General installation

document
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 General installation document

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 General installation document Table of Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5

Different types of disturbances . . . . . . . . . . . . . 1 - 6

Cable classification and laying . . . . . . . . . . . . . 1 - 7
Cable classification . . . . . . . . . . . . . . . . . . . . . . . . 1 - 7
1.Power and installation cables . . . . . . . . . . . . . . . 1 - 7
2. Control cables for input and output signals . . . 1 - 7
3. Supply cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 7
4. Measuring cables. . . . . . . . . . . . . . . . . . . . . . . . . 1 - 7
Cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 7
Cable connection . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 7
Cable laying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 8
Noise sources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 9
Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 9
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Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 10
Earthing (grounding) . . . . . . . . . . . . . . . . . . . . . . 1 - 10
Contactor cabinets. . . . . . . . . . . . . . . . . . . . . . . . 1 - 11
Connection of contactors . . . . . . . . . . . . . . . . . . 1 - 12
Environmental specification . . . . . . . . . . . . . . . . 1 - 13
Air conditioned rooms . . . . . . . . . . . . . . . . . . . . . 1 - 13
Offices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 13
Process rooms. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 13
Outdoors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 13

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 General installation document Introduction

Introduction
Electronic control systems delivered by Tetra Pak are designed to function
reliably in difficult electrical environments. The systems comply with the
requirements stated in Swedish Standard SS436 l5 03 PL3.
To obtain a high reliability of service and the greatest possible resistance
against disturbances in plants with electronic control systems it is necessary
to follow certain standards. It is as important to choose noise safe devices as
to make sure that earthing, screening, cable laying etc. are done in a proper
way.
This manual contains rules which have to be followed in order to obtain a
high reliability for the delivered control system.
Chapter 2 deals with different types of disturbances which can influence an
electronic control system. In chapter 3 there is a classiffication of cables due
to purpose. There are also instructions about cable laying and screening. In
chapter 4 there is a part on power supply and earthing . Finally, chapter 5
deals with contactor cabinets.
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Different types of disturbances General installation document

Different types of disturbances

Disturbances can in general be defined as a not desired electrical influence in
a signal loop. If a noise voltage exceeds a certain threshold value, then there
might be a more or less serious influence on the action. This can lead to an
unauthorized action or the absence of an action. If the noise voltage exceeds
the strength limit of the device, then the components may be destroyed.
Whether an electronic equipment is disturbed or not depends on its principal
and practical design and the electrical environment.
The electrical environment depends on two factors: the noise source and the
coupling (junction) between the noise source and the electronic equipment.
An electronic control system normally consists of several units located at
different places in a plant. The case of each device (unit) is normally
connected to earth whilst the devices are connected with one another by
means of signal and control cables and most often supplied by external
power supplies. Circuit noise from external noise sources enters the
electronic system through (via) all joints, i. e. earthconductors, power supply
cables and signal cables.
Disturbances could be divided into three types:
• Circuit noise

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• Electrostatic discharge (induction)
• Radio interference

The most effective remedy against disturbances is to keep the unit at a

distance from the noise source (power cable, relay board etc.) and to use the
proper type of cable (screeened etc.)

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 General installation document Cable classification and laying

Cable classification and laying

When laying cables it is very important not to mix different signal types
within the same cable as to separate the cables. The different cable types
should be laid in a suitable distance away from each other. Signal and return
cables should be laid well gathered.
Do not place signal cables in a shorter distance than 30 cm away from power
and installation cables!

Cable classification
1.Power and installation cables
These are cables which feed inductive and resistive loads such as motors,
heaters, lighting etc.
2. Control cables for input and output signals
Cables which carry control signals to and from the control system at voltages
of AC or DC 15, 24 or 48V.
3. Supply cables
Cables carrying supply voltages to the control system. They must not be laid
together with power and installation cables.
4. Measuring cables
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These cables carry analogue or digital signals from transducers, often at very
low currents and voltages. Special requirements may apply to such cables.
Cables of the types 2,3, and 4 are known as signal cables in the following.

Cable types
Signal cables normally consist of standard installation cables or control
cables, i.e. single or multi stranded screened or unscreened, PVC insulated
cables with a conductor area of 0.5 - 1.5 mm² and number of conductors as
shown in the cable list.
Any special cable requirements are specified in the cable lists.

Cable connection
The connection should be made according to the cable interconnection list.
Thus, signals must not be interchanged between cables, since the signals are
allocated to the cables in such a way as to minimize disturbance. Screen on a
screened cable is to be connected to the neutral bar at one end of the cable
according to the cable interconnection list.

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Cable classification and laying General installation document

Cable laying
Cables should be laid so that electrical noise from power cables will not be
picked up by signal cables. The distance between signal cables and power
cables laid parallel to each ather should be at least 30 cm. It is therefore
normally advisable to use separate cable shelves.

Signal cables
Double cable shelf 30 cm
Power cables

Cable shelves on different heights

Signal cables Power cables

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Single cable shelf

30 cm
Cable shelves on the same height with a distance of 30 cm
in between.

If it is not possible to maintain a distance of 30 cm between different cable

types, the signal cables must be screened, either by screening within the
cables or by employing cable shelves which completely enclose the cables.
Distances between the cables can then be reduced to a minimum of 10 cm.
Power and signal cables may be laid within less than 10 cm of each other for
short distances (not greater than 1 m.), e.g. from the cable shelf to the safety
isolating switch.
Power and signal cables must cross each other at right angles or nearly so.

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 General installation document Cable classification and laying

Noise sources
Signal cables must be laid at least 250 cm away from any noise source.
Examples of noise sources are welding devices, microwave ovens and motor
control centres.

Welding
In welding, the earth terminal must not be connected to electronic cabinets,
panels and cable shelves belonging to the control system. Special caution
must be used when using welding devices employing high-frequency
arcstriking (TIG).

Welding <100 cm
device

Weld ground has to be done at a maximal distance of 100 cm

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from the welding seam.

Cable shelf

Welding
device

Do not connect weld ground to the cable shelf!

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Cable classification and laying General installation document

Power supply
Power supply to the control system should be taken from a fuseboard
supplied directly from a low voltage switch gear. The separate supply cable
shall contain a protective earth conductor for protective earthing of the
control system, zero conductor and phase conductor. No other equipment
should be connected to the fuse board.

High voltage supply

Low voltage switch gear

Separate supply

M Computer

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Large motor
Lighting
Process terminals
Instrumentation
Separate distribution
M M M unit for control system
Contactor board

Earthing (grounding)
There are two types of earthing:
• Protective earth must be connected to all panels including racks and
cabinets according to valid rules.
• Signal earth for the control system ist to be kept insulated from
protective earth with the exeption of one point which ist to be connected
directly to the earth electrode via an insulated cable
(≥ 10 mm²). The resistance between this point and the earth electrode
must not exceed two ohms.

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 General installation document Cable classification and laying

Contactor cabinets
Contactor cabinets and other cabinets to be connected to the control system
should be installed so that interference from motor cables will not influence
the signal cables . The same applies to internal connections within the
cabinets.

Power supply

1 Fuses

Contactors
2
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Terminals Terminals
for input for outputs
and output 3 to motors
signals

The example shows that:

1) Signal and power cables should cross each other at right angles.
2) Where both cable types must run parallel with one another, they should
be placed as far apart as possible. However, separation may be less than
10 cm over a distance not exceeding 1 m.
3) Terminals for signal cables and power cables must be separated.

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Cable classification and laying General installation document

Connection of contactors
Contactors should be connected to the control system by means of signal
cables. It is suggested that the electrical interconnection is made according to
the diagram below.

Controlvolt. neutral
Output signal

Controlvoltage
Input signal

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M

3
4

1) Auxilliary relay
2) Contactor
3) Protective motor switch
4) Safety isolating switch
Note! Local regulations governing safety precautions must be adhered to at
all times.

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 General installation document Cable classification and laying

Environmental specification
The environment has a great influence on the performance of automation
equipment. Various equipment locations have been divided into four
environmental groups (see below).
Air conditioned rooms
Temperature ............................. +18-+28°C
Relative humidity....................... 35-70%
Degree of protection ................. IP20, semiprotection
Air pollution ............................... Incoming air filtered
Vibration .................................... 0.015 mm, 0.2 g
Bump......................................... <0.5g
Power supply:
Voltage tolerance ...................... ±10%
Frequency tolerance ................. ±2%
Offices
Temperature ............................. +10-+40°C
Relative humidity....................... 20-85%
Degree of protection ................. IP20, semiprotection
Vibration .................................... 0.15 mm, 2 g
Bump......................................... <5g
Power supply:
Voltage tolerance ...................... ±10%
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Frequency tolerance ................. ±2%

Process rooms
Temperature ............................. +5-+45°C
Relative humidity....................... 15-95%
Degree of protection ................. IP54, dust protected and protected against
splashing water
Vibration .................................... 0.15-0.70 mm, 2-10 g
Bump......................................... 5g
Power supply:
Voltage tolerance ...................... +10% - -15%
Frequency tolerance ................. ±5%
Outdoors
Temperature ............................. -25-+45°C
Relative humidity....................... 15-95%
Degree of protection ................. IP56, dust protected and protected against heavy
seas
Vibration .................................... 0.15-0.70 mm, 2-10 g
Bump......................................... 5g
Power supply:
Voltage tolerance ...................... 10% - -15%
Frequency tolerance ................. ±5%

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