Solutions

PowerLogic
Solutions
Volume 3, Issue 2 Code Compliance or Warranty
Compliance?
In this issue, we —Grounding of Sensitive Process Machines
discuss problems and
solutions related to
improperly installed The Problem
ground rods. A manufacturer of molded case circuit breakers was replacing failed
printed circuit boards in its computerized numerically-controlled
machine (CNC). After a thunderstorm, the machine’s self-diagnostic
system sometimes registered a component problem. The machine
would not start up, delaying the day’s production cycle. Plant
electronics technicians identified and
replaced failed boards, then returned
the CNC to operation. Each time it
occurred, the problem cost thousands
of dollars in repairs and lost
production.

The manufacturer called Square D

Company’s Power Quality/Energy
Figure 1. A ground rod Management (PQ/EM) engineers to
improperly installed on determine the cause of the failures.
a sensitive machine. PQ/EM saw that, though the plant had
Though the grounded the CNC machine in
manufacturer’s accordance with the manufacturer’s
instructions were
followed, the NEC code installation manual, the ground was
was still violated. in clear violation of the National
Electrical Code.

This apparent contradiction demonstrates a disturbing trend: some

grounding practices that are designed to decrease data errors
in sensitive machines can actually violate safety rules and
cause equipment damage. The conflicting requirements can be
overcome, but never by compromising employee safety.

Key Concepts and Terms

Safety Grounding and Machine Operation. The problem
experienced by this plant is not uncommon. Manufacturers of sensitive
machines have discovered that isolated ground rods can decrease the
number of such nuisance problems as rebooting, data errors, and
intermittent shutdowns. This decrease is due to the reduced amount of
voltage transients or noise on the ground rod as compared with the
common building grounding system. Because of the reduction in data
errors attributed to the ground rod, some manufacturers include this
requirement in their installation instructions — even to the point of
PowerLogic
Solutions
implying that the machine warranty will not
be honored if the ground rod is not installed!
During thunderstorms or ground faults,
however, the driven ground rod becomes a
liability, creating shock hazards for employees
and damaging voltages on sensitive machine
components. Figure 2 illustrates the extremely
large transient voltages that can develop
between driven ground rods due to lightning
currents and earth resistance. Though ground
faults in the machine itself may not draw
Figure 2. Lightning
currents create large
voltages between
separate driven
ground rods.
Source Transformer
Earth Resistance, Typical Value = 10 ohms
Ground Rod #1
Lightning-Induced Current Flowing in Earth, Typical Value = 1,000 Amperes
Resulting Voltage Between Ground Rods = 10,000 Volts
enough current to trip overcurrent protective
devices, they can create a touch potential
2 hazard for employees.
The National Electrical Code1 (NEC)
specifically prohibits the use of earthing as the net result is that the machines see no voltage
sole means of equipment grounding in
Section 250-51. Some have used other
sections of the NEC to justify earth
grounding. Although Section 250-21 does
allow alternative grounding means when
“objectionable ground currents” flow, it also
states “currents that introduce noise or data
errors in electronic equipment shall not be
considered the objectionable currents
addressed in this section.”
PowerLogic Solutions
is produced by In this issue of the Solutions, we discuss
Square D Company’s effective means of reducing ground system
Power Management
noise without introducing safety hazards.
Operation. Each issue First, we explain why isolated connections
presents a common
to earth are not required for sensitive
power system
machine operation.
problem, and offers
guidance on how to
1
Earley, Sheehan, and Caloggero, National Electrical Code
solve it.
Handbook, 7th Edition, National Fire Protection Association, 1996.
Bonding versus Earthing. In the United
States, we use the term grounding to refer to at
least five related, but different, electrical
power practices. It’s when we confuse two
grounding issues, bonding and earthing , that
problems occur. Bonding is the intentional
connection of all metallic building
components — structural steel, machine
cabinets, electrical distribution enclosures,
water pipes, metal raceways, and grounding
conductors. Earthing is the attachment of
a bonded metallic system to earth, typically
through ground rods.
Note that earthing
is not required for
sensitive machine
operation. Modern
aircraft, for example,
CNC Machine are packed with
sensitive computers
and electronic
devices. These
devices operate
Ground Rod #2
correctly without an
attachment to earth.
They rely on a
bonded metallic
system — the
airplane framework,
skin, structural supports, raceways, and
grounding conductors — to serve as ground
reference. If this bonded system rises in
voltage with respect to earth, all machines on
board experience the increase together. The
potential with respect to each other. Once the
airplane lands, any voltage potential between
the plane and earth must be discharged by an
electrode that bypasses the rubber tires.
The Solution
Remove the Shock Hazard. The immediate
solution to the plant’s illegal ground rod was
to connect a grounding conductor (1/0
copper) from the ground rod to the nearest
part of the building bonding system, in this
case, the structural steel. This connection
eliminates the shock potential during storms
by reducing the resistance between the
ground rod and the building system.
The next step in the solution was to eliminate
the wiring errors (shown in figure 3) and to
install a ground wire from the source to the
 480V Grounded Source Busway Address the
Operating
Safety Switch 1 Line Isolator/Suppression Device Problems
Chronologically.
3 Once the extra
Voltage To Other Machine
Regulator ground rod has
2
been connected
1 Neutral used as ground conductor; to the rest of the
no ground wire. bonded system,
2 Surge arrestor leads too long, coiled
at ground bus.
operating
3 Neutral wire tied to ground bus. CNC Machine problems must
4 Wire strands broken under lug. 4 be addressed. As
5 Vacuum cleaner plugged into step-
down transformer receptacle load 5 mentioned
side of line isolation, regulator
6 above, the next
devices.
6 Separate ground rod violates NEC; step involved
causes shock hazard, equipment correcting the
failure. Ground Rod
wiring errors
Figure 3: Square D power quality engineers identified six CNC machine wiring and identified in the
grounding errors. site survey (see
figure 4). For the
CNC. The primary reason that the isolated breaker facility, these steps were adequate. For
ground rod is effective in decreasing operating other situations, use the following checklist:
problems is that the building bonded system 1. Connect ground rod to bonded system and
experiences voltage transients, impressed on it install grounding conductor from power
due to wiring errors. One common error is the source to eliminate the safety hazard.
improper connection of neutral wires to
2. Correct wiring and grounding errors on the
ground busses or ground wires to neutral
power system serving the sensitive machine.
busses. This error allows neutral currents to
flow on the bonded system, thereby creating 3. Install a step-down transformer
voltage transients on the bonded system. (separately-derived source) to serve only
Neutral wires are only allowed to be the process machine. Derive a new neutral
connected to the bonded system at a service to ground bonding point at the load side of
entrance, or at a step-down transformer (called this transformer. 3
a separately-derived source by the NEC). 4. Any remaining operating problems are
probably caused by communications
Notice in figure 3 that the plant had installed ground loops. Ground loops are
both a voltage regulator and a noise suppres- introduced by communication wiring
sion device ahead of the CNC machine. These between sensitive machines fed from
devices are often
applied to solve 480V Grounded Source Busway
the nuisance
operating Safety Switch 1 Line Isolator/Suppression Device
problems
brought on by 3
To Other Machine
Voltage
ground system
transients.
Regulator 2
Suppression
devices are not
cure-all devices, 1 Add ground wire; re-route neutral.
however, and 2 Shorten leads from arrestor to CNC Machine
are sometimes
ground bus.
3 Replace white neutral wire with ground wire and
4
unnecessary route properly.
5
4 Replace wire connections.
when wiring and 5 Provide different 480V source to 6 Figure 4: Square D
grounding step-down transformer for receptacles. recommended changes
6 Bond ground rod to building
problems are ground system.
to the existing wiring and
Ground Rod grounding system.
corrected first.
PowerLogic
Solutions
different power sources. Communication
ground loops may require more elaborate
correction schemes, like optical isolation.
Conclusions
The plant had installed a CNC process
machine in accordance with the
manufacturer’s recommendations.
Unfortunately, those recommendations
included the requirement for a separate
ground to serve as the only means of
equipment grounding. While this practice may
reduce data errors in sensitive process
machines, it violates the NEC, creates a shock
hazard for employees, and causes a potential
difference which may damage sensitive
electronic components.
Test Your PQ
Power Quotient questions in this issue are
from Volume 3, Issue 1, as well as from this
issue. Answers are below.
1. Isolated ground rods are acceptable as the
sole equipment grounding method.
2. Ungrounded power systems are often used
on critical production or life-safety loads.
3. Ground faults always trip overcurrent
protective devices, whatever the source
transformer grounding method.
4 • Power Quality Consulting
4. Sometimes, normal wiring and grounding
practices are insufficient to ensure proper
operation of sensitive equipment.
5. Voltage regulators or noise suppression
devices are excellent devices for correcting
any power quality problem.
6. PowerLogic Circuit Monitors can be
configured to accurately monitor power
parameters and sense ground faults on
ungrounded systems.
True, vol 3, no 1
False, vol 3, no 2
True, vol 3, no 2
False, vol 3, no 1.
True, vol 3, no 1.
False, vol 3, no 2.
Answers:
POWERLOGIC, SQUARE D, and are
Registered Trademarks of Square D Company.
Bulletin No. 3000HO9702 10M DL 8/97
The plant eliminated the shock hazard by
connecting the ground rod to the remainder of
the building’s bonded system. To reduce errors,
plant electricians also corrected wiring errors in
the power system serving the CNC machine.
Data errors in sensitive machines can be
much more difficult to eliminate. To ensure
that your sensitive equipment is not affected
by ground noise, Square D can recommend
different levels of noise suppression tech-
niques or equipment. All of these solution
alternatives are safe and can be implemented
to satisfy stringent manufacturer warranty
requirements.
Square D’s
Power
Management
Operation
offers complete
power quality consulting services to
ensure that power problems do not
impact your operation. Contact our
power management experts for
information about the following:
• Energy Management Consulting
• Harmonic Filters
• Power Factor Correction
• Power Management Training and
Technical Support
• Digital Simulation Studies
• Remote Monitoring Services
• Data Collection and Analysis
6. Our number is 1-888-PWR-MGMT.
5.
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