Earthing Recommendations

For Programmable Controller Systems

ES30001 Part-I (Rev.-2) JULY 2001

Earthing Recomendations - PLC

ES30001 (Part-I)

Earthing Recomendations - PLC

Contents
1. Scope ......................................................................................................................................... 5
2. Definitions ............................................................................................................................... 5
3. Function of Plant Earth ........................................................................................................ 5
4. Function of Primary Earth ..................................................................................................... 6
5. Function of Secondary Earth ................................................................................................. 9
6. Earthing of Multiple panels ................................................................................................. 12
7. Earthing of Panels with Multiple Power feeds .................................................................. 14
8. Earthing of Remote Stations ............................................................................................... 14
9. Connecting MMI, Peripherals .............................................................................................. 14
10. Cables and Conduits ............................................................................................................ 15
11. Verification of Earth Connections ...................................................................................... 15
12. Earth pit ................................................................................................................................. 17
13. Summary ................................................................................................................................ 18

Earthing Recomendations - PLC

Notes ...................................................................................................................................... 19

Disclaimer
"Larsen & Toubro Limited, its affiliates and employees disclaim all liabilities & warranties (including lost
profits or any other incidental damages) for accuracy, currency, completeness of the information contained
herein
In line with the companys policy of continuous development. The information contained in this document is
subject to change without prior notice.
Selection of materials and/or equipment is at the sole risk of the user of this publication.
The contents of this document are property of Larsen & Toubro Limited. No part of this document may be
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without the express written permission of Larsen & Toubro Limited."

Document Information
Document #:
Revision:
Release date:

ES30001-Part-I
2
July 2001

Credits

Earthing Recomendations - PLC

Technical team:
Omkar Saroop
Sujit Dey
A A Samson

Revised by (Rev. -2)

R.K.Pandagare
R.M.Karlekar

1.

Scope

The Part 1 recommendations apply primarily to the Programmable Logic Controller (PLC), their
Remote Stations and associated peripherals, such as MMIs and are primarily for addressing
Electromagnetic interference and Electromagnetic compatibility (EMI/EMC)
Part 1 does not address the Drives and their interconnections with the PLC systems.

Definitions

2.1

Panel: The metal enclosure in which the PLC and the associated equipment are
mounted and housed.

2.2

PLC System: Comprises of the Power supply Units, CPU, I/Os, Mountbases.
Communication Interfaces &remote stations.

2.3

Primary Earth: The earth connected to the Panel.

2.4

Secondary Earth: The earth connected to the PLC system.

2.5

Plant Earth: The earth to which the lightning conductor, earth conductors of other
equipment in the Plant are connected. (E.g. MCC , PCC, H.T Switchgear)

2.6

Equipotential Ground Plane : Ground plane exhibiting zero potential difference

between any two points on it. It does not matter what the absolute potential of the
ground plane to the earth may be at.

2.7

Cable Shield: The metal braid cover on the cables carrying communication signals and
instrumentation signals i.e. analog signal, low voltage digital signal etc.

2.8

Cable Armor: The metal stripes covering the high power cables.

2.9

Signal Ground: This is the return path associated with an analog signal.

2.10

Digital Ground: This is the return path associated with the digital logic signal.

3.

Function of Plant Earth

The function of the plant earth is to limit over-voltages on the plant structure, equipment and
exposed metal sections. These surfaces may get electrically elevated from the zero potential of
earth due to high fault currents or due to lightning strikes. The plant earth conductor provides
a path for these currents to the earth.

Earthing Recomendations - PLC

2.

4.

Function of Primary Earth

The aim of the Primary Earth is to limit over-voltages, due to fault currents etc., on the
exposed Panel surface to ensure the personnels safety against electric shock hazards, refer
figure1& 1a. The Primary earth pit is a separate pit. The Plant earth pit must not be used as
Primary earth pit. This is to ensure that the momentary changes in the plant earth potential do
not directly reflect on the panel.
4.1

The Panel accessible parts, i.e. Panel chassis, framework & fixed metal parts, shall be
connected to the Primary Earth busbar within the Panel. This requirement can be met
by the normal structural parts providing electrical continuity. Paint may be scrapped at
the metallic joints to provide a good continuity.

4.2

Connections to Primary Earth busbar within the panel shall be such that connection is
maintained even when the Panel is opened or any removable part is removed.

4.3

Primary Earth pit shall be connected to the Plant Earth. This connection shall not be
just by the virtue of mounting of the Panel on the mounting rail or support on the
floor of the Plant. A cable shall provide connection between the Panel Primary Earth
bus bar and a separate earth pit. This earth pit shall be called Primary Earth pit. The
connection between the Primary earth pit and the Plant earth is described in section 6.

4.4

All the connections to the Primary Earth bus bar within the panel shall be of screw type
of brass or other non corrosive metal. The clamping means shall be adequately locked
against accidental loosening and it shall not be possible to loosen them without the aid
of a tool.

4.5

The Primary Earth pit shall have no other functions than those described above.

4.6

The Primary Earth pit shall be graphically represented as

4.7

Within the panel the Primary Earth wire shall be of color green with yellow stripes.

4.8

The gauge of the Primary Earth wire shall be,

Within the Panel: 1.5 mm2, multistrand copper wire with insulation.
!
Panel to pit:
10 mm2, multistrand copper or equivalent
aluminium wire, with insulation.
!

Earthing Recomendations - PLC

4.9

The following are connected to the Primary Earth:

4.9.1

The Panel.

4.9.2

The primary neutral terminal of all input/isolation transformers.

4.9.3

Primary shield of all input/isolation transformers.

4.9.4

Earth terminal of all Field Power supplies I/O (External to the PLC System),
Displays, Switch matrix.

4.9.5

Incandescent Lamps & sockets.

4.9.6

All other parts of the Panel which are electrically isolated.

Figure 1: Primary Earth

1
P N E

P2
N2
E2

10

9
P2
N2
E2

3
2

123456789012345678901234567890121234567890
123456789012345678901234567890121234567890
123456789012345678901234567890121234567890
123456789012345678901234567890121234567890
123456789012345678901234567890121234567890
P1

P2

N1

N2

E1

E2

4
5
6
Legend
1
2
3
4
5
6
7
8
9
10
P1, N1, E1
P2, N2, E2
P, N, E
Dashed lines
Solid lines

Panel
Primary earth busbar
Secondary earth busbar
Primary earth pit
Control transformer
Shorting of the primary sheild
Plant earth
Field power supply
CPU power supply
I/O Modules
Primary power (100V/230V)
Seondary power (100VAC)
Auxillary power (230VAC)
Not connected to primary earth
Connected to primary earth

Earthing Recomendations - PLC

Figure 1a: Primary Earth (Multiple feeds)

1
P N E

PS
P2
N2
E2

10
9
PS
P2
N2
E2

3
2

7A

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123456789012345678901234567890121234567890123456
12345678901234567890123456789012123456789012345678901234
12345678901234567890123456789012123456789012345678901234
12345678901234567890123456789012123456789012345678901234
P1

P2

P1

P2

N1

N2

N1

N2

E1

E2

E1

E2

Earthing Recomendations - PLC

4
5A

5B

6A

6B

Legend
1
2
3
4
5A, 5B
6A, 6B
7A
8
9
10
P1, N1, E1
P2, N3, E2
P3, N3, E3
P, N, E
Dashed lines
Solid lines

Panel
Primary earth busbar
Secondary earth busbar
Primary earth pit
Control transformer
Shorting of the primary sheild
Plant earth
Field power supply
CPU power supply
I/O Modules
Primary power (100V/230V)
Secondary power (CPU)
Secondary power (I/O)
Auxillary power (230VAC)
Not connected to primary earth
Connected to primary earth

5.

Function of Secondary Earth

Primary aim of the Secondary Earth is to provide low impedance path to the noise currents
induced by RFI/EMI and the leakage currents in the PLC system. Refer to figure 2 & 2a.
5.1

All the metallic parts of the PLC hardware and the earth terminals on the I/O modules
of the PLC system shall be connected to the Secondary Earth bus bar.

5.2

The PLC hardware must be isolated from the Panel by means of insulating spacers.

5.3

The Secondary Earth conductor from the Panel must be connected to a separate Earth
pit. This Earth pit is called Secondary Earth .Within the Panel the Secondary Earth bus
bar shall be isolated from the Primary Earth bus bar by mounting it on insulating
bushes.

5.4

All the connections of the Secondary Earth within the panel shall be of screw type of
brass or other non corrosive metal. The clamping means shall be adequately locked.

5.5

The Secondary Earth shall be graphically be represented as

5.6

Within the panel the Secondary Earth wire shall be of color green.

5.7

The gauge of the Secondary Earth wire shall be:

Within the Panel: 1.5 mm2, multistrand copper wire with insulation.
!
Panel to pit:
6 mm2, multistrand copper or equivalent
aluminium wire, with insulation.
!

The following are connected to the Secondary Earth bus bar .

5.8.1

Secondary Shield of the transformer feeding the PLC Power supply Units.

5.8.2

Earth terminal of the Power Supplies for the PLC system (local I/O, remote I/O
interfaces & commutation devices).

5.8.3

All Mountbases, chassis of devices in 5.8.2.

5.8.4

Earth terminal of power line filter.

Earthing Recomendations - PLC

5.8

Figure 2: Secondary Earth (Single feed)

1
8

P N E

P2
N2
E2

10
11
12345678901234567890123456789012123456789012
12345678901234567890123456789012123456789012

9
P2
N2
E2

3
2

123456789012345678901234567890121234567890
123456789012345678901234567890121234567890
123456789012345678901234567890121234567890
123456789012345678901234567890121234567890
123456789012345678901234567890121234567890
P1

P2

N1

N2

E1

E2

4
5

Earthing Recomendations - PLC

Legend
1
2
3
4
5
6
7
8
9
10
11
P1, N1, E1
P2, N2, E2
P, N, E
Dashed lines
Solid lines

10

Panel
Primary earth busbar
Secondary earth busbar
Secondary earth pit
Control transformer
Shorting of the secondary sheild
Mountbase
Basic power supply
I/O Module
Sheilded I/O wire
Sheild terminal on the I/O module
Primary power (100V/230V)
Seondary power (100VAC)
Auxillary power (230VAC)
Not connected to secondary earth
Connected to secondary earth

Figure 2a: Secondary Earth (Multiple feeds)

1
8

P N E

P2
N2
E2

10
11
12345678901234567890123456789012123456789012345678901234567890121
12345678901234567890123456789012123456789012345678901234567890121

9
P2
N2
E2

3
2

123456789012345678901234567890121234567890
123456789012345678901234567890121234567890
123456789012345678901234567890121234567890
123456789012345678901234567890121234567890
123456789012345678901234567890121234567890
P1

P2

P1

P3

N1

N2

N1

N3

E1

E2

E1

E3

4
6A

5B

6B

Legend
1
2
3
4
5A,5B
6A, 6B
7
8
9
10
11
P1, N1, E1
P2, N2, E2
P3, N3, E3
P, N, E
Dashed lines
Solid lines

Panel
Primary earth busbar
Secondary earth busbar
Secondary earth pit
Control transformer
Shorting of the secondary sheild
Mountbase
Basic power supply
I/O Module
Sheilded I/O wire
Sheild terminal on the I/O module
Primary power (100V/230V)
Seondary power (100VAC)
Secondary power (I/O)
Auxillary power (230VAC)
Not connected to secondary earth
Connected to secondary earth

11

Earthing Recomendations - PLC

5A

6.

Earthing of Multiple panels

6.1

Separate Primary and Secondary Earth conductor shall run from the Panel to the
Primary and Secondary earth pits respectively. Refer figures 3 , 4, 5 & 6.

6.2

In case of multiple adjacent Panels. The earth conductors of the non powered cabinets
must be connected to the respective earth busbar in the powered cabinet that has
connection to the Primary and the Secondary earth pits respectively.

6.3

The earth conductors from the adjacent Panels shall be connected in a single point
termination. Daisy chaining of connection is not permitted. See figure 3.

6.4

Each Panel with separate power feed, on the same floor, shall run separate Primary &
Secondary earth conductors from the Panel to respective earth pits. See figure 4.

6.5

Each Panel with a separate power feed, on different floors / buildings shall run
separate Primary & Secondary earth conductors from the Panel to separate set of earth
pits or to common earth pits depending on the distance between the two locations. See
figure 5. (Minimum distance between Primary & Secondary Earth pits shall be > = 30
Meters.

6.6

The Primary, Secondary and the Plant earth pits shall be shorted with each other. The
shorting shall be a single point connection. Daisy chaining of connections is not
permitted.

6.7

The wire gauge for interconnection of earth pits shall be 25 mm2, multistrand copper
or equivalent aluminum wire, with insulation.

Figure 3: Earthing of adjacent panels (With same power feed)

7
P1

P2

N1

N2

Earthing Recomendations - PLC

2
1

6
6
4

12

Legend for figures 3, 4 & 5

1.
2.
3.
4.
5.
6.
7.

Primary earth busbar

Secondary earth busbar
Secondary earth
Primary earth
Plant earth
Pit level earth short
Transformer

Figure 4: Earthing of adjacent panels (With different power feed)

P1
N1

P2

P1

N2

N1

P2
N2

2
1

6
6
4

Figure 5: Panels on different floors (With same or different power feeds)

2
1

6
6
4

13

Earthing Recomendations - PLC

2
1

7.
7.1

8.
8.1

Earthing of Panels with Multiple

Power feeds
Same procedure as in section 6 to be followed.

Earthing of Remote Stations

Each Panel of the Remote station shall be individually earthed as in section 4, 5 & 6.
Refer figure 6.

Figure 6: Earthing of two remote panels

Distance between
two panels > 30m

7
2
1

2
1

Legend

Earthing Recomendations - PLC

1.
2.
3.
4.
5.
6.
7.

9.

Primary earth busbar

Secondary earth busbar
Secondary earth
Primary earth
Plant earth
Pit level earth short
Communication cable

Connecting MMI, Peripherals

This is aimed at the RS232 connection on the Modules used for interfacing PLC system to a
MMI, peripherals or other RS232 based system.
The aim is to isolate the ground/earth of the two system with the intention of breaking the
ground current loops formed by the potential differences between the two Systems ground/
earth.
The isolation may be achieved by means of intermediate device providing isolation between
the PLC and MMI system. This device may be external to the PLC / MMI System. E.g. RS232
optical isolators.

14

10. Cables and Conduits

All communication cables should be run in conductive metallic conduits. The conduit should be
connected to the Plant earth not just by the virtue of its contact with the building steel. It
should be intentionally connected to the Plant earth at least at one location, preferably at
multiple locations. The conduits must not be directly connected to the Primary earth as they may
be prone to lightning strikes.
The Cable shields of the all the I/O cables (analog signals, digital signals) shall be connected to
the Shield terminal identified on the respective I/O module. They shall not be connected to any
other point in the System.

11. Verification of Earth Connections

Within the Panel
11.1.1 At the input of transformers the voltage across L to N & L to E should be same.
11.1.2 Measure the continuity of grounding electrode conductor from the earth pit (for
Primary & Secondary earth).
11.1.2.1

Disconnect the cabinet power supplies i.e. Complete shut down.

11.1.2.2

Lay a separate cable X1 from the primary earth bus bar in panel up to
the primary earth pit & ensure the continuity of X1 w.r.t. X

11.1.2.3

Lay a separate cable X2 from the Secondary earth bus bar in panel
upto the Secondary earth pit & ensure continuety of X2 w.r.t. X

11.1.3 Check the pit level continuity between Primary & Secondary earth.
11.1.4 Conduct megger test at 500V dc. This is to be conducted before mounting I/O
modules or any other modules.
11.1.5 Measure the insulation between primary & secondary earth bus bars in panel,
these test should be reapeted at site with multimeter.
11.1.5.1

Disconnect Primary as well as Secondary earth out going grounding

conductor.

11.1.5.2

Connect a resistance meter (ohm meter) between Primary earth &

Secondary earth bus bar.

11.1.5.3

Observe the resistance. It shall be greater than 1 Megohm.

11.1.5.4

Re connect the Primary & Secondary Earth Conductors to their

respective earth bus bars.

15

Earthing Recomendations - PLC

11.1

11.2

Outside the Panel

11.2.1 Fall of potential method. (Refer figure 7)
Two auxiliary earth electrodes, are placed at a distance of 15m from the test
electrodes as shown in the figure 7. The test electrodes and the current
electrodes shall be so placed that they are independent of the resistance area of
each other. If the test electrode is in the form of rod or pipe ,the auxiliary
current electrode C shall be placed at least 30 meters away from it and the
auxiliary potential electrode B shall be placed midway between them.
A known current is passed between the electrodes A & C and the potential
difference between the electrodes A & B is measured.
The resistance of the test electrodes A is then given by R = V/I. The auxiliary
electrodes B & C usually consists of 12.5mm diameter mild steel rod driven up
to 1m into ground.
11.2.2 Impedance of earth electrode shall be less than 5 ohms.
11.2.3 Impedance of earth pit must be checked once in a year.

Figure 7: Fall of potential method

(For measuring earth electrode resistance. Refer IEEE-344)

Earthing Recomendations - PLC

Current
Source

V
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12"

15m

Electrode "A"
Test electrode

16

12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
#12"

15m

12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
#12

Above earth level

Below earth level

Electrode "B" Electrode "C"

Potential
Current electrode
electrode

12. Earth pit

12.1

Typical installation of pipe earth electrode is shown in figure 8.

12.2

The distance between any two earth pits should be greater than 30 meters.

12.3

Keep the surrounding soil of the earth pit moist.

12.4

The effect of soil temperature on soil resistivity is more influencing near and below
freezing point, necessitating the installation of earth electrode at depths to which frost
will not penetrate. The minimum depth of the earth rod must be 2.5 meters.

Figure 8: Typical installation of earth pipe electrode

(For detailed dimensions refer IS3043)
1

Below earth level

Legend
1.
2.
3.

Concrete structure with lid

Cast iron or copper pipe
Homogeneous layer of
coke, charcoal, salt &
sand
4. Earth conductor (inter-pit
& equipment)
5. Funnel for watering soil
6. Exothermic bond or
brazing or connection by
non-ferrous, noncorrosive clamping device.

#$ "
ID=100mm
" 400mm #

17

Earthing Recomendations - PLC

"

Above earth level

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2500mm

13. Summary
13.1

Primary Earth connections:

13.1.1 The Panel.
13.1.2 The primary neutral terminal of all input/isolation transformers.
13.1.3 Primary shield of all input/isolation transformers.
13.1.4 Earth terminal of all Field Power supplies I/O (External to the PLC System),
Displays, Switch matrix.
13.1.5 Incandescent Lamps.

13.2

Secondary Earth connections:

13.2.1 Secondary Shield of the transformer feeding the PLC Power supply Units.
13.2.2 Earth terminal of the Power Supplies for the PLC system (local I/O, remote I/
O interfaces & commutation devices).
13.2.3 All Mountbases chassis devices in 12.2.3.
13.2.4 Earth terminal of the power line filters.

13.3

Dos:
13.3.1 Isolate the Mountbase from the Panel.
13.3.2 Run separate earth conductors to Primary & Secondary earth pits.
13.3.3 Short Primary, Secondary and Plant earth pits at pit level only.
13.3.4 Make Earth connections for Remote station similar to CPU stations.
13.3.5 Short the Remote stations & CPU station earth at the pit level.
13.3.6 Use port Isolators for RS232 communication port.

13.4

Donts:

Earthing Recomendations - PLC

13.4.1 Short Primary & Secondary earth bus bars within the Panel.

18

Notes

19
Earthing Recomendations - PLC

P.O. Box 7025, New Delhi 110002

P.O. Box 8119, Mumbai 400051
! P.O. Box 619, Calcutta 700071
! Post Bag 5247, Chennai 600002
!
!

20

Phone: (11) 372 1830

Phone: (22) 654 1300
Phone: (33) 242 2301/5
Phone: (44) 852 2141

Fax: 371 3802

Fax: 654 1344
Fax: 242 7587/1025
Fax: 852 0769

ES30001 Part-I (Rev.-2) JULY 2001

Earthing Recomendations - PLC

Control & Automation Section

LARSEN & TOUBRO LIMITED