Instrumentation and Control Device Protection

Best Practices for Grounding and Bonding

PLUGTRAB Devices

TRABTECH
Application Note
2552A © PHOENIX CONTACT - 02/2009

1 Overview 2 Grounding of PLUGTRAB PT Surge

Reliability and “uptime” are essential, and the data and I/O
signals are often overlooked as sources of problems. Many
times the data and I/O signals provide the “back doors”
from which damaging transients can enter a control system
and cause damage. Contrary to popular belief, manufactur-
ers of industrial electronics seldom provide adequate surge
protection in their equipment.
Protectors
For a surge protector to be effective, it must be properly
grounded with a low impedance connection.
NOTE
Proper bonding is important to ensure grounds
are at equal potential and grounding is
effective.

To facilitate the grounding of the PLUGTRAB PT, the base

element automatically makes the surge protection ground
connection to the DIN rail.

Figure 1. PLUGTRAB PT

The Phoenix Contact PLUGTRAB PT series allows these

previously vulnerable pathways to maintain the reliability
originally intended. The PLUGTRAB PT series offers pro-
tection from even the toughest of transients - those caused
by direct or close-by lightning events.
 Instrumentation and Control Device Protection

IN OUT

REarth

Figure 2. Poor Practice - Two-point Grounding

2.1 Connecting the Grounds - Poor Practice

The use of separate connections and/or ground rods,
as shown in Figure 2, can cause unwanted voltages to
develop from surge currents flowing across the earth-
ground impedance. This voltage is in addition to the limiting
voltage of the PLUGTRAB PT, and can be considerable.
Even with small values of surge current, voltage potentials
of greater than 1000 V can be measured at the protected
equipment.

IN OUT

Figure 3. Best Practice - Single-point Grounding

2.2 Connecting the Grounds - Best Practice

For maximum performance, the ground connection of the
equipment or I/O system should be made directly to the
PLUGTRAB PT, as shown in Figure 3. This means the
equipment ground is at the same potential as the surge
protection circuit ground. This limits the large potential
difference from the surge current discharge to the surge
protection device. The only voltage that reaches the
protected electronic device is the limiting voltage of the
PLUGTRAB PT.

2 Phoenix Contact 2552A

 Instrumentation and Control Device Protection

Unprotected Protected Protection of

IN OUT Control Equipment
Controller
Input/Output

Analog IN

IN OUT

Analog OUT

To Common
Ground

Figure 4. PT…X2-BE with shields grounded through mounting rail

2.3 Proper Grounding

The PLUGTRAB prevents surge energy from reaching the
control equipment by diverting this energy to the ground
circuit. Figure 4 shows a grounding block attached to the
DIN rail. A ground wire should be connected from the
grounding block to the AC power ground. The wire should
be:
−− the same diameter/gauge as the power ground wire.
−− not placed next to or near a signal wire.
During a surge event, energy can come from several signal
cables. If multiple PLUGTRABs are used to protect differ-
ent signal lines, they will all divert the surge energy to the
ground, via the DIN rail, requiring a large diameter wire.

2552A Phoenix Contact • P.O. Box 4100 • Harrisburg, PA 17111-0100 • USA 3

Sales: 1-800-888-7388 • Technical Service: 1-800-888-7388
www.phoenixcontact.com