Novi Popovac plant

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Automation Concept
Novi Popovac Plant

Remarks to this document:

This document defines the basics of the automation concept for the Novi Popovac
(NP) plant. The basis for it was a draft document done by the NP personnel.
This new release has been worked out during an E-workshop in November 2007 by
the NP plant personnel together with HGRS assistance.
The document will serve as basis to work out all needed mechanical end electrical
documents to apply this new automation standard for PCS upgrade projects and
new projects in Novi Popovac plant.
The here described concept refers as much as possible to the Holcim standard
criteria which have to be taken in consideration in unclear understanding.
The document is mostly complete yet. Several topics have to be completed by the
plant.
They are marked in red.

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Modifications
Version
V 1.0

Date
30.11.2007

Modification
First release created during the E-workshop
in Nov 2007 in Novi Popovac on the basis of
a draft release V6.6 from NP personnel

Autor
NP Personnel
R. Stingelin HGRS

APPENDIX "Typical IO wiring" has been

revised by the NP plant personnel.
This release will be frozen in HGRS as
internal Report.

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Content
1. General Standards..............................................................................................................................6
1.1 Automation System.........................................................................................................................6
1.2 HAC...............................................................................................................................................6
1.3 Cabling concept.............................................................................................................................6
1.4 Documentation...............................................................................................................................6
1.5 Voltage levels.................................................................................................................................7
2. Local Controls.....................................................................................................................................8
2.1 Types of local commands................................................................................................................8
2.2 Code definition for local commands to use in HDRS....................................................................10
2.2.1 Code for the buttons...............................................................................................................10
2.2.2 Codes for command box type................................................................................................10
2.2.3 Code example for local controls in HDRS.............................................................................11
3. Local Isolators...................................................................................................................................12
4. Cabling..............................................................................................................................................12
4.1 Standard for cables......................................................................................................................12
4.1.1 Color abbreviations DIN IEC 757..........................................................................................12
4.1.2 Colors of power cables (IEC / DIN VDE 293).......................................................................12
4.1.3 Standard control cables (DIN 47100) ....................................................................................13
4.1.4 Direct wiring..........................................................................................................................14
4.1.5 Cross sections for power cables.............................................................................................14
4.1.6 Typical cable definition in HDRS (Field F4A)......................................................................14
5. DMC Standard..................................................................................................................................15
5.1 General DMC Design...................................................................................................................15
5.2 Mechanical DMC module design.................................................................................................15
5.2.1 Wiring and cabling for DMC.................................................................................................16
5.2.2 Typical wiring for a 230V single phase consumer control.....................................................19
5.2.3 Typical wiring for a 24V consumer control...........................................................................22
5.3 Code definition for MCC treatment in HDRS...............................................................................23
5.3.1 List for voltages.....................................................................................................................23
5.3.2 Code for supply location........................................................................................................23
5.3.3 List for DMC-types................................................................................................................24
5.3.4 List for DMC standard power ranges.....................................................................................24
5.3.5 Examples for DMC-Code......................................................................................................24
6. Subsystems........................................................................................................................................25
7. Control room concept ......................................................................................................................26
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7.1 CCR, Engineering and Production meeting Room.......................................................................26

7.2 PLC and PC & Server Room........................................................................................................27
8. UPS concept......................................................................................................................................28
9. PCS / HMI Concept and Layout......................................................................................................29
10. PCS IO Box design.........................................................................................................................30
10.1 Concept for the DMC and DIO box............................................................................................30
10.2 Typical DIO module design........................................................................................................31
10.2.1 Typical wiring for field IO Box (DIO).................................................................................31
11. Standard wiring..............................................................................................................................32
11.1 Standard wiring of local motor control......................................................................................32
11.2 Standard wiring of local valve control ......................................................................................32
11.3 Typical wiring of DMC interface signals for Motors/Valves......................................................33
11.4 Standard wiring of MCC interface signals for valves and single phase consumers
...........................................................................................................................................................38
11.4.1 Typical wiring for a 24V consumer control.........................................................................39
11.5 Typical wiring of analog devices................................................................................................41
11.6 Typical wiring of digital devices.................................................................................................42
11.7 Wiring for rope switches............................................................................................................44
12. Other engineering standards.........................................................................................................46
12.1 List of used standard record sets in HDRS.................................................................................46
12.2 List of used formal records sets in HDRS...................................................................................47
12.3 Definitions in HDRS for direct wiring in DMC..........................................................................48
13. Appendix Action list......................................................................................................................49
14. Appendix Typical IO wiring applied in NP plant........................................................................50
14.1 IO-wiring ET200S......................................................................................................................50
14.1.1 Digital Input 24V 2 wire .....................................................................................................50
14.1.2 Digital Input 24V 3 wire .....................................................................................................51
14.1.3 Digital Output 24V..............................................................................................................51
14.1.4 Analog Input 24V 2 wire.....................................................................................................52
14.1.5 Analog Input 24V 4 wire.....................................................................................................52
14.1.6 RTD Input 2 wire.................................................................................................................53
14.1.7 RTD Input 3 wire.................................................................................................................53
14.1.8 RTD Input 4 wire.................................................................................................................54
14.1.9 Analog Output current.........................................................................................................54
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1.

GENERAL STANDARDS

1.1

Automation System

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The PCS standard will be made from Standard-Hardware and also from Standard
software as following:

PCS software standard is Siemens (CEMAT Holcim) based on Holcim

design criteria and on process control system SIMATIC PCS 7.

Process stations shall be S7-416. IO modules for DMC and Field IO (DIO) will
be ET200S.

The engineering will be done with the HDRS database

1.2

HAC
The HAC is currently used and will be applied for all new projects and PCS upgrade.
HAC coding and Electrical flow sheets (E-Flow sheets) shall be updated before each
control system implementation.

1.3

Cabling concept
Following cabling basics has been agreed:

The two wire concept will be applied:

2 wires = 1 signal = 1 data record
1 wire = 1 terminal

If the shield has to be electrically connected, this should be done on the field
IO box side

Decentralized MCC (DMC) and Field I/O will be applied

The field bus will be a redundant with fiber optic ring combined with copper
bus segments (Profibus)

1.4

Documentation
HDRS is the engineering and documentation database of HGRS. It contains all
mechanical, electrical and signal information, required for programming and serving
the PCS.

HDRS03 will be applied for project execution and maintenance including the
documentation

E-Flowsheets will be done as per Holcims standards with standards symbols

linked to HAC.

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1.5

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Voltage levels
Voltage level
High Voltage MV

Voltage
Remark
110'000 MV Incoming

Medium Voltage distribution MV

6000

MV Distribution

Low Voltage (VSD)

690

Used for VSD

Low Voltage LV (3 phase)

Low Voltage LV (single phase)

400
230

LV Drives (MCC)
Low power consumers
(Instruments, valves etc)

Control Voltage

24

PCS IO devices, Transmitters etc.

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2.

LOCAL CONTROLS

2.1

Types of local commands

Typical arrangements of local commands for drive- and valve controls combined in DMC
box
Normal
Reversible

Valve
open only

0
(Seldom applied)

Normal
increase/decrease

Reversible
increase/decrease

If a motor has no DMC (e.g. big mill motor) these local command arrangements will
be placed on the door of a field IO box or on a separate box near the drive (very
seldom).

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For bucket elevators two DMC circuits will be built together in one box. Due to safety
rules both motors have to be local isolated and locked with separated isolators.
Existing DMC will be modified accordingly.
Typical arrangements of local commands for a bucket elevator
-with a main drive and an auxiliary drive combined in one DMC box
Normal main and auxiliary drive
Main

Aux

Local command control for valves integrated into a Field IO box

Open only

Open / Close

Field IO box

Field IO box

In case of space problems a start/stop button pair for

valves can be replaced with a 2 position tip switch.

Actual existing two position switches for valves will be replaced by push button pairs
or by spring-returned switches during the PCS upgrade

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2.2

Code definition for local commands to use in HDRS

2.2.1

Code for the buttons

Code

G
S
F
R
O
C
I
D
X
Y
Z
U
D

2.2.2

Type command button

Button GO
Button STOP
Button FORWARD
Button REVERSE
Button OPEN
Button CLOSE
Button INCREMENT
Button DECREMENT
Start to X position (Open)
Start to Y position (Close)
Start to Z position (middle position)
Button UP
Button Down

Label
START
STOP
NAPRED
NAZAD
OTVARANJE
ZATVARANJE
POVEAVANJE
SMANJIVANJE
POZICIONER ZATVOREN
POZICIONER OTVOREN
POZICIONER SREDINA
GORE
DOLE

Codes for command box type

Code

1B
2B
3B
4B
5B

Number of command button

1 Button
2 Button
3 Button
4 Button
5 Button

2S

2 Position Switch (for valves only)

Code

Location of command button

On DMC box
On Field IO box (DIO)
On Local command box (seldom used)

D
F
L

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Code example for local controls in HDRS

Code

2BD-GS
3BD-FRS
4BD-GSID
2SD-OC
3B
..D
.. -FRS

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Description
2 button / GO STOP
3 buttons / FORWARD, REVERSE
4 buttons / GO, STOP, INCREMENT, DECREMENT
2 position switch Open / Close (for valves only)
How much buttons used
e.g. 3B = 3 buttons
D = button in DMC integrated
F = Buttons in Filed IO box (DIO)
L = Local command box
delimiter
Type of buttons applied

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LOCAL ISOLATORS
In the DMC's the motor circuit breakers can also be switched manually. Therefore
they will be applied also as local isolators. In the exceptional case of use of a
separated local isolator, the isolator type will be written direct to the assigned field in
HDRS.

4.

CABLING

4.1

Standard for cables

4.1.1

Color abbreviations DIN IEC 757

English abbrev.
DIN IEC 757
(DIN VDE 0293)

Color
black
brown
red
orange
yellow
green
blue
violet
grey
white
pink
turquoise

4.1.2

Abbrev
BK
BN
RD
OG
YE
GN
BU
VT
GY
WH
PK
TQ

Colors of power cables (IEC / DIN VDE 293)

Cable
Type
New application L N PE
New application L1 L2 L3 PE

Color Color Color

L1
L2
L3
BN
BN
BK
GY

Color
N
BU

Color
PE
YE/GN
YE/GN

HAC
code
P03
P04

Most of these existing power cables match these definitions.

In case of old cables they will be changed during the PCS upgrade

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Standard control cables (DIN 47100)

Colors of control cable (DIN 47 100)
Wire No

Cable
4 wires
(H04)

1
2
3
4

WH
BN
GN
YE

Cross section is 0.5mm2. The cable has a shield with shield wire
Actual several already installed control cables have no shield.
In future only control cables with shield will be applied

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4.1.4

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Direct wiring
For direct wiring in the MCC panels and IO field boxes wire pairs with color
combination as following will be used:

4.1.5

Wire

Color

DI signal wire +

GY

DI signal wire -

PK

DO signal wire +

BK

DO signal wire -

PK

Ana signal wire +

OR

Ana signal wire -

PK

24V Supply wire +

RD

24V Supply wire -

BU

Cross sections for power cables

Current

Cross section

[A]

[mm2]

<=

001.5

<=

16

002.5

<=

20

004

<=

25

006

<=

40

010

Cross section for cables longer than the indicated max length has to be calculated
manually

4.1.6

Typical cable definition in HDRS (Field F4A)

Example HDR Field F4A

Description

P03-001.5

Power cable 3 x 1.5

mm2

P04-004

Power cable 3 x 10

mm2

H04

Control cable

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5.

DMC STANDARD

5.1

General DMC Design

Generally, the following topics have to be treated:

5.2

Types of DMC modules

Standard DMC drawings

Mechanical DMC module design

Following two typical examples for DMC as they have been already applied and will
be applied also in the future
Typical DMC for motor normal

Typical DMC for motor reversible

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5.2.1

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Wiring and cabling for DMC

The already existing wiring and cabling for the DMC will be applied with a minimum
of modification for future applications.
The main design for the infrastructure for DMC and field IO boxes (DIO) will be
similar.
(See also the description for the field IO boxes below in this document)
Following the actual used example for a normal drive and a reversible drive:
Motor normal

DMC Standard IO

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Additional field IO

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Motor reversible

DMC Standard IO

Additional field IO

Motor with VSD and soft starter

PTC's will be connected direct to the VSD or soft starter. Its signal will be defined in
HDRS as virtual objects with a HAC like @@@-@@@.TM
Temperature measurements on the drive windings have to be done as individual
measurement fore every PT100 with ET200 RTD modules.
Direct supplied consumers with breaker protection.
For direct supplied 400V consumers (e.g. actuators, subsystems etc) the DMC will
be reduced to the breaker/isolator. As standard signals only the signal :K and :DK
will be applied.
Based on the examples above, standard drawings have to be created for the
following types of 3 phase LV consumers:
- DMC for normal drive (3ph)
- DMC for reversible drive (3ph)
- DMC for LV VSD normal drive (3ph)
- DMC for LV VSD reversible drive (3ph)
- DMC for LV Soft starter normal drive (3ph)
- DMC for Damper drive (3ph)
- DMC for Bucket elevator with main and auxiliary drive (3ph)
- DMC for Direct Breaker Load (3ph)

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The wires for standardized signals in the DMC will be labeled as following
Signal
M1:D
M1:DX
M1:DY
M1:DK
M1:K
M1:R
M1:RX
M1:RY
M1:S
M1:G
M1:GX
M1:GY
M1:INC
M1:DEC

Wire
+
+
+
+
+
+
+
+
+
+
+
+
+
+
-

Wire label
D+
DDX+
DXDY+
DYDK+
DKK+
KR+
RRX+
RXRY+
RYS+
SG+
GGX+
GXGY+
GYINC+
INCDEC+
DEC-

In the HDRS the color information will be defined as combination of the wire color
and the wire label.
(e.g.)
Signal
M1:R

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Wire
+
-

HDRS color definition in field F4B2 / F4C2

GY/D+
PK/D-

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5.2.2

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Typical wiring for a 230V single phase consumer control

The following types for single phase consumers will be applied:
Type of 230V consumer

Applied for

Direct supplied non switched consumers

protected by a common breaker
Direct supplied relays switched consumers
protected by a common breaker
Direct supplied non switched consumers
protected by it own common breaker with
auxiliary contact (signal :K)
Direct supplied relays switched consumers
protected by it own common breaker with
auxiliary contact (signal :K) and with a relays
contact feedback (signal .R)

Digital and analog sensors

and transmitters etc
Valves, warning devices etc
e.g. 230 V actuator
seldom used
e.g. heating's etc

The signal wiring of all these four typicals will be done by direct signal connection to
the hardware terminals the equipment:
Following the four typicals:
Direct supplied 230V consumer with
common beaker
L
N
PE

Hardware concept for direct supplied

230V consumer with common beaker
N

521-BE1.L1

Common breaker

PE

to load

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PE N L

L
P N L
to load

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Direct supplied 230V consumer

with it own beaker

Hardware concept for direct supplied

230V consumer with it own beaker.

L
N
PE

L
N
12

:K

PE

521-MW1.V1

11

to load

PE N L

PE N L
to load

:K
to IO

Hardware concept for a relays switched 230V

consumer with common beaker

Relays switched 230V consumer

with common beaker

L
N
PE

+ A1
PE

to load

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A2

:D

521-MW1.V1

Common breaker

PE N L

Relays
24 V DC

PE N L
to load

:D
To IO

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Relays switched 230V reversible consumer with

common beaker
L
N
PE

Hardware concept for a relays switched 230V reversible

consumer with common beaker
N

Common breaker

+ A1

+ A1
PE

:DX

A2

521-MW1.V1

:DY

A2

Relays
24 V DC

PE N L1 L2

Relays
24 V DC

L1 L2

:DX

PE N L1 L2
to load

to load

Relays switched 230V consumer with beaker

and relays contact feedback

:DY
To IO

Hardware concept for a Relays switched 230V consumer

with beaker and relays contact feedback
L

L
N
PE

12

:K

21
22
+ A1
PE

:R

521-MW1.V1

11

PE N L

Relays
24 V DC

:D

A2
PE N L
to load

:D

:R

to IO

:K
to IO

to load

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5.2.3

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Typical wiring for a 24V consumer control

For several 24V consumers (e.g. warning devices) the following typical wiring will be
used as already applied.
Relays switched consumer 24V supplied
24V
0V

Hardware concept for a relays switched reversible

consumer 24V supplied
0V 24V

+ A1

:DX

+ A1
- A2
0V

:DY

521-MW1.V1

- A2

0V X Y

Relays
24 V DC

Relays
24 V DC

to load

0V X Y
to load

:DX

:DY
To IO

Single phase consumer controls will be placed in DMCs, in field IO Boxes or in

separate panels.

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5.3

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Code definition for MCC treatment in HDRS

This code is helpful to define MCC types in HDRS

5.3.1

List for voltages

Voltage code

Description

110K
020K
6000
0690
0400
0230
0024

110 kV AC
20 kV AC
6 kV AC
690 V Ac
400 V Ac
230 V AC
24 V DC

In a real application only the needed types have to be defined and used
5.3.2

Code for supply location

For the different supply locations the following code will be applied
Feed-Type
FB
PP
DM
SS
LV
MV

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Description
Field Box
Power Panel (for non process loads)
Decentralized MCC (DMC)
Sub Station (for MV motors)
Low Voltage Distribution
Medium Voltage Distribution (for MV motors)

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5.3.3
List for DMC-types
The following code will be applied:

5.3.4

DMC-Type
NOR
NSS
NFC

Description
NORmal drive
Normal drive SoftStart
Normal Frequency Converter

REV
RSS
RFC

REVersible drive
Reversible drive Soft Start
Reversible Frequency Converter

POS
SUB

POSitioning drive (reversible)

SUBsystem

NRL
NRC

Normal ReLays
Normal Relays with Contact feedback

DIR
DBR

DIRect feed to consumer (with common breaker)

Direct feed with BReaker

XXX

Special

List for DMC standard power ranges

The power steps to realize different DMC module sizes will be the followings

5.3.5

Power code

Description

015
045
110
132

DMC < 15 kW
DMC < 45 kW
DMC < 110 kW
DMC <132 kW

Examples for DMC-Code

Code

Description

6000-MV-NOR-2200
0400-DM-REV-015
0230-DM-POS-015
0230-FB-NRL

6 kV normal drive
400 V reversible drive- 15 KW
230 V positioning drive (damper)
230 V Load (Valve) from IO in Field box

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SUBSYSTEMS
Subsystem should be connected standardized as described in the Holcim standard
design criteria. The Interface signals are similar to e normal drive standard
Alternatively, the subsystem could be connected by a bus to the PCS
Following is the typical shown in Holcim Design Criteria (Edition March 2007)

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CONTROL ROOM CONCEPT

To plan a control room the following topics have to be taken in consideration:
- Separate area for process operation
- Separate areas for process analysis, system maintenance, engineering etc
- Separate room for servers and PCS's
- Ergonomic design for 24 h working
- Air condition
- Ergonomic placement of the operator stations to get an over view over all
processes
The already existing control room concept in the plant will be treated later on
by NP.

7.1

CCR, Engineering and Production meeting Room

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7.2

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PLC and PC & Server Room

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8.

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UPS CONCEPT
Following is the typical given in Holcim Design Criteria (Edition March 2007)

The already existing UPS concept in the plant will be treated later on by NP.

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PCS / HMI CONCEPT AND LAYOUT

Actual applied layout.

The concept for the new PCS will be created in a separated Document by NP
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10.

PCS IO BOX DESIGN

10.1

Concept for the DMC and DIO box

230V normal net
230V by UPS
.IA

:K

:K

:R
230V

230V

24V

Optical
device
Optional

:D

:D

24V

24 V
Field

24 V
IO Modules

Field sensors
e. g. level
switches
etc

Actuators
e.g valves
Flashes
etc.

Actuators
e.g valves
Flashes
etc.

IO wiring
Signals
from Field

Concept drawing for local IO box

One alarm signal in every DMC or DIO box, common for all breakers, will be
foreseen as IO to the PCS. Its HAC will be the DIO HAC and HAC78 = .IA
Name example for the breaker alarm signal: 531-3S1.IA
The basic rules to name a DMC or DIO are:
HAC 78 = U1 in HDRS means always a DMC or DIO
(For VSD and soft starters the HAC .C1 will be applied as before)
The DMC boxes have the HAC of the assigned motor with HAC 78 = .U1.
Name example of such a DMC: 531-BC1.U1)
Additional Field IO boxes (DIO) will get a name of the next placed mech. equipment
without a drive. (e.g. a silo -3S1).
Name example of such a DIO:
531-3S1.U1
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Typical DIO module design

Typical actual mechanical DIO design

10.2.1

Typical wiring for field IO Box (DIO)

Drawing of an actual applied DIO.
The wiring has to be revised as following:

Auxiliary contacts to the breaker have to be added.

These auxiliary contacts of these breakers have to be connected in chain as

an input signal

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11.

STANDARD WIRING

11.1

Standard wiring of local motor control

These typical for local motor commends are not foreseen to use, but there are here
already prepared for future needs in very seldom cases
Motor reversible for VSD
Local seperator

Local control
Reversible + VSD

.M1:U
.M1:U

.M1:S

.M1:GX

.M1:GY

.M1:INC

.M1:DEC

11.2

L01

WH

L02

BN

L03

GN

L04

YE

L05

WH

L06

BN

L07

GN

L08

YE

L09

WH

L10

BN

L11

GN

L12

YE

Cable
H04

Cable
H04

Cable
H04

Standard wiring of local valve control

Valve 3 solenoid
Local control
valve 3 sol.
L01
L02
L03
L04
.V1:GX

.V1:GY

.V1:GZ

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L05

WH

L06

BN

L07

GN

L08

YE

L09

WH

L10

BN

L11

GN

L12

YE

Cable
H04

Cable
H04

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Typical wiring of DMC interface signals for Motors/Valves

The following standards match mostly the existing concept except the DMC for
reversible drive with VSD. Actual not matching connections will be modified during
the PCS upgrade
DMC Motor normal
Direct wiring to IO in DMC
D+
.M1:D

.M1:DK
.M1:K
.M1:R
.M1:G
.M1:S

DDK+
DKK+
KR+
RG+
GS+
S-

1
A4
A8
A4
A8
A3
A7

J1+
..J1
Power measurement
optional

J1-

3
4
7
8

235896279.doc

3
5
7
1
3
5
7
2
4
6
8

1
2
5
6

DO-0
DO-1

2DO
4

DI-0
DI-1
DI-2

4DI

Standard

DI-3

AI-0

AI-1

2AI
4-20mA

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DMC Motor VSD normal

Direct wiring to IO in DMC

1
A4
DK+
.M1:DK
.M1:K

DKK+
K-

A8
A4
A8

G+
.M1:G
.M1:S
.M1:INC

GS+

A3

SINC+

A7

INC-

A4

DEC+
.M1:DEC

DEC-

A8
A3
A7

..J1
Power measurement
optional

J1+
J1-

3
4
7
8

235896279.doc

3
5
7
1
3
5
7
2
4
6
8
1
3
5
7
2
4
6
8

1
2
5
6

DO-0
DO-1

2DO
4

DI-0
DI-1
DI-2

4DI

DI-3
5

DI-0

Standard

DI-1
DI-2

4DI

DI-3

AI-0

AI-1

2AI
4-20mA

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DMC Motor reversible

Direct wiring to IO in DMC

DX+
.M1:DX

.M1:DK
.M1:K
.M1:RX
.M1:GX
.M1:S
.M1:DY

DXDK+
DKK+
KRX+
RXGX+
GXS+
SDY+
DY-

1
A4
A8
A4
A8
A3
A7
A4
A8

RY+
.M1:RY
.M1:GY

RYGY+
GY-

A4
A8
A3
A7

J1+
..J1
Power measurement
optional

J1-

3
4
7
8

235896279.doc

3
5
7
1
3
5
7
2
4
6
8
1
3
5
7
1
3
5
7
2
4
6
8

1
2
5
6

DO-0
DO-1

2DO
4

DI-0
DI-1
DI-2

4DI

DI-3
5

DO-0
DO-1

2DO
6

DI-0

Standard

DI-1
DI-2

4DI

DI-3

AI-0

AI-1

2AI
4-20mA

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DMC Motor VSD reversible

Direct wiring to IO in DMC

1
A4
DK+
.M1:DK
.M1:K

DKK+
K-

A8
A4
A8

GX+
.M1:GX
.M1:S

GXS+
S-

A3
A7
A4

GY+
.M1:GY
.M1:INC
.M1:DEC

GYINC+
INCDEC+
DEC-

A8
A3
A7

J1+
..J1
Power measurement
optional

J1-

3
4
7
8

3
5
7
1
3
5
7
2
4
6
8
1
3
5
7
2
4
6
8

1
2
5
6

DO-0
DO-1

2DO
4

DI-0
DI-1
DI-2

4DI

DI-3
5

DI-0
DI-1
DI-2

4DI

Standard

DI-3

AI-0

AI-1

2AI
4-20mA

This typical drawing for reversible drive with VSD is not similar to the existing
standard layout. The already existing DMC's (approx 2 3) will be modified
according the new standard during the PCS upgrade

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DMC Motor normal 2 drives

Direct wiring to IO in DMC

D+
.M1:D

.M1:DK
.M1:K
.M1:R
.M1:G
.M1:S
.M2:D

.M2:DK
.M2:K
.M2:R
.M2:G
.M2:S

DDK+
DKK+
KR+
RG+
GS+
SD+
DDK+
DKK+
KR+
RG+
GS+
S-

1
A4
A8
A4
A8
A3
A7
A4
A8
A4
A8
A3
A7

J1+
..J1
Power measurement
optional

J1-

3
4
7
8

235896279.doc

3
5
7
1
3
5
7
2
4
6
8
1
3
5
7
1
3
5
7
2
4
6
8

1
2
5
6

DO-0
DO-1

2DO
4

DI-0

Main drive M1

DI-1
DI-2

4DI

Standard

DI-3
5

DO-0
DO-1

2DO
6

DI-0

Aux drive M2
DI-1
DI-2

4DI

Standard

DI-3

AI-0

AI-1

2AI
4-20mA

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Standard wiring of MCC interface signals for valves and single phase
consumers
Relays switched 230V consumer
with common beaker
L
N
PE
Common breaker

+ A1
PE

D+
:D

D-

A2

1
A4

3
5

A8

DO-0
DO-1

2DO

to load

Relays switched 230V reversible consumer with

common beaker
L
N
PE
Common breaker

+ A1
-

A2

+ A1
PE

DX+
:DX

DXDY+
DY-

:DY

1
A4
A8

3
5
7

DO-0
DO-1

2DO

A2

L1 L2

to load

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Relays switched 230V consumer with beaker

and relays contact feedback
L
N
PE

1
A4
K+

12

:K

11

KR+

21

R-

A7

+ A1

PE

A3

:R

22

A8

3
5

DI-1

7
2

DI-2

4
6

4DI

DI-3

:D

A2
D+

1
A4

Dto load

11.4.1

DI-0

A8

DO-0

3
5

DO-1

2DO

Typical wiring for a 24V consumer control

For 24V valves the following typical wiring will be applied as already done
Relays switched consumer 24V supplied
24V
0V

+ A1
-

A2

+ A1
0V

DX+
:DX

DXDY+
DY-

:DY

1
A4
A8

3
5
7

DO-0
DO-1

2DO

A2

to load

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Direct supplied 230V consumer

with it own beaker
L
N
PE

1
A4
12
11

K+
:K

K-

A8
A3

PE

L
A7

3
5
7
2
4
6
8

DI-0
DI-1
DI-2

4DI

DI-3

to load

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Typical wiring of analog devices

2 wire transmitter

From
sensor

+
4-20mA

WH
BN
GN
YE

Cable
H04

3
4
7
8

1
2
5
6

AI-0

AI-1

2AI
4-20mA

4 wire transmitter 24V supply

From
sensor

24V

4-20mA

WH
BN
GN
YE

Cable
H04

3
4
7
8

1
2
5
6

AI-0

AI-1

2AI
4-20mA

4 wire transmitter 230V supply

230 V supply

From
sensor

230V

4-20mA

WH
BN
GN
YE

Cable
H04

3
4
7
8

235896279.doc

1
2
5
6

AI-0

AI-1

2AI
4-20mA

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RTD Input 2Wire

RTD
WH
BN
GN
YE

Cable
H04

AI-1

AI-0

2AI
RTD

RTD Input 3Wire

RTD
WH
BN
GN
YE

Cable
H04

AI-1

AI-0

2AI
RTD
DD

RTD Input 4Wire

RTD
WH
BN
GN
YE

Cable
H04

11.6

AI-1

AI-0

2AI
RTD

Typical wiring of digital devices

Digital devices DI 2 wire Dn(contact) e.g. position switch, rope switch, drift switch,
notice, etc.

contact

WH
BN
GN
YE

1
Cable
H04

A4
A8
A3
A7

235896279.doc

3
5
7
2
4
6
8

DI-0
DI-1
DI-2

4DI

DI-3

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Digital devices DI 3 wire (proximity)

??
??
??

WH
BN
GN
YE

2/3 wire
proximity)

1
Cable
H04

A4
A8
A3
A7

3
5
7
2
4
6
8

DI-0
DI-1
DI-2

4DI

DI-3

Digital devices DO (contact) e.g. relay for valve, light, etc.

24 V load

235896279.doc

WH
BN
GN
YE

1
Cable
H04

A4
A8

3
5
7

DO-0
DO-1

2DO

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Wiring for rope switches

To follow the rules of safety NP plant will apply the HDRS recommendations from
standard design criteria.
Actual the rope switches have two contacts (2 x NC) but only one is wired by a
3 wire cable to the IO.
All cables for rope switches will be changed to apply the recommended cabling
concept as following
Concept of cabling for rope switches
Direct serial connection of rope switches in the DMC box

DMC
DI

Rope switch
.R1

DI

Rope switch
.R1

E51-BC1.R0

H04

1
2
3
4

H04

Bridge has to
be removed for
security loop

Safety
relay
E51-BC1.R0

Optional cascading for

more than 2 rope switches

1
2
3
4

C1

C2

Typical for rope switch interlock to MCC

(no interface relays)

521-BC1.R0

from
Rope switches
.R2 :R1

1 2 3 4

.R0
Interlock
to MCC

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Concept of cabling for rope switches (long belt)

Direct serial connection of rope switches for long distances in DIO and DMC

.R1

DMC

E51-BC1.R0

H04

DI

Rope switch
.R1

DIO

DI

Rope switch

Bridge has to
be removed for
security loop

1
2
3
4
H04

H04

.R0

Safety
relay
E51-BC1.R0
1
2
3
4

Optional cascading for

more than 2 rope switches

C1

DI

Rope switch
.R1

E51-BC1.R0

H04

DI

Rope switch
.R1

C2

1
2
3
4

H04

Safety
relay
E51-BC1.R0

Optional cascading for

more than 2 rope switches

235896279.doc

1
2
3
4

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12.

OTHER ENGINEERING STANDARDS

12.1

List of used standard record sets in HDRS

For standard record sets a HAC compliant code has to be used with the following
rules:
- The exact HAC structure has to be used like ###-###.###:#..
- For HAC 1 8 every understandable code can be created.
- HAC 9 11 has to be similar to the normally used HAC in HDRS
Using this rules the standard record sets can be used for automatic signal
generation
The following code can be applied in HDRS:

Code

ST1-DMC.MN
ST1-DMC.MR
ST1-DMC.DA
ST1-DMC.V1
ST1-DMC.V2
ST1-DMC.H1
ST1-DMC.FN
ST1-DMC.FR
ST1-ACT.Z1
ST1-DMC.MN:S
ST1-DMC.MN:K
ST1
DMC
FBX
etc
.
MN
MR
etc

Description
Examples of object HAC for standard record set

Examples for signals in a standard record set

ST1 = STandard 1 for DMCs

Delimiter
HAC for supply location (module):
DMC = Normal MCC
FBX = Field IO Box
PPA = Power Panel
Delimiter
HAC for object type:
MN = Motor Normal
MR = Motor Reversible
DA = Motor DAmper (Positioning motor)
V1 = Valve 1 solenoid
V2 = Valve 2 solenoid
FN = Frequency converter Normal
FR = Frequency converter Reversible

Create additional other standard records as you think to need them

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List of used formal records sets in HDRS

As for standard record sets you can define a HAC compliant code to be used for
formal records as template with a similar code structure
Formal records cannot be used for automatic signal generation
These formal records can be used as template to copy them to a real record
Code

FRM-DIG.D1
FRM-DIG.G1
FRM-DIG.R1
FRM-DIG.SI
FRM-DIG.SN
FRM-DIG.X1
FRM-DIG.Y1

Description
Formal records for a drift switch
Formal records for a start notification gong/flash
Formal for a rope switch
Formal for a speed switch
Formal for a speed switch
Formal for a digital switch signal (e.g. pos switch)

FRM-DIG.LM
FRM-DIG.TM

Formal for a dig limit switch max signal (HH) 230V supply
Formal for a dig limit switch max signal (HH) no supply

FRM-ANA.S1
FRM-ANA.S1:SP
FRM-ANA.T1

Formal for a analogue signal 4 wire type (internal supplied)

with set point

FRM-ANA.T2
FRM-ANA.T3
FRM-ANA.T4
FRM-ANA.TA
FRM-ANA.TB
FRM-ANA.TC

FRM
-ANA.
-

.X1

Formal for a analogue signal 2 wire type (through signal

supplied
Formal for a analogue signal 4 wire type (24 V supplied)
Formal for a analogue signal 4 wire type (120V supplied)
Formal for a analogue signal 4 wire type (internal supplied)
Formal for a analogue signal 2 wire type (RTD)
Formal for a analogue signal 3 wire type (RTD)
Formal for a analogue signal 4 wire type (RTD)

FRM = FoRMal record for new Projects (incl. field IO)

HAC for record group:
ANA = Analogue signal examples
DIG = Digital signal examples
HAC for object type:

Create additional other formal records as you think to need them

Remark:

235896279.doc

Formal HAC (e.g. FRM-DIG.R1) represents no real HAC.

Copying formal records, a complete real HAC has top be applied.
(e.g. FRM-DIG.RF to 521-BC1.R1)
After copying formal records, all field content starting with the char
"_" (place holder) has to be defined accordingly

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Definitions in HDRS for direct wiring in DMC

Related to the cable color definitions for direct wiring and to the signal definition for
the standardized signals in the DMC the color code for HDRS will be applied as
following:
Example for new DMC
Signal HAC

.M1:K
.M1:D

HAC field
F4B2
F4C2
F4B2
F4C2

Color code Field F4B2

GY/K+
PK/KBK/D+
PK/D-

Example for old DMC

Signal HAC

.M1:K

HAC field
F4B2
F4C2

Color code Field F4B2

../K+
../K-

The color code will be replaced by two points (..)

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49 / 54

APPENDIX

Action list

After finalizing this basic document the following works have to be done:

The wiring concept (A0 drawing) should by modified and finalized

All standard drawings for wiring and cabling, codes, color lists, etc, needed for
the electricians (Pocket book), have to be created.

For all defined DMC types and for the DIO standrd have to be created the
following documents:
- The mechanical layout drawing
- The electrical drawing
- The item list

The HDRS database for the standard signal records has to be created or
modified according the definitions in the cabling standard

The catalog file has to be revised according the applied terminal sockets

A training wall to train the electricians on the new cabling concept should be
created in the electro workshop including:
- All important equipment in field and MCC
- All needed lists from a HDRS database for this training.
A part of the E50 training group can be used for this training project.
e. g. The bucket elevator with all its sensors and additional one or two typical
analog sensors. (4-20ma, PT100, etc)

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14.

APPENDIX

Typical IO wiring applied in NP plant

14.1

IO-wiring ET200S

14.1.1

Digital Input 24V 2 wire

Module
+ wire

DC24V

-wire

DI0

+ wire
-wire
shield

PE

Typical HDRS data

Cabel Type
Terminal(+)
Terminal(-)
Terminal 3
Terminal 4
Terminal 5

H04
##
##

6ES7 131-4BD00-0AA0
/ 4 x Digital Input 24 V
Length [m]
color (+)
color (-)
color 3
color 4
color 5

for trunk cable only

col
col

Term/Col
Term/Col
Term/Col
Term/Col

A
B
C
D

Termination
Terminal(+)
Terminal(-)
Marshalling 3
Marshalling 4
Marshalling 5

E1A.F002/02/01
03
01

Cable 2
length2 [m]

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Digital Input 24V 3 wire

+ wire

Module
+ wire

DC24V

-wire

DI0

-wire
shield

shield
DI0
PE

6ES7 131-4BD00-0AA0
/ 4 x Digital Input 24 V

Typical HDRS data

Cabel Type

H04

Terminal(+)
Terminal(-)
Terminal 3
Terminal 4
Terminal 5

##
##

Length [m]
color (+)
color (-)
color 3
color 4
color 5

for trunk cable only

col
col
col

Term/Col
Term/Col
Term/Col
Term/Col

A
B
C
D

Termination
Terminal(+)
Terminal(-)
Marshalling 3
Marshalling 4
Marshalling 5

E1A.F002/02/01
03
01
A4

Cable 2
length2 [m]

14.1.3

Digital Output 24V

Module
+ wire
-wire
+ wire

DO0

-wire

shield

shield
PE

Typical HDRS data

6ES7 132-4BB00-0AA0
/ 2 x Digital Output 24 V

Cabel Type

H04

Length [m]

Terminal(+)
Terminal(-)
Terminal 3
Terminal 4
Terminal 5

##
##

color (+)
color (-)
color 3
color 4
color 5

for trunk cable only

col
col

Term/Col
Term/Col
Term/Col
Term/Col

A
B
C
D

Termination
Terminal(+)
Terminal(-)
Marshalling 3
Marshalling 4
Marshalling 5

E1A.F002/04/01
03
01

Cable 2
length2 [m]

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Analog Input 24V 2 wire

+ wire

Module

-wire
shield

+ wire
En+

-wire
shield

En-

PE

6ES7 134-4GB10-0AB0
/ 2 x Analog Intput 24 V 2 wire

Typical HDRS data

Cabel Type
Terminal(+)
Terminal(-)
Terminal 3
Terminal 4
Terminal 5

H04

Length [m]

##
##

color (+)
color (-)
color 3
color 4
color 5

for trunk cable only

col
col

Term/Col
Term/Col
Term/Col
Term/Col

A
B
C
D

Termination
Terminal(+)
Terminal(-)
Marshalling 3
Marshalling 4
Marshalling 5

E1A.F002/04/00
03
01
02 to 04

Cable 2
length2 [m]

14.1.5

Analog Input 24V 4 wire

Module

+ wire

+24VDC
+ wire
supply
- +

supply
- +

M0+

-wire

-wire
shield

M0-

shield

-24VDC

PE

Typical HDRS data

6ES7 134-4GB10-0AB0
/ 2 x Analog Intput 24 V 4 wire

Cabel Type

H04

Length [m]

Terminal(+)
Terminal(-)
Terminal 3
Terminal 4
Terminal 5

##
##
+
-

color (+)
color (-)
color 3
color 4
color 5

for trunk cable only

col
col
col
col

Term/Col
Term/Col
Term/Col
Term/Col

A
B
C
D

Termination
Terminal(+)
Terminal(-)
Marshalling 3
Marshalling 4
Marshalling 5

E1A.F002/05/01
01
02
03
04

Cable 2
length2 [m]

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RTD Input 2 wire

+ wire
-wire
shield

Typical HDRS data

6ES7 134-4JB50-0AB0 / 2 x RTD Input 2 wire

Cabel Type

H04

Length [m]

Terminal(+)
Terminal(-)
Terminal 3
Terminal 4
Terminal 5

##
##

color (+)
color (-)
color 3
color 4
color 5

for trunk cable only

col
col

Term/Col
Term/Col
Term/Col
Term/Col

A
B
C
D

Termination
Terminal(+)
Terminal(-)
Marshalling 3
Marshalling 4
Marshalling 5

E1A.F002/06/01
01
02
01 to 03
02 to 04

Cable 2
length2 [m]

14.1.7

RTD Input 3 wire

+ wire
-wire
shield

Typical HDRS data

Cabel Type
Terminal(+)
Terminal(-)
Terminal 3
Terminal 4
Terminal 5

H04
##
##
comp +

6ES7 134-4JB50-0AB0 / 2 x RTD Input 3 wire

Length [m]
color (+)
color (-)
color 3
color 4
color 5

for trunk cable only

col
col
col

Term/Col
Term/Col
Term/Col
Term/Col

A
B
C
D

Termination
Terminal(+)
Terminal(-)
Marshalling 3
Marshalling 4
Marshalling 5

E1A.F002/06/01
01
02
03
02 to 04

Cable 2
length2 [m]

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RTD Input 4 wire

+ wire
-wire
shield

Typical HDRS data

Cabel Type
Terminal(+)
Terminal(-)
Terminal 3
Terminal 4
Terminal 5

H04
##
##
comp +
comp -

6ES7 134-4JB50-0AB0 / 2 x RTD Input 4 wire

Length [m]
color (+)
color (-)
color 3
color 4
color 5

for trunk cable only

col
col
col
col

Term/Col
Term/Col
Term/Col
Term/Col

A
B
C
D

Termination
Terminal(+)
Terminal(-)
Marshalling 3
Marshalling 4
Marshalling 5

E1A.F002/06/01
01
02
03
04

Cable 2
length2 [m]

14.1.9

Analog Output current

If the device input is not galvanic
separated, then an additional
separation has to be foreseen

+ wire
-wire
- +

shield

Typical HDRS data

6ES7 135-4GB00-0AB0 / 2 x Analog Output current

Cabel Type

H04

Length [m]

Terminal(+)
Terminal(-)
Terminal 3
Terminal 4
Terminal 5

##
##

color (+)
color (-)
color 3
color 4
color 5

for trunk cable only

col
col

Term/Col
Term/Col
Term/Col
Term/Col

A
B
C
D

Termination
Terminal(+)
Terminal(-)
Marshalling 3
Marshalling 4
Marshalling 5

E1A.F002/06/01
01
03

Cable 2
length2 [m]

235896279.doc

924.06.2011