INSTALLATION AND WIRING CHAPTER 5 In This Chapter... Safety Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–2 Introduction to the Productivity3000 Mechanical Design . . . . . . . . . . . . . . . . . . .5–5 Dimensions and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–6 Mounting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 5: Installation and Wiring Safety Guidelines A1 2 3 4 5 6 7 8 9 10 11 12 14 14 A B C D NOTE: Products with CE marks perform their required functions safely and adhere to relevant standards as specified by CE directives provided they are used according to their intended purpose and that the instructions in this manual are adhered to. The protection provided by the equipment may be impaired if this equipment is used in a manner not specified in this manual.
Chapter 5: Installation and Wiring Three Levels of Protection WARNING: The control program must not be the only form of protection for any problems that may result in a risk of personal injury or equipment damage. The publications mentioned provide many ideas and requirements for system safety. At a minimum, you should follow these regulations. Also, you should use the following techniques, which provide three levels of system control. 1. Orderly system shutdown sequence in the PAC control program.
Chapter 5: Installation and Wiring Emergency Stop Circuits Emergency stop (E-Stop) circuits are a critical part of automation safety. For each machine controlled by a PAC, provide an emergency stop device that is wired outside the PAC and easily accessed by the machine operator. E-stop devices are commonly wired through a master control relay (MCR) or a safety control relay (SCR) that will remove power from the PAC I/O system in an emergency.
Chapter 5: Installation and Wiring Introduction to the Productivity3000 Mechanical Design The Productivity3000 is a modular system that requires a base to accommodate the various modules. Bases are available with 3, 5, 8 and 11 I/O module slots. The bases contain additional dedicated slots for the power supply and the CPU. You can place any I/O module in any I/O slot without power budget or module type restrictions.
Chapter 5: Installation and Wiring Dimensions and Installation A 2 3 4 5 3 3 3 3 3 3 3 3 3 3 3 3 3 Before installing the PAC system you will need to know the dimensions of the components considered. These diagrams provide the base dimensions to use in defining your enclosure specifications. Remember to leave room for potential expansion. If you are using other components in your system, refer to the appropriate manual to determine how those units can affect mounting dimensions.
Chapter 5: Installation and Wiring Mounting Guidelines Enclosures Your selection of a proper enclosure is important to ensure safe and proper operation of your Productivity3000 system. Applications for the Productivity3000 system vary and may require additional hardware considerations.
Chapter 5: Installation and Wiring A 2 3 4 5 3 3 3 3 3 3 3 3 3 3 3 3 3 2” 50mm min 2” 50mm min 3” 76mm min 7 7.2” 2” 183mm min 3” 76mm min 2” 50mm min Ground Braid Copper Lugs Panel or Single Point Ground OK Panel Star Washers Star Washers AIRFLOW 3” [76mm] NOTE: Add 3 inches (76 mm) to mounting depth when using ZIPLink cable ZL-CBL40. 5–8 Hardware User Manual, 4th Edition, Rev.
Chapter 5: Installation and Wiring In addition to the panel layout guidelines, other specifications can affect the installation of a PAC system. Always consider the following: • Environmental Specifications • Power Requirements • Agency Approvals • Enclosure Selection and Component Dimensions Class 1, Division 2 Approval This equipment is suitable for use in Class 1, Division 2, Zone 2, groups A, B, C and D or non–hazardous locations only.
Chapter 5: Installation and Wiring Using Mounting Rails The Productivity3000 bases can be secured to the cabinet using mounting rails. You should use rails that conform to DIN EN standard 50 022. We offer a complete line of DIN rail, DINnectors and DIN rail mounted apparatus. These rails are approximately 35mm high, with a depth of 7.5mm. If you mount the base on a rail, you should also consider using end brackets on each side of the base.
Chapter 5: Installation and Wiring Installing the Power Supply A 2 3 4 5 3 3 3 3 3 3 3 3 3 3 3 3 3 Step One: Locate the left most socket in the base. Step Two: Insert the Power Supply at a 45° angle into the notch located at the top of the base and rotate down until seated in socket. Step Three: Snap the two retaining tabs into the locked position. WARNING: Explosion hazard – Do not connect or disconnect connectors or operate switches while circuit is live unless the area is known to be non-hazardous.
Chapter 5: Installation and Wiring Installing the CPU This installation procedure also applies to the P3-EX expansion module and the P3-RS/P3-RX remote slave modules. A 2 3 4 5 3 3 3 3 3 3 3 3 3 3 3 3 3 Step One: Locate the two sockets next to the power supply; the CPU will be inserted into this location. Step Two: Insert the CPU at a 45° angle into the notch located at the top of the base and rotate down until seated. Step Three: Snap retaining tab into the locked position.
Chapter 5: Installation and Wiring Installing the I/O Modules WARNING: Do not apply field power until the Align here following steps are completed. See hotswapping procedure for exceptions. Step One: Align circuit card with slot and press firmly to seat module into connector. Step Two: Pull top and Align here bottom locking tabs toward module face. Click indicates lock is engaged. Step Three: Attach field wiring using optional terminal block or ZIPLink wiring system and install cover.
Chapter 5: Installation and Wiring Wiring Guidelines A 2 3 4 5 3 3 3 3 3 3 3 3 3 3 3 3 3 Wiring to the Power Supply Connect the AC or DC power source input wiring to the power supply as shown. The power supply terminals can accept up to 14 AWG solid or stranded wire. Do not overtighten the terminal screws; the recommended torque is 7 to 9 inch-pounds (0.882 to 1.02 Nm). WARNING: Once the power wiring is connected, secure the terminal block cover in the closed position.
Chapter 5: Installation and Wiring Fuse Protection Some of the Input and Output I/O module circuits do not have internal fuses. In order to protect your modules, we suggest you add external fuses to your I/O wiring. A fast-blow fuse with a lower current rating than the I/O bank’s common current rating can be wired to each common. Or, a fuse with a rating of slightly less than the maximum current per output point can be added to each output.
Chapter 5: Installation and Wiring I/O Module Wiring Options A 2 3 4 5 3 3 3 3 3 3 3 3 3 3 3 3 3 There are two available methods for wiring most I/O modules: The ZIPLink wiring system or hand wiring to the optional removable I/O module terminal blocks. NOTE: The high-density 32-point and 64-point I/O module design requires the use of the ZIPLink wiring system. Thermocouple and RTD modules are not compatible with the ZIPLink system and are shipped with the terminal blocks included.
Chapter 5: Installation and Wiring Productivity3000 Input Module ZIPLink Selector ZIPLink PLC Input # of Module Module Terms Component Part No. Productivity3000 Output Module ZIPLink Selector ZIPLink PLC Cable Part No. Output Module # of Module Terms Component Part No. Cable Part No.
Chapter 5: Installation and Wiring Removable Terminal Blocks (Optional) The hand wiring method consists of purchasing the optional removable I/O module terminal block (part no. P3-RTB) and hand wiring from the I/O terminal block to a DIN rail mounted terminal block. A 2 3 4 5 3 3 3 3 3 3 3 3 3 3 3 3 3 Removable Terminal Block P3-RTB Terminal Block Removal 2. Loosen selfjacking screws to disengage terminal block. 3. Grip opened door along edge to avoid flexing door and pull terminal block from module.
Chapter 5: Installation and Wiring Planning the I/O Wiring Routes The following guidelines provide general information on how to wire the I/O connections to Productivity3000 PAC's. For specific information on wiring a particular I/O module refer to the module specifications in Chapter 2. 1. If using removable terminal blocks, follow the wire size guidelines in the I/O modules specifications in Chapter 2. 2. Always use a continuous length of wire. Do not splice wires to attain a needed length. 3.
Chapter 5: Installation and Wiring System Wiring Strategies A 2 3 4 5 3 3 3 3 3 3 3 3 3 3 3 3 3 The Productivity3000 system is very flexible and will work in many different wiring configurations. By studying this section before actual installation, you can find the best wiring strategy for your application. This will help to lower system cost and wiring errors, and avoid safety problems.
Chapter 5: Installation and Wiring Sinking/Sourcing Concepts Before wiring field devices to the PAC I/O, it’s necessary to have a basic understanding of “sinking” and “sourcing” concepts. Use of these terms occurs frequently in input or output circuit discussions. The purpose of this section is to explain the terms.
Chapter 5: Installation and Wiring I/O “Common Terminal” Concepts A 2 3 4 5 3 3 3 3 3 3 3 3 3 3 3 3 3 In order for a PAC I/O circuit to operate, current must enter at one terminal and exit at another. This means at least two terminals are associated with every I/O point. In the figure below, the input or output terminal is the main path for the current. One additional terminal must provide the return path to the power supply.
Chapter 5: Installation and Wiring DC Input Wiring Methods I/O modules with DC inputs can be wired as either sinking or sourcing inputs. The dual diodes (shown in this diagram) allow current to flow in either direction. Inputs grouped by a common point must be either all sinking or all sourcing. DC inputs typically operate in the range of +12-24 VDC.
Chapter 5: Installation and Wiring PAC DC Sinking Output to Sinking Load Device In the example below, a sinking output point is connected to the sinking input of a field device load. In this case, both the PAC output and field device input are sinking type. Since the circuit must have one sourcing and one sinking device, we add sourcing capability to the PAC output by using a pull-up resistor. In the circuit below, we connect Rpull-up from the output to the DC output circuit power input.
Chapter 5: Installation and Wiring Relay Outputs - Wiring Methods Relay outputs are available for the Productivity3000.
Chapter 5: Installation and Wiring Relay Outputs – Transient Suppression for Inductive Loads in a Control System A 2 3 4 5 3 3 3 3 3 3 3 3 3 3 3 3 3 The following pages are intended to give a quick overview of the negative effects of transient voltages on a control system and provide some simple advice on how to effectively minimize them. The need for transient suppression is often not apparent to the newcomers in the automation world.
Chapter 5: Installation and Wiring PLC's Integrated Transient Suppressors Although the PLC's outputs typically have integrated suppressors to protect against transients, they are not capable of handling them all. It is usually necessary to have some additional transient suppression for an inductive load. Here is another example using the same 24V/125mA/3W relay used earlier.
Chapter 5: Installation and Wiring Types of Additional Transient Protection A 2 3 4 5 3 3 3 3 3 3 3 3 3 3 3 3 3 DC Coils: The most effective protection against transients from a DC coil is a flyback diode. A flyback diode can reduce the transient to roughly 1V over the supply voltage, as shown in this example.
Chapter 5: Installation and Wiring Two more common options for DC coils are Metal Oxide Varistors (MOV) or TVS diodes. These devices should be connected across the driver (PLC output) for best protection as shown below. The optimum voltage rating for the suppressor is the lowest rated voltage available that will NOT conduct at the supply voltage, while allowing a safe margin. AutomationDirect's ZL-TSD8-24 transorb module is a good choice for 24VDC circuits. It is a bank of 8 uni-directional 30V TVS diodes.
Chapter 5: Installation and Wiring Notes: A 2 3 4 5 3 3 3 3 3 3 3 3 3 3 3 3 3 5–30 Hardware User Manual, 4th Edition, Rev.
