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Section
Contents
Page
1.1
1.2
1.3
1.4
Shielded Cables
1.4-1 Choice of cable
1.4-2 Where should the connection be made?
8
8
9
1.5
10
2 Wiring Rules
11
13
3.1
Electromagnetic Caging
13
3.2
14
3.3
15
3.4
21
3.5
22
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1
Electromagnetic Compatibility
of Industrial Networks and Fieldbuses
Section
Contents
Page
25
4.1
Electromagnetic Caging
25
4.2
Islands
26
4.3
28
28
29
31
33
4.4
34
35
5.1
Wiring Connections
35
5.2
36
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2
Introduction
This document (1) is intended for designers, contractors and installers of all SCHNEIDER
ELECTRIC installations containing digital connections.
With the rapid changes taking place in industrial application electronics and for the
reasons below it is no longer possible to ignore the problems of electromagnetic
compatibility.
Equipment complying with industrial standards (electromagnetic compatibility) operates
effectively when it is stand-alone
Precautions should be taken, however, when devices are interconnected (networked
equipment, distributed control systems, remote I/O, etc) to ensure that they operate
effectively in their electromagnetic environment
For each installation configuration (fieldbus or industrial local network), ensure that there
are no additional requirements given in the relevant documentation (example : maximum
length, number of cable ducts, distance between two ducts)
Warning
CE marking is obligatory in Europe. It does not, in itself, guarantee the actual
performance of systems in terms of EMC.
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P1
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P2
Section 11
Summary and Definitions
1 Summary and Definitions
1.1
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3
1.2
The role of an earth grounding network is to discharge to ground all leakage and fault
currents from equipment, common mode currents from external cables (mainly power and
telecommunication) and direct lightning current.
Physically, low resistance (in relation to a distant earth ground) is much less relevant than
the local equipotentiality of the building. In fact, the most sensitive lines are those which
connect equipment together. In order to limit circulation of common mode currents on
cables which do not leave the building, voltages between equipment interconnected on the
site must be limited.
Interconnecting buried networks is recommended. When the area of a building is small,
that is, approximately ten square meters, a simple buried belt is sufficient. For new
buildings with a large surface area, we recommend linking buried conductors in a cage
measuring approximately 10 m on each side.
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4
Electronic equipment and systems are (or are to be) interconnected. The best way of
ensuring efficient operation is to maintain good equipotentiality between the different
devices. Unlike safety of personnel which is an LF constraint, inter-device equipotentiality
must remain satisfactory, particularly for digital equipment, up to very high frequencies.
In cases of incompatibility, safety rules take precedence over EMC constraints.
In cases of incompatibility between the recommendations in this manual and specific
instructions for a device, the latter take precedence.
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5
1.3
Electrical signals are normally transmitted in differential mode. All power supplies and
electronic signals are transmitted in differential mode. The current flows out along one
conductor and returns along the other. Differential voltage is measured between the
conductors.
When the inward and outward conductors are side by side and separated from currents
which cause interference, differential mode interference is negligeable in most
cases.
IDM
UDM
IDM
Common mode is an interference mode in which the current flows in the same direction
on all the conductors and returns via the machine ground.
ICM
ICM
UCM
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6
A machine ground (a conductive enclosure for example) acts as the reference potential
for electronic signals and the reference return for common mode currents. Any common
mode current which, via a cable, penetrates a device isolated from machine grounds,
leaves it again via the other cables. When machine grounds are inefficiently linked, a cable
carrying a common mode current has an interfering effect on all the others. Effective
electromagnetic caging reduces this phenomenon.
HF interference transmitted along cables in common mode is the main EMC
problem.
The TN-C neutral point connection, by combining the neutral conductor (marked N, which
is live) with the protective conductor (marked PE) allows high currents to circulate through
the machine grounds. This system is therefore harmful to the equipotentiality of the site and
to the magnetic environment. The TN-S neutral point connection (with or without residual
differential current protection) is far preferable.
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7
1.4
Shielded Cables
Steel tape
Average
Longitudinal drain
Braid
Good
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8
From a few MHz, the protective effect can reach several hundred MHz using a single braid
if the shielding connections are suitable. Flexible, strong shielding makes installation fairly
simple, and is compatible with Sub-D or mini-DIN connectors.
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9
1.5
Family
1
Cables
Analog
Digital
and telecomm.
Relay
Power supply
Comprising :
supply and measuring circuits
for analog sensors
digital and databus circuits
EMC behavior
These signals are sensitive
These signals are sensitive.
They also cause interference
for family 1
These signals cause interference
for families 1 and 2
These signals cause interference
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10
Section
2
Wiring
rules 2
2 Wiring Rules
Whenever possible, installers must observe the following rules.
Rule no. 1 :
The outward and return conductors must always be adjacent to each other.
For digital or analog signals, the use of pairs is a minimum requirement. Special attention
should be paid to wiring inside enclosures which use separated conductors. The wires
must be labeled by signal type and by pair.
Special case : the wiring for chains of emergency stop and alarm systems must never be
single wire point-to-point but in pairs.
Rule no. 2 :
Fastening all connections against grounding equipotential structures is
recommended in order to benefit from an HF protective effect.
The ideal would be to systematically use shielded cables or shielded multiple strands.
However, the use of ducts for conducting cables provides a satisfactory level of protection
in most cases. As a minimum requirement, connection cables between or within buildings
should also have a grounding connection : grounding wire or cable ducts.
For connections inside enclosures and machines, cables should be systematically
fastened against metal plate. In order to maintain the correct protective effect, the following
ratio should be observed :
Distance between cables
>5
Radius of thickest cable
d/R > 5
Cable causing
interference
Signal cable
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11
Rule no. 3 :
Only pairs for analog, digital and telecommunication signals may be adjacent to
each other in the same bundle or laid in the same cable group.
Relay, speed drive, supply and power circuits should be separated from the above
pairs.
When installing variable speed drives, it is important to ensure that power connections
are clearly separated from data links.
Whenever possible, a cable duct should be reserved for power connections in
enclosures.
Rule no. 4 :
The same connector should not be used for connecting different families (except
for relay, supply and power circuits).
If the same connector is used for both analog and digital signals, these must be
separated by a row of pins at the 0 V connection.
Rule no. 5 :
All unused conductors in a cable should be systematically connected to the chassis
ground at both ends (except for analog cables).
This provides a protective effect with a factor of approximately 5 at HF.
Rule no. 6 :
Power cables do not need to be shielded if they are filtered.
The power outputs of variable speed drives must therefore be either shielded or filtered.
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12
Section 33
Wiring of Enclosures and Small Machines
3 Wiring of Enclosures and Small Machines
3.1
Electromagnetic Caging
Linking the grounding elements inside an enclosure or a small machine is essential since
these elements are directly accessible to electronic equipment. All the metal structures
of the bay will thus be interconnected. Equipotential connections for safety purposes
must be complemented by direct connections between all elements in the machine or
enclosure.
Systematic use of a grid or cage at the back of the enclosure for mounting all
equipment is recommended.
Electromagnetic caging :
DIN rail + enclosure ground
Grounding strip
Safety conductors
3.2
RILSAN clip
Grounding braid
YES
NO
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14
3.3
PRP
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15
Grounding strip
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16
Fairly good
Grounding
strip
Poor
Good
Excellent
PRP on chassis
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17
When connecting to screw terminals where use of a jumper for shielding connections is
not possible, the pigtail must be as short as possible. This type of connection should be
avoided.
Ground terminals with metal mounting
system using the DIN rail
Grounding
strip
No
Acceptable if
connection
very short
Yes
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18
When using a connector, its design must ensure 360 electrical continuity between the
cable shielding and the machine ground.
Connector with
grounding bosses
Contact between
the connector shell
and shielding
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19
Installing filters
The effectiveness of an AC power supply filter is determined at HF by its mounting rather
than by its electrical operation. Three rules must be followed when mounting a filter :
the filter must be referenced plate to plate
the upstream and downstream cables must be wired on each side of the filter in order
to limit stray coupling between the input and output
the upstream and downstream cables must be fastened against the plate in order to
limit radiation from the input to the output
Filtered conductor
Capacitive or
inductive
coupling
No
Conductor
subjected to
interference
Emission
and/or
pick-up
No
Filter
Fasten
against the
plate
Yes
Screw directly onto
the plate of the
chassis
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20
3.4
Numerical controllers, variable speed drives and PLCs can all occupy the same enclosure
provided that :
the speed drives are installed with shielded cables
all the wiring rules described above are observed : use a PRP or grounding strip for
example.
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21
3.5
Cable ducts outside enclosures must be made of metal if over 3 m long. These ducts
must have end-to-end electrical continuity and be directly connected to the grounds
of enclosures and machines using trunking joints or connection bars.
Any other cable should only be used in cases where no other solution is possible.
If a single duct is used, it must be no longer than 30 m if possible. Unshielded cables
must be fixed in the corners of the ducts as shown in the figure below.
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22
Unshielded
analog cables
Relay cables
Unshielded
digital cables
Shielded
digital cables
Shielded
analog cables
Vertical separation in the duct avoids mixing incompatible cables (see section 1.5). A metal
cover on signal half-ducts is recommended. It should be noted that a full metal cover on
the duct does not improve EMC. Take possible future developments into consideration.
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23
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24
44
4.1
Electromagnetic Caging
Computer
island or room
< 2m
Metal
casing
Vertical
grounding
Iron strip
<3m
1 m
< 10 m
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25
4.2
Islands
Horizontal cable
duct
Equipment
Vertical cable
duct
Iron strip
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26
When equipment is grouped into several enclosures side by side, they are bolted
together and thus make up an island.
Conductive false floors can be used to create effective caging. For practical reasons, only
one out of three supports needs to be connected. This then gives a cage of 1.80 m2.
In this case the different grounding connections can be made using either copper round
bars, wide and short connector bars or tinned braid. Whenever possible, direct contact
should be made.
When two enclosures are side by side, they should be directly interconnected by at least
2 contacts at the top and bottom of the bays.
Ensure that paint does not prevent electrical contact. The use of lock washers is highly
recommended.
Interconnection of grounds
The cross-section of straps is not relevant since only their length is important. The
grounding connections must not exceed 50 cm.
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27
4.3
4.3-1 Principle
All cables must be routed with protective effects by fastening them to grounding
structures.
Metal cable ductswith end-to-end electrical continuity should therefore be systematically
used outside enclosures.
Use trunking joints to make the connections.
It is very important that trunking joints or connector bars are used to make these
connections rather than braids and particularly round conductors. These cable ducts
must be connected, using the same methods, to the grounds of enclosures and
machines, after removing any paint to ensure good contact.
A vertical separation in the duct is used to avoid mixing incompatible cables (see
section 1.5).
It should be noted that a full metal cover on these ducts does not improve EMC.
equivalent
to
equivalent
to
Effectiveness
A backup cable (ground cable, see section 4.4) should only be used in cases where
no other solution is possible.
For each communication network, as a function in particular of its speed and the cable
gauge used, a maximum initial limit for segment lengths (without repeater) must be
observed. This limit, shown in product documentation, may only be reached if the
installation conditions are satisfactory in terms of EMC (in particular : cables laid in
metal ducts with end-to-end electrical continuity connected to electromagnetic caging
and earth ground).
A maximum theoretical length for electromagnetic compatibilityshould therefore
be defined. This second limit is theoretical since it is usually greater than the first
one. It is used to optimize installation conditions and must be observed together with
the first limit. It also applies to a segment without a regenerative repeater.
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28
Power cables
Relay
cables
Digital cables
(unshielded)
Analog cables
(unshielded)
Digital cables
(shielded)
Analog cables
(shielded)
These special limits all derive from the same EMC Theoretical Length or ETL.
Reaching this ETL assumes that the following three optimum conditions have
been met :
abc-
a second duct, at least 30 cm away, is reserved for power and relay cables,
no more than 50% of the duct capacity is used,
there are no analog cables or unshielded digital cables.
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29
The EMC theoretical length is on average 1200 meters, but this value can vary
depending on the type of communication network.
The ETL is : 2000 m for FIP at 1 MBit/s and for Unitelway, 1000 m for ModbusPlus
and for Ethway with 50 Ohm triaxial cable, 700 m for Mapway, and 400 m for the X Bus
system used by PREMIUM PLCs.
Whenever one of the 3 conditions is not met over the total length, the physical length of
the duct must be assigned a coefficient in order to maintain electromagnetic compatibility.
These coefficients Ki, defined in the table below, measure the degree to which the
protective effect is reduced. The resulting authorized length will therefore be less than
the ETL.
In addition, in the case of single ducts for power and signal cables, the coefficient
will, if necessary, take into account the absence of any metal separation or metal
covers on them.
Sym- Installation condition
bol
Coef- Total
ficient length (1)
Ki
ETL x 1/Ki
600 m
600 m
600 m
300 m
K50
50% or more
of duct filled
K10
Ducts separated
by 10 cm (instead
of 30 cm)
or
10 cm
10 cm
K8
Without cover on
signal half-duct
or
200 m
K0
Without separation
or
12
100 m
(1) Maximum total length if this is the only unfavorable condition (with ETL = 1200 m)
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30
Power cables
Relay cables
Shielded digital cables
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31
Example 2 : Shielded digital connections less than 300 m, without analog cable
As soon as the length calculated in an installation condition is no longer sufficient (100 m
in the first example) the EMC of the configuration must be improved.
Power
cables
Relay
cables
Shielded
digital
cables
A vertical separation in the duct is used to avoid mixing incompatible cables. A metal
cover on the half-duct of signal cables limits the interference from signals.
This is why the value of the coefficient then changes from 12 (=K0) to only 4 (=K6), giving
(with ETL = 1200 m) the maximum length : ETL / 4 = 300 m.
The EMC conditions to be observed are thus :
each half-duct is no more than 50% full
the separation is made of metal and in contact with the duct throughout its length
the cover is in contact with the separation throughout its length.
Take possible future developments into consideration.
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32
Ki coefficients
Calculations
Results
20 m
40 m
20 m x 24
40 m x 4
480 m
160 m
480 m + 160 m
640 m
Total (60 m)
The result of 640 m now being lower than ETL = 1200 m, the 60 m length installed will
comply with EMC requirements.
Ki coefficients
Calculations
Results
700 m
300 m
none
K50 (=2) and K10 (=2)
300 m x 4
700 m
1200 m
700 m + 1200 m
1900 m
Total (1000 m)
The result of 1900 m being lower than ETL = 2000 m, the installed length will comply with
EMC requirements and only the preceding condition remains (no small-gauge pairs used).
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33
4.4
The protective effect of a cable duct is approximately 50 between 1 MHz and 100 MHz.
Other protective effects are possible in cases where this type of equipment cannot be
used. Welded wire cable ducts are less effective and often more expensive than plate
ducting.
Welded wire cable duct :
Protective efffect 10
Protective efffect 5
Grounding cable :
Protective efffect 5
Grounding cable
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34
5.1
Wiring Connections
Connections between buildings have two characteristics which can result in risks for
the installation :
poor equipotentiality between the grounding elements of installations
large loop areas between data cables and grounding elements.
Before installing and connecting a data cable between two buildings, it is essential
to check that the two ground connections of the buildings are interconnected.
All grounds which are simultaneously accessible must be connected to the same
ground connection (or at least to a set of interconnected ground connections). This
constraint is fundamental for the safety of personnel.
The second risk related to connections between buildings is the loop area between
data cables and grounding elements.
This loop is particularly critical in the event of an indirect lightning strike on the site. The
overvoltages induced in these loops through indirect impact of lightning are in the order of
a hundred volts per square meter.
In order to limit this risk, all cables laid between two buildings must be duplicated
35 mm2).
by a large-gauge equipotential connection (
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35
5.2
Common mode currents coming from outside must be discharged to the grounding
network at their point of entry to the site in order to limit any potential difference
between equipment.
Any conducting trunking entering a building (conducting cable, conducting piping
or isolated piping carrying a conducting fluid) must be connected to the earth
ground at their point of entry to the building, using the shortest possible distance.
Overvoltage protectors should be placed at the entry points in buildings for power,
telecommunication and signal cables (data, alarms, access controls, video surveillance,
etc). The effectiveness of such devices largely depends on their installation.
Overvoltage protectors (varistors, arresters, etc) should be directly connected to the
ground of the electrical panel or equipment they are protecting. Connecting an
overvoltage protector only to the earth ground (instead of the machine ground) is not
effective.
Whenever possible, the boards for power, telecommunication and signal protection
should be located close to a grounding strip.
Network
Shielded
isolation
transformer
AC
supply
cable
Upstream L.V.
lightning
conductors
Ground of the
transformer
Earth
ground
PE
For data links between buildings, the use of optical fibre is highly recommended. This type
of connection is completely free of loop problems between buildings.
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36