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AC Drives - Electrical Solutions Corp

1. Max Drive Suppi 3 Line Reactor Catalog Volts HP kW KVA 1 2 Open Style 1321 1305 AA02A 240 0 5 15 3R4 A AA03A 240 0 75 20 3R4 A AA04A 240 1 30 3R8 A AAD8A 240 2 50 3R8 A AA12A 240 3 75 3R18 A BAO1A 480 0 5 15 3R2 B BA02A 480 0 75 20 3R2 B BA03A 480 1 30 3R4 B BAO4A 480 2 50 3R4 B BA06A 480 3 75 3R8 B BAO9A 480 5 100 3R18 B PowerFlex 70 20AB2P2 240 0 5 25 3R2 D 20AB4P2 240 1 50 3R4 A 20AB6P8 240 2 100 3R8 A 20AB9P6 240 3 125 3R12 A 20AB015 240 5 150 3R18 A 20AB022 240 7 5 250 3R25 A 20AB028 240 10 300 3R35 A 20AC1P3 400 0 37 15 3R2 B 20AC2P1 400 0 75 20 3R2 B 20AC3P4 400 1 5 30 3R4 B 20AC5P0 400 2 2 50 3R4 B 20AC8P0 400 4 75 3R8 B 20AC011 400 5 5 100 3R12 B 20AC015 400 7 5 150 3R18 B 20AC022 400 11 250 3R25 B 20AC027 400 15 300 3R35 B 20AD1P1 480 0 5 15 3R2 B 20AD2P1 480 1 30 3R2 B 20AD3P4 480 2 50 3R4 B 20AD5P0 480 3 75 3R4 B 20AD8P0 480 5 100 3R8 B 20AD011 480 7 5 120 3R12 B 20AD015 480 10 150 3R18 B 20AD022 480 15 250 3R25 B 20AD027 480 20 300 3R35 B 20AE0P9 600 0 5 15 3R1 B 20AE1P7 600 1 20 3R2 B 20AE2P7 600 2 30 3R2 B 20AE3P9 600 3 50 3R4 B 20AE6P1 600 5 75 3R8 C 20AE9P0 600 7 5 120 3R8 C 20AE011 600 10 150 3R12 B 20AE017 600 15 250 3R18 B 20AE022 600 20 300 3R25 B PowerFlex 700 Power Distribution 2 5
2. Reactor at No External Devices w 1204 TFB2 Term w 1204 TFA1 Terminator Drive Motor Motor Motor Motor Bor A B 1329 1329R L 1850V A or B 1329 A B 1329 A 1329 Drive Drive kW Motor Any any Any Any Cable Type 4 Cable Type Cable Type y any any Frame HP kW HP Cable Cable Cable Cable shi Unshid Cable Shid Unshid shid Unshid Cable Cable Cable A1 0 37 0 5 0 37 0 5 12 2 33 5 914 914 30 5 61 0 30 5 161 0 914 229 1829 40 110 300 300 100 200 100 200 300 75 600 0 75 1 0 75 1 12 2 133 5 914 914 30 5 130 5 130 5 130 5 914 122 9 182 9 40 110 300 300 100 100 100 100 300 75 600 0 37 0 5 112 2 133 5 914 914 Use 1204 TFA1 30 5 161 0 130 5 161 0 914 122 9 1829 40 110 300 300 100 200 100 200 300 75 600 1 2 1 5 11 2 1 5 112 2 133 5 914 914 30 5 130 5 61 0 161 0 914 229 1829 40 110 300 300 100 100 200 200 300 75 600 0 75 1 112 2 133 5 914 914 30 5 130 5 61 0 161 0 914 122 9 1829 40 110 300 300 100 100 200 200 300 75 600 0 37 0 5 112 2 133 5 114 3 121 9 30 5 130 5 161 0 161 0 1121 9 229 1829 40 110 375 400 100 100 200 200 400 75 600 A2 1 5 2 15 2 17 6 12 2 914 914 91 4 914 91 4 305 30 5 914 61 0 914 229 1829 25
3. Max Drive Suppi 3 Line Reactor Catalog Volts HP kW KVA 1 2 Open Style 1321 20BB2P2 240 0 5 25 3R2 D 20BB4P2 240 1 50 3R4 A 20BB6P8 240 2 100 3R8 A 20BB9P6 240 3 125 3R12 A 20BB015 240 5 150 3R18 A 20BB022 240 75 250 3R25 A 20BB028 240 10 300 3R35 A 20BB042 240 15 450 3R45 A 20BB054 240 20 600 3R80 A 20BC1P3 400 0 37 15 3R2 B 20BC2P1 400 0 75 25 3R2 B 20BC3P5 400 1 5 50 3R4 B 20BC5P0 400 2 2 50 3R4 B 20BC8P7 400 4 100 3R8 B 20BC011 400 5 5 120 3R12 B 20BC015 400 7 5 150 3R18 B 20BC022 400 11 200 3R25 B 20BC030 400 15 3000 3R35 B 20BC037 400 18 5 350 3R45 B 20BC043 400 22 450 3R45 B 20BC056 400 30 600 3R55 B 20BC072 400 37 700 3R80 B 20BC105 400 55 1000 3R130 B 20BC125 400 55 1000 3R130 B 20BD1P1 480 0 5 25 3R2 B 20BD2P1 480 1 30 3R2 B 20BD3P4 480 2 50 3R4 B 20BD5P0 480 3 75 3R4 B 20BD8P0 480 5 100 3R8 B 20BD011 480 75 120 3R12 B 20BD014 480 10 150 3R18 B 20BD022 480 15 250 3R25 B 20BD027 480 20 300 3R35 B 20BD034 480 25 400 3R35 B 20BD040 480 30 450 3R45 B 20BD052 480 40 600 3R55 B 20BD065 480 50 750 3R80 B 20BD077 480 60 900 3R80 B 20BD096 480 75 1000 3R100 B 20BD125 480 100 1000 3R130 B 20BD156 480 125 1000 3R160 B 2 6 Power Distribution 1336 Family e Plus e Plus ll e IMPACT e FORCE Max Drive Suppi 3 Line React
4. For information on See page System Configurations 2 1 AC Line Impedance 2 3 Surge Protection MOVs 2 7 Common Mode Capacitors 2 8 The type of transformer and the connection configuration feeding a drive plays an important role in its performance and safety The following is a brief description of some of the more common configurations and a discussion of their virtues and shortcomings Figure 2 1 Delta Wye with Grounded Wye Neutral Ja Figure 2 1 on page 2 1 is the most common It provides re balancing of unbalanced voltage with a 30 degree phase shift Depending on the output connections from the drive to motor the grounded neutral may be a path for common mode current caused by the drive output see Chapter 3 and Chapter 6 Figure 2 2 Delta Delta with Grounded Leg KT Figure 2 2 on page 2 1 is a common configuration providing voltage re balancing with no phase shift between input and output Again depending on the output connections from the drive to motor the grounded neutral may be a path for common mode current caused by the drive output 2 2 Power Distribution Figure 2 3 Ungrounded Secondary Fa Grounding the transformer secondary is essential to the safety of personnel and safe operation of the drive Leaving the secondary floating allows dangerously high voltages between the chassis of the drive and the internal power structure components Exceeding the voltage rating of the drive s input
5. 40 300 300 300 300 300 100 100 300 200 300 75 600 1 2 1 5 7 6 112 2 114 3 182 9 91 4 182 9 182 9 30 5 30 5 91 4 61 0 182 9 22 9 182 9 25 40 375 600 300 600 600 100 100 300 200 600 75 600 0 75 1 17 6 112 2 114 3 182 9 182 9 182 9 182 9 30 5 30 5 91 4 61 0 182 9 229 182 9 25 40 375 600 600 600 600 100 100 300 200 600 75 600 0 37 0 5 7 6 12 2 114 3 182 9 182 9 182 9 182 9 30 5 30 5 91 4 61 0 1829 22 9 182 9 25 40 375 600 600 600 600 100 100 300 200 600 75 600 2 2 3 2 2 3 7 6 122 914 914 182 9 182 9 182 9 Use 1204 TFB2 229 182 9 25 40 300 300 600 600 600 75 600 15 2 17 6 112 2 114 3 182 9 182 9 182 9 182 9 22 9 182 9 25 40 375 600 600 600 600 75 600 0 75 1 17 6 12 2 114 3 182 9 182 9 182 9 182 9 22 9 182 9 25 40 375 600 600 600 600 75 600 0 37 0 5 17 6 112 2 114 3 182 9 182 9 182 9 182 9 22 9 182 9 25 40 375 600 600 600 600 75 600 A3 3 7 5 3 7 5 17 6 112 2 1114 3 Note 182 9 182 9 182 9 22 9 182 9 25 40 375 600 600 600 75 600 22 8 17 6 12 2 114 3 Forapplications 182 9 182 9 182 9 22 9 182 9 25 40 375 installations using 600 600 600 75 600 15 2 76 122 t14 3 Mew motors no 1829 1829
6. 49 6261 9410 Fax 49 6261 17741 Asia Pacific Rockwell Automation 55 Newton Road 11 01 02 Revenue House Singapore 307987 Tel 65 351 6723 Fax 65 355 1733 U S Allen Bradley Drives Technical Support Tel 1 262 512 8176 Fax 1 262 512 2222 Email support drives ra rockwell com Online www ab com support abdrives Publication DRIVES INO01A EN P October 2002 P N Supersedes N A Copyright 2002 Rockwell Automation All rights reserved Printed in USA
7. Allen Bradley Wiring and Grounding Guidelines for Pulse Width Modulated PWM AC Drives Installation Instructions Rockwell Automation S7 T T1 Important User Information Solid state equipment has operational characteristics differing from those of electromechanical equipment Safety Guidelines for the Application Installation and Maintenance of Solid State Controls Publication SGI 1 1 available from your local Allen Bradley Sales Office or online at http www ab com manuals gi describes some important differences between solid state equipment and hard wired electromechanical devices Because of this difference and also because of the wide variety of uses for solid state equipment all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable In no event will the Allen Bradley Company be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment The examples and diagrams in this manual are included solely for illustrative purposes Because of the many variables and requirements associated with any particular installation the Allen Bradley Company cannot assume responsibility or liability for actual use based on the examples and diagrams No patent liability is assumed by Allen Bradley Company with respect to use of information circuits equipment or software described in
8. Shielded Un Shielded Shielded Un Shielded Shielded Un motor kHz e o shielded 0 shielded 6 o shielded 6 o shielded HP Cable Type 0 5 2 4 6 8 10 1 2 425 425 4 425 425 6 8 10 2 2 600 600 4 600 600 6 8 10 3 2 4 6 8 10 5 2 4 6 8 10 7 5 2 4 6 8 10 10 2 4 6 8 10 15 2 4 6 8 10 20 2 4 6 8 1 o Cable is Alcatel C1202 or equivalent Shielded cable with twisted conductors and no filler Cable is Belden 295xx series or equivalent Motor Cable Length Restrictions Tables A 11 Table A J PowerFlex 70 Drive with RWR or Eliminator Contact Technical Support for data not shown Carrier Type A Motor Type B Motor 1488 V Motor 1329 R L 480V frequency Shielded Shielded Un Shielded Shielded Un Shielded Shielded Un Shielded Shielded Un drive kHz e o shielded 1 shielded O o shielded o shielded motor Cable Type 0 5 2 4 600 600 6 8 10 1 2 4 600 600 6 8 10 2 2 4 600 600 6 8 10 3 2 4 600 600 6 8 10 5 2 4 600 600 6 8 10 75 2 4 200 600 6 8 10 10 2 4 200 600 6 8 10 15 2 4 6 8 10 20 2 4 6 8 10 Cable is Alcatel C1202 Or equivalent Shielded cable with twisted conductors and no filler Cable is Belden 295xx series or equivalent
9. 182 9 229 182 9 25 40 375 estrictions in lead qq 600 600 75 600 length due to volt 0 75 1 76 122 1143 208 reflection are 1829 182 9 182 9 22 9 182 9 25 40 375 necessary You 600 600 _ 600 75 _ 600 0 37 0 5 17 6 12 2 114 3 should observe 182 9 182 9 182 9 22 9 182 9 25 40 375 standard practices 600 600 600 75 600 A4 5 5 15 5 5 15 7 6 12 2 114 3 for voltage drop 182 9 182 9 182 9 244 182 9 7 5 20 7 5 20 25 40 375 cable capacitance 600 600 600 80 600 B 11 22 11 22 76 122 114 3 andotherissues 14859 182 9 182 9 244 1829 15 30 15 30 25 40 375 For PE su 600 600 600 80 600 C 3045 9045 76 122 11143 NON 1829 1829 1182 9 76 2 1829 X40 X60 40 60 25 40 375 turer for insulation 600 600 600 250 600 D 45 112 45 112 12 2 305 114 3 rating 182 9 182 9 182 9 61 0 914 60 X150 60 150 40 100 375 600 600 600 200 300 E 112 187 112 187 12 2 153 3 1143 182 9 182 9 182 9 182 9 182 9 150 250 150 250 40 175 375 600 600 600 600 600 F 187 336 187 336 18 3 153 3 114 3 182 9 182 9 182 9 182 9 182 9 250 450 250 450 60 175 375 600 600 600 600 600 G 187 448 187 448 18 3 533 114 3 182 9 182 9 182 9 182 9 182 9 X250 600 250 600 60 175 375 600 600 600
10. 225ft 152m NR NR 45m 150ft 61m 200ft 45m 150ft 76m 250ft 500ft 0 5 15m 50ft 182m 600ft 182m NR NR 76m 250ft 61m 200ft 76m 250ft 121m 400ft 600ft 0 5 0 5 15m 50ft 45m 150ft 106m NR NR NR NR NR NR 350ft 1 IMPORTANT A 3 reactor reduces motor stress but may cause a degradation of motor waveform quality Reactors must have a turn to turn insulating rating of 2100 volts or higher Reactors are not recommended for lightly loaded applications because over voltage trips may result at low output frequencies NR Not Recommended A 6 Motor Cable Length Restrictions Tables Table A E 160 Drive 480V Voltage Peak 380 460V Motor Motor Cable Only RWR at Drive Reactor at Motor Ratings leia Shielded Unshielded Shielded Unshielded Shielded Unshielded ating Volts p p meters feet meters feet meters feet meters feet meters feet meters feet 40kW 1000 13 7 45 6 1 20 160 525 183 600 99 1 325 915 300 5HP 1200 27 4 90 12 2 40 160 525 183 600 160 525 130 425 1600 160 525 145 475 160 525 183 600 160 525 183 600 2 2kW 1000 12 2 40 12 2 40 160 525 183 600 686 225 76 2 250 3HP 1200 274 90 18 3 60 160 525 183 600 991 325 130 425 1600 160 525 152 500 160 525 183 600 160 525 183 600 1 5kW 1000 12 2 40 12 2 40 130 425 183 600 991 325 915 300 2HP 1200 274 90 183 60 1
11. A 12 Motor Cable Length Restrictions Tables Table A K PowerFlex 700 Drive 480V Contact Technical Support for data not shown Carrier Type A Motor Type B Motor 1488 V Motor frequency Shielded Shielded Unshielded Shielded Shielded Unshielded Shielded Shielded Unshielded 480V drive kHz motor HP Cable Type 0 5 4 50 25 75 50 220 320 220 420 8 40 20 75 40 220 220 220 420 1 4 8 2 4 8 3 4 8 5 4 25 25 75 40 420 520 420 620 8 25 25 75 40 420 275 420 520 7 5 4 8 10 4 8 15 4 20 20 40 50 420 620 420 620 8 20 20 40 40 420 520 420 520 25 4 20 20 40 50 620 620 620 620 8 20 20 40 40 620 420 620 620 Motor Cable Length Restrictions Tables A 13 Notes A 14 Motor Cable Length Restrictions Tables Notes Glossary Ambient Air Air around any equipment cabinet See surrounding air for more detail Armored A fixed geometry cable that has a protective sheath of continuous metal Capacitive Coupling Current or voltage that is induced on one circuit by another because of their close physical proximity For drive installations it is generally seen in two areas 1 Coupling between motor leads of two drives such that the operating drive induces voltage onto the motor leads and thus the motor of a non operating drive 2 Coupling between the conductors or shields of motor leads that creates a requirement for more current than th
12. 2 Mounting Plate 4 1 Installation EMC Specific 4 1 L Length Restrictions 5 2 Line Impedance AC 2 3 M Manual Usage P 1 Index 2 Mode Capicators Common 2 8 Moisture 4 14 Motor 1329R L A 1 1488V A 1 Type A A 1 Type B A 1 Motor Cable Length 1 8 A 8 Motor Cable Length Restrictions A 1 Motor Cables 1 7 Motors Grounding 3 2 Mounting 4 1 MOV Configuration 2 8 MOV Surge Protection 2 7 N Noise Related Grounds 3 2 P PE Grounding 3 2 Power Cables Input 1 7 Power Distribution 2 1 PowerFlex 4 A 8 PowerFlex 70 A 9 PowerFlex 70 Drive with Reactor A 10 PowerFlex 70 Drive with RWR or Eliminator A 11 PowerFlex 700 Drive A 12 Precautions P 2 R Recommended Documentation P 1 Reflected Wave 5 1 Description 5 1 Wire 5 1 Reflective Wave Protection A 8 Restrictions Length 5 2 RFI Filter Grounding 3 2 Routing Wire 4 7 RWR Reflective Wave Reducer A 8 S Safety Grounds Building Steel 3 1 Grounding PE or Ground 3 2 Motors 3 2 RFI Filter Grounding 3 2 Safety Grounds Grounding 3 1 Shield Termination 4 11 Shields Cable 3 6 Signal Wire 1 9 Recommended 1 9 Standard Installation 4 1 System Configuration 2 1 Delta Delta with Grounded Leg 2 1 Delta Wye with Grounded Wye 2 1 High Resistance Ground 2 2 Ungrounded Secondary 2 2 T Termination Shield via Pigtail Lead 4 4 Via Circular Clamp 4 11 Via Gland Clamp 4 12 Via Pigtail Lead 4 12 Termination Conductor 4 13 Termination Control TB 4 13 Terminati
13. 5 3 7 5 NR NR NA NR 182 9 335 3 NR 61 0 182 9 600 1100 200 600 2 2 3 NR NR NA NR 182 9 335 3 NR 61 0 182 9 600 1100 200 600 1 5 2 NR NR 182 9 NR 182 9 335 3 NR 61 0 182 9 600 600 1100 200 600 0 75 1 NR NR 182 9 NR 182 9 335 3 NR 61 0 182 9 600 600 1100 200 600 0 37 0 5 NR NR 182 9 NR 182 9 335 3 NR 61 0 182 9 600 600 1100 200 600 5 5 15 5 5 15 NR 9 1 182 9 91 4 182 9 182 9 NR 61 0 182 9 30 5 914 182 9 7 5 20 7 5 20 30 600 300 600 600 200 600 100 300 600 C 18 5 45 18 5 45 INR 9 1 182 9 91 4 1829 182 9 NR 61 0 182 9 30 5 191 4 182 9 25 60 25 60 30 600 300 600 600 200 600 100 300 600 D 56 93 56 93 NR 9 1 182 9 91 4 1829 182 9 NR 61 0 182 9 61 0 191 4 182 9 75 125 75 125 30 600 300 600 600 200 600 200 300 600 E 112 224 112 224 NR 9 1 182 9 91 4 182 9 182 9 NR 61 0 182 9 182 9 182 9 182 9 150 X300 150 X300 30 600 300 600 600 200 600 600 600 600 F 261 298 261 298 INR 9 1 182 9 91 4 182 9 182 9 NR 61 0 182 9 182 9 182 9 182 9 350 400 350 400 30 600 300 600 600 200 600 600 600 600 G 224 448 224 448 INR 9 1 182 9 91 4 182 9 182 9 NR 61 0 182 9 182 9 182 9 182 9 300 600 300 600 30 600 300 600 600 200 600 600 600 600 NR Not Recommended NA Not
14. 600 600 Motor Cable Length Restrictions Tables A 3 Table A B 1336 PLUS I IMPACT Drive 600V in meters feet No External Devices w 1204 TFB2 Terminator w 1204 TFA1 Terminator Reactor at Drive Motor Motor Motor Motor 1329R L 1329R L 1329R L 1329R L A B A B A B JA F e Drive Drive kW Motor kW Any Any Any Any Any Any Any Any Any Any Any Any Frame HP HP Cable Cable Cable Cable Cable Cable Cable Cable Cable Cable Cable Cable 0 75 1 0 75 1 182 9 335 3 61 0 182 9 ot 600 1100 200 600 Recommended 0 37 0 5 NR NR NA NR 182 9 335 3 NR 61 0 182 9 600 1100 200 600 1 5 2 1 5 2 NR NR NA NR 182 9 335 3 NR 61 0 182 9 600 1100 200 600 1 2 1 5 INR NR NA NR 182 9 1335 3 NR 61 0 182 9 600 1100 200 600 0 75 1 NR NR 182 9 NR 182 9 335 3 NR 61 0 182 9 600 600 1100 200 600 0 37 0 5 NR NR 182 9 NR 182 9 335 3 NR 61 0 182 9 600 600 1100 200 600 2 2 3 2 2 3 NR NR NA NR 182 9 335 3 NR 61 0 182 9 600 1100 200 600 1 5 2 NR NR NA NR 182 9 1335 3 NR 61 0 182 9 600 1100 200 600 0 75 1 NR NR 182 9 NR 182 9 335 3 NR 61 0 182 9 600 600 1100 200 600 0 37 0 5 NR NR 182 9 NR 182 9 335 3 NR 61 0 182 9 600 600 1100 200 600 3 7
15. Available at time of printing O Values shown are for nominal input voltage drive carrier frequency of 2 kHz or as shown and surrounding air temperature at the motor of 40 C Consult factory regarding operation at carrier frequencies above 2 kHz Multiply values by 0 85 for high line conditions For input voltages of 380 400 or 415V AC multiply the table values by 1 25 1 20 or 1 15 respectively 3 reactor reduces motor and cable stress but may cause a degradation of motor waveform quality Reactors must have a turn turn insulation rating of 2100 Volts or higher e Includes wire in conduit 9 Values shown are for nominal input voltage and drive carrier frequency of 2 kHz Consult factory regarding operation at carrier frequencies above 2 kHz When used on 600V systems 1329R L motors have a corona inception voltage rating of approximately 1850V O These distance restrictions are due to charging of cable capacitance and may vary from application to application A 4 Motor Cable Length Restrictions Tables Table A C 1305 Drive 480V in meters feet No External Devices at the Motor 480V Using a Motor with Insulation Vp_p Drive Motor Type A Type B 1329R L HP HP Shielded Unshielded 480V 480V Any Cable Any Cable Cable Cable Maximum Carrier Frequency 4 kHz 4 kHz 2 kHz 2 kHz High Line Derate Multiplier 0 85 0 85 0 55 0 55 5 5 9m 30ft 30m 100ft 121
16. Back Panel Back Panel Star Washer Bolt Mounting Bracket or Ground Bus Flat Washer N Nut Flat Washer Nut Star Washer Paint Free Area Star Washer If mounting bracket is coated with a non conductive material anodized painted etc scrape the material off around the mounting hole If the drive chassis does not lay flat before the nuts bolts are tightened use additional washers as shims so that the chassis does not bend when you tighten the nuts Conduit Entry Entry Plates In most cases the conduit entry plate will be a paint free conductive material The surface of the plate should be clean of oil or contaminants If the plate is painted use a connector that cuts through the paint and makes a high guality connection to the plate material Or Remove the paint around the holes to the bare metal one inch in from the edge of the plate Grind down the paint on the top and bottom surfaces Use a high guality joint compound when reassembling to avoid corrosion 4 4 Practices Cable Connectors Glands Choose cable connectors or glands that offer the best cable protection shield termination and ground contact Refer to Shield Termination on page 4 11 for more information Shield terminating connectors The cable connector selected must provide good 360 contact and low transfer impedance from the shield or armor of the cable to the conduit entry plate at both the motor and the drive or drive cabinet for e
17. MOV Metal Oxide Varistor protection devices could cause a catastrophic failure In all cases the input power to the drive should be referenced to ground If the system is ungrounded other general precautions such as a system level ground fault detector or system level line to ground suppressor may be necessary or an isolation transformer must be considered with the secondary of the transformer grounded Refer to local codes regarding safety requirements Figure 2 4 High Resistance Ground Ja Grounding the wye secondary neutral through a resistor is an acceptable method of grounding Under a short circuit secondary condition any of the output phases to ground will not exceed the normal line to line voltage This is within the rating of the MOV input protection devices on the drive The resistor is often used to detect ground current by monitoring the associated voltage drop Since high frequency ground current can flow through this resistor care should be taken to properly connect the drive motor leads using the recommended cables and methods In some cases multiple drives that may have one or more internal references to ground on one transformer can produce a cumulative ground current that can trigger the ground fault interrupt circuit Power Distribution 2 3 AC Line Impedance 160 To prevent excess current that may damage drives during events such as line disturbances or certain types of ground faults drives should have a m
18. across these voids If the corona inception voltage CIV for the air void is reached ozone is produced Ozone attacks the PVC insulation leading to a breakdown in cable insulation Asymmetrical construction of the insulation has also been observed for some manufacturers of PVC wire A wire with a 15 mil specification was observed to have an insulation thickness of 10 mil at some points The smaller the insulation thickness the less voltage the wire can withstand THHN jacket material has a relatively brittle nylon that lends itself to damage i e nicks and cuts when pulled through conduit on long wire runs This issue is of even greater concern when the wire is being pulled through multiple 90 bends in the conduit These nicks may be a starting point for CIV leading to insulation degradation During operation the conductor heats up and a coldflow condition may occur with PVC insulation at points where the unsupported weight of the wire may stretch the insulation This has been observed at 90 bends where wire is dropped down to equipment from an above wireway This coldflow condition produces thin spots in the insulation which lowers the cable s voltage withstand capability The U S NEC 1996 code defines dry damp and wet locations 7 31 and permits the use of heat resistant thermoplastic wire in both dry and damp applications Table 310 13 However PVC insulation material is more susceptible to absorbing moisture t
19. dividers Within A Cabinet When multiple equipment is mounted in a common enclosure group the input and output conduit armor to one side of the cabinet as shown in Separating Susceptible Circuits on page 4 8 Separating any Programmable Logic Controller PLC or other susceptible equipment cabling to the opposite side will minimize many effects of drive induced noise currents 4 8 Practices Figure 4 8 Separating Susceptible Circuits PWM Drives Programmable Logic Controller and Other Control Circuits Sensitive Drive Power Equipment Wiring Drive Control and Communications Wiring Power Distribution Terminals Ground Bus OT 000000000000 O Common mode noise current returning on the output conduit shielding or armor can flow into the cabinet bond and most likely exit through the adjacent input conduit armor bond near the cabinet top well away from sensitive equipment such as the PLC Common mode current on the return ground wire from the motor will flow to the copper PE bus and back up the input PE ground wire also away from sensitive equipment Refer to Proper Cabinet Ground Drives amp Susceptible Equipment on page 4 9 If a cabinet PE ground wire is run it should be conne
20. information needed to properly wire and ground Pulse Width Modulated PWM AC drives For information on See page Who Should Use This Manual Preface 1 Recommended Documentation Preface 1 Manual Conventions Preface 2 General Precautions Preface 2 This manual is intended for qualified personnel who plan and design installations of Pulse Width Modulated PWM AC drives The following publications provide general drive information Title Wiring and Grounding Practices for AC PWM Drives Publication Drives INO01 A EN P Available Installing Operating and Maintaining Engineered Drive Systems Reliance Electric D2 3115 2 Safety Guidelines for the Application Installation and Maintenance of Solid State Control SGI 1 1 www ab com manuals dr index3 html Safety IEEE Guide for the Installation of Electrical Equipment to Minimize Electrical Noise Inputs to Controllers from External Sources IEEE 518 Recommended Practice for Powering and Grounding Electronic Equipment IEEE Emerald Book IEEE STD 1100 Electromagnetic Interference and Compatibility Volume 3 N A RJ White publisher Don White Consultants Inc 1981 Grounding Bonding and Shielding for Electronic Equipment and Facilities Military Handbook 419 IEEE Recommended Practice for Grounding of Industrial and Commercial Power Systems IEEE Std 142 1991 National Electrical Code ANSI
21. long wire runs Keep the motor cable lengths within the limits set by the drive s user manual Various issues including cable charging current and reflected wave voltage stress may exist If the cable restriction is listed because of excessive coupling current apply the methods to calculate total cable length as shown in Figure 1 8 on page 1 8 If the restriction is due to 1 8 Wire Types i 91 4 300 182 9 600 Cable for Discrete Drive I O Analog Signal and Encoder Cable voltage reflection and motor protection tabular data is available Refer to Appendix A for exact distances allowed Figure 1 8 Motor Cable Length All examples represent motor cable length of 182 9 meters 600 feet 15 2 Vv 91 4 300 167 6 550 152 4 500 Discrete I O such as Start and Stop commands can be wired to the drive using a variety of cabling Shielded cable is recommended as it can help reduce cross coupled noise from power cables Standard individual conductors that meet the general reguirements for type temperature gauge and applicable codes are acceptable if they are routed away from higher voltage cables to minimize noise coupling Although multi conductor cable may be less expensive to install Control wires should be separated from power wires by at least 0 3 meters 1 foot Table 1 B Recommended Control Wire for Digital I O Minimum T
22. mode noise Other cable types for wet locations include continuous welded armor cables or CLX designation Description Wire Types And Effects On Them Chapter 5 Reflected Wave This chapter discusses the reflected wave phenomenon and its impact on drive systems For information on See page Description 5 1 Wire Types And Effects On Them 5 1 Length Restrictions For Motor Protection 5 2 The inverter section of a drive does not produce sinusoidal voltage but rather a series of voltage pulses created from the DC bus These pulses travel down the motor cables to the motor The pulses are then reflected back to the drive The reflection is dependent on the rise time of the drive output voltage cable characteristics cable length and motor impedance If the voltage reflection is combined with another subsequent pulse peak voltages can be at a destructive level A single IGBT drive output may have reflected wave transient voltage stresses of up to twice 2 pu or per unit the DC bus voltage between its own output wires Multiple drive output wires in a single conduit or wire tray further increase output wire voltage stress between multi drive output wires that are touching Drive 1 may have a 2 pu stress while drive 2 may simultaneously have a 2 pu stress Wires with dielectric constants greater than 4 cause the voltage stress to shift to the air gap between the wires that are barely touching This electric f
23. of the general specifications dicated by the environment of the installation including temperature flexibility moisture characteristics and chemical resistance In addition a braided shield should be included and specified by the cable manufacturer as having coverage of at least 75 An additional foil shield can greatly improve noise containment Wire Types 1 5 A good example of recommended cable is Belden 295xx xx determines gauge This cable has 4 XLPE insulated conductors with a 100 coverage foil and an 85 coverage copper braided shield with drain wire surrounded by a PVC jacket Figure 1 5 Shielded Cable with Four Conductors TIP Other types of shielded cable are available but the selection of these types may limit the allowable cable length Particularly some of the newer cables twist 4 conductors of THHN wire and wrap them tightly with a foil shield This construction can greatly increase the cable charging current required and reduce the overall drive performance Unless specified in the individual distance tables as tested with the drive theses cables are not recommended and their performance against the lead length limits supplied is not known For more information about motor cable lead restrictions refer Appendix A Conduit on page 4 10 Moisture on page 4 14 and Wire Types And Effects On Them on page 5 1 on THHN wire Armored Cable Cable with continuous aluminum armor is often recommended in dri
24. relief as well They do require to drill mounting holes 4 12 Practices Figure 4 13 Plain Copper Saddle Clamp Shield Termination via Pigtail Lead If a shield terminating connector is not available the ground conductors and or shields must be terminated to the appropriate ground terminal If necessary use a compression fitting on the ground conductor s or shield together as they leave the cable fitting Pigtail termination is the least effective method of noise containment It is not recommended if e the cable length is greater than 1 m 39 in or extends beyond the panel e being used in very noisy areas e the cables are for very noise sensitive signals for example registration or encoder cables e strain relief is required If a pigtail is used pull and twist the exposed shield after separation from the conductors To extend the length solder a flying lead to the braid Shield Termination via Gland Clamp Conductive gland grounding see Figure 4 14 on page 4 13 is a simple method for terminating shields but may carry unnecessary cost It is normally only required for extreme applications such as radar aerospace etc It is the most effective method and offers excellent strain relief It is only applicable when entry is through a cabinet surface or bulkhead Conductor Termination Practices 4 13 Figure 4 14 Gland Clamp Terminate power motor and control connections to the drive t
25. s analog inputs are from isolated devices and the output signal is not referenced to the ground the drive s inputs do not need to be isolated An isolated input is recommended to reduce the possibility of induced noise if the transducer s signal is referenced to ground and the ground potentials are varied Refer to Noise Related Grounds on page 3 2 An external isolator can be installed if the drive does not provide input isolation Mounting Chapter 4 Practices This chapter discusses various installation practices For information on See page Mounting 4 1 Conduit Entry 4 3 Ground Connections 4 5 Wire Routin 4 7 Conduit 4 10 Cable Trays 4 10 Shield Termination 4 11 Conductor Termination 4 13 Moisture 4 14 Standard Installations A steel enclosure is recommended EMC Specific Installations A steel enclosure is recommended A steel enclosure can help guard against radiated noise to meet EMC standards If the enclosure door has a viewing window it should be a laminated screen or a conductive optical substrate to block EMC Do not rely on the hinge for electrical contact between the door and the enclosure install a bonding wire For doors 2 m 78 in in height bond two or three three is preferred braided straps top bottom and center EMC seals are not normally required for industrial systems Equipment Mounting Plate To make use of the panel as a part of the groundi
26. safe and adequate connections For individual ground connections star washers and ring lugs should be used to make connections to mounting plates or other flat surfaces that do not provide proper compression lugs If a ground bus system is used in a cabinet follow the bus bar mounting diagrams 4 6 Practices Figure 4 5 Connections to Ground Bus Ground Bus Component A Tapped Hole Grounding Conductors s N Ground Lug Bolt A Component Star W Grounding tar Washer Conductor Figure 4 6 Ground Connections to Enclosure Wall Welded Stud Ground Lug Paint Free Bolt Area Star Washer DA y 2 Ground L gt 4 round Lug Star Washer Star Washer Nut Component Nut Component Star Washer Ground Conductor Ground Conductor Practices 4 7 Wire Routing Do not lay one ground lug directly on top of the other This type of connection can become loose due to compression of the metal lugs Sandwich the first lug between a star washer and a nut with another star washer following After tightening the nut sandwich the second lug between the first nut and a second nut with a captive star washer Figure 4 7 Multiple Connections to Ground Stud or Bolts When routing wiring to a drive separate high voltage power and motor leads from I O and signal leads To maintain separate routes route these in separate conduit or use tray
27. the addition of external devices to limit voltage reflections at the motor reflected wave phenomena See Table A G for recommendations The reflected wave data applies to all frequencies of 2 to 16 kHz Reflected wave effects do not need to be considered for 240V ratings Table A G PowerFlex 4 Drive 480V No external devices Type A Type B 1329R L meters feet meters feet meters feet 15 49 40 131 170 558 Motor Cable Length Restrictions Tables A 9 Table A H PowerFlex 70 480 V No External Devices 480V Carrier Type A Type B 1488V Motor 11329 R L drive frequency Shielded Shielded Un Shielded Shielded Un Shielded Shielded Un Shielded Shielded Un motor kHz e o shielded 6 o shielded 6 o shielded 0 shielded HP Cable Type 0 5 2 60 40 175 60 175 150 175 150 4 60 40 175 60 175 130 175 150 6 60 40 175 50 175 130 175 150 8 60 40 175 50 175 130 175 150 10 60 40 175 50 175 130 175 150 1 2 70 30 275 55 275 180 275 350 4 70 30 250 55 250 180 250 300 6 70 30 250 55 250 170 250 280 8 70 30 250 55 250 160 250 260 10 70 30 200 55 250 160 250 240 2 2 70 40 275 75 275 500 275 500 4 70 40 250 75 250 400 250 400 6 70 40 250 75 250 360 250 400 8 70 40 240 75 250 260 250 400 10 70 40 220 75 250 260 250 400 3 2 70 40 220 75 425 600 425 600 4 70 40 220 75 400 520
28. the conductors and tightly wrap the bundle with a foil shield may cause unnecessary drive tripping Unless specifically stated in the table the distances listed ARE NOT applicable to this type of cable Actual distances for this cable type may be considerably less Type A Motor e No phase paper or misplaced phase paper e Lower quality insulation systems e Corona inception voltages between 850 and 1000 volts Type B Motor e Properly placed phase paper e Medium quality insulation systems e Corona inception voltages between 1000 and 1200 volts 1488V Motor e Meets NEMA MG 1 1998 section 31 standard e Insulation can withstand voltage spikes of 3 1 times rated motor voltage due to inverter operation 1329 R L Motor e AC variable speed motors are Control Matched for use with Allen Bradley drives e Motor designed to meet or exceed the requirements of the Federal Energy Act of 1992 e Optimized for variable speed operation and include premium inverter grade insulation systems which meet or exceed NEMA MGI1 Part 31 40 4 2 A 2 Motor Cable Length Restrictions Tables TIP To increase the distance between the drive and the motor some device RWR or Terminator needs to be added to the system Table A A 1336 PLUS IMPACT Drive 380 480V in meters feet
29. this manual Reproduction of the contents of this manual in whole or in part without written permission of the Allen Bradley Company is prohibited Throughout this manual we use notes to make you aware of safety considerations circumstances that can lead to personal injury or death property ATTENTION Identifies information about practices or damage or economic loss Attentions help you e identify a hazard e avoid the hazard e recognize the consequences Important Identifies information that is especially important for successful application and understanding of the product Shock Hazard labels may be located on or inside the drive to h alert people that dangerous voltage may be present Preface Chapter 1 Chapter 2 Important User Information Overview Who Should Use This Manual P 1 Recommended Documentation P 1 Manual Conventions see ins aia P 2 General Pr cautions taaan aaa shee KR srg Banks ea in a ttes P 2 Wire Types General seins sitiena busi a Sheed ocean Sud S Se ne inl ut Maa ea 1 1 Materi li kz tt steka diodi da ss ade Mol oe U Bios a Asa S 1 1 Etero COVE A RSA S i is AS A Be i RE 1 1 Temperature RUN ses pestle gag hight un abe de Siw ate eed as 1 1 CEE BE a cee tS n t ey kana Deere aia tar aah he aed sy Es wd Rhee ae ag 1 2 Number of Conductors 1 2 Ins
30. 0 85 0 85 0 85 0 85 0 85 5 5 15m 50ft 182m 600ft 182m NR NR 91m 300ft 61m 200ft 91m 300ft 121m 400ft 600ft 3 15m 50ft 182m 600ft 182m 91m 300ft 121m 99m 325ft 61m 200ft 152m 500ft 121m 400ft 600ft 400ft 2 15m 50ft 182m 600ft 182m 121m 400ft 182m 99m 325ft 61m 200ft 182m 600ft 121m 400ft 600ft 600ft 1 15m 50ft 182m 600ft 182m 121m 400ft 182m 99m 325ft 61m 200ft 182m 600ft 121m 400ft 600ft 600ft 0 5 15m 50ft 182m 600ft 182m 182m 600ft 182m 99m 325ft 61m 200ft 182m 600ft 121m 400ft 600ft 600ft 3 3 15m 50ft 91m 300ft 182m NR NR 91m 300ft 61m 200ft 91m 300ft 121m 400ft 600ft 2 15m 50ft 182m 600ft 182m 91m 300ft 121m 99m 325ft 61m 200ft 152m 500ft 121m 400ft 600ft 400ft 1 15m 50ft 182m 600ft 182m 91m 300ft 182m 99m 325ft 61m 200ft 182m 600ft 121m 400ft 600ft 600ft 0 5 15m 50ft 182m 600ft 182m 121m 400ft 182m 99m 325ft 61m 200ft 182m 600ft 121m 400ft 600ft 600ft 2 2 15m 50ft 76m 250ft 167m NR NR 91m 300ft 61m 200ft 91m 300ft 121m 400ft 550ft 1 15m 50ft 182m 600ft 182m 61m 200ft 61m 99m 325ft 61m 200ft 121m 400ft 121m 400ft 600ft 200ft 0 5 15m 50ft 182m 600ft 182m 91m 300ft 121m 99m 325ft 61m 200ft 152m 500ft 121m 400ft 600ft 400ft 1 1 15m 50ft 68m
31. 30 425 183 600 130 425 137 450 1600 152 500 152 500 130 425 183 600 165 540 183 600 0 75kW 1000 16 8 55 12 2 40 99 1 325 183 600 99 1 325 107 350 1HP 1200 38 1 125 18 3 60 99 1 325 183 600 152 500 137 450 1600 152 500 152 500 991 325 183 600 152 500 183 600 0 55kW 1000 13 7 45 12 2 40 91 5 300 183 600 915 300 91 5 300 0 75 HP 1200 38 1 125 18 3 60 91 5 300 183 600 152 500 152 500 1600 152 500 152 500 915 300 183 600 152 500 183 600 0 37kW 1000 13 7 45 274 90 91 5 300 130 425 91 5 300 130 425 0 5 HP 1200 38 1 125 549 180 915 300 130 425 152 500 152 500 1600 152 500 152 500 91 5 300 130 425 152 500 152 500 Table A F 160 Drive 240 amp 480V Cable Charging Current Motor Cable Length Restrictions Tables A 7 480V kHz Motor Cable Only RWR at Drive Reactor at Motor Ratings Shielded O Unshielded Shielded O Unshielded Shielded O Unshielded meters feet meters feet meters feet meters feet meters feet meters feet 4 0 kW 2 107 850 183 600 915 300 183 600 122 400 183 600 5 HP 4 130 425 183 600 107 350 183 600 137 450 138 600 8 145 475 152 500 NR 137 450 152 500 2 2kW 2 110 860 183 600 854 280 183 600 122 400 183 600 3 HP 4 114 375 183 600 838 275 183
32. 400 600 6 70 40 220 75 425 520 425 600 8 70 40 220 75 400 380 400 580 10 70 40 220 75 400 380 400 550 5 2 80 40 280 80 450 600 450 600 4 80 40 280 80 400 600 400 600 6 80 40 280 80 400 560 400 600 8 80 40 280 80 300 400 300 600 10 80 40 280 80 300 360 300 580 7 5 2 50 40 300 60 400 600 400 600 4 50 40 300 60 400 600 400 600 6 50 40 300 60 400 520 400 600 8 50 40 300 60 400 400 400 560 10 50 40 300 60 300 320 300 500 10 2 50 40 300 60 400 600 400 600 4 50 40 300 60 400 600 400 600 6 50 40 300 60 400 560 400 600 8 50 40 300 60 400 440 400 560 10 50 40 300 60 300 380 300 520 15 2 80 50 600 80 600 600 600 600 4 80 50 400 80 600 600 600 600 6 80 50 400 80 600 600 600 600 8 80 50 400 80 600 500 600 600 10 80 50 400 80 600 400 600 480 20 2 70 50 600 80 600 600 600 600 4 70 50 400 80 600 600 600 600 6 70 50 200 80 600 600 600 600 8 70 50 160 80 600 600 600 600 10 70 50 160 80 600 340 600 600 Cable is Alcatel C1202 or equivalent Shielded cable with twisted conductors and no filler Cable is Belden 295xx series or equivalent A 10 Motor Cable Length Restrictions Tables Table AI PowerFlex 70 Drive With Reactor Contact Technical Support for data not shown 480V Carrier Type A Motor Type B Motor 1488 Volt motor 1329 R L drive frequency Shielded Shielded Un Shielded
33. 600 122 400 183 600 8 122 400 152 500 NR 122 400 152 500 1 5kW 2 91 5 300 168 550 838 275 183 600 91 5 300 183 600 2 HP 4 91 5 300 168 550 838 275 183 600 91 5 300 152 500 8 99 1 325 152 500 NR 107 350 152 500 0 75kW 2 61 200 114 375 let 200 130 425 686 225 122 400 1 HP 4 68 6 225 114 375 61 200 130 425 686 225 114 375 8 76 2 250 114 375 NR 68 6 225 122 400 0 55kW 2 54 9 180 107 350 549 180 114 375 549 180 107 350 0 75 HP 4 54 9 180 107 350 549 180 114 1375 549 180 107 350 8 54 9 180 107 350 NR 54 9 180 107 350 0 37kw 2 30 5 100 991 325 305 100 107 350 305 100 91 5 300 0 5HP 4 30 5 100 99 1 325 305 100 107 350 80 5 100 107 350 8 30 5 100 99 1 325 NR 30 5 100 107 350 240V Ratings No Reactor RWR at Drive Reactor at Motor 0 37 to 4 0 kW Shielded O Unshielded Shielded O Unshielded Shielded O Unshielded 0 5 to 5 HP meters feet meters feet meters feet meters feet meters feet meters feet 2 through 8 kHz 160 525 183 600 NR 160 525 183 600 O When using shielded cable at lightly loaded conditions cable length recommendations for drives rated 0 75 kW 1 HP and below are 61 meters 200 feet A 8 Motor Cable Length Restrictions Tables PowerFlex 4 Reflected Wave Protection Install the drive as close to the motor as possible Installations with long motor cables may require
34. 600V 90 C 194 F RHH RHW 2 Anixter 7V 7xxxx 3G or equivalent Three bare copper conductors with XLPE insulation and impervious corrugated continuously welded aluminum armor Black sunlight resistanct PVC jacket overall Three copper grounds on 10 AWG and smaller Figure 1 6 Armored Cable with Three Ground Conductors Optional PVC Outer Sheath Armor Optional Foil Copper Tape and or inner PVC Jacket European Style Cable Conductors with XLPE Insulation Cable used in many installations in Europe should conform to the CE Low Voltage Directive 73 23 EEC Generally recommended are flexible cables with a recommended bend radius of 20 times the cable diameter for movable cable and 6 times the cable diameter for fixed installations The screen shield should be between 70 and 85 coverage Insulation for both conductors and the outer sheath is PVC The number and color of individual conductors may vary but the recommendation is for 3 phase conductors customer preferred color and one ground conductor Green Yellow Olflex Classic 100SY or Olflex Classic 110CY are examples Input Power Cables Motor Cables Wire Types 1 7 Figure 1 7 European Style Multi Conductor Cable Filler PVC Outer Single Ground Screen Conductor In general the selection of cable for AC input power to a drive has no special requirements Some installations may suggest shielded cable to prevent coupling of noise
35. Common Mode Capacitors Figure 2 5 Typical MOV Configuration R PHASE TO PHASE MOV RATING S Includes Two Phase to Phase MOV s T PHASE TO GROUND MOV RATING Includes One Phase to Phase MOV and One Phase to Ground MOV Suitable isolation is required for the drive when there is potential for abnormally high phase to ground voltages in excess of 125 for nominal line to line voltage or the supply ground is tied to another system or equipment that could cause the ground potential to vary with operation An isolation transformer is strongly recommended when this condition exists With ungrounded distribution systems the phase to ground MOV connection could become a continuous current path to ground Energy ratings are listed for each drive see Figure 2 5 on page 2 8 Exceeding the published phase to phase phase to ground voltage or energy ratings may cause physical damage to the MOV Theses devices should be removed when the drive is used in an ungrounded distribution system Many drives also contain common mode capacitors that are referenced to ground To guard against drive damage these devices should be disconnected if the drive is installed on an ungrounded distribution system where the line to ground voltages on any phase could exceed 125 of the nominal line to line voltage Check the appropriate user manual for instructions on removal of these devices Many drives offer jumpers to remove these devices from the circuitry when used i
36. Cross Linked Polyethylene UL Underwriters Laboratories Glossary 4 Numerics 1305 Drive A 4 1305 Drive with Line Device A 5 1336 Plus Il Impact Drive A 2 1336 PLUS II Impact Drive 600V A 3 160 Drive Cable Charing Current A 7 160 Drive Voltage Peak A 6 A Analog Signal Cable 1 8 C Cable Shield Defintion A 1 Unshield Defintion A 1 Cable Shields 3 6 Cable Trays 4 10 Capacitive Current Cable Length Recommendations A 7 Common Mode Noise 6 1 Cable 6 2 Causes 6 1 Conduit 6 1 Containing 6 1 Communications 1 9 ControlNet 1 9 DeviceNet 1 9 Ethernet 1 10 Remote Data Highway 1 10 I O 1 10 RS232 485 1 11 Serial 1 11 Conduit 4 10 Connectors 4 4 Entry Plates 4 3 Conduit Cable Connectors 4 4 Control Wire 1 8 Counduit Entry 4 3 D Delta Delta with Grounded Leg 2 1 Delta Wye with Grounded Wye 2 1 Discrete Drive I O Cable 1 8 Index Drive 1305 A 4 1305 Drive with Line Device A 5 1336 PLUS II Impact A 2 1336 PLUS Il Impact 600V A 3 160 Cable Charing Current A 7 160 Voltage Peak A 6 PowerFlex 4 A 8 PowerFlex 70 A 9 PowerFlex 70 with Reactor A 10 PowerFlex 70 with RWR or Eliminator A 11 PowerFlex 700 A 12 E Encoder Cable 1 8 G Glands 4 4 Ground Connections 4 5 Ground Fully Grounded System 3 3 Ground High Resistance 3 3 Grounding 3 1 Practices 3 4 Grounding Practices 4 1 Grounds Noise Related 3 2 H High Resistance Ground 2 2 Inputs Isolated 3 6 Installation 4 1 Layout 4
37. Greater Surge Protection MOVs Power Distribution 2 7 Max Drive Supply 3 Line Reactor Catalog Volts HP kW KVA 1 2 Open Style 1321 B700 480 700 5000 3R850 B B800 480 800 5000 3R1000 B CWF10 600 1 25 3R4 C CWF20 600 2 50 3R4 C CWF30 600 3 75 3R8 C CWF50 600 5 100 3R8 B CWF75 600 7 5 200 3R8 B CWF100 600 10 200 3R12 B C015 600 15 300 3R18 B C020 600 20 350 3R25 B C025 600 25 500 3R25 B C030 600 30 600 3R35 B C040 600 40 700 3R45 B C050 600 50 850 3R55 B C060 600 60 900 3R80 B C075 600 75 950 3R80 B C100 600 100 1200 3R100 B C125 600 125 1400 3R130 B C150 600 150 1500 3R160 B C200 600 200 2200 3R200 B C250 600 250 2500 3R250 B C300 600 300 3000 3R320 B C350 600 350 3000 3R400 B C400 600 400 4000 3R400 B C450 600 450 4500 3R500 B C500 600 500 5000 3R500 B C600 600 600 5000 3R600 B C650 600 650 5000 3R750 B C700 600 700 5000 3R850 B FN 1 C800 600 800 5000 3R850 B FN 1 ion for additional inductance Most drives are designed to operate on three phase supply systems whose line voltages are symmetrical Most drives are equipped with a MOV that provides voltage surge protection and phase to phase plus phase to ground protection designed to meet IEEE 587 The MOV circuit is designed for surge suppression transient line protection only not continuous operation 2 8 Power Distribution THREE PHASE AC INPUT GROUND
38. NFPA 70 Articles 250 725 5 725 15 725 52 and 800 52 Noise Reduction Techniques in N A Henry W Ott Electronic Systems Published by Wiley Interscience Grounding for the Control of EMI N A Hugh W Denny Published by Don White Consultants p 2 Overview Manual Conventions General Precautions Title Publication Available Cable Alternatives for PWM AC IEEE Paper No Drive Applications PCIC 99 23 EMI Emissions of Modern PWM N A IEEE Industry Applications AC Drives Magazine Nov Dec 1999 EMC for Product Designers N A Tim Williams Published by Newnes The following words are used throughout the manual to describe an action Word Meaning Can Possible able to do something Cannot Not possible not able to do something May Permitted allowed Must Unavoidable you must do this Shall Required and necessary Should Recommended Should Not Not recommended voltage on the bus capacitors has discharged before performing ATTENTION To avoid an electric shock hazard verify that the any work on the drive Measure the DC bus voltage at the DC amp DC terminals of the Power Terminal Block The voltage must be Zero General Chapter 1 Wire Types This chapter provides recommendations for different types of wiring For information on See page General 1 1 Input Power Cables 1 7 Motor Cables 1 7 Cable for Discrete Drive 1 0 1 8 Analog Sign
39. al and Encoder Cable 1 8 Communications 1 9 AC drive installations along with drive characteristics have specific requirements for cables used in installations Recommendations are made to address specific issues such as noise standards wire integrity and safety Most significantly since drives can create voltages well in excess of line voltage the industry standard cables that have been used in the past may not represent the best choice for customers using variable speed drives Drive installations benefit from the use of cable that is significantly different than that used to wire contactors and fuse blocks The following section covers the major issues and proper selection of cable In general the significant selection criteria are wire gauge shielding geometry type of coating and resistance to moisture and temperature Material Always use copper wire Exterior Cover Whether shielded or unshielded the cable must be chosen to meet all of the application requirements Consideration must be given to insulation value and resistance to moisture contaminants corrosive agents and other invasive elements Consult the cable manufacturer for the proper selection Temperature Rating In general installations in surrounding air temperature of 50 should use 90 wire required for UL and installations in 40 surrounding air temperature should use 75 wire also required for UL Refer to the drive user manual for other restri
40. ampens the common mode noise and reduces its impact Figure 3 2 System with High Resistance Ground Re EARTH GROUND POTENTIAL A fully grounded system shown in Figure 3 3 provides a complete noise path and is the most susceptible to common mode noise issues Figure 3 3 Fully Grounded System EARTH GROUND POTENTIAL 3 4 Grounding The installation and grounding practices to reduce common mode noise issues can be categorized into three ratings The system used must weigh additional costs against the operating integrity of all system components If no sensitive equipment is present and noise is not be an issue the added cost of shielded cable and other components may not be justified Acceptable Grounding Practices The system shown below is an acceptable ground layout However conduit may not offer the lowest impedance path for any high frequency noise If the conduit is mounted so that it contacts the building steel it is likely that the building steel will offer a lower impedance path and allow noise to inhabit the ground grid Figure 3 4 Acceptable Grounding Connection to Drive Structure MOTOR FRAME or Optional Cabinet Via Conduit Connector CONDUIT INPUT TRANSFORMER lt q Connection to Ground Grid Girder or Ground Rod R Mod Connection to OPTIONAL ENCLOSURE Frame Cabinet Ground Bus Ground or Directly to Drive PE Terminal S BUILDING GROUND POTENTIAL Eff
41. connections Improper wiring could lead to incorrect drive operation Cables terminated here are typically shielded and the signals being carried are generally more sensitive to noise Carefully check the user manual for 4 14 Practices Moisture recommendations on shield termination Some shields can be terminated at the terminal block and others will be terminated at the entry point The U S NEC defines dry damp and wet locations It permits the use of heat resistant thermoplastic wire in both dry and damp applications Table 310 13 However PVC insulation material is more susceptible to absorbing moisture than XLPE Cross Linked polyethylene insulation material XHHW 2 identified for use in wet locations Because the PVC insulating material absorbs moisture the corona inception voltage CIV insulation capability of the damp or wet THHN was found to be less than 1 2 of the same wire when dry For this reason certain industries where water is prevalent in the environment have refrained from using THHN wire with IGBT drives Belden 29500 style cable is a PVC jacketed shielded type TC with XLPE conductor insulation designed to meet NEC code designation XHHW 2 use in wet locations per the U S NEC Table 310 13 Based on Rockwell Automation research tests have determined this cable is notably superior to loose wires in dry damp and wet applications and can significantly reduce capacitive coupling and common
42. cted from the same side of the cabinet as the conduit armor connections This keeps the common mode noise shunted away from the PLC backplane Common Mode Current on Ground Conductor Cabinet Backplane Subpanel Practices 4 9 Figure 4 9 Proper Cabinet Ground Drives amp Susceptible Equipment Output Conduit or Armor Bonded to Cabinet A A UV WPE UV WPE RS TPE i l Common Mode Current on Armor Pa or Conduit 1 TNH TN n wapi on Incoming Power Mn n ds in Conduit Armor i Beg l l DA HIE el al el dE C T A F i l A i 3 EA L y Within Conduit Do not route more than 3 sets of motor leads 3 drives in the same conduit Maintain fill rates per applicable electrical codes Do not run power or motor cables and control or communications cables in the same conduit Loops Antennas and Noise When routing signal or communications wires avoid routes that produce loops Wires that form a loop can form an efficient antenna Antennas work well in both receive and transmit mode
43. ction to Drive Structure or S Rati tye Motor Optional Cabinet Via Grounding OPTIONAL ENCLOSURE Frame Connector or Terminating Connection to Ground Shield at PE Terminal Cabinet Ground Bus or Directly to Drive PE Terminal BUILDING GROUND POTENTIAL 3 6 Grounding Cable Shields Motor and Input Cables Shields of motor and input cables must be grounded at both ends to provide a continuous noise path Control and Signal Cables Shields of control cables should be connected at one end only Never connect a shield to the common side of a logic circuit this will introduce noise into the logic circuit Connect each shield directly to a chassis ground Ground each shield at the end specified in the appropriate publication for the product The other end should be cut back and insulated Shields for cables from a cabinet to an external device must be connected at the cabinet end Shields for cables from one cabinet to another must be connected at the source end cabinet Splicing of Shields If the shielded cable needs to be stripped it should be stripped back as little as possible and ensure that continuity of the shield is not interrupted Single Point A single safety ground point or ground bus bar should be directly connected to the building steel for cabinet installations All circuits including the AC input ground conductor should be grounded independently and directly to this point bar Isolated Inputs If the drive
44. ctions 1 2 Wire Types The temperature rating of the wire affects the required gauge Be certain to meet all applicable national state and local codes Gauge The proper wire size is determined by a number of factors Each individual drive user manual lists a minimum and maximum wire gauge based on the amperage rating of the drive and the physical limitations of the terminal blocks Local or national electrical codes also set the required minimum gauge based on motor FLA Both of these requirements should be followed Number of Conductors While local or national electrical codes may determine the required number of conductors certain configurations are recommended Figure 1 1 on page 1 2 shows cable with a single ground conductor which is recommended for drives up to and including 200 HP 150 kW Figure 1 2 on page 1 2 shows cable with three ground conductors which is recommended for drives larger than 200 HP 150 kW The ground conductors should be spaced symmetrically around the power conductors The ground conductor s should be rated for full drive ampacity Figure 1 1 Cable with One Ground Conductor ONE GROUND CONDUCTOR Figure 1 2 Cable with Three Ground Conductors THREE GROUND CONDUCTORS Wire Types 1 3 Insulation Thickness and Concentricity Selected wire must have an insulation thickness of equal to or more then 15 mils 0 4 mm 0 015 in The quality of wire should not hav
45. e motor itself would demand CIV Corona Inception Voltage The amplitude of voltage on a motor or other electrical winding that produces corona ionization of air to ozone CIV is increased by adding phase paper placing windings in the proper pattern and reducing or eliminating air bubbles voids in the varnish applied Common Mode Core A ferrite bead or core that can be used to pass control communications or motor leads through to attenuate high frequency noise Catalog Number Part Number 1321 Mxxx Common Mode Noise Electrical noise typically high frequency that is imposed on the ground grid carriers in an electrical system Conduit Conductive ferrous electrical metal tubing used to contain and protect individual wires Damp Wet locations per U S NEC or local code Glossary 2 Discrete Individual hard wired inputs or outputs typically used for control of the drive Start Stop etc Dry Dry locations per U S NEC 7 31 or local code dv dt The rate of change of voltage over time Fill Rates The maximum number of conductors allowed in a conduit as determined by local state or national electrical code Fixed Geometry Cable whose construction fixes the physical position of each conductor within the overall coating usually with filler material that prevents individual conductors from moving IGBT Insulated Gate Bi Polar Transistor The typical power semi conductor device used in most PWM AC drives t
46. e set of cables can induce a hazardous voltage and or excessive noise on the cable set of another drive even when no power is applied to the second drive Seperation should also be maintained between power and control cables Dividers also provide excellent separation Figure 4 11 Cable Tray Practices 00 O Random Placement Not Recommended or Ds Bundled amp Anchored to Tray Recommended Shield Termination Practices 4 11 Refer to Splicing of Shields on page 3 6 to splice shielded cables The following methods are acceptable if the shield connection to the ground is not accomplished by the gland or connector Refer to the table associated with each type of clamp for advantages and disadvantages Termination via circular clamp Clamp the cable to the main panel closest to the shield terminal using the circular section clamping method The preferred method for grounding cable shields is clamping the circular section of 360 bonding as shown in Commercial Cable Clamp Heavy Duty on page 4 11 It has the advantage of covering a wide variety of cable diameters and drilling mounting is not required Its disadvantages are cost and availability in all areas Figure 4 12 Commercial Cable Clamp Heavy Duty Plain copper saddle clamps as shown in Figure 4 13 on page 4 12 are sold in many areas for plumbing purposes but are very effective and available in a range of sizes They are low cost and offer good strain
47. e significant variations on concentricity of wire and insulation Figure 1 3 Insulation Concentricity ACCEPTABLE UNACCEPTABLE Geometry The physical relationship between individual conductors plays a large role in drive installation Individual conductors in conduit or cable tray have no fixed relationship and are subject to a variety of issues including cross coupling of noise induced voltages excess insulation stress and others Fixed geometry cable cable that keeps the spacing and orientation of the individual conductors constant offers significant advantages over individual loose conductors including reducing cross coupling noise and insulation stress Three types of fixed geometry multi conductor cables are discussed below Unshielded shielded and armored Unshielded Cable Properly designed multi conductor cable can provide superior performance in wet applications significantly reduce voltage stress on wire insulation and reduce cross coupling between drives 1 4 Wire Types Figure 1 4 Unshielded Multi Conductor Cable muter 00 PVC Outer Sheath Cg Single Ground Conductor The use of cables without shielding is generally acceptable for installations where electrical noise created by the drive does not interfere with the operation of other devices such as communications cards photoelectric switches weigh scales and others Be certain the installation does not require shielded cable to meet specific EMC standa
48. ective Grounding Practices This system replaces the conduit with shielded or armored cable that has a PVC exterior jacket This PVC jacket prevents accidental contact with building steel and reduces the possibility that noise will enter the ground grid Grounding 3 5 Figure 3 5 Effective Grounding Shielded or MOTOR FRAME Armored Cable with PVC Jacket INPUT TRANSFORMER Connection to Drive Structure or lt q Connection to SEN F oO Optional Cabinet Via Grounding ceca Panel Ground Bus Connector or Terminating Ground Rod air EO Shield at PE Terminal ra Connection to OPTIONAL ENCLOSURE Frame Cabinet Ground Bus Ground or Directly to Drive PE Terminal BUILDING GROUND POTENTIAL Optimal Recommended Grounding Practices The fully grounded system provides the best containment of common mode noise It uses PVC jacketed shielded cable on both the input and the output to the drive This method also provides a contained noise path to the transformer to keep the ground grid as clean as possible Figure 3 6 Optimum Grounding Shielded or Shielded or MOTOR FRAME Armored Cable 1 Armored Cable with PVC Jacket with PVC Jacket INPUT TRANSFORMER lt q Connection to Ground Grid N Connection to Drive Structure or Girder or Ground Rod Optional Cabinet Via Grounding Connector or Terminating Shield at PE Terminal Conne
49. efore the filter must only be used in installations with grounded AC supply systems and be permanently installed and solidly grounded to the building power distribution ground Ensure the incoming supply neutral is solidly connected to the same building power distribution ground Grounding must not rely on flexible cables or any plug or socket that may be accidentally disconnected Some codes may require redundant ground connections Periodically check the integrity of all connections Refer to the instructions supplied with the filter Grounding Motors The motor frame or stator core must be connected directly to the drive PE connection with a separate ground conductor It is recommended that each motor frame be grounded to building steel at the motor It is important to take care when installing the PWM AC drive because output can produce high frequency common mode coupled from output to ground noise which may cause sensitive equipment to malfunction The grounding system used can greatly affect the amount of noise and its impact on the system The power system used is likely to be one of three types e Ungrounded System e System with High Resistance Ground e Fully Grounded System Grounding 3 3 An ungrounded system as shown in Figure 3 1 breaks the common mode noise path and so does not generally have noise issues Figure 3 1 Ungrounded System EARTH GROUND POTENTIAL A system with a high resistance ground shown in Figure 3 2 d
50. ended contact with grid ground structure due to straps support etc The AC resistance characteristics of earth are generally variable and unpredictable making it difficult to predict how noise current will divide between wire conduit or the ground grid 6 2 Common Mode Noise Shielded or Armored Power Cable The predominant return path for common mode noise is the shield armor itself when using shielded or armored power cables Unlike conduit the shield armor is isolated from accidental contact with grounds by a PVC outer coating Making the majority of noise current flow in the controlled path and very little high frequency noise flows into the ground grid Noise current returning on the shield or safety ground wire is routed to the drive PE terminal down to the cabinet PE ground bus and then directly to the grounded neutral of the drive source transformer The cable s radiated emissions are minimal because the armor completely covers the noisy power wires Also the armor prevents EMI coupling to other signal cables that might be routed in the same cable tray Another effective method of reducing common mode noise is to attenuate it before it can reach the ground grid Installing a common mode ferrite core on the output cables can reduce the amplitude of the noise to a level that makes it relatively harmless to sensitive equipment or circuits Common mode cores are most effective when multiple drives are located in a relatively smal
51. ere is a possibility for electrical noise from drive operation to interfere with adjacent sensitive electronic equipment especially in areas where many drives are concentrated Generating common mode currents by varying frequency inverters is similar to the common mode currents that occur with DC drives Although AC drives produce a much higher frequency then DC drives 250 kHz 6MHz Inverters have a greater potential for exciting circuit resonance because of very fast turn on switches causing common mode currents to look for the lowest impedance path back to the inverter The dv dt and di dt from the circulating ground currents can couple into the signal and logic circuits causing improper operation and possible circuit damage When conventional grounding techniques do not work you must use high frequency bonding techniques High Frequency bonding techniques must be employed when the conventional grounding techniques fail If these techniques are not followed bearing currents increase circuit boards have the potential to fail prematurely and the ground system has higher then normal current problems with computer systems and distributed control systems Cable type has a great effect on the ability to contain common mode noise in a system that incorporates a drive Conduit Combining the ground conductor and the conduit absorb most capacitive current and returns it to the drive without polluting the ground grid A conduit may still have unint
52. erminal blocks User manuals list minimum and maximum wire gauges tightening torque for terminals and recommended lug types if stud connections are provided Check for recommended conduit connector gland locations to help maintain separation of power and control wiring Bending radii minimums per the applicable electrical code should be followed Power TB Power terminals are normally fixed non pull apart and can be cage clamps barrier strips or studs for ring type crimp lugs depending on the drive style and rating Cage clamp styles may require a non standard screwdriver Crimp lugs will require a crimping tool On smaller sizes a stripping gauge may be provided on the drive to assist in the amount of insulation to remove Normally the three phase input is not phase sensitive That is the sequence of A B C phases has no effect on the operation of the drive or the direction of motor rotation Control TB Control terminal blocks are either pull apart or fixed non pull apart Terminals will be either spring clamp type or barrier strip A stripping gauge may be provided on the drive to assist in the amount of insulation to remove Some control connections such as analog input and output signals are polarity sensitive Consult the applicable user manual for correct connection Signal TB If an encoder or tachometer feedback is used a separate terminal block or blocks may be provided Consult the user manual for these phase sensitive
53. everal types of RG 6 quad shield cables that may be appropriate The standard cable recommended is A B Cat 1786 RG6 Quad Shield coax Belden 3092A Country state or local codes such as the U S NEC govern the installation For Use this Cable Type Light Industrial e Standard PVC e CM CL2 Heavy Industrial e Lay on Armored e Light Interlocking Armor High Low Temperature or Corrosive e Plenum FEP Harsh Chemicals e CMP CL2P Festooning or Flexing e High Flex Moisture direct burial with flooding e Flood Burial compound fungus resistant The allowable length of segments and installation of terminating resistors play a significant part in the installation Again refer to the ControlNet Coax Cable System Planning and Installation Manual for detailed specifics Ethernet The Ethernet communications interface wiring is very detailed as to the type of cable connectors and routing Because of the amount of detail required to bring Ethernet into the industrial environment planning an installation should be done by following all recommendations in the Ethernet IP Media Planning and Installation Guide publication ENET IN001 In general Ethernet systems consist of specific cable types STP shielded Cable or UTP unshielded cable using RJ45 connectors that meet the IP67 standard and are appropriate for the environment Cables should also meet TIA EIA standards at industrial temperatures Shielded cable is always recommended
54. ga aad rte Sain og aly ee Re cal s 4 10 Cable Tray sissy fes ovat Met OR ears hones an a gener E enacts Pas ein Ada et cnet diane 4 10 Shield Terminations ss sce games ete secte viel aoe aie sine eee eee creer val Kas 4 11 Termination via circular clamp 4 11 Shield Termination via Pigtail Lead 4 12 Shield Termination via Gland Clamp 4 12 Conductor Termination reeta e ae ee eo ea be he he aed a 4 13 Power IB data at is Ra eet dd Toate toes 4 13 Control TB ecran mme matt a ns ag dean 4 13 Signal TB Sag ele ae eee A chee eR eo ee ae oe SR a 4 13 MOISES E OAS A Gee a 4 14 Reflected Wave DeScriptiOn ss bis We chee aguti aaa uly vija s 5 1 Wire Types And Effects On Them 5 1 Length Restrictions For Motor Protection 5 2 Common Mode Noise What Causes Common Mode Noise 6 1 Containing Common Mode Noise With Cabling 6 1 Conduit steel tintin yyy boli Shaya kris Gadd at adidas 6 1 Shielded or Armored Power Cable 2 6 2 Appendix A Glossary Index Motor Cable Length Restrictions Tables Who Should Use This Manual Recommended Documentation Overview Preface The purpose of this manual is to provide you with the basic
55. han XLPE Cross Linked polyethylene insulation material XHHN 2 identified for use in wet locations Because the PVC insulating material absorbs moisture the Corona Inception Voltage insulation capability of the damp or wet THHN was found to be less than 1 2 of the same wire when dry For this reason certain industries where water is prevalent in the environment have refrained from using THHN wire with IGBT drives Rockwell Automation strongly suggests the use of XLPE insulation for wet areas To protect the motor from reflected waves limit the length of the motor cables from the drive to the motor Each drive s user manual lists the lead length limitations based on drive size and the quality of the insulation system in the chosen motor If the distance between drive and motor must exceed these limits contact the local office or factory for analysis and advice Refer to Appendix A for complete tables What Causes Common Mode Noise Containing Common Mode Noise With Cabling Chapter 6 Common Mode Noise This chapter discusses common mode noise and its impact on drive systems For information on See page What Causes Common Mode Noise 6 1 Containing Common Mode Noise With Cabling 6 1 Faster output dv dt transitions of IGBT drives increase the possibility for increased Common Mode CM electrical noise Common Mode Noise is a type of electrical noise induced on signals with respect to ground Th
56. ield may be high enough to ionize the air surrounding the wire insulation and cause a partial discharge mechanism corona to occur The electric field distribution between wires increases the possibility for corona and greater ozone production This ozone attacks the PVC insulation and produces carbon tracking leading to the possibility of insulation breakdown Based on field and internal testing Rockwell Automation Allen Bradley has determined conductors manufactured with Poly Vinyl Chloride PVC wire insulation are subject to a variety of manufacturing inconsistencies which can lead to premature insulation degradation when used with IGBT drives Flame retardant heat resistant thermoplastic insulation is the type of insulation listed in the NEC code for the THHN wire designation This type of insulation is commonly referred to as PVC In addition to manufacturing inconsistencies the physical properties of the cable can change due to environment installation and operation which can also lead to premature insulation degradation The following is a summary of our findings 5 2 Reflected Wave Length Restrictions For Motor Protection Due to inconsistencies in manufacturing processes or wire pulling air voids can also occur in the THHN wire between the nylon jacket and PVC insulation Because the dielectric constant of air is much lower than the dielectric constant of the insulating material the transient reflected wave voltage might appear
57. inimum amount of impedance in front of them In many installations this impedance comes from the supply transformer and the supply cables In certain cases an additional transformer or reactor is recommended If any of the following conditions exist serious consideration should be given to adding a line reactor in front of the drive A Line impedance is less than 1 B Available short circuit current is greater than 100 000 Amps AND the drive is less then 5 HP C Supply transformer exceeds the value in Table 2 A D Line has switched Power Factor correction capacitors E Line has frequent lightning strikes or voltage spikes in excess of 6000V Peak F Line has frequent power interruptions or voltage dips in excess of 200V AC The recommendations are merely advisory and may not address all situations User judgement must be exercised to assure a quality installation Table 2 A AC Line Impedance Recommendations Max Drive Supply 3 Line Reactor Catalog Volts HP kW KvA 1 2 Open Style 1321 AA02 240 0 5 15 3R4 B AA03 240 0 75 20 3R4 A AA04 240 1 30 3R4 A AA08 240 2 50 3R8 A AA12 240 3 75 3R12 A AA18 240 5 100 3R18 A BA01 480 0 5 15 3R2 B BA02 480 0 75 20 3R2 A BA03 480 1 30 3R2 A BA04 480 2 50 3R4 B BA06 480 3 75 3R8 B BA10 480 5 100 3R18 B 2 4 Power Distribution
58. ith separate copper wire or wires of the appropriate gauge Most equipment has specific provisions to connect a safety ground or PE protective earth directly to it Building Steel If intentionally bonded at the service entrance the incoming supply neutral or ground will be bonded to the building ground Building steel is judged to be the best representation of ground or earth The structural steel of a building is generally bonded together to provide a consistent ground potential If other means of grounding are used such as ground rods the user should understand the voltage potential between ground rods in different areas of the installation Type of soil ground water level and other environmental factors can greatly affect the voltage potential between ground points if they are not bonded to each other 3 2 Grounding Noise Related Grounds Grounding PE or Ground The drive safety ground PE must be connected to system or earth ground This is the safety ground for the drive that is required by code This point must be connected to adjacent building steel girder joist a floor ground rod bus bar or building ground grid Grounding points must comply with national and local industrial safety regulations or electrical codes Some codes may require redundant ground paths and periodic examination of connection integrity RFI Filter Grounding Using an optional RFI filter may result in relatively high ground leakage currents Ther
59. l area As a general rule IF the distance between the drive and motor or the distance between drive and input transformer is greater than 75 feet AND IF sensitive circuits with leads greater then 75 feet such as encoders analog or capacitive sensors are routed in or out of the cabinet near the drive or transformer THEN Common mode chokes should be installed Appendix A Motor Cable Length Restrictions Tables The distances listed in each table are valid only for specific cable constructions and may not be accurate for lesser cable designs particularly if the length restriction is due to cable charging current indicated in tables by shading When choosing the proper cable note the following definitions Unshielded Cable e Tray cable fixed geometry without foil or braided shield but including an exterior cover e Individual wires not routed in metallic conduit Shielded Cable e Individual conductors routed in metallic conduit e Fixed geometry cables with no twist in the conductors and with foil or braided shield of at least 75 coverage e Continuous weld or interlocked armored cables with no twist in the conductors may have and optional foil shield Important Certain shielded cable constructions may cause excessive cable charging currents and may interfere with proper application performance particularly on smaller drive ratings Shielded cables that do not maintain a fixed geometry but rather twist
60. lectrical bonding Use a connector with 3 ground bushings when using a cable with 3 ground conductors Figure 4 3 Terminating the Shield with a Connector Metal connector body Braid wires pulled back in a 360 makes direct contact with pattern around the ground cone of the the braid wires connector Metal locknut bonds the connector to the panel Drain wires pulled back in a 360 pattern around the ground cone of the connector Shield termination via Pigtail Lead If a shield terminating connector is not available the ground conductors or shields must be terminated to the appropriate ground terminal If necessary use a compression fitting for ground conductor s and or shields together as they leave the cable fitting Practices 4 5 Figure 4 4 Terminating the Shield with a Pigtail Lead Exposed shield PTT V T2 O W T3 re O e PE Flying lead soldered to braid Pigtail termination is the least effective method of noise containment It is not recommended if e the cable length is greater than 1 m 39 in or extends beyond the panel e in very noisy areas e the cables are for very noise sensitive signals for example registration or encoder cables e strain relief is required If a pigtail is used pull and twist the exposed shield after separation from the conductors Solder a flying lead to the braid to extend its length Ground Connections Ground conductors should be connected with care to assure
61. m 400ft 121m 400ft 3 9m 30ft 30m 100ft 121m 400ft 121m 400ft 2 9m 30ft 30m 100ft 121m 400ft 121m 400ft 1 9m 30ft 30m 100ft 121m 400ft 121m 400ft 0 5 9m 30ft 30m 100ft 121m 400ft 121m 400ft 3 3 9m 30ft 30m 100ft 91m 300ft 121m 400ft 2 9m 30ft 30m 100ft 121m 400ft 121m 400ft 1 9m 30ft 30m 100ft 121m 400ft 121m 400ft 0 5 9m 30ft 30m 100ft 121m 400ft 121m 400ft 2 2 9m 30ft 30m 100ft 76 m 250ft 121m 400ft 1 9m 30ft 30m 100ft 121m 400ft 121m 400ft 0 5 9m 30ft 30m 100ft 121m 400ft 121m 400ft 1 1 9m 30ft 30m 100ft 68 m 225ft 121m 400ft 0 5 9m 30ft 30m 100ft 121m 400ft 121m 400ft 0 5 0 5 9m 30ft 30m 100ft 45m 150ft 106 m 350ft Motor Cable Length Restrictions Tables A 5 Table A D 1305 Drive 480V in meters feet With 1204 TFB2 Reactor Dat the Drive Terminator With 1204 TFA1 Terminator Using a Motor with Using a Motor with Insulation Vp p Insulation Vp p Using a Motor with Insulation Vp p Drive HP Motor HP Type A Type B or 1329R L Type A or Type B Type A Type B 460V 460V Any Cable Shielded Unshielded Shielded Unshielded Shielded Unshielded Shielded Unshielded Maximum Carrier Frequency 2 kHz 2 kHz 2 kHz 2 kHz 2 kHz 2 kHz 2 kHz 2 kHz 2 kHz High Line Derating Multiplier 0 85 0 85 0 85 0 85
62. n an ungrounded system Grounding Safety Grounds Chapter 3 Grounding This chapter discusses various grounding schemes for safety and noise reduction An effectively grounded system or product is one that is intentionally connected to earth through a ground connection or connections of sufficiently low impedance and having sufficient current carrying capacity to prevent the buildup of voltages which may result in undue hazard to connected equipment or to persons as defined by the US National Electric Code NFPA70 Article 100B Grounding of a drive or drive system is done for 2 basic reasons safety defined above and noise containment or reduction While the safety ground system and the noise current return circuit may sometimes share the same path and components they should be considered different circuits with different requirements For information on See page Grounding Safety Grounds 3 1 Noise Related Grounds 3 2 The object of safety grounding is to ensure that all metalwork is at the same ground or Earth potential at power frequencies Impedance between the drive and the building system ground must conform to the requirements of national and local industrial safety regulations or electrical codes These will vary based on country type of distribution system and other factors Periodically check the integrity of all ground connections General safety dictates that all metal parts are connected to earth w
63. nding PE or Ground 3 2 RET Filter Grounding ici ban Hi aka mee eA ee 3 2 Grounding Motors 3 2 Noise Related Grounds ecards 3 2 Acceptable Grounding Practices 3 4 Effective Grounding Practices 3 4 Optimal Recommended Grounding Practices 3 5 Cable Shields cit wot ded tt LE DA oe Reh et le tak 3 6 Isolated Inputs iia sale rasas eee ens neal es j 3 6 Practices Mount ss nf eg diet di doh ace heed SEER 4 1 Standard Installations sein mistika k t as kam weed ae dae 4 1 EMC Specific Installations 4 1 Equipment Mounting Plate 4 1 Ladino 4 2 Conduit ENY seses aei ta is saja bd ta 4 3 Entry Plate coo io a O o eed ao Ds 4 3 Cable Connectors Glands 4 4 Shield termination via Pigtail Lead 4 4 Ground Connections ss oes sigh ete mares ae aes 4 5 Wire Routing oo e eee ek ka eine Shiba heed ee oe du ea die que eS 4 7 MWithin A Cabinet css ahead bene ls k au Seth as 4 7 Within Conduit ces ica cua ment ant part he tea due drag lens Atis ijas g eas 4 9 Loops Antennas and Noise 4 9 Conduit ss nina bean dk A
64. ng system a zinc plated mild steel mounting plate is preferred If the mounting plate is painted remove the paint at each mounting point of every piece of metal clad equipment including DIN rails Zinc plated steel is strongly recommended due to its inherent ability to bond with the device chassis and resist corrosion If a painted panel is used and areas of paint are removed any future corrosion of the unprotected mild steel will compromise noise performance Plain stainless steel panels are 4 2 Practices Mounting Bracket or Ground Bus Flat Washer Nut ae also acceptable but are inferior to zinc plated mild steel due to their higher ohms per square resistance Layout Plan the cabinet layout so that drives are separated from sensitive equipment Choose conduit entry points that allow any common mode noise to remain away from PLCs and other equipment that may be susceptible to noise Refer to Moisture on page 4 14 for additional information Hardware You can mount the drive and or mounting panel with either bolts or welded studs Figure 4 1 Stud Mounting of Ground Bus or Chassis to Back Panel Welded Stud Back Panel Paint Free Area Flat Washer If mounting bracket is coated with a non conductive material anodized painted etc scrape the material off around the mounting hole Practices 4 3 Figure 4 2 Bolt Mounting of Ground Bus or Chassis to
65. oday mil 0 001 inches MOV Metal Oxide Varistor NEC United States National Electric Code NFPA70 PVC Polyvinyl Chloride typically thermoplastic Glossary 3 RWR Reflected Waver Reducer an RL network mounted at or near the drive used to reduce the amplitude and rise time of the reflected wave pulses Cat No 1204 RWR2 09 B or 1204 RWR2 09 C Shielded Cable containing a foil or braided metal shield surrounding the conductors Usually found in multi conductor cable Shield coverage should be at least 75 Signal Individual hard wired analog inputs or outputs typically used to issue reference commands or process information to or from the drive Surrounding Air Temperature The temperature of the air around the drive If the drive is free standing or wall mounted the surrounding air temperature is room temperature If the drive is mounted inside another cabinet the surrounding air temperature is the interior temperature of that cabinet Terminator An RC network mounted at or near the motor used to reduce the amplitude and rise time of the reflected wave pulses Catalog Number 1204 TFxx THHN THWN U S designations for individual conductor wire typically 75 C or 90 C rated and with PVC insulation and nylon coating Unshielded Cable containing no braided or foil sheath surrounding the conductors Can be multi conductor cable or individual conductors Wet Locations with moisture present see Damp XLPE
66. on Power TB 4 13 Termination Signal TB 4 13 U Ungrounded Secondary 2 2 Ungrounded System Example 3 3 W Wire Control 1 8 Signal 1 9 Wire Routing 4 7 Antennas 4 9 Loops 4 9 Noise 4 9 Within a Cabinet 4 7 Within Conduit 4 9 Index 3 Wire Types 1 1 Concentricity 1 3 Conductors 1 2 Exterior Cover 1 1 Gauge 1 2 Geometry 1 3 Insulation Thickness 1 3 Material 1 1 Temperature Rating 1 1 Unshielded Cable 1 3 WireTypes General 1 1 Index 4 Notes Index 5 Notes www rockwellautomation com Corporate Headquarters Rockwell Automation 777 East Wisconsin Avenue Suite 1400 Milwaukee WI 53202 5302 USA Tel 1 414 212 5200 Fax 1 414 212 5201 Headquarters for Allen Bradley Products Rockwell Software Products and Global Manufacturing Solutions Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Rockwell Automation SA NV Vorstlaan Boulevard du Souverain 36 BP 3A B 1170 Brussels Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation 27 F Citicorp Centre 18 Whitfield Road Causeway Bay Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Headquarters for Dodge and Reliance Electric Products Americas Rockwell Automation 6040 Ponders Court Greenville SC 29615 4617 USA Tel 1 864 297 4800 Fax 1 864 281 2433 Europe Rockwell Automation BrihlstraBe 22 D 74834 Elztal Dallau Germany Tel
67. onto the cable see Chapter 2 and in some cases shielded cable may be required to meet noise standards such as CE for Europe C Tick for Australia New Zealand and others This may be especially true if an input filter is required to meet a standard Each individual drive user manual will show the requirements for meeting these types of standards Additionally individual industries may have required standards due to environment or experience For AC variable frequency drive applications that must meet EMC standards such as CE Rockwell Automation may recommend that the same type of shielded cable specified for the AC motors be used between the drive and transformer Check the individual user manuals for specific additional requirements in these situations The majority of recommendations regarding drive cable address issues caused by the nature of the drive output A PWM drive creates AC motor current by sending DC voltage pulses to the motor in a specific pattern These pulses affect the wire insulation and can be a source of electrical noise The rise time amplitude and frequency of these pulses must be considered when choosing a wire cable type The choice of cable must consider 1 The effects of the drive output once the cable is installed 2 The need for the cable to contain noise caused by the drive output 3 The amount of cable charging current available from the drive 4 Possible voltage drop and subsequent loss of torque for
68. or Catalog Volts HP kW KVA 1 2 Open Style 1321 AQF05 240 0 5 25 3R4 A AQF07 240 0 75 25 3R4 A AQF10 240 1 50 3R8 A AQF15 240 1 5 75 3R8 A AQF20 240 2 100 3R12 A AQF30 240 3 200 3R12 A AQF50 240 5 275 3R25 A A007 240 7 5 300 3R25 A A010 240 10 350 3R35 A A015 240 15 600 3R45 A A020 240 20 800 3R80 A A025 240 25 900 3R80 A A030 240 30 950 3R80 A A040 240 40 1000 3R130 A A050 240 50 1200 3R160 A A060 240 60 1400 3R200 A A075 240 75 1500 3R250 A A100 240 100 2200 3R320 A A125 240 125 2500 3R320 A BRF05 480 0 5 25 3R2 B BRF07 480 0 75 30 3R2 B BRF10 480 1 30 3R4 B BRF15 480 1 5 50 3R4 B BRF20 480 2 50 3R8 B BRF30 480 3 75 3R8 B BRF50 480 5 100 3R12 B BRF75 480 7 5 200 3R18 B BRF100 480 10 275 3R25 B BRF150 480 15 300 3R25 B BRF200 480 20 350 3R25 B B015 480 15 350 3R25 B B020 480 20 425 3R35 B B025 480 25 550 3R35 B B030 480 30 600 3R45 B BX040 480 40 750 3R55 B B040 480 40 800 3R55 B B050 480 50 900 3R80 B BX060 480 60 950 3R80 B B060 480 60 950 3R100 B B075 480 75 1000 3R100 B B100 480 100 1200 3R130 B B125 480 125 1400 3R160 B BX150 480 150 1500 3R200 B B150 480 150 2000 3R200 B B200 480 200 2200 3R250 B B250 480 250 2500 3R320 B B300 480 300 3000 3R400 B B350 480 350 3500 3R500 B B400 480 400 4000 3R500 B B450 480 450 4500 3R600 B B500 480 500 5000 3R600 B B600 480 600 5000 3R750 B 1336 Family e Plus Plus Il Impact Force Maximum suggested KVA supply without considera 2 2000 KVA represents 2MVA and
69. rds such as CE or C Tick Cable should have 3 phase conductors and a fully rated individual ground conductor or 3 symmetrical ground conductors whose ampacity equals the phase conductor The outer sheathing and other mechanical characteristics should be chosen to suit the installation environment Consideration should be given to surrounding air temperature chemical environment flexibility and other factors as necessary Shielded Cable Shielded cable contains all of the general benefits of multi conductor cable with the added benefit of a copper braided shield that can contain much of the noise generated by a typical AC Drive Strong consideration for shielded cable should be given for installations with sensitive equipment such as weigh scales capacitive proximity switches and other devices that may be affected by electrical noise in the distribution system Applications with large numbers of drives in a similar location imposed EMC regulations or a high degree of communications networking are also good candidates for shielded cable Shielded cable may also help reduce shaft voltage and induced bearing currents for some applications In addition the increased size of shielded cable may help extend the distance that the motor can be located from the drive without the addition of motor protective devices such as terminator networks Refer to Chapter 5 for information regarding reflected wave phenomena Consideration should be given to all
70. s these loops can be responsible for noise received into the system and noise radiated from the system Run feed and return wires together rather than allow a loop to form Twisting the pair together further reduces the antenna effects Refer to Avoiding Loops in Wiring on page 4 10 4 10 Practices Conduit Cable Trays Figure 4 10 Avoiding Loops in Wiring i Not Recommended Good Solution Better Solution Conduit must be magnetic steel and be installed so as to provide a continuous electrical path through the conduit itself This path can become important in the containment of high frequency noise To avoid nicking use caution when pulling the wire Insulation damage can occur when nylon coated wiring such as THHN or THWN is pulled through conduit particularly 90 bends Nicking can significantly reduce or remove the insulation Use great care when pulling nylon coated Do not use water based lubricants with nylon coated wire such as THHN Do not route more than 3 sets of drive cables in one conduit Maintain the proper fill rates per the applicable electrical codes When laying cable in cable trays do not randomly distribute them Power cables for each drive should be bundled together and anchored to the tray Refer to Figure 4 11 on page 4 10 A minimum separation of one cable width should be maintained between bundles to reduce overheating and cross coupling Current flowing in on
71. ulation Thickness and Concentricity 1 3 GEOMEILY 82e ed ania a ede bt tuant distant is 1 3 Unshielded Cable sa arto 1 3 Shielded Cables kn se eS ies she be bee We eee SOA Re ok Be ee ee ee 1 4 Armored Cable 5s a eines VA dees Wiha ara ade diets Meade bee afa 1 5 European Style Cable ietu nio Oe leg asas aus ts Oe ee 1 6 Input Power Cables senna a E E rs tenseur tatin 1 7 Motor Cables a ht Lt bebe CS ORG oaks BY ng Bed Ait wis Lies aed 1 7 Cable for Discrete Drive LO etd r date Aa Aa a at MG 1 8 Analog Signal and Encoder Cable 1 8 COMMUNICATIONS Bonn ta yt Ai poked eet 1 9 DEVICENET RE NN Dalasa AS S Ne ere 1 9 CONTTOINET EE cavers Re a Te OR Re 1 9 Ethernet tanen donne attendent j t ger PRU a ges es SE a ne Ua de 1 10 Remote I O and Data Highway Plus DH 1 10 Seal RS 232 PASS dis era anne au tii 1 11 Power Distribution System Configurations 2 1 AG Tine Impedance mt a et is i A ane V hs 2 3 Surge Protection MOVS 2 7 Common Mode Capacitors 2 8 Chapter 3 Chapter 4 Chapter 5 Chapter 6 Grounding Grounding Safety Grounds 3 1 B ulding Steel eso wens nent sox ches Oey Sees ane Meee ely Me eh ane mate 3 1 Grou
72. ve system applications or specific industries It offers most of the advantages of standard shielded cable and also combines considerable mechanical strength and resistance to moisture It can be installed in concealed and exposed manners and removes the requirement for conduit EMT in the installation It can also be directly buried or embedded in concrete Because noise containment can be affected by incidental grounding of the armor to building steel see Chapter 2 when the cable is mounted it is recommended the armored cable have an overall PVC jacket Interlocked armor is acceptable for shorter cable runs but continuous welded armor is preferred Best performance is achieved with 3 spaced ground conductors but acceptable performance below 200 HP is provided via a single ground conductor 1 6 Wire Types Table 1 A Recommended Shielded Armored Cable Location Stand Option 1 Rating Type 600 V 90 C 194 F XHHW2 RHW 2 Anixter B209500 B209507 Belden 29501 29507 or equivalent Description Four tinned copper conductors with XLPE insulation Copper braid aluminum foil combination shield and tinned copper drain wire PVC jacket Standard Option 2 Tray rated 600V 90 C 194 F RHH RHW 2 Anixter OLF 7xxxxx or equivalent Three tinned copper conductors with XLPE insulation 5mil single helical copper tape 25 overlap min with three PVC jacket Class amp Il Division 8 11 Tray rated
73. viceNet network Refer to DeviceNet Cable System Planning and Installation Manual publication DN 6 72 In general there are 4 acceptable cable types for DeviceNet media These include 1 Round Thick cable with an outside diameter of 12 2 mm 0 48 in normally used for trunk lines but can also be used for drop lines 2 Round Thin cable with an outside diameter of 6 9 mm 0 27 in normally used for drop lines but may also be used for trunk lines 3 Flat cable normally used for trunk lines 4 KwikLink drop cable used only in KwikLink systems Round cable contains five wires one twisted pair red and black for 24V DC power one twisted pair blue and white for signal and a drain wire bare Flat cable contains four wires one pair red and black for 24V DC power and one pair blue and white for signal Drop cable for KwikLink is a 4 wire unshielded gray cable The distance between points installation of terminating resistors and chosen baud rate all play a significant part in the installation Again refer to the DeviceNet Cable System Planning and Installation Manual for detailed specifics ControlNet ControlNet cable options topology distances allowed and techniques used are very specific to the ControlNet network For more information refer to ControlNet Coax Cable System Planning and Installation Manual publication 1786 6 2 1 1 10 Wire Types Depending on the environment at the installation site there are s
74. when the installation may include welding electrostatic processes drives over 10 HP Motor Control Centers high power RF radiation or devices carrying current in excess of 100 Amps Shield handling and single point grounding also discussed in this document play an extremely important role in the proper operation of Ethernet installations Finally there are distance and routing limitations published in detail Remote I O and Data Highway Plus DH Only 1770 CD Belden 9463 is tested and approved for Remote I O and DH installations Wire Types 1 11 The maximum cable length depends on the chosen baud rate Baud Rate Maximum Cable Length 57 6 KBPS 3 048 m 10 000 ft 115 2 KBPS 1524 m 5000 ft 230 4 KBPS 762 m 2500 ft All three connections blue shield and clear must be connected at each node Do not connect in star topology Only two cables may be connected at any wiring point Use either series or daisy chain topology at all points Serial RS232 485 Standard practices for serial communications wiring should be followed Belden 3106A or equivalent is recommended for RS232 It contains one twisted pair and 1 signal common Recommended cable for RS485 is 2 twisted pair with each pair individually shielded 1 12 Wire Types Notes System Configurations Chapter 2 Power Distribution This chapter discusses different power distribution schemes and factors which affect drive performance
75. ype Wire Type s Description Insulation Rating Unshielded Per US NEC or applicable national 300V 60 C or local code 140 F Shielded Multi conductor shielded cable 0 750 mm 18AWG such as Belden 8770 or equiv 3 conductor shielded Always use shielded cable with copper wire Wire with insulation rating of 300V or greater is recommended Analog signal wires should be separated from power wires by at least 0 3 meters 1 foot It is recommended that encoder cables be run in a separate conduit If signal cables must cross power cables cross at right angles Communications Wire Types 1 9 Table 1 C Recommended Signal Wire Signal Minimum Type Wire Type s Description Insulation Rating Standard Belden 8760 9460 or equiv 0 750 mm 18 AWG twisted 300V Analog I O pair 100 shield with drain 75 90 C Belden 8770 or equiv 0 750 mm 18AWG 3 cond 167 194 F shielded for remote pot only Encoder _ Less than or equal to 30 m 98 ft 0 196 mm 24AWG Pulse I O Belden 9730 or equiv individually shielded Greater than 30 m 98 ft 0 750 mm 18 AWG twisted Belden 9773 or equiv pair shielded 1 Ifthe wires are short and contained within a cabinet which has no sensitive circuits the use of shielded wire may not be necessary but is always recommended DeviceNet DeviceNet cable options topology distances allowed and techniques used are very specific to the De

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