The problem of board-mounted AC inlets is not limited to the ground connection. Board-mounted AC inlets often have strain applied to them by the enclosure. This strain is transmitted to the soldered connections to the board. Solder cold-flows, and is basically unable to provide a mechanical connection (except in copper plumbing). Eventually, the connections will fail, become resistive, and overheat due to (normal) current and arcing. Fire.
Don’t rely on solder for a mechanical joint. Best regards, Rich From: Ted Eckert <[email protected]> Sent: Tuesday, September 24, 2019 10:49 AM To: [email protected] Subject: Re: [PSES] Grounding of metal cabinet In my opinion, board-mounted AC inlets are inadvisable at best. The problems extend to more than the risk of an open circuit during a ground fault. The AC inlet is used for connection of a flexible cord, and that cord will flex. Movement of the cord will put strain on the connector’s solder joints on the board. At some point, the strain will lift a pad, pull out the through-plating, crack the solder or otherwise interrupt the connection. This could happen on the ground pin leading to an open ground connection, or it could happen on a current-carrying pin leading to arcing, I personally prefer to see flying leads from an AC inlet to the circuit board. Flexible stranded wires should be used, and the ground pin should go directly to the chassis. It isn’t the most inexpensive solution, but I believe it reduces the possibility of a safety issue. Best regards, Ted Eckert Microsoft Corporation The opinions experessed are my own and do not necessarily reflect those of my employer. From: Pete Perkins <[email protected] <mailto:[email protected]> > Sent: Tuesday, September 24, 2019 10:30 AM To: Ted Eckert <[email protected] <mailto:[email protected]> >; [email protected] <mailto:[email protected]> Subject: RE: [PSES] Grounding of metal cabinet Ted et al. Since we’re discussing scenarios, let’s look at another case (which I’ve seen in practice). The issue becomes more difficult when the power inlet is mounted directly on (and, hopefully secured) then soldered to the circuit board and the manufacturer’s expectation is that screwing the circuit board down to the metal chassis provides the correct bonding for grounding. The first thing that will most likely happen is that this fault current will melt out the solder connection to the ground pin from the inlet to the circuit board and open this circuit. There may not be any accessible grounded parts (screws, connectors, etc.) on the unit but it is interconnected by cables (egg HDMI, POE, USB etc.) which carry the chassis ground between units. This fault current diverts to the ground connection provided by the cable which is not designed to be robust enough to carry the full fault current which is needed to blow the circuit breaker for the circuit providing power to this unit which has developed a hazardous fault. The protection, which seems to be in place, cannot be fully relied upon to function as needed and interrupt the current to the device and provide protection. :>) br, Pete Peter E Perkins, PE Principal Product Safety & Regulatory Affairs Consultant PO Box 1067 Albany, Ore 97321-0413 503/452-1201 IEEE Life Fellow <mailto:[email protected]> [email protected] Entropy ain’t what it used to be From: Ted Eckert <[email protected] <mailto:[email protected]> > Sent: Tuesday, September 24, 2019 6:55 AM To: [email protected] <mailto:[email protected]> Subject: Re: [PSES] Grounding of metal cabinet The rationale I remember learning is that the main grounding/earthing connection must be made in a way such that any repairs would not need to disconnect that main grounding connection. Let me use Mr. Woodgate’s examples. If you have an insulating terminal block, replacing the terminal block could disrupt the grounding connection. If the repair person fails to connect the ground on the load side, the device will likely still function, but it will have lost its safety ground. If you connect incoming ground to the chassis first, and then to the terminal block, replacing the terminal block would not disrupt the grounding connection even if the wiring on the terminal block is connected incorrectly. However, if you have a grounding terminal block, where the ground connection in the block is a direct metal connection to the chassis, replacing the terminal block would reconnect the incoming ground to the chassis. Of course the ground wring to the terminal block could be done incorrectly, but you have at least removed some of the risk of a missing grounding connection. When using appliance couplers, filtered couplers can serve multiple purposes. They can not only provide EMC filtering, they make a direct bond between incoming ground and the chassis. This would serve a similar safety purpose as a grounding terminal block. Of course, for cord connected equipment, there is the repair of replacing the cord that requires disconnecting the ground wire. All we can do is to make the design fool-resistant. Nothing can be foolproof in this world of talented fools. Best regards, Ted Eckert Microsoft Corporation The opinions experessed are my own and do not necessarily reflect those of my employer. From: Bill Owsley <[email protected] <mailto:[email protected]> > Sent: Monday, September 23, 2019 9:45 PM To: [email protected] <mailto:[email protected]> Subject: Re: [PSES] Grounding of metal cabinet Our safety regulators have insisted that power cord safety ground/earth go first to the metal chassis, with rare exceptions. Exception, the majority of chassis is plastic, with internal metal structures to tie it all together. Only the screw heads are exposed and tied to some of the internal metal chassis. A complex system of wires, washers, terminals, etc. were needed to ensure it was all one complex earth grounded structure. I AM NOT a safety engineer, but I do know a few ! - Bill On Monday, September 23, 2019, 07:42:11 PM EDT, Pete Perkins <[email protected] <mailto:[email protected]> > wrote: This is a great discussion. It took some work to get most of the world to use a solid, direct earth/ground connection in cabinets and equipment. CSA published detailed connection diagrams and pushed direct connection into many product standards with good results. The struggle has been since the modularization of components and units has come into play. This raises questions as to how to interconnect everything together in a way that preserves the integrity of the earthing/grounding connection when it is a principle safeguard against electric shock. As an OF (= Old Fellow, in polite company) I prefer that the earth/ground wire be tied to the mechanical structure of the cabinet or equipment first then carried to the distribution components. It is very difficult to destroy the integrity of this earthing first philosophy. There are many scenarios where the quick install/quick connect terminal block can be disconnected from the earthed rail and leave the cabinet/equipment without the needed earthing/grounding connection. Let’s keep the focus on providing the highest integrity protection scheme in place (and common practice). :>) br, Pete Peter E Perkins, PE Principal Product Safety & Regulatory Affairs Consultant PO Box 1067 Albany, Ore 97321-0413 503/452-1201 IEEE Life Fellow <mailto:[email protected]> [email protected] Entropy ain’t what it used to be From: John Woodgate <[email protected] <mailto:[email protected]> > Sent: Monday, September 23, 2019 4:19 AM To: [email protected] <mailto:[email protected]> Subject: Re: [PSES] Grounding of metal cabinet The question is how the cabinet is earthed if the PE wire goes to a terminal block. If a wire comes out of the terminal block to a stud on the cabinet, that is less reliable than a solid connection. I suggest you take the advice. It doesn't apply if the 'terminal block' is not an insulating block with metal inserts but a metal block firmly attached to the cabinet. Best wishes John Woodgate OOO-Own Opinions Only J M Woodgate and Associates www.woodjohn.uk <https://nam06.safelinks.protection.outlook.com/?url=http%3A%2F%2Fwww.woodjohn.uk&data=02%7C01%7CTed.Eckert%40MICROSOFT.COM%7C0499b9f2c8514ea23a6408d74114dd8d%7C72f988bf86f141af91ab2d7cd011db47%7C1%7C0%7C637049430187259539&sdata=p6gW%2FyfcAGCDwY8zmF%2FMshm637hsQ8xyvujuETvWo1A%3D&reserved=0> Rayleigh, Essex UK On 2019-09-23 11:33, Amund Westin wrote: A flexible 1-phase AC cable is entering a metal cabinet and the PE-wire is directly connected to an Earth terminal block (green/yellow). Some years ago, a safety engineer told me that the earth wire should first be connected to a ground stud inside the cabinet via a lug terminal climp and fastened with a nut. From the stud, a green/yellow wire should connect to the Earth terminal block. I thought it’s OK to go directly to the Earth terminal block, right? … BR Amund Westin - ---------------------------------------------------------------- This message is from the IEEE Product Safety Engineering Society emc-pstc discussion list. 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To post a message to the list, send your e-mail to <[email protected] <mailto:[email protected]> > All emc-pstc postings are archived and searchable on the web at: http://www.ieee-pses.org/emc-pstc.html Attachments are not permitted but the IEEE PSES Online Communities site at http://product-compliance.oc.ieee.org/ can be used for graphics (in well-used formats), large files, etc. Website: http://www.ieee-pses.org/ Instructions: http://www.ieee-pses.org/list.html (including how to unsubscribe) <http://www.ieee-pses.org/list.html> List rules: http://www.ieee-pses.org/listrules.html For help, send mail to the list administrators: Scott Douglas <[email protected] <mailto:[email protected]> > Mike Cantwell <[email protected] <mailto:[email protected]> > For policy questions, send mail to: Jim Bacher <[email protected] <mailto:[email protected]> > David Heald <[email protected] <mailto:[email protected]> > - ---------------------------------------------------------------- This message is from the IEEE Product Safety Engineering Society emc-pstc discussion list. To post a message to the list, send your e-mail to <[email protected]> All emc-pstc postings are archived and searchable on the web at: http://www.ieee-pses.org/emc-pstc.html Attachments are not permitted but the IEEE PSES Online Communities site at http://product-compliance.oc.ieee.org/ can be used for graphics (in well-used formats), large files, etc. Website: http://www.ieee-pses.org/ Instructions: http://www.ieee-pses.org/list.html (including how to unsubscribe) List rules: http://www.ieee-pses.org/listrules.html For help, send mail to the list administrators: Scott Douglas <[email protected]> Mike Cantwell <[email protected]> For policy questions, send mail to: Jim Bacher: <[email protected]> David Heald: <[email protected]>
