Automation 101:

An Industry Guide To

Control System
Engineering
A Condensed Guide to Automation Control
System Specification, Design and Installation

A Publication of

Version 1.0

TABLE OF
CONTENTS
Introduction
Chapter 1 ------------ Consider Safety First
Chapter 2 ------------ Identifying Processes
for Automation
Chapter 3 ------------ Specify Devices
Chapter 4 ------------ Design
Chapter 5 ------------ Build

Chapter 6 ------------ Install and Start-up

Chapter 7 ------------ Maintain
Additional Resources

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Introduction

The following is a general guide to the specification, design and

installation of automated control systems. The information and
references are presented in a logical order that will take you from
the skills required to recognize an operation or process that may
be suited for automating, to tips on setting up a program to
maintain the control system. Whether an expert or a novice at
electrical control devices and systems, the information presented
should give you a check list to use in the steps to implementing an
automated control system.

The engineers first problem in any

design situation is to discover what the
problem really is.

- Unknown

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CHAPTER

1
Consider Safety First

Safety

4 Things to Consider
The first most important item to consider before attempting an
automated control system, or even a simple on/off control for a pump, is
safety, both for personnel that may be working with or near the automated
equipment, as well as to prevent damage to the equipment.
To minimize the risk of potential safety problems, you should follow all
applicable local, state and national codes that regulate the installation and
operation of your control system, along with the equipment or process it is
designed to control. These codes vary by area and usually change over
time, constantly being reviewed and updated. It will be your responsibility to
determine which codes should be followed and to verify that the equipment,
installation, and operation is in compliance with the latest revision of these
codes. It would be wise to educate yourself as much as possible about
electricity and electrical equipment in general. A good understanding of
basic electricity, including DC and AC theory and practice, Ohms Law, etc.
will go a long way in helping you understand the various codes and
standards.

Want to learn some basic principles of electricity?

We cover the basics of DC and AC theory, Ohms Law,
Kirchoffs Laws, and more in our blog post entitled
Basic Electrical Theory
Visit N2ADC.com/us-ca to read more!

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1. Avoid Endangering Your Personnel

Most likely your control system will be dealing with electrical energy, so
your first goal will be to eliminate the risk of fire and electrical shock to
personnel. At a minimum, you should follow all applicable sections of these
two organizations.

National Fire Protection Association (NFPA) fire code

National Electrical Manufacturers Association (NEMA)
Some pertinent sections are:
o ICS 1: General Standards for Industrial Control and Systems
o ICS 3: Industrial Systems
o ICS 6: Enclosures for Industrial Control Systems

Please keep in mind that if the automated control system you are
developing needs to be accepted in the international market, the National
Electrical Code (NEC), as a publication of NFPA, is being harmonized with
the International Electrotechnical Commission (IEC) (Website: www.iec.ch/)
and the European Hazardous Location Ratings. For more information, check
the Instrument Society of Americas (ISA) Website at www.isa.org.
Additional resources on the subject can be found at www.ul.com/hazloc/.

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2. Lockout/Tagout
Another area of safety that needs to be considered for automated control
systems is lockout/tagout procedures as specified by Occupational Safety
and Health Administration (OSHA). "Lockout/tagout" refers to specific
practices and procedures to safeguard operators and maintenance
personnel from the unexpected energization or startup of machinery and
equipment, or the release of hazardous energy during service or
maintenance activities. In order to have your control system make use of a
lockout/tagout procedure, the design should include the ability to shut off,
neutralize, or isolate any energy source, such as the main electrical feed,
but also any pneumatic, hydraulic or mechanical energy storage device. The
means to do this should be considered in the initial design of the automated
control system. Additional information can be found on OSHAs Website.

3. Avoiding Device Failures

There are many reasons why the electrical devices that you will use in
the design of your automated control system should be listed, approved or
registered with a testing laboratory. One reason is to ensure that the device
meets standards that will prevent failure that could cause catastrophic
results. Another reason might be for insurance or compliance purposes. One
of the most specified and premier safety testing laboratories is Underwriters
Laboratories (UL). The most applicable area of interest for control systems
is ULs Standard for Safety 508A. If your control system panel requires
being built to UL508A, then you will need to contract directly with UL to
become a UL508A panel builder or use an existing UL508A panel builder.
Compliance to UL508A for AutomationDirect.com products can be found on
our Website at N2ADC.com/fci7t.

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4. Other Safety Considerations

Emergency Stop The control system must provide a quick manual

method of disconnecting all system power to the machinery, equipment
or process. The disconnect device or switch must be clearly labeled
Emergency Stop.

Accidental Powering of Outputs - Do not rely on the automation

control system alone to provide a safe operating environment. You
should use external electromechanical devices, such as relays or limit
switches that are independent of any electronic controlling device, such
as a solid state relay or a PLC (Programmable Logic Controller) output
module, to provide protection for any part of the system that may cause
personal injury or damage. These devices should be installed in a
manner that prevents any machine operations from occurring
unexpectedly.
Ex. If the machine has a jammed part, the controlling system or
PLC program can turn off the motor rotating a saw blade.
However, since the operator must open a guard to remove the
part, you should also include a bypass switch that disconnects all
system power any time the guard is opened.
External safety devices such as light curtains, magnetic safety
switches and safety relays can be integrated into your system design.

Orderly Equipment Shutdown Whether using a control system

designed around relays and timers or a PLC, an orderly system
shutdown sequence should be included in your design. If a fault is
detected, then any mechanical motion, valve position, etc., needs to be
returned to its fail-safe position and the equipment/process stopped.

Grounding To prevent electrical shock, incorporate good grounding

practices in the design, construction and installation of your system.
Use protective devices for faulted conductors to prevent fire, and also
realize that good grounding practices can reduce electromagnetic and
radiated noise interference to sensitive electronic devices.

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Control Power Distribution Develop a power distribution scheme in

the control system circuitry, according to code, that ensures all circuits
are protected with fusing, circuit breakers or other interrupting means
coordinated such that only the faulted circuit will be opened (deenergized), allowing other powered equipment and devices to continue
to operate.

Unauthorized Access Make sure all enclosures and cabinets that

have energized circuits are secured to prevent unauthorized personnel
from gaining access without the proper tool, key or other authorized
means. Mechanical trapped key systems can be used to protect
access to one or more physical locations of equipment in a control
system.

Finger-Safe Another safety area to consider is the use of devices that

have finger-safe terminal connections, which are surrounded by
insulated guarding. The use of protective guards over live circuits
should also be considered, even on control panels that have limited
access, so it is safer for maintenance electricians and authorized
personnel to troubleshoot or make adjustments to electrical control
devices.

Dead Fronts Dead fronts should be used on control system

enclosures where the operator needs to make adjustments to devices,
such as selector switches, thumbwheels, potentiometers, etc., and the
controls need to be inside the enclosure so as to protect them from
outside weather conditions. The dead front is normally an interior door
that is mounted in front of the main control panel. The outside enclosure
door may still require key entry by the operator, but the dead front
interior door with adjustable devices is interlocked so that it requires a
switch to open it, disconnecting power to the electrical devices mounted
on the main control panel.

Closed-loop Control It is your responsibility in any type of closedloop control system to ensure that if the feedback signal is lost, the
system shuts down so as not to cause injury to personnel or damage to
the equipment.

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CHAPTER

2
Identifying Processes for
Automation

10

Identifying

Processes for Automation

After considering safety, the next step in configuring an automated
control system is to identify what can be automated. It will help if you have
an understanding of basic hydraulics, pneumatics, mechanical operating
mechanisms, electronics, control sequences, etc. and a solid knowledge of
the operation or process that you are going to automate.
You should understand how to control motion and movement, regulate
the flow of fluids, dispense granular materials, orient parts, sense product in
position, detect when an operation is complete, etc.

As an example
Lets say we have a conveyor that moves our product from point A to
point B. The conveyor is powered by a 3-phase AC motor, which is
turned off and on by a manually controlled motor starter and includes,
for fire protection, both short circuit and overload protection. The
system requires an operator to stand at the motor starter, watching as
the product reaches the entrance to the conveyor, and turning the
conveyor on to move the product. Then the operator must also turn the
conveyor off once the product has reached the discharge end.

Check out this

Brewed tea and
coffee container
filling machine at
N2ADC.com/neyxb

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How Can this Process be Automated?

To automate the conveyor, we will need to replace the manually
controlled motor starter with an electrically controlled motor starter, including
short circuit and overload protection. We will need to size the motor starter
to work with the existing conveyor motor. (Visit N2ADC.com/xu5ln for
information on specifying and sizing motor starters.)
Using sensors to start and stop the process
We will need to identify where to locate sensors such as limit switches,
photoelectric sensors, proximity sensors, etc. that will indicate when an
operation is completed. This is required so our control system knows when
to proceed to the next step in our operation. As an example, we usually see
that we need a limit switch to detect when a pneumatic cylinder is fully
extended, as in the case when the cylinder is used to push our product onto
a conveyor. The cylinder fully extended signal is used to de-energize the
solenoid valve that provided the air pressure to the pneumatic cylinder. We
also need a limit switch to indicate when the cylinder has fully retracted, to
provide a signal to the start/stop control of the conveyor that the product
push cylinder is out of the way for the next product.
Using sensors to indicate if the product is present
Another application for a sensor is to indicate when the product has
reached the conveyor. The sensor can be a limit switch with a roller arm that
comes in contact with the product, or a photoelectric sensor that can detect
the product by using an infrared beam of light. The photoelectric approach
may be the better choice because the position of the product on the
conveyor belt may vary. (Refer to our website for information on selecting
photoelectric sensors or visit N2ADC.com/yzrq6)

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Continue looking for opportunities to control and sense

We would continue with this analysis, looking at each piece of equipment
or component in our system, and select a device that could control or sense
it. Some examples include an electrical solenoid valve to control water used
to wash residue from a product, or a pneumatic valve to control air pressure
to a cylinder operating a gate that diverts product on a conveyor, or
energizing a control relay to signal that a product is in position on a scale.
In some instances we may need to vary the speed, rate or position of our
controlling device, such as varying the speed of a conveyor, changing the
amount a valve opens to control a flow rate, or remotely changing the
setpoint level for a tank. This could be accomplished by using an analog
output signal. An analog output signal is a varying signal that corresponds to
the real value we have determined and calibrated into the device. For
example, a 0 to 10 VDC signal could represent a conveyor speed of 0 to
500 feet per minute. An analog signal to the speed controlling device for the
conveyor motor of 5VDC would result in a conveyor speed of 250 feet per
minute.

Viking Range Automates Product Testing: Read how Viking

Range automated its testing lab at N2ADC.com/21eeq.

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13

Identifying I/O and Controllers

The task of identifying devices to control motion, flow, events, etc. and
sensing completion is basically identifying the I/O (inputs and outputs) of our
control system. Please keep in mind that by identifying devices that can be
controlled by a PLC output module and identifying sensing devices that
provide a signal to a PLC input module, these same devices can also be
used in simple control circuits where the only requirements are relays and
timers.
HMI Requirements
You will also want to determine if your automated control system will benefit
from the use of an operator interface, also referred to as a Human Machine
Interface (HMI). If your process requires making changes to setpoint values,
process time, flow rates, etc., then the use of an HMI is the best way to
proceed. In these situations, you most likely will need a PLC that can easily
communicate with the HMI device.
SCADA?
If your application requires keeping data records for reference, traceability,
history, trending, meeting regulations, etc., then you should be looking at
using a control system that would fall into the category of a Supervisory
Control And Data Acquisition (SCADA) system. Most of these control
systems would be comprised of PLC-type I/O that interface to a PC with
appropriate software, or a PLC paired with data collection software.

Normal people believe that if it aint

broke, dont fix it. Engineers believe
that if it aint broke, it doesnt have
enough features yet.
- Scott Adams

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CHAPTER

3
Specifying Devices

15

Specifying Devices
What needs to be specified

Need help starting your

project documentation?

Download a FREE template

N2ADC.com/yknp2

In this chapter we will cover

how to specify the various
devices required for controlling
the equipment in an automated
system. Your specifications need
to include not only the
controlling devices for your
application, but also items such
as the housing or enclosure for
the devices, the type of wire
required to meet the various
codes, agency approvals required
for safety and insurance
purposes, environmental
conditions, etc.

As stated in Chapter One, special expertise is generally

required to design, wire, install, and operate industrial automation
control systems. Persons without such expertise or guidance
should not attempt to design control systems, but should consider
seeking the services of a qualified system integrator. Control
systems can fail and cause serious injury to personnel or damage
to equipment. The information in this series of articles is provided
as is without a guarantee of any kind.
Need a qualified System Integrator?
Our SI Direct program provides expert system
integration services to AutomationDirect
customers. More info visit: N2ADC.com/5bff2.

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Gathering Parameters and Specifications

With that said, the first skill we need to develop in this effort will
be the gathering of all the equipment parameters and
specifications needed to specify the devices required to control the
equipment. We need to be the proverbial detective who would ask
questions such as;

What is the operating voltage?

What is the power rating?
How much current does it draw?
What is the operating temperature range?
What is the relative humidity range?
What are the mounting dimensions?
What are the minimum mounting clearances?
What is the duty cycle?
How will the system be used?
Who will be using the control system?

Control System Devices to Specify

The devices you
need to specify in your
control system will
generally fall into one
of three categories;
input devices, output
devices and the
processing unit.

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1. The Processing Unit

All control systems can typically be
defined as having inputs, outputs and
some form of decision making going on
in between so that the outputs are
controlled based on the status of the
inputs. This device is the decisionmaking element. This element can be
performed by a PLC, where we have
inputs, outputs and a central processing
unit (CPU) that uses ladder logic
programming to make decisions based
on input status and the logical conditions
in the program.

What is a PLC?

Check out our video on

YouTube!
http://youtu.be/iWgHqqunsyE

A similar device that can be looked at in the same manner is a personal

computer (PC). PCs are used in some automated control systems as the
decision making element, together with industrial I/O modules. These PCbased systems rely on the communication ports or Ethernet connections to
monitor and control the I/O. The application software typically allows a
programmer to develop a graphical interface that gives an operator
interaction with the equipment or process. With some research and
experience, you will learn how to determine how much decision making
ability your control system requires. Cost restraints may require you to
compare implementing the control system with either a PLC, PC-based
control, or simple hardwired relay logic. But dont forget that a PLC or PCbased control system allows easier changes and future expansion.

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2. Discrete Input Devices

Discrete input devices are used to sense a condition, detect movement
or position, indicate a limit or set point has been reached, sense intervention
by an operator, detect an alarm, etc. Typical input devices may include limit
switches, photo sensors, pushbuttons, proximity sensors, etc. These input
signals are generally in an ON or OFF state. We can look at an input from a
device, such as a photo sensor used to detect an obstruction, and state that
when the photo sensor sees the obstruction the sensor is ON; in other
words we have a true condition. When the photo sensor is not obstructed,
then the input is OFF; or we can say the condition is false. These types of
signals are called discrete signals, meaning they are always in one of two
states; ON or OFF. They can be wired into a PLC input module and the PLC
can be programmed to use the status of the signals to execute the logic to
control the automated system. Or these same signals can be used in a
relay logic system, where control relays are hardwired as the logic.
Of importance to our specifications are the ratings of these input devices.
What is the operating voltage; 24, 120 or 240 Volt AC or DC?
If they are rated for DC, are they sinking or sourcing?
What distances can they sense?
How much force can be applied to the actuator?
How much current do they require?
As a note, most PLC DC input modules can be configured as sinking or sourcing.

Typical wiring for sinking and sourcing input devices

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Also keep in mind that when selecting a sensor device, such as to detect
the presence of product or sense the end of travel for a mechanism, it is
very important to consider the environment in which the sensor will operate.
This should not only include temperature and humidity ranges, but in some
cases, indoor or outdoor use, altitude, ability for the sensor to be washed
down, etc. For example, photoelectric sensors are sensitive to the
atmosphere in which they can efficiently work. If there is a lot of dust, dirt
and/or mist in the air, then the optics can easily become dirty or coated,
reducing their sensitivity and operating distance.

3. Discrete Output Devices

Discrete output devices are used to control actions such as motion,
start/stop of equipment like conveyors and pumps, on/off control of valves,
operator alerts/prompts, status indications, etc. Typical output devices
include relays, motor starters, and pilot lights etc. These types of output
signals are also discrete; either ON or OFF. The signals can be wired from a
PLC output module to control the devices, such as starting and stopping
motors, energizing a valve to control water flow, illuminating a pilot light to
alert an operator to a condition such as Bin Full, etc. The output signals
can also be wired directly to the controlling device based on hardwired relay
logic.
Of importance to our specifications are the ratings of these output devices.
What is the operating voltage; 24, 120 or 240 Volt AC or DC?
If they are rated for DC, are they sinking or sourcing?
What is the current draw?
What is the duty cycle?
What is the operating temperature range?
What are the mounting dimensions?

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For example, if our process uses a solenoid valve to control water flow to
a wash station, we would need to know the operating voltage of the valve
and how much current it draws. We also need to know not only the ON-state
current draw of a valve, but also the inrush current, so that we can properly
specify a PLC output module or a control relay. Although a valve may be
rated to draw 250mA continuous current, it may have an inrush of 800mA
when first energized. If a PLC output module has eight output points and
each point is rated for 1 amp continuous duty, after thermal considerations,
the entire output module has a total rating of 6 amps and therefore has a
common fuse rated at 6 amps. If we had solenoid valves connected to all
eight output points and our program called for them all to energize at the
same time, the total inrush current would be 8 x 800mA or 6.4 amps total,
and most likely would blow the fuse. The solution could be to select an
output module with a higher current rating or to use the ladder program to
sequence the valves, preventing them all from being energized at the same
time. Another option is to split up the valves between several output
modules, using the remaining points to power smaller loads such as pilot
lights. Certain output types may have derating curves depending on the
ambient temperature and the number of outputs energized. Keep in mind
that DC output modules can be sinking or sourcing type.

Typical wiring for sinking and sourcing output devices

What to learn more about Sinking and Sourcing?

Sinking = provides a path to supply common (-)
Sourcing = provides a path to supply source (+)
Learn more by reading our blog post on the topic.
Visit N2ADC.com/ciy3b

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4. Other Device Types That Will Need

Specifying

Analog Devices - Another area of inputs and outputs involve the use of
analog signals in a control system. Analog signals are variable and can
represent a range of values. As a quick example, we may want to
monitor the level of a liquid in a tank that is 100 feet tall. We can use a
sensor that will produce a signal that is represented by a voltage range
of 0 to 10 volts DC, with 0 feet being equal to 0VDC and 100 feet being
equal to 10VDC. Analog signals are typically linear, so a 5VDC signal
would tell us the tank level is at 50 feet. The analog signal could be
wired into a PLC analog input module, and in the ladder program we
could compare the actual level to a setpoint and produce a discrete
signal that would cause an output point to start a pump to raise or lower
the level.

Inductive Devices - When selecting a device to control a prime mover,

such as an industrial motor to power a conveyor, or a valve to control a
hydraulic cylinder, you will need to determine the ratings of the
controlled equipment:
o
o
o

What is the operating voltage?

What is the maximum current draw?
What type of environment is it being used in?

An industrial induction motor may have ratings such as 230/460 VAC, 3phase, 1725 RPM, a FLA (full load ampere) of 10.5 amps at 460VAC, etc.
This information can be obtained
from the manufactures catalog or
directly from the motor nameplate.
In the case of a motor, you will
need the various ratings to choose
the motor starter or possibly a
variable frequency drive for either
start/stop control or speed control
of the motor.

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Other Considerations
There are other points to consider in the specification of devices being
used in your automated control system; static electricity, duty cycle, surge
suppression, power, environment, agency approvals, enclosure type as
well as enclosure heating, cooling and lighting.

Static Electricity Most equipment and devices will operate down to

5% relative humidity. However, static electricity problems occur much
more frequently at humidity levels below 30%. Make sure you take
adequate precautions when you touch the equipment. Consider using
ground straps, anti-static floor coverings, etc. if you use the
equipment in low-humidity environments.

Duty Cycle - When using a solenoid valve, you will want to know its
operating voltage, nominal current draw and current inrush to help
select the type of output device required to control its operation. It is
also important to have an understanding of the solenoid valves duty
cycle. We would not want to operate a solenoid valve rated at 50%
duty cycle in a continuous mode with an ON time of 10 seconds and
an OFF time of only two seconds. The short OFF time would not
allow for the solenoid to properly cool down.

Surge Suppression - Solenoid valves, motor starters, etc. make use

of an inductive coil for their operation and the coil can produce high
voltage spikes that can damage output devices and nearby electronic
equipment. It is always recommended to use some form of surge
suppression to eliminate these voltage spikes.

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DC Power - If using DC voltage from a power supply in your control

system, consider using a power supply rated for at least twice the
calculated load. This should satisfy one of the requirements if you
need to have your control system UL 508 approved and will allow the
power supply to operate at a lower temperature, thus increasing its
life.

Environmental Specifications - The table below is an example of

NEMAs common environmental specifications that generally apply to
automation equipment. IEC also has a list of common environmental
specification designations for enclosures and equipment.

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Agency Approvals - Some applications require agency approvals for

particular components. Some of these required approvals are:

UL (Underwriters' Laboratories, Inc.)

CUL (Canadian Underwriters' Laboratories, Inc.)
CE (European Economic Union)

The requirements for any of these agency approvals need to be part of your
specification and will determine the selection of most of your controlling devices.

Enclosures - Selecting a proper enclosure is important to ensure safe

and proper operation of your equipment. The minimum considerations
for enclosures should include:

Conformance to electrical standards (Reference NEC)

Protection from the elements in an industrial environment (Reference NEMA,
particularly section ICS_6)
Common ground reference (Reference NEC)
Access to the equipment (Reference OSHA)
Security or restricted access (Reference OSHA)
Sufficient space for proper installation and maintenance of equipment

We need to consider the environment where the enclosure will be located.

Outdoors? Indoors? Washdown required?

Enclosure Heating/Cooling - Ensure that the devices used in your

control system arent subject to overheating, or if installed in a colder
climate, the devices arent being used below the listed low temperature
operating range. Your control system, because of its physical location,
may require you to have both a cooling system, such as an A/C unit,
and a small heating unit as part of the same enclosure. This will ensure
the devices are always operating within their temperature specifications.
Basic thermal management is not difficult for most automated control
systems. Investing a little thought during the specification stage can
save you a great deal of redesign down the road.

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Enclosure Lighting - It is always a good idea to include interior

lighting for your control system enclosure or cabinet to help during
routine maintenance to the control system.

Additional Resources You can find these

additional resources in the Appendix of this
book or by visiting the links below.

Worksheet for Choosing a Controller --------------- N2ADC.com/l8jv4

How to Select an Enclosure ---------------------------- N2ADC.com/o8hyv
What do the NEMA Ratings Mean? ------------------ N2ADC.com/n2230
Understanding Enclosure Cooling ------------------ N2ADC.com/3btpr
Selecting an Enclosure Fan or Air Conditioner - N2ADC.com/q1bjh
Selecting a Heat Exchanger ---------------------------- N2ADC.com/oo2ty

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CHAPTER

4
Design

27

Design

Putting ideas on paper

The design for our control system will be in the form of a documenting
task. The challenge will be to get our design specifics down on paper so that
it can be easily understood. It is important that anyone can look at our
documents in the future and be able to interpret the information. Useful to us
at this step will be any notes and lists that were developed during the
Identifying and Specifying phases of our automated control system.

Optimist will tell you the glass is

half-full; the pessimist, half-empty;
and the engineer will tell you the
glass is twice the size it needs to be.
- anonymous

Use these tricks to help you

remember!

Inductive and Capacitive Circuits

Color Coding for Resistors
The Visible Color Spectrum
Algebraic Expressions
A Short Way to Remember Pi
Visit: N2ADC.com/el-m8

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28

Sequence of Operation
In most cases, the first step in designing our control system will be to
define the process or actions to take place, by way of a sequence of
operations description. The sequence should show or list each operational
step in our process.
Our particular application may be better suited to using a flowchart that
shows the sequence of operation by means of decision-making steps and
actions that need to take place. A flowchart can be developed with graph
paper and a pencil, or an application software program such as Microsoft
Visio. Microsoft Word also has a built-in drawing tool that contains flowchart
symbols.
In some cases, the application may be better suited to using a timing
chart, in which each condition and event is graphed in a time relationship to
each other, as shown below.

Flowchart

Timing Chart

Once we have a sequence of operation developed and a list of our

input and output devices, we can determine if our automated control
system is best suited for hard-wired relay logic or can benefit from a
PLC. For example, a PLC can be cost-effective when used in place of
a half dozen industrial relays and a couple electronic timers. It adds the
flexibility of making future logic changes without the labor of making
wiring changes.

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Schematic
The next step in our design is to develop a schematic. Most electrical
designers and engineers define a schematic as a drawing that shows the
logical wiring of an automated control system. A control schematic is
normally drawn in the form of a ladder, showing the various wiring
conditions. This analogy of a ladder is what PLC ladder logic was based
upon. It made the transition to PLC ladder logic easier for engineers and
electricians because they were accustomed to troubleshooting hard-wired
relay control systems documented in a ladder fashion.
It is normal practice to show input type devices on the left-hand side of
drawings and output devices on the right-hand side. For example, the
symbols for protective devices (fuses), contacts and overload relay
elements are shown to the left, while the symbol for the motor is shown to
the right.

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The schematic should start with the incoming power, including protective
devices such as circuit breakers and/or fuses. Our design should show the
distribution of the AC power and include all circuitry and required devices for
conformance to the National Electrical Code (NEC) and any local codes that
might apply in our area.
It is normal practice to show any high-voltage devices, such as 3-phase
motors, 480 or 240VAC auxiliary equipment, etc. in this first section of the
schematic. Next, we will show a control power transformer used to step the
higher incoming voltage down to our system control voltage (115VAC). Our
control voltage can be something other than 115VAC; for example, we could
have a control voltage of 24VDC, which is common for many electrical
control devices. The control transformer needs to be sized (VA rating) based
on our known or calculated load of devices that will be powered from the
transformer in our automated control system.
At this point in our schematic, we need to look at device wiring isolation
strategies. PLCs provide ideal isolation because its circuitry is divided into
three main regions separated by isolation boundaries as shown below. The
PLCs main power supply includes a transformer that provides isolation, and
the input and output circuits that use opto-couplers to provide additional
isolation. When wiring a PLC, it is extremely important to avoid making
external connections that connect logic side circuits to any other.

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Electrical isolation provides safety, so that a fault in one area does not
damage another. Using the figure below as a reference, we see a
transformer which provides magnetic isolation between its primary (high
voltage) and secondary (control voltage) sides. A powerline filter provides
isolation between the control power source and the electronic devices.

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The previous image also shows some general suggestions for device
grounding and distributing the control power to various devices, along with
individually fusing these devices.
Proper grounding is one of the most important things in good
automated control system design. The more details we can show on the
schematic to reflect all points that need to be grounded, the better chance
we have of a properly grounded control system that provides both safety
and functionality.
Why is grounding important? Electronic instrumentation such as PLCs
and field I/O are typically surrounded by various types of electronic devices
and wires. These electronic devices may include power supplies,
input/output signals from other instrumentation, and even devices that are
near the instrumentation enclosure. All these may present a risk of
Electromagnetic Interference (EMI) or transient interference. This type of
interference may cause failure or erratic operation of the device.
We should consider using a second transformer to source AC power to
DC power supplies. Input circuits should be utilized to isolate the output
circuits and prevent voltage from the output transients (spikes) from being
induced into the input circuits. In some cases, we may need to use a
constant voltage transformer to stabilize the incoming AC power source
supplying the PLC to minimize shutdowns due to power surges, voltage dips
and brownouts. When using a constant voltage transformer to power a PLC,
the sensors connected to the PLC inputs should use the same power
source. Otherwise, the AC source voltage could drop low enough to cause
inaccurate input data. Also, the use of an isolation transformer, for example
115VAC primary to 115VAC secondary, can provide additional suppression
of EMI from other equipment. Isolation transformers should be used near
equipment that produces excessive electrical noise.
If DC power is required in our control system, we need to calculate the
worst case amperage draw (load) of all the devices that will be powered
from the DC supply. We also need to look at the amount of ripple the
devices being powered can tolerate and select a DC power supply that can
meet the most stringent requirement. Ripple is the amplitude of the AC
component that rides on the DC voltage signal. A typical rating for most
applications involving DC powered sensors would be 100mV peak-to-peak.
It is also a good idea to double the calculated amperage capacity of the DC
power supply. This is especially important if our control system needs to
meet UL (Underwriters Laboratories, Inc.) 508A standard.

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The next section of our schematic will show the hard-wired devices that
are powered from our control voltage (115VAC). If our control logic is based
on hard-wired relays, this is where we would show the hard-wired
connections, along with the normal 115VAC powered devices, such as DC
power supplies, 115VAC power to PLC power supplies, auxiliary devices, etc.
The figure below is a partial example of the hard-wired section of our
schematic.

This is a good time to mention surge suppression. Surge suppression

devices are an important component in achieving a reliable power
distribution system. These devices protect the electronic components from
sudden power surges that can cause considerable damage. Inductive load
devices (devices with a coil) generate transient voltages when de-energized
with a relay contact. When a relay contact is closed it "bounces," which
energizes and de-energizes the coil until the "bouncing" stops. The transient
voltages generated are much larger in amplitude than the supply voltage,
especially with a DC supply.

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If using a PLC, the final section of our schematic will show the input and
output modules with their device wiring. Below is an example of the wiring
for an input module.

We would make use of reference line numbering and, in most cases, we

would show all of the input modules first, then the output modules. If we
have analog I/O, we would want to show the analog input modules, then the
analog output modules, and finally any specialty modules such as high
speed counters or communications. Generally we would use one sheet of
our schematic to show each module.

As technology advances, it
reverses the characteristics of
every situation again and again.
The age of automation is going to
be the age of do it yourself.
- Marshall McLuhan

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Panel Layout
Once we have our schematic finalized, the next step is a panel layout
drawing. In most cases, the actual panel is referred to as a subpanel. We
can mount all the components to a structure (the subpanel), wire all the
components, and do this before mounting the subpanel in the control
system enclosure. The panel layout drawing should be done to scale and
include dimensions for the panel builder to follow when laying out the
components. Special attention should be given to component location and
spacing. We need to follow the manufacturer-recommended mounting
distances and clearances. Below is a partial example of a panel layout
drawing.

The higher voltage devices (those that operate at 240/480 VAC) should
be mounted toward the top of the panel, keeping as much distance as
possible between the high-voltage devices and any electronic devices, such
as PLCs, DC power supplies, electronic timers, etc. Keeping the highvoltage devices toward the top allows us to cover all of the high-voltage
devices with a non-conductive safety shield for personnel safety. It keeps
the lower voltage devices grouped together, allowing access to wiring
terminals that will aid in troubleshooting our control system. In some cases,
a metal partition between the high-voltage section of our control panel and
any sensitive electronic devices can act as a shield from any EMI generated
by the high-voltage devices.

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In our panel layout design, we need to include wire duct between the
various components. The wire duct simplifies the wire routing between
components, keeps the wires in place, makes working with the wires easier,
and gives the panel a well-organized look. We should also make use of
terminal blocks in our design. Terminal blocks can be sized, organized and
even color-coded to handle the different types of signals that enter and
leave our control panel. We may choose to use black for high voltage, red
for inputs, violet for outputs, etc. We should try to locate the terminal blocks
so they provide the best wire routing from the components to the terminal
blocks. The terminal blocks also make it convenient for the electrician to
terminate his field wiring when the control enclosure is installed.

Bill of Materials
The Bill of Materials (BOM) should list each component in our automated
control system, the quantity of each component, any designations or
marks that allow us to easily identify the component on our schematic, a
description of the component, and its part number. We can also have
comments or remarks about the component that will help the panel builder
know what needs to be done when the control panel is being built. Below is
a short example of a bill of materials. The BOM can be in the form of a table
drawn on one of the sheets along with the schematic and panel layout. It
can also be done as a spreadsheet, which would allow easy indexing and
future referencing.

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Wiring Diagram
A wiring diagram, sometimes referred to as an interconnecting diagram,
is used mainly for installation by the electrician for routing and terminating
the wiring between the various devices and enclosures in the control
system. It should include all control enclosures or cabinets, any external
devices that are wired into control enclosures, junction boxes, conduits,
wireways, etc. The wiring diagram usually includes conduit sizes, distances,
number of conductors between devices, wire sizes, colors, wire numbers,
terminal blocks, etc. The wiring diagram is also useful for system startup
and later for locating wire routing and devices during troubleshooting.
Bellow is an example of a wiring diagram.

Strive for perfection in everything

you do. Take the best that exists
and make it better. When it does not
exist, design it.
- Sir Henry Royce

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Design Tools
Although all of the tasks related to documenting the design can be
performed with nothing more than a pencil, paper and a ruler, it is normally
more efficient to use a software drafting utility, such as AutoDesks
AutoCAD or AutoCAD LT software. The biggest advantage in using a
software drafting program to create schematics, panel layouts, bill of
materials and wiring diagrams is the ability to re-use the work for future
electrical control system designs. The drafting software can also be used to
create our sequence of operation, flowchart or timing diagram. Add-ins for
various drafting software packages can be geared toward electrical control
system design. These add-ins contain pre-constructed elements of different
manufacturers electrical devices. This may include schematics of PLC I/O
modules, power supplies, communication devices, etc. These preconstructed elements also include scaled outlines of relays, motor starters,
terminal blocks, etc. that can be dropped into your panel layout design.
This type of software has the ability to act as a database for components
that would be used in our control system design and can aid in coordinating
the components between our schematic, panel layout and bill of materials.

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CHAPTER

5
Build

40

Build

Let the Fun Begin!

Lets review some practical suggestion and guidelines on
building your control panels for easier installation and
maintenance.
During the design of our control panel, we pointed out the
benefits of using a removable subpanel. In building the subpanel,
it is best to secure the components from the front side. This will
make it easier to replace any failed device or component in the
future.
We can also make installation and maintenance easier by
using terminal blocks mounted to the subpanel that will connect to
all external devices. This will allow the installing electrician to
quickly dress and terminate the field wires. Another terminating
method that has added benefits is to design our control panel with
mating connectors so that the field wiring could be plugged into
connectors mounted on the panel.

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Wiring Recommendations
The following guidelines provide general information on how to wire most
automation equipment. For specific information on wiring a particular PLC or
device, refer to the installation manual included with your equipment.

Review terminal connection specifications for capacity - for example, a PLC

input module terminal may accept one 16AWG or two 18AWG size wires. Do
not exceed the recommended capacity.
Always use a continuous length of wire. Do not splice wires to attain a needed
length.
Use the shortest possible wire length.
Use wire trays for routing where possible.
Avoid running wires near high energy wiring.
Avoid running input wiring close to output wiring where possible.
To minimize voltage drops when wires must run a long distance, consider
using multiple wires for the return line.
Avoid running DC wiring in close proximity to AC wiring where possible.
Avoid creating sharp bends in the wires.
Install a powerline filter to reduce power surges and EMI/RFI noise.

! Warning:
Providing a safe operating environment for personnel and equipment is
your responsibility and should be a primary goal during system
planning and installation. Automation systems can fail and may result in
situations that can cause serious injury to personnel or damage to
equipment. Do not rely on the automation system alone to provide a
safe operating environment. Use external electro-mechanical devices,
such as relays or limit switches that are independent of the automation
equipment, to provide protection for any part of the system that may
cause personal injury or damage.
! Warning:
Every automation application is different. Therefore, there may be
special requirements for your particular application. Be sure to follow
all National, State, and local government requirements for the proper
installation and use of your equipment.

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Grounding
Electronic instrumentation such as PLCs and field I/O are typically
surrounded by various types of electronic devices and wires. All these may
present a risk of Electromagnetic Interference (EMI) or transient
interference. This type of interference may cause erratic operation of
components and cause failures.
In addition to device interference, automation equipment and devices
could be damaged by powerful line surges. These line surges may come
from common voltage fluctuations from a power supply, lightning, or
unintentional contact with a high voltage line. A power surge will cause a
temporary failure, fuse burn-up, or even very serious damage to the
equipment.
Grounding provides a low impedance path that limits these voltages and
stabilizes interference. Grounding is a must to protect your automation
equipment and devices from serious damage, failures, and even potential
risk to users.
Grounding is the foundation of achieving a reliable power distribution
system. During the panel and control system build, it is important that a
reliable grounding system be implemented. Poor grounding or improper or
defective wiring may be the cause of most problems affecting power quality.
The following is a list of existing grounding standards that may be used for
reference:

IEEE Green Book (Standard 142)

IEEE Emerald Book (Standard 1100)
UL96A, Installation Requirements for Lighting Protection Systems
IAEA 1996 (International Association of Electrical Inspectors) Soars Book on
Grounding
EC&M - Practical Guide to Quality Power for Electronic Equipment
Military Handbook - Grounding Bonding and Shielding of Electronic
Equipment

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Once all the important considerations mentioned above have been

determined, the mounting, bonding, and grounding of the chassis may be
started. The following list provides a brief explanation of each of these
terms:

Mounting: refers to the actual physical installation of each device, instrument

or component to either the subpanel or other connected equipment.
Bonding: refers to the joining of metallic parts of a chassis such as; frames,
shields, assemblies and enclosures. Joining or bonding these components
properly reduces the interference from EMI and ground noise.
Grounding: refers to a connection to a grounding conductor to provide
overload and interference protection.

As mentioned before, grounding protects the instrumentation, devices, or

components from power surges and reduces the effect of EMI and ground
noise. The below figure shows a typical method for grounding the subpanel
to the enclosure cabinet to assure proper grounding.
Note: Please remember that
bonding and grounding are
important safety requirements that
are mandatory by local codes and
regulations. The installer must
verify the local codes to determine
what grounding and bonding
methods are permitted. Always
make sure that power supplies are
properly grounded to ensure
elimination of electronic noise
interference.
Note: When using ground lugs and
installing more than one on the
same stud, make sure to install the
first lug between two star washers
and tie it with a nut. Install the
second lug over the nut of the first
lug followed by a star washer and
another tightened nut.

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Shielded Cables
A shielded cable is an insulated cable consisting of strands of copper or
other material enclosed with a metallic shield underneath a jacketed sheath.
Shielded cables are used to reduce the interference from electrical noise.
Some instrumentation requires the use of shielded cables for specific
connections. When installing instrumentation, verify whether any connection
requires a shielded cable. Failure to use the shielded cable will result in
erratic readings or signals from the instrumentation. If the product being
installed requires shielded cables, the grounding specifications provided by
the manufacturer manual must be followed. Improper installation of shielded
cables may cause a ground loop that will cause failure on a processor or
would allow noise into the logic circuit.
There are various types of shielded cable available for different uses.
The shielded cables listed below are the most commonly used for
automation control systems and instrumentation:

Foil Shield: These cables consist of aluminum foil laminated to a polyester or

polypropylene film. The film provides mechanical strength and additional
insulation. The foil shield provides 100% cable coverage for electrostatic
shielded protection. Foil shields are normally used for protection against
capacitive (electric field) coupling where shielded coverage is more important
than low DC resistance.
Braided Shield: These cables consist of groups of tinned, bare copper, or
aluminum strands. One set is woven in a clockwise direction, then interwoven
with another set in a counter-clockwise direction. Braided shields provide
superior performance against diffusion coupling, where low DC resistance is
important, and to a lesser extent, capacitive and inductive coupling.
Spiral Shield: The spiral shield consists of wire (usually copper) wrapped in a
spiral around the inner cable core. The spiral shield is used for functional
shielding against diffusion and capacitive coupling at audio frequencies only.
Combination Shield: These cables consist of more than one layer of
shielding. The combination shield is used to shield against high frequency
radiated emissions coupling and electrostatic discharge (ESD.) It combines
the low resistance of braid with 100% coverage of foil shields and is one of
the more commonly used types of shielded cable in todays industry.
This figure shows a typical cross sectional area of a
shielded cable that makes use of combination shields.

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45

Mounting of Electronic Instrumentation

Electronic instrumentation is typically installed inside an enclosure with
other devices. Therefore, the installation of the instrumentation must take
into consideration that the panel layout accommodates all the necessary
components. In addition to the panel layout, the following specifications
should be considered:
Electronic instrumentation can be affected by interference from other
electronic devices or EMI. This interference causes static that may
interrupt communications or signals from other devices. Address these
considerations to prevent any possibility of interference with your
equipment:
Environmental specifications that cover the operating temperature,
humidity, vibration, noise immunity, etc.
Power requirements are specific to each piece of equipment.
When installing instrumentation always make sure to follow the
manufacturer's power requirement guidelines for your specific
piece of equipment.
Use components with Agency Approvals such as UL, CE, etc.
Make enclosure selections based on component dimensions,
recommended mounting clearances, heat dissipation and EMI.
If installing a PLC base or chassis, which consists mainly of mounting,
bonding, and grounding, it is very critical to the proper operation of the
PLC and its related devices to closely follow the manufacturers
recommendations. There are many cases of a PLC experiencing
noise problems, when the problem is found to be that the base wasnt
grounded to the subpanel.

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46

Wiring and I/O Testing

The last item to consider at the completion of building your control panels
is to do a complete I/O checkout. This will assure that the point-to-point
wiring between the I/O module terminals and the field wiring terminal blocks
has been done correctly.
To start, create a list with each I/O point shown and include any details of
what criteria is being tested. It is also helpful to include a check box that can
be used to check off each point after it is tested. Normally this list can be
created from an I/O list or tag name list that was created when designing
your PLC ladder logic or HMI operator interface.
Include the test criteria for each point on the list. As an example, discrete
input and output points would be listed as normally OFF and then checked
for their ON state. Analog points, both input and output, could be checked
at different values. For example, if using a current input module, you may
want to simulate 4mA (low value), 12mA (middle value) and 20mA (high
value).
The actual testing normally requires a two-person team. One person
uses a PC connected to the PLC to view the status of each point tested and
to simulate outputs, and the other person physically applies a signal to
inputs and monitors outputs with the use of an indicator on discrete outputs
and a meter on analog outputs.
At this point, you can also perform simple testing of your control program
by simulating the inputs and ensuring the logic performs as expected.

Learn more about I/O for PLCs

Understand the difference between
Discrete I/O and Analog I/O in this
blog post!

Visit: N2ADC.com/ve5cw
f

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47

CHAPTER

6
Install and Start-up

48

Install

It all comes together!

Our control system may be installed by a combination of
contractors and in-house personnel. Personnel will need access to
our schematics/wiring diagrams, as well as installation drawings
showing the physical locations and mechanical requirements for
all field devices. These drawings should include notations for
mounting, type of conduit and wire, etc. Field devices such as
sensor and motors would typically be installed by mechanical
specialists and wired by electrical specialists. Power and field
wiring would then be run through conduit or wireways and
terminated at the control locations (our enclosures containing the
PLC, I/O, or hardwired control devices).

I love it when a plan

comes together.
- John Hannibal Smith

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49

Plan for Safety

As we have stressed, the best way to provide a safe operating
environment is to make personnel and equipment safety part of the planning
process. Examine every aspect of the system to determine which areas are
critical to operator or machine safety.
If you are not familiar with system installation practices, or your company
does not have established installation guidelines, you should obtain
additional information from the following sources:
NEMA: The National Electrical Manufacturers Association, located in
Washington, D.C., publishes many different documents that discuss
standards for industrial control systems. You can order these publications
directly from NEMA. Some of these include:

ICS 1: General Standards for Industrial Control and Systems

ICS 3: Industrial Systems
ICS 6: Enclosures for Industrial Control Systems

NEC: The National Electrical Code provides regulations for the installation
and use of various types of electrical equipment. Copies of the NEC
Handbook can often be obtained from your local electrical equipment
distributor or your local library.
Local and State Agencies: Many local governments and state
governments have additional requirements above and beyond those
described in the NEC Handbook. Check with your local Electrical Inspector
or Fire Marshal office for information.

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Start-up
The Moment of Truth!
The startup of our automated control system begins once we have
installed our control system enclosure and auxiliary equipment, terminated
all field wiring, and completed required testing. This process is also called
commissioning the automated control system and related
equipment/process.
As a starting point, it is best to isolate the various sections of our control
system power wiring by removing the fuses and/or opening circuit breakers.
The best tool to use during commissioning is the schematic diagrams. We
will want to start at the incoming power, and basically work our way through
the entire schematic.
As a first step, we may want to apply power to the main circuit breaker or
fused disconnect of our control system. Then, measure the voltage for
proper values, phase-to-phase and each phase-to-ground, if the incoming
power is three phase. Next, we can turn on the main circuit protector and
check the voltage at each device that is fed from the main source. Then start
turning the circuit breakers on or replace the fuses one circuit at a time and
make additional voltage checks as well as test equipment operation that
may be powered from the circuit.
Keep in mind that every control system will not be the same. Therefore,
each system will require a different strategy to bring the equipment online
safely. Consider having motors uncoupled from their respective loads, air
pressure off, disabling hydraulics, and using Lockout/Tagout (LOTO)
procedures. Measure voltages as you go. If using a PLC, connect a PC to it
and monitor the I/O to make sure their states are responding correctly.
During this time it is best to have a null (empty) program in the PLC so you
do not energize actual equipment while continuity testing is in progress.

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Once you have tested electrical continuity and corrected any wiring
errors or problems, you can connect all uncoupled devices and load the
control program into the PLC.
Testing the logic of your program should be done with safety in mind. If
you will be energizing live loads as you test, ensure all personnel are aware
and a technician is physically observing operations in the event of a
malfunction or incorrect programming. You may want to disable all outputs
and enable one section of the program at a time to test.

Read awesome
application stories!
Automation System Retrofit
Transforms 175-ton Hydraulic
forming press.
www.N2ADC.com/rkwo5

And Affordable Retrofit Prevents

Expensive Replacements.
www.N2ADC.com/z82-d

Find these application stories and more at Library.AutomationDirect.com

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AutomationDirect parts you used. We may feature you
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CHAPTER

7
Maintain

53

Maintain

Keeping your Baby Running!

It is important to develop a routine maintenance schedule for your
automated control system. Having a routine schedule for checking critical
components and devices in the system will increase the longevity of the
system and more importantly, it will help reduce future problems. Set up the
schedule based on a monthly or quarterly time period, depending on the
item to be done. The following are some of the items you may want to
consider in your maintenance schedule:

Check and record voltages at various circuits

Tighten all connections (with power removed)
Check backup batteries, and/or replace on a routine schedule
Check indicators and perform lamp tests
Visually inspect for loose or frayed wiring, moisture in enclosure, etc.
Check to make sure plug-in connectors are tight and secured
Test all alarm systems, horns, sirens, etc.
Check and record any configuration settings
Perform and record calibrations
Check all I/O points on a yearly basis
Check and record power usage
Check equipment run times for determining maintenance or replacement
Measure device current to set a benchmark and compare for changes
Review any diagnostic history, including events and alarms
Check diagnostics that may be programmed into the HMI operator interface

This wraps up this eBook on automated control system specification,

design and installation. We hope you have found this information useful. I
know that youre sad that our time together has come to an end, but take
heart because there is plenty more where this came from. Just visit us at
AutomationDirect.com/Newsletter to sign up for our newsletter and you will
be the first to get all the goodies from AutomationDirect.com.
This eBook is based on an article series featured in our AutomationNotebook entitled A Condensed Guide to
Automation Control System Specification. Written by Tom Elavsky.

in

54

Get the Best Value In

Programmable
Controllers
Buy from AutomationDirect.com and get
FREE Tech Support and Software!

Learn More

55

Appendix

AKA Awesome Stuff to help you out!

Steps for Choosing a Controller ------------------------------- p.57
Understanding Discrete & Analog I/O ------------------------ p.60

Equipment Specification Template ---------------------------- p.64

Specifying and Sizing Motor Starters ------------------------- p.68
What photoelectric sensor is best for me? ------------------ p.70
Choosing the Right Proximity Sensor ------------------------ p.71
Sinking and Sourcing Concepts ------------------------------- p.75
What do the NEMA Ratings Mean? -------------------------- p.78
Understanding Enclosure Cooling ---------------------------- p.80
Selecting an Enclosure Fan or Air Conditioner ------------- p.82
Selecting a Heat Exchanger ------------------------------------ p.84
Maintenance Check List ---------------------------------------- p. 86
Memory Aids ------------------------------------------------------- p.87
A Guide to Common Automation Terms --------------------- p.89

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Steps for Choosing a Controller

Choosing the most effective controller for your application depends on a number of
factors. Use the steps below to help you know what to consider when determining
programmable controller requirements. You can download a PDF worksheet with space
for recording determinations for your system by visiting N2ADC.com/l8jv4

Step 1:
Determine whether your system is new or
existing: Will your system be installed from
scratch or are there existing products
already installed? The rest of your system
will need to be compatible with new
components.
Why this is important: Certain controller
products may not be compatible with
others. Making sure your existing products
are compatible with any new products you
are researching will save you time and
money. Check appropriate entry.

Step 2:
Consider any environmental issues that will affect your application (temperature, dust,
vibration, codes specific to your facility, etc.).
Why this is important: Certain environments may affect the operation of a controller.
For example, typical controllers have an operating temperature of 0-55 degrees Celsius
(32-130 degrees F). If your application will include any extreme environmental conditions,
or you have specific codes at your facility that must be met, you will need to either
research products that meet those specifications or design the installation to meet
requirements. Check appropriate entry.

Step 3:
Determine how many discrete devices your system will have. Which types (AC, DC, etc.)
are needed?
Why this is important: The number and type of devices your system will include is
directly linked to the amount of I/O that will be necessary for your system. You will need
to choose a controller that supports your I/O count requirements and has modules that
support your signal types. Enter quantities and type based on corresponding field devices

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57

Steps for Choosing a Controller

Step 4:
Determine how many analog devices your system will have. Which types (voltage,
current, temperature, etc.) are needed?
Why this is important: The number and type of devices your system will include is
directly linked to the amount of I/O that will be necessary for your system. You will need
to choose a controller that supports your I/O count requirements and has modules that
support your signal types. Enter quantities and type based on corresponding field devices

Step 5:
Determine whether your system will require any specialty features: Will your application
require high-speed counting or positioning? What about a real-time clock or other
specialty feature?
Why this is important: Specialty functions are not necessarily available in a controller
CPU or in standard I/O modules. Understanding the special functions your system may
perform will help you determine whether or not you will need to purchase additional
specialty modules. Check all features required..

Step 6:
Determine the type of CPU you will need: How much memory will your system require?
How many devices will your system have (determines data memory)? How large is your
program, and what types of instructions will your program include (determines program
memory)? How fast a scan time do you need?
Why this is important: Data memory refers to the amount of memory needed for
dynamic data manipulation and storage in the system. For example, counter and timer
instructions typically use data memory to store setpoints, current values, and other
internal flags. If the application requires historical data retention, such as measured
device values over a long period of time, the size of the data tables required may
determine the CPU model you choose. Program memory is the amount of memory
needed to store the sequence of program instructions that have been selected to perform
the application. Each type of instruction requires a specific amount of program memory,
typically defined in a programming manual. Applications that are basically sequential in
nature can rely on the I/O device rule of thumb to estimate program memory (five words
of memory for each I/O device); complex applications will be more difficult to judge.
If scan time is important in your application, consider the CPU processor speed as well
as instruction execution speed. Some CPUs are faster at boolean logic but slower with
data handling instructions.

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Steps for Choosing a Controller

If special functions such as PID are required, the CPU you select may make those
functions easier to perform. For program memory required, follow this rule of thumb: 5
words of program memory for each discrete device and 25 words for each analog device.
Check or calculate all requirements that apply.

Step 7:
Determine where your I/O will be located: Will your system require only local I/O, or both
local and remote I/O locations?
Why this is important: If subsystems will be needed at long distances from the CPU,
you will need a controller that supports remote I/O. You will also have to determine if the
remote distances and speeds supported will be adequate for your application. Serial and
Ethernet-based I/O hardware are two typical choices available for most systems. This I/O
may also be referred to as distributed I/O, and may require a particular protocol, such as
Modbus.

Step 8:
Determine your communication requirements: Will your system be communicating to
other networks, systems or field devices?
Why this is important: Communication ports (other than the programming port) are not
always included with a controller. Knowing your system communication requirements will
help you choose a CPU that supports your communication requirements, or additional
communication modules if necessary. Check any/all communications.

Step 9:
Determine your programming requirements: Does your application require only
traditional programming instructions, or are special instructions necessary?
Why this is important: Certain controllers may not support every type of instruction.
You will need to choose a model that supports all instructions that you may need for a
specific application. For example, built-in PID functions are much easier to use than
writing your own code to perform closed-loop process control. Typical instructions such
as timers, counters, etc. are available in most controllers; note any other special
instructions required here. Check any/all programming functions required.

Download a PDF worksheet with space for recording the determinations for your
system by visiting N2ADC.com/l8jv4

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Understanding Discrete and Analog I/O

So what do you think, is this glass half full or half empty? For
me, that could be a little difficult to answer and could vary based
on the day Im having, but if we are asking about the level, why
not let the PLC answer? In fact, why not have the PLC tell us
the level, the temperature of the water, the flow rate at which it
was filled, the available capacity of the glass and the pressure
exerted on the bottom?
Ok, normally you wouldnt use a PLC for such a small application, but on a larger
scale, say a reservoir, it is possible for the PLC to answer all of those questions. But how
can we make the PLC even see this reservoir, let alone tell us how full it is? Well Im
glad you asked, or I asked, or whatever. We need a device that can allow the PLC to
take information in from its surroundings and process it. We also need a device that will
allow the PLC to affect its surroundings as needed. What we need is I/O, and what I
mean by I/O is Inputs and Outputs. For this discussion, well focus on the two main types
of I/O: analog and discrete.

Discrete I/O
Lets take the simplest first, discrete. Discrete signals are signals that are either on or
off, true or false. Think of a light switch in your house. The switch either turns the light on
or it turns it off, unless it is a florescent tube then its probably still blinking. Because
discrete signals exist in one of these two states, they are represented with a square wave
as seen below.

In the PLC world, there are many uses for discrete I/O. Some of the devices that
supply on/off signals are pushbuttons, photoeyes, limit switches, float switches and
proximity switches. In my startup days, I did a lot of work with a certain parcel service.
They use a lot of on/off sensing and control in order to track packages and get them to
the right destination or truck. Photoeyes, which are devices that emit an infrared light
beam and can sense when that beam has been broken, are used extensively to detect

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Understanding Discrete and Analog I/O

and track packages through their sorting process. The application of your control system
will determine the types of discrete devices you choose. There are a variety of discrete
end devices and modules that can be used in a PLC system to send and receive on/off
signals. These devices can be AC or DC and are available in different voltage ranges. 024VDC and 0-230VAC are two voltage ranges available, with 0 being the OFF signal and
24VDC or 230VAC being the ON signal. Usually there is a threshold for detection, where
the 0-24VDC module will detect anything over 22VDC as the ON signal and anything
below 2VDC as the OFF. Now lets look at analog.

Analog I/O
Analog signals are signals that can vary or change. We live in an analog world and
our senses are analog receivers. Feel how hot it is!, Can you speak up? and Look at
all the colors! are statements that show how the variation in analog signals like
temperature, sound, and light can affect our senses. Back to the light switch example;
lets now install a little mood lighting in our home. Instead of the regular on/off switch we
are going to use a dimmer switch. The dimmer switch will vary the resistance in the line,
causing the light to dim or brighten as we choose. Newer dimmer switches have
advanced to be more efficient but for this example we are going old school. The voltage
supplied to the light will not be a constant level but a changing one set between the upper
and lower limits. This is usually represented by a sine wave.

Using Transducers
Position, level, temperature, pressure, flow and speed are just some of the
measurements that analog devices can provide to a control system. You are probably
asking yourself: How does pressure, which is a physical quantity, become an electrical
signal? That is a great question! The conversion is done using transducers. A transducer
will take a physical quantity like pressure and convert it to an electrical signal. A lot of
transducers use the physical quantity to control the resistance in the electrical circuit. For
example, an RTD (Resistance Temperature Detector) will change its resistance value
based on heat. As heat increases so does the resistance in the circuit, altering the
supplied voltage or current. Same holds true for pressure transducers that use strain
gauges. As pressure is applied to the strain gauge, the resistance in the circuit goes up
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Understanding Discrete and Analog I/O

and the voltage or current level changes. Some flow detectors will use the flow of a fluid
to push a fin that is connected to a rotary potentiometer. Faster flow equals more
resistance change. One of the coolest transducers that I ran across in my days working
in the offshore oil industry was the sand detector. This transducer was acoustic and was
attached to pipes that were drawing oil out from the sea floor. It would actually listen for
sand rubbing against the inside of the pipe. The amount of sound was converted into an
analog signal used to alert personnel if the drilling was drawing out too much sand, which
could collapse the well.
The electrical signals that transducers provide can be voltage or current based. 4 to
20mA, 0 to 20mA, 0 to 10VDC and -10 to +10 VDC are a few of the available ranges
produced by transducers. The PLC supplies the voltage or current and the transducer will
return a value in its configured range. That value will be proportional to the amount of
pressure, flow, etc. that is present. We now arrive at two important parts of this
discussion: scaling and resolution.

Scaling
Scaling is when we take the raw voltage or current value returned and translate it into
a meaningful measurement. Lets say I have a 4-20mA flow meter that is returning an
8mA signal to the PLC. That would mean that 8mA of fluid is flowing at this time, right? Of
course not. We need to take the raw value and scale it to something meaningful, lets say
gallons per minute. We know from the manufacturer that the flow meter is calibrated to
read a flow of 0 to 200 gpm. Therefore, we can scale the raw value 4-20mA to equal 0200 gpm in our system. Normally, this can be done using the programming software, as
seen below, and after our value of 8mA is scaled we see that there is currently a flow of
50 gallons per minute.

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Understanding Discrete and Analog I/O

Resolution
Now lets look at resolution. Resolution and accuracy go hand in hand; the more
resolution you have, the more accurate your measurement will be. Analog modules are
rated with the resolution they provide. 12-bit, 13-bit and 16-bit resolutions are a few that
are available. So what does it mean to have a 4-20mA module with a 12-bit resolution? A
12-bit binary word can have 4096 different combinations. Therefore, our module with a
12-bit resolution can have 4096 (4095 with a sign) different measurements within the 420mA range. In other words, the 4-20 range can be broken into 4096 different pieces.
The more pieces, the more accurate. How accurate? Well, our total range is 16mA (20
minus 4) and if we divide our total range by 4096 pieces, we see that our module can
detect each 0.00390625mA of change.

Noise
One last thing, when using analog signals it is important to remember that they are
highly susceptible to noise. Noise can cause wrong readings and erratic behavior in a
control system. Take a look at the diagram below. My system will open a pressure relief
valve on a tank when the raw pressure signal from inside the tank reaches 5.9VDC. With
the returning signal on the left thats no problem. With the noise induced on the right,
good luck!

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Equipment Specification Template

So you found a task that youd like to automate but you need a way to
sort out what pieces are needed and how they fit together. At this phase of
development, organization is key. When specifying a project, staying
organized can keep you on track and help you see the big picture. Flow
charts, graphs and spreadsheets are a few tools that can not only help you
visualize the process but also track your progress.
So, how about an example:
To the right, you see the bulk
shipping conveyor line for a factory.
What is this factory producing? Well,
this is our example so it can be
anything you choose. Since I like to
eat, especially the sweet stuff, my
factory is producing candy bars, and
boy, are they delicious!
Chad here has the important task of verifying that each of the boxes
leaving the factory is filled with the appropriate amount of candy bars. Each
box will hold 150 bars. We dont expect Chad to count each candy bar, so
he uses a scale to weigh each box. As the filled boxes come down the line,
he stops the conveyor, weighs the box and if correct, sends the box on to
our palletizing system. The boxes are then put on pallets and shipped to our
major customers. If the box is not the right weight, then Chad will send the
box back to the filling station. This process works, but it is slowing down our
delivery time. In order to stay competitive we need to get these candy bars
out as quickly as possible, so we decide to automate.
Below is an example of how the automation will work and the planning
involved. First, the static scale will be replaced with a conveyor scale so we
can alleviate the belt stoppages. The conveyor scale will communicate with
a PLC (programmable logic controller) inside of our control enclosure. The
scale will inform the PLC when a box is present, the weight of the box and
when the box has cleared the scale. The PLC will then determine if the box
needs to go back to be refilled or not. If it does need to be refilled, a diverter
arm will extend and guide the box to the recirculating conveyor belt.

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Equipment Specification Template

Using the Equipment Specification Template
In order to stay organized as we
specify equipment for our example project
outlined above, we have put together a
spread sheet with three different tabs.
We have labeled our tabs: Project Plan, Conceptual Drawing, Parts
List. Let's take a look at each of these tabs; if you would like to follow
along you can download our example template by clicking here.
Project Plan: On this tab we included the high-level information
that we needed to ensure that everyone was aware of what was
included in this project. We gave the project a name, we described
it, and outlined the plan. Next we pointed out some important
requirements that our system will have to conform to. We point out
Environmental Concerns, System Power Constraints, Scan
Time/High-Speed Requirements, and the Network Protocol. (Note
that depending on your project and environment you might need to
highlights some additional requirements, but for our example we
will keep it simple.)

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Equipment Specification Template

Conceptual Drawing: Our next tab is dedicated to our conceptual

drawings. Drawings are a very important part of our planning
process because it takes what is in your mind and lays it out so
others can see it. This help to ensure that everyone is on the same
page but it also helps us to identify any needs or problems that we
might not have otherwise seen.

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Equipment Specification Template

Parts List: On the parts list tab we have taken the time to list out
all the parts we think are needed for this project. We also took the
time to list the specifications, part number and a link to for each
part. This tab serves multiple functions. First, while filling it out, it
will help trigger things in your mind you forgot you would need.
Also it will help ensure that come installation day you don't have to
halt all work to order another part. Additionally, by providing
specifications and links for all part numbers you can refer to this list
in the future if you need to find replacement parts or technical
documentation.

Conclusion
Device specification is a major part of the automating process but it is
only a part. Because of that, the devices chosen at this point are not
concrete. In later phases of development, issues may arise that can cause
the choices made here to change. One final thought on system
specification; when specifying a system always plan for safety, use
redundancy where needed and consider future expansion possibilities.
Download Template at: N2ADC.com/yknp2

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Specifying and Sizing Motor Starters

There are four basic motor control options available: Basic contactors,
traditional starters, manual motor starters, or combination starters. A basic
contactor is a special purpose relay that is used to control large electrical
currents. Similarly, a traditional starter utilizes overload relays, auxiliary and alarm
contacts, and mechanical interlocks to create a reversing unit. On the other hand
a manual motor starter is a protective device for motor use that provides optimal
protection by integrating the functions of a molded case circuit breaker and
thermal overload relay into a compact unit. In comparison, a combination starter
is comprised of combining a manual motor starter and a magnetic contactor to
achieve a compact motor control that minimizes enclosure space requirements.
Simply follow these 3 steps to choose the best fit.

1. What Does the Application Require

Basic
Contactors Only

Traditional
Starters

Combination
Starters

Manual Motor
Starters

Contactor
Manual Motor
Starters(MMS)

Typical Applications:

Electronic
switching

Contactor &
Overload Relay

Lighting
Typical Applications:
Resistive loads
Non-motorrelated inductive
loads
Disconnect
switches
VFD
bypass/isolation

Inductive motor
starting and
control
NEC 430 and
409 fulfillment
Nm starter
replacement/
retrofit

Manual Motor
Starter, Contactor,
Link Module, and
Base Plate

Typical Applications:
Inductive motor
starting and
manual control

Typical Applications:
Inductive motor
starting and
control

NEC 430
fulfillment
Lockout/tagout

NEC 430 and

409 fulfillment

UL 508, Type E

Lockout/tagout

Not AC-4 rated

UL 508, Type F

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Specifying and Sizing Motor Starters

2. Consider These Factors When Selecting

Components:
Load type: Resistive (AC-1) or inductive (AC-3)
Duty cycle: One direction, reversing, plugging (AC-4)
Horsepower (hp) and full load amperage (FLA)

3. Select Your Components.

Parts listed here are Fuji Electric motor controls components available at
www.AutmationDirect.com/Motor-Controls.

Basic
Contactors Only

Traditional
Starters

Combination
Starters

Manual Motor
Starters

Duo Series

Duo Series

Duo Series

Duo Series

SC-E Contactor

SC-E Contactor

BM3 Manual
Motor Starter

BM3 Manual
Motor Starter

1/2 to 100 hp @
480 V

TK-E Overload
Relay

1/2 to 100 hp @
480 V

9-150 A (AC-3)

1/2 to 100 hp @
480 V

SC-EContactor
BZ0L Link Module

Odyssey Series

Odyssey Series

3N Contactor

3N Contactor

60 to 300 hp

3N Overload
Relay

180-361 A (AC3)

BZ0BP Base
Plate
1/2 to 100 hp @
480 V

60 to 300 hp

If you would like to learn more visit www.AutomationDirect.com/motor-controls.

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What photoelectric sensor is best for me?

There are many different styles of photoelectric sensors, but really only four basic
technologies: through-beam, reflective, diffuse, and background suppression. The chart
describes some advantages and disadvantages of each technology.

Type

Through-beam

Advantages

Most accurate

Longest sensing range

Very reliable

Cost less than throughbeam

Reflective

Only slightly less accurate

than through-beam
Sensing range better than
diffuse

Disadvantages
Must install at two points on
system: emitter and receiver
Costly must purchase both
emitter and receiver

Must install at two points on

system: sensor and reflector

Slightly more costly than

diffuse

Sensing range less than

through-beam

Very reliable
Only install at one point

Diffuse

Background
Suppression

Cost less than throughbeam or reflective

Effective with reflective

backgrounds

Less accurate than throughbeam or reflective

More setup time involved

Cost more than diffuse,

reflective or through-beam
Most setup time required

If you would like to learn more visit www.AutomationDirect.com/Photoelectric.

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Choosing the Right Proximity Sensor

Proximity sensors allow non-contact detection of objects. Therefore, they are used in
many industries, including manufacturing, robotics, semiconductor, and many more.
Inductive sensors detect metallic objects while capacitive sensors detect all other
materials. Ultrasonic sensors detect all materials by using sound wave reflections to
determine presence.
All applications have certain specific needs, but, in general, the following steps will
help you choose the correct sensor for your application:

Step 1:
What is the sensing distance required?
The sensing distance is the distance between the tip of the sensor and the object to
be sensed. In our catalog, the selection guide and the specifications table for each
sensor family lists the sensing distances.
Some things to keep in mind are:
A. In many applications, it is beneficial to place the sensor as far as possible from the
sensing object due to temperature concerns. If a sensor is placed too close to a hot
temperature source, the sensor will fail quicker and require more maintenance.
Greater distance may be achieved with extended and triple range sensors. In many
applications, a sensor may not be mountable close to the sensed object. In this case,
longer sensing distances are needed. For example, AutomationDirect extended
sensing distance sensors are offered in 8mm to 30mm diameters, and triple sensing
distance sensors in 8mm and 12mm formats.
In many cases, using an extended distance sensor to get the sensor farther away from
the detected object can be beneficial to the life of the sensor. For example, without an
extended distance sensor you may not be able to place the sensor far enough away
from the detectable object, or you may need to buy more expensive high temperature
sensors. Another example would be a mechanical overshoot situation, where mounting
the sensor farther from the detection object may eliminate unneeded contact with the
sensor, thereby extending the life of the sensor.
These are just a few examples, but the benefits of using extended distance sensors are
obvious in many applications. Think of how extended distance sensors could save you
time and money in your application.

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Choosing the Right Proximity Sensor

B. The material being sensed (i.e. brass, copper, aluminum, steel, etc.)
makes a difference in the type of sensor needed.
Note: If you are sensing a non-metallic object, you must use a
capacitive sensor.
The sensing distances we specified in our catalog were calculated
using FE360 material. Many materials are more difficult to sense and
require a shorter distance from the sensor tip to the object sensed.
If sensing a material that is difficult to sense, you may consider using
our unique stainless steel sensing technology. This will measure
virtually all materials at the specified distances.

Step 2:
How much space is available for mounting the sensor?
Have you ever tried using a round sensor or short body version, and not been able to
make it fit? Rectangular sensors can meet your needs. The same technology used in a
standard round proximity sensor is enclosed in a rectangular housing. This technology
includes sensing distances, electrical protection and switching frequencies similar to
round sensors.

Step 3:
Is a shielded or unshielded sensor needed?
Shielded and unshielded sensors are also referred to as
embeddable and non-embeddable. Unshielded sensors
allow longer sensing distances but shielded sensors
allow flush mounting.

Step 4:
Consider environmental placement concerns.
Will the sensor be placed underwater, in a high-temperature environment, continually
splashed with oil, etc.? This will determine the type of sensor you may use. In the
selection table and in the specification tables for each sensor family in our catalog, we list
the environmental protection degree ratings. Most of our sensors are rated IEC-IP67 and
others are rated IP65 or IP68; we also carry a range of IP69K rated sensors for harsh
conditions.

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Choosing the Right Proximity Sensor

IP65: Protection from live or moving parts, dust, and protection from water jets from
any direction.
IP67: Protection from live or moving parts, dust, and protection from immersion in
water.
IP68: Protection from live or moving parts, dust, and protection from submersion in
water under pressure.
IP69K: Protection against high-pressure/steam-jet cleaning.

Step 5:
What is the sensor output connected to?
Note: If using AC sensors, please skip this step.
The type of output required must be determined (i.e., NPN, PNP or analog). Most PLC
products will accept any output. If connecting to a solid state relay, a PNP output is
needed.

Step 6a:

Step 6b:

Do I need 2, 3, or 4-wire discrete

outputs?

Do I need analog outputs?

This is somewhat determined by what

the sensor will be connected to. Some
simple guidelines to use are:

This is determined by the sensor

application and what the sensor will
be connected to. Sensors with
analog outputs produce an output
signal approximately proportional to
the targets distance from sensor.
If you only need to sense presence
of an object, you do not need an
analog output. Note that many
discrete-output proximity sensors
come with "adjustable" ranges, i.e.
"adjustable from 20-80 mm". This
means only that you can set the
target distance for presence
detection within that range; it does
not mean you are getting a variable
output.

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Choosing the Right Proximity Sensor

Step 7:
Determine output connection type.
Do you want an axial cable factory attached to the sensor (pigtail) or a quick-disconnect
cable?
There are many advantages to using a quick-disconnect cable, such as easier
maintenance and replacement. All proximity sensors will fail in time and using a Q/D
(quick-disconnect) cable allows for simple replacement. Factory attached axial cables
come in a 2 meter length. In our catalog, CD08/CD12 Q/D cables come in 2 meter, 5
meter, and 7 meter lengths. Extension cables are available in 1 meter and 3 meter
lengths to extend the length of the standard Q/D cables.

Q/D cables are offered in PVC and PUR jackets for meeting the requirements of all
applications. Axial cables typically come with a PVC jacket. PVC is a general purpose
insulation while PUR provides excellent oxidation, oil and ozone resistance. PUR is
beneficial if the cable is exposed to oils or placed in direct sunlight.
There are also advantages to a factory attached axial cable:
Cost: The cable is integrated into the sensor and included in the price. Q/D cables
must be purchased separately.

Environmental Impact: Since the cable is sealed into the sensor, there is less chance
of oil, water or dust penetration into the sensor, which could cause failure.

If you would like to learn more visit N2ADC.com/4iiuk

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Sinking and Sourcing Concepts

When choosing the type of input or output module for your PLC system, it is very
important to have a solid understanding of sinking and sourcing concepts. Use of these
terms occurs frequently in discussion of input or output circuits. It is the goal of this
section to make these concepts easy to understand, so you can make the right choice
the first time when selecting the type of I/O points for your application. This section
provides short definitions, followed by general example circuits.
First you will notice that the diagrams on this page are associated with only DC
circuits and not AC, because of the reference to (+) and (-) polarities. Therefore, sinking
and sourcing terminology applies only to DC input and output circuits. Input and output
points that are sinking or sourcing can conduct current in one direction only. This
means it is possible to connect the external supply and field device to the I/O point,
with current trying to flow in the wrong direction, and the circuit will not operate.
However, the supply and field device can be connected correctly every time based on
an understanding of sourcing and sinking.
The figure to the right depicts a sinking input. To
properly connect the external supply, it must be
connected so the input provides a path to supply
common(-). So, start at the PLC input terminal, follow
through the input sensing circuit, exit at the common
terminal, & connect the supply (-) to the common
terminal. By adding the switch between the supply (+)
and the input, the circuit is completed. Current flows in
the direction of the arrow when the switch is closed.
By applying the circuit principles to the four possible combinations of input/output
sinking/sourcing types, there are four circuits, as shown below. The common terminal
is the terminal that serves as the common return path for all I/O points in the bank.

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Sinking and Sourcing Concepts

Sink/source I/O circuits combine sinking and
sourcing capabilities. This means that the I/O
circuitry in the PLC will allow current to flow in
either direction, as shown at the right. The
common terminal connects to one polarity, and
the I/O point connects to the other polarity
(through the field device). This provides
flexibility in making connections to your field
power supply. Please note:
Wire all I/O points with a shared common as
either sinking or sourcing.
Do not use an AC power supply on a DC
sink/source I/O point.
Below are detailed electrical diagrams for sinking and sourcing configurations, showing
typical PLC input module and field device circuitry.

Common terminals and how to use them.

In order for a PLC I/O circuit to operate, current must enter at one terminal and exit at
another. This means at least two terminals are associated with every I/O point. In the
figure below, the input or output terminal is the main path for the current. One additional
terminal must provide the return path to the power supply. Together, the main path and
the return path create a loop, or a complete circuit for current to flow.

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Sinking and Sourcing Concepts Cont.

If there was unlimited space and budget for I/O terminals, then every I/O point could have
two dedicated terminals. However, providing this level of flexibility is not practical or even
necessary for most applications. So, most input or output points on PLCs are in groups
that share the return path (called commons). The figure below shows a group (or bank)
of four input points that share a common return path. In this way, the four inputs require
only five terminals instead of eight.

NOTE: Assuming all input circuits have a similar resistance, the current at the common
terminal is four times greater than the current at any one of the inputs. This effect is
especially important to note for output circuits, where the current through a
common terminal can reach several amperes. You will need to decide whether to fuse
each output point individually, or to put a fuse in the common terminal path.

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What do The NEMA Ratings Mean?

Designed to house all kinds of electrical components from simple terminal blocks, to
industrial automation systems, to high voltage switchgear, NEMA enclosures are also
used in industrial applications to house motor controls, drives, PLC/PC control systems,
pushbuttons, and termination systems. NEMA enclosures meet the National Electrical
Manufacturers Association standards for performance and protection of the electrical
equipment installed within them. They are typically made from carbon steel or stainless
steel. But, how do you know which one is best for your application? This article defines
some NEMA ratings for enclosures that are used in industrial settings. Along with a
description clarifying what each NEMA rating actually means, you'll also find an
explanation on what the enclosures are typically used for. Hubbell-Wiegmann enclosures
mentioned are sold by AutomationDirect.
NEMA 1
NEMA 1 enclosures are typically used for protecting controls and
terminations from objects and personnel. This style of enclosure,
while offering a latching door, does not have a gasketed sealing
surface. NEMA 1 enclosures are used in applications where
sealing out dust, oil, and water is not required. Motor start/stop
stations are often housed in NEMA 1 enclosures.
NEMA 3R
NEMA 3R enclosures are typically used in outdoor applications for
wiring and junction boxes. This style of enclosure provides
protection against falling rain, sleet, snow, and external ice
formation. Indoors they protect against dripping water. This style of
enclosure does not have a gasketed sealing surface. Some
models have hasps for padlocking.
NEMA 3S
NEMA 3S enclosures are intended for outdoor use primarily to
provide a degree of protection against windblown dust, rain, sleet,
and to provide for operation of external mechanisms when ice
laden.

NEMA 4
NEMA 4 enclosures are used in many applications where an
occasional washdown occurs or where machine tool cutter coolant
is used. They also serve in applications where a
pressurized stream of water will be used. NEMA 4 enclosures are
gasketed and the door is clamped for maximum sealing. They
have continuous hinges, mounting feet, and padlock hasps. NEMA
4 enclosures are available in sizes from small wall mounts to twodoor floor mount models.

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What do The NEMA Ratings Mean?

NEMA 4X
NEMA 4X enclosures are made of stainless steel or plastic. NEMA
4X enclosures are used in harsher environments than standard
NEMA 4 units. Applications where corrosive materials and caustic
cleaners are used necessitate the use of a NEMA 4X enclosure.
Applications include food, such as meat/poultry processing facilities,
where total washdown with disinfectants occur repeatedly and
petro-chemical facilities, including offshore petroleum sites. NEMA
4X is used when protection from the worst environments is
required. NEMA 4X enclosures are available in sizes from small
wall mounts to two-door floor mount models. Wiegmann NEMA 4X
enclosures are made of 304 stainless steel.
NEMA 6P
NEMA 6P enclosures are intended for indoor or outdoor use
primarily to provide a degree of protection against the entry of water
during prolonged submersion at a limited depth.
NEMA 12
NEMA 12 enclosures are designed to prevent the ingress of dust,
water, and oil. NEMA 12 enclosures are most often used for indoor
applications of automation control and electronic drives systems.
Some examples are packaging, material handling, non-corrosive
process control, and manufacturing applications. Gasketed doors
seal the enclosure's contents from airborne contaminants and nonpressurized water and oil. NEMA 12 enclosures are available in
sizes from small wall mounts to two-door floor mount models.
NEMA 4 & 12
Wiegmanns 412 enclosures combine the attributes of NEMA 4
and NEMA 12 in an attractive, clean line enclosure. This enclosure
features reversible doors for left or right opening, concealed hinges,
and rear mounting holes for a more attractive installation.
Optional mounting feet are available for conventional wall mounting.
Wiegmanns 412 enclosures are available in wall mount models up
to 60" x 36".
NEMA 13
NEMA 13 enclosures are intended for indoor use primarily to
provide a degree of protection against dust, spraying of water, oil,
and non-corrosive coolant.

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Understanding Enclosure Cooling

You need to cool down - Heat inside an enclosure can decrease the life expectancy
of controlling units such as your PLC, HMI, AC drives and other items. Excessive heat
can cause nuisance faults from your electrical and electronic components: for example,
overloads tripping unexpectedly. Heat will also change the expected performance of
circuit breakers and fuses, which can cause whole systems to shut down. So, if you have
any electronic equipment or other heat sensitive devices, you may want to consider
these enclosure cooling tips.
What causes all that heat?
There are basically two sources that can cause the enclosures internal temperature to
rise above the ratings of the control equipment.
Internal Sources The same items that
can be damaged by heat may also be
the source of the heat. These include
items such as:

Power supplies
Servos
AC Drives/inverters
Soft starters
Transformers
PLC systems
Communication products
HMI systems
Battery back-up systems

External Sources Other sources of

heat that can cause the internal
temperature of your enclosure to rise
above a desired level involve the
external environment. These include
items such as:

Industrial ovens
Solar heat gain
Foundry equipment
Blast furnaces

How to Get the Heat Out

How do you get the heat out of your enclosure and away from those critical components?
Here are three basic enclosure cooling tips and methods.

1. Natural Convection Cooling

If the ambient temperature outside the
enclosure is cooler than the inside of
the enclosure, then the heat can be
dissipated into the atmosphere by
radiating it through the surface of the
enclosure and through the use of
louvers or grilles with filters.

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Understanding Enclosure Cooling

2. Forced Convection
Cooling
If you have clean and cool ambient
air outside of the enclosure, then a
simple forced-air system may be
adequate. A system such as a filter
fan and the associated grille with the
appropriate filter may be an
acceptable option.

3. Closed Loop Cooling

A system that will keep the ambient
air separate from the
internal enclosure air is needed if the
environment is harsh, there are
washdown requirements, heavy dust
and debris or the presence
of airborne chemicals, and the
ambient temperature is as high as or
higher than the desired internal
temperature. Air conditioners are an
example of a closed loop system.
Learn more about enclosure cooling by reading this blog post and more online at
N2ADC.com/3btpr

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Selecting an Enclosure Fan or Air Conditioner

Internal and external sources often cause enclosure internal temperatures to rise above
the ratings of the control equipment. Internally, the same items that can be damaged by
heat (power supplies, PLC systems, AC drives/inverters, HMI systems, battery back-up
systems, servos, etc.) may also be the source of the heat. Externally, sources of heat
that can cause the internal temperature of your enclosure to rise above a desired level
include items such as industrial ovens, blast furnaces, foundry equipment, solar heat
gain, and more. But, how do you get the heat out of your enclosure and away from those
critical components? Here are factors to consider when selecting an enclosure fan or air
conditioner.

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Selecting an Enclosure Fan or Air Conditioner

Air Conditioner Selection
To select the proper size air conditioner, the worst-case conditions should be considered,
but take care not to choose an oversized unit.
There are two main factors in choosing an uninsulated metal NEMA rated enclosure located
indoors: 1.) Internal heat load 2.) Heat load transfer
Internal Heat Load
Internal heat load is the heat generated by
the components inside the enclosure.
This can be determined by a few
different methods. The preferred method
is to add the maximum heat output
specifications that the manufacturers list
for all the equipment installed in the
cabinet. This is typically given in Watts,
so use the following conversion:
BTU per Hour = Watts x 3.413
Example: The Watt-loss chart for the
AutomationDirect.com GS3 drives shows
that a GS3-2020 AC drive has a Watt-loss
of 750 watts.
BTU per Hour = 750 watts x 3.413
BTU per Hour = 2559

Air Conditioner Selection Example

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Selecting a Heat Exchanger

Heat inside an enclosure can decrease the life expectancy of controlling units such as
your PLC, HMI, AC drives and other items. Excessive heat can cause nuisance faults
from your electrical and electronic components. Heat will also change the expected
performance of circuit breakers and fuses, which can cause whole systems to shut down
unexpectedly. So, if you have any electronic equipment or other heat sensitive devices,
you may need cooling. If you have determined that a heat exchanger is the best cooling
option for your enclosure, consider these factors in selecting the right capacity.

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Selecting a Heat Exchanger

Parts in example are available at:

N2ADC.com/w0jl8

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Maintenance Check List

Because each machine is unique, you will want to develop your own maintenance check
list, but we hope that our list below will help give you a good jumpstart. You can
download a Excel template for a maintenance check by visiting N2ADC.com/g50mf.

Check and record voltages at various circuits

Tighten all connections (with power removed)
Check backup batteries, and/or replace on a routine schedule
Check indicators and perform lamp tests
Visually inspect for loose or frayed wiring, moisture in enclosure, etc.
Check to make sure plug-in connectors are tight and secured
Test all alarm systems, horns, sirens, etc.
Check and record any configuration settings
Perform and record calibrations
Check all I/O points on a yearly basis
Check and record power usage
Check equipment run times for determining maintenance or
replacement
Measure device current to set a benchmark and compare for
changes
Review any diagnostic history, including events and alarms
Check diagnostics that may be programmed into the HMI operator
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Memory Aids
We all have used an acronym, mnemonic, rhyme, word association, or other technique
to help us remember information, lists, events, etc. I know they work because most of
them are still stuck in my head. See how many of the following you may remember.

Resistor Color Code Better Be Right Or Your Great Big Venture Goes West
Color bands are used to represent numeric values in ohms on certain types of resistors.
The numbers 0 through 9 are represented by the colors black, brown, red, orange,
yellow, green, blue, violet, gray, and white respectively. The first and second band are
typically the resistors first two significant digits, the third band is the number of zeros
following the first two digits, and the forth band is the resistors tolerance. There are
many variations to this type of resistor coding, but to recall the basic color order, you can
memorize the saying Better Be Right Or Your Great Big Venture Goes West. A little
investigation will most likely discover many other sayings for memorizing the resistor
color code, some not as elegant as the one we have shared.

Visible Color Spectrum Roy G. Biv

To remember the main colors that we may see in a rainbow, or viewing the result of light
that has traveled through a prism, think of Roy G. Biv. The colors with the longest to
shortest wave length are Red, Orange, Yellow, Green, Blue, Indigo and Violet. You may
have noticed that other than Indigo, the color spectrum order matches part of the
Resistor Color Code.

ELI the ICE Man

In an AC circuit involving inductance or capacitance, the voltage and current in the circuit
will be out of phase with each other. An inductive circuit will cause a phase shift in one
direction and a capacitive circuit will cause the opposite. To remember which is which,
think of ELI the ICE man, where E = Voltage, I = Current, L = Inductor, and C =
Capacitor, therefore: ELI (Inductive Circuit) Voltage leads Current ICE (Capacitive
Circuit) Current leads Voltage

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Memory Aids
Algebraic Expressions
Solving algebraic expressions can be somewhat confusing unless we understand the
order of operations that have been defined. Take the following equation: 7 + 6 / 2 2 * 3
= In which order do we solve the various elements? Can we take 7, add it to 6, then
divide the result by 2, or maybe divide 6 by 2 and take the result away from 7? Luckily
the order has been defined for us. We solve algebraic expressions by doing the
computations in Parentheses first, if they are present, followed by Exponents, then either
Multiplication or Division (order does not matter), and finally either Addition or Subtraction
(again order does not matter). An easy way to remember this order is to memorize the
saying Please Excuse My Dear Aunt Sally.

Value of Pi
If you forget Pi = 3.14159, you can get a quick approximation on a simple calculator by
solving 22/7, or for more accuracy while just a bit harder to remember, solve 355/113.

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A Guide to Common Automation Terms

The glossary below is an excerpt from Jon Stenersons Fundamentals of Programmable
Logic Controllers, Sensors, and Communications. For the complete list, go to the
Technical Support section of the AutomationDirect Web site.

Accumulated value: Applies to the use of timers and counters. The accumulated
value is the present count or time.
Accuracy: The deviation between the actual position and the theoretical position.
Address: Number used to specify a storage location in memory.
Analog: Signal with a smooth range of possible values. For example, a
temperature that could vary between 60 and 300 degrees would be analog in
nature.
Backplane: Bus in the back of a PLC chassis. It is a printed circuit board with
sockets that accept various modules.
Baud rate: Speed of serial communications. The number of bits per second
transmitted. For example, RS-232 is normally used with a baud rate of 9600. This
would be about 9600 bits per second. It takes about 10 bits in serial to send an
ASCII character so that a baud rate of 9600 would transmit about 960 characters
per second.
Binary: Base-two number system. Binary is a system in which ones and zeros are
used to represent numbers.
Binary-coded decimal (BCD): A number system. Each decimal number is
represented by four binary bits. For example, the decimal number 967 would be
represented by 1001 0110 0111 in BCD.
Bit: Binary digit. The smallest element of binary data. A bit will be either a zero or a
one.
Byte: Eight bits or two nibbles. (A nibble is 4 bits.)
Central processing unit (CPU): Microprocessor portion of the PLC. It is the
portion of the PLC that handles the logic.
Compare instruction: PLC instruction that is used to test numerical values for
equal, greater than, or less than relationships.
Contact: Symbol used in programming PLCs to represent inputs. There are
normally open and normally closed contacts. Contacts are also the conductors in
electrical devices such as starters.
Contactor: Special-purpose relay that is used to control large electrical current.
Current sinking: Refers to an output device (typically an NPN transistor) that
allows current flow from the load through the output to ground.
Current sourcing: Output device (typically a PNP transistor) that allows current
flow from the output through the load and then to ground.

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Data table: A consecutive group of user references (data) of the same size that
can be accessed with table read/write functions.
Debugging: Process of finding problems (bugs) in any system.
Digital output: An output that can have two states: on or off. These are also called
discrete outputs.
Downtime: The time a system is not available for production or operation is called
downtime. Downtime can be caused by breakdowns in systems.
EEPROM: Electrically erasable programmable read only memory.
Energize: Instruction that causes a bit to be a one. This turns an output on.
Examine-off: Contact used in ladder logic. It is a normally closed contact. The
contact is true (or closed) if the real-world input associated with itis off.
Examine-on: Contact used in ladder logic programming. Called a normally open
contact. This type of contact is true (or closed) if the real- world input associated
with it is on.
Firmware: A series of instructions contained in read-only memory (ROM) that are
used for the operating system functions. Some manufacturers offer upgrades for
PLCs. This is often done by replacing a ROM chip. Thus the combination of
software and hardware lead to it being called firmware.
Force: Refers to changing the state of actual I/O by changing the bit status in the
PLC. In other words, a person can force an output on by changing the bit
associated with the real-world output to a 1. Forcing is normally used to
troubleshoot a system.
Ground: Direct connection between equipment (chassis) and earth ground.
Hexadecimal: Numbering system that utilizes base 16.
Hysteresis: A dead band that is purposely introduced to eliminate false reads in the
case of a sensor. In an encoder hysteresis would be introduced in the electronics to
prevent ambiguities if the system happens to dither on a transition.
Image table: Area used to store the status of input and output bits.
Instruction set: Instructions that are available to program the PLC.
I/O (input/output): Used to speak about the number of inputs and outputs that are
needed for a system, or the number of inputs and outputs thata particular
programmable logic controller can handle.
IP rating: Rating system established by the IEC that defines the protection offered
by electrical enclosures. It is similar to the NEMA rating system.
K: Abbreviation for the number 1000. In computer language it is equal to two to the
tenth, or 1024.
Ladder diagram: Programmable controller language that uses contacts and coils to
define a control sequence.
LAN: See Local area network.

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LAN: See Local area network.

Leakage current: Small amount of current that flows through load-powered
sensors. The small current is necessary for the operation of the sensor. The small
amount of current flow is normally not sensed by the PLC input. If the leakage is too
great a bleeder resistor must be used to avoid false inputs at the PLC.
LED (light-emitting diode): A solid-state semiconductor that emits red, green, or
yellow light or invisible infrared radiation.
Line driver: A line driver is a differential output driver intended for use with a
differential receiver. These are usually used where long lines and high frequency
are required and noise may be a problem.
Line-powered sensor: Normally, three-wire sensors, although four-wire sensors
also exist. The line-powered sensor is powered from the power supply. A separate
wire (the third) is used for the output line.
Load: Any device that current flows through and produces a voltage drop.
Load-powered sensor: A load-powered sensor has two wires. A small leakage
current flows through the sensor even when the output is off. The current is required
to operate the sensor electronics.
LSB: Least significant bit.
Master: The master on a network is the device that controls communication traffic.
The master of a network usually polls every slave to check if it has something to
transmit. In a master-slave configuration, only the active master can place a
message on the bus. The slave can reply only if it receives a frame from the master
that contains a logical token that explicitly enables the slave to reply.
Master control relay (MCR): Hardwired relay that can be deenergized by any
hardwired series-connected switch. Used to deenergize all devices. If one
emergency switch is hit it must cause the master control relay to drop power to all
devices. There is also a master control relay available in most PLCs. The master
control relay in the PLC is not sufficient to meet safety requirements.
Microsecond: A microsecond is one millionth (0.000001) of a second.
Millisecond: A millisecond is one thousandth (.001) of a second.
MSB: Most significant bit.
Network: System that is connected to devices or computers for communication
purposes.
Nonretentive coil: A coil that will turn off upon removal of applied power to the
CPU.
Nonretentive timer: Timer that loses the time if the input enable signal is lost.
Nonvolatile memory: Memory in a controller that does not require power to retain
its contents.
Octal: Number system based on the number 8, utilizing numbers 0 through 7.

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Off-delay timer: This is a type of timer that is on immediately when it receives its
input enable. It turns off after it reaches its preset time.
Off-line programming: Programming that is done while not attached to the actual
device. For example, a PLC program can be written for a PLC without being
attached. The program can then be downloaded to the PLC.
On-delay timer: Timer that does not turn on until its time has reached the preset
time value.
One-shot contact: Contact that is only on for one scan when activated.
Parity: Bit used to help check for data integrity during a data communication.
Peer-to-peer: This is communication that occurs between similar devices. For
example, two PLCs communicating would be peer-to-peer. A PLC communicating to
a computer would be device-to-host.
PID (Proportional, integral, derivative) control: Control algorithm that is used to
closely control processes such as temperature, mixture, position, and velocity. The
proportional portion takes care of the magnitude of the error. The integral takes care
of small errors over time. The derivative compensates for the rate of error change.
PLC: Programmable logic controller.
Programmable controller: A special-purpose computer. Programmed in ladder
logic. It was also designed so that devices could be easily interfaced with it.
PPR (Pulses per revolution): This refers to the number of pulses an encoder
produces in one revolution.
Quadrature: Two output channels out of phase with each other by 90 degrees.
Retentive coil: A coil that will remain in its last state, even though power was
removed.
Retentive timer: Timer that retains the present count even if the input enable signal
is lost. When the input enable is active again, the timer begins to count again from
where it left off.
ROM (read-only memory): This is operating system memory. ROM is nonvolatile.
It is not lost when the power is turned off.
RS-232: Common serial communications standard. This standard specifies the
purpose of each of 25 pins. It does not specify connectors or which pins must be
used.
RS-422: Standards for two types of serial communication. RS-422 is a balanced
serial mode. This means that the transmit and receive lines have their own common
instead of sharing one like RS-232. Balanced mode is more noise immune. This
allows for higher data transmission rates and longer transmission distances.
RS-485: Similar to the RS-422 standard. Receivers have additional sensitivity which
allows for longer distances and more communication drops. Includes some extra
protection for receiver circuits.

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Scan time: Amount of time it takes a programmable controller to evaluate a

ladder diagram. The PLC continuously scans the ladder diagram. The time it takes
to evaluate it once is the scan time. It is typically in the low-millisecond range.
Sequencer: Instruction type that is used to program a sequential operation.
Serial communication: Sending of data one bit at a time. The data is represented
by a coding system such as ASCII.
Slave: On a master-slave configured network, there is usually one master and
several slaves. The slaves are nodes of the network that can transmit informations
to the master only when they are polled (called) from it. The rest of the time a slave
never transmits anything.
Thermocouple: A thermocouple is a sensing transducer. It changes a temperature
to a current. The current can then be measured and converted to a binary
equivalent that the PLC can understand.
Thumbwheel: Device used by an operator to enter a number between 0 and 9.
Thumbwheels are combined to enter larger numbers. Thumbwheels typically output
BCD numbers to a device.
Timer: Instruction used to accumulate time until a certain value is achieved. The
timer then changes its output state.
UL (Underwriters Laboratory): Organization that operates laboratories to
investigate systems with respect to safety.
User memory: Memory used to store user information. The users program,
timer/counter values, input/output status, and so on, are all stored in user memory.
Volatile memory: Memory that is lost when power is lost.
Watchdog timer: Timer that can be used for safety. For example, if there is an
event or sequence that must occur within a certain amount of time, a watchdog
timer can be set to shut the system down in case the time is exceeded.
Word: Length of data in bits that a microprocessor can handle. For example, a
word for a 16-bit computer would be 16 bits long, or two bytes. A 32-bit computer
would have a 32-bit word.

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