SECTION 2 - SITE ENVIRONMENT

INTRODUCTION

Site environment covers the physical and environmental

requirements of equipment and work areas. It includes site
requirements for atmospheric conditions (temperature and
humidity), lighting, noise, space, storage and safety. Planning
the site environment is important because it affects not only
the operation of system equipment, but also the productivity
and safety of personnel.

PREPARING THE SITE

There are many facets to the task of preparing a site to meet

certain physical and environmental requirements. This is
especially true when those requirements consider the needs
of both system equipment and personnel. Bailey can specify
the environmental requirements of its manufactured sys-
tems, but can only make general recommendations for a suit-
able environment for personnel. Bailey recommends following
up-to-date human factors engineering practices to insure a
safe and comfortable working environment. Process control
systems can function properly across a range of environmen-
tal conditions that fall beyond environmental extremes for
people. This simplifies the system’s environmental prepara-
tion of work areas used by personnel. Designing the site envi-
ronment with respect to the comfort zone for human beings
will meet the environmental requirements of equipment. Con-
sult a human factors engineer or other available source of
information on process control system ergonomics when pre-
paring the environment of your particular site.

PHYSICAL REQUIREMENTS

Physical requirements cover the mechanical aspects of equip-

ment installation. The physical requirements include the load
bearing of floors, equipment and work space, and mechanical
shock and vibration damping.

Load Bearing of Floors

The floor of the installation site must be capable of bearing

the weight of the equipment. Refer to Appendix B for equip-
ment weights when determining the floor load bearing
requirements. Floors, such as reinforced concrete that are
suitable for heavy manufacturing equipment, are normally
suitable for supporting all INFI 90 units.

INTRODUCTION
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Space

Installed cabinets must have enough space around them so

that doors can be opened and side panels removed (if applica-
ble). The installation drawings in Appendix G show the mini-
mum space required for INFI 90 units. Additional spacing
may be required to allow for removal of components.

Control rooms should be large enough to hold system hard-

ware and allow service and operating personnel to move
through and work in the area easily. Additional room may be
needed for routing, shielding and spacing signal wiring or AC
power distribution. Sections 3 and 4 contain information on
AC power distribution and system grounding. Refer to the
information in those sections if necessary when planning for
the space requirements of a particular system. The layout
should allow operators and personnel doing routine service to
work simultaneously without being in each other's way.

The dimensions of working space near live areas operating at

600 volts (nominal) or less and likely to require examination,
adjustment or maintenance while live should follow the
guidelines in Table 2-1. Distances should be measured from
the live parts if exposed or from the enclosure front or open-
ing if enclosed. Always consider concrete, brick, structural
steel members or tile walls to be grounded. Additionally, the
work space should be at least 762 millimeters (30 inches)
wide in front of electrical equipment (see Figure 2-1). Refer to
the National Electrical Code for other work space require-
ments such as headroom and access to working spaces.

Table 2-1. Working Clearances

Nominal Minimum Clear Distance in Meters (Feet)

Voltage to
Ground (V) Condition 1 Condition 2 Condition 3

0 - 150 1 (3.33) 1 (3.33) 1 (3.33)

151 - 600 1 (3.33) 1.07 (3.5) 1.22 (4)
NOTE: These dimensions comply to the Canadian Electrical Code.

Explanation of conditions in Table 2-1:

Condition 1 - exposed live parts on one side and no live or

grounded parts on the other side of the working space, or
exposed live parts on both sides effectively guarded by suit-
able wood or other insulating materials. Insulated wire or
insulated bus bars operating at not over 300 volts shall not
be considered live parts.

Condition 2 - exposed live parts on one side and grounded

parts on the other side.

PHYSICAL REQUIREMENTS
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PLANT FLOOR

762 MM (30 IN.)

MINIMUM GROUNDED
W ORKING CONCRETE
LIVE W IDTH WALL
PARTS

MINIMUM CLEAR
DISTANCE FOR
CABINET
CONDITION 1
(TOP VIEW )
(TABLE 2-1)
TP25204A

Figure 2-1. Minimum Clearances for Working

Space Near Live Areas

Condition 3 - exposed live parts on both sides of the work

space (not guarded as provided in condition 1) with the oper-
ator between the live parts.

Exceptions to conditions in Table 2-1:

Exception 1 - working space shall not be required behind

assemblies such as dead-front switchboards or motor control
center, where there are no renewable or adjustable parts
such as fuses or switches on the back and where all connec-
tions are accessible from locations other than the back.

Exception 2 - smaller spaces may be permitted where good

judgment dictates that the particular arrangement of the
installation will provide adequate accessibility, and all exposed
live parts are at a voltage no greater than 30 volts RMS or
42 VDC for dry locations, 15 VDC for wet locations.

Mechanical Shock and Vibration

Do not subject the equipment to mechanical shock during or

after installation. The control room should be free from shock
or vibration that could affect the performance of system opera-
tors. When designing the control room, care should be taken to
shield system operators from excessive low frequency vibration.
High amplitude horizontal or vertical vibration near the reso-
nant frequency of the human body (approximately five hertz)
hampers vision, hand coordination and reaction time. It is not
practical to project mechanical shock and vibration tolerances
for all possible conditions at various installation sites. If exces-
sive levels of vibration are expected, do a site survey to decide if
work areas or equipment need vibration damping.

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ENVIRONMENTAL REQUIREMENTS

The environmental requirements of an installation site

include air quality, temperature, humidity and lighting.
Included are special environmental constraints when trans-
porting and storing equipment.

The ambient environment affects both equipment and the

performance and comfort of system operators. Personnel
should not have to expend so much mental and physical
energy at coping with environmentally imposed stress that it
diminishes their capacity to do their work. Controlling envi-
ronmental distraction helps increase productivity and pro-
vides a comfortable and safer place to work.

Air Quality

Almost all industrial processes contain gaseous, solid (particu-

late) or liquid contaminants. Some contaminants can cause
corrosive damage to INFI 90 equipment. Increased tempera-
ture or humidity can accelerate the corrosive effects of con-
taminants. Solid airborne contaminants accelerate wear to
moving parts, and because of possible high velocity may result
in mechanical corrosion to parts. Solid contaminants can
accumulate on surfaces and result in heat buildup, electrical
part shorting or improper operation of mechanical and electro-
mechanical components. Components susceptible to solid con-
taminants include switches, relays, printers and disk drives.

Select an installation site that is free of corrosive and conductive

contaminants to maintain the reliability and life span of the
INFI 90 equipment. Observe the following conditions when
installing an operator interface station (OIS) and printers in an
area free of any gases, liquids and airborne solids (such as dust):

1. The particulate in the area must be nonconductive and

cannot exceed severity level one as defined in 2Instrument
Society of America Standard S71.04, Environmental Condi-
tions for Process Measurement and Control Systems Con-
tamination Influences.

2. Maintain a preventive maintenance program to curtail

dust buildup and clean or replace filters regularly.

Relocate INFI 90 PCU and OIS driver electronics cabinets

when conductive particles are present or where gaseous, liq-
uid or solid contaminant levels exceed severity level one of
ISA S71.04. If it is impossible to relocate the system, mount
PCU and OIS electronics in NEMA 4 rated enclosures. OIS
operator panels are available that can handle most of these
site conditions. Operator panels link via wire or fiber optic
cables to driver cabinets typically mounted in cable spread-
ing, power distribution and control areas.

ENVIRONMENTAL REQUIREMENTS
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Temperature and Humidity

Temperature and humidity levels must be maintained to pro-

vide a comfortable ambient environment for personnel and to
control electrostatic charge buildup. The recommended
humidity for control rooms containing INFI 90 systems is
40 percent to minimize electrostatic buildup on equipment or
personnel. Refer to Appendix B for the temperature and
humidity requirements of a specific piece of INFI 90 equip-
ment. Use this information to decide if your particular site
needs additional temperature or humidity control.

The information in Appendices A and D can be used to calcu-

late the heat that will be generated within a cabinet. Specifi-
cations in Appendix A show the heat dissipation of INFI 90
operator interface stations and consoles, and cabinet power
supplies. The specifications in Appendix D show the heat dis-
sipation of individual INFI 90 modules.

Air Conditioned Locations

Maintain air conditioned control room environments at a

temperature of 21 degrees to 23 degrees Celsius (70 degrees
to 74 degrees Fahrenheit) with a minimum of 40 percent rela-
tive humidity. When sizing air conditioning equipment, con-
sider the heat dissipation (watts (BTU/Hr)) of the INFI 90
equipment during normal operation. Refer to Appendices A
and D for normal heat dissipation of specific INFI 90 equip-
ment and modules.

Lighting

Based on various ergonomic studies, the recommended light

intensity in the OIS and printer work areas is 300 to 500 lux
(28 to 47 foot-candles) on horizontal work surfaces, keyboards
and display consoles. Data preparation areas should be
lighted from 970 to 1080 lux (90 to 100 foot-candles) on hori-
zontal work surfaces. Lighting should be indirect to reduce
glare on station or console monitor screens. Indirect lighting
should be adjustable so that system operators can adjust the
intensity level to meet their individual needs. Use adjustable
direct lighting if supplemental lighting for individual work-
spaces is required.

Electrical Noise

Any unwanted, extraneous, electrical signal induced in an

electronic system is noise. Noise signals may be a steady
state signal or may be of a transient (noise spike) nature.
Noise can be caused by electromagnetic interference (EMI) or
radio frequency interference (RFI). The nature and frequency
spectrum of noise depend on its source. Common noise

ENVIRONMENTAL REQUIREMENTS
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SITE ENVIRONMENT ®

sources include large electrical rotating machinery producing

strong time-varying magnetic fields, large relays, contacts
and silicon-controlled rectifier (SCR) circuits. These devices
place noise transients on power lines or induce transients in
adjacent cabling. Electrical noise-producing equipment is
found in most process control systems. Therefore, it is highly
unlikely to separate the system from all sources of noise.
Thus a means of controlling noise is necessary.

General rules for controlling electrical noise are:

1. Select proper signal wires and cables designed to mini-

mize noise pickup (refer to Section 5).

2. Establish an effective grounding and shielding system.

When encountering persistent or difficult noise problems,
special techniques and filtering methods may be necessary to
reduce the noise to an acceptable level (refer to Section 4).

3. Route signal wiring away from noise-producing equip-

ment (refer to Section 5).

Care should be taken when using transmitting type commu-

nication equipment near the control system. Keep control
equipment cabinet doors closed. Only use transmitting type
communication equipment at a distance of two meters
(6.6 feet) or more from the cabinets and consoles. It is best to
use communication equipment that does not generate radio
frequency interference, such as a wire telephone or intercom
system.

LIGHTNING

Lightning can affect control systems by opening distribution

circuits to interrupt power or by creating electrical noise in
the system. Voltage and current surges created by lightning
enter the system through conductive paths. Power or commu-
nication lines, piping, structural steel and ducts can create
these conductive paths that allow a current surge to pass.
These current surges may pass through portions of system
hardware on the way to earth. This can create an electromag-
netic pulse that induces noise impulse voltages and currents
in the interconnections of the system. Thus these noise sig-
nals do not have to flow through system conductors to corrupt
system data. Additionally, surges may travel a considerable
distance through power and communication lines and still
affect the system.

Complete protection from possible system damage during an

electrical storm requires a series of protective devices
because of the tremendous energy in a lightning strike. Com-
plete protection includes protecting the power distribution
lines, and having filters and effective equipment grounding at

ENVIRONMENTAL REQUIREMENTS
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 SITE ENVIRONMENT

the cabinet. Effective ways to protect a control system from

lightning are:

• Install low voltage transient suppressors (typically

480-volt line to ground or greater) before the service
entrance to the building to protect equipment down-
stream of power entry.

• Use supplemental suppression devices at or near control

equipment to prevent a residual surge, generated from a
lightning strike or generated inside the building, from
entering equipment.

• Protect communication lines that travel between build-

ings. Primary protection should be located where the
communication lines enter the building with secondary
protection closer to control equipment.

• Identify and eliminate unwanted paths where surge can

enter equipment or the control room. These paths may be
power lines, communication lines, process control lines,
water pipes, ducts or other structural members.

• In lightning prone areas and as normal good construction

practice, buildings of reinforced concrete should be con-
structed with steel reinforcement welded together to pro-
vide good continuity. Any structural steel bolted to
reinforced columns should be electrically bonded using
large conductors or metal straps.

• Use a perimeter conductor to connect all driven ground

rods that are attached to lightning protection downwires.
This helps equalize the voltage gradient around the build-
ing at the time of the lightning strike.

Do not use a lightning protection ground system as an electrical

safety ground required by the National Electrical Code. Each
grounding system must be complete in its own right and not
use any of the other system components for integrity. However,
this does not imply that the two systems should be isolated. A
lightning protection system utilizing lightning rods or other
techniques must be coordinated with the electrical equipment
grounding system. A lightning protection ground system should
electrically connect to the electrical safety ground system.

Give special attention to conductive building members that are

within 1.83 meters (six feet) of an exterior lightning downwire.
Avoid damage which could be caused by a side flash from the
downwire to a conductive building member by making an
interconnection (with or without a spark gap) to the downwire.
This interconnection predetermines the side path taken by a
lightning strike if sufficient surge is present. Without this side
path, a surge could take an alternate path provided by a con-
ductive building member and cause damage to equipment.

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OVERVOLTAGE TRANSIENTS

Overvoltage transients can be present in any electrical sys-

tem, but they are more severe and frequent in industrial
power systems. Typical overvoltage transient sources are
high voltage systems, inductive-capacitance resonance
effects, switching surges, arc welders, rectifiers, fluorescent
lights, relays, and variable speed and frequency drives. Start-
ing and stopping inductive reactant components such as
transformers, motors, and solenoids cause overvoltage tran-
sients on power lines. Additional sources of overvoltage tran-
sients can be lightning and electrostatic discharge.

Overvoltage transients affect microprocessors, semiconduc-

tors, CMOS gates, and other types of integrated circuits. Low
power electronic devices, computers, programmable control-
lers, and industrial controls are very susceptible to damage
and reduced reliability when exposed to overvoltage tran-
sients. Overvoltage transients that subject conductor insula-
tion to voltages greater than its dielectric strength cause
insulation breakdown and eventual failure.

Any interruption of current flow to inductive-reactive equip-

ment (transformers, motors, and solenoids) can generate
overvoltage transients on power lines of up to 15 times the
source voltage. The high frequency of these overvoltage tran-
sients and the inductive nature of the electrical system prop-
agates the overvoltage transients freely throughout the entire
distribution system. Utility companies maintain the voltage,
frequency and sine wave form to acceptable limits at their
substations. However, they cannot control customers who
connect and disconnect large loads, lightning strikes, insula-
tion breakdowns, cyclical loads, or other sources of tran-
sients. Therefore, overvoltage transients on incoming power
lines can exist. The magnitude and frequency of these power
line overvoltage transients combined with in-plant generated
overvoltage transients presents a serious problem for systems
using susceptible electronic controllers.

There are several methods available for protecting electrical

and electronic devices from being damaged by overvoltage
transients on power lines. Those methods include power
feeds, isolation transformers, and packaged transient voltage
surge suppressors. Because the location and magnitude of
transients are unpredictable, the best solution is to mount
surge suppressors at various locations in the electrical sys-
tem. For adequate protection of critical equipment such as
microprocessor-based control systems, a surge suppressor
should be installed at the equipment. If possible, a larger
surge suppressor should be installed at the power distribu-
tion panel that is supplying power to the system.

ENVIRONMENTAL REQUIREMENTS
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Electrostatic Discharge

In addition to the noise-reducing techniques previously

described, there should be an effort to eliminate noise from
electrostatic discharge. More importantly, electrostatic dis-
charge causes static sensitive devices to prematurely fail. To
prevent electrostatic discharge:

1. Use antistatic carpeting or other floor coverings in the

control room.

2. Provide antistatic mats for use when working with modules.

3. Always wear a wrist strap that is connected to earth

ground when working at a process control unit cabinet or
handling modules. Where required, use an antistatic work
surface when working with modules.

4. Follow the guidelines in this instruction when installing

the grounding network for the INFI 90 system.

5. Always maintain a humidity level of 40% or greater.

NONOPERATING ENVIRONMENT

There are exceptions to the environmental requirements

when the system is not operating, in storage or en route to
the site.

Transportation

Limit the amount of shock and vibration the INFI 90 system

receives during transportation. The monitor, hard drives and
floppy disk drives within a console (OIS) are sensitive to
vibration. Those items are specially packaged for transporta-
tion. An air ride van is recommended for transportation over
land. Nonoperating environmental conditions apply during
transportation and are listed in Table C-1.

Storage

INFI 90 equipment should remain in its original package for

storage. In particular, INFI 90 modules must remain in their
static shielding packaging. Nonoperating environmental con-
ditions apply during storage (refer to Table C-1).

Power supplies should be powered at least once a year for an

hour or more. When operating equipment during the con-
struction period, the operating environmental conditions
apply. Protect the equipment from exposure to excessive dust
during the construction period.

NONOPERATING ENVIRONMENT
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SYSTEM CONFIGURATION PLANNING

The configuration of process control equipment within a par-

ticular system dictates the response to the controlled process
of that system. Configuration may include such items as
cross-limits, interlocks, alarms, dealing with bad quality and
safety control equipment. Modern electronic process control
equipment based on semiconductor technology is highly reli-
able and can be expected to provide long trouble-free service.
However, component failures that disrupt process control are
still possible. In addition, power line induced failures, fail-
ures caused by human error, static discharge, conducted and
radiated EMI, acts of nature such as lightning strikes, and
accidents can cause disruption of process control.

When designing, implementing or modifying a process control

system configuration, factors that can cause disruption of
process control must be taken into consideration as part of
the process algorithm. Guidelines and standards are avail-
able to assist the designer in planning a configuration that
can account for those factors. However, those guidelines and
standards are not a configuration design handbook. They do
not supplant the need for good engineering practice and com-
petent engineering judgment. The more commonly used stan-
dards and guidelines are:

CSA Standard C22.2 No. 0.8-M1986 Safety Functions

Incorporating Electronic Technology - prescribes guide-
lines for the design, evaluation and testing of electronic safety
functions. It applies to individual electronic components,
assemblies and systems, including software and hardware,
that perform safety functions.

Factory Mutual Engineering Corp. Loss Prevention Data

5-27/14-27 - contains descriptions of and recommendations
for electronic programmable controllers used in process con-
trol systems and industrial equipment. It includes installa-
tion and maintenance practices, and methods of improving
reliability with redundant components and systems.

Factory Mutual Engineering Corp. Loss Prevention Data

6-5 - contains descriptions and recommendations for oil and
gas fired multiple burner boilers.

Industrial Risk Insurers IR Information P.3.8 Program-

mable Logic Controllers for Use with Burner Manage-
ment Systems dated April 3, 1987 - provides guidance in
evaluating the safety of programmable logic controllers in
burner management systems. It also provides information
regarding potential failures modes.

SYSTEM CONFIGURATION PLANNING

2 - 10 I-E96-500B
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American National Standards Institute/National Fire

Protection Association Standard ANSI/NFPA No. 85A
through 85I - covers single and multiple burner boilers.

American National Standards Institute/National Fire

Protection Association Standard ANSI/NFPA No. 86C -
covers ovens and furnaces.

Assistance is also available from Bailey technical support, the

underwriters insuring the premises and from the insurer's
technical advisers or testing laboratory.

NOTE: System configurations installed or modified by anyone

without written consent of Bailey Controls Company is the respon-
sibility of the persons installing or modifying the configuration.

It is not within the scope of this document to give detailed

recommendations on system configuration because each site
is unique. Design and implementation of a particular systems
configuration requires a detailed and intimate knowledge of
the specific process characteristics of that system and the
system equipment.

FIRE PROTECTION

Each installation site should have adequate fire protection.

Fire protection must meet local fire and safety codes. Usually,
the Bailey system being installed at a site has been custom
designed for the process control needs of that site. Therefore,
additional fire protection may be desirable to protect your
investment. Additionally, the loss of process data or other
information (stored on electronic media) due to a fire or its
associated affects can interrupt business and possibly cause
a larger economic loss. For more information about fire pro-
tection, refer to the American National Standards Institute/
National Fire Protection Association Standard ANSI/NFPA
No. 75, Protection of Electronic Computer/Data Process-
ing Equipment or other applicable local fire codes. The NFPA
standard contains complete information on the design of fire
protection systems for electronic equipment. Do not use dry
chemical extinguishers. Dry chemical type extinguishers
will destroy printed circuit board traces.

FIRE PROTECTION
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