Chapter 2 - AutomationDirect
Contents
1. 2 BUS Bar 50mm dl o OOO EM Panel Ground Earth Ground Terminal Note there is a minimum of 2 560mm clearance between the panel door and the nearest DL305 component Fang one fas Component La Chassis iG omg CEE Ke VY Star Washers Star Washers Ground DL305 User Manual Rev D 2 7 Installation and Safety Guidelines In addition to the panel layout guidelines there are other specifications that can affect the definition and installation of a PLC system You should always consider the following areas whenever you install any PLC system e Environmental Specifications e Power Supply Specifications e Agency Approvals e Enclosure Selection and Component Dimensions Environmental Specifications The following table lists the environmental specifications that generally apply to the DL305 system CPU Bases I O modules I O module operation may fluctuate depending on the ambient temperature and your application Please refer to the appropriate I O module chapters for the temperature derating curves applying to specific modules Storage temperature 4 F to 158 F 20 C to 70 C Ambient operating 32 F to 140 F 0 C to 60 C temperature Ambie2. DL305 User Manual Rev D Installation and Safety Guidelines Component Dimensions Part 2 1 37 34 8mm UO modules EH g mm SF T ya 118 6mm Ke S E ke Fi SS 4 65 118nn 8 UO Pts 4 86 123mm 16 I O Pts gt SS A E ja 2 D D o gogo aS co EK SO e D mm T UO module w 24 pin connector iss KU 1 37 E 348mm 24 pin connector m k A nl FT ke imm M CH O O i a D Q OO S 2 06 52 4mm 123mm 9 d ae Ss diim A Bescht F Data communication units Prom Writer Unit has the same dimensions 1 5 4 33 38mm 110mm D O O O oO O O O 4 65 ER 118mm Se oo oo oo oo oo oo O DL305 User Manual Rev D Installation and Safety Guidelines Base Mounting Dimensions Below are the mounting dimensions which should be used when mounting DL305 bases Make sure you have followed the installation guidelines for proper spacing 11 41 290mm 5 slot
3. Installation and Safety Guidelines z Panel Design Specifications It is important to design your panel properly to help ensure the DL305 products operate within their environmental and electrical limits Proper installation of your DL305 system requires an in depth understanding of electrical control systems The system installation should comply with the appropriate electrical codes and standards for your area It is important that your system also conforms to the operating standards for the application to insure proper performance The DL305 equipment should only be installed by personnel familiar with electrical industrial applications The DL305 installation should provide proper ventilation spacing and grounding to ensure the equipment will operate as specified The diagram on the next page references the items in the following list 1 The bases should be mounted horizontally to provide proper ventilation 2 There should be a minimum of 7 2 183mm and a maximum of 13 75 850mm between bases 3 A minimum clearance of 2 50mm between the base and the top bottom and right side of the cabinet should be provided 4 Aminimum clearance of 3 75mm between the base and the left side of the cabinet should be provided 5 There must be a minimum of 2 clearance between the panel door and the nearest DL305 component 6 The ground terminal on the DL305 base must be connected to a single point ground Copper stranded
4. 2 13 UO Wiring This information provides a general idea on how to wire the different types of modules in the DL305 system For specific information on wiring a particular module refer to the specification sheet in the appropriate I O chapter or manual UO Wiring You should consider these guidelines when wiring your system Guidelines 1 There is a limit to the size of wire the modules can accept The table below lists the maximum AWG for each module type Smaller AWG is acceptable to use for each of the modules 8 point 12 16 point 16 2 Always use a continuous length of wire do not combine wires to attain a needed length Use the shortest possible cable length Use wire trays for routing where possible Avoid running wires near high energy wiring Avoid running input wiring in close proximity to output wiring where possible 7 To minimize voltage drops when wires must run a long distance consider using multiple wires for the return line 8 Avoid running DC wiring in close proximity to AC wiring where possible 9 Avoid creating sharp bends in the wires Sy o GU H E He a DI 35 oa a D Di Wu D lt ET St ZS DL305 User Manual Rev D 2 14 Installation and Safety Guidelines Wiring the Different There are three main types of module faces for the DL305 I O These module faces Module Types are lift covers over terminal blocks flip covers over terminal blocks and D shell compatib
5. component dimensions and should be used to define your enclosure specifications Remember to leave room for potential expansion Appendix D provides the weights for each component DL305 User Manual Rev D Installation and Safety Guidelines 11 41 94 5 slot base Romm 24mm AR Handheld Programer H on side view of A e amp 4 Base 4 84 3 54 123mm 90mm mc o Yor 4 41 112mm 15 55 D 8slotbase mm 5 35 136mm 14 76 x 375mm i E a 4 84 3 54 123mm 90mm QD CT Q o Ho F as D W 18 30 a a 10 slot base m 465mm GE 17 51 iat P mm qi h amp J lt 123mm E mi on dol t UO Expander cable Handheld programmer cable besi S Zeg E v BEA Handheld programmer 1 37 CPU 8 3 86 he 96mm gt bei Fe 4 A 4 al 4 67 4 65 118 6mm 148mm 00000000000 00000000000
6. stop switches etc DL305 User Manual Rev D Three Levels of Protection Emergency Stops Guard Limit Switch Installation and Safety Guidelines The publications mentioned provide many ideas and requirements for system safety At a minimum you should follow these regulations Using the techniques listed below will further help reduce the risk of safety problems e Emergency stop switch for disconnecting system power e Mechanical disconnect for output module power e Orderly system shutdown sequence in the PLC control program It is recommended that emergency stop circuits be incorporated into the system for every machine controlled by a PLC For maximum safety in a PLC system these circuits must not be wired into the controller but should be hardwired external to the PLC The emergency stop switches should be easily accessed by the operator and are generally wired into a master control relay MCR or a safety control relay SCR that will remove power from the PLC I O system in an emergency MCRs and SCRs provide a convenient means for removing power from the I O system during an emergency situation by de energizing an MCR or SCR coil power to the input optional and output devices is removed This event occurs when any emergency stop switch opens However the PLC continues to receive power and operate even though all its inputs and outputs are disabled The MCR circuit could be extended by placing a PLC fault relay cl
7. Installation and Safety Guidelines In This Chapter Safety Guidelines Panel Design Specifications Component Dimensions Base Mounting Dimensions Installing Components in the Base UO Wiring ei Installation and Safety Guidelines Safety Guidelines y Guidelines Plan for Safety E o KS bei Kei xe E KR E fer 5 w bo wn E WARNING Providing a safe operating environment for personnel and equipment is your responsibility and should be your 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 You should use external electromechanical devices such as relays or limit switches that are independent of the PLC system to provide protection for any part of the system that may cause personal injury or damage Every automation application is different so there may be special requirements for your particular application Make sure you follow all National State and local government requirements for the proper installation and use of your equipment The best way to provide a safe operating environment is to make personnel and equipment safety part of the planning process You should examine every aspect of the system to determine which areas are critical to operator or machine sa
8. an 0 2 V p p 24VDC 20 28V less than 1 2V p p 5VDC 4 75 5 25V less than 0 1V p p 9VDC 8 0 12 0V less than 0 2 V p p 24VDC 20 28V less than 1 2V p p 5VDC 4 75 5 25V less than 0 1V p p QVDC 8 0 12 0V less than 0 2 V p p 24VDC 20 28V less than 1 2V p p DL305 User Manual Rev D 2 8 Installation and Safety Guidelines Agency Approvals Some applications require agency approvals Typical agency approvals which your application may require are Enclosures y Guidelines fa S aal Wa el GG Oj Ca amp e Kal UL Underwriters Laboratories Inc CSA Canadian Standards Association FM Factory Mutual Research Corporation CUL Canadian Underwriters Laboratories Inc Your selection of a proper enclosure is important to ensure safe and proper operation of your DL305 system Applications of DL305 systems vary and may require additional features The minimum considerations for enclosures include Conformance to electrical standards Protection from the elements in an industrial environment Common ground reference Maintenance of specified ambient temperature Access to equipment Security or restricted access Sufficient space for proper installation and maintenance of equipment Component Dimensions Before installing your PLC system you will need to know the dimensions for the components in your system The diagrams on the following pages provide the
9. base S 10 63 270mm Handheld Programer H on side view of m g 4 84 A 54 123mm J A 90mm S S S A Q Q L S 4 41 a 112mm e CO 15 55 D 5 35 E e 8 slot base 398mm L s as 14 76 Dy 375mm 55 AT 3 SEN r D D a i D 4 84 A SI 3 54 123mm VJ Si 90mm Q a lt zj nE ever er TE E 18 30 a 3 54 90mm b isisisieteetaerztel o Installing Components in the Base When inserting components into the base align the PC board s of the module with the grooves on the top and bottom of the base Push the module straight into the base until it is firmly seated in the backplane connector Align module to slots in base and slide in DL305 User Manual Rev D Installation and Safety Guidelines Base Wiring The following diagram shows the terminal connections located on the power supply of the DL305 bases WARNING Damage will occur to the base power supply if 220 VAC is X Z connected to the 115 VAC terminal connections Once the power wiring is a ont connected install the prot
10. ective cover When the cover is removed there is a risk of electrical shock if you accidentally touch the connection terminals 110 220 VAC 24VDC Terminal Strip Terminal Strip gt N Ka amp Line m D com 115V 24VDC SS D Neutral ia D e 230VAC 5S bs s RUN E RUN ES is ES Gi cane E D e Ge gll IG c S Expansion Base This is an example of how to connect power when using local CPU and Expansion Wiring bases 110VAC 220VAC 24VDC Line Neutral oO O O a O 110VAC A 220VAC E 24VDC 8 A ES ES gt eil Local CPU Local CPU Local CPU S S S onm Q onm s onm Q O S 6 al O 110VAC B TA 220VAC B 24VDC 71 A El Si gt IEI Expansion ja Expansion Expansion Base 1 l Base 1 p l Base 1 L onm Q onm J0 onm Q 110VAC 18 220VAC 24VDC t Expansion Expansion Expansion ase 2 l ase 2 l ase 2 l m H m Ee O m m a DL305 User Manual Rev D Installation and Safety Guidelines
11. fety If you are not familiar with PLC system installation practices or your company does not have established installation guidelines you should obtain additional information from the following sources e NEMA The National Electrical Manufacturers Association located in Washington 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 ICS 6 Enclosures for Industrial Control Systems e NEC 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 e Local and State Agencies many local governments and state governments have additional requirements above and beyond those described in the NEC Handbook Check with your local Electrical Inspector or Fire Marshall office for information Safety Techniques The publications mentioned provide many ideas and requirements for system safety Ata minimum you should follow these regulations Also you should use the following techniques which may help reduce the risk of safety concerns e Orderly system shutdown sequence in the PLC control program e System power disconnects guard limits emergency
12. le sockets If the module you are using has a cover you can remove the cover either by lifting from the bottom or by flipping the door open Some of the modules have removable terminal blocks These modules can be recognized by the squeeze tabs on the top and bottom of the terminal block To remove the terminal block press the squeeze tabs and pull the terminal block away from the module WARNING For some modules field device power may still be present on the 3 Te terminal block even though the PLC system is turned off To minimize the risk on of electrical shock check all field device power before you remove the connector T oree O ae Tab 2 e ER Bes S J e V SS i i Squeeze Tab Removable Terminal Block y Guidelines EZ AIG i Fan bi KS bei Kei xe E KR E fer 5 w bo wn E zi d i N f ei Si al AE es Removable Cover D shell Connector DL305 User Manual Rev D
13. nt humidity seUljepind D 2 Gi D 5 di 2 Wei D 2 bel o lt 5 to 95 relative humidity non condensing MIL STD 810C Method 514 2 MIL STD 810C Method 516 2 NEMA ICS3 304 1 uS width rectangular wave No corrosive gases Vibration resistance Shock resistance Noise immunity Atmosphere Power the base power supply specifications The power source must be capable of suppling voltage and current complying with Input Voltage Range 100 240 VAC 20 5 30 VDC lt 10 100 240 VAC 100 240 VAC 10 15 ripple 10 15 10 15 47 63Hz 47 63Hz 47 63Hz Base Power 70 VA max 46W 48 Watts 70 VA max 57W 70 VA max 57W Consumption Inrush Current max 30A 30A 30A 30A Dielectric Strength 1500VAC for 1 minute between terminals of AC P S Run output Common 24VDC 1500VAC for 1 minute between 24VDC input terminals and Run output 1500VAC for 1 minute between terminals of AC P S Run output Common 24VDC 2000VAC for 1 minute between terminals of AC P S Run output Common 24VDC Insulation Resistance gt 10MQ at 500VDC gt 10MQ at 500VDC gt 10MQ at 500VDC gt 10MQ at 500VDC Power Supply Output Voltage Ranges and Ripple 5VDC 4 75 5 25V less than 0 1V p p 9VDC 8 5 13 5V less than 0 2 V p p 24VDC 20 28V less than 1 2V p p 5VDC 4 75 5 25V less than 0 1V p p 9VDC 8 5 13 5V less th
14. osed during normal PLC operation in series with any other emergency stop conditions This would cause the MCR circuit to drop the PLC I O power in case of a PLC failure memory error UO communications error etc Use E Stop and Master Relay a E erop Power On Guard Master Limit o loe e Tesch 1 Master Relay Contacts Master Relay tact Contacts 5 N N o en o To disconnect PLC Power Output SC Module Saw Contacts Arbor To disconnect output SE module power DL305 User Manual Rev D seUljepind gt D 2 D D 5 dl SS 2 Wa D a D I ga lt y Guidelines E o KS bei Kei xe E e der 5 w bo wn fe Installation and Safety Guidelines Emergency Power Disconnect Orderly System Shutdown we TER l Class 1 Division 2 Approval T A properly rated emergency power disconnect should be used to power the PLC controlled system as ameans of removing the power from the entire control system It may be necessary to install a capacitor across the disconnect to protect against a condition known as outrush This condition occurs when the output triacs are turned off by powering off the disconnect thus causing the energy stored in the inductive loads to seek the sho
15. perly To do this place a temperature probe in the panel close the door and operate the system until the ambient temperature has stabilized If the ambient temperature is not within the operating specification for the DL305 system measures such as installing a cooling heating source must be taken to get the ambient temperature within the DL305 operating specifications DL305 User Manual Rev D Installation and Safety Guidelines 9 Device mounting bolts and ground braid termination bolts should be 10 copper bolts or equivalent Tapped holes instead of nut bolt arrangements should be used whenever possible To assure good contact on termination areas impediments such as paint coating or corrosion should be removed in the area of contact 10 The DL305 systems are designed to be powered by 110 VAC 220 VAC or 24 VDC normally available throughout an industrial environment Isolation transformers and noise suppression devices are not normally necessary but may be helpful in eliminating reducing suspected power problems gt Z O3 E 0 UI o o 0 aS P 50m o2 ee DL305 CPU Base min Temperature io al Probe CH Le kl 5 az S 2 o TC 2 _ Power z Source v eo 19 7 2 1377 DL305 Local Expasion Base 183 350mm O olf
16. rtest distance to ground which is often through the triacs After an emergency shutdown or any other type of power interruption there may be requirements that must be met before the PLC control program can be restarted For example there may be specific register values that must be established or maintained from the state prior to the shutdown before operations can resume In this case you may want to use retentive memory locations or include constants in the control program to ensure a known starting point The first level of protection should be included in the PLC control program which can be used to identify machine problems You should analyze your application and identify any shutdown sequences that must be performed These types of problems are usually things such as jammed parts etc that do not pose a risk of personal injury or equipment damage WARNING The control program should not be the only form of protection for any problems that may result in a risk of personal injury or equipment damage This equipment is suitable for use in Class 1 Division 2 groups A B C and D or non hazardous locations only WARNING Explosion Hazard Substitution of components may impair suitability for Class 1 Division 2 Do not disconnect equipment unless power has been switched off or area is known to be non hazardous DL305 User Manual Rev D
17. wire should be used for this connection to achieve a low impedance Copper eye lugs should be crimped and soldered to the ends of the stranded wire to assure good surface contact You should also remove anodized finishes and use copper lugs and star washers at termination points A rule of thumb is to achieve a 0 1 ohm of DC resistance between the DL305 base and the single point of ground 7 There mustbe a single point of ground i e copper bus bar for all devices in the panel requiring an earth ground return The single point of ground must be connected to the panel ground termination The panel ground termination must be connected to earth ground For this connection you should use 12 AWG stranded copper wire as a minimum Minimum wire sizes color coding and general safety practices should comply with appropriate electrical codes and standards for your area A good common ground reference Earth ground is essential for proper operation of the DL305 The DL305 system and components are designed to operate with acommon ground reference There are several methods of providing an adequate common ground reference These methods include a Installing a ground rod as close to the panel as possible b Connection to the incoming power system ground Sy o n H E 0 SS W 55 oa aN D S br D2 lt 8 Installations where the ambient temperature may approach the lower or upper limits of the specifications should be evaluated pro
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