Cabling for Variable Frequency Drives

Brian Shuman, RCDD

Senior Product Development Engineer
November 3-4, 2010
Agenda
VFD's and their impact on your design
VFD Technology requires Cable Solutions
Noise ssues, Cable Longevity, System Longevity
VFD Cable installation considerations
General Recommendations and Conclusion
VFD Schematic
VariabIe Frequency Drives' Impact on
Your Design
VFDs have a significant affect on your installation
VFDs pull power off your source line in chunks and
produce very high frequency outputs
Source for harmonics
They can create significant EM and RF
They can affect other parts of the system and
neighboring systems
CabIe's RoIe in Drive System
ts Ability to Withstand the Operating
Conditions Caused by the Drive System
How it Affects Other Drive System
Components & Surrounding Equipment
CriticaI CabIe Characteristics
Ability to provide 20+ year service life
Voltage withstand capability
Sizing for currents present in Drive Systems
Environmental survival
Reduce Standing Waves
mpacts motor life, cable life, and noise levels
Cable is one of several factors in overall reflected
wave picture
Reduce radiated/coupled noise from Drive System
VFD Operation Issues
Reflected Waves
Cable Charging
Corona Discharge
Radiated Noise
Conducted Noise
RefIected Wave
Impedance Mismatch
CabIe Type ( Test
Frequency of 60Hz)
Impedance
(Ohms)
Voltage at
Motor
Terminals
Length of
CabIe
SampIe
Foil/Braid 78 1220 V 132 ft
Shielded PVC-
Nylon/PVC
38 1260 V 120 ft
Un-Shielded PVC-
Nylon/PVC
58 1220 V 106 ft
Cu - Tape Shield 58 1230 V 128 ft
Impedance vs. Peak VoItage
CabIe Charging

XLPE,
RHW-2
Focus Cable
XLPE,
XHHW-2
Standard Wire
Thickness
PVC 15 mil -
Nylon 4 mil,
THHN
Capacitance:
30pf/ft
Capacitance:
40pf/ft
Capacitance:
80pf/ft
Corona Effect - BottIing FaciIity
Copper
Conductor
1 5 miI PVC
InsuIation
1 5 miI PVC
InsuIation
Copper
Conductor
High E fieId in
1 miI air gap
Based on ~ 30% humidity exacerbated by high moisture
environments, longer runs, or smaller air gaps
InsuIation MateriaIs Comparison
Thermoplastic insulations are not recommended
Shorter life expectancy under long-term voltage stress
Less resistant to temperature extremes caused by corona
discharge sometimes present in drive applications
Thin insulations increase likelihood for corona inception
Thermoset materials (XLPE) are recommended
Exhibit ideal durability qualities for both temperature
extremes and aging characteristics under long-term
voltage stress
Due to their required thickness to meet TC standards, it
will further enhance cable longevity by reducing likelihood
of corona discharge
Radiated Emissions
Radiated Emissions
Radiated (coupled) Noise to nearby cables
High frequency, high amplitude noise
corresponding to leading-edge of PWM carrier
signal and reflected wave can be coupled to
adjacent cables (and components)
Noise on adjacent cables and components may
cause other systems to malfunction
Other susceptible equipment often affected:
encoders, capacitive sensors, thermocouples,
proximity sensors, network communications.
Radiated Noise from Motor
Source for common-mode noise
Motor frame (shell) acts like a shield to
capture radiated noise
This captured noise has two paths to
ground
Through the motor frame to the
ground grid back to the drive
Through the cable back to the
Drive
SOLUTON:
Contain the noise on the cable and
keep the noise off your ground grid
Motor Frame
acts like a
shield
Drains the
noise to
ground
Radiated Emissions
Radiated SignaI
without ShieId
Radiated SignaI
with Braid ShieId
Measured with a voltage pick-up antenna set-up using a
Cable with an 85% braid-only vs. an unshielded cable
CoupIed Noise - AII CabIes Compared
Noise CoupIed on UnshId Comm. CabIe
-16
-12
-8
-4
0
4
8
12
16
Time
V
o
I
t
s
Foil/Braid
Cu Tape
Armored
Foil
Conducted Noise
Conducted Noise
Conducted (common mode) noise from the motor affects
nearby equipment
High levels of noise couples between the windings of
the motor to building ground through the frame of the
motor
Unshielded motor leads in a conduit couple VFD output
to ground via conduit fasteners
Digital systems and proper grounding are effective at
isolating most low-frequency current
Drive square wave output couples noise that resembles
square digital communication pulses (ie 24V and 5V
systems)
Common Mode Noise (Termination)
Common Mode noise takes
path of least resistance
Factors affecting this are
infinite humidity, distance,
design, load, source, etc.
Following graph indicates
impedance across multiple
frequencies for each cable
Reduced shield and ground
impedance results in reduced
common-mode noise outside
the cable
DRVE FRAME
MOTOR
WNDNGS

MOTOR
FRAME
LTTLE HF
CURRENT
PVC
ARMOR
OR
SHELD
PE GRD
PE TE N
USER #1
PE TE N
USER #2
PE TE N
USER #n
SOLUTON: SHELD CONTROLS HF NOSE CURRENT PATH
A+
A-
+
-
PE
I
ao
Courtesy of Rockwell Automation
ShieId Resistance Comparison
* Lower resistance = improved common-mode performance
ShieId Impedance High Freq
0
5
10
15
20
25
30
35
40
5 10 100 200 300 400 500 600 800 1000
Frequency (kHz)
I
m
p
e
d
a
n
c
e

(
O
h
m
s
)
Foil/Braid
Cu Tape
Armored
Foil
VFD CabIe Advantages
CIassic VFD CabIe Features
.045 XLPE nsulation (NEC TYPE XHHW-2/RHW-2)
Full Size, nsulated Ground Wire
Shielding
85% TC Braid for EM (Low Frequencies)
100% Alum/Mylar Tape for RF (High Frequencies)
Full Size, Uninsulated Drain Wire
ndustrial Grade PVC Jacket Sunlight Resistant.
TC-ER Exposed Runs
Dual Rated 1000V/600V
MSHA Approved
Available w/ #16PR
for signals in small sizes
Large-size VFD CabIe Features
XHHW-2 nsulation
Full Size, sectioned, un-insulated
ground wires
Two, contra helically applied
copper tape shields
Each shield is 2 mils thick, with a
20-25% overlap for superior shield
coverage and low-impedance path
to ground even after installation
ndustrial Grade PVC Jacket
Sunlight Resistant.
TC-ER Exposed Runs
Dual Rated 1000V/600V
MSHA approved
New VFD CabIe Designs
Small and Large Gauge Cables available
with 2000 volt rating
Small and Large Gauge Cables available
in Low Smoke Zero Halogen designs
Environmentally friendly
Small and Large Gauge Cables available
in MC listed designs
Aluminum or steel interlocked armor
VFD CabIe Advantages
Thick, wet rated insulation = lower capacitance.
Foil + Braid / Cu Tape = better noise protection.
Full Size Drain wire + Ground = easier
termination.
TC-ER rating = no conduit required
Small OD = Small bend radius for tight enclosures
VFD FIex Life
29501
3 cond #14 XLPE + 1 #14 gnd PVC foil + braid PVC
Flexed 1.98 million flexes at 6 radius
29502
3 cond #12 XLPE + 1 #12 gnd PVC foil + braid PVC
flexed 1.82 million flexes at 6 radius
Both were tested on the Belden C-track tester
Single axis, continuous DCR monitoring
VFD CabIe InstaIIation & Termination
InstaIIation of VFD CabIe
Flexible stranding and smaller diameter allow for
bends 50% tighter than comparable VFD cables
Glands required are much less expensive and
simpler to use
Type TC ER listing allows for reduced cost and
installation flexibility
InstaIIation of VFD CabIe
Multipoint grounding is recommended,
reducing common-mode noise while harmonic
noise is drained off by the "supersized neutral
(ground)
Terminate ground (and drain if present) with a
lug or terminal strip on each end
Termination kits are available
InstaIIation of VFD CabIe (cont)
Avoid sharp bends with the conductors
Cable glands with a conductive gasket should be
used to connect the shield to the motor junction
box and drive enclosure
This avoids a gap in the shield coverage
The jacket should also be inserted into the
gland
Avoid loose conductors!
InstaIIation of VFD CabIe (cont)
Use parallel runs for high horsepower
drives/motors
Terminal strips or lugs typically required
Cable must be adequately supported
Follow local, regional and national codes, laws
and standards
VFD CabIe Termination
OptionaI
Taping
Motor Frame Housing
Tinned
Drain
Wire
Frame PE GND
Stud or Screw
Tinned
Drain
Wire
METAL or PLASTIC connector
into drive paneI or cabinet
100%
AI/MyIar
foiI
85%
tinned
Cu
braid
System PE GND
OptionaI
Taping
Motor Junction Box Housing
Motor Frame Housing
Tinned
Drain
Wire
Frame PE GND
Stud or Screw
Tinned
Drain
Wire
METAL or PLASTIC connector
into drive paneI or cabinet
100%
AI/MyIar
foiI
85%
tinned
Cu
braid
System PE GND
Motor Frame
Housing
85
tinned
Cu
braid
Foil
Shield
Ground
Wire
Drain
Wire
Frame PE GND
Stud or Screw
Optional taping
OI Ioil and braid
ConcIusion & Questions
Unshielded motor leads, unshielded cable, AL foil-only
shielded cable, and thermoplastic insulated cables are
not recommended for VFD/VSD applications
At a minimum, 30 mils of XLPE or similar insulation
should be used
Shields should be a heavy wall 100% coverage
system
Ground conductors should be oversized to handle
harmonic currents
Run lengths should be minimized and special care
must be given to proximity of the drive, motor, and
cable to susceptible components
Questions