Manual digsy

compact
Chapter D
General Installation Guidelines
Drawing - Number: 04 68 271 000/A
Issued: 29.08.02
Stored: 29.08.02
Version: 1.0.0
File name: 04-68271A HB DCE Chapter D GIG
Prepared by: Hans-Dieter Kaiser
This manual was prepared with great care. The details and data in this document are regularly checked and updated and
are at any time subject to change without notice. Nevertheless, INTER CONTROL does not assume liability for the
correctness of the details/data in this document, since, despite great effort, mistakes cannot always be completely ruled out.
In addition, INTER CONTROL reserves the right to make at any time technical changes to the product, which can also result
in deviations from the contents of this document.
The document includes information that enjoys protection of copyright. No part of this publication may be reproduced and/or
translated into other languages without the prior written permission of INTER CONTROL.
Of course, any ideas and suggestions regarding amendments, or notes concerning possible mistakes in this document are
welcome. Please refer to INTER CONTROL.
INTER CONTROL
Hermann Khler Elektrik GmbH & Co. KG
Schafhofstrae 30
D-90411 Nrnberg
Germany
Tel.: ++49 911 9522-5
Fax: ++49 911 9522-857
E-mail: info@intercontrol.de
Internet: http://www.intercontrol.de
Chapter D - General Installation Guidelines
Manual
digsy

compact
04 68 271 000/A
Version 1.0.0
Page D-2
Table of contents
D GENERAL INSTALLATION GUIDELINES.............................................................................. D-3
D.1 Connecting the protective conductor................................................................................ D-3
D.2 Wiring proposal for switching gear cabinet...................................................................... D-4
D.3 General wiring guidelines................................................................................................. D-6
Table of figures
Figure D.1: Wiring of a control unit in a switchgear cabinet........................................................... D-4
Figure D.2: Cable connection in switchgear cabinet (see also Figure D.1) ................................... D-5
Chapter D - General Installation Guidelines
Manual
digsy

compact
04 68 271 000/A
Version 1.0.0
Page D-3
D GENERAL INSTALLATION GUIDELINES
D.1 Connecting the protective conductor
For safety reasons and for reasons of the Electro-Magnetic Compatibility (EMC) an optimal
protective ground terminal has to be assured.
The protective conductor (PE) or the ground of the vehicle is to be connected via the star-point
(central GND bar) in the switchgear cabinet to the ground screw provided for on the system
housing and/or the controller case (see illustration D.1 and illustration D.2).
This measure serves to improve the interference immunity.
ATTENTION:
From ground screw (PE) of the system housing a connection of wire cross-
section min. 2.5mm must be leaded as short as possible to the PE section of
the power supply unit or chassis/ground in the vehicle.
When using connectors featuring metal hoods and a shield, it is
possible to eliminate an additional overall-shield connection to the
ground terminal of the control unit housing.
In the case of shielded cables use always metal hoods.
The metal hoods must be conductively fastened to the housing.
In the case of potential differences between several PE - (GND) - points
(e.g., in the case of separated power supplies via different circuits) the
shield of the connecting cable must only be grounded on one side
of the control unit.
If twisted-pair, shielded cables are used the connector housings has to
be connected to GND too.
The individual shields on the open cable end must
not be connected to the overall shield or PE.
Chapter D - General Installation Guidelines
Manual
digsy

compact
04 68 271 000/A
Version 1.0.0
Page D-4
D.2 Wiring proposal for switching gear cabinet
Figure D.1: Wiring of a control unit in a switchgear cabinet
,
Data cable PE - machine
Mains or
power line
EMC Filter for power
line
EMC Filter for data
Chapter D - General Installation Guidelines
Manual
digsy

compact
04 68 271 000/A
Version 1.0.0
Page D-5
Figure D.2: Cable connection in switchgear cabinet (see al so Figure D.1)
A = Prior to connecting painted housing parts the lacquer/varnish coat on the points of
connection has to be removed.
B = Fold the shield backward and ground it coaxially with the nickel-plated cable clamps.
C = PE-bar or ground-bar made of Al, Cu or Fe nickel-plated.
D = Nickel-plated or varnished mounting plate with bare/un-insulated area around the fastening
holes (coating or lacquer must have been removed).
E = Fastening bolts on the mounting plate of the switchgear cabinet.
F = PE- GND connection to the machine. When using the device in a vehicle, the connection
from the switchgear cabinet to the chassis has to be established in the same way as the
connection from the mounting plate to the switchgear cabinet.
G = Nickel-plated washer to insure a conducting connection.
H = Nickel-plated cable clamp.
K = Connection (large-surface contact) to switching cabinet door (e.g. braided Cu-conductor).
PE or GNDbar
PE or GNDbar
Chapter D - General Installation Guidelines
Manual
digsy

compact
04 68 271 000/A
Version 1.0.0
Page D-6
D.3 General wiring guidelines
The following wiring rules should always be considered:
PE-conductors must always be wired according to VDE-regulations or equivalent regulations.
In addition, the whole mounting plate is to be used as a grounding surface.
That means: all metal parts such as housing, rails etc. are to be connected via short low-resistance
HF-connections to the mounting plate (braided Cu-conductors, nickel-plated screws etc.).
ATTENTION:
The connecting points must be free from coating/oxide, i.e., prior to connection
the varnish/coating has to be removed from the surface (see Figure D2)
The areas of the control electronics, power electronics and mains-ON/OFF must be geometrically
separated (they must not be located next to each other). This area of separation also applies to the
closed cabinet door.
ATTENTION:
All the metal parts must have low-resistance HF-connections.
1. Bright and bare connecting points
2. Surfaces protected against corrosion, e.g.: nickel-plating.
3. If possible, no oxide films on the blank surface (no coating or anodization)!
4. Connections of large-surface contact
5. Connections must be as short as possible
Beside to the normal connection to PE or GND, the VDE-rules or their equivalents of other
countries have to be considered with respect to metal parts and their HF-characteristics.