Emerson ControlWave Series Site Considerations For Equipment Installation, Grounding, And Wiring Manual

Emerson ControlWave Series Site Considerations For Equipment Installation, Grounding, And Wiring Manual

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Site Considerations for Equipment Installation, Grounding, and Wiring Manual
D301452X012
October 2019
Site Considerations for Equipment
Installation, Grounding, and Wiring
Manual
FB3000 Remote Terminal Unit (RTU)
FB1100/1200 Flow Computer
FB2100/2200 Flow Computer
ROC800, FloBoss
107, ControlWave
Family of Flow Computers and RTUs
Remote Automation Solutions

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  • Page 1 Site Considerations for Equipment Installation, Grounding, and Wiring Manual D301452X012 October 2019 Site Considerations for Equipment Installation, Grounding, and Wiring Manual FB3000 Remote Terminal Unit (RTU) FB1100/1200 Flow Computer FB2100/2200 Flow Computer ROC800, FloBoss ™ 107, ControlWave ™ Family of Flow Computers and RTUs Remote Automation Solutions...
  • Page 2 Emerson office. You can also receive the same quality training via our live, interactive Emerson Virtual Classroom and save on travel costs. For our complete schedule and further information, contact the Remote Automation Solutions Training Department at 800-338-8158 or email us at education@emerson.com.
  • Page 3: Table Of Contents

    Site Considerations for Equipment Installation, Grounding, and Wiring Manual D301452X012 October 2019 Contents Section 1: Overview Safety Labels ......................... 1 Major Topics ......................... 2 Section 2: Protection Protecting Equipment Systems ..................... 3 2.1.1 Quality is Conformance to Requirements ..............3 Protecting Equipment and Personnel ..................
  • Page 4 Site Considerations for Equipment Installation, Grounding, and Wiring Manual D301452X012 October 2019 5.2.7 Observe High Power Conductors and Signal Warning ..........29 5.2.8 Use Proper Wire Size ....................29 5.2.9 Use Lightning Arresters & Surge Protectors .............. 30 5.2.10 Secure Wiring Connections ..................30 Section 6: Grounding and Bonding a Solar PV Array Code Requirements ......................
  • Page 5: Section 1: Overview

    Note Information contained in this document is for educational purposes. Emerson Remote Automation Solutions offers no warranties or guarantees on the effectiveness of the safety of techniques described herein. Where the safety of installations and personnel is concerned, refer to the National Electrical Code Rules and rules of local regulatory agencies.
  • Page 6: Major Topics

    Site Considerations for Equipment Installation, Grounding, and Wiring Manual D301452X012 October 2019 CAUTION DANGER TO PERSONNEL AND EQUIPMENT Observed all precautionary signs posted on the equipment. Failure to do so may result in injury to personnel or cause damage to the equipment. SAFETY FIRST General instructions and safety reminders.
  • Page 7: Section 2: Protection

    Site Considerations for Equipment Installation, Grounding, and Wiring Manual D301452X012 October 2019 Section 2: Protection This section covers the following topics: ▪ Protecting Equipment Systems ▪ Protecting Equipment and Personnel ▪ Other Site Safety Considerations Protecting Equipment Systems Electrical equipment is susceptible to damage from a variety of natural and man-made phenomena.
  • Page 8: Considerations For Protecting Personnel

    Site Considerations for Equipment Installation, Grounding, and Wiring Manual D301452X012 October 2019 materials (HAZMAT) training on materials present (or potentially present) as required by OSHA, the customer, and other regulatory agencies. Considerations for Protecting Personnel Always evaluate the site environment as though your life depends on it. Make sure that you understand the physical nature of the location where you will be working.
  • Page 9: Other Site Safety Considerations

    Site Considerations for Equipment Installation, Grounding, and Wiring Manual D301452X012 October 2019 Table 2-2: Considerations for Protecting Equipment Guide Reference Environment: Class I, Division 2 – See appendices in hardware instruction Nonincendive manual. Environment: Class I, Division 1 - Intrinsically Safe Other: Safe or unrated area Earth Ground - Established by...
  • Page 10 Site Considerations for Equipment Installation, Grounding, and Wiring Manual D301452X012 October 2019 AC-powered equipment with a conductive case should have the case grounded. If you do not see a chassis ground wire, do not assume that it is safe to touch this equipment. If you notice that equipment has been grounded to pipes, conduit, structural steel, etc., you should be cautious.
  • Page 11: Section 3: Grounding And Isolation

    Isolating Equipment from the Pipeline Power and Ground Systems Controllers and flow computers from Emerson Remote Automation Solutions support DC power systems. AC power supplies are not provided. Our devices typically include a ground lug that accommodates up to a #4 AWG size stranded copper wire for establishing a connection to Earth ground.
  • Page 12: Establishing A Good Earth Ground

    Site Considerations for Equipment Installation, Grounding, and Wiring Manual D301452X012 October 2019 3.3.1 Establishing a Good Earth Ground A common misconception of a ground is that it consists of nothing more than a metal pipe driven into the soil. While such a ground may function for some applications, it is not suitable for a complex system of sophisticated electronic equipment.
  • Page 13 Site Considerations for Equipment Installation, Grounding, and Wiring Manual D301452X012 September 2019 3.3.1.2 Soil Types Table 3-1 details good and poor soil types. Table 3-1: Soil Types Good Poor Damp Loam Back Fill Salty Soil or Sand Dry Soil Farm Land Sand Washed by a Lot of Rain Dry Sand (Desert) Rocky Soil...
  • Page 14 Site Considerations for Equipment Installation, Grounding, and Wiring Manual D301452X012 October 2019 Figure 3-3: Basic Ground Bed Soil Test Setup with Additional Ground Rods With the addition of the additional ground rouds, if the GRTU still reads more than 10 ohms, mix a generous amount of cooking salt, ice cream salt, or rock salt with water and then pour about 2.5 to 5 gallons of this solution around each rod (including the test rods).
  • Page 15: Ground Wire Considerations

    Site Considerations for Equipment Installation, Grounding, and Wiring Manual D301452X012 September 2019 Rocky soil can pose many grounding problems, probably requiring a counterpoise or copper plate. Constructing a trench at the grounding site and mixing the fill with a hygroscopic salt such as calcium chloride may help for a time.
  • Page 16: Other Grounding Considerations

    Site Considerations for Equipment Installation, Grounding, and Wiring Manual D301452X012 October 2019 General Considerations The following considerations are provided for the installation of controller/flow computer system grounds: ▪ Size of ground wire (running to earth ground) should be #4 AWG. It is recommended that stranded copper wire is used for this application and that the length should be as short as possible.
  • Page 17: Isolating Equipment From The Pipeline

    Site Considerations for Equipment Installation, Grounding, and Wiring Manual D301452X012 September 2019 Gas lines also require special grounding considerations. If a gas meter run includes a thermocouple or RTD sensor installed in a thermowell, connect the well (not the sensor) to a gas discharge-type lightning arrester as shown in Figure 3-7.
  • Page 18: Meter Runs With Cathodic Protection

    Site Considerations for Equipment Installation, Grounding, and Wiring Manual D301452X012 October 2019 Figure 3-8: Remote Installation without Cathodic Protection 3.4.2 Meter Runs with Cathodic Protection Dielectric isolators are available and are always recommended as an added measure in isolating the flow computer from the pipeline even though the flow computer does provide 500V galvanic isolation from the pipeline and should not be affected by cathodic protection or other EMF on the pipeline.
  • Page 19 Site Considerations for Equipment Installation, Grounding, and Wiring Manual D301452X012 September 2019 ▪ All conductive tubing that runs between the pipeline and mounting valve manifold and/or the unit’s multivariable pressure transducer. ▪ All conductive connections or tubing runs between the flow computer and turbine meter, pulse transducer, or any other device that is mounted on the pipeline.
  • Page 20 Site Considerations for Equipment Installation, Grounding, and Wiring Manual D301452X012 October 2019 Figure 3-10: Remote Installation (with Cathodic Protection) Grounding and Isolation...
  • Page 21: Section 4: Lightning Arresters And Surge Protectors

    Site Considerations for Equipment Installation, Grounding, and Wiring Manual D301452X012 October 2019 Section 4: Lightning Arresters and Surge Protectors This section covers the following topics: Strike ▪ ▪ Use of Lightning Arresters and Surge Protector Strike Lightning takes the form of a pulse that typically has a 2 µS rise and a 10 µS to 40 µS decay to a 50% level.
  • Page 22 Site Considerations for Equipment Installation, Grounding, and Wiring Manual D301452X012 October 2019 Figure 4-1: Chance of Being Struck by Lightning Thunderstorms are cloud formations that produce lightning strikes. Across the United States there is an average of 30 thunderstorm days per year. Any given storm may produce from one to several strikes.
  • Page 23 Site Considerations for Equipment Installation, Grounding, and Wiring Manual D301452X012 October 2019 Chart 1 Chart 2 LAT.° 0.170 0.200 0.236 0.280 0.325 1069 1306 Note for these charts: I = Thunderstorm Days Per Year (isokeraunic number) A = Stroke activity for associated isokeraunic area B = Height/Stroke coefficient for associated latitude For Example: On Long Island, New York (isokeraunic number 20), Chart 1 indicates A to be 85.
  • Page 24: Antenna Caution

    Site Considerations for Equipment Installation, Grounding, and Wiring Manual D301452X012 October 2019 protection considerations listed below for units installed in areas with a high possibility or history of stroke activity. Units interfaced to a modem: In series with the phone line (as far away as possible from the equipment) - for indoor installations the lightning arrester should typically be located at the point where the line enters the structure.
  • Page 25 Site Considerations for Equipment Installation, Grounding, and Wiring Manual D301452X012 October 2019 H. Only connect the antenna cable to the radio after the mast has been properly grounded and the lead-in cable has been properly connected to lightning arresters which in turn have each been properly connected to a known good earth ground.
  • Page 26: Ground Propagation

    Site Considerations for Equipment Installation, Grounding, and Wiring Manual D301452X012 October 2019 For all systems it is best to have all communication equipment input/output grounds tied together. However additional communication equipment lightning arresters and surge protectors should be tied to the same system ground. System ground consists of the tower leg grounds, utility ground, and bulkhead equipment ground stakes that are tied together via bare copper wire.
  • Page 27: Use Of Lightning Arresters And Surge Protectors

    Site Considerations for Equipment Installation, Grounding, and Wiring Manual D301452X012 October 2019 ▪ Ensure that all above-ground interconnect runs have minimum radius bends of eight inches, run away from other conductors, and use large solid wire or a solid strap. ▪...
  • Page 28 Site Considerations for Equipment Installation, Grounding, and Wiring Manual D301452X012 October 2019 Figure 4-3: Lightning Arresters and Surge Protectors Figure 4-4: Protecting Equipment with Lightning Arresters and Surge Protectors Lightning Arresters and Surge Protectors...
  • Page 29 Site Considerations for Equipment Installation, Grounding, and Wiring Manual D301452X012 October 2019 Figure 4-5: Protecting Equipment with Lightning Arresters Lightning Arresters and Surge Protectors...
  • Page 30 Site Considerations for Equipment Installation, Grounding, and Wiring Manual D301452X012 October 2019 Lightning Arresters and Surge Protectors...
  • Page 31: Section 5: Wiring Techniques

    Site Considerations for Equipment Installation, Grounding, and Wiring Manual D301452X012 October 2019 Section 5: Wiring Techniques This section covers the following topics: ▪ Overview ▪ Intrument Wiring Overview This section provides information on good wiring practices, including good wire preparation and connection techniques.
  • Page 32: Use Twisted Shielded Pair Wiring (With Overall Insulation)

    Site Considerations for Equipment Installation, Grounding, and Wiring Manual D301452X012 October 2019 connections to a twisted shielded pair (with overall vinyl covering) to every end device. To make start-ups easier, do not use common returns. Figure 5-1. Field-wired Circuit without a Common Return Figure 5-2.
  • Page 33: Use Known Good Earth Grounds

    Site Considerations for Equipment Installation, Grounding, and Wiring Manual D301452X012 October 2019 5.2.4 Use Known Good Earth Grounds Controllers/flow computers should only have one connection to earth ground; this connection is provided via the ground lug. Since these units are DC-based systems, grounding does not take into account AC power grounding considerations.
  • Page 34: Use Lightning Arresters & Surge Protectors

    Site Considerations for Equipment Installation, Grounding, and Wiring Manual D301452X012 October 2019 Provide external strain relief (using tie wrap, etc.) to prevent the loss of slack at the controller/flow computer. Be careful to use wire that is appropriately sized for the load. Refer to the equipment manufacturer’s specifications and the National Electrical Code Handbook for information on wire size and wire resistance.
  • Page 35 Site Considerations for Equipment Installation, Grounding, and Wiring Manual D301452X012 October 2019 nicking the wire(s) when stripping insulation. Remember, nicked conductors will lead to future problems. Also remember to provide some cabling slack and strain relief. If installing stranded or braided wiring, be sure to tightly twist the end (in the same direction as manufactured).
  • Page 36 Site Considerations for Equipment Installation, Grounding, and Wiring Manual D301452X012 October 2019 Wiring Techniques...
  • Page 37: Section 6: Grounding And Bonding A Solar Pv Array

    Site Considerations for Equipment Installation, Grounding, and Wiring Manual D301452X012 October 2019 Section 6: Grounding and Bonding a Solar PV Array This section covers the following topics: ▪ Code Requirements ▪ Ground Attachment ▪ Non-Conductive Components ▪ Non-Conductive Coatings ▪ Grounding Method ▪...
  • Page 38: Non-Conductive Components

    Site Considerations for Equipment Installation, Grounding, and Wiring Manual D301452X012 October 2019 Figure 6-1. Model 30J 30W Solar Panel Protective Grounding Spot face this area to remove anodizing prior to attaching ground wire in accordance with local electrical code requirements Note that for other solar panels without a specific earth grounding point (like the Model 30J) you may employ any available mounting hole that is not already being used to mount the panel for this purpose or you may drill a new hole in an appropriate location.
  • Page 39: Grounding Method

    Site Considerations for Equipment Installation, Grounding, and Wiring Manual D301452X012 October 2019 Either carefully abrade away the anodizing at the ground point or use sharp-edged stainless-steel star washers between the ring lug and the surface (see Figure 6-2) to break through the brittle anodized layer.
  • Page 40: Corrosion Protection

    Site Considerations for Equipment Installation, Grounding, and Wiring Manual D301452X012 October 2019 electrode used. It is usually some type of terminal assembly where the bare copper wire of the grounding conductor is inserted into an aperture and then clamped firmly in place by tightening a screw or bolt.
  • Page 41 Site Considerations for Equipment Installation, Grounding, and Wiring Manual D301452X012 October 2019 Grounding and Bonding of Solar PV Array...
  • Page 42 Emerson Automation Solutions Remote Automation Solutions Emerson FZE P.O. Box 17033 © 2005-2019 Remote Automation Solutions, a business unit of Emerson Automation Jebel Ali Free Zone – South 2 Solutions. All rights reserved. Dubai U.A.E. This publication is for informational purposes only. While every effort has been made to ensure...

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