Wiring Best Practices

Overview

This section describes the wiring guidelines and associated best practices to be respected when using the TM3 system.

DANGER
	HAZARD OF ELECTRIC SHOCK, EXPLOSION OR ARC FLASH Disconnect all power from all equipment including connected devices prior to removing any covers or doors, or installing or removing any accessories, hardware, cables, or wires except under the specific conditions specified in the appropriate hardware guide for this equipment. Always use a properly rated voltage sensing device to confirm the power is off where and when indicated. Replace and secure all covers, accessories, hardware, cables, and wires and confirm that a proper ground connection exists before applying power to the unit. Use only the specified voltage when operating this equipment and any associated products. Failure to follow these instructions will result in death or serious injury.

DANGER

HAZARD OF ELECTRIC SHOCK, EXPLOSION OR ARC FLASH

Disconnect all power from all equipment including connected devices prior to removing any covers or doors, or installing or removing any accessories, hardware, cables, or wires except under the specific conditions specified in the appropriate hardware guide for this equipment.
Always use a properly rated voltage sensing device to confirm the power is off where and when indicated.
Replace and secure all covers, accessories, hardware, cables, and wires and confirm that a proper ground connection exists before applying power to the unit.
Use only the specified voltage when operating this equipment and any associated products.

Failure to follow these instructions will result in death or serious injury.

WARNING
	LOSS OF CONTROL Perform a Failure Mode and Effects Analysis (FMEA), or equivalent risk analysis, of your application, and apply preventive and detective controls before implementation. Provide a fallback state for undesired control events or sequences. Provide separate or redundant control paths wherever required. Supply appropriate parameters, particularly for limits. Review the implications of transmission delays and take actions to mitigate them. Review the implications of communication link interruptions and take actions to mitigate them. Provide independent paths for control functions (for example, emergency stop, over-limit conditions, and error conditions) according to your risk assessment, and applicable codes and regulations. Apply local accident prevention and safety regulations and guidelines.¹ Test each implementation of a system for proper operation before placing it into service. Failure to follow these instructions can result in death, serious injury, or equipment damage.

WARNING

LOSS OF CONTROL

Perform a Failure Mode and Effects Analysis (FMEA), or equivalent risk analysis, of your application, and apply preventive and detective controls before implementation.
Provide a fallback state for undesired control events or sequences.
Provide separate or redundant control paths wherever required.
Supply appropriate parameters, particularly for limits.
Review the implications of transmission delays and take actions to mitigate them.
Review the implications of communication link interruptions and take actions to mitigate them.
Provide independent paths for control functions (for example, emergency stop, over-limit conditions, and error conditions) according to your risk assessment, and applicable codes and regulations.
Apply local accident prevention and safety regulations and guidelines.¹
Test each implementation of a system for proper operation before placing it into service.

Failure to follow these instructions can result in death, serious injury, or equipment damage.

¹ For additional information, refer to NEMA ICS 1.1 (latest edition), Safety Guidelines for the Application, Installation, and Maintenance of Solid State Control and to NEMA ICS 7.1 (latest edition), Safety Standards for Construction and Guide for Selection, Installation and Operation of Adjustable-Speed Drive Systems or their equivalent governing your particular location.

Wiring Guidelines

The following rules must be applied when wiring a TM3 system:

I/O and communication wiring must be kept separate from the power wiring. Route these 2 types of wiring in separate cable ducting.
Verify that the operating conditions and environment are within the specification values.
Use proper wire sizes to meet voltage and current requirements.
Use copper conductors.
Use twisted-pair, shielded cables for analog, and/or fast I/O.
Use twisted-pair, shielded cables for networks, and field bus.

WARNING
	UNINTENDED EQUIPMENT OPERATION Use shielded cables for all fast I/O, analog I/O, and communication signals. Ground cable shields for all fast I/O, analog I/O, and communication signals at a single point¹. Route communications and I/O cables separately from power cables. Failure to follow these instructions can result in death, serious injury, or equipment damage.

¹Multipoint grounding is permissible if connections are made to an equipotential ground plane dimensioned to help avoid cable shield damage in the event of power system short-circuit currents.

NOTE: Surface temperatures may exceed 60 °C (140 °F).

To conform to IEC 61010 standards, route primary wiring (wires connected to power mains) separately and apart from secondary wiring (extra low voltage wiring coming from intervening power sources). If that is not possible, double insulation is required such as conduit or cable gains.

Rules for Removable Screw Terminal Block

The following tables show the cable types and wire sizes for a 3.81 pitch removable screw terminal block (I/Os and power supply):

The following tables show the cable types and wire sizes for a 5.08 pitch removable screw terminal block (I/Os and power supply):

The use of copper conductors is required.

DANGER
	FIRE HAZARD Use only the correct wire sizes for the maximum current capacity of the I/O channels and power supplies. Failure to follow these instructions will result in death or serious injury.

Rules for Removable Spring Terminal Block

The following tables show the cable types and wire sizes for a 3.81 pitch removable spring terminal block (I/Os and power supply):

The following tables show the cable types and wire sizes for a 5.08 pitch removable spring terminal block (I/Os and power supply):

The use of copper conductors is required.

DANGER
	FIRE HAZARD Use only the correct wire sizes for the maximum current capacity of the I/O channels and power supplies. Failure to follow these instructions will result in death or serious injury.

The spring clamp connectors of the terminal block are designed for only one wire or one cable end. Two wires to the same connector must be installed with a double wire cable end to help prevent loosening.

DANGER
	LOOSE WIRING CAUSES ELECTRIC SHOCK Do not insert more than one wire per connector of the spring terminal blocks unless using a double wire cable end (ferrule). Failure to follow these instructions will result in death or serious injury.