessarily typical examples rather than specific requirements. Wiring
for your instrumentation system will probably be similar but not an exact
duplicate of these examples.
Two types of power distribution systems can be used to supply ac power to the
PROVOX instrumentation system equipment. The first type, a System-Level Power
Distribution System, should be used for buildings containing both system
cabinets and consoles or computers. Tho second type, a Remote-Area Power
Distribution System, should be used for buildings containing only system
cabinets or only consoles and computers. This system could also be used in
large buildings, helping to avoid problems associated with routing an isolated
power system over long distances to various areas within the building.
Regardless of the distribution system used, an isolation transformer is re-
quired to isolate power supplied to the PROVOX instrumentation system equip-
ment from the power supplied to nil other functions in a controlled process
-3-
-I
Wj/Wv "S.SWo.
1
Table
,. VoU.g* - * ~ * f*
4
"
M
Voltage
Range (V)
108 to 125
216 to 250
108 to 125
216 to 250
86 to 113
102 to 132
172 to 226
204 to 264
Frequency Rahge'
x
(Hz)
58 to 62
48 to 52
**
59.8 to 60.1**
49.9 to 50.1
58 to 62
86 to 113
172 to 226
187 to 242
204 to 264
'slU-P>.e or rtree-phaae powr reared.
**
nl l t -phase-or three-phase power t
H

ipj.it puaoo frequency range i s
W n I * . * * . t ^ ' I ' S Video T . . U . - c d
0
-4-
*
system. The power from the isolated distribution system should be connected
only to the PROVOX equipment, and a separate distribution system iBi.r*tfuifred
for each building containing PROVOX equipment.
The PROVOX system cabinets and consoles require single-phase power, whereas
the computers require either split-phase or three-phase power. If a multi-
phase distribution system is required, exercise care to balance the load
between phases at each power panel, minimizing any voltage differentials
between the ac neutral and the grounding conductors.
System-Level Power Distribution
Typical system-level power distribution systems are shown in figures 2 through
/. Input ac power is supplied through an isolation transformer with the
PROVOX ac ground point established at or near the transformer. The ac circuit
conductors are routed through the main power panel (containing the main dis-
connect switch) into the main power circuit breaker panel.
In the main power circuit breaker panel, the neutral conductor is bonded to a
bus bar that is electrically isolated from the grounding conductor and from
the circuit breaker panel. The grounding conductor is connected to a separate
bus bar that may be bonded to the circuit breaker panel and connected exter-
nally to the PROVOX ac ground point.
The ac circuit conductors are then routed to the local-area circuit breaker
panels, with each panel dedicated to either system cabinets or to consoles and
computers, as shown in figures 3 and 4. Inside the local-area circuit breaker
panel, the neutral and grounding conductors are bonded to separate bus bavs
that are isolated from the panel and from each other. From the bus bars In
the main circuit breaker panel to the point of final connection at the PROVOX
equipment, all ac circuit conductors are electrically isolated from their
conduits and circuit breaker panels.
A l l ac power for the system cabinets is routed either from a local-area cir-
cuit breaker panel as shown in figure 3 or from a remote-area circuit breaker
panel as shown in figure 5, and is connected to the cabinet power distribution
panel assembly for internal routing from there. Each power distribution panel
assembly contains up to three separate ac connections as shown in figure 8.
One twiatlock receptacle is dedicated to the primary power supply of a cab-
inet, and the second twistlock receptacle is dedicated to the redundant power
supply, if supply redundancy is selected. The third connection, a duplex
receptacle, is used for the cooling fans within the cabinet.
Each twistlock receptacle in a nominal 100- or 115-volt ac power distribution
panel assembly must ba supplied from a separate 20-amp circuit breaker (15
ampB for the 200-, 220-, or 240-volt ac sources). Figure 1 shows the typical
inrush current of the power supplies, which should be used In selectLng the
riate circuit breaker. The duplex receptacle may be connected in paral-
-..j fii<. receptacles or It may use a separate circuit
ffsS^^^^
5
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M
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1,
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tt
breaker.
-5-
PN4: 003
K l < J 7 i 9
Al l ac conductors from the c i r c ui t breaker panels to the r ecept acl es In a
power di s t r i but i on panel assembly must be provided by the user and are t ermi n-
at ed di r ect l y at each r ecept acl e. Standard factory-assembly methods provide
the fl exi bl e conduit for ac wi ri ng from the cabi net entry t o the power di s -
t r i but i on panel assembly. All ac power suppl i ed to a si ngl e cabinet grouping
(up to si x system cabi net s) must come from the same ci r cui t breaker panel .
ojnso_le_s_and_Comu_tes
Al l ac power for the PROVOX console or computer equipment i s routed ei t her
from a l ocal - ar ea c i r c ui t breaker panel as shown in figure 4 or from a remote-
ar ea c i r c ui t breaker panel as shown in f i gur e 6. The speci fi ed ac power
requirements must be met by the power suppl i ed at t he point of connection to
the console or computer equipment (t hese requi rement s are l i s t e d in t abl e 1) .
There should be no more than a 5-vol t peak-t o-peak di f f er ent i al between the
neut r al conductor and the grounding conductor, measured at the point of con-
nect i on for a ful l y powered system.
Power Is suppl i ed to a l l components of t he PROVOX consoles from a u t i l i t y
power s t r i p l ocat ed i nsi de each console bay as shown i n figure 9. All u t i l i t y
power s t r i ps in a console grouping must r ecei ve power from the same ci r cui t
breaker panel . Each nominal 115-vol t ac u t i l i t y power s t r i p i s supplied
si ngl e-phase power from a separat e 20-amp c i r c ui t breaker (10 amps for 230
vol t s ac) . The connection to the console i s made inside the u t i l i t y power
s t r i p to t hr ee wi res ( pi gt ai l s l i c e s ) .
Power i s suppl i ed to a l l components of the PROVOX computers from power s t r i ps
located in the computer cabinet bays. These power s t r i ps ar e supplied from
computer power di s t r i but i on uni t . For a 120-vol t , 60-hertz ac si ngl e bay
computer, the computer power di s t r i but i on uni t must be supplied with s p l i t -
phase 120/240 vol t ac or t hree-phase 120/208 volt ac power; for a multibay
computer, t hree-phase 120/208 vol t ac power must be supplied. Each phase
conductor must be supplied through a separ at e 20-amp ci r cui t breaker (part of
a ganged c i r c ui t br eaker ) . For a 230-vol t , 50-hert!! si ngl e bay computer, the
computer power di s t r i but i on uni t must be suppl i ed from a 20-amp, 230-vol t ,
si ngl e-phase branch c i r c u i t . For a multibay computer, the computer power
di s t r i but i on uni t must be suppl i ed from a 30-amp, 230-volt, si ngl e-phase
branch c i r c u i t . The connection to the computer power di s t r i but i on uni t i s
made to a terminal block mounted Insi de the uni t .
Console and HPilte.r_Peripheral qulment
Al l per i pher al equipment are suppl i ed from the u t i l i t y power s t r i ps i ns i de the
console or computer cabi net or from remote i sol at ed ground r ecept acl es (shown
i n fi gures 4 and 6 and det ai l ed in fi gure 7) . Each peri pheral uni t must
recei ve I t s ac power from the same c i r c ui t breaker panel as the common el ec-
t r oni cs uni t with which i t I nt er f aces. The l oads Imposed on the u t i l i t y power
s t r i ps by the per i pher al s and the common el ect r oni cs unit should be balanced
between the u t i l i t y power s t r i ps as much as pos s i bl e.
- 6 -
PN4:003
0 0 7 2 0
R e m o t e - A r e a Power D i s t r i b u t i o n
T n < r A l r e m o t e - a r e a oower d i s t r i b u t i o n s y s t e m s are s h o w n in figures 5 and 6.
I n p u t c p i e r is su
p
P
pTied t h r o u g h a n i s o l a t i o n t r a n s f o r m e r w i t h the PROVOX ac
input m . y v w c ,
AO
^ ..
th(J
t r a n s f o r m e r . The ac circuit con-
K o l s ^ ^ ^ ^ ^ P.n.1 * its associated u power
d i s c o n n e c t switch to the r e m o t e - a r e a circuit b r e a k e r p a n e l .
In the r e m o t e - a r e a ci r cu i t b r e a k e r p a n e l , the n e u t r a l c o n d u c t o r is bonded to a
b u s b a r t h a t Is e l e c t r i c a l l y i s o l a t e d from the g r o u n d i n g conductor and from
the c i r c u i t breaker p a n e l . T h e g r o u n d i n g c o n d u c t o r is bonded to a separate
b u s bar thlt m a y l e b o n d e d to the circuit b r e a k e r p a n e l and connected e x t e r -
n l l v to t h e PROVOX ac g r o u n d . From the b u s bars In the circuit breaker panel
to L p o i n t of c o n n e c a o n at the P R O V O X e q u i p m e n t , a l l ac circuit conductors
I r e e le ct r i ca lly i s o l a t e d from their c o n d u i t s . D i s t r i b u t i o n to the system
c a b i n e t s o r tc> the c o n s o l e s and c o m p u t e r s a r e then routed a s described above
for the s y s t e m - l e v e l power d i s t r i b u t i o n s y s t e m .
DC POWER W I R I N G A N D D I S T R I B U T I O N
A l l s y s t e m c a b i n e t s c o n t a i n i n g c o n t r o l l e r , m u l t i p l e x e r , o r communications
f i l e s a r e powered by a 24- v o lt dc po w e r d i s t r i b u t i o n s y s t e m . When the files
a r e installed In a P R O V O X s y s t e m c a b i n e t , their dc po w e r is supplied from a
la m i n a t e d bus bar located o n the left side of the c a b i n e t . Power to this bus
c a n be o b t a i n e d from the PROVOX i n s t r u m e n t a t i o n system standard dc power
s u p p l i e s o r from a u s e r - s u p p l i e d s o u r c e w i t h i n the p r o c e s s i n g plant. The dc
p o w e r s u p p l i e s m o u n t at the bottom of a ca b i n e t and a r e prov ided with a c power
t h r o u g h t h e power d i s t r i b u t i o n p a n e l . Two dc p o w e r s u p p l i e s can be used for
r e d u n d a n c y in a s i n g l e ca b i n e t with both s u p p l i e s c o n n e c t e d to be load sharing
t h r o u g h the power d i s t r i b u t i o n p a n e l . D e t a i l s for w i r i n g the dc power sup-
p l i e s c a n be found in the a p p r o p r i a t e p o w e r s u p p l y and po w e r d i s t r i b u t i o n
p a n e l i n s t a l l a t i o n pla n n i n g n o t e s . F o r a d d i t i o n a l r e d u n d a n cy and power outage
p r o t e c t i o n , a u a e r - s u p p l i c d dc p o w e r s o u r c e (e i t h e r b a t t e r i e s or d c power
s u p p l i e s ) can be c o n n e c t e d to the dc po w e r d i s t r i b u t i o n s y s t e m of a c a b i n e t .
A l t h o u g h the bus v o l t a g e i s n o m i n a l l y +2 4 v o l t 8 d c , the d i f f e r e n t v o lt a g e s
a v a i l a b l e from b a t t e r i O B and power s u p p l i e s plu s the v a r y i n g v oltage drops
t h a t o c c u r in the c o n n e c t i n g w i r i n g could cause the v o l t a g e at the equipment
to be s i g n i f i c a n t l y h i g h e r or l o w e r . Be sure that the v o l t a g e at equipment
t e r m i n a l c o n n e c t i o n s is w i t h i n the t o le r a n ce s p e c i f i e d for each i n d i v i d u a l
pr o d u ct (see the a p p r o p r i a t e product b u l l e t i n for these s p e c i f i c a t i o n s ) .
S y s t e m C a b i n e t DC P o w e r R e q u i r e m e n t s
T h e dc p o w e r for a system ca b i n e t is generated by a PROVOX p o w e r supply unit
m o u n t e d in a c a b i n e t . T h e output of a power B u pply ia r o u t e d through the
p o w e r d i s t r i b u t i o n panel for load sharing b e f o r e b e i n g c o n n e c t e d to the lam-
inated b u s bar In the c a b i n e t .
F i g u r e 10 shows the typical t e r m i n a t i o n s for the p o w e r a u p p l y , power d i s t r i b -
u t i o n p a n e l , and b u s b a r . F i g u r e 11, c a b i n e t s I through 3, shows a typical
-7-
, .
L
i t. n,
f
nrimarv s u p p l i e s , and one redundant s u p p l y,
s ys te m with three cnblnctfl, three P 5 J '
w l t | |
,
t h e t h r c e
primary supplies
The redundant supply 1B normally loadi .hating w i t t i
d
J
t u r b

c e a t th e
so a l l four supplies are in use.
T h e r e w t LL
lteB
'
or
the redundant .sup.ly.
bus bar with a failure oE one of '** P ' ^ f ^ S ^ 1 Ground Point- < *L0 PJ a s
T h e redundant supply must be connected to the same uoc
the primary supplies that it is backing up.
. , . J M o u r e 11 c a b i ne ts 4 and 5. This method can
An alternate method is ^ . / " ^ ^ ^ V t a " r e q u i r e a total input current of
bo used when two o r *t?\
h
*M to ge the r and receive power from
T X V X ' A^ed
b
u
U
ndan
a
t
r8
p
o
C
wer supply is al s o shown connected to the
power distribution p ane l .
\\r. Power Distribution
M l dc power to the card files located in the system cabinets is obtained from
the cabinet laminated bus b a r . The card fil e te rminatio ns of typical products
a r e shown in figure 10 and detailed in the Ins tal l atio n planning note for each
p ro du c t. Each product requires +24 volts dc and p o we r supply common ( P SC ) ,
w i th some products additionally requiring s ignal common ( SC ) , The SC terminal
is to be used only by some card files as s ho wn in figure 10 and should not be
used by othet devices u nl e s s the power and signal returns are isolated. The
card file terminations are made to the laminated b u s bar by using a minimum of
12 AWG (2.1 mm diameter) stranded w i r e w i th a red color- coded wire for +24V,
b l ac k for PSC, and white for SC.
T h e SC and PSC should be maintained s e p arate until they are connected to the
l o c a l Ground Point ( LGP) or Mas te r Ground Point ( M G P ) , discussed In later
s e ctio ns on ground wiring. The SC and PSC can be connected together at a
point ( prior to PR0 V0 X dc ground) where there is no power supply or battery
re tu rn current flow to ground. Care should be taken to make sure that a
voltage measurement between the PSC and SC is always less than 20 0 millivolts
dc at each card file in a powered system.
Field Transmitter Power
Transmitters should not be powered directly from the +24V bus bar but should
be provided from the fused terminations that we re designed exclusively for
powering the transmitters on the individual card fi l e s .
Battery Backup
Battery backup re qu ire me nts can be met b y c o nne c ting a user- supplied battery
stack to the battery terminations on the p o we r dis trib u tio n panel, as shown in
figures 12 and 13. Any time the Inputs to the power distribution panel fall
b e l o w +23 volts dc , the battery stack is au to matic al l y switched on l ine . When
the lino power is back to no rmal , the battery stack w i l l be switched off line,
letting the power supplies again provide power to the system.
It should be noted that separate battery s tack s are required for cabinets 1
through 3 and for cabine ts 4 and 5 in figure 12, as they are on separate LG P s .
A separate battery a tack is required for e a c h I.GP, and each connection to the
-8'
PtU:003
battery stack must be separately fused to protect I t s output. The fuse huld
be sized for a maximum continuous load of 35 amps aa required by thfe^bus^Bar
in the system cabinet.
The memory sections of the common electronics unit of consoles and computers
are supplied with and protected by battery backup. If the ac power to a
console or computer should f ai l , the contents of the memory will remain valid
for one hour. The console or computer will cease operation, but will retain
the operating system, programs, and configuration information as long as the
memory i s valid. Upon restoration of ac power to the console or computer
operation will resume from the point where i t was interrupted (if the memory
i s s t i l l valid), If the memory Is no longer vali d, the operating system
programs, and configuration must be reloaded.
User-Supplied +24 Volt I)C Feeder Line
A user-designed dc power system, to be used with the system cabinet equipment,
must meet the input voltage requirements of that equipment. The PROVOX in-
strumentation system i s designed to operate from 21 to 28 volts dc at the bus
bar. Any user-supplied dc power system must be capable of powering up under
f ul l load conditions.
Figure 14 shows system cabinets powered by a user-supplied +24-volt dc feeder
l i ne. Each power input to the bus bar must be fused to protect both system
cabinet equipment and the plant +24-volt dc line. The bus bar must be fused
for a maximum continuous current of 35 amps. This system requires a separate
LGP for SC and PSC. A separate 24-volt return is required for each PSC LGP as
shown. The SC LGP and the PSC LGP must remain isolated unt i l they are con-
nected at the MGP. There should be no current flow from the MGP to the PROVOX
dc ground.
POWER ALARM WIRING
The PROVOX instrumentation system cabi net s are equipped with alarm ci r cui t s
incorporated into several of the various units within the cabinets. Standard
factory-assembled wiring connects these several alarms in each cabinet Into a
seri es ci rcui t that terminates as dry contacts In the power distribution
panel. The dry contacts can then be connected to your alarm system. The
alarm ci rcui t la an integral part of the power converter card used In the
following uni ts:
o Type CP6201 Controller Card File Unit
o Type DH6001 Local Traffic Director Unit
o Type DH6002 Network Traffic Director Unit
>
o Type DH6003 Data Concentrator Unit
o Type DN6001 Multiplexer Control Unit
- 9 -
The controller card f i l e,
l o
cal t raffi c di rect or, or network t raffi c mr~*
can have two power converter cards i nst al l ed in a single card f i l e" . h . ^ ^ '
two alarm ci r cui t relays in a fi l e can also be connected in ser i es' F ^ W *
more, the power distribution panel contains a low-voltage or min I'nJr ,
failure detection ci rcui t that can deenergize the al am re?ay T h e T J " T
?
provides a dry contact closure indication of abnormal c o Li Uo n f t o T ?
nal alarm annunciator that is wired to your specifications
a n e
*
t e r
~
tlTS^'J^
C l r C U i t S f

r 3 8 l
8
l e c a b l n e t a r e c
n"cted in seri es' for
the typical wiring as shown in figure 10, each individual ci rcui t or I, ,
bination of ci rcui t s can be connected to produce an al ar , 1 X ^ 7 U To
SYSTEM GROUNDS
Poor or faul t y grounds are among the most common causes of el ect r oni c system
problems. The ground system network for the PROVOX i nst rument at i on system i s
a very cr i t i cal consideration since t hi s network refl ect s the accuracy of the
entire control system. Thus, the extra time and effort spent in laying out a
good ground system will be rewarded by easier startup and more reliable oper-
at i on. The PROVOX Instrumentation system uses three separate grounds:
I. PROVOX AC GroundThis i s the single-point ground for a l l PROVOX ac
connections, providing the safety ground for al l ac-powered devices as
well as the ground reference for the consoles and computers. The ac
ground must conform to al l l ocal , st at e, and national el ect ri cal code
requirements for a ground system. Furthermore, in cases of plant ground
or ground-grid systems, i t i s recommended that al l welding devices,
motors, et c. be grounded at different points on the grid than the points
used for the I' ROVOX equipment connections. In case of grounding for a
lightning protection device, the ground must not be connected to the
PROVOX ac ground; by most code requirements, the lightning ground must be
a minimum of at least 6 feet (1.8 meters) from any electrode of any other
ground system.
!. PROVOX DC GroundThis is an i sol at ed, single-point ground that provides
u reference for the dc power and analog signals of the system cabinet
equipment. The design goal for the PROVOX dc ground Is to provide a
ground of such quality thjat i t measures I ohm or less to true eart h.
There are several methods that can be used to obtain a high quality earth
ground system, and these methods wi l l vary depending upon the soil type
and moisture content at the individual location (earth ground systems are
discussed in a l at er paragraph). Once the appropriate ground system i s
designed and Inst al l ed, the system should be tested periodically to
assure that the quality of the ground system i s maintained. Ground
systems t est i ng i s discussed in a l at er paragraph,
After Inst al l i ng the ground system, a megohmmeter test should show a
maximum impedance of 3 ohms between the PROVOX dc ground and true eart h.
If necessary, the ground system should be improved unt i l the 3-ohm imped-
ance requirement i s achieved.
-10-
3. Cabinet GroundThe cabinet ground is a separate ground from the PROVOX
dc ground and cannot be connected to the same point. However, it can be
located at the same point as the PROVOX ac ground, plant ground, or even
a point other than these two grounds (such as the building steel). The
cabinet ground provides protection to both equipment and personnel from
accidental shock hazards. It also provides a direct drain line for any
electromagnetic interference (EMI) to which the components of the cabinet
may be subjected. This ground must meet all code requirements for a
ground system. The cabinet grounds are connected directly to the cab-
inet, usually at one of the four mounting studs on the bottom corners of
a system cabinet.
Standard factory-assembly methods connect the signal common (SC) and power
supply common (PSC) ground wiring from the various card file assemblies of a
system cabinet to the SC and PSC terminal lugs on the laminated bus bar of a
cabinet. However, unless specifically selected, no further ground wiring is
done within a cabinet, but muot be supplied and connected by the user.
o Signal Common (SC)This is the voltage reference for all single-ended
signals in the system. The signal common is connected to the laminated
bus bar at the base of the cabinet.
o Power Supply Common (PSC)This Is the power return for all +24-volt dc
power connections in the system. The PSC must be isolated from the SC
connections until they are joined at a designated ground point. If they
are not isolated, the high currents that flow In the PSC circuits could
cause several hundred millivolts of difference in apparent signal values
by adding a voltage into the SC circuit. The PSC is connected to the
laminated bus bar at the base of the cabinet.
CAUTION
If the PSC or SC ci r cui t s are not properly connected,
property damage can result because of the excessive
voltage differences on the two grounds; this voltage
difference cannot exceed a maximum of 200 mi l l i vol t s
dc at each and every card f i l e . He sure that the
commonB are properly i nst al l ed before energizing the
system for t est or operation.
'A system grounding assembly to aid in producing a single-point termination
within a cabinet i s available as an optional selection that can be i nst al l ed
ei t her at the factory or in the field aft er the infltrumentatlon oystem deliv-
ery. The typical cabinet grounding aaaerably is shown In figure 16, Both
versions of the grounding assembly [ I . e . , locnl ground point (I.CP) or master
ground point (MGP) assembly] mount onto i sol at i on brackets at the bottom front
of a cabinet. ' A local ground point assembly wi l l handle up to six cabinets in
ei t her the in-line or back-to-back configuration, for connections to the SC
and I'SC lugs on the laminated bus bar, thus keeping the two ci rcui t s separated
unt i l a common point i s reached. The PSC connections are made to the left
half, and the SC connections are made to the right half of the U3P, as shown
11
PN4:003
007.. 5
in figure 11 through 14. The LGP assembly has one lug on the left half that
is available for a battery backup return line connection ^ " 18 * [)*
4 IJI * j M O D Those two lugs accept wire sizes of AWG I/O
middle for connection to a MGP. These two i"8 Li.. <. . ^n ^Hn n ...
to 4/0 (8.3 to 11.7 mm). For a single grouping of cabinets fonnectloncan
be made directly from the LGP assembly to theJRO VO X dcsingle-point earth
ground. For more than one cabinet grouping, an MGP assembly should be us
d
t o
i . . 4
0
touother before being connected to the
connect the several cabinet groupings togecner O C U L C
6
single-point earth ground.
GROUND WIRING
j i j .-
u
..r.niv common for the PROVOX instrumentation
The signal common and power supply commun .. ---*< n
. , . i . 4 J ,, oonnrate wires to their respective tie
system should each be carried on separate WAH-O r
points. The wiring si
Z
e recommended for use with these grounI points is AWG
No. 8 (3.3 nun diameter) with their lengths being as i } " " " ^ ^ ' * *
SC and PSC wiring should be insulated to avoid unintentional ground connec-
tions that can occur if the wires touch the netal cabinet or each other.
The SC and PSC circuits from each cabinet should be joined at a single point.
A local ground point can be established for each group of bln 1th the
SC and Pic circuits for each cabinet connected to that.point The left side
of the local ground point assembly bar should be reserved for the PSC leads
and the right side reserved for SC leads; the leads should not be Intermixed.
A single re should then be run from the local ground point assemblyt.
master* ground point assembly located in one of the cab inets of ^grouping.
A single wire is then run from each master ground point assembly to the PROVOX
dc single-point earth ground.
In some situations, a single-point ground may not be practical or feasible.
For example, cabinets that are connected only by the data highway need not be
returned to the same single-point ground. However, the same ground point
should be used in the following cases:
o The cabinets are located in the same area.
o The cabinets are bolted together to form one contlglous assembly or
unit.
o The cabinets share the same single-ended signal. This will occur if
one transmitter is connected to two points in separate cabinets or
if an output from a controller or multiplexer is used as a remote
set point for a unit in another cabinet.
If redundant or backup power supplies are being used, a backup power supply is
required for each local-ground point area being powered, and a separate return
line must be used for each LGP of the system. Although separate areas can be
tied together at a master ground point assembly, power supply return currents
between the separate areas should be minimized. The return currents must not
be run through'the single-point earth ground. Regardless of whether a singlc-
or multinle-ooint ground approach is chosen, plant grounds for the PROVOX
J nawuwnutlw ayato. ahouWnot be used to ground non-PROVOX instrumentation
-12'
PN4;003
0V...O
system equipment, especially high-current devices such as motor contactors and
power transformers.
Figure 10 shows the ground and power connections for cabinets with PROVOX
power supplies; typical arrangements are also shown in figures 11 through 14.
In either case, the redundant supply and the primary supplies that it supports
must be connected to the same LGP assembly.
A power supply system can be supported by user-supplied battery or separate dc
power source to protect against commercial ac power failure, A separate
battery stack is required for each LGP. Figure 12 Illustrates the connections
for a battery backup to the power supplies, using separate battery stacks for
each local ground point. If this arrangement Is impractical, a common battery
stack can be used, but the ground system may need two sets of local ground
pointsone for the signal common and one for the power supply coatnon cir-
cuits. Figure 13 illustrates the connections for a battery backup to the
power supplies when one battery stack Is supplying power for the system.
COMMON GROUNDING BETWEEN PROVOX INSTRUMENTATION AND OTHER PERIPHERAL DEVICES
AND SYSTEMS
Other peripheral devices and systems for the PROVOX instrumentation system can
include such equipment as an associated high-speed printer, a mass storage
device such as a disk system, a secondary computer, or even the control con-
sole Itself. Although physically separated by several feet, a comason ground-
ing system should exist. For any area of the instrumentation system where
more than one grouping of equipment exists, the common grounding system must
be designed so that it does not create excessive current loops. All three
ground system types are necessary (i.e., PROVOX ac, PROVOX dc, and cabinet
ground, as described above) for a particular local area. Regardless of the
ground types used, the interconnecting wiring must be of sufficient size to
safely and adequately handle the currents involved. Figure 15 shows a typical
ground connection between the PROVOX system cabinet and a Fisher ac Series
100 instrumentation unit.
Remote Peripherals
When perlpherlals must be powered from other than console or computer utility
power strips, they will be powered from isolated ground receptacles. An
isolated ground receptacle, as shown in figure 7, must be installed or con-
structed In such a way that the ground terminal is electrically Isolated from
the conduit. The ground terminal must be isolated from any contact with a
ground or grounding system through its mounting hardware.
Shield Grounding System
A shield grounding system is used in the system cabinets to provide a common
termination point for shielded field wiring. Field wiring Is described in
detail in the signal wiring and data highway guidelines installation planning
note.
-13-
.WW^JSRW&SMam ,,
PH4:0O3
The shield ground point (SGP) is a copper bus bar that can be mounted in the
horizontal cable trays located in the system cabinet. The SGP provides
grounding for the signal cable shields. The SGP has connections for up to 45
separate shield terminations plus a similar connection for grounding the SGP
to the RETMA rails of the system cabinet.
0 0 7 2 7
Signal cable shields must be grounded to properly shield the signal wiring.
In general, the cable shield should be terminated only at the power source
end. When the source is either +24 volts or the current output section of
controller or multiplexer units, the cable shield should be terminated in the
system cabinet. The SGP is the grounding bar that should be used to terminate
all signal cable shields that are to be terminated inside the system cabinet.
Consoles and Computers
The PROVOX consoles and computers are grounded only from the ground bus as
shown in figures 4 and 6. The conduit carrying the circuit conductors is
electrically isolated from the console or computer cabinet. It is further
recommended that the grounding conductor cable to consoles and computers be
made up of a large number of small conductors [such as No. 8 AWG composed of
168 strands of No. 30 AWG (0.25 mm diameter)], If a multiconductor cable is
being used to supply power to the point of connection, then a second cable
should be connected in parallel with the grounding conductor in the multi-
conductor cable, and this second cable should be of the type mentioned above
and must be routed with the multiconductor cable.
f

EARTH GROUNDS
There are basically two types of earth ground systems that are used as a
single-point plant ground, These are (1) earth ground rods and (2) watered
chemically treated earth grounds. With either type of earth ground, geograph-
ical separation of the various local areas of the instrumentation system may
require that more than one earth ground be installed. The wiring to the
single-point ground should be as short and direct as possible.
Installing an Earth Ground Rod System
A checkerboard pattern of interconnected ground stakes as shown in figure 17
produces a very good earth ground rod system. The stakes should be driven
into the earth deeply enough to reach the water table of the locality. An
alternative ground rod system makes use of a star-shaped grid pattern of
conductors radiating from a single point and covered by moist earth. Resist-
ance for an earth ground rod system varies, depending upon the soil type and
the moisture content of water table depth. The following dimensions and
values provide a general estimate of the requirements to produce a good ground
with a rod system:
o Twenty 0,5-inch (12.7 mm) rods spaced as shown in figure 17 and
driven to a depth of 8 feet (2.4 meters) will produce a resistance
of about 4 ohms in a dry, gravelly area. However, the resistance
value will drop rapidly if the moisture content is high,
-14-
PN4:003
o An eight-conductor st ar configuration, made from solid or standard
wire conductors with 1-inch (25 mm) diameter and 150-foot (45.7
meters) length wi l l produce a resistance of about 1 ohm in the same
dry gravel as above. Again, a high moisture content will drop the
resistance value.
U i i / 2 8
Resistance measurements for the above two ground rod systems are made in
accordance with the instructions for ground systems testing in this note.
Installing a Watered, Chemically Treated Earth Ground System
If soil conditions make installation of a ground rod system impractical, an
effective alternative is the watered, chemicalLy treated system. Each ground
rod in the system must be treated in the same manner. If more than one ground
rod (electrode) is needed for the system, arrange the additional electrodes in
a grid pattern as shown in figure 17. Use the following procedure to install
each electrode:
1. Drill a 10-inch (25 cm) minimum diameter hole to a depth of at least
4 feet (1.2 m) below the top of the water retention soil strata
(usually clay) or to a minimum depth of at least 15 feet (4.6 m), if
the clay layer is located deeper than 15 feet. Figure 18 shows the
dimensions for the chemical ground system.
2. Fill the hole with 6 inches (.15 cm) of mixed chemicals as shown in
figure 18.
3. The chemical mix recommended is 75-percent hydrated gypsum (hydrous
calcium sulfate), 20-percent bentonite (an absorptive and colloidal
clay), and 5-percent sodium sulfate.
4. Hang and center the electrode and the steel watering pipe in the
well.
5. Fill the well with chemicals to 6 inches (15 cm) above the top of
the electrode.
6. Pour about 20 to 30 gallons (76 to 114 liters) of water through the
steel watering pipe, and allow the chemicals to settle (approxi-
mately 12 to 24 hours).
7. Refill the well with chemicals to 6 inches (15 cm) above the top of
the electrodes.
8. Backfill the well with earth to 3 feet (1 m) below the surface.
9. Install the concrete pipe well and the galvanized steel conduits for
connections to the control room, other local area ground systems,
and other rods in the grid system, as required. Then, backfill
around the well, covering the various conduits.
PN4: 003
]
1 0. Fi l l the concret e pipe wel l with eart h to the bottom of the well
tamping l i gh t l y .
c n e w e l I

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F
n
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d r
i
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8
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m t h e c o n d u
i t s , as shown
in figure 1 8. Then, connect each ground wire t o the el ect rode
12. I ns t a l l the perforat ed s t e e l cover over the concret e pi pe^weU .
GROUND SYSTEMS TESTING
Ai l ground systems should be e l e c t r i c a l l y t est ed for r es i s t ance upon i ns t a l l a -
t i on and then t est ed at two-month i nt er val s t her eaf t er for the f i r s t year.
After the f i r s t year, the system r es i s t ance can be checked at six-month i nt er -
vnls. The r es i s t ance between the grounding point s in t he inst rument at ion
system and the eart h ground should be kept as low as possi bl e to avoid i n-
ducing offset vol t ages as a r e s u l t of the excessive cur r ent s in the various
ground loops. The maximum permi ssi bl e r es i s t ance depends upon the current in
the ground wire and t he par t i cul ar process t ol er ances . For example, a 10-
mi l l i vol t drop in the s i gnal common lead can int roduce an of f s et (or er r or ) of
0. 2 5 percent of span in a 1- t o 5-volt analog s i gnal .
The effect i veness of t he ear t h ground rods used for a s i ngl e- poi nt processing
pl ant ground system can be conveni ent l y measured with a megohmmeter equipped
with an al t er nat i ng cur r ent gener at or . Figure 19 i l l u s t r a t e s a t ypi cal t es t
confi gurat i on and the t es t lead connections for t es t i ng a ground system. The
auxi l i ar y el ect rodes (l abel ed P2 and C2) should be driven t o a depth compar-
able with t hat of the - ground system under t e s t . When a known current (as
i ndi cat ed on the ammeter of the megohmmeter) i s passed through the eart h
ground under t es t and auxi l i ar y el ect rode C2, the volt met er i ndi cat es the
pot ent i al di fference es t abl i s hed between the eart h ground under t es t and the
ot her auxi l i ar y el ect rode (P2 ). The r es i s t ance R to ear t h of t he eart h ground
system under t es t i s the r a t i o of the pot ent i al di fference V t o the current I
( i . e . , vol t age/ current or R - V/ I ) . Resistance for an i nst rument at i on system
ground should be 1^ ohm or l e s s . If t hi s r es i s t ance i s not obt ai ned, the
ground system should be reworked u nt i l t hat val ue, or l e s s , i s obt ai ned.
LIGHTNING PROTECTION
In an area where damage from e l e c t r i c a l storms could occur i t i s r
0

m
n,
Q
, ^
t hat a l i ght ni ng pr ot ect i on system be i ns t al l ed to prot ec \ o , / qu L T
personnel . This pr ot ect i on should include prot ect i on for the bui l di ne T.
power di s t r bution system, and any cabl es t hat run out s i de to the f i e l d e r to
i 2 Tof Z T * ' ,
B u
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V
h l e l d e d
< ^ l e s in conduit can e l i mi L e h majo -
i t y of the t r a ns i e nt s , unl ess the area experiences a di r ect s t r i ke to cround
Any ground system used with l i ght ni ng prot ect i on devices must be i s o l l t l Tt o L
he ? i
r
r n l n r
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Any
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the l i ght ni ng ground system i s required to be separated by a minimum of 6 feet
(1 . 8 meters) from any el ect r ode t hat i s part of the l i ght ni ng ground s ys t e^!
-16'
J PM:003
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PN4: 003
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round and Power System Connections for Cabinets with PR0V0X Power
y Stack Backup (Using Separate Stacks for Each Local Ground Point)
as

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Cabinets with +24 Volt dc Feeder Line (User-Supplied Power)
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NOTES:
[ [ > wmiNa I C T WM N LOCAL A M A ANO M A S T M G R OUND
POINTS SHOULD HI AT HART NO I/O AWQ | l ] mmOIA I
T0 4/OAWO|I1 ? mmOIA)
[> WWNO TO PnOV OX OC OROUNO SHOULD l AT HAST
NO 4/OAW(J|T1 7 mmOIA |
[2> SArfTY OnOUND SHOULD B I AT LM B TOJ IN. ( U' r nH
BRAIOCDWine
A2760
Figure 15. Common Grounding Connections between PROVOX Instru-
mentation System und other Peripheral Devices or Systems
30
PN4:003
1
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V
007
;
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0
j>
u
yi if u t ii c u i w t v B j BB : : f 1
I. i ' ;
3 7 A 4 7 5 1 - A OR
. I I V J T U J I U . . i t i i . :r. .. jriu J UL . . rr , TI. .
MASTER QROUNO POINT AtSEMBLV
37A4680-A
47A4860-A
D 1502
Figure 16. Typical System Cabinet Grounding Assembly Showing
Details for Locnl Ground Point (LGP) and Master
Ground Point (MGP) Assemblies
-31-
007
A2762
CABU Til
POINTS
-LUiL-
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Nf AH CONIIIOL CIWTIKI
UIK ADDITIONAl lUCTnOOU IN UKIO A> MOUIIUO
in
Fi gur e 17. I n s t a l l a t i o n and I nt e r conne ct i on
for Typi cal Ear t h Ground Rod System
- 32

PH4
003
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normal
m o r e inn\liTii, technique for r e n d e r i n g el ectrica l
i:; cal l ed intrinsic s a fety. 1 h i s t e c h n i q u e invol ve
it puss il l< tos the ciii iii I to he loc'iitAiQ 7 n | Q
energ y under the circuit cannot conta in enoug h
I Milt i Mini i t ion:, to cause ignition in the ha.', i rdous .st.iusplien
intni'is io safety b a r r i e r s a n ; de s i g n e d to assure s a fe v o l t a g e s and cu r r e n t s
for instruments m o u n t e d in h a z a r d o u s - r a t e d a t m o s p h e r e s ; Each b a r r i e r s e r ve s
a:; the interl a ce betw een the fiel d- mounted instrument and its a s s ocia ted
control lor or i n s t r u m e n t . T h e ba rriers .ire g rounded to .i bus b a r , and tbf bus
bar is con n e ct e d to ea rth g round. T h e s tra p or c a b l e p r o v i d i n g this satety
ground must be rug g ed e n o u g h to prevent accidental p h y s i c a l d a m a g e whil e
pr o v i d i n g ,i r e s i s t a n c e of l ess titan 1 ohm between the h a r r i e r m o u n t i n g stud
and the ea rth g r o u n d po i n t . Field instruments in i n t r i n s i c a l l y safe s ys tems
can he instal l ed and o p e r a t e d in their w o r k i n g l oca t i on s without danger to
pers onnel or pl a n t .
Groundinjg P r a c t i c e s
T h r e e compl ete g r o u n d i n g s y s t e m s a re used w ith the P R O V O X i n s t r u m e n t a t i o n
s ys tem: (1) P R O V O X a c g r o u n d , (2) P ROVOX dc g r o u n d , and (3) a ca binet s hiel d
or safety g r o u n d . T h e s e t h r e e g round s ys tems must r e m a i n s e pa r a t e d until they
a re connected at the singJje-p_ojjjt jilant e a r t h g r ou n d or at an a p p r o p r i a t e
i n t e r m e d i a t e p o i n t . T he l a m i n a t e d bus ba r in the P ROVOX s ys tem cabinets
pr o v i d e s signal c o m m o n (SC) and po w e r suppl y common (P SC) c o n n e c t i o n s for each
card fi l e ; it a l s o a i d s in k eeping the three ground s y s t e m s s e pa r a t e . A
s hiel d g round p o i n t , as s h o w n in figure 1 , is a c o p p e r b u s bar that can b e
mounted in the h o r i z o n t a l c a b l e trays l ocated in the s y s t e m c a b i n e t . The
shiel d g round po i n t is p r o v i d e d for g rou nding the s i g n a l cabl e s h i e l d s to the
ca binet and has c o n n e c t i o n s for up to 45 s epa ra te s hiel d t e r m i n a t i o n s pl us a
s imil a r c o n n e c t i o n to the R E T M A rail of the system c a b i n e t . F or a d d i t i o n a l
i n fo r m a t i o n on g r o u n d i n g p r a c t i c e s , see the d o c u m e n t s l i s t e d in tabl e I.
In a d d i t i o n to the SC and P SC c o n n e c t i o n s , pr o v i d e al l c a b i n e t s , c o n s o l e s , and
expos ed m e t a l s u r fa c e s that m a y b e c o m e energized d u e to a s ys tem fault w i t h a
good ea rth ground for s a fe t y , Use s e pa r a t e , insul ated g r o u n d w i r e s for al l
pow er s uppl y and s i g n a l common c o n n e c t i o n s . Sa fety g r o u n d w ires need not be
ins ul a ted. For a d d i t i o n a l ground i n s t a l l a t i o n and test m e a s u r e m e n t informa-
tion, see the rel a ted d o c u m e n t s l isted in tabl e I,
DATA HIGHWAY GUI D R U N K S
DejiCiptjU)n
T he PROVOX data h i g h w a y , w h i c h provides the c o m m u n i c a t i o n s b e t w e e n the va r i ou s
devices in a d i s t r i b u t e d pr o c e s s control system, u s e s a m u l t i d r o p c o n n e c t i o n
as opposed to a s t a r or radial, c o n n e c t i o n . The m u l t i d r o p c o n n e c t i o n method
requires pl a nning and routing of the highway in a si?rial m a n n e r . The total
communica tions c o n n e c t i o n s for .i P ROVOX i n s t rumen tnt ion s ys tem w ith reihindanrv
is shown in figure A. Knell lorn I area o| the s ys tem can ha ve up to .10 local
devices (UV; that are cont ro I I oil hy
a mc
' ".>:!.! I.TPs p l u s up t o s i x i i et wor l . d o v i i e : . (ND) < ,:u be >,
w.wk t r a f f i c d i r e c l o r (N' TD). AM i n t e r l a c e I M I I M I I i
al t r a i l i o d i r e c t o r ( LTD) . J.'p to, ' *
' i i t r o l I IMI by t he ;iet
I o t he d a t a Is i i-hwav
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