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regarding the products or services described herein or their use or applicability. All sales are governed by our terms
and conditions, which are available on request. We reserve the right to modify or improve the design or
specification of such products at any time without notice.

See the CE statement in the Preface to this manual.

Emerson Automation Solutions

1100 W. Louis Henna Blvd.

Round Rock, TX 78681

Contents
Preface: Read this section first. ..................................................................................... 1
About this manual ............................................................................................................................................................ 1
Important ......................................................................................................................................................................... 1
Conventions for wire colors in wiring diagrams ................................................................................................................. 2
Using this manual ............................................................................................................................................................. 3
CE statement .................................................................................................................................................................... 3
Conventions used in this manual ...................................................................................................................................... 3
Definitions used in this manual ........................................................................................................................................ 3
General definitions ................................................................................................................................................... 3
Power and grounding definitions .............................................................................................................................. 4

Introduction ................................................................................................ 7
A solid foundation ............................................................................................................................................................ 7
Best engineering practices ................................................................................................................................................. 7
Principles of proper site preparation .................................................................................................................................. 7

DeltaV power and power quality ................................................................. 9

Connecting plant power to DeltaV ................................................................................................................................... 9
AC power from a grid ............................................................................................................................................. 10
DeltaV AC distribution and grounding system ....................................................................................................... 13
DC distribution system .......................................................................................................................................... 14
Floating AC and high-resistance grounded systems typically with marine applications ............................................. 16

Protection from surges and lightning .............................................................................................................................. 19

Power quality .................................................................................................................................................................. 23
Why clean power? .................................................................................................................................................. 23
How to establish and maintain clean power ............................................................................................................ 27
Isolation to protect from power quality issues ......................................................................................................... 31

Isolation transformers ..................................................................................................................................................... 32

Protection from other equipment on AC power grid ....................................................................................................... 33
Backup/redundancy for higher availability ...................................................................................................................... 34
Backup power recommendations ............................................................................................................................ 34
Types of redundancy .............................................................................................................................................. 34

DeltaV system cabinets and enclosures ...................................................... 36

Environmental considerations ......................................................................................................................................... 36
Environmental areas ............................................................................................................................................... 36
Dust and corrosive vapor control ............................................................................................................................ 37
Temperature control ............................................................................................................................................... 37
Humidity control ................................................................................................................................................... 37
 Environmental control during transport and storage ............................................................................................... 37
Using protective enclosures ..................................................................................................................................... 37
Industry standards for environmental conditions..................................................................................................... 38

DeltaV power quality ...................................................................................................................................................... 39

Filtering and surge suppression ............................................................................................................................... 39
AC/DC bulk power supplies ................................................................................................................................... 39

DeltaV power and grounding schema options and examples ........................................................................................... 40

Bulk power supply example designs ........................................................................................................................ 41
DC/DC bulk power supplies .................................................................................................................................. 49
DeltaV DC system power supply (SPS) .................................................................................................................. 52
DC power wire size ................................................................................................................................................ 52
Adjusting system power supply input voltage .......................................................................................................... 52
Equalizing supply output voltage with redundancy modules.................................................................................... 52

DeltaV cabinet and enclosure grounding ......................................................................................................................... 52

Chassis ground (CG) .............................................................................................................................................. 56
DC ground (DCG) ................................................................................................................................................ 56
Shield termination and grounding .......................................................................................................................... 57
Supplying additional power to extended I/O carriers ............................................................................................... 57
Power and grounding for DeltaV CHARMs ........................................................................................................... 59

Warning labels ................................................................................................................................................................ 65

Hazardous area design and installation ............................................................................................................................ 65
Qualifications of personnel ..................................................................................................................................... 66
Control drawings and installation instructions ........................................................................................................ 66
Zone 1 carrier power and grounding ....................................................................................................................... 66
Intrinsic safety considerations ................................................................................................................................. 66
IS CHARMs shield bars ......................................................................................................................................... 68

Power and grounding for DeltaV Safety Instrumented Systems (SIS) .............................................................................. 71
Safety Critical SIS component power ...................................................................................................................... 71
Using bulk power supplies in DeltaV SIS systems ................................................................................................... 72

Signal wiring.............................................................................................. 82
Selecting cables ............................................................................................................................................................... 82
Best signal wiring practices .............................................................................................................................................. 82
Protecting I/O signals from AC line noise ............................................................................................................... 83
I/O signal cable runs ............................................................................................................................................... 86
Low-level I/O signal cable runs through junction boxes .......................................................................................... 89
Resistor-capacitor snubbers ..................................................................................................................................... 89

I/O bus signal wiring ...................................................................................................................................................... 89

HART wiring ......................................................................................................................................................... 89
AS-interface wiring ................................................................................................................................................. 90
DeviceNet wiring ................................................................................................................................................... 91
FOUNDATION fieldbus wiring ............................................................................................................................ 93
Profibus DP wiring ................................................................................................................................................. 93

Ground design for DeltaV ......................................................................... 95

Grounding purposes and functions ................................................................................................................................. 95
Control system ground considerations ............................................................................................................................ 96
Maintaining ground integrity .......................................................................................................................................... 96
Grounding a control system effectively............................................................................................................................ 96
Using existing ground networks ...................................................................................................................................... 98
Types of ground systems ................................................................................................................................................. 98
Star or single-point ground ..................................................................................................................................... 98
Mesh star ground network ...................................................................................................................................... 99

Organizing the ground network .................................................................................................................................... 102

Notes ................................................................................................................................................................... 102

Improving the earthing sub-system ............................................................................................................................... 103

Resistance, reactance, and impedance.................................................................................................................... 103
Soil resistivity ....................................................................................................................................................... 103
Design and installation practices that ensure low impedance ................................................................................. 105
Ground conductor sizing ...................................................................................................................................... 106
Ground bus construction ...................................................................................................................................... 107
Recommended method of connecting ground cable to a ground bar ..................................................................... 109
Marking ground components ............................................................................................................................... 110

Enclosure grounding ..................................................................................................................................................... 110

Grounding for CHARMs and remote enclosures .................................................................................................. 110

Multi-story Buildings .................................................................................................................................................... 110

Appendix A Interference and transients............................................................. 114

Static coupling .............................................................................................................................................................. 114
Voltage differentials ...................................................................................................................................................... 114
Inductive coupling ........................................................................................................................................................ 115

Appendix B Shield earthing for high-integrity ground systems.......................... 117

Appendix C Earthing and grounding ................................................................ 118

Designing an earth ground system ................................................................................................................................ 118

Appendix D Earth grounds in water and ice ...................................................... 124

Testing an earth ground ................................................................................................................................................ 124
Three-point testing method .................................................................................................................................. 124
Two-point testing method .................................................................................................................................... 126
Slope testing method ............................................................................................................................................ 126

Annually inspecting an earth ground system ................................................................................................................. 126

Appendix E Effects of heat and air flow inside an enclosure .............................. 127
General ......................................................................................................................................................................... 127
Heat impact on mean time between failure (MTBF) ..................................................................................................... 127
Airflow considerations .................................................................................................................................................. 128
Heat-related issues ........................................................................................................................................................ 128
Solutions ...................................................................................................................................................................... 129
Measuring enclosure hot spots ...................................................................................................................................... 130
Maintenance considerations .......................................................................................................................................... 130
Controlling humidity.................................................................................................................................................... 130
Heating and cooling calculations .................................................................................................................................. 131
Cooling calculations to control heat generated within enclosures ........................................................................... 131
Cooling calculations to control heat transferred into enclosures ............................................................................. 132
Calculating the effects of a pressurization system ................................................................................................... 133

Conclusions .................................................................................................................................................................. 133

Appendix F Wire-color conventions ................................................................. 134

Appendix G Emerson DeltaV control and installation drawings....................... 135

Appendix H Warning labels .............................................................................. 137

Appendix I Power and Grounding Audit Worksheets ..................................... 139

Introduction ................................................................................................................................................................. 139
Purpose......................................................................................................................................................................... 139
Intended audience ........................................................................................................................................................ 139
System audit during fault conditions ............................................................................................................................. 139
Product data sheets ....................................................................................................................................................... 139
Required equipment ..................................................................................................................................................... 139
Definitions ................................................................................................................................................................... 140
Comments .................................................................................................................................................................... 141
Building installation worksheet ..................................................................................................................................... 141
Cabinet installation worksheet ...................................................................................................................................... 146
Earthing installation worksheet ..................................................................................................................................... 156

Appendix J Environmental considerations ....................................................... 161

Electrostatic protection ................................................................................................................................................. 161
Material sensitivity to static electricity ................................................................................................................... 161
Electrostatic sources .............................................................................................................................................. 161
Preventing static electricity buildup ...................................................................................................................... 162
Using grounding devices ....................................................................................................................................... 162
Flooding the air with ions ..................................................................................................................................... 163
Using static shielding containers ........................................................................................................................... 163
Handling static-sensitive devices ........................................................................................................................... 163
Airborne contaminants size chart .................................................................................................................................. 164
Atmospheric dust size chart ........................................................................................................................................... 165
Mechanical influences on the control environment ....................................................................................................... 166
Proper installation ................................................................................................................................................ 167
External protection methods ................................................................................................................................. 167
Product specifications ........................................................................................................................................... 167

Electromagnetic effects ................................................................................................................................................. 167

Electromagnetic measurement .............................................................................................................................. 167
Radio operation in a near field area ....................................................................................................................... 168
Applicable electromagnetic signal standards .......................................................................................................... 168
Reducing EMI levels............................................................................................................................................. 168
Determining EMI levels ....................................................................................................................................... 169
EMI effects on magnetic media ............................................................................................................................. 169

Corrosive Environments ............................................................................................................................................... 170

Corrosion effects on the control system environment ............................................................................................ 170
Classifying corrosive environments in the presence of sulfides ............................................................................... 170
Classifying corrosive environments in the presence of sulfides and chlorides .......................................................... 171
General method for identifying the environment .................................................................................................. 171
Humidity effects on reactivity results .................................................................................................................... 171
Designing to environmental classifications ............................................................................................................ 172

Dusty environments...................................................................................................................................................... 173

Minimizing the effects of dust .............................................................................................................................. 173
Protecting against dust .......................................................................................................................................... 173

Modifying the environment .......................................................................................................................................... 173

Modifying the control system environment ........................................................................................................... 173
Control room installations .................................................................................................................................... 174
Production floor and remote installations ............................................................................................................. 174
Enclosure and room air pressure calculations......................................................................................................... 175
Maintaining environmental control systems .......................................................................................................... 175

Appendix K References ..................................................................................... 177

General reference .......................................................................................................................................................... 177
Power transmission reference ........................................................................................................................................ 177
Reference books for personnel and property safety ........................................................................................................ 177
American standards ....................................................................................................................................................... 177
The Institute of Electrical and Electronics Engineers Inc. IEEE standards ..................................................................... 178
Canadian Standards Association standards .................................................................................................................... 178
European international standards .................................................................................................................................. 178
Lightning references ...................................................................................................................................................... 179
US Military Handbook ................................................................................................................................................. 180
Illustrations
Figure 0-1 Using this manual ............................................................................................................................. 3
Figure 2-1 Typical power generation and distribution ...................................................................................... 11
Figure 2-2 Isolated 3-phase system with redundant power ................................................................................ 13
Figure 2-3 Isolated single-phase system with redundant power ......................................................................... 14
Figure 2-4 Bussed DC power ........................................................................................................................... 16
Figure 2-5 Three-phase floating power for marine applications ........................................................................ 17
Figure 2-6 EMC immunity zones ..................................................................................................................... 20
Figure 2-7 Lightning protection zones .............................................................................................................. 20
Figure 2-8 SPD Grounding for DeltaV ............................................................................................................ 22
Figure 2-9 Isolated CHARM enclosure with SPDs ........................................................................................... 23
Figure 2-10 Power distribution decision flowchart ........................................................................................... 28
Figure 3-1Simplex DeltaV bulk power supply .................................................................................................. 42
Figure 3-2 Redundant bulk power for simplex controllers ................................................................................ 44
Figure 3-3 Redundant bulk power simplex controller with surge protection ..................................................... 45
Figure 3-4 Redundant independent bulk power supplies for redundant controllers .......................................... 46
Figure 3-5 Highest integrity and highest availability ......................................................................................... 48
Figure 3-6 Simplex plant DC power................................................................................................................. 50
Figure 3-7 Redundant 24 VDC plant power .................................................................................................... 51
Figure 3-8 Simplex S series controller ............................................................................................................... 53
Figure 3-9 Redundant S Series Controller ........................................................................................................ 54
Figure 3-10 m-Series with extended carrier power ............................................................................................ 55
Figure 3-11 s-series redundant extended power to left extender ........................................................................ 58
Figure 3-12 S-Series redundant extended power between extender and carriers................................................. 59
Figure 3-13 High-integrity power and grounding for a CHARM enclosure...................................................... 61
Figure 3-14 Highest-integrity power and grounding for a CHARM enclosure.................................................. 62
Figure 3-15 High-integrity CHARM with added shield bus ............................................................................. 63
Figure 3-16 CHARMs with DC supply ........................................................................................................... 64
Figure 3-17 IS CHARMs enclosure .................................................................................................................. 68
Figure 3-18 IS with non-IS CHARMs enclosure .............................................................................................. 69
Figure 3-19 IS CHARMs with separate IS shield bus ....................................................................................... 70
Figure 3-20 IS Carrier based IO cards .............................................................................................................. 71
Figure 3-21 SLS redundant power - high integrity with good availability ......................................................... 73
Figure 3-22 SLS redundant power with isolation transformers and surge suppression ....................................... 74
Figure 3-23 SLS redundant power - highest integrity with highest availability .................................................. 75
Figure 3-24 SLS Highest integrity and highest availability - surge protection and isolation transformers .......... 76
Figure 3-25 SLS with single feed ...................................................................................................................... 77
Figure 3-26 SLS with redundant independent feeds ......................................................................................... 78
Figure 3-27 CSLS Highest integrity power and grounding with injected power................................................ 79
Figure 3-28 CSLS CHARMs with redundant field power injection .................................................................. 80
Figure 4-1 Proper shield management .............................................................................................................. 85
Figure 4-2 Instrument shielding details ............................................................................................................ 86
Figure 4-3 Three- and four-wire instrument shielding details ........................................................................... 87
Figure 4-4 I.S. instrument shielding details ...................................................................................................... 88
Figure 4-5 AS-i bus grounding and power ........................................................................................................ 91
Figure 4-6 DeviceNet power and grounding..................................................................................................... 92
Figure 4-7 Profibus DP power and grounding .................................................................................................. 94
Figure 5-1 Single-point star grounding system.................................................................................................. 99
Figure 5-2 Mesh star ground network ............................................................................................................ 100
Figure 5-3 Hybrid star mesh ground network................................................................................................. 101
Figure 5-4 Separate DeltaV ground ................................................................................................................ 102
Figure 5-5 Local area ground bus ................................................................................................................... 108
Figure 5-6 Ground-bar isolating standoffs ...................................................................................................... 109
Figure 5-7 Modified PANI method ................................................................................................................ 110
Figure 5-8 Multi story building with one power source .................................................................................. 112
Figure 5-9 Multi-story building with multiple power sources ......................................................................... 113

Figure A-1 Return paths for static coupled interference .......................................................................... 114
Figure A-2 Static coupling caused by voltage differential ........................................................................ 115
Figure A-3 Inductive coupling from down-conductor into signal cable ................................................... 116
Figure A-4 Example design for plant ground grid ................................................................................... 119
Figure A-5 Typical Ufer ground system below grade .............................................................................. 120
Figure A-6 Example connecting to existing ground rods ......................................................................... 120
Figure A-7 Example connecting to existing counterpoise ........................................................................ 121
Figure A-8 Example connecting to an existing ground grid..................................................................... 121
Figure A-9 Example connecting to Ufer ground ..................................................................................... 122
Figure A-10 Example connecting to existing buried steel plate.................................................................. 123
Figure A-11 Three-point method for testing earth ground........................................................................ 125
Figure A-12 Two-point method for testing earth ground.......................................................................... 126
Figure A-13 Relative sizes of common air contaminants ........................................................................... 165
Figure A-14 Size distribution of a typical atmospheric dust sample ........................................................... 166

Tables
Table 0-1 Wire colors in DC wiring diagrams .................................................................................................... 2
Table 0-2 Wire colors in AC wiring diagrams..................................................................................................... 2
Table 2-1 Standardized global power .................................................................................................................. 9
Table 2-2 Causes of power disruptions ............................................................................................................. 12
Table 2-3 Solutions for power interference: UPS or CVT? ............................................................................... 25
Table 2-4 Additional solutions for power interference ...................................................................................... 26
Table 2-5 Typical transfomer attenuation......................................................................................................... 32
Table 3-1 Hazardous materials Classes, Divisions, and Zones ........................................................................... 65
Table 4-1 Minimum cable separation distances ................................................................................................ 84
Table 5-1 Resistivity of soils and resistance of single rods ............................................................................... 104
Table 5-2 Ground wire sizing ......................................................................................................................... 106
Table 5-3 Braided cable construction types (as an alternative) ........................................................................ 107
Table A-1 Depths and measuring points for three-point testing method................................................ 125
Table A-2 Correlation between temperature and MTBF ....................................................................... 128
Table A-3 DeltaV Control and Installation Drawings ........................................................................... 135
Table A-4 Common sources of static electricity ..................................................................................... 162
Table A-5 Copper reactivity rates .......................................................................................................... 170
Table A-6 Classification of chemically active contaminants in cm3/m3 (ppm) ........................................ 170
Table A-7 Environmental characterization by visual changes in copper ................................................. 171
Table A-8 Interpreting humidity effects ................................................................................................ 172
Table A-9 Constant percentage ............................................................................................................. 175
Preface: Read this section first.

About this manual

This manual explains how to design and prepare control-system electrical power and ground networks before
installing a DeltaV system. This manual also explains how to protect the DeltaV system from harsh
environments before and after system installation. Applying the information in this manual can save you much
time and expense by significantly increasing the reliability and availability of the control system and by making
the system easier to start up and maintain.

The power and grounding practices described in this manual are based on best engineering practices, gleaned
from years of experience, and on industry standards. In addition to this manual, you may need other DeltaV and
industry publications to obtain complete information for preparing your site. References to related industry
standards appear throughout the manual.

This manual supersedes all previous Emerson manuals with respect to power, grounding, and surge suppression,
including the following manuals:

• D800053, Quick Start Guide for DeltaV Power, Grounding, and Surge Suppression
• D800015, Site Preparation and Design for DeltaV Digital Automation Systems

Each edition of this manual is applicable to all DeltaV versions. Therefore, information in previous editions is
carried forward to this edition.

This edition includes the following updates to earlier editions:

• Added clarification on the use of Notes, Cautions, and Warnings in this manual.
• Added clarification on the required sizing of DC reference wire to the DCG.
• Added clarification on the use of color in wiring diagrams in this manual.
• Revised Figure 3-28 to add fused terminal blocks.
• Corrected errors in Table 4-1.
• Added Appendix F about wire-color conventions.

Important
Complying with the codes and regulations of authorities having jurisdiction is essential to ensuring personnel
safety. The guidelines and recommendations in this manual are intended to meet or exceed applicable codes and
regulations. If differences occur between this manual and the codes and regulations of authorities having
jurisdiction, those codes and regulations must take precedence.

All DeltaV installation procedures must be performed by qualified personnel and DeltaV equipment must be
used only for the purposes described.

1
Conventions for wire colors in wiring diagrams
The following tables show the conventions used in this document for wire colors in wiring diagrams.
Table 0-1 Wire colors in DC wiring diagrams

Wire Color Wire Function

Red DC power
Black DC return
Green DC ground
Green with yellow stripes Chassis ground/protective earth

Table 0-2 Wire colors in AC wiring diagrams

Wire Color Wire Function

Blue Neutral
Brown Line
Green with yellow stripes Chassis ground/protective earth

These wire-color conventions are based on International Electrotechnical Commission (IEC) guidelines and do
not constitute a recommendation by Emerson. Wire-color conventions vary by world area and by customer
standards. For example, many North American installations use green for safety ground wires, but IEC rejects
that practice. In all cases, you must follow the codes and regulations of authorities having jurisdiction.

For more information about wire-color conventions, refer to Appendix F of this manual.

2
Using this manual
The following figure illustrates the organizational structure of this manual.
Figure 0-1 Using this manual

Disconnect SPD
L1
DCS Power DeltaV DCS Power
Type 2
SPD

L2
L L
L3
N
+24VDC Primary Power N
+24VDC

PE 24VDC PE
24VRtn 24VRtn

DeltaV
Primary Power
AC Primary AC Primary 24VDC

UPS Transfer Switch L

+24VDC
L
+24VDC
L1
L2
Rectifier Inverter L1
L2
N
PE
N
PE
24VRtn 24VRtn
L3 L3
N
DeltaV DeltaV
G
G Secondary Power Secondary Power
PE
Neutral Ground 24VDC 24VDC
Battery Bank or
Flywheel Storage AC Secondary
G L3 L2 L1 PE Ground
Power Distribution

AC Secondary
Chassis Ground DC Ground Chassis Ground DC Ground
L1 Isolation Transformer L1 (CG)
Shield Bars
(DCG) (CG)
Shield Bars
(DCG)
L2 N Φ1
L3 L2 AC
G L3 Primary 1
G Φ2
AC
Φ3
Primary 2
Ground
AC
G N L3 L2 L1 Primary 3
Power Distribution

DCS Power DCS Power L

L +24VDC
Disconnect SPD +24VDC N
L1 Isolation Transformer N DeltaV PE
L1 L1 PE 24VRtn
Primary Power
Type 2
SPD

L2 L2 N 24VRtn
L3 L3
G
L2
AC Primary 24VDC
L3
G
DeltaV
AC Primary Primary Power
24VDC
Ground Φ1
AC
Secondary 1 L DeltaV L

Chapter 2 – POWER
Φ2 +24VDC +24VDC
AC N Secondary N
PE PE
Φ3
Secondary 2 24VRtn Power 24VRtn
DeltaV

QUALITY
AC 24VDC Secondary Power
G N L3 L2 L1
Power Distribution
Secondary 3 24VDC

AC Secondary AC Secondary

Shield Bars
Chassis Ground DC Ground
DC Ground
(CG) (DCG)
Building Steel

Bonding
Jumper

Chapter 3 – CABINETS AND ENCLOSURES

DeltaV Instrument
Ground (DIG)
Local Area
Local Area
Ground (CG)

Chassis Ground
Ground
DC Ground

Chapter 4 – SIGNAL WIRING

AC Power

AC Power

Chassis
Ground

Ground

DC Ground (DCG)
IS
(DCG)

(CG)

Earth
Lightning Electrode

Chapter 5 –
System Network
Plant
Earthing
Connection GROUND DESIGN

CE statement
This manual describes installation and maintenance procedures for products that have been tested to be in
compliance with appropriate CE directives. To maintain compliance, these products must be installed and
maintained according to the procedures described in this document. Failure to follow the procedures may
compromise compliance.

Conventions used in this manual

Notes provide clarification, emphasis, or exceptions. Cautions provide guidance that you must follow to ensure
the highest reliability and availability. Warnings provide guidance that you must follow to prevent a safety risk
or equipment damage.

Definitions used in this manual

The following list defines terms used in this manual.

General definitions
BPCS--Basic process control system. IEC 61511 defines BPCS as “a system which responds to input signals
from the process, its associated equipment, other programmable systems and/or operators and generates output

3
signals causing the process and its associated equipment to operate in the desired manner but which does not
perform any SIF (Safety Instrumented Function).”

Control system--Also known as a basic process control system (BPCS). All components including workstations,
network hardware, bulk power supplies, controllers, I/O components, and field devices.

DCS – Distributed control system which includes the distributed BPCS and SIS systems.

Availability--Power and grounding designs and implementations that minimize process interruptions due to
loss of power.

Highest availability--A design that incorporates redundant power sources to minimize process upsets. This
design will also require the Highest Integrity system design.

Integrity--The elements of power and grounding designs that ensure that the DeltaV system is not disturbed by
external influences due to unwanted power-quality events.

Highest integrity--A system design method that is solidly grounded and that includes power conditioning to
provide clean power by using UPSs (uninterruptable power supplies), isolation transformers, and/or surge
suppression devices.

Local area--All instruments powered by a common isolation transformer or isolated AC source where all
grounds terminate at a single point.

Remote instrument enclosure (RIE)--Standalone modular building manufactured complete with redundant
power feeds, power panels and infrastructure, gas and smoke detection, HVAC, UPS, network and server
cabinets, DeltaV cabinets, and third-party cabinets completely wired and tested ready to ship to a customer site
as a turnkey system.

SIS--DeltaV Safety Instrumented System including Safety Logic Solvers and DeltaV SIS CHARMs. IEC 61511
defines SIS as “instrumented system used to implement one or more SIFs.”

System--A group of equipment bound together by a single-point ground.

Enclosure--A secure, controlled environment that limits access to trained and qualified personnel. For example,
an enclosure can be a lockable room, a single cabinet, a cabinet grouping, a panel, or a rack.

Power and grounding definitions

AC ground--Grounding required by local codes to bond control system cabinets and metal enclosures to the
separately derived source ground. The AC ground might also be referred to as protective earth (PE), safety ground,
or fault ground. Refer to NFPA70 Article 250 – National Electric Code; IEC Standard 60364-4-44, Canadian
Standards Association (CSA) C22.1 Section 10, and C22.2 No.0.4.

AC power source--The incoming AC power to a system from AC sources such as commercial power, UPS,
generator, and motor control center (MCC) power panels.

Bulk power supply--AC/DC or DC/DC power supplies that feed power to the DeltaV hardware. These power
supplies may be mounted in the same cabinet with the DeltaV hardware, or in separate bulk power supply
cabinets or other locations.

4
Chassis ground (CG)—DeltaV’s non-isolated ground scheme. All DeltaV enclosures and protective earth
connections within the DeltaV enclosures connect to the CG system, which connects to the DeltaV
Instrumentation Ground (DIG) and then to the plant grid. This provides an equipotential low-impedance path
for unwanted noise to return to its source.

Local area CG--DeltaV CG busbar used to consolidate CG cables from multiple DeltaV Cabinets in a localized
area.

Clean power-- Power without known power-quality issues such as transients, harmonics, surges, and sags.
Power-conditioning equipment such as UPSs, isolation transformers, and surge protection devices (SPDs)
typically provide power to the control system.

Equipotential bonding system--A system in which every location in the grounding network is at the same
potential voltage. Used in this document to refer to both protective and functional equipotential bonding, as
defined in IEC 60364-4-44 444.3.3.

DC ground (DCG)--DeltaV isolated DC ground reference scheme to which all DC power source commons are
connected. IEC refers to this as functional earthing. Refer to IEC 60364-5-54 541.3.11.

Local area DCG--DeltaV DCG busbar used to consolidate DCG cables from multiple DeltaV Cabinets in a
localized area.

DeltaV instrument ground (DIG)--The final point of the equipotential bonding system connecting the
DeltaV CG (chassis ground) and DCG (DC ground) to the plant grounding system. This is often referred to in
industry as the master reference ground (MRG). IEC refers to this as the main earthing terminal in IEC 60364-
5-54 541.3.9.

Earthing electrode network--A foundation electrode network such as a Ufer or platform; a bonded grid
network; a triad; or a ring. In addition, each type of grounding system such as functional earth, protective earth
(safety), or lightning earthing may be connected to a unique earth electrode network. All earthing electrode
networks must be bonded together.

EMC--Electromagnetic compatibility: the study of the effects of electromagnetic energy on equipment and the
immunity of equipment to those effects.

Equipment grounding conductor (EGC)--The conductive path that provides a ground-fault current path and
connects normally non–current-carrying metal parts of equipment together and to the system grounded
conductor or to the grounding electrode conductor, or both. Some codes, regulations, and world areas refer to
the EGC as a protective earthing conductor or an Equipment Bonding Conductor.

Functional earth--Earthing a point or points in a system or in an installation or in equipment, for purposes

other than electrical safety. Refer to IEC 60364-5-54 541.3.11.

Isolation transformer--A shielded transformer with galvanic separation between primary and secondary circuits.
This provides both normal-mode and common-mode noise attenuation. An isolation transformer creates an
independent electrical system also called a separately derived system with a local ground reference.

Plant ground grid--Common ground system of the plant to which all electrical power system protective
earthing grounds are connected.

5
Protective earth (PE)--Protective conductor provided for protective earthing. Refer to IEC 60364 -
International Electrotechnical Commission (IEC).

Safety ground--Grounding system for personnel protection. NFPA70 National Electrical Code refers to this as
equipment grounding conductor or grounding electrode system. EU/IEC refers to this as protective earthing
conductor (PE) or earthing electrode network. Refer to NFPA70:2017 Article 250 – National Electric Code; IEC
Standard 60364-4-44.

Safety extra-low-voltage system (SELV)--An extra-low-voltage system that is electrically isolated from the
earth and from other systems in such a way that a single fault cannot give rise to the risk of electric shock.
DeltaV is designed and certified as an SELV.

System power supply--DeltaV DC/DC power supplies mounted in the DeltaV carrier providing power to the
DeltaV controllers and I/O cards.

6
 Introduction

A solid foundation
Before you install a DeltaV Digital Automation System, your site must be electrically and environmentally
prepared to receive the system. Proper site preparation is foundational to personnel safety and to control system
efficiency and reliability. This manual provides most of the information you need to prepare your site before
installing a DeltaV Digital Automation System.

Following the appropriate national and local electrical codes is essential to ensuring personnel safety. Efficient
and reliable system operation is greatly enhanced when power distribution systems, ground systems, and signal
wiring follow best engineering practices. Temperature, humidity, dust, and corrosive vapors must be maintained
within system specifications.

These guidelines and recommendations cover most situations. At some sites, specific circumstances may require
alternative approaches. If your site requires a different approach, contact your Emerson Local Business Partner or
Field Sales Office (LBP/FSO). Before contact, you may want to prepare drawings of your proposed power and
grounding system for their review.

Product-specific information and guidance details are found in Books Online; the supporting installation and
reference documents included in the DeltaV DVD Documentation Library provided with each system; and are
available through Guardian Support. Contact your Emerson Local Business Partner or Field Sales Office
(LBP/FSO) for assistance in locating these documents.

Best engineering practices

The recommendations in this document are based on what Emerson considers best engineering practices. These
best practices apply to any control system. The following principles provide a foundation for system design with
respect to mitigating interference issues through power and grounding.

Wiring for system grounds, chassis grounds, AC grounds, DC reference grounds, and DeltaV instrumentation
grounds (DIG) should be connected as shown in the illustrations. This is the best practice to resolve power
quality issues such as magnetic interference, radio signals, electrical spikes, and lightning discharges.
Compromising the power and grounding design can degrade control system performance and can jeopardize
personnel safety.

Principles of proper site preparation

• A system is only as good as its foundation. System operation will never be better than the
integrity of its AC power, DC power, and ground networks.
• Power, ground, and surge should always be considered together because they frequently
interact. A system where power, ground, and surge suppression work in unison is the most
stable system. Clean power with surge protection minimizes electronics damage and errors in
your system's control signals.
• Electrical noise effects are normally minimized by using isolated AC power sources and single-
point grounding schemes, by protecting against undue influence on I/O signals from stray
magnetic fields, and by selecting appropriately sized and designed cables and pathways,
including adequate cable separation.
7
• Minimize EMI noise and RF interference to increase system reliability.
• Shielded, twisted-pair cable for traditional I/O results in the best solution to provide electrical
noise immunity.
• Use the shortest possible power and ground cables to minimize overall impedance.
• Minimize exposure to extreme environmental conditions such as temperature, humidity, and
corrosive elements.
• There is no single, perfect solution that can eliminate all unwanted interference. However, a
stable ground reference (1 Ω to 5 Ω) can protect the control system from facility faults,
lightning, and other voltage events affecting other ground areas. A single-point, dedicated
connection for the DeltaV isolated DCG bus to true earth ground minimizes electrical noise
interference from other ground systems.
• Make sure no other system in the plant is connected to the DeltaV Instrumented Ground
(DIG).
• Not all applications require the same level of power and grounding design. Mission-critical
sites, such as refining, petrochemical, and safety instrumented systems, require the highest level
of power, ground, and surge integrity and protection. However, not all systems need the same
level of availability. Many processes can accommodate an interruption due to a safety trip.
Assuring a safe shutdown of the process is the requirement of a safety system. An interruption
in many processes does not always result in significant financial loss. Therefore, many systems
economically do not justify the highest availability, but safety systems require the highest
integrity systems.

8
 DeltaV power and power quality

Connecting plant power to DeltaV

The power and grounding practices in this chapter have been established over decades to provide excellent
protection against electrical surges and transients in industrial installations. The electrical system installation
must meet the local area codes and regulations to insure personnel safety and protection of property. The most
common methodology is based on a solidly grounded AC power distribution system as recognized by the
National Electrical Code (NEC) NFPA 70, the Canadian Standards Association (CSA), the International
Electrotechnical Commission (IEC), the Institute of Electrical and Electronics Engineers Inc. (IEEE), and most
world area electrical codes. Other grounding methodologies can also provide good alternatives for customer
requirements. For more information, refer to the Types of ground systems section in Chapter 5 of this manual.

Industrial power is supplied through a three-phase (3 ∅) transformer and stepped down to a nominal plantwide
voltage level. The National Electric Code (NEC) and IEC define low voltage (LV) as at or below 1000 VAC.
CSA C22.1-15 defines low voltage as any voltage exceeding 30 V but not exceeding 750 V. The following table,
adapted from a table in IEC 60038 Standard Voltages, lists the harmonized global voltage levels for low-voltage
AC power. Many industries have separate feeds from two substations or one substation along with generators to
provide redundant power.
Table 2-1 Standardized global power

Three-phase four-wire or three-wire systems Single-phase three-wire systems

Normal Voltage (V) Normal Voltage

50 Hz 60 Hz 60 Hz

- 120/208 120/240d

230c 240c -

230/400a 230/400a -

- 277/480 -

- 480 -

- 347/600 -

- 600 -

400/690c -

1,000 -

a. In Europe and many other regions, most facilities with 220/380 V and 240/415 V systems have made
the transition to 230/400 V.
b. In Europe and many other regions, most facilities with 380/660 V systems have made the transition to
400/ 690 V.
9
 c. 200 V and 220 V are also used in some countries.
d. 100/200 V are also used with 50 Hz and 60 Hz systems in some countries.

To maintain the highest power factor, maximize efficiency, and reduce harmonics and unwanted noise, it is
always best to maintain a balanced system. The secondary side of most 3 ∅ LV isolation transformers in North
America is a 120/208 VAC or 277/480 VAC 60 Hz wye with a solidly grounded system. Europe typically
distributes low-voltage (LV) power through 230/400 VAC 50 Hz system.

To maintain optimal control for a distributed control system (DCS), the DCS must be powered from a
separately derived source. This separately derived power can be provided from three-phase AC feeds, single-
phase AC feeds, or distributed DC feeds. Separately derived power is very important for reducing unwanted
interference.

AC power to the DeltaV bulk power supplies can also be provided from a separately derived AC floating or
resistance grounded system, however, DeltaV’s DC system must have its DC return solidly grounded to meet
and maintain EMC and certifications for safety.

AC power from a grid

Worldwide power is a constantly evolving entity. Today, power is produced from generation, such as
hydroelectric; nuclear, coal, or natural gas through steam turbine; wind; or photovoltaic. The three-phase voltage
is then stepped up through a transformer and delivered on transmission lines at high-voltage (HV) or ultra-high-
voltage (UHV) alternating current with a fundamental frequency of either 60 Hz or 50 Hz. This HV or UHV is
ultimately reduced to a medium voltage at the distribution substations. Many industrial customers are supplied
medium voltage which is further reduced to meet their plants requirements, typically 400 to 600 VAC.

Regional and national power grids exist throughout the world. This network of power is connected, rerouted,
and distributed at the substations to produce power, as shown for example in the following figure. To make this
system work in unison, the various power sources must synchronize their generation frequency, voltage, and
phase.

10
Figure 2-1 Typical power generation and distribution

Hydro Power Nuclear Power

Wind Farm
Plant
Plant

Turbines
Generator Turbine Generator
Generators

Breakers Breakers
Step-up Step-up
transformers transformers
Plant Plant Plant
substation substation substation

High Voltage
Transmission Lines

Bulk Power
Substations

Subtransmission

Subtransmission Subtransmission
Lines Lines

Subtransmission
Substation

Distribution Distribution
Substation Substation

Service Service

An integrated control system must maintain a relatively steady state condition by rapidly reacting to transient
events and the dynamic conditions introduced both from the sources and loads connected to the grid. A 1976
IEEE report on power disruption listed the following most common causes of disruptive events.

11
Table 2-2 Causes of power disruptions

Weather Miscellaneous System Components System Operation

Blizzard/snow Airplane/helicopter Electrical & mechanical: System conditions:
Cold Animal/bird/snake Fuel supply Stability
Flood Vehicle: Generating unit failure High/low voltage
Heat Automobile/truck Transformer failure High/low frequency
Hurricane Crane Switchgear failure Line overload
Ice Dig-in Conductor failure Transformer overload
Lightning Fire/explosion Tower, pole attachment Unbalanced load
Rain Sabotage/vandalism Insulation failure: Neighboring power system
Tornado Tree Transmission line Public appeal:
Wind Unknown Substation Commercial & industrial
Other Other Surge arrester All customers
Cable failure Voltage Reduction:
Voltage control equipment: 0-2% voltage reduction
Voltage regulator Greater than 2-8%
Automatic tap changer voltage reduction
Capacitor Rotating blackout
Reactor Utility personnel:
Protection and control: System operator error
Relay failure Power plant operator error
Communication signal error Field operator error
Supervisory control error Maintenance error
Other

Substations are configured and interconnected radially with lateral services; through loops; or in networked grids
of interconnected feeders supplied from several substations. Power may be provided to Industrial customers from
any of these types of distribution systems or their facility may be the sole recipient of one of these distribution
networks.

Generating plants, transmission systems, distribution substations and integrated control systems use switches,
relays, and fuses to redistribute power and, in most cases, reapply power to correct for disruptions. Many
disruptions are intermittent and cleared once power is restored to the circuit. For example, if a tree limb falls
across a transmission line causing a temporary short: 1) the short is detected; 2) the circuit with the short is
removed from the power network; 3) a reclosing breaker is activated to reestablish the original power source to
the network after the fault has cleared. This type of situation can cause multiple power quality issues for control
systems, such as interruptions, sags, undervoltage, swells on reclosure, or transients from the event or reclosure
attempts.

Care should be taken when deriving control system power from multiple sources. If the sources are from two
independent distribution substations, a localized power control interconnect system between the distribution
substations should be in place to assure equality of voltage, frequency, and phase. If the phase from source one is
not completely matched to that of source two, there may be additional neutral current from these separately
derived systems with a commonly grounded neutral.

12
DeltaV AC distribution and grounding system
A well-engineered AC distribution system meets or exceeds all electrical codes and standards. For a typical
DeltaV node being powered from the plant’s AC distribution system, the power should be supplied through an
isolation transformer or UPS with a good AC ground network established at or near the transformer or UPS.

AC conductors are routed from the AC source to the main disconnect panel (containing the main disconnect
breaker or fuse) and then into branch disconnect panels. For large DeltaV systems, multiple branch disconnect
panels should always be used. Multiple branch panels enable you to dedicate power to particular areas of the
system, its enclosures, and to DeltaV workstations. Figure 2-2 below is an isolated three-phase system with
redundant power. A double-conversion UPS provides isolated power to the primary. An isolation transformer
and transfer switch provide a maintenance bypass for UPS service. The secondary power is provided with an
isolation transformer. The loads of the three-phase power system should be balanced if sourcing single-phase
power as shown in figure below.
Figure 2-2 Isolated 3-phase system with redundant power

When connecting multiple grounding systems together, such as the plant ground grid and the lightning
grounding in the figure above and the DeltaV Instrument Ground (DIG), the lightning ground should have its
bonding connection as far as practical from the DIG bonding location on the plant ground grid.
13
The following figure shows an isolated single-phase system with redundant power. When connecting single-
phase power from three-phase plant power distribution, it is important to choose the correct phasing between
legs of the service to maintain proper load balancing. A balanced load on the three-phase power reduces
harmonics. Harmonics in the system can result in transformer overheating and other power-quality issues.
Figure 2-3 Isolated single-phase system with redundant power

DC distribution system
Many facilities supply power to control systems through a distributed DC power bus. DC busses typically range
from 24 VDC to 28 VDC. These lower DC voltages are safer for personnel in case of shock, and they lessen the
risk of fire and explosion. Disadvantages of DC distribution include higher costs, higher susceptibility to noise,
and higher power losses. The voltage at the DC source is always greater than the voltage at the various taps
throughout the plant due to resistance losses with increased distance.

Adding a separate DC/DC power supply between the DC distribution taps and DeltaV has the following
advantages:

14
 • It establishes a separately derived zero-equipotential ground reference. Many DC distribution systems
do not have grounded DC returns. Additionally, DC systems that are grounded at the distribution
center return may not be at the same ground potential as the DeltaV Instrument Ground (DIG).
• It isolates DeltaV equipment from other equipment also connected to the DC bus in the following
ways:
o Stabilizes voltage fluctuations caused by other equipment.
o Provides isolation from noise on the power lines.
• DeltaV certifications for safety, EMC, ATEX/IECEx and Low Voltage all require a solidly grounded
DC system. (ATEX is the name commonly given to the two European Directives for controlling
explosive atmospheres. IECEx is a system that provides an internationally accepted means of proving
compliance with IEC standards.)

DC/DC power supplies must be adequately sized for the DeltaV system, must have the proper certifications for
the applicable area, and should be 100 ft (about 30 m) or less from the DeltaV equipment to minimize the
susceptibility to noise.

For noisy environments, consider additional surge protection. Low-voltage DC lines are more susceptible to
noise than are higher-voltage power lines.

15
Figure 2-4 Bussed DC power

+ -
24VDC Bulk Power
Secondary
+ -
24VDC Bulk Power

24Vreturn

24Vreturn

24Vreturn

24Vreturn

24Vreturn

24Vreturn
24VDC

24VDC

24VDC

24VDC

24VDC

24VDC
Primary
Type 3 Type 3 Type 3 Type 3 Type 3 Type 3
SPD SPD SPD SPD SPD SPD

DC/DC DC/DC DC/DC DC/DC DC/DC DC/DC

Isolated
Local DC

CHARM Enclosure CHARM Enclosure CHARM Enclosure

Communications with
DeltaV Should be
connected via. Fiber-
optic cable for distance
exceeding 200 ft.
FUSE

FUSE

FUSE

FUSE
FUSE

FUSE

Insolated Bus Insolated Bus Insolated Bus

Chassis Ground DC Ground Chassis Ground DC Ground Chassis Ground DC Ground

(CG) (DCG) (CG) (DCG) (CG) (DCG)

Local Area Chassis Local Area

Ground (CG) DC Ground
(DCG)
Steel

DeltaV Instrument Ground

(DIG)
Power Ground

Chassis Ground (CG)

IS Ground
DC Ground (DCG)

Earth Electrode
Triad
Network

Floating AC and high-resistance grounded systems typically with marine applications

Marine power as it applies in this manual refers to shipboard or offshore platform power. Most marine
applications for control systems use low voltage (LV) < 1000VAC for the power source. However, marine
propulsion is often derived from medium voltage (MV) generation. Redundancy is provided from MV
generator-sets which are stepped-down through transformers to provide the LV power systems for control.

Reasons for using a floating ground are to maintain high availability and to prevent oxidation or plating through
electrolysis. Marine applications typically use floating AC to obtain high power availability. An example of a
floating AC system as described in IEC 60364-1 is an IT power system. DeltaV bulk power supplies can be used
in many power schemes including floating IT power designs.

16
Warning: Floating or high resistance ground systems allow for a single ground fault to occur without loss of
power to critical systems. A second fault will result in loss of power and/or hazard to personnel and property.
Fault sensing and alarming will allow maintenance to locate and correct the ground fault.

Some equipment failure conditions can produce an imbalance in the line currents when using floating power.
For example, bearing wear will cause a rotational imbalance that will affect the line currents. When a non-
hazardous current imbalance is detected, an alarm alerts personnel to the need to troubleshoot and clear the
issue. This sensing is important to maintain power availability to the process.

Detection of current imbalance is accomplished by measuring leakage with current monitors, such as those listed
below, which compare the phase to phase and phase to ground current. The resultant current or net current will
be zero. Minor imbalances are a result of wire insulation breakdown or load issues. When an imbalance is
observed, action can be taken depending on the severity of the issue. If the imbalance is minor, such as early
signs of insulation breakdown, the cable can be replaced at the next scheduled preventive maintenance if the
issue does not progress.

The following figure shows a marine application that incorporates surge protection, earth leakage detection, and
a solution for phase imbalance or loss of a phase.
Figure 2-5 Three-phase floating power for marine applications

DCS Marine Power

Disconnect SPD
L1
Type 2

L1
SPD

3ɸ AC
L2
L1
L3 L2 +24VDC
Primary 1 L2 DeltaV
UPS
L3
L3
Transfer Switch Primary
L1
L2
Rectifier Inverter L1 PE 24VRtn
24VDC
L3
L2 µ µ
Current
MEDIUM VOLTAGE BUS1

MEDIUM VOLTAGE BUS2

m<3 L1 L2 L3
L3
G
G
U
Imbalance
L2
GND
L3
Relay
Battery Bank or
Flywheel Storage 3ɸ AC
L1
L1
Ground L2 +24VDC
Secondary 1 L3
L2
L3
PE 24VRtn
DeltaV
L1 Isolation Transformer L1 L1 L2 L3
µ µ
Secondary
m<3
L2 Φ1 24VDC
L3
L2 3ɸ AC U
L2 Shield Bar
L3
G
Primary 1 L3
Current
Φ2
L3 L2 L1
Power Distribution 3ɸ AC Imbalance Relay
Primary 2
Φ3
3ɸ AC Isolated
Ground
G L3 L2 L1 Primary 3 Ground Earth Leakage
Power
Distribution
Monitor
Earth Leakage Primary LV
Detection Distribution Bus

Disconnect SPD
Isolation Transformer
L1 L1
DCS Marine Power
L1
Type 2
SPD

L2 L2 L2
L3 L3 L1
L3 3ɸ AC L1
L2 +24VDC
G
Primary 2 L3
L2 DeltaV
L3
PE 24VRtn Primary
µ µ
24VDC
Ground m<3 L1 L2 L3 Current
Φ1 3ɸ AC U
Imbalance
Secondary 1
L2
L3
Relay
Φ2 3ɸ AC L1
Secondary 2 3ɸ AC L1
Φ3
L2
L2 +24VDC
3ɸ AC Secondary 2 L3
L3
Secondary 3 PE 24VRtn
G L3 L2 L1
Power
DeltaV
Earth Leakage
Distribution
m<3 L1 L2 L3
µ µ
Secondary
Detection
Secondary LV U
24VDC
Structural Steel

Distribution Bus L2
L3
Shield Bar
Current
Imbalance Relay
DeltaV Isolated
Instrument Ground Earth Leakage
Ground (DIG) Monitor

The surge protection device (SPD) is solidly grounded and if properly maintained will not be a source of
leakage. In other words, leakage detection from the SPD to the structure is not generally required because the
ground connection is only used in the event of a high voltage surge. The SPD at the first disconnect from the
Medium Voltage (MV) distributed 3-phase bus can be either type 1 or type 2 depending on the conditions at
the site. The SPD will attenuate surges from phase to phase or phase to hull/structure.

A single isolated ground path should be maintained from the isolation transformers, UPS, transfer switch
through to the distribution disconnect to ensure that any leakage current is detected through dedicated ground

17
wires. Earth leakage current will be detected by the current transformer (CT) located between the disconnect
and the DIG at the structure. The ground bus in the DeltaV cabinet will be isolated and monitored by a leakage
detector. Once leakage is detected the source should be located and eliminated.

Current imbalance relays as shown in the DeltaV cabinets can be set to monitor phase imbalance. This
imbalance can be an indication of an issue such as loss of one of the three phases or a component failure.

Offshore applications use the hull of the ship or platform as the ground reference. Leakage current to and
throughout the structure will result in a build-up of non-conductive oxidation, i.e. electrolysis. Therefore, it is
important to detect and eliminate the cause of the leakage.

The following detection methods are used to maintain the integrity of the hull, to assure the availability of the
process, and to protect personnel and property:

Differential ground fault protection is a process of detecting an imbalance in the pole current with respect to a
ground, either functional earth or protective.

Differential current monitor is the method and/or device to measure the pole current imbalance by means of
current transformers (CT). This is the most general term for current monitoring in that it can measure a single
pole with respect to ground; pole to pole; multiple pole current sharing; or multiple pole and the ground
leakage.

Differential relays are used in conjunction with Differential current monitors to achieve a level of protection in
cases of current imbalance by interrupting circuits with faults. In cases with multiple power sources they may
also be used to reconfigure circuit power from the fault to the non-fault circuits.

Residual current devices (RCD) – Measures imbalance in power lines. These RCDs will detect if the current
supplied has an equal and opposite current through the return pole conductor(s). If leakage is detected, the RCD
interrupts all poles. The interrupt can be fast acting or delayed. Two types of RCDs are RCCB and RCBO listed
below.

Residual-current circuit breaker (RCCB) opens power circuits when a current imbalance exists between the poles.

Residual-current circuit breaker with overcurrent protection (RCBO) – protect against current imbalance between
the poles, short-circuit, overloads, and earth faults by interrupting power circuits during an event.

Residual current relays are used in conjunction with Residual current devices to achieve a level of protection in
cases of current imbalance by interrupting circuits with faults. In cases with multiple power sources they may
also be used to reconfigure circuit power from the fault to the non-fault circuits.

Earth Leakage detectors (ELD) are used in a grounded power system, such as low voltage AC power, DC power,
or signal wires.

Ground Fault Circuit Interrupter (GFCI) as defined by Article 100 of the NEC “A device intended for the
protection of personnel that functions to de-energize a circuit or portion thereof within an established period of
time when a current to ground exceeds the values established for a Class A device.” The Class A devices will
trip when the current to ground is <= 6mA. GFCIs are primarily used in North America with applications in
residential and office environments. The GFCIs are in the form of receptacle or breaker and can be considered a
non-inclusive subset of differential ground fault protection.

18
Another method of increasing power availability is using a high-resistance grounding system. If you use floating
or high-resistance ground, insulation and interrupt devices must be sufficiently sized to accommodate the
possibility of line-to-line fault conditions. Residual current devices (RCDs) should also be incorporated on the
supply lines to quickly detect leakage current and provide power interruption if required.

Although AC power and isolated input or output field power can be floating, the DeltaV DC power must
remain solidly grounded.

Warning: Use only DeltaV isolated AC I/O products with floating or high-resistance ground. DeltaV AC
discrete I/O products are tested and certified for use with solidly grounded AC systems and should not be used
on a floating or high-resistance ground.

Note: Isolated AC channels are permitted.

Emerson bulk power supplies can provide up to 1500 VDC isolation from AC power and must be installed in
accordance with the manufacturers' instructions. AC power and grounding is governed by the applicable codes
and regulations and is independent of the DeltaV DC power requirements.

If you are using a high-resistance ground, install a surge protection device (SPD) with filters immediately before
the DeltaV bulk power supply. SPDs protect the integrity of the DeltaV system from re-strike transients. Re-
strike transients are generated in HRGs to find system faults.

Protection from surges and lightning

It is often estimated that 60% of process interruptions come from surges or noise from industrial equipment. In
moderate to high lightning regions, 40% of process interruptions are due to lightning either directly or
indirectly. Therefore, DeltaV power requires surge protection for the highest integrity systems. All systems
should be reviewed for adequate protection from surges and noise to ensure the reliability and availability of the
DCS controls.

It is beyond the scope of this manual to design lightning systems or recommend surge protection devices for
service entrance power. Refer to NFPA 780 Standard for the Installation of Lightning Protection Systems: 2017 and
the IEC 62305 series Protection against lightning for more detailed information about lightning protection
techniques.

There are similarities between surge management for industrial applications and surge management for
lightning. Industrial applications as in IEC 61131-4:2004 include surge management for lightning in the
exposed areas of plants and other disruptive electromagnetic pulse (EMP) events internal to the facility, but the
lightning control specifications focus only on surges from atmospheric discharge events. The following figure
from IEC 61131-4:2004 shows typical EMC Immunity Zones for an industrial application. Power and signals
need to be appropriately conditioned for the environment, availability, and integrity level required for the
process application.

19
Figure 2-6 EMC immunity zones

A similar correlation can be made from the lightning protection zone (LPZ) of the figure below.
Figure 2-7 Lightning protection zones

20
Higher availability and integrity require greater protection from surges. Lightning protection zones, immunity
zones; and hazardous location zones do not have a perfect one-to-one correlation. For example, immunity zone
C is similar to LPZ1; immunity zone B is similar to LPZ2; and immunity zone A is similar to LPZ3.

One common misbelief is that surge suppression is not necessary if the process is in an area with a low risk of
lightning. It is prudent to include isolation, such as a UPS or isolation transformer, with surge suppression at
every zone boundary to maintain high availability and high integrity in industrial applications. For an example,
refer to Figure 2-6.

Surge protection devices (SPD) are designed to specific standards such as UL 1449:2015 Standard for Safety
Surge Protective Devices for North America and Internationally in IEC 61643-11:2011 Low-voltage surge
protective devices -Part 11 Surge protective devices connected to low-voltage power systems – requirements and test
methods. This manual uses the UL type designation for SPDs, which classifies the SPD class as Type 1, Type 2,
and Type 3.

Low-voltage (LV) service entrances from LPZ0 to LPZ1 should have a Type 1 SPD. If your application requires
high availability or high integrity, you should use SPDs regardless of the frequency of lightning in the area.

SPD should be coordinated between LPZs to limit energy entering more sensitive LPZs.

DeltaV products meet industrial surge requirements and criteria listed in IEC 61326-1 Electrical equipment for
measurement, control and laboratory use – EMC requirements – Part 1: General requirements Table 2 – Immunity
test requirements for equipment intended to be used in an industrial electromagnetic environment. For control
systems located entirely within and powered in a Zone C or LPZ 3, no additional surge protection should be
required. However, some degree of filtering and isolation, such as that provided by an isolation transformer, may
still be necessary.

Figure 2-7 show standalone DeltaV systems that are powered from separately derived sources, such as those in
Figure 2-2 and Figure 2-3. This is often the case of remote buildings that are not close to the main plant
grounding system. These remote DeltaV centers will require separate localized grounding, such as a triad. When
there are several remote systems that are in the near proximity cost can be minimized by connecting to local
grounding busses with a single DIG/triad. For installations where the distance to the separately derived source is
greater than 100 m, the best engineering practice is to include SPDs for mitigation of noise interference in
DeltaV systems. All surge protection devices should be designed in a coordinated effort as seen in Figure 2-5 and
Figure 2-6. Surge protection devices used with remote DeltaV enclosures as depicted in Figure 2-7 should be
SPD Type 3. The SPD in the enclosure below will protect transients from Line-Line and Line/Neutral-Ground.
Unwanted energy will dissipate through the remote triad and/or the ground at the separately derived source.
When a transient event occurs, the energy will seek multiple paths back to the origin. In a system with multiple
ground points, SPD ground to triad or SPD ground to plant ground grid, the unwanted energy dissipates more
quickly and has less influence on the control system. The following figure illustrates grounding of SPDs for
DeltaV.

21
Figure 2-8 SPD Grounding for DeltaV

DCS Power L
+24VDC
N
PE
24VRtn
DeltaV
SPD Type 3 w/ Fuse Primary Power
L1 24VDC

Type 3
AC Primary 1

SPD
N

L
+24VDC
N
PE
24VRtn
DeltaV
Secondary Power
SPD Type 3 w/ Fuse
24VDC
L1

Type 3
SPD
AC Secondary 1
N

Shield Bar

Chassis Ground DC Ground

(CG) (DCG)

DCS Power L
+24VDC
N
PE
24VRtn
DeltaV
SPD Type 3 w/ Fuse Primary Power
L1 24VDC

Type 3
AC Primary 2

SPD
N

L
+24VDC
N
PE
24VRtn
DeltaV
Secondary Power
SPD Type 3 w/ Fuse
24VDC
L1
Type 3
SPD

AC Secondary 2
N

Local Area Local Area Shield Bar

Chassis Ground DC Ground
(CG) (DCG) Chassis Ground DC Ground
(CG) (DCG)
DeltaV
Building Steel

Instrument
Ground (DIG)

DCS Power L
+24VDC
N
PE
24VRtn
DeltaV
DC Ground
AC Power

Ground (CG)
AC Power

IS Ground

Primary Power
Ground
Ground

Chassis

(DCG)

SPD Type 3 w/ Fuse

L1 24VDC
Type 3

AC Primary 3
SPD

L
+24VDC
N
PE
24VRtn
Earth DeltaV
Electrode Secondary Power
SPD Type 3 w/ Fuse
Network 24VDC
L1
Type 3
SPD

AC Secondary 3
N

Triad
Shield Bar

Chassis Ground DC Ground

(CG) (DCG)

22
If the DeltaV system is farther than 100 m (300 ft) from the power distribution source, or if there is a high
lightning or disruptive risk, install SPDs as shown in Figure 2-8. In addition to the surge suppression provided
by SPDs, these devices also enable the creation of a separately derived ground. The SPDs do not provide a
galvanically isolated ground as could be established by an isolation transformer, but they do provide good
isolation, enabling the grounding system to mitigate interference.

Field wiring may also require surge suppression if the signals enter a protection zone outside the zone the
controller and cards are in. When SPDs are used with field wires it is best to have SPDs at both ends of the field
transmitter/receiver pair.

In small systems, such as a remote CHARM enclosure, the DC Ground and the Chassis Ground can be
connected inside the enclosure and taken to a low impedance ground.
Figure 2-9 Isolated CHARM enclosure with SPDs

Power quality
Why clean power?
From a service entrance, plant distribution networks can drop AC input voltage by five percent or more between
the entrance and the power connections to various portions of the control system. Additionally, electrical
disturbances can be induced on plant power lines by surges and starting transients from large motors and other
23
loads connected to the plant AC distribution system. These disturbances can cause momentary line-voltage
reductions as well as possible wave-shape distortions such as spikes. Starting large motors may momentarily drop
line voltage up to 15%. To maintain adequate power quality, electrical disturbances must be designed around or
controlled.

To operate your DeltaV system at the highest level of integrity (that is, to maintain the system with the least
amount of disruptive events due to power anomalies), a properly designed power conditioning system should be
considered.

DeltaV requires clean AC power. Clean AC power is a sinusoidal wave that maintains its characteristics with
both linear and non- linear loads. The following commonly used standards address power quality:

• IEEE 1159-2009 Recommended Practice for Monitoring Electric Power Quality

• IEEE 519-2014 Recommended Practices and Requirements for Harmonic Control in Electrical Power
Systems
• IEC 61000-3-11 Electromagnetic compatibility (EMC) Limitations of voltage changes, voltage fluctuations
and flicker in public low voltage supply systems
• IEC 61000-3-12 Electromagnetic compatibility (EMC) Limits for harmonic currents produced by equipment
connected to public low voltage systems
• IEC 61000-4-30 Testing and measurement techniques – Power quality measurement methods

Table 2-3 and Table 2-4 list the most prevalent factors that influence the quality of power. Common causes for
power quality issues with corresponding recommendations for corrective measures can also be found in the
tables.

Caution: Any three-phase source, such as transformer or UPS, providing power to a DeltaV system must only
power DeltaV products, safety systems, or the control system. Therefore, no VFDs, HVAC, motors, fans,
compressors, ballasts, and so on shall be connected to any output phase of a transformer or UPS that is also used
to power the DeltaV system.

24
Table 2-3 Solutions for power interference: UPS or CVT?

Type of interference Possible effect Common causes Preventive Comment

measures
Interruptions DeltaV restart. Utility faults, UPS or CVT DeltaV systems
load switching, powered by Emerson
breaker trips, or bulk power supplies can
equipment withstand power
failures. interruptions up to
20 ms.

Sag Possible DeltaV Start-up loads UPS or CVT DeltaV systems

restart if voltage drawing excessive powered by Emerson
drops below current, bulk power supplies can
lower power equipment faults. withstand sags up to 20
supply limit. ms.

Undervoltage Loss of power to Utility faults or UPS or CVT DeltaV systems

the DeltaV load changes. powered by Emerson
system. bulk power supplies can
withstand loss of power
up to 20 ms.

Swell Possible power Loads shifting, UPS or CVT

supply damage if utility faults.
voltage remains
at increased
levels greater
than power
supply limit.
Overvoltage Possible power Loads shifting, UPS or CVT
supply damage if utility faults.
voltage remains
at increased
levels greater
than power
supply limit.

Caution: The primary power source should be free of power interruptions longer than 20 ms. A power
interruption longer than 20 ms can cause loss of configuration data, process data, and even loss of process
control.

25
Table 2-4 Additional solutions for power interference

Type of interference Possible effect Common causes Preventive Comment

measures
Impulse transient Impulse Lightning Use appropriate Typically, bulk
transients in excess causing voltage surge protection supplies are certified
of 1,500 V may gradients in devices (SPD). to have either double
destroy channel excess of The SPD or reinforced
or system if 1,500 V. should be sized insulation to
transient is on for the worst withstand 1,500 V.
power feeds. surge area that The DeltaV system is
either the protected with
power or shields transient voltage
enter. suppression to
1,500V.
Oscillatory transient Data loss with Overall system Double
possible damage. response to conversion UPS
impulse or load with filtering.
switching from
inductive or
capacitive loads.

EFI/RMI noise Data loss, system Transmitters, Isolation

corruption. faulty transformer
equipment, (common mode
ineffective <1.5MHz),
grounding, close filter (normal
proximity to mode 10 KHz
EMI/RFI to 10 MHz)
source. UPS with
filtered output
Notching Data loss, system Variable Filters or UPS Isolate VFDs. Never
corruption. frequency drives with filtered allow generating
(VFDs), welders, output. devices, such as
lighting. VFDs, to use the
same power feed or
an adjacent leg on a
three-phase system.
Harmonics Overheating Non-linear loads. Could correct
which can at the source
shorten the life with active
of power harmonic filter,
supplies. Harmonic
Mitigating
Transformer

A double-conversion uninterruptible power supply can also mitigate most power quality issues.
26
Isolation transformers are an excellent means to significantly reduce common-mode noise, typically up to 750
kHz. The isolation transformer also allows for a separately derived source of power that creates a stable ground
reference point close to the DeltaV system. Filters are a readily available solution for normal-mode noise
reduction in the range of a few hertz up to 10 MHz. Surge suppressor/filters can prevent surge voltages from
indirect lightning or large upstream power faults from damaging control equipment. They also reduce normal-
mode noise. A power quality evaluation of the site can easily determine the best solution to meet your individual
requirements.

UPSs that supply power to control systems should be double-conversion types. Typically, their input voltage is
provided from low voltage (100 VAC to 600 VAC) feeders, with either single- or three-phase power. The AC
power from the source is rectified to DC and used as leveling power to maintain batteries or to supply energy for
a flywheel. The inverter stage produces harmonic-free AC sine wave output using power from the DC storage
section - batteries or a flywheel. Use only UPSs that reproduce high-quality sine waves. Other UPSs produce
modified sine waves that are rich in harmonics and detrimental to control systems.

Most UPSs provide a degree of protection from power failure, power sag, and power surges. However, some
UPSs provide an excellent solution for most of the power quality issues found in Table 2-3 and Table 2-4.

A bypass transformer with static switchover allowing for UPS maintenance is either supplied as an integral
component or can be connected externally to the UPS. If you are using the type of UPS recommended above,
select a shielded bypass transformer.

Some UPSs provide three-phase output power. When using a UPS with a three-phase output, all phases should
be connected only to the control system and to non-interfering equipment. Never connect one phase to the
DeltaV system and another phase to a VFD or air-conditioning unit, for example.

How to establish and maintain clean power

Most industrial applications share power with a wide variety of devices including large motors, furnaces, large
lighting systems, and HVAC systems. Control applications that can tolerate disruptive events require little or
limited consideration for power quality. However, if your application requires a high degree of consistent system
integrity with minimal disruption, careful consideration for methods to achieve and maintain clean power is
important. Use the following flowchart and options provide guidance to achieve the most economical and
effective solution for your site's AC power requirements.

27
Figure 2-10 Power distribution decision flowchart

Evaluate Power
needs for DeltaV
Site

No Is Power Failure, Sag, Yes, use a UPS

or Surge present?

Is Noise, which could Yes Is Noise, which could

No No Yes
potentially cause disruptive potentially cause disruptive
events, present? events present?

Use UPS(s) with at least Use UPS(s) with

Power Failure Power Failure
No Is Power Source in close Power Sag Power Sag
Yes
proximity (< 100 m) to Power Surge Power Surge
DeltaV? Undervoltage protection Undervoltage protection
Overvoltage Protection Overvoltage Protection
Line noise elimination
Frequency variation correction
Is Noise at Switching Transient filter
No Yes
Frequencies > 750Khz Harmonic Interference filter
Use Transformer or UPS(s) present?
to Establish a Separately
derived ground reference at Use an
DeltaV DIG
Isolation Transformer
and Suppressor/Filter or Filter in
close proximity to Bulk Supply
Use an
Isolation Transformer Or

UPS(s) with
Power Failure
Power Sag
Power Surge
Undervoltage protection
Overvoltage Protection
Line noise elimination
Frequency variation
correction
Switching Transient filter
Harmonic Interference filter

Chose Number of
AC Sources required

28
Single AC source:

Option A

Highest integrity

• UPS with the following features:

o Neutral/ground bond point to establish a separately derived ground reference
o Power failure, power sag, and power surge protection
o Capable of regulating under-voltage and over-voltage input power
o Line noise elimination, frequency variation correction, switching transient filter harmonic
interference filter
• UPS to DeltaV cabinet distance of less than 100 meters
• Surge suppressor/filter prior to bulk supply
• Bypass isolated transformer with single isolated shielding
• Power lines in armored cable or metal conduit (optional)

Option B

• UPS with the following features:

o Neutral/ground bond point to establish a separately derived ground reference
o Power failure, power sag, and power surge protection
o Capable of regulating under-voltage and over-voltage input power
• UPS to DeltaV cabinet distance of less than 100 meters
• Surge suppressor/filter prior to bulk supply (optional if signal shields are not located in Zone 0 or Zone
1 lightning area)
• Bypass isolated transformer with single isolated shielding
• Power lines in armored cable or metal conduit (optional)

Option C

• Isolation transformer
• Neutral/ground bond point to establish a separately derived ground reference
• Transformer to DeltaV cabinet distance of less than 100 meters
• Surge suppressor/filter prior to bulk supply (optional if signal shields are not located in Zone 0 or Zone
1 lightning area)
• Power lines in armored cable or metal conduit (optional)

Option D (clean-power: AC source <100m)

• Surge suppressor/filter prior to bulk supply (optional if signal shields are not located in Zone 0 or Zone
1 lightning area)
• Power lines in armored cable or metal conduit (optional)

29
Option E (clean-power: AC source <300m)

• Surge suppressor/filter prior to bulk supply

• Power lines in armored cable or metal conduit

Two AC sources:

Option F

Highest integrity

AC source (1 & 2)

• UPS with the following features:

o Neutral/ground bond point to establish a separately derived ground reference
o Power failure, power sag, and power surge protection
o Capable of regulating under-voltage and over-voltage input power
o Line noise elimination, frequency variation correction, switching transient filter harmonic
interference filter
• UPS to DeltaV cabinet distance of less than 100 meters
• Surge suppressor/filter prior to bulk supply
• Bypass isolated transformer with single isolated shielding
• Power lines in armored cable or metal conduit (optional)

Option G

Highest integrity

AC source (1)

• UPS with the following features:

o Neutral/ground bond point to establish a separately derived ground reference
o Power failure, power sag, and power surge protection
o Capable of regulating under-voltage and over-voltage input power
o Line noise elimination, frequency variation correction, switching transient filter harmonic
interference filter
• UPS to DeltaV cabinet distance of less than 100 meters
• Surge suppressor/filter prior to bulk supply
• Bypass isolated transformer with single isolated shielding
• Power lines in armored cable or metal conduit (optional)

AC source (2)

• Isolation transformer
• Neutral/ground bond point to establish a separately derived ground reference
• Transformer to DeltaV cabinet distance of less than 100 meters
• Surge suppressor/filter prior to bulk supply
30
 • Power lines in armored cable or metal conduit (optional)

Option H

AC source (1 & 2)

• Isolation transformer
• Neutral/ground bond point to establish a separately derived ground reference
• Transformer to DeltaV cabinet distance of less than 100 meters
• Surge suppressor/filter prior to bulk supply
• Power lines in armored cable or metal conduit (optional)

Option I (clean-power: AC source <100m)

AC source (1 & 2)

• Surge suppressor/filter prior to bulk supplies (optional if signal shields are not located in Zone 0 or
Zone 1 lightning area)
• Power lines in armored cable or metal conduit (optional)

Option J (clean-power: AC source <300m)

AC source (1 & 2)

• Surge suppressor/filter prior to bulk supplies

• Power lines in armored cable or metal conduit

Caution: Emerson defines clean power for DeltaV according to the descriptions in EN 61000-3-11
Electromagnetic compatibility (EMC) – Part 3-11: Limitation of voltage changes, voltage fluctuations and flicker in
public low-voltage supply systems –Equipment with rated current ≤75 A and subject to conditional connection, and
EN61000-3-12: Electromagnetic compatibility (EMC) –Part 3-12: Limits for harmonic currents produced by
equipment connected to public low-voltage systems with input current >16A and ≤75 A per phase.

Isolation to protect from power quality issues

It is extremely important to isolate the AC ground system from undue noise and transients emanating from
other equipment. An isolation transformer is one of the most cost-effective means to provide clean AC power to
electronic devices such as PCs, network switches, and AC/DC power supplies. AC powered devices in the
control system such as workstation computers, servers, and network communication gear, can be very sensitive
to poor AC power quality and inadequate grounding. It is important to protect these devices from transient
noise emanating from process equipment. Experience has shown that it is prudent to install a separately derived
source as can be accomplished with an isolation transformer. Designing an isolation transformer into the original
system will be less expensive than adding it during plant startup or after a period of troubled operation.

Isolation transformers have been successfully used for many years to supply clean power for control systems,
medical systems, and computer centers. The isolation transformer also provides a location to establish a
separately derived ground.

31
For a comparison of the attenuation benefits for the various degrees of shielding available, refer to the following
table.
Table 2-5 Typical transfomer attenuation

Type of shielding Attenuation ratio Typical attenuation

No shield 10:1 12 dB to 20 dB
Single shield 1000:1 50 dB to 60 dB
Double shield 10,000:1 65 dB to 90 dB
Triple shield 100,000:1 90 dB to 120 dB

In addition to the common-mode rejection provided by isolation transformers, many transformers can be
purchased with filters on their output stage. The filter attenuates normal-mode noise. Shielded transformers with
filtered outputs provide noise reduction from a few hertz to up to 750 kHz in both common and normal mode.

Isolation transformers
Some literature defines isolation transformers as transformers with a one-to-one primary-to-secondary ratio. The
voltage at the output (secondary/load side) is equal to the voltage at the input (primary/source/line side). In this
manual, we use isolation transformer to refer to any transformer that provides galvanic isolation between the
primary and secondary. This galvanic isolation allows a means to establish a separately derived system. The
transformer may be three phase or single phase; step-up, step-down, or one-to-one; and provide shielding or
filtering.

An isolation transformer should be installed between the commercial power source and the main AC power
disconnect panel for a DeltaV system. For best isolation, each building or site containing DeltaV instruments
should have a dedicated isolation transformer and distribution network. Other systems, such as emergency shut-
down (ESD) systems must have their own isolated source of power.

When DeltaV systems are spread across different locations in the same building and the distances between the
instruments and their AC power sources are more than 100 m (300 ft), each group of DeltaV instrumentation
should have its own isolation transformer. Based on field experience, both electrical resistance and induced
electrical noise can become factors affecting reliable system operation when longer lengths are used.

There are many considerations when choosing an isolation transformer. Will single-phase or three-phase power
be available? Does the power environment or area necessitate single-shielded or double-shielded transformers?
Are there other specialized isolation transformer types, such as ferroresonant, harmonic mitigating, or k-factor
transformers, that are required to meet your need? Considerations should also include the hazardous area
classification requirement.

Single- or double- shielded isolation transformers--Many factors influence the choice of selecting the proper
isolation transformer. The level of power quality desired to maintain the process availability is the most
important consideration. Most applications require an isolation transformer with a single shield between the
primary and the secondary winding. However, in some industrial areas the poor power quality may lend itself to
choosing a double shielded isolation transformer. In addition to the isolation transformer reducing power line
interference, the Isolation transformer also provides a means to develop a separately derived ground.

32
K-factor transformers--Todays electronics cause harmonic rich non-linear loads. Because of potential safety
concerns from overheating using standard three phase transformers with non-linear loads K-factor transformers
were developed. Transformers with a larger K-factor can tolerate more harmonics while operating within the
temperature range of their insulation. A K-factor of 1 indicates a linear load. Typical values of K-factors are 4, 9,
13, 20, 30 and 40. In addition to the design of these transformers to accommodate increase in eddy currents
resulting in greater heat generation, the neutral return must be oversized to at least 1.73 (√3) for possible
unwanted harmonic current in addition to the sizing requirements for the phase to neutral current. These
transformers do not reduce the triplen harmonics which are additive in the neutral conductor, they simply
tolerate them. In K-factor transformers the triplen harmonics can not only pass phase to phase, but also from
secondary side to the primary conductors. Therefore, if a K-factor transformer is used as an isolation transformer
it is recommended that the transformer be double shielded to prevent the harmonics from being transferred
from secondary to primary or vice versa.

Harmonic mitigating transformers (HMT)--Shielded three phase delta-wye transformers with zig-zag wye
configuration, known as Harmonic Mitigating Transformers, are a good solution for isolating imbalanced loads
from the main plant power feed. Since harmonic cancelation is accomplished in the transformer’s flux the
oversized neutral is not required. Triple harmonics are not passed from the secondary to the primary as they are
with standard delta-wye or k-factor transformers because their energy is eliminated due to the flux cancelation in
the secondary windings. HMT are also known as phase shifting transformers and are available with the typical
phase shift configured for -15°, 0°, +15°, and 30° shifts. To maintain sinusoidal voltage waveforms with
minimal harmonic distortion, multiple HPT with complementary phase shift to other HMT are required
through the facility. In addition to the flux cancelation form the core secondary windings multiple HMT with
proper phase shifting provide sine wave recombination to offer very efficient clean power. The location of HMT
is optimized when these transformers are placed close to (~50 ft. from) the source power bus. Because the
isolation transformers that are most advantageous for DeltaV should be located as close as possible to the DeltaV
equipment and HMT are further optimized by a coordinated effort from a system perspective, little if any
benefit is realized from HMT over shielded delta-wye transformers for three phase isolated power.

Ferroresonant transformers as isolation transformers--Constant Voltage Transformers (CVT) or

Ferroresonant Transformers are transformers designed to be in the state of near core saturation. By maintaining
the core in the saturation region, the transformers can tolerate frequency shifts; voltage fluctuation, such as sag
and swell; transient interference, half cycle ride through, and provide harmonic isolation. To maintain this level
of stability a tuned tank circuit is used by connecting galvanically isolated windings with capacitors. The circuit
is used to create a passive filter by manipulating the core flux to compensate for most unwanted interference.
The trade-off with this CVT is that efficiencies vary greatly with load. At full load the efficiency is comparable to
the efficiency of standard isolation transformers in the range of 93% to 96%. However, at half load the CVT is
between 75% and 85% efficiency. The resonate tank circuit of a CVT requires additional core material which
adds to the weight and also increases the audible noise. For most industrial locations if noise and weight is not
an issue the CVT if sized properly is an excellent choice for an insolation transformer.

Protection from other equipment on AC power grid

Best practice is to provide separate AC power for the DCS. Noise producing equipment should not be
connected to this power source. Devices such as variable frequency drives (VFD), AC and DC Motors, ballasts,
heaters, compressors, and HVAC connected to the plant power can cause electrical noise disturbances which if

33
not addressed can adversely interfere with the process control systems. Various devices are available for noise
suppression.

Noise-suppression devices used for isolation of interfering sources from plant power:

• Power filter/conditioners
o Reactors
o Chokes
o Transformer reactor combination
• Line conditioners
o Harmonic mitigating transformers
o Active harmonic canceling filters
• Voltage regulating power sources
o Constant Voltage Transformer
o Uninterruptible power supplies (UPS)
• Motor-generator sets

Backup/redundancy for higher availability

Backup power recommendations
Backup power may be required to achieve defined levels of reliability and availability for process control systems.
You can back up the source only or back up every power supply in the control system, such as backup power for
every controller. As a minimum, you should back up all critical portions of the control system.

Consider backup power if:

• Power loss causes a process reaction that creates a hazardous condition or an extensive loss of product.
• The primary power source has a history of failure or of fluctuations beyond the specified tolerance of
equipment input power.
• The process requires electrical power for control because there are no non-electrical means available for
control.
• The primary power source cannot meet the 20-millisecond requirement for uninterrupted power.
• Power loss from a commercial power source is probable.
• Power loss requires manual setting of relays or solenoids.
• Power loss can cause the process to enter an uncontrollable state.
• Power loss causes a process reaction that creates a hazardous condition or an extensive loss of product.

Uninterruptible power supplies (UPS) are a recommended backup means. Small supplies are available to back up
selected plant areas. Large supplies are available to back up entire systems. When large supplies back up control
equipment spread across plant areas, each area must be electrically isolated in a manner duplicating primary
source isolation.

Types of redundancy
• Power feeds – separate substations
• Generators
• Uninterruptable Power Supplies
• Bulk Power
34
 o AC/DC per Cabinet
o AC/DC per Enclosure
o DC/DC

UPS systems can be replaced by backup generator units, as long as the generator or any filtering placed on the
generator output provides AC power within required DeltaV product specifications. Be sure to follow the
generator manufacturer's grounding requirements.

Most larger facilities have the capability of obtaining power from multiple sources. Many plants have an option
of separate feeds from utility sub-stations, solar, wind, or generators. If the highest availability is an important
consideration it is best to provide the entire power stream from separate feeders if possible. While it is ideal to
have a UPS system and a Generator system to maintain ride-thru during minor to sustained power
interruptions, your own process requirements will dictate the best power solution for your facility.

35
 DeltaV system cabinets and enclosures

Environmental considerations
A combination of temperature, humidity, dust (such as fly-ash and carbon), and corrosive vapors (such as
hydrogen sulfide) can cause gradual performance degradation, intermittent failures, and complete breakdown of
a control system. For maximum product availability and expected mean time between failures (MTBF), specified
operating conditions must be maintained.

Adverse environmental conditions such as temperature, humidity, and pollutants must be identified and
corrected. Various means for identifying environmental conditions are commercially available. Environmental
specifications for DeltaV products are provided in the DeltaV DVD Documentation Library. Contact your
Emerson Local Business Partner or Field Sales Office (LBP/FSO) for assistance in locating these documents.
Refer to Appendix J for more information about environmental considerations.

Environmental areas
Most control system instruments are designed to operate in one of the following environmental areas:

• Manned control or computer rooms with tightly controlled environmental conditions. These areas are
normally air conditioned for temperature and humidity control and include filtering of harmful vapors.
• Areas of controlled environmental conditions with wider ranges. Typically, these areas are rack rooms
containing controllers, I/O interface cards, and power supplies.
• Areas of controlled environmental conditions with even wider ranges. Typically, these areas use special
enclosures and sealed transmitters and transducers to protect instrumentation.

Each area includes operating conditions, as defined in ISA Standard 51.1-1979 (R1993), Process Instrumentation
Terminology. For control system instruments, very important conditions are ambient temperature, relative
humidity, harmful vapors, and electromagnetic interference.

ISA Standard 51.1-1979 (R1993), Process Instrumentation Terminology includes the following definitions of
limits:

Reference Operating Limits--Range of operating conditions within which changes in performance

characteristics are negligible.

Normal Operating Limits--Range of operating conditions within which changes in performance characteristics
are within design specifications. The limits can include operating influences which are conditions that affect
performance characteristics within a range.

Operative Limits--Range of operating conditions to which a device may be subjected without permanent
impairment of operating characteristics. Upon returning to normal operating limits, a device may require
adjustment to restore its normal performance. For DeltaV products, re-adjustment is normally not applicable.

Storage & Transportation Limits--Range of ambient conditions within which a device may be stored or
transported.

36
Dust and corrosive vapor control
Environments of airborne dust and corrosive vapor are classified as G1 through GX. Refer to ANSI ISA-S71.04-
2013, Environmental Conditions for Process Measurement and Control Systems: Airborne Contaminants, for
descriptions and classifications. Environmental control equipment is selected based on the area classification.

Temperature control
Cooling, heating, or ventilation systems are required if the temperature of the air surrounding control
instruments is outside of the instrument's nominal specified operating temperature range.

A common misconception is that the equipment can successfully operate at the limits of the product’s
specifications, such as temperature. However, in case of prolonged extreme temperature, product degradation
will occur much more rapidly. For more information, refer to Appendix E.

For room or area temperature control, the amount of cooling, heating, or ventilation is found by calculating the
heat load caused by the instruments and adding an allowance for personnel, lighting, other power equipment,
and heat gain or loss through walls and windows. The total heat load is the quantity of heat that must be
removed from the equipment area within a given period. Cooling, heating, and ventilation systems must be large
enough to handle the load.

When room or area temperature cannot be economically controlled, enclosures can be used. Within enclosures,
component placement and airflow around them must be considered.

See the white paper Effects of Heat and Airflow Inside an Enclosure for more details. It is available from your
Emerson local business partner or field sales office (LBP/FSO).

Humidity control
Relative humidity must be maintained within specified instrument operating ranges. Low relative humidity
allows electrostatic buildup and discharge, which can permanently damage instruments. High relative humidity
can result in corrosive vapors dissolving in moisture condensed on the instruments and forming acids, which can
also permanently damage instruments. Refer to Appendix J.

Environmental control during transport and storage

All instruments should be transported and stored within their specified temperature limits, relative humidity
limits, environmental classifications, and static protection. Most instrument damage from corrosive
environments occurs either during storage or during construction periods, when instruments are already installed
but not protected from a poorly controlled environment.

Emerson electronic components are supplied in static protective packaging. These Emerson-supplied DeltaV
components are often removed from their packaging and installed in an enclosure by a fabrication or integration
facility. Protection from damage due to static must be taken during installation in an enclosure and during
transport. Refer to the Electrostatic protection section of Appendix I for more information. The DeltaV DCG bar
should be grounded to the enclosure chassis with a temporary jumper until final installation and connection of
the permanent ground system. Refer to Figure 3-1 for example.

Using protective enclosures

DeltaV products are G3 rated. Enclosures are available to protect DeltaV systems from harsher environments.
Enclosures typically range from simple sheet-metal boxes to hazardous area rated enclosures. Enclosures must
dissipate internal heat so that temperatures do not exceed ratings for installed equipment.
37
Refer to Emerson’s control drawings for enclosure requirements appropriate for your process area.

Enclosure placement must consider the space needed to service, remove, or replace installed equipment.

To determine the correct enclosure, consider the following:

• Emerson’s applicable control and installation drawings

• Maximum external ambient temperature
• Maximum allowed internal temperature of the enclosure.
• Maximum rated temperature for any device in the enclosure
• Power dissipation of enclosed devices, especially power supplies (usually the greatest source of internal
heat)
• Correct I/O carrier mounting
• Adequate airflow through DeltaV I/O cards
• Wiring, raceways, and other hardware within the enclosure must allow for adequate airflow through
DeltaV I/O cards and power supplies.
• Physical dimensions of devices to be enclosed
• Placement of devices to be enclosed
• Risk of equipment damage caused by harsh environments
• Enclosure designs must consider the impact of temperature on the individual components within the
enclosure.
• Temperature sensors within the enclosure should be placed in a location to best capture and alarm the
worst-case temperature on the components.
• The enclosure design and location of fans or other methods of providing cooling or heating must avoid
hot spots within the enclosure.
• Heat-producing components such as power supplies should be placed high in the enclosure.
• Calculate the cooling requirements within an enclosure using the heat load information available for the
DeltaV components. Refer to Installing Your DeltaV Digital Automation System or DeltaV Books Online
for more information.
• DeltaV CHARMs enclosures are not designed to be mounted in direct sunlight. Use a heat shield or
other covering if the location is exposed to direct sunlight.

Refer to Appendix H for more information, and work with your Emerson local business partner or field sales
office (LBP/FSO) to obtain proper enclosures.

Industry standards for environmental conditions

Refer to the following industry standards for more environmental information:

Electrical Equipment for Measurement, Control and Laboratory Use - EMC Requirements, Publication IEC 61326-1
(2012-07). International Electrotechnical Commission.

Electrical Equipment for Measurement, Control and Laboratory Use - EMC Requirements, Publication IEC 61326-
3-1 (2017). International Electrotechnical Commission.

Electrical Equipment for Measurement, Control and Laboratory Use - EMC Requirements, Publication IEC 61326-
3-2 (2017). International Electrotechnical Commission.

38
Environmental Conditions for Process Measurement and Control Systems: Temperature and Humidity, ISA-S71.01-
1985. International Society of Automation.

Environmental Conditions for Process Measurement and Control Systems: Airborne Contaminants, ANSI/ISA-
S71.04-2013. American National Standards Institute/International Society of Automation.

DeltaV power quality

DeltaV power sources must be clean and free of noise. Highest integrity designs include clean power sources
with surge protection. Highest integrity with the highest availability requires redundant clean power sources
with surge protection.

Impulse transients exceeding 1,500 V on power feeds can destroy a channel or an entire system. Lightning causes
voltage gradients exceeding 1,500 V. Appropriate surge protection devices (SPD) should be considered. The
SPD should be sized for the worst surge area that either the power or the shields enter. Typically, bulk supplies
are certified to have either double or reinforced insulation to withstand 1500 V. The DeltaV system is protected
with transient voltage suppression to 1,500 V.

Emerson recommends that power for noise-producing equipment mounted in the cabinet or enclosure be fed
from a separate utility AC source. Small systems may not allow for a separate utility AC source. For these
systems, the noise-producing equipment such as fans, utility receptacle, and AC cabinet lighting are to be
powered on the line side of the SPDs for the DeltaV equipment.

Note: LED luminaires are better than fluorescent luminaires for DeltaV cabinets and enclosures.

Note: DC fans in DeltaV cabinets or enclosures must be non-commutating.

Refer to DeltaV power and power quality of this manual for more detailed information about power quality.

Filtering and surge suppression

Highest-integrity designs include filtering and surge-suppression devices (SPDs) on the incoming power feeds to
DeltaV power supplies.

• Type 3 SPDs are appropriate for DeltaV.

• If surge suppression is included in the field instruments connected to DeltaV, a matching suppression
device must be provided for the DeltaV I/O.
• Proper grounding for the SPDs is shown in the diagrams later in this chapter.

Refer to Chapter 2 of this manual for further guidance on filtering and surge suppression.

AC/DC bulk power supplies

AC/DC DeltaV bulk power supplies may be mounted in the same enclosures with the DeltaV hardware or in
separate bulk power supply cabinets.

The output power quality of bulk power supplies, which power the DeltaV DC system power supplies (SPS), is
very important. Large electrical noise amplitudes and large power variations on the output can be passed through
to controllers and I/O cards if they are greater than the filtering provided by the DeltaV system power supplies
and hardware.

39
AC/DC bulk power supplies available from Emerson are preferred over third-party units because they have been
evaluated for optimum performance with DeltaV basic process control systems (BPCS) and DeltaV safety
instrumented systems (SIS). In addition, they have compatible certifications with DeltaV.

However, if you purchase bulk power supplies from a third-party vendor, make sure the supplies you purchase
meet or exceeds the specifications listed in DeltaV Books Online. Select supplies with temperature ratings
appropriate for the installation environment. If necessary, install them in protective enclosures that can provide
adequate temperature control and additional environmental control.

Bulk power supply basic features

• Built-in alarm contacts
• Redundancy module for high-availability applications
• Adjustable voltage output
• Visual fault indication
• DIN-rail or panel mounting
• Fully certified for area of installation
• Must provide double or reinforced insulation from Primary to Secondary.

High-availability designs use AC/DC bulk power supply redundancy and DeltaV system power supply (SPS)
redundancy. A redundant bulk supply can be mounted in the same enclosure as a primary bulk supply or in a
separate enclosure. In either case, the redundant supply must be connected to the same DC ground bus (DCG)
as the associated primary supply.

If a redundant DeltaV DC system power supply backs up a primary DeltaV DC system power supply, the
redundant supply must be located on the same carrier system as the primary supply.

Redundant power supplies must be sized such that if one supply fails, its backup power supply has the capacity
to power the entire load. A new installation should include capability for expansion. A rule of thumb is to size
the power supply for a maximum load of 70%.

DeltaV power and grounding schema options and examples

DeltaV’s Basic Process Control Systems (BPCS) carrier-based IO and CHARMs are not required to follow a
specific recommended wiring scheme. However, Emerson encourages you to follow our highest integrity
recommendations for power and grounding installation practices. Emerson has included recommendations that
are considered less than the highest integrity for an installation for added flexibility in selecting the design that
best matches the application’s requirements. Designs with less than the highest integrity power and grounding
recommendations should be reviewed with Customer Support and the designated projects team from Emerson
during the design phase and construction phases to ensure that they meet the customer’s goals for the
installation.

To convert AC power to the 24 VDC power required for products such as system power supplies (SPS),
CHARM I/O card (CIOC), safety instrumented system (SIS) products, and DC field power, a bulk power
configuration is normally used. It is sometimes preferable to create a separate AC to DC panel that is accessible
only by qualified electricians. If the system contains only DC I/O cards, field technicians can service the DeltaV
panels without working near AC voltage sources above 50 V. Refer to NFPA70E:2015 Standard for Electrical
Safety in the Workplace.

40
Typically, 100 VAC to 230 VAC at 50 Hz or 60 Hz is supplied from power disconnect panels fed from double
conversion uninterruptable power supplies (UPS) or through isolation transformers to the AC panel. A
sufficiently sized disconnect is located before each bulk power supply.

For higher availability, AC feeds from two independent power sources supply the two bulk supplies. DC power
from one bulk power supply feeds the primary DeltaV system power supply (SPS), CIOC, CHARMs smart
logic solver (CSLS), or smart logic solver (SLS). The DC Power from the second bulk power supply feeds the
secondary SPS, CIOC, CSLS or SLS. DC Power from the two Bulk Power supplies are then fed into a dual
redundancy module to power the DeltaV I/O field power requirements. If one of the AC feeds fail or one of the
bulk power supplies fail, the redundancy module shifts the load to the remaining power supply.

All configurations should be weighed from a cost-benefit perspective. If the highest integrity and highest
availability is justified, a design with a combination of redundant bulk power supplies and redundant clean
power sources is required. Filter/Surge Suppression should be included if the AC power is not provided from a
Dual Conversion UPS or an isolation transformer.

For the highest availability, four bulk AC to DC power supplies are provided AC from the two independent
power sources with their DC outputs connected through redundancy modules for the Primary and Secondary
DeltaV System Power Supplies (SPS).

Highest integrity installations can also be accomplished utilizing a redundant pair or pairs of AC to DC bulk
power supplies in N+1 configurations.

Bulk power supply example designs

The following figures provide guidance that covers typical best practices for the schema powering and grounding
the DeltaV systems.

The figures in this chapter show several possible methods, with varying integrity and varying availability, for
providing power to S-Series or M-Series DeltaV hardware. These bulk power schemes could also be utilized to
feed DeltaV CHARMs enclosures.

Warning: In all cases, the 24 VDC return (-) terminal of the power supplies feeding DeltaV must be connected
to DeltaV DC ground. The bussed DC ground wire is connected to the DC ground isolated bus (DCG). For
wiring inside DeltaV cabinets, Emerson recommends 14 AWG (2.5 mm2) minimum wire size. Wire inside
DeltaV cabinets must be large enough to handle the maximum current of the largest bulk power supply during a
fault condition.

Figure 3-1 shows a simplex bulk power supply feeding simplex system power supplies similar to the ones shown
in Figure 3-8. Loss of the AC feed results in a loss of power the system power supplies. This results in a
controller shutdown. The field power is supplied from a separate AC to DC bulk power supply.

41
Figure 3-1Simplex DeltaV bulk power supply

Enclosure (A)

Enclosure (B) DeltaV Power

24VDC
Enclosure (C)

Fuse TB
Fuse TB
Fuse TB
Enclosure (A)

Enclosure (B) Field Power

24VDC
Enclosure (C)

Fuse TB
Fuse TB
Fuse TB

AC/DC AC/DC
Power Power
Supply Supply
PS1 PS2
AC DC 24V AC DC 24V
100-240V 100-240V
N L N L

CB1 CB3

AC Chassis DC Ground
Power Ground (CG) Temporary Jumper (DCG)
during testing and
transport Isolated Bus
Adjacent Enclosure
Enclosure door
To DIG Enclosure PE Ground Lug
To DIG
For External Ground Wire Sizes See Chapter 5

42
Figure 3-2 shows a higher availability with redundant bulk power supplies to feed the simplex system power
supplies in Figure 3-8. Each bulk power supply receives AC from a different clean power source and provides
DC power to the simplex system power supplies through a redundancy module. Loss of one of the AC feeds
does not result in a loss of the system power supplies. However, a high voltage spike that gets through a bulk
power supply, or a power supply that fails to a high DC voltage might result in loss of the system power supplies
and a controller shutdown. The field power is supplied from a separate redundant AC to DC power supply pair
with a redundancy module.

43
Figure 3-2 Redundant bulk power for simplex controllers

Enclosure (A)

Enclosure (B) DeltaV Power

24VDC
Enclosure (C)

Fuse TB
Fuse TB
Fuse TB
Enclosure (A)
Field Power
Enclosure (B)
24VDC
Enclosure (C)

Fuse TB
Fuse TB
Fuse TB
Chassis Chassis
Ground Ground

Output Output

AC/DC
Max.

AC/DC AC/DC
Max.
80A 80A
AC/DC
Power Dual
Redundancy
Power Power Dual
Redundancy
Power
Supply Module Supply Supply Module Supply
PS1 PS2 PS3 PS4
AC DC 24V Input 1 Input 2 AC DC 24V AC DC 24V Input 1 Input 2 AC DC 24V
DC 24-28V DC 24-28V DC 24-28V DC 24-28V
100-240V 40A 40A
100-240V 100-240V 40A 40A
100-240V

N L N L N L N L

CB1 CB2 CB3 CB4

Primary
AC Power

Secondary
AC Power
Chassis DC Ground
Ground (CG) Temporary Jumper (DCG)
during testing and
transport Isolated Bus
Adjacent Enclosure
Enclosure door For External Ground
To DIG Enclosure PE Ground Lug Wire Sizes See Chapter 5
To DIG

Filter/surge-suppression devices are added in the following figure for added protection if the AC power sources
are not provided from a UPS or Isolation transformer or if the area has a high susceptibility to lightning or
disruptive power events.

44
Figure 3-3 Redundant bulk power simplex controller with surge protection

DeltaV Power
24VDC

Fuse TB
Field Power
24VDC

Fuse TB
Chassis Chassis
Ground Ground

Output Output

AC/DC AC/DC AC/DC

Max.

AC/DC
Max.
80A 80A

Power Dual
Redundancy
Power Power Dual
Redundancy
Power
Supply Module Supply Supply Module Supply
PS1 PS2 PS3 PS4
AC DC 24V Input 1 Input 2 AC DC 24V AC DC 24V Input 1 Input 2 AC DC 24V
DC 24-28V DC 24-28V DC 24-28V DC 24-28V
100-240V 40A 40A
100-240V 100-240V 40A 40A
100-240V

N L N L N L N L

N L N L
SPD with

SPD with
Filter

Filter

CB3 CB4

N L N L

CB1 CB2

Primary
AC Power

Secondary
AC Power Chassis DC Ground
Ground (CG) Temporary Jumper (DCG)
during testing and
transport Isolated Bus
Adjacent Enclosure
Enclosure door For External Ground
To DIG Enclosure PE Ground Lug Wire Sizes See Chapter 5
To DIG

The following figure shows higher availability using two bulk power supplies to independently feed the primary
and secondary System Power Supplies. DeltaV field instrumentation power is fed from a redundant pair of bulk
power supplies.

45
Figure 3-4 Redundant independent bulk power supplies for redundant controllers

Primary DeltaV
Power
24VDC

Fuse TB
Secondary DeltaV
Power
24VDC

DeltaV

Fuse TB
Field Power
24VDC

Fuse TB
Chassis
Ground

Output
Max.

AC/DC AC/DC AC/DC AC/DC

80A

Dual
Power Power Power Redundancy
Power
Supply Supply Supply Module Supply
PS1 PS2 PS3 PS4

AC DC 24V AC DC 24V AC DC 24V Input 1 Input 2 AC DC 24V

DC 24-28V DC 24-28V
100-240V 100-240V 100-240V 40A 40A 100-240V

N L N L N L N L

CB1 CB2 CB3 CB4

Primary
AC Power

Secondary
AC Power Chassis DC Ground
Ground (CG) Temporary Jumper (DCG)
during testing and
transport Isolated Bus
Adjacent Enclosure
Enclosure door For External Ground
To DIG Enclosure PE Ground Lug Wire Sizes See Chapter 5
To DIG

Each bulk power supply receives AC from a different clean power source and provides DC power to either a
primary system power supply or a secondary system power supply. The primary bulk supply backs up a primary
system power supply and the secondary bulk power supply backs up a secondary system power supply. The field
46
power is supplied from a separate redundant AC to DC power supply pair with a redundancy module. In this
scheme, the failure of an AC power sources or the loss of one of the bulk supplies will result in the primary
controller switching its control to the secondary controller. The controllers are fully redundant and designed to
switchover the control bumpless.

The practice of connecting a set of power supplies through OR’ing diodes with a common connection to the
primary and secondary System Power Supplies is not recommended. This method was followed for many years
as a lower cost approach to providing power supply redundancy. With the OR’ing diode approach, a single
point failure between the Primary and Secondary DeltaV controllers connected to the same voltage supply can
occur. This method can result in process upsets when high DC voltage causes both the primary and secondary
controllers to shut down. While not a normal failure mode, a power supply can fail at higher than the acceptable
DC voltage for the System Power Supply, resulting in a controller shutdown. Additionally, a high voltage spike
might pass through a DC power supply and result in the primary and secondary shutdown on high voltage.
Clean power and surge protection from Isolation/Regulation transformers or additional SPDs are required for
feeding power supplies in this OR’ing diode schema due to the added risk. If a project decides to utilize this
approach, the risks need to be fully understood and evaluated with the customer and project team.

Figure 3-5 shows the highest availability and highest integrity scheme. This configuration provides a redundant
power supply pair with a redundancy module for each the primary and the secondary system power supply feeds.
For highest integrity, it includes filter/surge suppression devices (SPDs) added on the AC feeds to the bulk
power supplies. This is important if the AC power sources are not from a double conversion UPS or from proper
isolation transformers. These SPDs might also be required if the AC power feeds to the bulk power supplies are
long or if the area has a high susceptibility to lightning or disruptive power events.

47
Figure 3-5 Highest integrity and highest availability

Primary
DeltaV Power
24VDC

Secondary

Fuse TB
DeltaV Power
24VDC

Fuse TB
Chassis Chassis
Ground Ground

Output Output

AC/DC
Max.

AC/DC AC/DC
Max.
80A 80A
AC/DC
Power Dual
Redundancy
Power Power Dual
Redundancy
Power
Supply Module Supply Supply Module Supply
PS1 PS2 PS3 PS4
AC DC 24V Input 1 Input 2 AC DC 24V AC DC 24V Input 1 Input 2 AC DC 24V
DC 24-28V DC 24-28V DC 24-28V DC 24-28V
100-240V 40A 40A
100-240V 100-240V 40A 40A
100-240V

N L N L N L N L

N L

N L N L
SPD with

N L
Filter

SPD with
SPD with

SPD with
Filter
Filter

Filter
N L

N L N L
N L

CB1
CB2 CB3
CB4

Primary
AC Power

Secondary Chassis DC Ground

AC Power Ground (CG) Temporary Jumper
(DCG)
during testing and
transport Isolated Bus
Adjacent Enclosure
To DIG Enclosure door For External Ground
Enclosure PE Ground Lug Wire Sizes See Chapter 5
To DIG

Note: Field power supplies are not shown.

This scheme avoids a signal point of failure in the power feed circuits. Each pair of bulk power supplies would
have feeds from two independent clean power sources. Loss of a single AC feed or loss of a single bulk power
supply does not result in a loss of power to any of the system power supplies.

48
A separate redundant pair of bulk power supplies with redundancy module would supply field instrumentation
power.

Highest integrity requires AC from dedicated clean power. This can be accomplished with isolation transformers
or UPSs, or by adding filter surge suppression.

DC/DC bulk power supplies

If you use existing plant DC, isolate the plant power from process instrumentation by using 24 V DC/DC
power supplies certified for your location to provide the DeltaV 24 VDC power. For redundant 24 VDC power,
use two DC/DC power supplies, each wired separately. Transient noise due to other equipment connected to
the 24 VDC supply system, or transient noise induced on long DC cable runs, can interfere with the control
system. For the highest integrity, install a surge suppression device immediately before the DC/DC converter.
When power is provided from a plant DC source, a separately derived ground will be accomplished by the use
DC/DC power supplies. DC/DC supplies assures criteria A is maintained as stated in IEC 61326-1, which states
that equipment will operate normally in the presence of a potential disruptive event. (Refer to Figure 2-3.)
Figure 3-6 and Figure 3-7 provide examples of applications using existing 24 VDC power systems.

49
Figure 3-6 Simplex plant DC power

DeltaV Power
24VDC
Field Power

Fuse TB
24VDC

Fuse TB
Output Output
24VDC 24VDC

DC/DC DC/DC
Power Power
Supply Supply
PS1 PS2
Input Input
24VDC 24VDC

L N L N

Optional DC SPD
SPD

SPD

L N L N

CB1 CB2

24VDC Nominal

Chassis DC Ground
Ground (CG) (DCG)

Isolated Bus
Adjacent Enclosure
Enclosure door
To DIG Enclosure PE Ground Lug
For Wire Sizes See Chapter 5
To DIG

50
Figure 3-7 Redundant 24 VDC plant power

Primary DeltaV
Power 24VDC
Secondary DeltaV

Fuse TB
Power 24VDC

DeltaV

Fuse TB
Field Power
24VDC

Fuse TB
Output
Output Output
24VDC
24VDC 24VDC

DC/DC DC/DC DC/DC

Power Power Power
Supply Supply Supply
PS1 PS2 PS3
Input Input Input
24VDC 24VDC 24VDC

L N L N L N

Optional DC SPD
SPD

SPD

SPD
Optional DC SPD

L N L N L N

CB1 CB2 CB3

24VDC Nominal

24VDC Nominal

Chassis DC Ground
Ground (CG) (DCG)
Isolated Bus
Adjacent Enclosure
Enclosure door
To DIG Enclosure PE Ground Lug
To DIG
For Wire Sizes See Chapter 5

The power supply configuration in Figure 3-7 can supply power to DeltaV systems such as those shown in
Figure 3-9, Figure 3-11, and Figure 3-12.
51
For additional information, refer to the DC distribution system section of Chapter 2 and DC feed to DeltaV
CHARMs enclosure from bulk power supply cabinets or from plant DC power systems later in this chapter.

DeltaV DC system power supply (SPS)

The DeltaV DC/DC system power supply (SPS) provides additional filtering for the DeltaV controllers and
carrier-mounted I/O Cards. The SPS receives DC power from bulk power supplies or other in-plant DC
sources. The SPS accepts input power at 24 VDC.

Note: M-Series system power supplies are available for use with AC power feeds or 12 VDC bulk power supply
feeds. Emerson recommends using 24 VDC bulk power supply feeds to the DeltaV hardware for all new or
upgraded installations.

DC power wire size

Select the size and length of DC power wiring to minimize the voltage drop between a DC bulk power supply
and the DeltaV hardware (typically 3% or less as described NFPA 70 Article 210.19). Wire sizes between the DC
bulk power supply source and the DC power distribution system are often between 6 and 14 AWG (16 to 2.5
mm2), dependent on the design of your bulk power supply system.

Although 14 AWG is frequently used inside cabinets, caution should be exercised, because larger wire sizes may
be necessary to accommodate for losses in the cable. Design for the worst case to ensure that the voltage, with
the system fully loaded, meets Emerson’s voltage recommendations in this manual and in DeltaV Books Online.

Adjusting system power supply input voltage

When all system power supply wiring is complete and before process startup, measure voltages across the DeltaV
System Power Supply (SPS) input terminals. Emerson recommends measuring voltages at SPS input terminals
because measuring at the bulk power supply does not account for losses. If the bulk supplies have voltage-
adjustable outputs, adjust each bulk supply to obtain 24 +/- 0.2 V at each SPS.

Note: For M-series systems with 12 VDC SPS input, adjust the voltage to obtain 12.3 VDC.

Consider adding a voltage check to your regular preventative maintenance schedule.

Equalizing supply output voltage with redundancy modules

If your system power supply redundancy, balancing the load between bulk power supplies is a best practice.
Some power supplies include load-sharing circuitry, but in other cases you should adjust the voltage outputs. Set
the voltage outputs of two power supplies to within 0.2 V.

DeltaV cabinet and enclosure grounding

For system power supplies powered by 24 VDC, or M-Series SPS fed from AC power sources, connect the SPS
return to the DCG bus bar, as shown in the following figures.

52
Figure 3-8 Simplex S series controller

14 AWG (2.5mm2)
Field … Field Devices as required
Power
24VDC Note: Bulk Power DC- must be referenced to DCG. This diagram is based on
the DC- reference for the grouping of DeltaV cabinets being implemented at
the Bulk Power Supplies. This reference connection can be accomplished in
the DeltaV cabinet, or in the Bulk Power Supply Cabinet.
DeltaV
Power Note: Do not connect System Power Supply(SPS) reference to DCG for M-Series fed from
24VDC 12Vdc Bulk Power.

14 AWG
(2.5mm2) DC Ground
(DCG)
Isolated Bus
14 AWG (2.5mm2)
Chassis Ground Adjacent Enclosure 6 AWG (16mm2)
To DIG (CG) Enclosure door
To DIG For Wire Sizes See Chapter 5 Enclosure PE Ground Lug (Minimum)

53
Figure 3-9 Redundant S Series Controller

The following figure shows a redundant M-Series System Power Supply (SPS) with extended power.

54
Figure 3-10 m-Series with extended carrier power

Primary
24 VDC
Secondary
24 VDC

Fuse TB
Fuse TB
Field

Fuse TB
Fuse TB
Power
24 VDC

Fuse TB
Fuse TB
Cards
Field
Power
24 VDC

Jumper

Jumper

Jumper

Jumper

DC Ground
Chassis
(DCG)
Ground (CG)
Isolated Bus
DIG Adjacent Enclosure Door
Enclosures DIG Enclosure PE Ground Lug
Adjacent Enclosures
For External Ground
Wire Sizes See Chapter 5

55
Note: For M-Series systems with 12 VDC SPS input, do not attach the SPS return to the carrier ground
terminal. The SPS provides the ground reference through the 12 VDC return.

Note: Never daisy-chain the DC return to bulk power supplies and then to the DCG bus bar. This creates DC
return current flow in the DCG bus bar. Always tie an individual wire from the negative or return of each bulk
power supply to the DCG bus bar.

DC ground wires should always be as short as possible and, where several are routed to a DCG bus bar, should
be routed as close to each other as possible.

Chassis ground (CG)

The DeltaV cabinet/enclosure chassis ground (CG) bus internal to the enclosure provides the low impedance
path to the DeltaV Instrument Ground (DIG) as described in Chapter 5. Connect the incoming power feeds’
equipment grounding conductors, all internal components’ chassis grounds, enclosure doors, and the cabinet
ground stud to this bar. The best practice is to connect signal cable shield bars to the chassis ground bus(CG).

Connect this CG bus to the Local Area DeltaV Chassis Bus bar, or directly to the DeltaV Instrument Ground
(DIG), with properly sized ground cables as defined in Chapter 5.

Chassis ground must remain separate from all DC ground reference connections. In a group of bayed enclosures,
grounds should be routed to the center enclosure when possible.

DC ground (DCG)
The DeltaV DC ground maintains a stable low-noise reference for the DeltaV signal returns and DC power
supply commons.

The DeltaV DC ground system is what IEC refers to as functional earth or functional earthing, as noted in
Chapter 1 of this manual. NFPA 70 National Electrical Code does not have an equivalent term.

DC Ground (DCG) bus is DeltaV’s isolated ground reference. Connect the DC power supplies’ negative returns
reference to the DCG bus. To avoid ground loops and DC- currents from flowing through the DCG, connect
the DC- for a power supply or a redundant power supply pair to the DCG once. This connection can be made
within the DeltaV cabinet, or in the DC bulk power supply cabinet if separate from the DeltaV cabinet. The
diagrams provided in this manual show this connection in the DC bulk power supply cabinets when multiple
DeltaV cabinets are fed from on bulk power supply system. This ensures a solid return reference for the DC
power supplies and minimizes possible currents flowing through the DCG system.

DC ground busses inside the enclosure are isolated from the enclosure metal and serve as the termination point
for DC grounds to maintain a zero equipotential.

DeltaV components operate on DC. A signal change is quantified as the change from a reference. The DC
negative is the reference used by DeltaV. DeltaV components that are connected to DC negative references at
different potentials can yield inaccurate measurements. Referencing all DC negatives by terminating at one
reference point and isolating/insulating the references from all external sources that could bias the reference
potential ensures the functionality and accuracy of the signals.

DC ground wires should be insulated to avoid unintentional ground loops that can occur if bare ground wires
touch metal enclosure framing or each other.

56
After installation and prior to process startup, verify these DCG wires and bus bar are properly isolated from the
CG and cabinet enclosure. Refer to the checklists in Appendix I for verifying site power and grounding.

Connect the enclosure DCG bus to the local area DeltaV DC bus bar, or directly to the DIG.

Shield termination and grounding

Ground shields at one end only to prevent ground loops. If a shield is connected to a carrier shield bar or a CG
bus, do not connect it to the field device. Figure 4-1, Figure 4-2 and Figure 4-4 are illustrations of correct shield
ground connections.

Ground shields to a chassis ground and not to the DC ground. Shield grounding at the DCS cabinet can be
accomplished using the DeltaV carrier shield bars, or by installing a separate shield bar. Shield bars are to be
connected to the CG bus.

M-series horizontal and vertical narrow shield bars

When carriers are plugged into each other, carrier shield bar continuity may be accomplished with jumpers, and
then one connection made from the chain to a CG ground bus. However, when carriers are connected by carrier
extenders, never jumper shield bars across the extension. At extensions, connect shield bars to a CG ground bus
as shown in Figure 3-10.

S-series and M-series vertical wide shield bars

For S-series and M-series vertical wide shield bars, shield bar continuity is maintained through the carrier
backplane connectors. Figure 3-11 and Figure 3-12 illustrate this for S-series.

CHARMs shield bars

Shield bar continuity is maintained through the baseplate backplane connectors, as shown in Figure 3-11.

Supplying additional power to extended I/O carriers

A single set of System Power Supplies may not supply the current requirements for multiple carriers filled with
cards that require more power. Additional System Power Supplies can be installed to power the additional carrier
loads. Refer to DeltaV Books Online for information about using additional System Power Supplies. Figure
3-10, Figure 3-11, and Figure 3-12 show recommended solutions for M-series and S-series power and grounding
with extended carrier power.

57
Figure 3-11 s-series redundant extended power to left extender

58
Figure 3-12 S-Series redundant extended power between extender and carriers

Power and grounding for DeltaV CHARMs

Because CHARMs are often used in remote locations, they usually have dedicated local redundant power
supplies. If CHARM I/O subsystems are powered by AC sources, the power must be very clean. This clean
power is usually obtained by isolation transformers located close to the CHARM cabinet. For higher availability
and higher integrity, provide power from UPS circuits or a combination of a UPS for the primary power and an
isolation transformer for the secondary power. In addition to the UPS and isolation transformers, type 2 surge

59
suppressors can be installed before the isolation transformers. If the distance between the transformer and the
DeltaV enclosure is greater than 100 meters, a type 3 SPD should be installed before the bulk power supplies as
shown in Figure 3-7. In an area highly susceptible to noise, both the type 2 and type 3 SPDs should be installed
in their respective locations to obtain the highest integrity and availability.

A clean power source for DeltaV is considered power that is at or better than stated in EN 61000-3-11
Electromagnetic compatibility (EMC) – Part 3-11: Limitation of voltage changes, voltage fluctuations and flicker in
public low-voltage supply systems –Equipment with rated current ≤75 A and subject to conditional connection, and
EN61000-3-12: Electromagnetic compatibility (EMC) –Part 3-12: Limits for harmonic currents produced by
equipment connected to public low-voltage systems with input current >16A and ≤75 A per phase.

Separately Derived Ground and Power Source Close to the CHARMs enclosure
If the distance to the AC power source is short (less than a few meters); communication to the DeltaV controller
is through fiber; and there is no galvanic connection to any other field devices, then the chassis ground and DC
ground can be connected together inside the cabinet. This permits the use of one cable from the junction box
(JB) to the next ground location. For example, if the optically isolated CHARM JB is attached to the steel girder
on a drilling rig with the transformers also mounted to the steel directly under the JB, then weld the ground bar
to the steel close to the transformers to establish both a separately derived protective earth and JB equipment
ground (earth).

Power and Grounding Scenarios for CHARMs Enclosures

24 VDC power for the CHARMS can be provided with Power Supplies within the CHARMs enclosure, from
Bulk Power Supply Cabinets, or from Plant DC power systems.

The following figure shows a high-integrity power and grounding scheme for a CHARM enclosure.

60
Figure 3-13 High-integrity power and grounding for a CHARM enclosure

CHARM Enclosure

Communications with
DeltaV Should be
connected via. Fiber-
optic cable for distance
exceeding 200 ft.
DC ok

AC/DC
Power
Supply
Isolation
Transformer
PS1 PS2

AC 100-240V

N L

Follow CB1 CB2

local
codes

Isolation
Transformer

Follow Temporary Jumper

Follow local during testing and
local codes
codes transport

Isolated Bus
Chassis Ground
(CG) DC Ground(DCG)
See Chapter 5 for
correct wire size

Wire sized equal

or greater than
maximum power Building Steel
feed DIG

The following figure adds surge suppression devices to achieve the highest integrity design if the isolation
transformer is not close to the CHARM enclosure or if the area includes a high risk of electrical noise.

61
Figure 3-14 Highest-integrity power and grounding for a CHARM enclosure

CHARM Enclosure

Communications with
DeltaV Should be
connected via. Fiber-
optic cable for distance
exceeding 200 ft.

Isolation
Transformer

N L N L

SPD SPD

N L N L

G CB
1
CB
2

Follow
local
codes

Isolation
Transformer

Follow
local
codes

Isolated Bus
Chassis Ground
Wire sized equal
(CG) DC Ground(DCG)
or greater than
maximum power
feed See Chapter 5 for
correct wire size

Building Steel
DIG

Customers with a Separate Isolated Shield Ground System

Some customers maintain a separate Isolated Shield grounding scheme. The following design adds a third
isolated shield ground bar to support the customer’s standard for maintaining an isolated shield ground system,
and meets Emerson’s best practice of keeping shield grounding separate from the DC ground system.

62
Figure 3-15 High-integrity CHARM with added shield bus

CHARM Enclosure

Communications with
DeltaV Should be
connected via. Fiber-
optic cable for distance
exceeding 200 ft.

Isolation
Transformer

AC Feed 1
N

G CB
1
CB
2

Follow
local
codes

Isolation
Transformer

AC Feed 2
N

Follow
local
codes

Chassis Ground Isolated Bus

(CG) DC Ground(DCG) Shield Bus
See Chapter 5 for
correct wire size
Wire sized equal
or greater than
maximum power
feed
Building Steel
DIG

DC feed to DeltaV CHARMs enclosure from bulk power supply cabinets or from plant DC power systems
Bulk 24VDC power can be supplied to the CHARMs cabinet. A DC/DC power supply is recommended for
distances greater than 100 ft. or when using an existing plant DC distribution system. For more information,
refer to the DC distribution system section of Chapter 2 and the DC/DC bulk power supplies section of this
chapter.

63
Figure 3-16 CHARMs with DC supply

CHARM Enclosure

Communications with
DeltaV Should be
connected via. Fiber-
optic cable for distance
exceeding 200 ft.

DC/DC DC/DC
Power Power
Supply Supply
PS1 PS2

Optional DC SPD
L N L N
SPD

SPD

L N L N

CB1 CB2

24VDC Nominal

24VDC Nominal

Follow local
codes for
PE Ground

DC Ground Chassis Ground

(DCG) Isolated Bus (CG)

For External Ground

wire sizes see Chapter 5

Building Steel
DIG

64
Warning labels
Warning labels are a best practice, very important for personnel safety, and required by local codes. Warning
labels are required by the applicable codes and regulations and often require multiple languages per these codes.
Refer to Appendix H for some examples of typical warning labels.

Hazardous area design and installation

Power and grounding design for hazardous areas must meet the applicable codes and regulations for the regional
area of installation and must be implemented in accordance with the manufacturer’s control drawings or
installation instructions. In applications where flammable vapors, liquids, or gases may be present, special wiring
practices or other special handling must be used. The design and installation must be implemented by qualified
design personnel.

In North America, hazardous locations are separated into three Classes based on the explosive characteristics of
the materials. The classes of material are further separated into Divisions or Zones based on the risk of fire or
explosion that the material poses. The Zone system has three levels of hazard. The Division system has only two
levels.
Table 3-1 Hazardous materials Classes, Divisions, and Zones

Hazardous materials Class/Division system Zone system

Gasses or vapors Class I, Division 1 Zone 0

Class I, Division 2 Zone 1
Zone 2

Most DeltaV control products can be installed in Class I Division 2, and Zone 2 in egress protection IP54
enclosures. The range of DeltaV products can interface to field instrumentation in Hazardous areas including
Class I Division 1, Class I Division2, Zone 0, Zone 1, and Zone 2. Refer to NFPA70 Article 500 and IEC 60079
series.

IEC 60079-14:2013 defines Zones as follows:

Hazardous area-- area in which an explosive atmosphere is present, or may be expected to be present, in
quantities such as to require special precautions for the construction, installation and use of equipment.

Zones--hazardous areas classified into zones based upon the frequency of the occurrence and duration of an
explosive atmosphere.

Zone 0--place in which an explosive atmosphere consisting of a mixture with air of flammable substances in the
form of gas or vapour is present continuously or for long periods or frequently.

Zone 1--place in which an explosive atmosphere consisting of a mixture with air of flammable substances in the
form of gas or vapour is likely to occur in normal operation occasionally.

Zone 2--place in which an explosive atmosphere consisting of a mixture with air of flammable substances in the
form of gas or vapour is not likely to occur in normal operation but, if it does occur, will persist for a short
period only.

65
NFPA 70:2017 Article 500 defines Class I locations as follows:

Class I Locations. Class I locations are those in which flammable gases, flammable liquid–produced vapors, or
combustible liquid–produced vapors are or may be present in the air in quantities sufficient to produce explosive
or ignitable mixtures.

Qualifications of personnel
In accordance with IEC 60079-14: 2013, the design of the installation, the selection of equipment, and the
erection of DeltaV shall be carried out only by persons whose training has included instruction on the various
types of protection and installation practices, relevant rules and regulations, and general principles of area
classification. The competency of persons shall be relevant to the type of work to be undertaken.

Appropriate continuing education or training shall be undertaken by personnel on a regular basis.

Note: Competency may be demonstrated in accordance with a training and assessment framework relevant to
national regulations or standards or user requirements.

Control drawings and installation instructions

Emerson provides control and installation instructions as part of the documentation installed with DeltaV.
These are available through Guardian support. The qualified system design personnel must verify the latest
control and installation documents for the system being designed. Contact Emerson’s Local Business Partner or
Field Sales Office to obtain a copy of the current documentation for the version of DeltaV you are using. Refer
to Appendix E for a listing of Emerson’s control and installation documents.

Zone 1 carrier power and grounding

For information about DeltaV Zone 1 equipment wiring, see Drawing 12P3292, DeltaV Type KJ7000 Series
Zone 1 I/O System Installation Instructions, and general installation information in DeltaV Books Online.

Intrinsic safety considerations

Incorporating intrinsically safe I/O systems
Intrinsically safe (IS) I/O systems are approved for instrumentation in hazardous areas. DeltaV IS solutions do
not require separate barriers and are easy to install.

The following requirements are important to consider in IS applications:

• Entity parameters must be verified and documented for intrinsically safe circuits.
• Codes and regulations require separation between intrinsically safe circuits and non-intrinsically safe
circuits.
• Shielding and grounding installation must meet all applicable codes and regulations
• Surge protection may be required if the risk assessment identifies susceptibility to lightning or other
surges, in accordance with IEC 60079-25:2010 section 12.
• Design must follow the vendor’s control and installation documents.

When using original equipment manufacturer (OEM) intrinsically safe I/O systems, consult the manufacturer's
power and grounding instructions for proper interface with DeltaV systems.

For more intrinsic safety information, refer to ISA-RP12.06.01-2003, Recommended Practice for Wiring Methods
for Hazardous (Classified) Locations Instrumentation Part 1: Intrinsic Safety; IEC 60079-11, Explosive atmospheres–

66
Part 11: Equipment protection by intrinsic safety "i"; IEC 60079-14, Explosive atmospheres – Part 14: Electrical
installations design, selection and erection; IEC 60079-25, Explosive atmospheres – Part 25: `Intrinsically safe
electrical systems; and NFPA70 National Electrical Code Article 504 Intrinsically Safe Systems.

IS CHARMs
IS CHARMs do not require separate barriers. Control drawings for IS CHARMs system can be found in
Appendix E. The IS circuit is a galvanically isolated circuit, isolated from earth in accordance with IEC 60079-
14:2013 Section 16.2.3 a.

The DC power supply reference for the CHARMs is to be connected to the isolated DC ground bus.

The following excerpt is from IEC 60079-25:2010 Section 11 Earthing and bonding of intrinsically safe systems:

In general, an intrinsically safe circuit shall either be fully floating or bonded to the reference potential associated
with a hazardous area at one point only. The level of isolation required (except at that one point) is to be
designed to withstand a 500 V insulation test in accordance with the dielectric strength requirement of IEC
60079-11. Where this requirement is not met, the circuit shall be considered to be earthed at that point. More
than one earth connection is permitted on a circuit, provided that the circuit is galvanically separated into sub-
circuits, each of which has only one earth point.

Screens shall be connected to earth or the structure in accordance with IEC 60079-14. Where a system is
intended for use in an installation where significant potential differences (greater than 10 V) between the
structure and the circuit can occur, the preferred technique is to use a circuit galvanically isolated from external
influences such as changes in ground potential at some distance from the structure. Exercise particular care if
part of the system is intended to be used in Zone 0 or Zone 20 locations or when the system has a very high level
of protection so as to conform to EPL Ma requirements.

The following is from IEC 60079-14:2013 Section 16.3 Installations to meet the requirements of EPL “Ga” or
“Da”:

If part of an intrinsically safe circuit is installed in locations requiring EPL “Ga” or “Da” such that the apparatus
and the associated apparatus are at risk of developing hazardous potential differences within the locations
requiring EPL “Ga” or “Da”, e.g., through the presence of atmospheric electricity, a surge protection device shall
be installed between each non-earth bonded core of the cable and the local structure as near as is reasonably
practicable, preferably within 1 m, to the entrance to the locations requiring EPL “Ga” or “Da”. Examples of
such locations are flammable liquid storage tanks, effluent treatment plants and distillation columns in
petrochemical works. A high risk of potential difference is generally associated with a distributed plant and/or
exposed equipment location, and the risk is not alleviated simply by using underground cables or tank
installation.

The surge protection device shall be capable of diverting a minimum peak discharge current of 10 kA (8/20 μs
impulse according to IEC 60060-1, ten operations). The connection between the protection device and the local
structure shall have a minimum cross-sectional area equivalent to 4 mm2 copper.

Note: The IEC acronym EPL refers to Equipment Protection Level, which is related to Hazardous Area Zones.

67
IS CHARMs shield bars
Several methods for connecting the screens to earth are viable. Signal cable screens must be connected in a
method that meets the codes and regulations for your region. One method is to connect the baseplate screen to
the CG ground bus bar, which is connected to the hazardous area ground system through the DIG, as shown in
the following figure.
Figure 3-17 IS CHARMs enclosure

IS CHARM Enclosure

Communications with
DeltaV Should be
connected via. Fiber-
optic cable for distance
exceeding 200 ft.
DC ok

AC/DC
Power
Supply
Isolation
Transformer
PS1 PS2

AC 100-240V

N L

Follow CB1 CB2

local
codes

Isolation 2
Transformer

Follow
Follow local
local codes
codes

Isolated Bus
Chassis Ground
(CG) DC Ground(DCG)

For External Ground Wire

Sizes See Chapter 5

Wire sized equal

or greater than
maximum power Building Steel
feed DIG-Must be connected to IS
Equipotential Ground System
with less than 1 ohm

Flexibility is provided with IS CHARMs to separate IS and non-IS shields. IS baseplate shield bars are isolated
from non-IS baseplate shield bars. The following figure references both the IS and non-IS shield bars to the CG
bar.

68
Figure 3-18 IS with non-IS CHARMs enclosure

-
Non IS / IS CHARM
Enclosure

Communications with
DeltaV Should be
connected via. Fiber-
optic cable for distance
exceeding 200 ft.
DC ok

AC/DC
Power
Supply
Isolation
Transformer
PS1 PS2

AC 100-240V

N L

N 1

Follow CB1 CB2

local
codes

Isolation 2
Transformer

Follow
Follow local
local codes
codes

Isolated Bus
Chassis Ground
(CG) DC Ground(DCG)

For External Ground Wire

Sizes See Chapter 5

Wire sized equal

or greater than
maximum power Building Steel
feed DIG-Must be connected to IS
Equipotential Ground System
with less than 1 ohm

Some customers request a separate IS Isolated Ground system in the CHARMs enclosure connected to the
hazardous area ground system.

69
Figure 3-19 IS CHARMs with separate IS shield bus

Non IS / IS CHARM
Enclosure

Communications with
DeltaV Should be
connected via. Fiber-
optic cable for distance
exceeding 200 ft.
DC ok

AC/DC
Power
Supply
Isolation
Transformer
PS1 PS2

AC 100-240V

N L

N 1

Follow CB1 CB2

local
codes

Isolation 2
Transformer

Follow
Follow local
local codes
codes

Isolated Bus
Chassis Ground
(CG) DC Ground(DCG) IS Shield Bar

For External Ground Wire

Sizes See Chapter 5

Wire sized equal To IS Equipotential

or greater than
maximum power Building Steel Ground
feed DIG

These ground methods provide proper electrical grounding for the IS CHARMs system. For more information,
refer to ISA-RP12.06.01-2003 Recommended Practice for Wiring Methods for Hazardous (Classified) Locations
Instrumentation Part 1: Intrinsic Safety.

IS carrier-based cards
The DeltaV M-Series IS power supply and Localbus Isolator provide isolation between M-Series IS cards and
the Delta non-IS system. The DC output of the IS power supply connects directly to the IS I/O cards through

70
the carrier backplane. The Localbus Isolator electrically isolates IS I/O cards from non-IS I/O cards. The
following figure shows the locations of the power supply and isolator on the IS I/O carrier.
Figure 3-20 IS Carrier based IO cards

The DC reference for the carrier is connected from the carrier grounding lug to the DC ground bus. The carrier
shield bar is connected to the chassis ground (CG) bus. These grounds provide proper electrical ground for the
I/O cards and the IS power supply. Power leads to the IS power supply are connected to a 24 VDC bulk power
supply. The IS power supply negative (-) terminal is grounded through the DC return reference ground at the
bulk power supply negative (-) terminal.

Power and grounding for DeltaV Safety Instrumented Systems (SIS)

DeltaV Safety Instrumented Systems (SIS) are required to follow the highest integrity recommendations for
installation, power, and grounding to meet warranty and support criteria. SIS includes all installations with
SLS1508 or CSLS in part or whole.

Safety Critical SIS component power

Safety Critical SIS components, such as SIS logic solvers and SISNet Repeaters, require 24 VDC power.
Although the power connectors on SLS1508 logic solvers and SISNet Repeaters have two positive and two
negative terminals, never daisy-chain power. Daisy-chaining can result in a loss of power to downstream
modules or repeaters if power is removed or lost at upstream modules or repeaters. In addition, a fault on one
component of the daisy chain devices can impact all components.

71
Using bulk power supplies in DeltaV SIS systems
DeltaV SIS systems should always use highest-availability and highest-integrity redundant power schemes with
bulk power supplies in the schemes. If one bulk supply fails, the other bulk supply takes up the whole load. The
following figures all show highest-integrity power and grounding schemes with varying levels of availability.
Highest integrity designs include surge/filters to provide clean power to the DeltaV SIS systems. This can be
accomplished with Type 3 SPDs for the CHARMs power supplies. Isolation transformers or double conversion
UPSs are acceptable if close to the CHARMs. If the distances from the power sources are further away, or if
there is a high lightning or disruptive risk, additional SPDs will be required. Refer to the Protection from surges
and lightning section of Chapter 2.

72
Figure 3-21 SLS redundant power - high integrity with good availability

Primary SLS
Power
24VDC

Fuse TB
Secondary SLS
Power
24VDC

Fuse TB

AC/DC AC/DC
Power Power
Supply Supply
PS1 PS2

AC DC 24V AC DC 24V
100-240V 100-240V
N L N L

N L
N L
SPD with

SPD with
Filter

Filter

N L
N L

CB1

CB4

Primary
AC
Power

Secondary Chassis DC Ground

AC Power Ground (CG) (DCG)

Isolated Bus
Adjacent Enclosure
Enclosure door
To DIG For External Ground Enclosure PE Ground Lug
Wire Sizes See Chapter 5
To DIG

73
Figure 3-22 SLS redundant power with isolation transformers and surge suppression

Enclosure
Primary SLS

Fuse TB
Power
24VDC

Secondary SLS
Power

Fuse TB
24VDC

AC/DC AC/DC
Power Power
Supply Supply
PS1 PS2

AC DC 24V AC DC 24V
100-240V 100-240V
N L N L

N L
N L

Isolation
SPD

SPD
Transformer

N L
N L

AC Feed 1

N
CB1 CB4

Isolation
Transformer

Follow
AC Feed 2 local
codes
N

Isolated Bus
G DC Ground
Chassis
Wire sized equal
Ground (CG) (DCG)
or greater than
maximum power
feed
Adjacent Enclosure
For External Ground
Enclosure door
Wire Sizes See Chapter 5 Enclosure PE Ground Lug
DIG

74
Figure 3-23 SLS redundant power - highest integrity with highest availability

Primary SLS
Power 24VDC

Fuse TB
Secondary SLS
Power24VDC

Fuse TB
Chassis Chassis
Ground Ground

Output Output

AC/DC AC/DC
Max.

AC/DC AC/DC
Max.
80A 80A

Power Dual
Redundancy
Power Power Dual
Redundancy
Power
Supply Module Supply Supply Module Supply
PS1 PS2 PS3 PS4
AC DC 24V Input 1 Input 2 AC DC 24V AC DC 24V Input 1 Input 2 AC DC 24V
DC 24-28V DC 24-28V DC 24-28V DC 24-28V
100-240V 40A 40A
100-240V 100-240V 40A 40A
100-240V

N L N L N L N L

N L N L
N L
N L
SPD with

SPD with

SPD with

SPD with
Filter

Filter

Filter

Filter
N L N L
N L
N L

CB1 CB2 CB3

CB4

Primary
AC Power

Secondary
AC Power Chassis DC Ground
Ground (CG)
(DCG)
Isolated Bus
Adjacent Enclosure
Enclosure door
To DIG Enclosure PE Ground Lug
For External Ground
Wire Sizes See Chapter 5 To DIG

75
Figure 3-24 SLS Highest integrity and highest availability - surge protection and isolation transformers

Enclosure Primary SLS

Power 24VDC

Fuse TB
Secondary SLS
Power24VDC

Fuse TB
Chassis Chassis
Ground Ground

Output Output

AC/DC AC/DC AC/DC

Max.

AC/DC
Max.
80A 80A

Power Dual
Redundancy
Power Power Dual
Redundancy
Power
Supply Module Supply Supply Module Supply
PS1 PS2 PS3 PS4
AC DC 24V Input 1 Input 2 AC DC 24V AC DC 24V Input 1 Input 2 AC DC 24V
DC 24-28V DC 24-28V DC 24-28V DC 24-28V
100-240V 40A 40A
100-240V 100-240V 40A 40A
100-240V

N L N L N L N L

N L N L
N L
N L
SPD

SPD

SPD

SPD
N L N L
N L
N L

Isolation
Transformer

AC Feed 1

CB1 CB2
N CB3
CB4

Isolation
Transformer
Follow
local
codes
AC Feed 2

G Chassis DC Ground
Wire sized equal Ground (CG) (DCG)
or greater than
maximum power Isolated Bus
feed Adjacent Enclosure
Enclosure door
Enclosure PE Ground Lug For External Ground
Wire Sizes See Chapter 5

DIG

Logic Solver configurations

The following two figures show power configurations for smart logic solvers (SLS). The first figure shows the
SLS powered by one 24 VDC feed from a redundant bulk power supply source. This scheme might be used with
a smaller system that can accept a safe shutdown on power events. The second figure shows a Logic Solver
powered by two independent 24 VDC feeds, one from the primary and one from the secondary bulk power
supply source. This eliminates risk of a shutdown due a signal point of failure on the common feed. This
method is recommended for added availability. In each case, note that the SIS power supply return, DeltaV
power supply return, and system power supply return are grounded at the DC ground bus, as required.

76
Figure 3-25 SLS with single feed

Note: Bulk Power DC- must be referenced to DCG. This diagram is based on the DC- reference for the
grouping of DeltaV cabinets being implemented at the Bulk Power Supplies. This reference
SLS Power connection can be accomplished in the DeltaV cabinet, or in the Bulk Power Supply Cabinet.
24VDC

Size Wire per ROW 1 ROW N ROW 1 ROW N

max. current
capacity

24VDC
Return 24VDC

DeltaV Power
24VDC

Jumper

32 Logic Solvers Total

120 ohm
terminator

120 ohm
terminator

14 AWG Row N Jumper

(2.5mm2)
14 AWG
(2.5mm2)

Chassis Ground
(CG)
Isolated Bus
Adjacent Enclosure
DC Ground (DCG) To DIG Enclosure door
To DIG For External Ground
Enclosure PE Ground Lug
Wire Sizes See Chapter 5

77
Figure 3-26 SLS with redundant independent feeds

Secondary
SLS Power
24VDC

ROW 1 ROW N ROW 1 ROW N

Size Wire Note: Bulk Power DC- must be referenced to DCG. This diagram is
per max. based on the DC- reference for the grouping of DeltaV cabinets being 24VDC 24VDC
Return Secondary
current implemented at the Bulk Power Supplies. This reference connection
capacity can be accomplished in the DeltaV cabinet, or in the Bulk Power
Supply Cabinet.

Primary
SLS
Power
ROW 1 ROW N ROW 1 ROW N
24VDC
ROW 1 ROW 1
SLS 1B SLS 3B

24VDC ROW 1 ROW 1

24VDC SLS 2B SLS 4B
Primar
Return
y

DeltaV
Power
24VDC

ROW 1 ROW 1 ROW 1 ROW 1

SLS 1B SLS 2B SLS 3B SLS 4B

32 Logic Solvers Total Jumper

ROW N
ROW N ROW N ROW N ROW N
SIS_NET 1A
SLS 1A ROW N SLS 2A ROW N SLS 3A ROW N SLS 4A ROW N ROW N
SLS 1B SLS 2B SLS 3B SLS 4B SIS_NET 1B

120 ohm
terminator

120 ohm
terminator

Row N Jumper
14 AWG
(2.5mm2) 14 AWG
(2.5mm2)
DC Ground
(DCG) Chassis
Ground (CG)
Isolated Bus
Adjacent Enclosure
For External Ground Enclosure door
To DIG Wire Sizes See Chapter 5 To DIG
Enclosure PE Ground Lug

78
The following figure shows the highest-integrity power and grounding scheme for a CHARMs SIS enclosure
with injected power.

Figure 3-27 CSLS Highest integrity power and grounding with injected power

CSLS
Assy
Communications with
DeltaV Should be
connected via. Fiber-
optic cable for distance
exceeding 200 ft.

Fuse TB
Fuse TB
Fuse TB

Fuse TB
Fuse TB
Fuse TB
`

Injected Power

SZ
Controller
Assy
PS1

Isolation
Transformer

CHARM
N L N L
Enclosure
SPD SPD
AC Feed 1 N L N L

G
CB CB
Follow local 1 2

codes

Isolation
Transformer

AC Feed 2
N

G Isolated Bus
Chassis Ground (CG) DC Ground (DCG)
Follow local
codes
Wire sized equal For External Ground Wire Sizes
or greater than
maximum power Building Steel See Chapter 5
feed DIG

The following figure shows redundant injected field power connected to a SIS CHARMs and Logic Solver
enclosure.

79
Figure 3-28 CSLS CHARMs with redundant field power injection

CSLS
Assy
Communications with
DeltaV Should be
connected via. Fiber-
optic cable for distance
exceeding 200 ft.
Fuse TB

Fuse TB

Fuse TB
Fuse TB

CHARM
PS1
Enclosure
with
Redundant
N L N L
Field Power
SPD SPD

N L N L

CB CB
1 2

AC
Power 1

AC
Power 2

Isolated Bus
Chassis Ground (CG) DC Ground (DCG)

For External Ground Wire Sizes

Building Steel See Chapter 5
DIG

Additional references
In addition to the power and grounding information in this chapter, the following documents contain
application and installation information you need for your DeltaV SIS system:

• D800025, Installing Your DeltaV SIS™ Process Safety System Hardware.

• D800028, DeltaV SIS Accessories Installation and Safety Manual.

80
• D800032, DeltaV SIS Process Safety System Safety Manual.
• D800033, DeltaV SIS Users Guide.
• D800056, DeltaV SIS™ CHARMs Smart Logic Solver Hardware Installation.
• D800057, DeltaV SIS™ CHARMs Smart Logic Solver Hardware Reference.
• D800058, DeltaV SIS with Electronic Marshalling Safety Manual.

81
 Signal wiring

Minimizing electrical noise induced on process control input and output (I/O) signals is extremely important for
reliable operation of any control system. Many external sources can produce electromagnetic interference (EMI)
on I/O signals. In addition, digital communication systems, traditional discrete signals, and fast-switching
discrete signals can make the inside of a system enclosure the hottest area for electrical interference, often as
cross-talk. This chapter describes best practices for minimizing electrical noise induced on I/O signals.

Selecting cables
For analog signals, Emerson recommends using shielded, twisted-pair cable to reduce noise.

Note: Using multi-pair cables can reduce installation costs. If you use multi-pair cables, use shielded, twisted-
pair wires with an overall metallic shield and a drain wire.

Very-low-amplitude signals, such as millivolt, thermocouple, and resistance-temperature signals, require more
protection from noise. Use commercially available, individually shielded, single-pair or multi-pair cables
specifically made for these applications. The cables must be separated from AC circuits, especially from AC
circuits containing motor or generator control solenoids, similar types of circuits with relatively high inrush
currents, and solid-state switching circuits.

Various industry standards, such as IEEE 518-1982, IEEE Guide for the Installation of Electrical Equipment to
Minimize Noise Inputs to Controllers from External Sources, 1 describe noise identification and classification as well
as recommended wiring practices.

Best signal wiring practices

This section contains guidelines based on best engineering practice. You should follow these guidelines unless a
good technical reason exists at your plant not to follow them. You must consider the risks if you apply
alternative methods.

• Use appropriately sized signal wire. DeltaV I/O termination blocks accept up to 3.3 mm2 (12 AWG)
stranded or solid wire. Wire sizes between 0.8 mm2 and 2.1 mm2 (18 AWG and 14 AWG) are typically
used. To select the appropriate wire size, determine the maximum current expected or the maximum
voltage drop permissible, and the wire length.
• Terminate signal cable shields to ground at one end only. Terminating cable shields to ground at both
ends of a signal wire can result in a ground loop. You can terminate the shield to a cable-shield ground
bar.
• Terminate unused conductors to ground at one end only. Terminating unused conductors to ground at
both ends of a wire can result in a ground loop. You can terminate an unused conductor to chassis
ground.
• Isolate ungrounded shield ends so that there is no possibility for the shield to touch other wires or metal
objects. You can use heat-shrink tubing or tape wrap to isolate the shield.

1
This standard has been withdrawn but it contains much useful information.
82
 • Do not daisy-chain carrier shield bars not adjacent to one another. Connect shield bars individually to
chassis ground (CG) bus bars in the enclosure.
• Leave at least one pair of spare leads in a multi-pair cable. Twenty-percent spares in multi-pair cables is
a common recommendation.
• For I/O bus systems (for example, FOUNDATION fieldbus, DeviceNet, Profibus, AS-Interface), use
only the cables specified for the bus type.
• Ensure that cables are run so that sharp metal edges cannot cut through cable insulation.
• Inspect terminations to ensure that wire insulation is stripped back cleanly and that no insulation is
under the termination.
• Avoid stray strands at stripped-back multi-strand wire that can short signals to other terminals. Avoid
allowing stray copper strands to fall into electronic components.
• Consider using wire ferrules, ring tongues, or flanged spade tongue connectors on terminations to
ensure good electrical connections. Some applications require these terminations.
• Use finger-safe terminal blocks with AC voltages greater than 50 V and DC voltages greater than 75 V
in accordance with EU low-voltage directive 2014/35/EU.

Caution: Do not connect unused cables to unconfigured DeltaV ports.

Protecting I/O signals from AC line noise

Interference from inductive coupling can occur when signal cables are routed close to, and especially parallel to,
AC lines such as power lines. It also can occur when control system equipment is not sufficiently separated from
transformers, motor controllers, variable frequency drives, rotating machinery, or other high-power equipment.

Long runs of adjacent cables have a greater potential for noise coupling than short runs. Therefore, the longer
the adjacent run, the greater the amount of spacing and shielding required. Redundant shielding can provide
additional noise protection in situations where the recommended distances cannot be met, but such shielding
must be evaluated on a case-by-case basis.

Different types of cable can also reduce AC noise. For example, the cable recommended for variable frequency
drive (VFD) applications also provides excellent shielding for AC power lines. Instrument cable with metallic
outer armor provides shielding but also adds cost.

To minimize the electrical noise effects from AC power lines, provide separation for parallel runs of twisted-pair
signal cables from AC power cables. Guidelines and recommendations for proper separation between signal
cables and AC power cables were documented by IEEE. Reference IEEE Std. 518-1992, IEEE Guide for the
Installation of Electrical Equipment to Minimize Noise Inputs to Controllers from External Sources. Similar
guidelines have also been documented in Process Industry Practices Process Control PIP PCCEL001,
Instrumentation Electrical Design Criteria.

The following table summarizes these guidelines into three installation groups: signal cables in metal conduit
separated from power cables in metal conduit, signal cables in cable tray from power cables in metal conduit or
signal cables in metal conduit from power cables in cable tray, and signal cables in cable tray from power cables
in cable tray.

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Table 4-1 Minimum cable separation distances

Voltage Current Minimum distance Minimum distance Minimum distance

between twisted-pair between twisted-pair between twisted-pair
signal cables in metal signal cables to AC signal cables to AC
conduit to AC power power cables – tray to power cables – tray to
cables in metal conduit metal conduit tray
50 to 250V < 20 A 8 cm (3 in.) 10 cm (4 in.) 15 cm (6 in.)
0 to 1000V 20 to 800 A 30 cm (12 in.) 46 cm (18 in.) 66 cm (26 in.)

• Conduit and cable tray spacing are defined as follows:

o Conduit spacing: Minimum distance between the outside surfaces of conduits.
o Cable tray spacing: Minimum distance between the top of one tray and the bottom of the tray
above or between the sides of adjacent trays. Trays based on metal, solidly grounded, with good
ground continuity
• Separate twisted-pair signal cable from devices that generate magnetic fields by a minimum of 1.5 m (5
ft) in tray or a minimum of 0.75 n (2.5 ft) in metal conduit. Emerson recommends 3-4.5 m (10-15 ft).
• Use shielded, twisted-pair cable with approximately eight crossovers per foot (26 crossovers per meter).
Shielded, twisted-pair cable is five to six times more effective in reducing noise coupling than shielded
cable alone.
• Emerson strongly recommends use different cable trays for signal cables and AC power lines. If you
cannot use different trays, make sure that you maintain minimum cable separation distances. Using tray
dividers can help maintain separation.
• For non-intrinsically safe low-level I/O signals, use continuous (non-spliced) cable from signal source to
receiver. Do not run low-level I/O signals parallel to high- current or high-voltage lines.
• Where magnetic fields from AC power lines are a source of interference, use twisted power leads to
reduce field strength.
• If signal cables and AC power lines must cross, do so at right angles. Power lines should be twisted on
both sides of the crossing for at least the recommended distances.
• If signal cable is individually shielded and grounded at one end according to cable-shield guidelines, you
can use armored cable grounded at both ends instead of conduit. Make sure that the signal cable is
insulated from the armor.
• You can use metal conduit for physical support and to reduce EMI interference.

Shield ground
Properly grounding signal cable shields helps ensure proper system operation by reducing electromagnetic and
electrostatic interference in signal wiring. To provide a ground path for this interference, connect shields at a
single point only, either to a DeltaV shield bar or to a well-grounded field device.

Individual pairs of wiring carrying a signal should have the pair shield grounded at one point. That point can be
at the field device, at a junction box, or at the DeltaV enclosure. Emerson recommends grounding signal cable
shields at the DeltaV enclosure. Consistency in selecting the location of a single grounding point reduces the risk
of creating ground loops, and makes it easier to troubleshoot grounding issues.

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One exception to the grounding recommendation is thermocouple shielding. Some thermocouples are isolated
from the sheath and some are not. If the sheath is in electrical contact with the metal thermowell, the shield may
be bonded to earth in the field. In that case, bonding again at the DeltaV enclosure, for example, would create a
ground loop that could induce unwanted energy onto the thermocouple leads.

Emerson strongly recommends connecting I/O cable shield grounds to chassis ground and not to DC ground.
This is a requirement rather than a recommendation for SIS equipment. Chassis ground routes electrical noise
back to the source, whereas DC ground is a passive ground that creates a zero equipotential reference for the
control system. Connecting cable shield grounds to DC ground introduces electrical noise and can cause errors.
All drawings in this manual show shields connected to chassis ground.

Be sure to strip the insulation of shield wires properly at the grounded end and wrap them at the ungrounded
end. Refer to the following figure for examples.
Figure 4-1 Proper shield management

Note: Keep the stripped length of wire as short as possible. 1-3 in. is typical.

Communication Grounding
Minimizing electrical noise induced on I/O signals is extremely important for reliable operation of any control
system. Many external sources can produce electromagnetic interference (EMI) on I/O signals. In addition,
digital communication systems, traditional discrete signals, and fast-switching discrete signals can make the
inside of a system enclosure the most susceptible area for electrical interference, often as cross-talk.

Electrical Noise Influences

Control system reliability can be substantially reduced when a system is subjected to unusually high amounts of
electrical noise. Different system components can be affected to different degrees. The following observations of
effects have been made during troubleshooting of many systems:

• Properly installed, traditional (classic, non-digital communication) I/O products that use 4-20 mA
analog I/O signals are influenced to a lesser degree by electrical noise.
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 • High-frequency electromagnetic noise generated by AC drives, insulated-gate bipolar transistor (IGBT)
power-switching devices, and other sources can affect control products from any supplier.
• Digital data signals used in bus communication systems may be susceptible to electrical noise if the
systems are not properly installed.
• If noise spikes on power supply ground to +24 VDC are greater than 1 V peak to peak, locate the noise
source and take remedial action.

I/O signal cable runs

The following figures show termination methods for cable shields.
Figure 4-2 Instrument shielding details

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Notes
1. Refer to the instrument manufacturer’s documentation and DeltaV Books Online for detailed
information about signal termination.
2. Use 14 AWG (2.5 mm2) to 18 AWG (0.75 mm2) stranded, twisted-pair wire with overall shield and
drain wire.
3. Use cable specified for thermocouple signals with overall shield and drain wire.
4. Ground shield at thermocouple for grounded thermocouples.
5. Ground shield at carrier shield bar for ungrounded thermocouples.
6. Use three/four conductor cable specified for RTD signals with overall shield and drain wire.
7. Shields should extend to within 2 in. of termination. For ends that are not terminated, trim and cover
with tape or heat shrink to prevent accidental grounding.
8. Pass-through only. Shields are grounded at one point only.
9. Normally, the signal is isolated from the case in four-wire transmitters. Therefore, grounding the case
does not cause a ground loop.
Figure 4-3 Three- and four-wire instrument shielding details

Notes
1. Refer to the instrument manufacturer’s documentation and DeltaV Books Online for detailed
information about signal termination.
2. Use 14 AWG (2.5 mm2) to 18 AWG (0.75 mm2) stranded, twisted-pair wire with overall shield and
drain wire.
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 3. Shields should extend to within 2 in. of termination. For ends that are not terminated, trim and cover
with tape or heat shrink to prevent accidental grounding.
4. Pass-through only. Shields are grounded at one point only.
5. Normally, the signal is isolated from the case in four-wire transmitters. Therefore, grounding the case
does not cause a ground loop.
6. Three-wire transmitters require a return path to the transmitter for the 4-20 mA signal.
Figure 4-4 I.S. instrument shielding details

Notes
1. Refer to the instrument manufacturer’s documentation and DeltaV Books Online for detailed
information about signal termination.
2. Use 14 AWG (2.5 mm2) to 18 AWG (0.75 mm2) stranded, twisted-pair wire with overall shield and
drain wire.

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 3. Intrinsically safe (I.S.) installations must conform to local codes and regulations. Refer to NEC Article
504, IEC 60079-11, and IEC 60079-25. See also ANSI/ISA RP12.6 Wiring practices for hazardous
(classified) locations, instrumentation, Part 1: Intrinsic Safety.
4. Devices must be I.S. certified if not considered a "simple apparatus." Refer to IEC 60079-11.
5. I.S. devices, cables, and connections shall be clearly marked and identifiable. Where color is used for this
purpose, it shall be light blue. Refer to IEC 60079-11.
6. Shields should extend to within 2 in. of termination. For ends that are not terminated, trim and cover
with tape or heat shrink to prevent accidental grounding.
7. Normally, the signal is isolated from the case in four-wire transmitters. Therefore, grounding the case
does not cause a ground loop.
8. I.S. CHARMS are intrinsically safe through galvanic isolation. A barrier is not required.

Low-level I/O signal cable runs through junction boxes

It is preferable to run low-level signal lines directly between sensing devices and the I/O terminal blocks, but the
lines may be run through junction boxes and marshalling panels if the integrity of the shield is not broken.

Thermocouple cables require special handling. You can run them through junction boxes and marshalling panels
if you install special connection blocks to maintain the integrity of the signal. However, it is better to run
thermocouple cables continuously between sensors and I/O terminals.

Multiple-pair cables specifically manufactured for multiple runs of the same sensing device type may be used.
Each pair must contain individual shielding. For adequate cable support, conduit may be used.

Resistor-capacitor snubbers
For discrete input and output signals, resistor-capacitor (R-C) snubbers may be necessary to suppress electrical
arcing. Refer to DeltaV Books Online for information about snubbers you can use for suppression.

I/O bus signal wiring

I/O bus systems, such as Fieldbus, AS-Interface, DeviceNet, and Profibus, must be properly designed and
installed. Otherwise, EMI and other electrical noise can produce errors in signals received and transmitted by
system instruments. Ground loops in shields are particularly harmful to bus communication.

Many of the same issues that affect I/O signal wiring also affect I/O bus wiring. However, each bus protocol is
subject to other issues. The following list provides a few examples:

• Standards set by the designated authority for the bus protocol.

• Digital communications speed or baud rate. Profibus DP is capable of up to 12 megabaud while
Fieldbus is capable of only 31.24 kilobaud.
• Underlying physical layer. For example, Fieldbus, Profibus PA, and AS-I use Manchester data encoding.

HART wiring
Current loops for communicating data back from a sensor as well as powering the field device have been around
for approximately 50 years. These current loops gained popularity due to electrical noise tolerance and ease of
installation compared to older methods, such as pneumatics. The first loop-powered field devices had a current
range of 10-50 mA. Modern devices have a current range of 4-20 mA. In the mid-1980s, Rosemount added a
new twist: Highway-Addressable Remote Transducer (HART) communication. The HART protocol uses the
Bell 202 modem frequency shift keying (FSK) physical layer to allow data to be overlaid onto the current loop.
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Overlaying this data allows much more information to be transmitted back and forth from the device to the
control system.

HART specifications include both communications protocol and hardware. For more information about HART
specifications, refer to the new FieldComm Web site: http://www.fieldcommgroup.org/

AS-interface wiring
The Actuator Sensor Interface (AS-i) is a digital, serial, bi-directional communications protocol and I/O bus
system that connects binary on/off devices, such as actuators, sensors, and discrete devices, to a DeltaV controller
through an AS-i card and the I/O subsystem.

The two-conductor AS-i cable supplies both power and data for field devices. An AS-i network can include
branches. Refer to AS-i specifications and standard IEC 62026-2 for design and engineering details. For more
information on AS-i and installation of AS-i devices, refer to the AS-i Web site: http://www.as-interface.net/ .

The AS-i system is based on a completely floating system. Therefore, an AS-i system is never grounded. Only
field device cases should be grounded to the nearest CG points, such as pipes and building steel. These items
must provide a good electrical ground to the plant ground grid. The power supply is grounded through the AC
ground in the AC power distribution system. Neither conductor of the AS-i communication bus is grounded. In
instances where a secondary flat cable supplies supplemental power to field devices, follow the power supply
manufacturer’s installation manual for properly grounding the voltage return (negative).

Note: Emerson recommends against connecting AS-i devices directly to AS-i card terminals. Use one AS-i cable
to connect the AS-i card to the power supply and use another AS-i cable to connect to field devices. If using
extenders and repeaters, refer to their data sheets for additional cable recommendations.

The following figure shows typical AS-i power and grounding. For more information on AS-i and installation of
AS-i devices, refer to the AS-i Web site: http://www.as-interface.net

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Figure 4-5 AS-i bus grounding and power

DeviceNet wiring
DeviceNet provides single-cable connection of field devices (for example, limit switches, photoelectric cells, valve
manifolds, motor starters, drives, and operator displays) to a DeltaV controller through a DeviceNet Interface
card and the I/O subsystem. Grounding specifications for a DeviceNet segment are in accordance with what was
known as the Open DeviceNet Vendors Association and is now called ODVA, Inc.

It is very important that you understand DeviceNet specifications before attempting an installation. These
specifications, along with general user guidelines, are available through the DeviceNet Web site:
http://www.odva.org. DeviceNet is documented under IEC 62026-3.

Note: When replacing the DeviceNet card in a DeltaV system, refer to the related Knowledge Base Articles
(KBA)s for information about properly wiring specific DeltaV DeviceNet cards.

The following important power and grounding guidelines apply to DeviceNet:

24 VDC power connects to the DeviceNet cable.

You can use more than one 24 VDC power supply, depending on the load requirements of connected devices.

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If you are using multiple power supplies, the power supply common voltage must not vary more than 5 VDC
between any two points on the network.

The current should never exceed the cable and connector ratings.

ODVA specifications require bonding the shield/drain of device multi-pair conductors to chassis ground at a
single point.

ODVA specifications describe specific methods to maintain proper signal and ground isolation. Use only devices
designed according to those specifications. For example, multiple DeviceNet power supply positives should be
isolated from each other.

The maximum length of the shield ground conductor to chassis ground is 3 m (10 ft).

To avoid ground loops, ensure that there is only one ground point for the entire network. That single ground
point should be as near as possible to the physical center of the network.
Figure 4-6 DeviceNet power and grounding

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FOUNDATION fieldbus wiring
FOUNDATION fieldbus (FF) is a digital, serial, bi-directional communications bus that interconnects field
devices, such as actuators, sensors, and discrete devices, with process controllers. FF systems must be properly
designed and installed. EMI and other electrical noise can produce errors in signals received and transmitted by
system instruments.

Refer to the DeltaV manual Fieldbus Installations in a DeltaV Digital Automation System (D800003) for
information about installing an FF system. Emerson recommends verifying proper operation before
commissioning the system. Record the verification results in the Fieldbus Segment Checkout Form in the
manual referenced above. The manual is available from your Emerson local business partner or field sales office
(LBP/FSO).

For more information about FF specifications, refer to the FieldComm Web site:
https://www.fieldcommgroup.org/. FF is a subsection of IEC 61158.

The following important grounding guideline applies to FF:

FF shields and drains are bonded to chassis ground. The shields and drain wires for the segment conductors
should be grounded at a single point to reduce ground loops.

Profibus DP wiring
Profibus DP is a digital, serial, bi-directional communications protocol and I/O bus system that can be used to
connect analog and discrete field devices to a DeltaV controller through a Profibus DP Interface card and the
I/O subsystem. The shielded, two-conductor Profibus DP cable passes data to and from field device and the
interface card. Profibus DP field devices use external sources for field device power.

Complete Profibus DP specifications are needed to properly install a Profibus DP system. Specifics can be found
on the Profibus Trade Organization (PTO) Web site: https://www.profibus.com/. Profibus DP is a subsection
of IEC 61158.

If you use the internal terminal block terminator, you do not need an external terminator, but you cannot
connect additional Profibus devices to terminals A2 and B2.

The following important power and grounding guidelines apply to Profibus DP:

• PTO specifications require cable shields to be connected to an equipotential ground system. In other
words, they connect all ground systems, such as functional ground, equipment ground, and chassis
ground together in an equipotential ground mesh. This is a distinctly different recommendation from
other I/O protocols, in which cable shields are connected to the chassis ground bus bar.
• Profibus DP specifications require bonding of the shield at every field device.

The following figure shows typical power and grounding connections for a Profibus DP system. These
connections are valid when an external terminator is used. Another Profibus DP system could be connected to
A2 and B2 in a similar manner as the system shown.

93
Figure 4-7 Profibus DP power and grounding

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 Ground design for DeltaV

Grounding has three main purposes: protecting people from harm, protecting equipment from damage, and
protecting the integrity of processes and data. The primary purpose of the DeltaV system ground is to protect
the integrity of processes and data in the DeltaV system. The DeltaV system ground is not intended to provide
safety grounding (which protects people) or fault grounding (which protects equipment). However, the
guidelines in this chapter are compatible with best practices in safety and fault grounding for your facility.

The DeltaV system ground consists of the direct current ground (DCG) and chassis ground (CG) subsystems.
Other sources may refer to DCG as isolated ground or instrument ground and to CG as safety ground or
protective earth. The following section defines the types of ground discussed in this chapter by explaining their
specific purposes and functions.

Grounding purposes and functions

Chassis ground provides a low-impedance path for unwanted electrical energy to return directly to its source. A
low-impedance path reduces the possibility of the energy affecting the control system adversely. Some sources
refer to this ground as AC ground.

DC ground is an isolated ground that provides a common equipotential for the control system. The DC ground
should normally be free of unwanted electrical energy.

Safety ground, also called protective earth, protects personnel from injury resulting from defective supply feeds.
For example, if the insulation of the line side of a 120 VAC power conductor becomes frayed, causing the
conductor to be in direct contact with a properly grounded metal enclosure, a protective interrupt, such as a fuse
or circuit breaker, opens. The ground conductor must be sized as large as the maximum AC conductor feeding
the load. This conductor should follow the same path as the line conductors to their source, that is, first
disconnect or separately derived source.

High-frequency ground systems improve signal integrity by reducing noise caused by machinery such as
variable-speed drives, welders, and commutated DC motors. Interference and transients from other
instrumentation and equipment is also greatly reduced with a properly constructed high-frequency ground
system. Skin effect causes high-frequency signals to travel close to the surface of conductors. For this reason, only
the outermost part of cables carries the high-frequency interference. For example, a 500 kHz signal uses 100% of
the copper in a 32 AWG wire, but only 36% of the copper in an 18 AWG wire. High frequency with respect to
control systems often encompasses a broad band of frequencies starting as low as 10 kHz. A properly constructed
high-frequency ground system uses the surface area of large conductors to minimize interference.

Stable DC reference ground is a low-impedance ground (1 Ω to 5 Ω) between the ground system—triad or plant
grid—and earth that maintains the control system at a stable reference. Utility power and lightning systems
should have their own grounding systems. The best practice is to connect all ground systems together. However,
there is finite impedance interconnecting each ground system. There are also impedance variations between all
points of the same system. When a fault occurs, it creates a short-duration voltage gradient where the fault
contacts the localized ground. If the control system has a low impedance to its DeltaV Instrument Ground
(DIG), such faults have less significant effects on the DeltaV Instrument Ground (DIG) potential.

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Lightning protection refers to preventing nearby lightning strikes from harming personnel or damaging
property.

Lightning mitigation refers to minimizing the risk of equipment failure caused by lightning. For DeltaV this is
accomplished by keeping the DeltaV grounding systems close together and interconnected. All metal enclosures
are connected to the safety ground system. Separately derived systems, such as isolation transformers and UPSs,
should be as close to the DeltaV systems as possible. Case studies have shown that induced energy because of
lightning strikes have disrupted and even damaged instrumentation equipment due to variance in ground
potentials at multiple locations. Keeping all metal components connected to the safety ground system equalizes
induced voltages. Multiple eddy current paths minimize the need for any single conductor to shunt the
equalization current.

Equipotential ground means that every location in the grounding network is at the same potential voltage. This
is the ideal solution for any grounded system. There are many grounding methods that can achieve this goal.
IEC 60364-4-44, Low-voltage electrical installations - Part 4-44: Protection for safety - Protection against voltage
disturbances and electromagnetic disturbances, is an excellent source for grounding topologies. When connecting
ground cables, avoid excessive service loops in the cables that can form inductors. The ground cables should be
in as direct a path as possible. When crossing power lines, maintain as great a separation as possible and ensure
that ground cables cross at right angles to power cables.

Control system ground considerations

Inadequate or faulty system ground networks are among the most common causes of control system faults.
Proper ground networks can greatly increase personnel safety and significantly improve control system operation
by eliminating the effects of potential deficiencies in the AC power quality. For example, good AC neutral
grounding usually minimizes or eliminates stray currents which can induce noise and operational errors into the
system.

Glitches in system operation are often traced to electrical ground faults only after hours are spent checking the
system itself. The extra time and effort spent in installing a good ground network is usually rewarded by easier
startup and more reliable operation. Emerson suggests that you review IEEE Standard 1100-2005 (IEEE
Emerald book), Recommended Practice for Power and Grounding Sensitive Electronic Equipment, for
additional information on industry-accepted methods to obtain good power and ground.

Maintaining ground integrity

No matter how good your process control system is, it cannot perform well if the power and ground systems
have degraded over time. Field experience shows that the number one issue with unmaintained power and
ground systems is poor electrical connections. Connections can corrode, loosen, and break. Therefore, it is
imperative that you schedule periodic, detailed inspection of your power and ground systems. Preventive
maintenance in this area can be rewarded with big savings from continuous, reliable control system performance.

Grounding a control system effectively

The following guidelines can help you obtain effective grounding:

• Provide a ground network dedicated to the control system. Do not connect the dedicated DeltaV
ground network with other plant ground systems until they meet at the earthing electrode network.
• Ground enclosures according to applicable codes and regulations as well as industrial standards.

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• Connect all enclosures within a group to the same ground point.
• Do not run DeltaV ground conductors in trays or raceways with AC conductors or energized
conductors. Maintain a minimum of 30 cm (12 in.) of separation between AC conductors and DeltaV
ground conductors.
• Use insulated ground conductors to avoid unintentional ground loops that can occur if a bare
conductor touches other conductive materials, including concrete, metal enclosure framing, or another
bare conductor.
• Provide a low-impedance, high-integrity ground path between all instrumentation and DeltaV system
plant ground connections. Create a common equipotential so that all components have a common
reference point for the entire control system. This includes control system power sources,
instrumentation, and DeltaV.
• Keep ground conductors as short as possible. Long runs make conductors more susceptible to unwanted
electrical noise.
• Verify that any unused ground wires are disconnected at both ends.
• Design the ground network so that it is accessible for testing and maintenance. The design and
installation of the grounding system should protect the system from damage due to physical hazards
such as foot traffic, vehicles such as forklifts, chemical spills, low points on building walls, wall corners,
or-low hanging conductors.
• Ground resistance recommendation for a new earthing electrode network is 1 Ω. For the highest
integrity ground system design, this resistance is the measurement of the grounding triad or other
components of the earthing electrode network without connection to an underground grid or ground
ring. This same 1 Ω is required for locations such as hospitals and communication systems requiring
high reliability. The maximum recommended resistance for a control system ground is 5 Ω.
• Use insulated grounding conductors unless the conductors are part of the earthing electrode network
and are used below grade.
• Although you can run ground conductors in ferrous conduits and raceways, the conduits and raceways
must themselves be properly grounded. In general, Emerson recommends using non-ferrous conduits
and raceways. Most importantly, do not run AC power conductors alongside DeltaV system ground
conductors. You may consider not using conduit or raceways at all.
• Use appropriately sized conductors. Conductor size in a noise-abatement system is not based on fault
current. Fault current, under normal conditions, should not run through this portion of the ground
system design. Fault current through the DeltaV system ground could create a process upset. The size of
the conductors is to dissipate unwanted transient energies.
• Do not connect large conductors to smaller conductors on the path from the control system to earth.
Those connections create choke points, or high-impedance points, that can cause unwanted high-
frequency energies to follow a lower-impedance path to a control system component.
• Design bus bars with enough connections for the number and sizes of cables to be connected.
Connecting too many cables to a bus bar can increase impedance, reducing the effectiveness of the
ground system. It also makes maintenance difficult.

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 • Follow the industry standard for bend radius of grounding conductors. This minimum bend radius is 8
times the overall diameter of the single insulated conductor. (Refer to NFPA 70 Article 300.34 and IEC
60092-352.)
• Do not daisy-chain ground conductors between individual enclosures or cabinets. This increases the
chance that an unwanted anomaly can propagate from one enclosure to the next enclosure.

Using existing ground networks

If you plan to use an existing ground network--for example, one that was built for use with an older control
system that is being replaced or supplemented—you should consider the following:

• Will the existing ground network provide the required level of power quality? For example, Emerson
recommends that the earthing electrode network measure 1-5 Ω of resistance. The following steps can
help ensure that your network meets that recommendation:
o Add more electrodes, ground rods or plates to increase surface area contact with the soil.
o Use longer ground rods to increase surface area contact with the soil.
o Use a chemical ground to decrease soil resistivity.
o Remove or repair any connections or bond points in the ground system that are corroded.
o Make sure there are no coatings such as paint or grease on the electrodes that can reduce the surface
area electrical contact.
• Corrosion, inappropriate connections and disconnections, and increased soil resistivity can degrade a
grounding network over time. Industry standards include visually inspecting the entire control system
ground once a year, and checking the resistance of the earthing electrode network at least once every 5
years.
• Older ground systems may not meet the requirements of newer control technologies. For example,
HART communications are especially susceptible to ground loops.
• If the ground system has not been well maintained, it is often more effective and economical to replace
the existing ground system.

Types of ground systems

There are many grounding methods that work very well to achieve common equipotential for grounding. IEC
60364-4-44, Low-voltage electrical installations - Part 4-44: Protection for safety - Protection against voltage
disturbances and electromagnetic disturbances, is an excellent source for grounding topologies. This section
provides a good sampling of some common grounding topologies.

Star or single-point ground

DeltaV functions extremely well using a star grounding topology as shown in the following figure. Note that
grounds are terminated on local area ground busses before final termination at the DIG. This method can save
significant cable costs.

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Figure 5-1 Single-point star grounding system

Mesh star ground network

Many control systems today are preassembled in structures with raised floors. This type of installation facilitates
a mesh star ground system as shown in the following figure. When connecting the DeltaV chassis ground to the
mesh, the ground cable or ground straps should be as short as possible. Mesh squares must be less than 2 m per

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side2. All mesh crossings should be exothermically welded or tightly bolted, maintaining corrosion-free joints
with a typical joint resistance of 500 μΩ 3.

Figure 5-2 Mesh star ground network

UPS
L1 Rectifier Inverter L1
L2 L2
L3 L3
G N
G

Battery Bank or
Flywheel Storage
PE Ground

L1 Isolation Transformer L1
L2 L2
L3 L3
G N
G

Ground

2
EC 60364-4-44, Low-voltage Electrical Installations Part 4-44: Protection for safety - Protection against voltage disturbances
and electromagnetic disturbances, Ed. 2.0, 2007.
3
IEEE Standard 1100-2005, Recommended Practice for Power and Grounding.

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Figure 5-3 Hybrid star mesh ground network

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Organizing the ground network
A high quality dedicated ground is used with DeltaV systems to provide a return path to earth and to provide a
reliable reference for precise measurement and control. The DeltaV instrument ground should be isolated from
all ancillary equipment and external feed grounds to a point as close to the earthing electrode network as
possible.

The figure illustrates an effective, organized ground network. It brings all grounds to a single point on the plant
ground grid. In this configuration, ground connections cannot produce ground loops. The network includes CG
and DCG ground busses located in enclosures, isolated master or local ground busses for each local area, a
DeltaV instrumentation ground (DIG), with a dedicated connection to the plant ground grid.

The following figure shows separation of DeltaV system ground and plant ancillary equipment and feeds.
Figure 5-4 Separate DeltaV ground

Notes
1. Conductor used to bond the source neutral ground of a separately derived instrument power system to
the DeltaV Instrumentation Ground (DIG), as required by NEC 250-30(a)(2), CSA C22.1 Section 10.
Refer to the Ground conductor sizing section of this chapter.
2. Conductors used to provide a low-impedance ground path for the DC power system and for EMI/RFI
noise protection for instruments and field wiring installed in enclosures.
3. Conductor used to connect the DeltaV Instrument Ground (DIG) directly to the plant ground grid.
This conductor also provides a low impedance ground path for EMI/RFI noise, as required by NEC
250-54-Supplemental Grounding Electrode 250-50(a)(2). Refer to the Ground conductor sizing section
of this chapter.
4. The DeltaV Instrumentation Ground must be effectively bonded to building steel [refer to NEC 250-
50(b)], and building steel must be properly grounded to earth ground.
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 5. Chassis ground bus and isolated DC ground bus (isolated from chassis) used to provide reference
ground for devices installed in the enclosure grouping. For distances greater than 10 ft (3 m) between
the AC or DC ground bus and isolated master or local ground bus, use stranded, insulated 1/0 to 4/0
AWG (50 to 120 mm2). For distances less than 10 ft (3 m), 2 AWG (35 mm2) cable may be used. Refer
to Table 5-2.
6. Side-by-side enclosures bolted together, but open to each other.
7. Cable used to bond grouped enclosures where an AC ground bus and a DC ground bus are installed in
open-sided grouped enclosures. Be sure to strap grouped enclosures together; do not depend on bolts to
provide ground. Use 12 mm (0.5 in.) wide, braided grounding strap for distances up to 15 cm (6 in.).
For longer bonding, use insulated 10 AWG (6 mm2) wire. Refer to NEC Table 250-122 and Article
250-119.
8. Enclosures in a local area, or side-by-side bolted together with panels between enclosures. Each
enclosure requires its own CG bus and DC ground bus. Use stranded, insulated 14 to 12 AWG (2.5 to
4 mm2) between instrument and shield grounds and the CG and DCG busses.
9. Local area ground busses are not necessary if a master ground bus will suffice. See Controlling Ground
System Costs in text.
10. A and Z depict the end points of ground paths. For optimum EMF protection, the maximum path
length is 100 m (300 ft). Use cables as described in the notes above.

Improving the earthing sub-system

Resistance, reactance, and impedance
Resistance is the opposition to current in a circuit when a voltage is applied. Reactance is the opposition to
current in a circuit specifically when a voltage with an alternating current is applied. Reactance is directly
proportional to the frequency of the alternating current. Impedance includes both resistance and reactance.
Large cables are recommended for grounding because the surface area provides a low-resistance path to ground
for high-frequency transients. As the frequency of unwanted energy increases, that energy begins to travel on the
surface, or skin, of the conductor rather than through the core of the conductor. Kinks in the conductor, and
running the conductor through ferrous conduit, increase the reactance and thus increase the impedance.
Reducing the size of a cable causes a linear increase in resistance but can cause an exponential increase in
reactance.

Reducing the impedance of the path to ground enables unwanted energy to return to its source instead of
interfering with the control system. A low-impedance path to ground minimizes the effects of natural and man-
made transients.

Soil resistivity
Different types of soil have varying levels of resistance to electricity because of their chemical composition. Soil
with high levels of electrolytes such as dissolved salts, bauxites, carbon, and iron, has lower resistivity. There are
several methods for measuring soil resistivity, including the Wenner method and use of soil sampling. The
Wenner method is a four-point method of determining resistivity by injecting a known current into the earth
with two probes and reading the voltages with the two other probes. If you know the voltage and the current,
you can calculate the resistance. Soil sampling places soil samples in specially designed boxes to measure the
resistance with laboratory instruments.

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The chemical composition of soil and its resulting resistivity varies vastly from one geographic area to another,
and even from one stratum to another.

The following table lists typical and average resistivity for several types of soil. The table is based on Table 10,
Resistivity of Soils and Resistance of Single Rods, in IEEE 142-1991, IEEE Recommended Practice for Grounding
of Industrial and Commercial Power Systems.
Table 5-1 Resistivity of soils and resistance of single rods

Soil Description Average Resistivity ( Resistance of 16 mm (5/8 in.) x 3 m

Ωm) (10 ft) Rod (Ω)

Well-graded gravel 600-1,000 180-300

Poorly graded gravel 1,000-2,500 300-750

Clayey gravel 200-400 60-120

Silty sand 100-800 30-150

Clayey sand 50-200 15-60

Silty or clayey sand with slight plasticity 30-80 9-24

Fine sandy or silty soil 80-300 24-90

A change of soil moisture from 0 to 30% (by weight) can decrease soil resistivity from 1 MΩ-m to below
10 Ω -m.

Soil compaction can either increase or decrease soil resistivity. If the soil is so compact that moisture is forced
out, the resistivity will be higher. However, if the compaction decreases the distance between conductive soil
components, the resistivity will be lower.

You can decrease the soil resistivity of the earthing electrode network in several ways. Adding minerals such as
coke breeze (carbon) or salts, adding other conductive elements or compounds, and adding moisture to the soil
all decrease resistivity.

Surface area – Having more surface area of the earthing electrode network in contact with the soil decreases the
ground resistance. A linear increase in soil resistivity requires an exponential increase in surface area. The amount
of surface area can be calculated before construction and adjusted during construction.

A well-designed DeltaV Instrument Ground often consists of a network of ground rods commonly referred to as
a triad. However, depending on the soil resistivity, your network may require more or fewer than three ground
rods. You can estimate the number of ground rods required based on the soil resistivity where the rods will be
installed. Emerson recommends a documented verification of resistance before finalizing installation (e.g., before
paving over the soil). Your network may require additional measures to achieve the optimal 1 Ω to earth.
Recognized industry guidance for the distance between ground rods is 2X the ground rod length. Closer
distances might work and meet the requirements, but are less efficient due an overlapping sphere of influence
between rods.

104
To take an example, one 16 mm (5/8 in.) x 3 m (10 ft) ground rod installed in 100 Ωm soil has a calculated
resistance of approximately 30 Ω to earth. Using three rods at the same depth, ~6m (20 ft) apart, results in
approximately 13 Ω.

Corrosion of grounding components can create points of higher resistance where components are bonded. An
example of this is copper sulfate forming where bare copper comes into contact with sulfur compounds in the
soil.

Design and installation practices that ensure low impedance

• Do not reduce the size of the ground conductor in the pathway from enclosures to earth. Large
conductors leaving enclosures must not be connected to smaller conductors on the path to the DIG, or
on the path from the DIG to earth.
• Ensure that the bend radius of all ground conductors meets the industry standard of 8 x diameter, as
discussed elsewhere in this chapter.
• Do not enclose ground conductors in ferrous conduit or raceways.
• Use bus bars for connecting conductors rather than clamping multiple conductors together.
• Design your system to minimize the effects of corrosion above and below grade. Corrosion can increase
the overall resistance over time, reducing the effectiveness of the ground system. The following factors
contribute to corrosion:
o Soil conditions – Highly acidic soils and moisture can attack below-grade earthing system
components.
o Cathodic reactions – Ground leakage current and contact between dissimilar metals can result
in higher resistance over time because of corrosion.
o Chemical reactions – Reactions with nearby chemical elements and compounds can cause
grounding components to erode.
• There are two methods of bonding sub-earthing components such as sub-earth electrodes, i.e., ground
rods, and conductors. These primary methods are cad welding and clamping, sometimes known as
Burndy clamping. Both methods have positive attributes. For example ,the clamping method allows for
maintenance and inspection, a priority with any ground system installation. The Cad welding method,
if done correctly, creates a solid bond and low resistance. However, it makes later inspection, testing,
and modification more difficult.
• Make sure that all ground rods (or ground components) are placed in ground wells of sufficient size to
allow a visual check as well as maintain the rod. It can be very difficult to use the necessary tools to
disconnect and then reconnect conductors from a ground rod in a small confined space such as a 8-inch
pipe used as a ground well. It can also disrupt local operations if it becomes necessary to dig in and
around a rod to gain access.
• Try to avoid covering much of the earth electrode network with asphalt or other impervious cover.
Impervious cover causes the soil to lose moisture and increases soil resistivity.
• Inspect sub-earth grounding components near grade by digging a few inches of soil away from the rods,
conductors, or straps. In many cases, you can see or feel corrosion just at the surface.
• Test the earth electrode network as described in IEEE Standard 81-2012, IEEE Guide for Measuring
Earth Resistivity, Ground Impedance, and Earth Surface Potentials of a Grounding System.

You can reduce the resistance of your grounding system by doing the following:

105
 • Decrease soil resistivity by adding non-corrosive, conductive salts or other soil additives.
• Increase conductor sizes.
• Bond all below-grade grounding components with uninsulated (bare) conductors to add to the overall
sub-earth portion of the ground system.
• Increase the surface area of the grounding components in contact with the soil. For example, you can
use longer grounding rods or increase the number of grounding rods.

Ground conductor sizing

Ground wire size is very important. Unwanted noise must be grounded through low-impedance wire to ensure
that noise is adequately attenuated and not re-radiated. The recommended wire sizes listed in Table 5-2
normally provide adequate attenuation. Use stranded wire, not solid wire. In general, stranded wire provides
both lower impedance and better noise attenuation than solid wire. The braided cable with construction
descriptors in Table 5-3 may be used as an alternative to Table 5-2. Braided cable has less impedance per foot
than normal stranded cable, usually offers greater flexibility, and is smaller and lighter.

For a single enclosure such as a CHARMs enclosure, or a group of adjacent enclosures with a relatively small
number of I/O points, you can connect the chassis ground and the DC ground busses together at the cabinet.
Ensure that the wire size, distances, and number of I/O points are within the specifications listed in Table 5-2.
Table 5-2 Ground wire sizing

I/O Cable length (ft)

points 10 25 50 100 300

64 8 AWG / 10 mm2 8 AWG / 10 mm2 8 AWG / 10 mm2 6 AWG / 16 mm2 2 AWG / 35 mm2

128 8 AWG / 10 mm2 8 AWG / 10 mm2 6 AWG / 16 mm2 2 AWG / 35 mm2 1/0 / 50 mm2

256 8 AWG / 10 mm2 6 AWG / 16 mm2 2 AWG / 35 mm2 1/0 / 50 mm2 2/0 / 70 mm2

512 6 AWG / 16 mm2 2 AWG / 35 mm2 1/0 / 50 mm2 2/0 / 70 mm2 3/0 / 95 mm2

1024 2 AWG / 35 mm2 1/0 / 50 mm2 2/0 / 70 mm2 3/0 / 95 mm2 4/0 / 120 mm2

2048 1/0 / 50 mm2 2/0 / 70 mm2 3/0 / 95 mm2 4/0 / 120 mm2 ---

4096 2/0 / 70 mm2 3/0 / 95 mm2 4/0 / 120 mm2 --- ---

8192 3/0 / 95 mm2 4/0 / 120 mm2 --- --- ---

106
Table 5-3 Braided cable construction types (as an alternative)

I/O Cable length (ft)

points
10 25 50

64 24-7-30 24-7-30 24-7-30

128 24-7-30 24-7-30 48-22-36

256 24-7-30 48-22-36 24-32-30

512 24-32-30 24-32-30 24-44-30

1024 24-32-30 24-44-30 2(24-32-30)

2048 24-44-30 2(24-32-30) 2(24-35-30)

4096 2(24-32-30) 2(24-35-30) 3(24-32-30)

8192 2(24-35-30) 3(24-32-30) ---

Ground bus construction

Ground bus bars should be made of copper, nickel-plated copper, copper-clad steel, or hard brass (B16).
Ground busses are available from local industrial electronics suppliers, or you can fabricate your own. DC
ground busses mount on isolated brackets to electrically isolate them from an enclosure. Busses normally allow
screw connections for wiring lugs. Lugs should accept wire sizes of 6 AWG to 4/0 AWG (16 to 120 mm2). In
purchasing or fabricating bus bars, observe the following guidelines:

• Select or design a bus bar for the number of conductor connections necessary and the conductor size
specified in Table 5-2. For example, if you are building a remote cabinet with 96 CHARMs I/O points,
and the distance to the nearest ground connection is 100 m (300 ft), use a bus bar with a single 1/0
(50mm2) conductor connection point and multiple 14 AWG (2.5 mm2) conductor connection points.
• Use isolating standoffs when mounting DC bus bars.
• Do not double up on a connection point with more than one conductor. For example, do not place two
lugs on one bus bar hole or more than one conductor under the same terminal clamp.
• Use two-hole lugs for ground conductors.
• The holes in the bus bars should be of the correct size and dimensionally placed for the lugs used.
• Torque lug bolts to specification, and mark each bolt to provide a visual indication if the bolt has
moved after being torqued.
• Field wiring may also require surge suppression if the signals enter a protection zone outside the zone
which includes the controller and cards. When SPDs are used with field wires it is best to have SPDs at
both ends of the field transmitter/receiver pair.
• If a coating is required to protect against corrosion, use a clear coating material to allow visual
inspection of the bolt, lug, and copper.

107
 • Use Belleville (conical spring) washers on the lug bolts to maintain consistent force in varying
temperatures.
• Label ground bars for identification.

The following figure shows a commercially available ground bar suitable for use with DeltaV. This kind of
ground bar is typically used in data centers. Verify the ground bars materials are compatible with the
environment where the bars will be installed.
Figure 5-5 Local area ground bus

108
The following figure shows properly installed isolating standoffs for a ground bar.
Figure 5-6 Ground-bar isolating standoffs

Recommended method of connecting ground cable to a ground bar

DeltaV recommends a modified PANI method for connecting ground conductors. PANI stands for “
producers, absorbers, non-isolated equipment, and isolated equipment,” and it allocates specific areas of a
ground bar for bonding. The PANI method prevents noise producers from coupling into the DeltaV ground
system. DeltaV recommends a modified PANI method for the DIG (or master reference ground bus bar), as
shown in the following figure.

109
Figure 5-7 Modified PANI method

Marking ground components

To aid in ground wire identification, use identifiable insulation colors (such as green or green with a yellow
stripe) or another labeling method that meets country codes. NFPA 70 (NEC) allows color coding using colored
electrical tape at the ends of conductors. Europe and other world areas following IEC standards restrict the use
of green and yellow striped wire to protective earth conductors. Follow the standards in use in your area.

Emerson recommends isolating DeltaV bus bars from other equipment grounds and labeling them as follows:

FOR CONTROL SYSTEM GROUND ONLY.

All bus bars associated with the control system, including enclosures, should be clearly identified as to their
location and purpose.

Enclosure grounding
A well-grounded conductive enclosure minimizes effects of electromagnetic interference (EMI) on equipment
and prevents accidental shock hazards to personnel. Enclosure grounding should be bonded with a conductor
connected to the local CG reference point.

Emerson recommends keeping the DeltaV DC ground system isolated from chassis ground until the single-
point connection at the DIG. Figure 5-4 shows grounding that retains proper separation. In a group of
enclosures, grounds should be routed to the center enclosure if possible.

Grounding for CHARMs and remote enclosures

For small DeltaV systems with low I/O counts, such as single CHARMs enclosures, all system grounds can be
connected to a single local ground, as shown in Figure 2-8.

Multi-story Buildings
The following figures show grounding for DeltaV systems in multi-story buildings. Note the following good
grounding practices shown in the figures:

110
 • Local area CG and DCG bars are installed on every other floor.
• All ground systems are bonded to the plant ground grid.
• The control system ground is connected to the plant ground grid at a location as far as possible from all
other ground subsystems, such as lightning mitigation and high-energy ground.
• DeltaV CG and DCG systems meet at the DIG as their single-point common ground reference.
• The neutral-to-ground connection of a separately derived power source is bonded to the same DIG as
the DeltaV systems it feeds.
• A separate building (Building B at bottom right of each figure) with a separately derived power source
and DeltaV system has its own DIG, triad, and separate connection to the plant ground grid.

Note: Installing more CG and DCG bars on floors with numerous DeltaV systems can save cabling costs.

111
Figure 5-8 Multi story building with one power source

Legend
DCS DCS DCS ∆ or Y = Isolation Transformer
in either ∆ or Y configuration
Enclosure Enclosure Enclosure
Shield Shield
DP = Disconnect Panel
DP
Bars Bars Shield Primary (red) = Primary power source
A.C. A.C. A.C. Bars
Grnds Grnds Grnds Backup (blue) = Backup power source
DP DCG
DCG CG DCG CG CG Green/Yellow) = Chassis Ground and
Protective Earth Grounds
Green = Control System Functional
Local Area DCG Local Area CG
Grounds
Building Steel 4th Floor

High Energy Equipment

Building Steel
3rd Floor

Isolation XFMRs
∆ or Y Primary
DCS DCS DCS
DP
Enclosure Enclosure Enclosure
Shield Shield Shield
Bars Bars Bars
∆ or Y Backup A.C. A.C. A.C.
Grnds Grnds Grnds
DP

DCG CG DCG DCG

CG CG

DP

Dedicated
Instrument Local Area Local Area
Ground (DIG) DCG CG 2nd Floor
DCS
DP Enclosure
Shield
DP DP Bars
A.C.
Grnds
Instrument Instrument
Primary Secondary DCG
Power Power CG
Panel Panel

1st Floor

DeltaV
Lightning Triad
System Earth Electrode
DeltaV Network
Triad

Plant Earthing
Connection

The following figure shows grounding for DeltaV systems with multiple separately derived power sources on
multiple stories. The neutral-to-ground connection of each power source is bonded to a local safety ground bar
before the DIG.

112
Figure 5-9 Multi-story building with multiple power sources

Legend
Isolation XFMRs DCS DCS DCS ∆ or Y = Isolation Transformer
∆ or Y Primary in either ∆ or Y configuration
Enclosure Enclosure Enclosure
DP Shield Shield
DP = Disconnect Panel
Bars Bars Shield Primary (red) = Primary power source
∆ or Y Backup A.C. A.C. A.C. Bars
Grnds Grnds Grnds Backup (blue) = Backup power source
DP
DCG DCG
CG DCG CG CG Green/Yellow) = Chassis Ground and
Protective Earth Grounds
Green = Control System Functional
Local Area DCG Local Area CG
Grounds
Building Steel 4th Floor

High Energy Equipment

Building Steel
3rd Floor

Isolation XFMRs
∆ or Y Primary
DCS DCS DCS
DP
Enclosure Enclosure Enclosure
Shield Shield Shield
Bars Bars Bars
∆ or Y Backup A.C. A.C. A.C.
Grnds Grnds Grnds
DP

DCG DCG
CG DCG CG CG

DP

Building Dedicated
Steel Instrument Local Area Local Area
Ground (DIG) DCG CG 2nd Floor
DCS
DP Enclosure
Shield
DP DP Bars
A.C.
Grnds
Instrument Instrument
Primary Secondary DCG
Power Power CG
Panel Panel

Dedicated
1st Floor Instrument
Ground (DIG)

DeltaV
Lightning Triad
System Earth Electrode
DeltaV Network
Triad

Plant Earthing
Connection

113
 Appendix A Interference and transients

Static coupling
Static coupling, also called capacitive coupling, can occur when signal shields run parallel to nearby noise
sources. Motor commutation, variable frequency drives, and tools such as welders can all result in static coupling
interference. The following figure shows two return paths for noise resulting from static coupling.
Figure A-1 Return paths for static coupled interference

The dashed return path through DeltaV represents the path noise takes when the shields are tied to the isolated
instrument ground. The noise returns to the location where the chassis ground and DC ground are first
connected to building steel. At that point a parallel path is established. Some current will travel through building
steel, with the remainder following the copper to steel, then to its source.

• Noise tends to return to its source following the path of least resistance.
• Steel is 10 times more resistive than copper.
• However, because of the skin effect and the multiple paths in the steel, the path through steel is 4.5
times less resistive overall than the copper path.

Connecting signal shields to building steel ensures that noise returns to its source more efficiently.

Voltage differentials
Voltage differentials can result from lightning, utility failures, equipment failures, and many other events
common in industry. For example, if lightning strikes one side of a structure and DeltaV signal wires travel into
the area near the lightning strike, static coupling can be induced on signal shields even if the associated DeltaV
enclosure is in a different part of the structure. The following figure represents a fault that causes a voltage
differential in a facility.
114
 Figure A-2 Static coupling caused by voltage differential

Typically, voltage differential faults that result from equipment failure, utility faults, or lightning create a
transient signal that subsides with a type a diminishing ring similar to the gate function (sin(x)/x). However, the
decay more closely resembles a zero-order Bessel function. Because noise tends to return to its source, the actual
elevation in impulse voltage at one area establishes a differential with respect to more remote locations. Multiple
paths through steel and copper grounds eventually equalize due to the heating (I2 •R) losses throughout the
numerous return eddy paths.

Inductive coupling
When signal wires are close to high current conductors, such as the down conductor on a lightning system,
lightning strikes induce a current on its air terminal and possibly the signal conductors too. A voltage differential
is established on the wire and ground system which dissipates through numerous eddy current paths as the
induced interference attempts to return to its source. The most direct path is the one in which the shield is
connected to building steel as close as possible.

Industry example: A 55 KV precipitator used to covert ash into small pellets that can be collected was located at
the top of a multistory chimney. The ground conductor was an exposed copper wire traversing the length of the
chimney into the ground grid. This ground cable was also connected to building steel on every floor. A signal
cable was run in parallel to the precipitator's ground wire, which caused a 90 VPP transient to be coupled onto
the signal during the precipitation process. This coupling process was due to inductive coupling as shown in the
following figure.

115
Figure A-3 Inductive coupling from down-conductor into signal cable

116
 Appendix B Shield earthing for high-integrity
ground systems

Perform a cost/benefit evaluation when choosing the proper location to land the shield drain wires. There is a
definite cost savings associated with connecting both the DC ground and the Chassis Ground (CG) together.
This requires only one functional ground connection to the DeltaV Instrumentation Ground (DIG). If however,
the highest integrity ground system yielding the least amount of disruptive events is required, then the shields
should be connected to the CG for the following reasons:

• Noise tends to return to its source following the path of least resistance.
• Scientific evidence confirms that noise on shields connected to DC ground adversely influences system
integrity. The Pin 1 Problem first recognized by Neil Muncy and documented in his 1994 Audio
Engineering Society paper has been confirmed in multiple studies. Although this issue has been of
particular concern to audio engineers, the conclusion applies to all engineering disciplines including
control systems.
• Standard recommending shields be connected to enclosure or chassis ground:
- ANSI/ISA-RP12.06.01-2003 Recommended Practice for Wiring Methods for Hazardous (Classified)
Locations Instrumentation Part 1: Intrinsic Safety requires that shields be connected to equipment or
chassis ground.

Equipment manufacturers are continually designing products to be smaller, with less weight, and at an increased
savings. This has led to products operating at higher frequencies resulting in electrical components, such as
indictors and transformers, being much smaller. Emerson has been and will remain a leader in providing a power
and grounding solutions for controlling equipment designed for today's adverse environments as well as
unforeseen future applications.

117
 Appendix C Earthing and grounding

Designing an earth ground system

An adequate earth ground is extremely important for both personnel safety and correct operation of a control
system. The earth ground absorbs stray AC or induced EMI currents from equipment grounds and safely
grounds the currents to earth. This section provides guidelines for constructing a good earth ground.

Building steel is not a good earth ground for process control systems. Sometimes, control room grid systems, if
they meet the requirements for good earth grounds (described below), can be used for a control system ground.
In all cases, construction of and connection to earth grounds must be made in accordance with local, state, and
federal codes.

Several process industry sources recommend a ground system resistance of one ohm or less between the control
system ground and true earth, with a maximum resistance of 5 Ω. A resistance of 1 Ω or less minimizes the
possibility of phantom errors in the control system caused by voltage drops in the ground system.

The control system ground must be at least as good as any other system ground in the plant. For example, if a
ground used with a radio communication system has one-ohm (or less) resistance to true earth, the control
system ground must have 1 Ω (or less) resistance to true earth. Both ground systems must be referenced to the
plant ground grid.

For a plant ground grid, multiple ground rods are much preferred over a single rod because:

• Rod-to-earth contact resistance of the individual rods are effectively placed in parallel, reducing overall
resistance.
• Personnel safety is enhanced because ground contact does not depend on a single rod.

The distance between rods in a multiple rod system must not be greater than twice the immersion depths of the
rods. For more information on installing and testing ground systems, you may wish to obtain the publication,
Getting Down to Earth from the Megger Group Limited.

If an existing grid is accessible and the grid-to-true-earth meets the resistance requirements, the existing grid can
be used for the control system ground. If the existing grid is not accessible or the resistance is not within
specifications, a new grid is required.

One point (preferably at a ground rod) on the grid and close to the control system is used for the DeltaV
dedicated connection. The control system ground is connected to the chosen ground rod with 4/0 AWG (120
mm2) shielded, stranded-copper cable. The cable at the rod end may be hydraulically crimped or thermally
welded to the rod.

For cable to cable connections, thermal welding historically provides good long term integrity. Field experience
infers that hydraulic crimping may provide better integrity for cable-to-rod or cable-to-building connection due
to occasional difficulty in making reliable thermal welds of these joints.

118
Figure A-4 Example design for plant ground grid

119
Figure A-5 Typical Ufer ground system below grade

Figure A-6 Example connecting to existing ground rods

120
Figure A-7 Example connecting to existing counterpoise

Figure A-8 Example connecting to an existing ground grid

121
 Figure A-9 Example connecting to Ufer ground

Note: Refer to Figure A-5 for footing detail.

122
Figure A-10 Example connecting to existing buried steel plate

123
 Appendix D Earth grounds in water and ice

Sometimes, good earth grounds by definition are not possible, such as earth grounds on oil and gas platforms
and where the earth is more likely to be ice or permafrost. Yet, it is still imperative to ground AC equipment for
personnel safety and to ground EMI signals for proper control system operation.

For oil and gas platforms anchored to the sea bottom, one of the platform legs is the connection to earth ground.
For floating platforms, a leg or some metal structure submerged deep in the sea is earth ground. All ground
systems on a platform must be connected to the same point so that they all have equal earth ground resistance.

For ice or permafrost locations, steel beams can be driven into the permafrost as far as practical. Two beams
located at opposite corners of the control system building are recommended. One beam provides earth ground
for AC equipment and the other beam provides earth ground for the control system. Both beams should provide
equal ground resistance, and each should be as close to one ohm resistance to earth as possible. Sometimes,
resistance considerably higher than one ohm may be the best that can be had. You simply attempt to obtain the
best earth ground possible. Be sure to use good bonding methods when connecting ground cables to the beams.

Testing an earth ground

The electrical resistance of an earth ground system must be tested to ensure that the system meets requirements.
The total resistance of the ground system is comprised of the resistance of the ground cable connection to the
grid, the resistance of the metal used in the plant ground grid, the resistance of the contact between the grid and
earth, and the resistance of the earth itself. For a DeltaV system, the recommended earth ground resistance is
1 Ω or less with a maximum resistance of 5 Ω.

There are several methods for testing earth ground resistance. The three-point (or Fall of Potential) method, the
two-point (or Direct) method, and the Slope method are frequently used. Various manuals are available from
tester manufacturers and consulting firms which detail earth ground resistance testing. Also, IEEE Standard 81,
IEEE Guide for Measuring Earth Resistivity, Ground Impedance, and Earth Surface Potentials of a Ground System,
contains descriptions of these methods.

Note: Several Internet sites contain helpful information about earth ground resistance measurements and
methods. Use an Internet search engine to search for “earth ground resistance measurement.” Fluke Products
and other vendors include application notes for earth ground measurements.

An earth ground tester is used to determine the total resistance of an earth ground system. The tester contains an
electric current source and connections for probes.

When earth ground systems must provide 5 Ω or less resistance, the resistance of the test leads can no longer be
assumed to be negligible, especially since the leads can be many feet or meters long. Therefore, lead resistance
should be measured and subtracted from the earth ground reading.

Three-point testing method

In this method, an electric current passes through earth between a current probe (C) and the ground grid being
tested (E). At a point between these locations, a third probe (P) is inserted in the ground. Standardized tables
give recommended distances between C, E, and P locations to obtain accurate measurements.

124
A typical point for P is 62% of the distance between C and E, as measured from E. The distance between C and
E depends on the depth of the ground rods.
Figure A-11 Three-point method for testing earth ground

Earth
Ground
Tester
Ohmmeter
E
C
P
Earth Ground
Under T est
1
E P C

Earth

62% of EC
Probes Used
for Testing
EC 2

Notes:
1 Disconnect any ground cables from the ground system while testing is in progress.
2 Probes used for testing are placed in a straight line from the earth ground under test.

Table A-1 Depths and measuring points for three-point testing method

Depth of ground rods at point E Points E and P Points E and C

6 ft (1.8 m) 45 ft (13.7 m) 72 ft (22.0 m)
8 ft (2.4 m) 50 ft (15.2 m) 80 ft (24.4 m)
10 ft (3.0 m) 55 ft (16.8 m) 88 ft (26.8 m)
12 ft (3.7 m) 60 ft (18.3 m) 96 ft (29.3 m)
18 ft (5.5 m) 71 ft (21.6 m) 115 ft (35.1 m)
20 ft (6.1 m) 74 ft (22.6 m) 120 ft (36.6 m)
30 ft (9.1 m) 86 ft (26.2 m) 140 ft (42.7 m)

Resistance value is obtained by measuring the current between C and E and the voltage between P and E. Many
earth ground testers convert these measurements to resistance and show the resistance on an ohmmeter. Ohm's
Law can be used to determine the resistance if an ammeter and voltmeter are used on the tester.

It is recommended that measurements be made and recorded in several directions from the ground system and
the values entered in a table. The values will indicate good earth ground areas and also high resistance areas to be
avoided. Since earth ground resistance varies with changes in ground moisture and temperature, resistance
measurements should be made at different times during a year.

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Two-point testing method
The two-point method, although not as accurate as the three-point method, can be used when there is
insufficient area to lay out probe locations for the three-point method. Area can be limited by obstacles such as
buildings, highways, railroads, and by other ground systems where the electrical currents in those systems could
influence the measurements of the system under test. Also, if measurements are attempted inside the perimeter
of a ground grid system, inaccurate readings can result.

The setup reduces the distance necessary to make a measurement. Terminals P and C are tied together and
connected to a known adequate ground system, such as that of a power utility neutral ground. Then, earth
ground resistance can be measured between the known system and the system under test. If a voltmeter is used
in conjunction with an ammeter, the voltmeter is connected between P/C and E.

Figure A-12 Two-point method for testing earth ground

Earth
Ground
Tester
Ohmmeter
E
C
P
Earth Ground
Under T est
1
E P/C

Earth

Probe Used for

Testing
Note:
1 Disconnect any ground cables from the ground system while testing is in progress.

Slope testing method

The Slope method can also be used when area for inserting probes is limited. This method uses a setup similar to
the two-point method, except that the probe P/C is moved to several locations in a straight line, and a
measurement is taken at each location. Locations are typically 20%, 40%, and 60% of the initial P/C distance to
E. With these measurements, a slope coefficient is calculated and the result compared to a standard table. From
the table, the best location for P/C can be found. Then, an earth ground resistance measurement is again taken
for this location, and recorded. Because this method is subject to many extenuating influences, several
measurements should be made in all directions from the earth ground system to ensure the accuracy of the
results.

Annually inspecting an earth ground system

As a preventive maintenance action, each connection on an earth ground system needs to be checked annually.
This check ensures that connections are tight, ground wires are in good condition, and no contamination or
corrosion exists that can compromise ground system integrity.

126
 Appendix E Effects of heat and air flow inside
an enclosure

General
Most DeltaV™ DCS and DeltaV SIS™ products, such as controllers, I/O cards, logic solvers, and related items,
are designed for natural airflow cooling. For maximum product availability and expected unit lifetime, sufficient
airflow through the products and proper ambient air temperature in and around them must be sufficient to
maintain the specified operating temperature range.

Environmental conditions such as elevated temperature can cause gradual performance degradation, intermittent
failures, and malfunctions in all electronic equipment. To prevent problems during the operation of both
control and safety systems, consider the effects of heat and airflow on equipment in enclosures when designing
DeltaV systems.

Heat impact on mean time between failure (MTBF)

For optimum reliability, electronic equipment must operate within its normal operating limits for ambient
temperature, relative humidity, and hourly variations of these. When the equipment is operated within the
specified temperature, reliability based on mean time between failure (MTBF) calculations can be expected. If
the equipment is operated at a higher temperature for long periods of time, the failure rate increases. Heat wears
out electronic components; as explained by the Arrhenius effect equation, for every 10 °C increase in operating
temperature, the failure rate doubles. This behavior is not specific to Emerson products. The reliability of any
electronic component is affected by heat.

The chart below shows an example of the effective drop in the MTBF value for each 10 °C rise in operating
temperature for a hypothetical device, during a hypothetical time period ranging from 12.5 years to 200 years.

127
 Table A-2 Correlation between temperature and MTBF

Temperature MTBF

25 °C 200 years

35 °C 100 years

45 °C 50 years

55 °C 25 years

65 °C 12.5 years

Consider the actual operating temperature when evaluating the useful life of electronic equipment, including
DeltaV and DeltaV SIS components.

Airflow considerations
Most DeltaV DCS and DeltaV SIS products, such as controllers, I/O cards, logic solvers and related items, are
designed for natural airflow cooling. For maximum product reliability, sufficient air flow through them and
proper ambient air temperature in and around them must be such that their specified operating temperature
range is maintained. Proper temperature levels promote good system health and product availability.

All DeltaV DCS and DeltaV SIS products are designed to operate within a specific temperature range, for
example, -40 °C to 70 °C. Consult the product datasheet for each product to determine the specific
temperature range. The published information indicates the temperature range a product can withstand;
however, running the product at the higher end of the temperature range for long periods of time increases the
failure rate of electronic components.

Heat-related issues
The following are some heat-related issues identified during design reviews and troubleshooting:

• Enclosure designs that do not allow adequate heat dissipation and airflow, resulting in very high internal
temperatures.
• Enclosure designs that lead to hot spots because of lack of air circulation in some areas of the enclosure.
• Enclosures located in areas of higher ambient temperatures caused by, for example, adjacent heat-
producing equipment or direct sunlight.
• Equipment, interconnected wiring, and cabling inside an enclosure so tightly packed that natural
airflow is inhibited.
• Wiring raceway mounted too close to devices, cutting off adequate airflow, especially if the raceway is
packed with wiring and cabling.
• Devices with opposite-side cooling slots and adjacent products mounted too close for adequate cooling
air.
• Devices that should be mounted either vertically or horizontally for adequate airflow, but are mounted
otherwise.
• Heavy heat-producing devices in the enclosure, such as power supplies generating high internal
temperatures.

128
Solutions
Consider the following methods of improving heat dissipation:

1. Proper placement of pieces of equipment in relationship to each other, including the following:
a. Power supplies
b. Raceways
c. Cable wiring into and out of the enclosure
d. Device placement for maximum air circulation

Notes: When designing an enclosure, consider the minimum distances specified by the equipment vendors. For
DeltaV equipment, consult the planning and design documentation. The wiring must at least conform to
NFPA, NEC, and applicable local, regional, and national codes to ensure that it can conduct load safely without
overheating.

2. Consider auxiliary designs for cooling and air flow.

a. Use side and top vents to move cool air in and hot air out.
b. Use instrument air and vortex coolers. Consider a filter system on the input line to ensure clean and
dry air.
i. Allows positive pressure inside the enclosure.
ii. Allows small amounts of air to improve airflow beyond convection alone.
iii. Allows normally cooler instrument air (often used to control dew point) to lower enclosure
internal temperature.
c. Use heat sinks or cooling fans.
d. Mount products in such a way as to take advantage of the built-in cooling openings.
e. Make sure the enclosure does not receive warm, moist air from other areas through conduit
openings.
3. Design circuits so that all the power does not dissipate inside an enclosure. For example, some circuits
such as an AS-Interface can be wired in parallel or series. Series wiring dissipates more energy inside
the unit and enclosure, whereas parallel wiring dissipates more energy in the field devices.
4. Place enclosure fans so that they work more efficiently and effectively.
a. Locate fans to move air in such a way that enclosure sheet metal can dissipate heat.
b. Locate fans to provide maximum airflow over and through all installed devices. Sometimes, fans are
mounted so that they are ineffective in actual cooling or providing critical airflow. Fan placement is
an important aspect of the enclosure design. Consider the following guidelines when selecting the
fan location for your application:
i. Place fans in the bottom of the enclosure to create positive pressure, and place vents at the
top rear of the enclosure to exhaust the hot air. This method can maximize cooling and
airflow because it works with the physics of convection currents.
ii. Place exhaust fans at the top back of the enclosure and pull air through from the bottom,
creating negative pressure. The drawback to this method is that air in connected conduits
can be pulled in.
iii. Roof cabinet fans have significant advantages over door cabinet fans because roof fans
generally have a bigger air-displacement capacity than door-mounted fans. Additionally,
the placement of roof fans right above the equipment ensures a bigger cooling effect than
door fans.
129
 5. Properly mounting devices with high heat loads

a. Mount devices with high heat loads near the top of the enclosure so the heat they dissipate does not
pass around or through other devices.

b. Mount devices with high heat loads near the sides of the enclosure.

c. Mount devices with high heat loads in such a way that natural airflow circulations (higher
temperature on one side and cooler temperature on the other) are generated.

6. Installing in a shaded area

a. Field enclosures exposed to direct sunlight are subject to solar energy absorption which can raise the
temperature inside the enclosure. Depending on the environmental conditions, sun shades or sun
shields should be considered to lower the temperature for both the enclosure and the electronic
components.

b. The temperature range specified for some field enclosures expects installation in a shaded area.
Installation should follow the field enclosure manufacturer’s recommendations and if needed, sun
shades or sun shields should be installed.

These methods can help maximum system availability and expected unit lifetime by better controlling enclosure
heat. Such control is fundamental to good enclosure design.

It is recommended to perform periodic audits to ensure proper temperature levels within enclosures as well as
identifying “hot spots.” Adequate airflow can be determined by measuring the inside temperature at the top,
middle, and bottom of the cabinet or enclosure. However, thermal images are the preferred method to measure
temperature. A hot spot reading could be an indicator of a bigger issue that needs to be reviewed and remedied.
Among other things the audit should confirm that fan directions, fan speed and that airflow is correct.

Measuring enclosure hot spots

After installing and starting up enclosure-mounted instruments, ensure adequate air flow by measuring the
inside temperature at the top, middle, and bottom of the enclosure. Make measurements with the equipment
powered and all fans running. The temperature difference between the air entering the enclosure, air anyplace in
the enclosure, and air at the top of the enclosure should not be more than 18 °F (10 °C).

Warning: Both AC power and 24 VDC power with large current capabilities are powering installed equipment.
To avoid personal injury and damage to equipment, use extreme caution when making temperature
measurements.

Maintenance considerations
Regular maintenance is very important. Air filters need to be cleaned or replaced periodically. Clogged air filters
will lead to poor air cooling, higher temperatures, and shorter expected unit lifetime.

Controlling humidity
Special emphasis must be placed on humidity control. When the atmosphere contains corrosive vapors, average
relative humidity must be kept below 50% to minimize the possibility of condensation, but not below the
minimum level in specified range where damage can occur from electrostatic discharges.

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Caution: Preventing condensation is extremely important. Corrosive vapors dissolving in condensation turn
into acids that slowly erode conductive lands, component leads, connector pins, and other metal on electronic
equipment. The equipment can become damaged beyond repair.

Heating and cooling calculations

In most cases, there are two sources of heat within an instrument enclosure. One source is heat generated by
enclosed instruments; a second source is ambient heat surrounding the enclosure. The second source may be
heat gain or loss, depending on the temperature difference between the inside and the outside of the enclosure.

You can calculate the amount of heating or cooling required to control enclosure temperature. The equations
below give approximate cooling requirements for heat control within enclosures. For the rate of heat production
surrounding enclosures, add an allowance for personnel, lighting, power equipment, and heat gain or loss
through walls and windows. Air conditioning, heating, or ventilation systems must be sized large enough to
handle the requirements.

It is important that you determine the total power dissipation for power supplies and process instruments in
each enclosure. Power supplies are the main generator of heat in enclosures. Heat dissipation for power supplies
is normally fairly stable over their typical power output range. Refer to the DeltaV manual Installing Your DeltaV
Digital Automation System and DeltaV Books Online to obtain product heat dissipation information.

Cooling calculations to control heat generated within enclosures

To calculate the cooling required to control heat generated within an enclosure, add the typical heat figures for
each process instrument and other equipment contained in the enclosure. If heat data is not available for an
instrument, use the following formula to develop the typical cooling required for the instrument:

qs = (Cs)(qr)(CLF)

where

qs = the cooling load, in BTU/hr.

Cs = the appliance coefficient, equivalent to device efficiency; that is, how much of the power input is converted
to heat. (In the absence of measured values, use 0.33).

qr = the heat dissipated by the load, in BTU/hr; you can find this amount by multiplying the load power in watts
(W) by 3.4.

CLF = the cooling load factor; generally, it applies to intermittent operations. For continuous operation, use 1.0.

With these assumptions, the equation becomes:

qs = 0.33(qr)

where

qr = 3.4 × V × I, for DC power

qr = 3.4 × V × I × pf, for single-phase AC power

qr = 3.4 × V × I × pf × 1.73, for three-phase AC power (assuming well-balanced loading of each phase in a
manner consistent with good engineering practice).
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(V = input voltage; I = input current; pf = power factor)

The resultant cooling-load measurement units are BTU per hour. Convert the load to tons of refrigeration by
dividing by 12,000.

Example: Example of calculating heat generated within an enclosure

A group of enclosures in a rack-room contain various combinations of instruments. What is the required cooling
load?

First, add the electrical current drawn by the equipment in each enclosure. For this example, the assumption is
270 A at 24 VDC total for all enclosures.

Next, apply the equation and determine the BTU per hour cooling required:

qs = 0.33 × 3.4 × 24 VDC × 270 A (DC)

qs = 7,271 BTU/hr

From this, the refrigeration requirement is:

Refrigeration = 7,271/12,000 = 0.61 tons

Cooling calculations to control heat transferred into enclosures

When enclosures are installed in uncontrolled temperature areas, such as an operating floor, the heat
transmission through the enclosure walls may have to be considered. If the outside temperature is higher than
inside, then additional cooling is usually required. If the outside temperature is lower, then reduced cooling, or
none at all, may be adequate. When installing equipment outdoors, solar loading, moisture migration, and so
forth also need to be considered.

The calculation for determining the cooling requirement to compensate for heat transfer is:

qs = (U)(A)(∆t)

where

U = the heat transfer coefficient for the enclosure; if the enclosure is metal, use U = 1.

A = the total exposed surface area of the enclosure (disregard unexposed surfaces such as back panels on back to
back enclosures or floor panels on floor-mounted enclosures.

∆t = the difference between the desired internal temperature and the temperature outside the enclosure.

Example: Example of calculating heat transferred into an enclosure

Assume an enclosure with 36 ft2 exposed metal surface and a temperature that averages 40 °F hotter than the
desired temperature inside the enclosure. The net heat gain is:

qs = (1)(36)(40) = 1,440 BTU/hr

From this, the refrigeration requirement is:

Refrigeration = 1,440/12,000 = 0.12 tons.

The 0.12 tons is the additional cooling required on top of cooling required for instrument heat.
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Calculating the effects of a pressurization system
When using a pressurized enclosure, the cooling or heating effect of the pressurized system can be determined by
using the following equation:

Cooling effect = 1.08 (CFM)(∆t) in BTU/hr

where:

CFM = cubic feet per minute of air flow.

∆t = the desired inside temperature minus the incoming air temperature of the pressurizing system.

Example: Example of calculating the temperature effect

of pressurizing an enclosure
Assume a NEMA 12 enclosure that is 4 ft by 4 ft by 1.5 ft and the desired internal temperature is to be
maintained at 75°F. For proper pressurization, the volume of incoming air is the enclosure volume (24 cubic
feet) times 0.05 (the percentage constant for NEMA 12 enclosures) = 1.2 CFM. The incoming air temperature
is 70°F.

The effective cooling of the incoming air is: Effect = 1.08(1.2)(75 - 70) = 6.43 BTU/hr

This figure is then used to determine the overall heat gain.

Note: If additional cooling is required, a vortex cooler can be added.

Conclusions
Achieving expected system reliability and longer expected unit lifetime is possible by proper system design and
maintenance. Please contact your local Emerson sales office for information about maintenance programs to
achieve maximum system availability.

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 Appendix F Wire-color conventions

Color coding to indicate the functions of different conductors varies by electrical code, industry practice, and
world area. Industry groups have attempted to introduce consistency in color-coding conventions and practices,
but differences remain.

Emerson's DeltaV products are sold worldwide, and Emerson does not mandate any color-coding convention.
Installers must understand and comply with the requirements of authorities having jurisdiction for the location
of each installation.

Electrical codes often mandate, prefer, recommend, or mention color-coding conventions. The tables that follow
provide simplified examples of color-coding conventions in four common electrical codes. This list is not all-
inclusive, and various electrical codes contain exceptions and special cases that you must observe.

1. Preferred or recommended.
2. Required.
3. Commonly used in industry but not mandated by NEC. Brown, orange, yellow, and gray are
commonly used for higher voltages. Black, red, blue, and white are commonly used for lower voltages.
AC ground is typically green, and DC ground is often green/yellow.
4. Orange is required on the high leg of a 4-wire delta with midpoint grounding.
5. Required for greater than 60 V.
6. IEC/EN 60445-2017 - Basic and safety principles for man-machine interface.
7. C-22.1-15 - Canadian Electrical Code, Part I.
8. NFPA70-2017 - National Electrical Code.
9. Government of India General Specifications for Electrical Work-2013; SP 30 (2011): National Electrical
Code of India.

134
 Appendix G Emerson DeltaV control
and installation drawings

The following table lists the current DeltaV control and installation drawings as of May 2017. Contact
Emerson’s Local Business Partner or Field Sales Office to obtain a copy of the current documentation for the
version of DeltaV you are using.
Table A-3 DeltaV Control and Installation Drawings

Drawing Title or function Modules

12P1293 FM Div 2 Installation Drawing M-Series, SIS/SLS

12P2046 ATEX Zone 2 M-Series, SIS/SLS

Installation Drawing

12P5401 FM Div 2 Installation Drawing CHARM I/O

12P5402 FM Div 2 Installation Drawing S-Series

12P5403 ATEX Zone 2 Installation Drawing CHARM I/O

12P5404 ATEX Zone 2 Installation Drawing S-Series

12P1892 DeltaV™ Scalable Process System, Class I Div. 2 M-Series IS

with Class I, II, III Div. 1 Field Circuits Installation
Instructions

12P1990 DeltaV™ Scalable Process System with Zone 0 Field M-Series IS

Circuits Installation Instructions

12P2524 DeltaV™ IS I/O Code of Practice for Installation M-Series IS

and Maintenance in Zone 2 Hazardous Areas

12P2822 Namur NE21 Installation Instructions All

12P3292 Type KJ7000 Series Zone 1 I/O System Installation KJ7000 Series
Instructions

12P3517 KJ17xx Single/Four Port Fiber Switch Installation KJ1710X1, KJ1740X1

Instructions

12P6122 Installation Control Drawing IS‐CHARMs IS‐CHARM Subsystem

Subsystem

12P6123 Installation Control Drawing IS‐CHARMs IS-CHARMs

12P6523 ATEX/IECEx Installation Instructions IS‐ IS‐CHARM Subsystem

CHARM Subsystem

135
For ordinary non-classified locations, Marine Certified installations, and other information, refer to the
applicable D8000xxxxxx hardware installation and reference manuals.

136
 Appendix H Warning labels

Cabinet and enclosure designs must provide proper shock protection and risk awareness for the safety of
personnel maintaining or troubleshooting the DeltaV system. As an example, local region codes and regulations
define access limits for non-electrically qualified personnel exposed to energized circuits. These codes and
regulations require only electrically qualified personnel to work at voltages equal to or greater than 50 VAC or
75 VDC. (NFPA70E Standard for Electrical Safety in the Workplace; EUR-Lex Directive 2014/35/EU)

The following are some examples of warning labels:

• If more than one bussed field power source is used at a bussed field power connector, place a label near
the connector. Add the following statement in appropriate local languages to the label:

WARNING: MORE THAN ONE LIVE CIRCUIT. SEE INSTALLATION DIAGRAM.

• If AC and DC field power are connected to the same connector, it must be marked with a warning label
as follows in appropriate local languages:

WARNING: THIS CONNECTOR CONTAINS BOTH 120 VAC (OR 240 VAC) AND 24 VDC.
BE SURE TO DISCONNECT BOTH AC AND DC POWER BEFORE UNPLUGGING THE
CONNECTOR.

Although you mark a connector with the warning label, connecting AC and DC field power on the same
connector is never recommended. Lethal voltages are possible. Additionally, it is never considered to be good
engineering practice to connect both AC and DC power to the same connector.

Warning labels should be in local language and are often required to be in multiple languages as seen in the
following figure.

137
138
 Appendix I Power and Grounding
Audit Worksheets

Introduction
When a PlantWeb Automation System is first installed, or when the system is not operating as designed, it is
sometimes necessary to perform a site audit to determine what factors could be contributing to the degraded
performance. Often these factors are external to the system and may include but not be limited to the power and
grounding quality.

Purpose
The worksheets in this section are intended to ensure the environment in which the system is situated and the
implementation of the power and grounding systems are correct. This document has no other purpose and is not
intended for issues outside of the subject of power and grounding, or complications arising from power and
grounding issues, such as electrical noise and component failures.

Worksheets and associated data sheets are used to guide the audit. The checklists provide a record of conditions
at the time of inspection and are an integral part of the Emerson Automation Solutions Systems Life Cycle
approach. The records assure compliance and are very helpful when used as part of an on-going maintenance
program. Note that all checklists may not be applicable to each particular situation and consideration should be
made for each and every audit.

Intended audience
The checklists are intended for use by Emerson personnel to perform a site and installation evaluation. This
document is intended to develop a report of work performed and the findings, if applicable.

System audit during fault conditions

System faults are often of a sporadic nature, causing the symptoms to appear for a short time only. It is
important to capture measurements while the fault condition exists. The nature of the fault condition may
require measurements to be taken over time to determine trends or to capture spurious events. It is important to
document the duration of monitoring and to note equipment being placed in and out of service and any process
or equipment upsets that occur during this time.

Product data sheets

Product data sheets and installation manuals are very important to verify the correct implementation. Please
assure the manuals and data sheets of all concerned equipment are available before certification commences.

Required equipment
Some or all of the following equipment is required to complete this worksheet:

• Power quality analyzer

• Clamp-on RMS (root mean square) ammeter (for AC and DC current measurements)
• Recording thermometer/humidity meter
• Fluke 199 or 200 MHz digital oscilloscope (for earth/noise verification)
• Calibrated 4-1/2 digit DVM with accuracy of ±0.05%, or better, true RMS algorithm.
139
 • Fluke 124/125 - 20 MHz digital scope meter (for field capacitance verification of Foundation Fieldbus
segments)
• Relcom FBT-6 Fieldbus monitor
• Fluke 1625 earth ground tester (or equivalent)
• Clamp-on ground resistance tester, such as an AEMC 6416 or Fluke 1630

You can substitute other equipment that meets the specifications of the listed equipment. Be sure to record the
specific equipment used in the tables at the back of the checklist.

Definitions
Buildings – Location of nodes of DeltaV equipment that may or may not be located within cabinets or
enclosures, but more than likely will be mounted on panel-mounted DIN rails. The building may be dedicated
to the use of the control system or there may be a room where the control system equipment and hardware are
located within the building. The building normally provides protection from weather and external elements, and
controls temperature and humidity for the equipment within. Buildings might be built by a fabrication facility
with some or all equipment installed and tested, then transported to the final designated location. Additional
names used for what is defined as building within this document are:

• Enclosure, as in remote instrument enclosures (RIEs)

• Shelter
• Remote instrument buildings (RIBs)

Equipment may be mounted in a cabinet that protects the equipment from the elements and meets the criteria
for controlling the environment. Under these circumstances, use this worksheet to verify the proper installation
of DeltaV nodes.

Cabinet – Possible location of the panel-mounted DeltaV equipment in buildings. A cabinet provides protection
to the control hardware within a building. This can include preventing errant intrusion by unauthorized
personnel, facilitating further climate control for the hardware, and segregating different areas of the control
hardware from other areas. An example of this might be a fire and gas system from the Basic Process Control
System (BPCS) or the power for the BPCS from the actual BPCS hardware it is powering. Another name for a
cabinet is an enclosure. Since this is common terminology for a building as well, this document will use cabinet
and building in its definition.

Earthing sub-system – This is the grounding system below grade. This could include the DeltaV triad, plant
grid, or building ground ring.

Triad – Common name for a series of ground rods, which could commonly be three ground rods and are part of
the earthing sub-system. These series of ground rods could be anywhere from a single to more than three rods.
The number of rods used has more to do with meeting the Emerson recommendation for a 1 ohm ground in the
soil and the soil resistivity.

Soil resistivity – This is a measurement of the ability of the soil to conduct electrical energy. A high soil
resistivity resists the flow of electrical energy and therefore requires a larger amount of surface area in contact
with the soil to conduct the same amount of electrical energy as a low-resistivity soil.

140
Comments
When commenting, please document the location of the verification. If possible, use pictures to supplement the
issue description.

Building installation worksheet

Verification of the proper grounding for buildings and shelters with multiple DeltaV nodes

Provided by Emerson Automation Solutions

Customer Name: _____________________________________________

Customer Contact: _____________________________________________

Location: _____________________________________________

Building Name/Designation: _____________________________________________

141
Good Engineering Practices / General Control System Components
Verification Answer If “No” Please comment
In the opinion of the auditor, is the building safe to By:
inspect, externally or internally? If not stop the audit and Yes / No / N.A. Date:
discuss with client.

Are servers, workstations, routers, etc. within the building By:

installed according to accompanied specific installation Yes / No / N.A. Date:
instructions and manuals?

Have all hotfixes been applied to the hardware and By:

Yes / No / N.A.
software? Date:

Are the proper procedures / equipment used for By:

assembling / connecting wiring, connectors and Yes / No / N.A. Date:
terminations (power, alarming, I/O, Busses, network,
etc.)?
Does a spot check on the used assembly procedures (e.g. By:
crimping of terminations, etc.) prove that proper Yes / No / N.A. Date:
materials, tools and procedures were used?

Visually inspect the interior building HVAC system. Are By:

the filters clean and is the system maintained? Does the Date:
system seem sized for the location and use for the
Yes / No / N.A.
building? Is there anything that could possibly affect the
ability of the HVAC system to maintain appropriate
temperatures for the DeltaV systems and components?

Visually inspect the exterior of the building. Does the By:

Yes / No / N.A.
exterior show corrosion and or excessive weathering?
Date:
Do the doors into building show a proper seal to By:
reasonably protect the interior of the building from the Yes / No / N.A.
outside environment, i.e., dust and rain? Date:

Are external building connections, made during site By:

installation (e.g. power & grounding) clearly tagged / Date:
identified? Are these connections properly bonded and Yes / No / N.A.
installed per best practices, such as bolting conductors
to clean and conductive surfaces?

Visually inspect the exterior of the building HVAC system. By:

Yes / No / N.A.
Is the system maintained and in good working order? Date:

Is all necessary documentation present and readily By:

Yes / No / N.A.
available for review? Date:

Comments:

142
Environmental Conditions of Building
Please refer to the Product Data Sheets (PDS) for each control system component as necessary

Verification Answer If “No” Please comment

Are the control components exposed to weather and By:

environment? if the system is still under construction will Yes / No / N.A. Date:
these cause adverse effects?

Is the heating and Cooling system within the Building By:

working properly? Is the thermostat (temperature control) Yes / No / N.A. Date:
set?

Is the temperature within the Building within the limits By:

specified in the design? (Measure at least one typical or a Date:
Yes / No / N.A.
worse case application if necessary) (Note any devices in
the cabinet creating possible excessive heat.)

By:
Is there evidence of high humidity or condensation within Date:
Yes / No / N.A.
the cabinets / enclosures?

Is there any indication that the control equipment has been By:
exposed to temperatures and humidity outside of the Date:
Yes / No / N.A.
specifications before this audit? Please use the comments
section to provide detail.

By:
Is the Building free of contamination due to the installation Date:
Yes / No / N.A.
(e.g. drill shavings, cement dust, dirt, etc.)?

Are the Control System components, any cabinets, and the By:
surrounding area free of dirt / dust and properly protected Yes / No / N.A. Date:
against contamination from such?

Comments:

143
Power & Grounding Connections within the Building
Verification Answer If “No” Please comment

Are the internal grounding connections performed per

design, properly terminated and labeled (proper size for Yes / No / N.A. By:
distance)? Date:

Are the cable sizes and type in accordance with the By:
intended use? (Insulated Vs. Un-insulated, Solid wire vs. Yes / No / N.A. Date:
small diameter multi strands, etc.)

Are the ground cable runs per the DeltaV Power and
Grounding Guide and conform to pertinent safety Yes / No / N.A. By:
regulations? Date:

Verify that ground conductors within the Building are not By:
Yes / No / N.A.
run in ferrous conduit or raceways. Date:

Are the lengths of all Power and Grounding cables from the By:
dedicated instrumentation points (power source and Date:
Yes / No / N.A.
dedicated plant ground connection) to the system less than
200 feet / 60 meters and installed as per design?

Is the Dedicated Instrumentation Ground (DIG) for the By:

Building connected to the lowest available dedicated
connection to true earth and is this connection’s resistance Yes / No / N.A. Date:
verified using one of the methods as described in the
DeltaV Power and Grounding Guide?

Is the DIG connection to true earth also connected to the By:

Plant Power Grid system as detailed in the DeltaV Power Yes / No / N.A. Date:
and Grounding Guide?

Is the Dedicated Power source for the control system using By:
a single neutral to ground bond at the source, which is Yes / No / N.A. Date:
connected to the DeltaV Instrument Ground?

Measure the neutral to ground (N/G) bond with a high By:

bandwidth oscilloscope as described in the “Required Date:
Yes / No / N.A.
Equipment” Section. The N/G Bond should measure less
than 1Vpp.

Are the applied Dedicated Power sources using proper By: Date:
Yes / No / N.A.
redundancy and / or UPSes, as intended by the customer?

Are all applicable power connections and distributions By:

installed, inspected, tagged and proved conforming to local Date:
Yes / No / N.A.
and national codes applicable to the end user (e.g. NEC,
CSA, IEC, NEN, etc.)?

144
 Comments:

Signoff
Project Number
Emerson Lead Engineer
Date of Service
Customer Representative Signature #1
Customer Representative Signature #2

145
Cabinet installation worksheet
Verification of the proper installation of cabinets containing one or more DeltaV nodes

Provided by Emerson Automation Solutions

Customer Name: _____________________________________________

Customer Contact: _____________________________________________

Location: _____________________________________________

Cabinet Name/Designation: _____________________________________________

146
Good Engineering Practices / General Systems

Verification Answer If “No” Please comment

In the opinion of the auditor, is the cabinet safe to inspect By:

externally or internally? If not, stop the audit and discuss Yes / No / N.A. Date:
with client.

Are sources of voltage above 50V properly isolated and By:

locked out per the site Emerson/Customer LOTO Yes / No / N.A. Date:
procedures?

By:
Are the proper procedures / equipment used for assembling Date:
/ connecting wiring, connectors and terminations (power, Yes / No / N.A.
alarming, I/O, Busses, network, etc.)?

By:
Does a spot check on the used assembly procedures (e.g. Date:
crimping of terminations, etc.) prove that proper materials, Yes / No / N.A.
tools and procedures were used?

By:
Is redundancy (controller, I/O, Power, network, etc.) Date:
Yes / No / N.A.
properly identified & tested?

Are Connections which should be made during site By:

installation (e.g. power & grounding) clearly tagged / Yes / No / N.A. Date:
identified?

By:
Are System Diagnostics performed with expected readings? Yes / No / N.A. Date:

By:
Are all firmware revisions verified? Yes / No / N.A. Date:

By:
Is all documentation present? Yes / No / N.A. Date:

Comments:

Internal Environmental Conditions of Cabinet

Please refer to the Product Data Sheets (PDS) for each control system component as necessary

147
 If “No”, Please comment
Verification Answer
below

Is the environment that system components are exposed to, By:

(temperature, humidity, vibration) as per design Date:
Yes / No / N.A.
specifications? If still under construction will these cause
adverse effects?

By:
Are system components free of contamination (e.g. drill Date:
Yes / No / N.A.
shavings, cement dust, etc.)

By:
Is the surrounding area free of dirt / dust and properly Date:
Yes / No / N.A.
protected against contamination of such?

If this is a new installation, will the internal components of By:

cabinet subject to conditions that do not meet DeltaV Yes / No / N.A. Date:
recommendations?

Comments:

148
Power & Grounding Connections
Please refer to the Product Data Sheet (PDS) for each control system component as necessary.

Verification Answer If “No” Please comment

By:
Are the Ground Conductors properly terminated and Yes / No / N.A.
Date:
labeled?

Are the cable sizes and type in accordance with the intended By:
Yes / No / N.A. Date:
use? (Insulated Vs. Un-insulated, Solid wire vs. small
diameter multi strands, size for distance, etc.)
Is the bend radius of the ground conductors with the By:
cabinet and leading outside of the cabinet meet DeltaV Date:
recommendations of a minimum of 8 times the diameter of Yes / No / N.A.
the cable? (~4 inches for a 4/0 conductor or 16 cm for a
120mm2 conductor)

Are the cable runs per DeltaV documentation and conform By:
to pertinent safety regulations? Are the ground conductors Date:
run in a cable tray with power? Are the ground conductors Yes / No / N.A.
in parallel to AC power conductors with less than 12 inches
or 31 cm between them?

Are the lengths of all Power and Grounding cables from the By:
dedicated instrumentation points (power source and Date:
Yes / No / N.A.
dedicated plant ground connection) to the system less than
300 feet / 100 meters and installed as per design?

Is the Dedicated Instrumentation Ground (DIG) connected to By:

the lowest available dedicated connection to true earth and Yes / No / N.A. Date:
is this connection’s resistance verified using one of the
methods as described in the DeltaV documentation?
By:
Is the DIG connection to true earth also connected to the Yes / No / N.A. Date:
separately derived power source for the cabinet?

By:
Are the Dedicated Power sources using a neutral to ground
Yes / No / N.A. Date:
bond at the source, which is connected to the DeltaV
Instrument Ground?

Are the applied dedicated Power sources using proper By:

Yes / No / N.A. Date:
redundancy and / or UPSes, as intended by the customer
intended availability for the cabinet?
Are all applicable power connections and distributions By:
installed, inspected, tagged and proved conforming to local Yes / No / N.A. Date:
and national codes applicable to the end user (e.g. NEC,
CSA, IEC, CE, NEN, etc.)?

Comments:

149
Cabinet Internals
Page _____ of _____
Please refer to the Product Data Sheets (PDS) for each control system
component as necessary

Complete this worksheet for each Cabinet

Verification Answer If “No” Please comment

Is the enclosure showing any signs of external or Internal By:

environmental damage? Date:
Yes / No
(Corrosion, rust, paint burns, paint flakes, etc.)

Is the temperature within the cabinets / enclosures within the By:

limits specified in the design (Measure at least one typical or a Date:
Yes / No /
worst-case application if necessary)? (Note any devices in the
N.A.
cabinet creating possible excessive heat.) Check any cabinet
thermostats for actuation and correct settings.

By:
Yes / No /
Are there signs of high humidity or condensation within the Date:
cabinets / enclosures? N.A.

By:
Yes / No
Are all cable entries in and out of the cabinet / enclosure sealed? Date:

Yes / No / By:
Are the enclosures properly positioned and secured within groups Date:
of enclosures, e.g. properly bolted together? N.A.

Are all tagged and identified connections (Power, Grounding, By:

Yes / No / Date:
communications, etc.) installed properly? Do they meet good
N.A.
engineering practices in their interconnection?

Are all connections solid and tightened? Is there good conduction Yes / No / By:
in all connections, no corrosion or hanging wire strands? N.A. Date:

Are added metal mounting parts, doors, etc., which can become By:
live during fault conditions, properly bonded (e.g. cutting screw / 6 Yes / No / Date:
mm2 or 12.7 mm braid wire) to provide equipotential under fault N.A.
conditions?

Are added metal mounting parts properly protected against the Yes / No / By:
possibility of causing short circuits e.g. when doors are closed? N.A. Date:

Is added equipment properly mounted for the intentioned Yes / No / By:

application (vibration, shipping, maintenance, safety, etc.)? N.A. Date:

Visually check the grounds in the enclosure. Does the Grounding By:
Yes / No /
at least meet requirements of Emerson’s Documentation and the Date:
N.A.
customer’s availability and integrity requirements?

Do all Conductors and Fiber meet industry standards for bend By:
radius in accordance with Emerson Documentation? This should Date:
Yes / No /
include fiber optic cables, Ethernet cables and ground conductors.
N.A.
Recommendations are a minimum of 8 times the diameter of an
insulated cable and 20 times the diameter of the fiber optic cable?

Are fiber cables and individual fibers properly protected from Yes / No / By:
damage? N.A. Date:

150
 Results: By:

_________
Ohms
Check the impedance and current flow of the Enclosure AC Yes / No / Date:
Grounding System. (Grounding Conductor to Earthing Subsystem) N.A. _________
AC mA

_________
DC mA

Results: By:

Check the impedance and current flow of the Enclosure DC _________O

Grounding System (Grounding Conductor to Earthing Subsystem) hms
Yes / No / Date:
Please note that any DC power to Ethernet switches and DC N.A. _________
ground returns on Bulk Power Supplies may need to be AC mA
disconnected for a valid test.
_________
DC mA

Calculate the DeltaV Carrier Power implementation By:

Yes / No /
N.A. Date:
(Make sure that no DeltaV Carrier is carrying more than 8.5 Amps)

Yes / No / By:
Are the used network components and the network installation as
N.A. Date:
per design?

Are all added cables certified for the application (e.g. CAT5 and Yes / No / By:
Fiber optic), properly terminated, labeled and color-coded? N.A. Date:

Are all network switches within the cabinet grounded properly to Yes / No / By:
Chassis Ground (CG)? N.A. Date:

Are network cables routed and installed conforming the guidelines By:
in the DeltaV Books on Line? Ethernet cables between switches Date:
Yes / No /
and DeltaV Controllers and CIOCs should be double shielded
N.A.
(metal cans on both ends). All other Ethernet cables should be
single bonded.

Comments:

151
AC Power System & Distribution for Each Cabinet
Page _____ of _____
Use this sheet for cabinets with at least one source of AC Power. Either the
primary, secondary, or utility power must be AC powered.

Recorded
Enclosure Location: Breaker Location: Complete
Value

Verify that all AC powered devices are switched off or disconnected, and locked
out, with client approval. Document client representative’s approval as necessary.

With disconnected AC power system, measure impedance of system from all Line
and Neutral connections to Ground
(Impedance MUST be High if the AC incoming feeds are disconnected from the panel
during this test. Neutral should measure low impedance if connected to a solidly
grounded source)
With lockouts removed, proper permits in place, and proper PPE, energize the AC
power system.
Primary AC Voltage is within nominal voltage per the engineering speciation of the
cabinet. Use a true RMS DVM for the measurements.

(Measured between Line and Neutral or phase to phase, as applicable)

Measure the frequency of the Primary AC Source. This should be within 1% of
power frequency, +/- 0.6 Hz for 60 Hz systems and +/- 0.5 Hz for 50 Hz systems.

If there is a Secondary AC Voltage is it within nominal voltage per the engineering

speciation of the cabinet? Use a true RMS DVM measurements.

(Measured between Line and Neutral or phase to phase, as applicable)

Measure the frequency of the Secondary AC Source, if used. This should be within
1% of power frequency, +/- 0.6 Hz for 60 Hz systems and +/- 0.5 Hz for 50 Hz
systems.

Check the Noise Level of the AC Power. Typical target is less than 3% (example 3.6
VAC at 120VAC). Measure with an oscilloscope. (Look for noise spikes and
excessive noise levels injected into the AC Power)
Ground to Neutral voltage is within specification (<+/-1.00V Vpp, as measured with
an oscilloscope)

Secondary AC Voltage is within specifications (Look for noise spikes and excessive
noise levels injected into the AC Power)

Ground to Neutral voltage is within specification

(<+/-1.00V Vpp, as measured with an oscilloscope)
Switch ON or reconnect all AC powered utility devices, with client approval.

Verify AC-powered fans, cooling devices, lights, etc. are not using the same
separately derived source of power as dedicated to the control system.

Verify if all AC-powered fans, cooling devices, lights, etc. are running and not
showing signs of wear.

Verify that LEDs of all AC powered devices indicate normal.

Comments:

152
 Page _____ of _____
DC Power System & Distribution for Each Cabinet

Breaker Recorded
Enclosure Location: Complete
Location: Value

Verify that all DC powered devices are switched off or disconnected. Make a note if
the Cabinet in use and cannot be powered down and isolated.

With disconnected DC power system, measure impedance of system from DC

supply positive and negative connections to chassis ground. (Impedance MUST be
High.)
(Note: Internal to a cabinet, Isolated grounds are to be kept separate from chassis
grounds and therefore should have a high impedance. This test is to insure AC and
chassis grounds are isolated from the DC isolated grounds. External to the cabinet,
isolated grounds meet chassis ground at the DIG, and therefore would read low
impedance. Certain networking components,
ie. Network Switches and CIOCs, have an impedance from their DC- to Chassis
Ground.)
Verify that power can safely be applied to the system. Isolate power to the field as
necessary to insure safety. Energize bulk power supplies.

Measure the voltage at the Primary Bulk Power Supply or Source.

Measure the voltage at the Secondary Bulk Power Supply or Source.

If the System DC Power is using 24 VDC:

Verify that the Primary System Power Supplies (SPS) 24 VDC inputs are within
specifications. (Nominal setting is 24.2 to 24.6 VDC. Absolute maximum at an SPS
input should be 28.8 VDC and 11 VDC at the last carrier.)

Verify that the Secondary SPS 24 VDC input are within specifications. (Nominal
setting is 24.2 to 24.6 VDC. Absolute maximum at an SPS input should be 28.8 VDC
and 11 VDC at the last carrier.)

If the SPS DC Power is using 12 VDC:

Verify that the Primary SPS 12 VDC input is within specifications. (Verify 12.1 to 12.3
VDC at SPS input and 11 VDC at the last carrier.)
Verify that the Secondary SPS 12 VDC input is within specifications. (Verify 12.1 to
12.3 VDC at SPS input and 11 VDC at the last carrier.)
Verify that the voltage drops are acceptable. (Typically 3 % or less)

Measure the AC noise level of the Bulk Power Supply +V to Chassis Ground @ a
resolution of 5 ms/div on the Scope. This should be done at the DeltaV SPS Input.
(200 mV P-P normal maximum, 1 VAC P-P absolute maximum)

(Make sure the scope filtering is off, Reading: 1 VACpp maximum)

Measure the AC noise level of the Secondary Bulk Power Supply +V to Chassis
Ground @ a resolution of 200 ms/div on the Scope. This should be done at the
DeltaV SPS Input. (200 mV P-P normal maximum, 1 VAC P-P absolute maximum)

(Make sure the scope filtering is off, Reading: 1 VACpp maximum)

Measure the voltage across any load sharing devices. Measure the voltage from
Input one to output and from Input 2 to output. A short will measure ~0VDC. An
open circuit will measure full voltage. (Note that load sharing devices usually will
measure between .3 and .7 VDC from input to output. Devices with high current
loads will measure slightly higher voltages.)

153
Verify if all DC powered fan’s and lights are operational and not showing signs of
wear.

Verify if LED’s of all DC powered devices indicate normal.

Comments:

Further comments and details of findings

154
 List of Equipment Used with this Worksheet

Manufacturer Type Serial number Comments

Comments:

Signoff
Project Number _____________________________________________

Emerson Lead Engineer _____________________________________________

Date of Service _____________________________________________

Customer Representative Signature #1 _____________________________________________

Customer Representative Signature #2 _____________________________________________

155
Earthing installation worksheet
Verification of the proper grounding for buildings and shelters containing one or more DeltaV nodes

Customer Name: _____________________________________________

Customer Contact: _____________________________________________

Location: _____________________________________________

System Name/Designation: _____________________________________________

156
Building / Shelter Electrode Earthing Connections

Answer
Verification
If “No” Please comment

Are the ground connections performed per design, properly terminated properly
Yes / No / N.A.
torqued (if applicable) and labeled?

Are the cable sizes and type in accordance with the intended use and distance in
compliance to the DeltaV Power and Grounding Guide? (Insulated Vs. Un-insulated, Yes / No / N.A.
Solid wire vs. small diameter multi strands, etc.)

Are the conductor runs installed according to the DeltaV Power and Grounding Guide
Yes / No / N.A.
and conforming to pertinent safety regulations?

Are the lengths of all Power and Grounding cables from the dedicated
instrumentation points (power source and dedicated plant ground connection) to the Yes / No / N.A.
system less than 300 feet / 100 meters and installed as per design?

Are all applicable power connections and distributions installed, inspected, tagged
and proved conforming to local and national codes applicable to the end user (e.g. Yes / No / N.A.
NEC, CSA, IEEE, CE, NEN, etc.)?

Is the Dedicated Instrumentation Ground (DIG) connected to the lowest available

dedicated connection to true earth and is this connection’s resistance verified using Yes / No / N.A.
one of the methods as described in the DeltaV Power and Grounding Guide?

Is there a dedicated Plant GRID or ground ring in use with the facility, specifically the
area under control? If so, Is the DIG connection to true earth also connected to this
Plant Power Grid or ring system as detailed in the DeltaV Power and Grounding
Yes / No / N.A.
Guide? (Note, the connection of the DIG to the Plant Power Grid to be at a location
separated from Lightning System Ground connections or AC Powered Equipment
grounding connections to the Grid.)

Are the Dedicated Power sources using a neutral to ground bond at the source,
Yes / No / N.A.
which is connected to the DeltaV Instrument Ground DIG)?

Are DeltaV ground cable routed with proper separation from A/C Power conductors
Yes / No / N.A.
and cables?

General Comments:

By:
Date:

157
Earthing Electrodes
(Use if the site has an installed earth electrode system either standalone or in conjunction with a plant grid or
ground ring.)

Answer
Verification
If “No” Please
comment

Is the DeltaV Earthing Electrodes connected to the DIG Bus Bar per the DeltaV Power and
Grounding Guide? The Grid or Ring should have a separate connection to the DIG Bus Bar,
Yes / No / N.A.
separate from the DIG connection to building steel or rebar. Other methods, such as
bonding CG and DCG at the Earthing Electrodes, is allowable, but not recommended.
(Follow Modified PANI order per DeltaV Power and Grounding Guide)

Verify that there is access to all electrodes or connections to the electrodes. This will
Yes / No / N.A.
allow the recommended annual visual inspection as well as any maintenance or testing

Check the soil and electrodes where the earthing electrode(s) or conductor(s) goes below
grade. Look for corrosion and valid material conduction. Continuous water covering the Yes / No / N.A.
electrode may be indicative of corrosion concerns.

Check for corroded connections, thermoweld or clamping, between earthing components. Yes / No / N.A.

Check the resistance of the entire earthing sub-system (Ground Rods) with a Clamp-on
Ground Resistance Tester. These checks should not include any possible Plant Grid Yes / No / N.A.
connections. The targeted value should be 1 ohm and no more than 5 ohms.

If the resistance measurement above is above 5 ohms, recheck the earthing sub-system
used for DeltaV Grounding system using a 3-point grounding test procedure. (IEEE Std 81) Yes / No / N.A.
Use the Fall of Potential Sheets for a single ground rod below. Copy sheets if necessary.
(Make sure to calculate out the testing resistance from the initial results)

General Section Comments:

By:

Date:

158
Fall of Potential Testing
Page _____ of _____

# GR#1 Resistance Resistance

GR#1 (feet) Resistance (ohms) GR#1 (feet)
(feet) (ohms) (ohms)

10

11

12

13

14

15

Comments:

159
 List of Equipment Used with this Worksheet

Manufacturer: Type: Serial number Comments

Comments:

Signoff
Project Number
Emerson Lead Engineer
Date of Service
Customer Representative Signature #1
Customer Representative Signature #2

160
 Appendix J Environmental considerations

Electrostatic protection
Material sensitivity to static electricity
Static electricity can cause damage in two ways: through direct discharge and through induction. Direct
discharge occurs when a static-sensitive device comes in contact with something that has a different electrical
potential. For example, a person who is statically charged can damage the device merely by touching it. Or, the
device itself can be statically charged, and then be damaged by coming into contact with a ground.

Statically charged objects also can cause inductive damage in a static-sensitive device. An electrically charged
object has a surrounding electrically charged field. If a static-sensitive device moves through the field, and the
field is strong enough, the field can induce a damaging current in the device. The faster a device passes through
the strong field, the greater the chance for such damage.

Occasionally, electrostatic damage is severe enough to cause instant device failure. In this case, normal testing
usually reveals that the device failed. Unfortunately, devices damaged by static electricity seldom fail outright.
The usual result is degradation of the semi-conductor junctions in the device. Normal testing may indicate a
properly functioning device, although its function may be degrading. Devices with junction degradation are also
prone to erratic behavior at elevated temperatures. Such failures are seldom traced back to their true cause.

Every semiconductor is, to some degree, static sensitive. Crystal and precision film resistors are also susceptible to
static. These devices can vary widely in their sensitivity.

Some can be damaged by less than 30 V, while others can withstand several thousand volts. Since the sensory
threshold for humans is about 3,000 V, damaging static voltage usually goes undetected.

Protection against electrostatic damage is built into some devices, but the degree of protection varies. Protection
is never total. Protection built into MOS devices, for example, lowers static sensitivity, but they still require
proper handling. A common myth is that devices mounted on printed circuit cards are protected from
electrostatic damage. This is not true. Printed circuit cards with static-sensitive devices should be protected using
the same handling procedures as used with individual static-sensitive devices.

Electrostatic sources
Static electricity is caused by physical contact, followed by separation, of dissimilar materials. This means that
static electricity can have an almost infinite number of sources. The generated voltage potential depends upon
the materials, the relative humidity, and other factors.

161
 Table A-4 Common sources of static electricity

Means of static generation Electrostatic voltage

10 to 20 percent relative 65 to 90 relative humidity

humidity

Walking across carpet 35,000 1,500

Walking over vinyl floor 12,000 250

Working at a bench 6,000 100

Picking up a vinyl envelope for 7,000 600

work instructions

Picking up a common poly bag 20,000 1,200

from bench

Sitting and moving in a chair 18,000 1,500

padded with polyurethane foam

Other common static electricity sources include the following:

• Clothing made from synthetic materials

• Rubber or plastic shoe soles
• Plastic tools, tote boxes, trays, and so forth (unless made from special antistatic plastic)
• Styrofoam packing material
• Cellophane wrappers and tape
• Moving air (for example, air moved by solder suckers, heat guns, cold sprays)

Preventing static electricity buildup

Static buildup can be prevented by using antistatic objects, antistatic coatings, and antistatic containers. An
antistatic object is typically non-conductive and has a thin, conductive surface layer built in. As long as this layer
is intact and moist, it lets static electricity dissipate. Common examples of antistatic objects are special antistatic
plastic bags, and plastic trays, tote boxes, work surfaces, and packing material.

Antistatic coatings are also available for products that are not already antistatic. The coatings form a conductive,
antistatic layer and can be applied to most nonconductive surfaces. But, these coatings may not function forever
or in all circumstances. If the antistatic layer dries out or friction wears it away, it can no longer prevent static
buildup. Some cleaning agents can dry out or neutralize the layer.

Antistatic containers are available which prevent the buildup of static electricity in devices placed inside.
However, they do not provide complete protection from external static fields.

Using grounding devices

Grounding devices are another way to prevent electrostatic damage. The most commonly used grounding
devices are grounded work surfaces, floor mats, and wrist straps. These devices should be connected to a good

162
earth ground, through a resistor of at least one megohm. The resistor acts as a current limiter to prevent a
possible shock hazard.

A grounded work surface drains to ground a static charge of a conductive object placed on the surface.
Grounded floor mats dissipate charges you may accumulate while walking on carpet or vinyl tile if your shoes are
conductive. (If your shoes have plastic or rubber soles, use heel straps as well as grounded floor mats.) A
grounded wrist strap drains static charges from charges you may accumulate from friction between your clothes
and you or between your shoes and the floor. The wrist strap must be worn next to the skin, not over clothing.

Remember that grounding devices cannot drain static charges from nonconductive objects. For example, a
statically charged nonconductive tote box placed on a grounded conductive work surface does not lose its static
charge. Likewise, grounded floor mats cannot ground rubber-soled shoes unless the shoes have conductive heel
straps. And although a grounded wrist strap drains a static charge from your body, the strap cannot ground a
static charge in synthetic, nonconductive clothing.

Flooding the air with ions

Ionization is an effective and convenient way to prevent static buildup in a small area such as a workstation. An
ionizer floods the area with both positive and negative ions. The ions neutralize any positive or negative static
charges in the area, even charges on nonconductive objects. Some ionizers produce a small amount of
electromagnetic interference that may affect sensitive test instruments. An ionizer may need more than a minute
to neutralize a strong static charge.

Using static shielding containers

Containers made of a special conductive plastic or conductive coated cardboard prevent electrostatic damage
during transportation and storage of static-sensitive devices. Unlike antistatic plastic, conductive plastic is
conductive through its entire depth. Static shielding containers take advantage of the Faraday cage effect; that is,
if a hollow conductive object is statically charged, the charge is only on the outer surface of the object. A device
in a closed static shielding container cannot be damaged by an external electrostatic discharge or static field. To
drain a static charge from the outside of a static shielding container, merely touch the container to a grounded
surface. The most common static shielding container is a conductive plastic bag. Others are conductive tote and
shipping boxes.

Handling static-sensitive devices

When handling static-sensitive devices, follow the guidelines below to prevent damage caused by static
electricity:

• Treat all printed circuit cards as static-sensitive devices and handle them as little as possible. Many
printed circuit cards contain static-sensitive devices. These devices vary in their sensitivity to static
electricity.
• Wear a grounded wrist strap whenever you handle printed circuit cards. Each enclosure should have a
grounded wrist strap with a protective 1 MΩ resistor. Connect the wrist strap to a point in the
enclosure that is connected to an AC ground bus or isolated local or master ground bus. Before
removing a card from a file, attach the wrist strap snugly to your wrist and wait about 10 seconds before
touching the card. Pull back shirt sleeves so that they do not touch the card. Hold a card only by its
edges; never touch components, the printed circuit, or the edge connectors.

163
 • Transport and store printed circuit cards in static shielding (not merely antistatic) containers. As long as
the container is sealed, electrostatic damage normally does not occur. Use static shielding bags or boxes
for storage and shipping of printed circuit cards. The factory ships printed circuit cards in boxes with
conductive liners. Labels on these boxes identify the contents as static sensitive.
• Do not put static-generating material inside a static-shielding container with printed circuit cards.
• Ground static shielding containers before removing printed circuit cards.
• Before removing cards from shipping containers, ground yourself and the box conductive liner. Save
such boxes for storage and future shipping of cards. Use only antistatic or static shielding packing
material.
• Work on or examine printed circuit cards only at a static-controlled work area with a grounded wrist
strap and a grounded table mat or table surface.
• Keep all static-producing materials well away from the work area. Ground all test equipment at the
work area.

Airborne contaminants size chart

Airborne contaminants can greatly reduce the reliability and life of electronic equipment. The chart compares
the relative size of common airborne contaminants and illustrates the effective ranges of popular filters per
American Society of Heating, Refrigeration, and Air Conditioning Engineers (A.S.H.R.A.E.) standards. The
chart is reproduced courtesy of Cambridge Filter Corporation, Syracuse, NY 13221-4906.

164
 Figure A-13 Relative sizes of common air contaminants

Atmospheric dust size chart

Dust accumulating on electronic equipment can significantly affect its operation and reliability. For proper filter
sizing, some idea of the sizes of dust normally found in an atmospheric sample is useful. The diagram on the
following page provides dust sizes, quantities, and percent by volume in a typical atmospheric sample. The
diagram is reproduced courtesy of Snyder General Corporation, Dallas, TX 75204.

165
 Figure A-14 Size distribution of a typical atmospheric dust sample

Note: Atmospheric dust varies considerably in particle size as well as constituents. In the table sample, there
were very few particles found larger than 30 microns in average diameter. With this as an upper limit, the
particles were divided into six size ranges as indicated, with Column 2 indicating the average particle size for
each group. For example, the largest group consisted of particles ranging between 30 and 10 microns - or an
average of 20 microns. In this size range, the number of particles found was 1,000, as shown in Column 3. This
represents the proportionate quantities by count and indicates the relative number of particles in each size range
based on 1,000 particles for the average 20 micron size.

Mechanical influences on the control environment

Mechanical influences are usually sinusoidal vibration and momentary shock. Reciprocating pumps and
compressors often cause vibrations and shock in a process plant. Process control equipment continuously
166
exposed to these effects may require additional protection to prevent mechanical (structural) stress to the
equipment.

Proper installation
In a vibration and shock environment, care must specifically be taken to properly anchor all process control
system components, especially controller and I/O cards, field instrument electronics, instrument cases, and wire
terminations. Small vibrations or shock can affect terminations, cable integrity, and card connector integrity,
causing a range of faults from intermittent operation to complete failure.

Proper support and connection methods must be included in system design to minimize faults. As a minimum,
equipment must be installed per equipment installation instructions, including proper tightening of mounting
bolts, clamps, etc.

External protection methods

Methods are available to eliminate or minimize mechanical effects. One often used method is the installation of
isolation pads or vibration-absorbing foundations under devices causing the effects. If offending devices cannot
be so mounted, it may be necessary to mount system cabinets and consoles on isolation pads or foundations.

Before a method is selected, the frequency and amplitude of vibrations and shock must be measured. Then,
isolation pads or foundations can be designed for adequate equipment protection.

Product specifications
For vibration and shock limits for DeltaV products, see Environmental Specifications in the manual, Installing
Your DeltaV Digital Automation System. Any method used to minimize mechanical influences should keep the
influences below specified limits.

Note: Limits apply to infrequent events. Equipment exposed to continuous vibration or shock may require
additional mounting considerations. Consult your Emerson Automation Solutions local business partner or field
sales office (LBP/FSO) for more information.

Electromagnetic effects
Electromagnetic measurement
Signals from sources closer than one meter are called near field signals. Signals from sources at a distance of one
meter or greater are called far field signals.

Near field signals consist of a radiation field and an induction field emitted by the radio antenna. In the near
field area, both the radiation field and the induction field are important. At a distance from the antenna equal to
the wavelength divided by 2 π , or slightly less than wavelength λ/6, the radiation field and the induction field
have equal intensity.

Far field signals consist of a radiation field and a remnant of an induction field emitted by the radio antenna. At
distances of greater than one meter from the antenna, and in the frequency range of most hand-held radios, only
the radiation field is of concern. The induction field at these distances has negligible effects.

Measuring radio signal field strength around enclosures should be part of a checkout procedure before startup,
and then periodically thereafter. However, significant errors can occur if the measuring instruments are set up
too closely to the antenna. And, in a near field area, radio signal field strength usually cannot be calculated or
tested in a repeatable manner.
167
Radio operation in a near field area
If hand-held radios are used in the near field area of enclosures, and the doors are open, the effect on the
equipment can be unpredictable. Some claims have been made that equipment will operate without negative
effects under these conditions, but even though no degradation initially may seem to occur, large near field
signals can begin circuit degradation that contributes to later circuit failures. Until a repeatable testing standard
is developed, no equipment design can be considered damage-resistant in near field signals, nor can the
equipment operation be considered predictable.

Applicable electromagnetic signal standards

In general, process control instruments are designed and tested to comply with appropriate industry standards
for electromagnetic immunity and emissions.

European harmonized standards

Instruments destined for both European and North American markets are tested according to selected EMC
directives of the European Union. The applicable standards are:

• Operator interface computers and workstations built around standard processing workstations and
computers from OEM suppliers are classified as Information Technology Equipment. This equipment
is typically installed in control rooms with Class 1 environments. The equipment complies with
standard EN55022 Class A or Class B for emissions and standard EN50082-1.1992 for immunity.
• Rack-room equipment such as controllers and I/O subsystems is designed for installation in Class 2
environments. This equipment is classified as Industrial Equipment and complies with standard
EN50081-2.1993 for emissions and standard EN50082-2.1995 for immunity.

Product data sheets usually indicate the electromagnetic compliance standards to which a product has been
tested and meets.

Process control-specific standards

Instruments destined for North American markets are tested according to IEC Standard
61326-1, Electrical Equipment for Measurement, Control, and Laboratory use-EMC Requirement. The standard
provides testing specifications for far field signals. Test procedures are done in accordance with this standard,
which includes closed enclosure doors and all equipment properly electrically grounded.

Reducing EMI levels

In addition to instrument design, installation quality and operating methods affect electromagnetic
compatibility. Closed enclosure doors and proper equipment grounding provide maximum protection from
electromagnetic interference (EMI). Power and signal leads run in rigid, metallic conduit that is solidly
connected to a low-impedance ground provide considerable protection.

To prevent signal-ground loops, electrically grounding the conduit at the power or signal source end only and
using non-conductive fittings to connect the conduit to enclosures is required for effective EMI protection.
Refer to earlier chapters in this manual for detailed electrical grounding information.

Using low-pass capacitive filters on instrument signal wires provide additional EMI protection. Such filters are
usually feed-through devices connected in series with instrument wires.

168
Minimizing radiation from a source also minimizes EMI. Therefore, do not mount radio antennas near a control
system. Also, avoid using radio communication while performing maintenance, especially when enclosure doors
are open.

Determining EMI levels

Hand-held, two-way radios are often the most likely source of electromagnetic interference around process
control equipment. Measuring field strength from the radios may not always be practical, but you can calculate
approximate field strength.
𝜆𝜆
For a field area of 𝑑𝑑 ≥ , use the following formula to calculate approximate field strength:
2𝜋𝜋

𝑘𝑘
𝐸𝐸 = � � �𝑝𝑝
𝑑𝑑
where

E = Electrical field intensity in V/m

d = Distance in m from antenna

p = Manufacturer’s advertised rating in W

λ = Wavelength in m
k = Coefficient found by testing

An analysis of tests run by the Electrical Research Association (E.R.A.) and the French research department of
Electricité de France (EdF) on hand-held two-way radios shows a wide variation for the coefficient k. Tests of
radios with power ratings between 0.5 W and 12 W at both VHF and UHF frequencies from six manufacturers
showed a range of coefficients from k = 0.45 to k = 3.35, with a mean of k = 1.6.

Therefore, the statistical average can be expressed as follows:

1.6
𝐸𝐸 = � � �𝑝𝑝
𝑑𝑑
Because testing by EdF was done in a shielded enclosure, we can assume an efficient ground plane, which could
result in a higher value for k. However, because two-way radios are usually held and keyed by plant maintenance
people, ground planes are normally less efficient and result in additional losses. With the additional losses, the
expression above is an adequate guide for approximating field strength.

EMI effects on magnetic media

Some software media, including diskettes and magnetic tape, must be protected from the effects of
electromagnetic radiation. Protection is best when the media is kept away from the source. Strong
electromagnetic fields can permanently alter or erase data such as your configuration databases on the media.

Caution: Magnetic media is especially sensitive to EMI. To prevent loss or corruption of stored data, never use
radio communication near magnetic media.

169
Corrosive Environments
Corrosion effects on the control system environment
Corrosive vapors as airborne contaminants can significantly decrease instrument life. In severe cases, corrosive
vapors can reduce an entire control system to an irreparable state in less than a year. Even more critically, a
severe corrosive environment can cause loss of accurate process control in less than thirty days.

Classifying corrosive environments in the presence of sulfides

Corrosive environments can be classified in terms of copper reactivity rates in the presence of reactive sulfides.
Table A-5 Copper reactivity rates

Mild Moderate Harsh Special

Class G1 Class G2 Class G3 Class GX

Less than 3001 Less than 1,0001 Less than 2,0001 Greater than 2,0001

1. Units are angstroms of film formation per 30-day exposure.

lists average gas concentration levels for various contaminants in the class ratings. These levels, for reference
purposes, approximate copper reactivity levels listed in , if relative humidity is less than 50 percent. For a given
gas concentration, the severity level increases by one level for each 10 percent increase in relative humidity above
50 percent, and also increases by at least one level for a relative humidity rate of change greater than 6 percent
per hour.

Class G1 through GX ratings shown in the tables are taken from ISA Standard S71.04, Environmental Conditions
for Process Measurement and Control Systems: Airborne Contaminants. The standard contains rating definitions
and application information. Emerson uses this standard as a guide for product design and environmental
measurement.
Table A-6 Classification of chemically active contaminants in cm3/m3 (ppm)

Contaminant Mild Moderate Harsh Special

Class G1 Class G2 Class G3 Class GX

Average value Average value Average value Average value

Hydrogen sulfide H2S ≤ 0.003 ≤ 0.01 ≤ 0.05 > 0.05

Sulphur dioxide SO2 ≤ 0.01 ≤ 0.1 ≤ 0.3 > 0.3

Chlorine Cl2 (relative ≤ 0.001 ≤ 0.002 ≤ 0.01 > 0.01

humidity @ 50%)

Hydrogen fluoride HF ≤ 0.001 ≤ 0.002 ≤ 0.01 > 0.01

Ammonia NH3 ≤ 0.5 ≤ 10 ≤ 25 > 25

Nitrogen Oxides NOx ≤ 0.5 ≤ 0.125 ≤ 1.25 > 1.25

170
 Ozone O3 ≤ 0.002 ≤ 0.025 ≤ 0.1 > 0.1

Classifying corrosive environments in the presence of sulfides and chlorides

The information in is based on copper reactivity where airborne contaminants are reactive sulfides. The
information does not account for the synergistic effect of other contaminants, such as chlorides. Typically, when
chlorides are added to sulfides, especially in the presence of high humidity, the combination causes copper
reactivity to be worse than the visual indication.

To obtain better indication of the combined effects of sulfides and chlorides, copper and silver reactivity is
measured to give an accurate indication of the potential for equipment corrosion. Both passive reactivity
coupons and active air-quality monitoring instruments are available from various environmental controls
suppliers such as Purafil Inc. (www.purafil.com).

Caution: Damage by corrosive atmospheres occurs to most control systems during initial installation and at
maintenance shutdowns. Also, if the system is stored in a harsh environment or exposed to corrosive vapors
when the environmental control system is not operational, damage will occur.

Emerson Process Management recommends measuring the levels of corrosive gasses in plant areas where the
control system will be located (control rooms, rack rooms, and preinstallation storage areas) with reactivity
coupons, and then properly preparing the site for adequate environment control before the control system is
received. Such precaution can prevent early instrument failure.

General method for identifying the environment

A general idea of the environment in your plant area can be determined by observing exposed copper, such as
power bus bars around switch gear and the trimmed ends of copper power wires.
Table A-7 Environmental characterization by visual changes in copper

Color of exposed copper Corrosion class

No visible change Class G1 (Mild)

Light golden-brown in 4 to 6 months, golden- Class G2 (Moderate)

brown in 12 months, or slow change over a lon- ger
period

Flaking film in 3 to 6 months Class G3 (Harsh)

Blue or black in any time period1 Class G3 (Harsh) or Class GX (Special)

1. If copper turns black in about three weeks, the atmosphere is extremely harsh to electronic components.
You should either lower the corrosive level or move the equipment to another location.

Humidity effects on reactivity results

The absence or presence of free moisture may attenuate or accelerate copper or silver reactivity. For instance,
when relative humidity is low, reactivity is slowed. Alternatively, when relative humidity is high, reactivity speeds
up. Both conditions can lead to misinterpretation of the atmosphere. The slow rate can provide a false sense that
a minor problem exists, whereas a fast rate can do the opposite.
171
To minimize misinterpretation, compare the sulfide film formations on the silver and copper coupons.
Table A-8 Interpreting humidity effects

Ratio of silver sulfide (Ag2S) to copper sulfide (CuS) Humidity indication

Ag2S ≤ 1.5 CuS Indicates low relative humidity

Ag2S > 0.5 < 1.5 CuS Indicates relative humidity has little effect

Ag2S ≤ 0.5 CuS Indicates high relative humidity

When low relative humidity is indicated, it implies that very little moisture condensed onto the coupons either
because the atmosphere contained little moisture inherently or the moisture was well controlled. The low
humidity may have caused the copper sulfide film formation to be attenuated. Additional testing of the
environment is recommended.

When few humidly effects are indicated, relative humidity conditions present during the test period are
considered not to have had any unusual effect on the copper sulfide film formation.

When high relative humidity is indicated, substantial moisture has condensed on the coupons. The humidity
may have caused the copper sulfide film formation to accelerate. Consideration should be given to controlling
the humidity in this environment.

Designing to environmental classifications

Electronic equipment can be designed for and protected from various levels of corrosive environments.
Equipment often found in process plants can survive various environments, using methods described below.

Mild (Class G1) environments

Most commercial personal computers and peripheral equipment with fan-cooled electronics (consisting of
multiple printed wiring boards and high-speed backplanes) will survive exposure to a mild (Class G1) corrosive
environment for a normal life of 10 years with no appreciable corrosion-induced failures.

Moderate (Class G2) environments

Electronic assemblies designed with special attention to minimizing exposed copper and silver can survive
exposure to a moderate (Class G2) corrosive environment for a normal life of 10 years with no appreciable
corrosion-induced failures.

Methods of minimizing exposed copper and silver include:

• Using tin-lead plating on all copper lands.
• Using solder masks on both sides of circuit boards.
• Using components and plating which do not contain exposed silver.
• Using high-quality backplane connectors with tin-lead or gold over nickel plating.

Harsh (Class G3) environments

Only fully sealed electronic equipment can survive in harsh (Class G3) environments. Thus, to survive a Class
G3 environment, Class G1 and G2 equipment requires installation in properly designed and sealed enclosures.

172
For example, an I/O file that meets the Class G2 category can be used in a Class G3 environment if the file is
first installed in a sealed housing that provides an internal Class G2 environment.

Special (Class GX) environments

Electronic assemblies can survive exposure to Special Class GX environments with specially designed and
packaged equipment. Specifications for the equipment and packaging depend on the application. Contact your
Emerson Process Management local business partner or field sales office for more information.

DeltaV product specifications information

DeltaV systems have built-in resistance to certain classes of environmental conditions. In addition, you can place
DeltaV controllers, I/O instruments, and associated equipment in environmentally protected enclosures. When
products in an enclosure or area have different ratings, the enclosure or area must be designed to protect the
product with the least resistance to a harsh environment.

Class G1 through GX specifications for DeltaV systems are listed in Installing your DeltaV Digital Automation
System. If your environment does not meet the specifications listed in the appendix, you should consider using
enclosures that provide the recommended environment.

Dusty environments
Uncontrolled dust can significantly increase instrument failure rates. Dust can cause failure by insulating
instruments from proper heat dissipation and by providing electrical short circuits through the dust buildup.

Minimizing the effects of dust

Normally, if instruments are installed in an atmosphere containing a particulate matter concentration of less
than 0.1 milligrams of particulates per cubic meter of dry air, the effects of dust are minimized. Appendix F
describes the size distribution of dust in a typical atmospheric sample.

Protecting against dust

Methods are available to reduce particulate size in the surrounding air and minimize the effects of dust
contamination. One of the most commonly used methods is to size air-inlet filters to meet the particulate size
requirement. Another frequently used method is to maintain positive pressure within instrument enclosures or
the entire equipment room.

It is important to renew filters periodically and keep all dust control equipment operating properly.

Modifying the environment

Modifying the control system environment
Controlling the environment to required specifications pays large dividends in extended instrument life and
overall system reliability. Depending on the severity of the environment and the system application, alternate
methods for controlling the environment are available.

The four items that any method must control are temperature, humidity, dust, and corrosive vapors. The
Airborne contaminants size chart and Atmospheric dust size chart show the size ranges of dust and other
airborne contaminants in typical atmospheres. Knowing the types and size of contaminants at the plant site
helps in determining the protection system needed.

173
Note: Engineering a proper environment requires qualified and proven environmental experts who can provide
a total system approach. Experience indicates that a casual approach to environmental control does not bring the
expected results.

Control room installations

Often the best method for controlling a corrosive environment is the installation of system instruments in an
environmentally controlled room. This method may prove to be the most cost-effective solution when flexibility
of a plant application is not inhibited. A controlled room not only protects equipment but it protects plant
personnel also.

HVAC system considerations

In a controlled room, the heating, ventilating, and air conditioning (HVAC) system is designed to provide the
specified control of temperature, humidity, dust, and corrosive vapors. It must maintain relative humidity under
50%, and it should have redundancy to maximize reliability.

Humidity control considerations

Humidity is the most important factor affecting corrosion rates when corrosive vapors are present. Control must
include both the average relative humidity and the rate of change per hour of the humidity. For example,
maintaining relative humidity at 45 percent with changes of less than 6 percent per hour reduces a moderate
(Class G2) environment to a mild (Class G1) one. An 80 percent relative humidity causes a harsh (Class G3)
environment when reactive chlorides are present at a concentration of 0.2 to 0.3 parts per billion.

Construction considerations
Where a controlled room environment is required, a minimum positive pressure of 0.08 inches of water column
(0.02 millibars) must be implemented and maintained. As a minimum, door air-lock systems are required.

Different types of construction produce different issues. For instance, cinder block walls are porous and allow
outside contaminants to progress through the walls and eventually contaminate room air. To inhibit
contaminants, the walls must be sealed with a waterproof coating, such as an epoxy-based or similar paint. The
sealing, along with positive pressure inside the room, effectively controls contaminant ingress. Concrete floors
can be a major dust source unless they are cleaned and sealed. The dust can clog air filters and, in turn, may
cause early instrument failure from excessive heat buildup.

Pipes, cables, and conduit passing through walls, floors, and ceilings require sealing to maintain positive air
pressure. Open pipes and conduit must be capped or plugged to prevent air passage. Additionally, cooking,
eating, and smoking activities must be excluded from the room once the control system is installed.

Blast-proof rooms require special construction and sealing techniques. Experts and contractors for this type of
construction should be consulted.

Production floor and remote installations

For installations located on the production floor or in remote areas, several methods are available to control the
environment. If a small room cannot be built, sealed enclosures may be used. The criteria for environmental
control in enclosures are the same as that for control rooms. As with control rooms, the amount and types of
control must be determined and then designed into the enclosure. For example, control might include
temperature only, humidity and particulate filtration only, or particulate filtration only.

174
 HVAC system considerations
If temperature control and humidity control are needed, they can be achieved using a small HVAC unit
mounted on the enclosure or a central unit that feeds several enclosures in various locations.

Purging system considerations

Often, remote process areas experience high temperature and high relative humidity, which change with weather
and time of year. In addition, dust contamination may be high, and high levels of corrosive gases may be
present.

A destructive remote process area environment can be overcome by using a purging system that supplies clean,
cool, dry air or inert gas to pressurize an enclosure. Correct enclosure size and type (normally plastic or fiberglass
in a corrosive environment), and maintaining air pressure of 0.08 inches of water column (0.02 millibars) in the
enclosure adds protection. Possible clean air sources are high quality instrument air and air from a locally placed
chemical and particulate filtration system.

Additionally, the purging system must be sized adequately to clean the air after an enclosure door has been
opened and then closed. Also, an enclosure should be located out of direct sunlight.

Enclosure and room air pressure calculations

An approximate calculation can be made to determine the air flow in cubic feet per minute (CFM) required to
maintain air pressure between 0.08 (0.02 millibars) and 0.1 inches (0.025 millibars) of water column.
Calculation is made with the following formula:

Air flow = (C) (width x height x depth of the enclosure or room)

C is a constant percentage of the area volumes needed to maintain the correct air pressure. Use the following
chart to determine the value of C.
Table A-9 Constant percentage

Enclosure type Percentage

NEMA 12 enclosure 5%

Blast proof room 1.5 to 3.0%

Sealed, concrete-block wall room 5 to 7%

Typical room construction 10 to 12%

Loose room construction 17 to 25%

Maintaining environmental control systems

Environmental control system maintenance is equally important as that of the process control system.

Caution: The importance of environmental control system maintenance cannot be overemphasized. Failure of
this system has a direct effect on the reliability of the process control system. Once corrosion begins on process
control equipment, the damage is normally not reversible.

175
Air filters are usually ignored. However, clogged air filters directly contribute to early instrument failure by
inhibiting proper instrument cooling. Clogged or used up chemical filters allow corrosive contaminants to
surround instruments. Damaged air-lock seals or propped-open air-lock doors allow contaminants to enter
otherwise protected rooms or enclosures. Periodic environmental control system maintenance must be part of
overall plant maintenance.

176
 Appendix K References

General reference
Joffe, Elya B. and Lock, Kai-Sang, Grounds for Grounding: A Circuit-to-System Handbook, IEEE Wiley & Sons,
2010.

Ott, Henry, Electromagnetic Compatibility Engineering, Wiley & Sons, 2009.

Vijayaraghavan, G., Brown, Mark, and Barnes, Malcolm, Practical Grounding, Bounding, Shielding and Surge
Protection, Elsevier, 2004.

Power transmission reference

Electrical Transmission and Distribution Reference Book, Westinghouse, 1950.

Reference books for personnel and property safety

Soares Book on Grounding and Bonding, 13th Edition, International Association of Electrical Inspectors, 2017.

National Electric Code (NEC) 2017 Handbook, NFPA 70, 2017.

BS 7671:2008 Requirements for Electrical Installations 17th Edition, IET Wiring Regulations, 2008.

Cook, Paul, Commentary on IET Wiring Regulations 17th Edition BS 7671:2008 Requirements for Electrical
Installations, Institute of Engineering and Technology, 2008.

American standards
ANSI/ISA-RP12.06.01-2003, Recommended Practice for Wiring Methods for Hazardous (Classified) Locations
Instrumentation Part 1: Intrinsic Safety.

ANSI/ISA-12.12.01:2015 / CAN/CSA C22.2 NO. 213-15, Nonincendive Electrical Equipment for Use in Class I
and II, Division 2 and Class III, Divisions 1 and 2 Hazardous (Classified) Locations.

ANSI/ISA-TR12.12.04:2011 - Electrical Equipment in a Class I, Division 2/Zone 2 Hazardous Location.

ISA Standard 51.1-1979 (R1993), Process Instrumentation Terminology.

ISA-71.01-1985 Environmental Conditions for Process Measurement and Control Systems: Temperature and
Humidity.

ISA-71.02-1991 Environmental Conditions for Process Measurement and Control Systems: Power.

ISA-71.03-1995 Environmental Conditions for Process Measurement and Control Systems: Mechanical Influences.

ANSI/ISA-71.04-2013 Environmental Conditions for Process Measurement and Control Systems: Airborne
Contaminants.

ISA-84.00.01-2004 Part 1 (IEC 61511-1 Mod) - Functional Safety: Safety Instrumented Systems for the Process
Industry Sector - Part 1: Framework, Definitions, System, Hardware and Software Requirements.

177
ISA-84.00.01:2004 Part 2 (IEC 61511-2 Mod) - Functional Safety: Safety Instrumented Systems for the Process
Industry Sector - Part 2: Guidelines for the Application of ANSI/ISA-84.00.01-2004 Part 1 (IEC 61511-1 Mod) –
Informative.

NFPA70:2017 National Electrical Code.

The Institute of Electrical and Electronics Engineers Inc. IEEE standards

IEEE Standard 45, Recommended Practice for Shipboard Electrical Installations.

IEEE Standard 81-2012, Guide for Measuring Earth Resistivity, Ground Impedance, and Earth Surface Potentials of
a Grounding System.

IEEE Standard 142-2007, Recommended Practices for Grounding of Industrial and Commercial Power Systems
(Green book).

IEEE Standard 493-2007, Recommended Practice for the Design of Reliable Industrial and Commercial Power
Systems (Gold book).

IEEE 518-1982(1), Guide for the Installation of Electrical Equipment to Minimize Noise Inputs to Controllers from
External Sources (not currently supported by IEEE).

IEEE Standard 519-2014, Recommended Practice and Requirements for Harmonic Control in Electrical Power
Systems.

IEEE Standard 1050-2004, Guide for Instrumentation and Control Equipment Grounding in Generating Stations.

IEEE Standard 1100-2005, Recommended Practice for Power and Grounding Electronic Equipment (Emerald book).

IEEE Standard 1159:2009, Recommended Practice for Monitoring Electric Power Quality.

IEEE Committee Report, “List of Transmission and Distribution Components for Use in Outage Reporting and
Reliability Calculations,” IEEE Transactions on Power Apparatus and Systems, PAS 95(4)(July/August 1976), pp.
1210-1215.

UL 1449:2015, Standard for Safety Surge Protective Devices.

Canadian Standards Association standards

(CSA) C22.1 Canadian Electrical Code

(CSA) C22.2 No. 0.4-04 Bonding of electrical equipment

(CSA) C22.2 No. 14-13 Industrial control equipment

European international standards

EN 61000-3-11 Ed. 1.0, Electromagnetic compatibility (EMC) - Part 3-11: Limits - Limitation of voltage changes,
voltage fluctuations and flicker in public low-voltage supply systems - Equipment with rated current ≤ 75 A and
subject to conditional connection.

EN 61000-3-12 Ed. 1.0, Electromagnetic compatibility (EMC) - Part 3-12: Limits - Limits for harmonic currents
produced by equipment connected to public low-voltage systems with input current > 16 A and ≤ 75 A per phase.

IEC 60038:2009, IEC Standard Voltages.

178
IEC 60079-0:2011-06, Explosive atmospheres – Part 0: Equipment – General requirements.

IEC 60079-7:2015-06, Explosive atmospheres – Part 7: Equipment protection by increased safety "e".

IEC 60079-11:2011-06, Explosive atmospheres – Part 11: Equipment protection by intrinsic safety "i".

IEC 60079-15:2010-01, Explosive atmospheres – Part 15: Equipment protection by type of protection "n".

IEC 60079-18:2014-12, Explosive atmospheres – Part 18: Equipment protection by encapsulation "m".

IEC 60079-25:2010-02, Explosive atmospheres – Part 25: Intrinsically safe systems.

IEC 60079-26:2014-10, Explosive atmospheres – Part 26: Equipment with equipment protection level (EPL) Ga.

IEC 60079-28:2006-08, Explosive atmospheres – Part 28: Protection of equipment and transmission systems using
optical radiation.

IEC 60204-1, Ed. 5.1 2009, Safety of Machinery -Electrical equipment of Machines - Part 1: General Requirements.

IEC 61326-1:2012-07, Electrical Equipment for Measurement, Control and Laboratory Use - EMC Requirements.

IEC 61326-3-1:2017 Electrical Equipment for Measurement, Control and Laboratory Use - EMC Requirements.

IEC 61326-3-2:2017 Electrical Equipment for Measurement, Control and Laboratory Use - EMC Requirements.

IEC 60364-1: Low-voltage electrical installations - Part 1: fundamental principles, assessment of general
characteristics, definitions.

IEC 60364-4-41: Low-voltage electrical installations - Part 4-41: protection for safety - protection against electric
shock.

IEC 60364-4-44: Low-voltage electrical installations - Part 4-44: protection for safety - protection against voltage
disturbances and electromagnetic disturbances.

IEC 60364-5-52: Low-voltage electrical installations - Part 5-52: selection and erection of electrical equipment –
wiring systems.

IEC 60364-5-54: Low-voltage electrical installations - Part 5-54: selection and erection of electrical equipment -
earthing arrangements and protective conductors.

IEC 61000-4-30: Testing and measurement techniques – Power quality measurement methods.

IEC 61131-4:2004, Programmable Controllers - Part 4: User guidelines.

IEC 61140, Ed. 3.1 2009, Protection Against Electric Shock - Common Aspects for Installation and Equipment.

IEC 61511-1 Ed. 1.0: 2003, Functional safety - Safety instrumented systems for the process industry sector - Part 1:
Framework, definitions, system, hardware and software requirements.

IEC 61643-11:2011, Low-voltage surge protective devices - Part 11.

Lightning references
NFPA 780, Standard for the Installation of Lightning Protection Systems, 2011. NUREG/CR-6866 ORNL/TM-
2001/140, Technical Basis for Regulatory Guidance on Lightning Protection in Nuclear Power Plants, 2011.
179
Lightning Protection for Engineers, National Lightning Safety Institute, 2016.

IEC 62305-1:2010, Protection against lightning - Part 1: General principles.

IEC 62305-2, Protection against lightning – Part 2: Risk Management.

IEC 62305-3, Protection against lightning – Part 3: Physical damage to structures and life hazard.

IEC 62305-4, Protection against lightning – Part 4: Electrical and Electronic Systems Within Structures.

US Military Handbook
MIL-HDBK-419A, Grounding, Bonding, and Shielding for Electronic Equipment and Facilities (Vol. 1 Basic
Theory; Vol. 2 Applications), 1987.

180