Section 5.

4 – PLC/DCS
Cabinet Construction

Next Slide 5.4.1

Section 5 Index
 PLC/DCS Control Cabinets

Top internal-wiring cable-trays are interconnected with Bottom field-wiring cable-trays are not interconnected Top internal-wiring cable-trays are interconnected with
each other, but not our bottom field-wiring cable-trays. with each other yet. each other – corresponding panel cuts are nicely done
and well protected against sharp-edges that could harm
our wiring.

Multiple panels needs to be interconnected with each other by means of common cable-trays/ducts for the internal and field wiring (200x150mm),
but each panel should be separated from each other using a non-combustible plate - e.g. using the original metal side covers and make proper cuts
for interconnecting the internal and field cable-trays/ducts (see photo far to the right).
Note: separating the panels by using non-combustible plates would minimize the damage in case of a fire.

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Section 5.4 Index
 PLC/DCS Control Cabinets
This is a good example of proper
wire terminations: clear/long-
lasting labels and proper cable-
shoes are used.

We should use proper rated/insulated cable-shoes and clear/long-lasting labels for terminating each cable-conductor/wire; take note that cupper is
very soft and which will be damaged when terminated directly without using a proper cable-shoe.
We should reserve sufficient space around the terminal-blocks (40mm to 50mm) in order to terminated the wiring conveniently.

Instrumentation Earth Bar (IE) and Protection

DC feeder terminal-blocks should
come along with fused LED fuse-
blown indicators, e.g. Phoenix’s
HESI-LED terminal-blocks, to ease
upon maintenance/trouble-shooting.
Earth Bar (PE) needs to be totally isolated from
each other and installed at the bottom of
corresponding control system panel (for
Each terminal-block should come along
attaching our incoming field-cables to
with a ‘knife’ disconnect for isolating the
corresponding bar directly) – corresponding bars
field from corresponding control system’s
should be made from galvanized cupper, at least
IO-cards when maintenance/welding
15-20mm wide and 2-3mm thick.
activities takes place.

Terminal blocks must be labeled properly, using unique and long-lasting labels; the labels
should identify IO-type as well, e.g. ‘DO’ to identify that corresponding terminal blocks are
assigned for Digital Outputs.
It is preferred using Phoenix made terminal-blocks.

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Section 5.4 Index
 PLC/DCS Control Cabinets

Terminals, cable-trays, wiring etc should be gray for non-Intrinsically Safe (non-IS) equipment.
Terminals, cable-trays, wiring etc should be blue for Intrinsically Safe (IS) equipment.
Terminals, cable-trays, wiring etc should be orange for SIL1/2/3/4 (Safety Integrity Leveled) equipment.
Corresponding IS/SIL-cabinets should contain IS/SIL equipment only; we should not allow non-IS/SIL equipment/wiring in such
cabinets to prevent mixing them up.

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Section 5.4 Index
 PLC/DCS Control Cabinets
Cabinets should be thought of as ‘2-
dimensional’. In other words, components
should only be mounted upon the back plate.
Mounting components on the sidewalls leads
to safety problems reaching around side
mounted items to get to terminals on the
back.

PLC/DCS control cabinets should be well organized, all wiring and incoming cabling properly labeled using long-lasting labels.
Cable-trays should be used to manage and guide all wiring/cabling properly, staying well below 60% of cable-tray filling – we
should see single insulated cables at the panel bottom and corresponding terminal blocks only.
PLC/DCS control cabinet bottoms should be sealed off properly to prevent dust, humid air or animals (such as rats) from penetrating
into corresponding cabinet.
PLC/DCS control cabinets should be IP31 rated or higher.

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Section 5.4 Index