Selection and design of an appropriate functional earth (FE) in fieldbus networks in the use of copper-based networks

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1 Selection and design of an appropriate functional earth (FE) in fieldbus networks in the use of copper-based networks Speaker: Dipl.-Ing. (FH) René Heidl Company: Indu-Sol GmbH Blumenstrasse Schmoelln Appropriate functional equipotential bonding system René Heidl, Indu-Sol GmbH

and stability of your automated network.

2 The company Control networks. Localise weak points. Ensure the system availability. Indu-Sol provides comprehensive products and appropriate solutions to improve the liability and stability of your automated network. We are your partner for planning, installation, operation & maintenance! 2 Appropriate functional equipotential bonding system René Heidl, Indu-Sol GmbH

History / milestones 2002 Foundation of Indu-Sol by the two General

Schmoelln because of increasing staff 20 2004 For the first time,

PROFIBUS-INspektor is launched on the market The intended record turnover

building in Schmoelln, Establishment of a companyspecific hardware

3 History / milestones 2002 Foundation of Indu-Sol by the two General Managers with its headquarter in Gera 2009 Relocation from Gera to Schmoelln because of increasing staff For the first time, Indu-Sol achieved an annual turnover of one million euros 2006 The PROFIBUS-INspektor is launched on the market The intended record turnover of five million euros is achieved 20 Take over of the complete company building in Schmoelln, Establishment of a companyspecific hardware development department Appropriate functional equipotential bonding system René Heidl, Indu-Sol GmbH

4 Locations Headquarters: Schmoelln, Thuringia, Germany Headquarter Schmoelln 4 Appropriate functional equipotential bonding system René Heidl, Indu-Sol GmbH

5 Our employees - our potential! Total: 89 employees Back office: employees in Sales/Order Processing/Marketing/Logistics 20 employees in R&D/ product management Customer service: 20 measuring engineers and service technicians 7 sales Training: students/trainees/interns 5 Appropriate functional equipotential bonding system René Heidl, Indu-Sol GmbH

Company development number of employes 85 89 00 65 5 9 2 7 22 0 2 5 4 2002 200 2004 2005 2006 2007 2008 2009 200 20 202 20 204 Plan 205 turnover in thausens of 2.04 2.484 0 757.00.486.

6 Company development number of employes Plan 205 turnover in thausens of Plan Appropriate functional equipotential bonding system René Heidl, Indu-Sol GmbH

components Business unit Services Status

7 System availability through reliable communications Business unit Products Monitoring tools INspektors PROmanage software Diagnostic tools Infrastructure components Business unit Services Status quo analysis/ acceptance testing of fieldbus networks Inspection Troubleshooting/ emergency service Commissioning Training Business unit Consulting/support Network planning Documentation Commissioning 7 Appropriate functional equipotential bonding system René Heidl, Indu-Sol GmbH

Our expertise Indu-Sol is: Specialist in

8 Our expertise Indu-Sol is: Specialist in all aspects of fieldbus technology and Industrial Ethernet cv Experienced expert in the fieldbus relevant EMC environment cv Pioneer and research partner in the field of wireless technology cv 8 Appropriate functional equipotential bonding system René Heidl, Indu-Sol GmbH

9 Workshop structure Applicable norms DIN EN 500 (VDE ) DIN EN (machine guideline) Combined Bonding Network C DIN VDE (installation of low-voltage systems) Chapter 8 equipotential system Summary Practical experiments Shielding effect Do I need a shielded cable How I contact the shield right The influence of high shield currents in star structure low resistance / in mesh structure low impedance Impacts of short circuit caused by isolation problems 9 Appropriate functional equipotential bonding system René Heidl, Indu-Sol GmbH

Current situation Intervention statistic on the reasons for disturbed fieldbusses (PB and PN) by the PI Troubleshooting working group Common EMC experiences 90% of all the EMC disturbances trace back

10 Current situation Intervention statistic on the reasons for disturbed fieldbusses (PB and PN) by the PI Troubleshooting working group Common EMC experiences 90% of all the EMC disturbances trace back to a faulty functional earth (FE) Common EMC experiences 80 % of the later EMC stability is determined by the quality of the functional equipotential system Indu-Sol EMC experiences most of the EMC field problems does (on the end) not base on fields around the housing and/or the cable runs 0 Appropriate functional equipotential bonding system René Heidl, Indu-Sol GmbH

11 Applicable informations protectiv earth (PE) function earth (FE) Functional earth by Wikipedia Function earth (FE) is used to build an electrical installation, electromagnetically stable. Function earth (FE) is significant for an undisturbed function of electronic devices especially in a electromagnetic polluted environment like industrial evironement. Function earth (FE) is essential for the functional operation of electrical plants. There are two earth types: protective earth (PE) and functional earth (FE). Appropriate functional equipotential bonding system René Heidl, Indu-Sol GmbH

12 Applicable recommendations from the PI 2 Appropriate functional equipotential bonding system René Heidl, Indu-Sol GmbH

13 Applicable recommendations from the PI Appropriate functional equipotential bonding system René Heidl, Indu-Sol GmbH

14 Applicable recommendations from the PI 4 Appropriate functional equipotential bonding system René Heidl, Indu-Sol GmbH

15 Applicable norms DIN EN 500 (VDE ) Functional equipotential bonding in process and building automation DIN EN 500 (VDE ) Application of earth and equipotential bonding measures in buildings with information technology equipment Introduction It is the purpose of EN 500 to ensure the best earthing and equipotential bonding measures in buildings, where the operation of information technology systems is provided. EN 500 should be adapted to new buildings at least, but also to existing buildings whenever possible (e.g. during renovation work). Scope of the norm a) Electrical safety for the IT equipment (protection against currents in case of a short circuit) b) Sufficient electromagnetic compatibility of the IT system (ensuring the EMC protection about the shields) c) Reliable signal reference potential within the entire plant 5 Appropriate functional equipotential bonding system René Heidl, Indu-Sol GmbH

16 Applicable norm DIN EN Functional equipotential bonding in factory automation DIN EN (machinery guideline) Safety of machinery; electrical equipment of machines 8 Equipotential bonding 8. General requirements This section provides for protective and functional equipotential bonding requirements. Objective of the functional equipotential bonding is the reduction (see 8.): of effects caused by isolation errors influencing machine operation; * Residual current in case of a short circuit of the effects on sensitive electrical equipment caused by electrical disturbances influencing machine operation. * Reduction of effects on the signal reference potential caused by the equipotential bonding * Ensuring the shielding function Usually, the functional equipotential bonding is provided by connecting it to the protective conductor system (C). However, where the level of electrical disturbances on the protective conductor system is not low enough for a proper functioning of the electrical equipment, connecting the functional equipotential bonding to an individual conductor for functional earthing might be required. 6 Appropriate functional equipotential bonding system René Heidl, Indu-Sol GmbH

17 Combined bonding network C Functional earth (FE) + Protective earth () = Combined (+FE) bonding network (C) Functional earth Functional earth Protective earth Protective earth 7 Appropriate functional equipotential bonding system René Heidl, Indu-Sol GmbH

18 Applicable directives DIN VDE DIN VDE Construction of low-voltage systems part protective provisions - Protection in case of interference voltages and electromagnetic disturbance Different structures for equipotential bonding conductors and und earthing conductors Protective conductors in a star structured network A star-shaped network like this is used in small installations like apartments or small commercial buildings and as equipment, because they are not connected with another by signal cables. Typ A (EN 500) star structure Typ A (EN 500) improved star structure Typ C (EN 500) mesh structure 8 Appropriate functional equipotential bonding system René Heidl, Indu-Sol GmbH

19 Résumé Summary of standards regarding tasks and application of functional equipotential bonding A goog FE guarantees the good shielding function (experiment ) C star structures are not usefully for FE, but improved star structures (experiment 2) A good C for FE purpose needs not only a low resisdens, but also a low impedancy to conduct higher frequenz curents Electrical safety against residual currents caused of short circuits inside the low voltage distribution system needs a good (FE) (experiment ) Good signal reference potential (no experiment because it is to device dependent) Usually the protective earth system (PE) takes also the task of the function earth system (FE). Called, common bonding network C. 9 Appropriate functional equipotential bonding system René Heidl, Indu-Sol GmbH

Measuring point shield G Signal generator Key: 2 4 20 Appropriate

20 Experiment : Shielding effects Indu-Sol GmbH Specialist in Fieldbus Technology * 20m PROFINET cable Signaladern Signaladern * Measuring point shield G Signal generator Key: Appropriate functional equipotential bonding system René Heidl, Indu-Sol GmbH

21 Experiment : Shielding effects Indu-Sol GmbH Specialist in Fieldbus Technology Earth conductors between cabinet & field Switch cabinet Field cabinet PLC BUS BUS BUS cable track FI M Experiment : Coupling path H-field motor phase to BUS cable 2 Appropriate functional equipotential bonding system René Heidl, Indu-Sol GmbH

22 Experiment : Shielding effects Indu-Sol GmbH Specialist in Fieldbus Technology Earth conductors between cabinet & field Switch cabinet Field cabinet PLC BUS BUS BUS cable track FI M Experiment : Coupling path H-field motor phase to BUS cable 22 Appropriate functional equipotential bonding system René Heidl, Indu-Sol GmbH

23 Experiment : Shielding effects Indu-Sol GmbH Specialist in Fieldbus Technology * 20m PROFINET cable Signaladern Signaladern * Measuring point shield G Signal generator Key: Appropriate functional equipotential bonding system René Heidl, Indu-Sol GmbH

24 Experiment : Shielding effects Indu-Sol GmbH Specialist in Fieldbus Technology * 20m PROFINET cable Inoise 6 Inoise 6 Inoise generator Hnoise generator * Measuring point shield G Signal generator Key: Appropriate functional equipotential bonding system René Heidl, Indu-Sol GmbH

25 Experiment : Shielding effects Indu-Sol GmbH Specialist in Fieldbus Technology Iparasitic * 20m PROFINET cable Inoise 6 6 Hnoise generator Inoise generator * Measuring point shield G Signal generator Key: Appropriate functional equipotential bonding system René Heidl, Indu-Sol GmbH

26 Experiment : Shielding effects Indu-Sol GmbH Specialist in Fieldbus Technology Iparasitic * 20m PROFINET cable Iparasitic 6 6 Ischirm Hstörgen Inoise generator * Measuring point shield Ishield G Signal generator Ishield Key: Ishield Ishield 2 20m 20m 4 MET (Main Earth Terminal) 26 Appropriate functional equipotential bonding system René Heidl, Indu-Sol GmbH

Résumé experiment End of experiment : Shielding One-sided shield connection, does not help Shield connection about capacitors (5nF), does not help Both-sided shield connection, without an additional

27 Résumé experiment End of experiment : Shielding One-sided shield connection, does not help Shield connection about capacitors (5nF), does not help Both-sided shield connection, without an additional FE connection, does not help Too long lines (resistance / impedance) in lead to a worse shielding effect. Short connectors, tinned (low-impedance) lead to better results. Start experiment 2: polluted is not suitable for FE Regarding EN 60204: The interference potential in must be keept sufficiently low, e.g. by well-structured (MESH-). 27 Appropriate functional equipotential bonding system René Heidl, Indu-Sol GmbH

28 Experiment 2: Star structure in low-resistance/ low-impedance Indu-Sol GmbH Specialist in Fieldbus Technology * 20m PROFINET cable 6 6 * Measuring point shield Key: m MET (Main earth terminal) 28 Appropriate functional equipotential bonding system René Heidl, Indu-Sol GmbH m Inoise generator G Signal generator

29 Experiment 2: Star structure in low-resistance/ low-impedance Indu-Sol GmbH Specialist in Fieldbus Technology Earth conductors between cabinet & field Switch cabinet Field cabinet PLC BUS BUS BUS FI M 29 Appropriate functional equipotential bonding system René Heidl, Indu-Sol GmbH

30 Experiment 2: Star structure in low-resistance/ low-impedance Indu-Sol GmbH Specialist in Fieldbus Technology Earth conductors between cabinet & field Switch cabinet Field cabinet PLC BUS BUS BUS cable track FI M MET Experiment 2: Coupling path H-field motor phase to line 0 Appropriate functional equipotential bonding system René Heidl, Indu-Sol GmbH

31 Experiment 2: Star structure in low-resistance/ low-impedance Indu-Sol GmbH Specialist in Fieldbus Technology * 20m PROFINET cable 6 6 * Measuring point shield Key: m MET (Main earth terminal) Appropriate functional equipotential bonding system René Heidl, Indu-Sol GmbH m Inoise generator G Signal generator

32 Experiment 2: Star structure in low-resistance/ low-impedance Indu-Sol GmbH Specialist in Fieldbus Technology * Iparasitic 20m PROFINET cable Iparasitic 6 6 I * Measuring point shield Key: I I m MET (Main Earth Terminal) 2 Appropriate functional equipotential bonding system René Heidl, Indu-Sol GmbH m Inoise generator G Signal generator

33 Experiment 2: Star structure in low-resistance/ low-impedance Indu-Sol GmbH Specialist in Fieldbus Technology * Iparasitic 20m PROFINET cable Iparasitic 6 6 I * Measuring point shield 20m shield discharging conductor I Key: I I m MET (Main earth terminal) Appropriate functional equipotential bonding system René Heidl, Indu-Sol GmbH m Inoise generator G Signal generator

34 Experiment 2: Star structure in low-resistance/ low-impedance Indu-Sol GmbH Specialist in Fieldbus Technology * Iparasitic 20m PROFINET cable Iparsitic 6 6 I 20m shield discharging conductor * Measuring point shield I Key: I I m MET (Main Earth Terminal) 4 Appropriate functional equipotential bonding system René Heidl, Indu-Sol GmbH m Inoise generator G Signal generator

35 Experiment 2: Star structure in low-resistance/ low-impedance Indu-Sol GmbH Specialist in Fieldbus Technology * 20m PROFINET cable m shield discharging conductor * Measuring point shield Key: I I m MET (Main Earth Terminal) 5 Appropriate functional equipotential bonding system René Heidl, Indu-Sol GmbH m Inoise generator G Signal generator

36 Résumé experiment 2 End of experiment 2: Star structure in is inapplicable for FE purposes The shields close the meshes in a star-shaped thus becoming a equipotential bonding conductor. 6 Appropriate functional equipotential bonding system René Heidl, Indu-Sol GmbH

Résumé experiment 2 End of experiment 2: Star structure in is inapplicable for purposes of FE A shield discharge conductor made of copper, that is as long as the shielded fieldbus cable (tinned

37 Résumé experiment 2 End of experiment 2: Star structure in is inapplicable for purposes of FE A shield discharge conductor made of copper, that is as long as the shielded fieldbus cable (tinned wire), does not help. If the point of interference is known, small local edges would help. If unknown, use mesh : Small-meshed (and max. 20m) Tinned wire (low-impedance, already in khz range) Blank in order to develop lots of grid points and thus small meshes Start experiment : Short circuit Fig.: Subsequent meshing of the existing 7 Appropriate functional equipotential bonding system René Heidl, Indu-Sol GmbH

38 Experiment : Short circuit Indu-Sol GmbH Specialist in Fieldbus Technology Iparasitic * 20m PROFINET cable Iparasitic 6 6 Ishort circuit * Measuring point shield Key: Ishort circuit 2 20m 4 MET (Main earth terminal) 8 Appropriate functional equipotential bonding system René Heidl, Indu-Sol GmbH

39 Experiment : Short circuit Indu-Sol GmbH Specialist in Fieldbus Technology Iparasitic * 20m PROFINET cable Iparasitic 6 6 Ishort circuit * Measuring point shield Key : Ishort circuit Ishort circuit 2 20m 20m 4 MET (Main earth terminal) 9 Appropriate functional equipotential bonding system René Heidl, Indu-Sol GmbH

40 Experiment : Short circuit Indu-Sol GmbH Specialist in Fieldbus Technology Iparasitic * 20m PROFINET-Kabel Iparasitic 6 6 Ishort circuit * Measuring point shield Ishort circuit Key: Ishort circuit Ishort circuit 2 20m 20m 4 MET (Main earth terminal) 40 Appropriate functional equipotential bonding system René Heidl, Indu-Sol GmbH

41 Résumé experiment End of experiment : Short circuit (insulation error) In the event of a bad protective equipotential bonding the shields serve as short circuit conductor. The short circuit current (even ) acts physically like a high-frequency current and prefers the path of least impedance (tinned wire, e.g. the shield). A low-impedance equipotential bonding (mesh ) protects the electronics. Conclusion: The functional equipotential bonding has lots of important functions and has to be planned. C is allowed only where the interference potential is low or rather the interference potential has to be reduced. 4 Appropriate functional equipotential bonding system René Heidl, Indu-Sol GmbH

42 Measuring tool EMC-INspektor V2 Fig. : EMC-INspektor V2 Fig. 2: Example of web interface EMC-INspektor V2 42 Appropriate functional equipotential bonding system René Heidl, Indu-Sol GmbH

Measuring tools MWMZ II and LSMZ I What does low-impedance mean and how to measure it?

0, ohm at 2,2 khz / max. 5% of phase current Protective equipotential b. conductor () - max.

0, ohm at 2,2 khz / max. 00mA Motor cable shields - max. 0, ohm at 2,2 khz / max. 00mA (ca.

mw) (comparative values: max. 60W Bandschutz / max.,8 W explosion protection) Fig.

43 Measuring tools MWMZ II and LSMZ I What does low-impedance mean and how to measure it? Conductor Resistance / Impedance Current Protective conductor (PE) - max. 0, ohm at 2,2 khz / max. 5% of phase current Protective equipotential b. conductor () - max. 0, ohm at 2,2 khz / max. 00mA (BGV A) Functional equipotential b. conductor (FE) - max. 0, ohm at 2,2 khz / max. 00mA Motor cable shields - max. 0, ohm at 2,2 khz / max. 00mA (ca. 27mW) Signal cable shields - max. 0,6 ohm at 2,2 khz / max. 40mA (ca. mw) (comparative values: max. 60W Bandschutz / max.,8 W explosion protection) Fig. : Mesh resistance measuring clamp MWMZ II Fig. 2: Leakage current clamp LSMZ I 4 Appropriate functional equipotential bonding system René Heidl, Indu-Sol GmbH

Contact Indu-Sol GmbH Blumenstrasse 04626 Schmoelln Telephone:

44 Contact Indu-Sol GmbH Blumenstrasse Schmoelln Telephone: +49 (0) Telefax: +49 (0) Homepage: 44 Appropriate functional equipotential bonding system René Heidl, Indu-Sol GmbH

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