Rockwell Automation Allen-Bradley 1305-AA02A Installation Instructions Manual Download Page 98

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Index-4

Reflected Wave

5-1

Effects on Wire Types

Length Restrictions

Reflective Wave Protection

Relays, Noise

Remote I/O

Resistance, Ground

RFI Filter Grounding

Routing

RWR (Reflective Wave Reducer)

A-8

Safety Grounds

Building Steel

3-1

Grounding PE or Ground

3-2

Safety Grounds, Grounding

3-1

Secondary, Ungrounded

2-3

Serial (RS232/485)

1-14

Shields

Cable

1-6

3-7

Termination

4-15

Signal

Analog Cable

Terminals

Wire

Solenoids, Noise

Spacing

Wiring

Standard Installation

4-1

Suppression, Noise

Contracts

Inductive Loads

Motor Starters

Motors

Relays

Suppressor

Surge Protection

MOV

2-17

Switch Contacts

Noise

6-3

6-4

System Configuration

Delta/Delta with Grounded Leg

2-2

Delta/Wye with Grounded Wye

2-1

High Resistance Ground

2-3

TN-S Five-Wire System

2-4

Ungrounded Secondary

2-3

TB (Terminal Block)

Control

Power

Temperature

Termination

Conductor

Control Terminal

Power Terminals

Shield via Pigtail (Lead)

Signal Terminals

Via Cable Clamp

Via Circular Clamp

Via Pigtail (Lead)

TN-S Five-Wire Systems

2-4

3-2

Transient Interference

Suppression

Ungrounded Secondary

Ungrounded System Example

Unshielded Cable

Varistors

Wire

Control

Insulation

Power

Summary of Contents for Allen-Bradley 1305-AA02A

Page 1: ...Installation Instructions Wiring and Grounding Guidelines for Pulse Width Modulated PWM AC Drives ...

Page 2: ...ability is assumed by Rockwell Automation Inc with respect to use of information circuits equipment or software described in this manual Reproduction of the contents of this manual in whole or in part without written permission of Rockwell Automation Inc is prohibited Throughout this manual when necessary we use notes to make you aware of safety considerations Important Identifies information that...

Page 3: ...delines for Pulse Width Modulated AC Drives publication DRIVES IN001 since the last release Manual Updates Change Page Revised guidelines for AC line impedance 2 5 Revised guidelines for multi drive protection 2 15 Revised guidelines for MOVs and common mode capacitors 2 17 Added footnote 4 A 10 ...

Page 4: ...ii Summary of Changes Notes ...

Page 5: ...2 Communications 1 12 Chapter 2 Power Distribution System Configurations 2 1 AC Line Voltage 2 4 AC Line Impedance 2 5 Surge Protection MOVs and Common Mode Capacitors 2 17 Chapter 3 Grounding Grounding Safety Grounds 3 1 Noise Related Grounds 3 3 Chapter 4 Practices Mounting 4 1 Conduit Entry 4 4 Ground Connections 4 6 Wire Routing 4 9 Conduit 4 13 Cable Trays 4 14 Shield Termination 4 15 Conduct...

Page 6: ...ith Cabling 6 2 How Electromechanical Switches Cause Transient Interference 6 3 How to Prevent or Mitigate Transient Interference from Electromechanical Switches 6 4 Enclosure Lighting 6 7 Appendix A Motor Cable Length Restrictions Tables PowerFlex 4 and 40 Drives A 8 PowerFlex 400 Drives A 8 Glossary Index ...

Page 7: ...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 Indust...

Page 8: ...321 2 0 www rockwellautomation com liiterature Title Publication Available 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 ATTENTION To avoid an electric shock hazard verify that the voltage on the bus capacitors has discharg...

Page 9: ...y and crush resistance Electrical characteristics including cable capacitance charging current resistance voltage drop current rating and insulation Insulation may be the most significant of these Since drives can create voltages well in excess of line voltage the industry standard cables used in the past may not represent the best choice for customers using variable speed drives Drive installatio...

Page 10: ...ave Voltage for New and Existing Wire Installations in Conduit or Cable Trays Conductor Environment Conductor Insulation Insulation Thickness XLPE PVC OK for 600V AC System No RWR or Terminator required 20 mil or 1 230V 400 460V 15 mil RWR or Terminator No RWR or Terminator Cable Length of Drives in Same Conduit or Wire Tray 50 ft 50 ft Single Drive Single Conduit or Wire Tray Multiple Drives in S...

Page 11: ...cal limitations of the terminal blocks Local or national electrical codes also set the required minimum gauge based on motor full load current 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 2 on page 1 3 shows cable with a single ground co...

Page 12: ...arge 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 i...

Page 13: ...g Type Description Type 1 2 AWG Standard Installations 100 hp or less 600V 90o C 194o F XHHW2 RHW 2 Four tinned copper conductors with XLPE insulation Type 2 2 AWG Standard Installations 100 hp or less with Brake Conductors 600V 90o C 194o F RHH RHW 2 Four tinned copper conductors with XLPE insulation plus one 1 shielded pair of brake conductors Type 3 500 MCM AWG Standard Installations 150 hp or ...

Page 14: ...ximity 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 inc...

Page 15: ...ation on these installations refer to Table 1 A on page 1 5 Figure 1 7 Type 1 Installation Shielded Cable with Four Conductors Type 2 Installation A good example of acceptable shielded cable for Type 2 installation is Anixter OLF 7xxxxx This is essentially the same cable as Type 1 plus one 1 shielded pair of brake conductors For more information on this installation refer to Table 1 A on page 1 5 ...

Page 16: ...uminum armor is often recommended in drive 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 Beca...

Page 17: ...EC 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 cu...

Page 18: ...these situations Motor Cables 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 c...

Page 19: ...e gauge and applicable codes are acceptable if they are routed away from higher voltage cables to minimize noise coupling However 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 182 9 600 91 4 300 91 4 300 15 2 50 167 6 550 152 4 500 15 2 50 15 2 50 All example...

Page 20: ...l Type Where Used Wire Type s Description Minimum Insulation Rating Standard Analog I O Belden 8760 9460 or equiv 0 750 mm2 18AWG twisted pair 100 shield with drain 5 5 If the 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 300V 75 90 ºC 167 194 ºF Remote Pot Belden 8770 or equiv 0 750 mm2 18AWG ...

Page 21: ...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 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 inter...

Page 22: ...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 The maximum cable length depends on the chosen baud rate 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 ...

Page 23: ...ues and shortcomings Delta Wye with Grounded Wye Neutral Delta Wye with Grounded Wye Neutral is the most common type of distribution system It provides re balancing of unbalanced voltage with a 30 degree phase shift The grounded neutral provides a direct path for common mode current caused by the drive output see Chapter 3 and Chapter 6 Rockwell Automation strongly recommends the use of grounded n...

Page 24: ...ne side tapped This tap the neutral is connected to earth The configuration is called the antiphase grounded neutral system The open delta transformer connection is limited to 58 of the 240V single phase transformer rating Closing the delta with a third single phase 240V transformer allows full rating for the two single phase 240V transformers The phase leg opposite the midpoint has an elevated vo...

Page 25: ...be considered with the secondary of the transformer grounded Refer to local codes regarding safety requirements High Resistance Ground 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 prote...

Page 26: ...th wire is a separate ground wire There is a single connection between ground and neutral typically in the distribution system There should be no connections between ground and neutral within the system cabinets AC Line Voltage In general all Allen Bradley drives are tolerant to a wide swing of AC line voltage Check the individual specification for the drives you are installing Incoming voltage im...

Page 27: ...nce recommendation tables Table 2 A on page 7 through Table 2 H on page 13 that are specific to each drive Using these tables will allow the largest transformer size for each product and rating based on specific differences in construction and is the preferred method to follow Otherwise use one of the two following more conservative methods 1 For drives without built in inductors add line impedanc...

Page 28: ... big for the drive and a line reactor should be added Zxfmr Vline line 3 Ixfmr rated Impedance Impedance is the nameplate impedance of the transformer Typical values range from 0 03 3 to 0 06 6 Zxfmr Vline line VA Impedance 2 or Zxfmr Vline line 3 Ixfmr rated Impedance Impedance is the nameplate impedance of the transformer Typical values range from 0 03 3 to 0 06 6 ohms 102 6 7 2 3 480V I 3 V Z r...

Page 29: ... 1 25 12 AA18 240 3 7 5 100 3R18 A 0 8 18 BA01 480 0 37 0 5 15 3R2 B 20 2 BA02 480 0 55 0 75 20 3R2 A 12 2 BA03 480 0 75 1 30 3R2 A 12 2 BA04 480 1 5 2 50 3R4 B 6 5 4 BA06 480 2 2 3 75 3R8 B 3 8 BA10 480 3 7 5 100 3R18 B 1 5 18 1 Shaded rows identify drive ratings without built in inductors 2 Maximum suggested KVA supply without consideration for additional inductance Drive Catalog 1 Volts kW hp M...

Page 30: ...yle 1321 Reactor Inductance mh Reactor Current Rating Amps PowerFlex 40 22BB2P3 240 0 4 0 5 25 3R4 B 6 5 4 22BB5P0 240 0 75 1 0 50 3R8 B 3 8 22BB8P0 240 1 5 2 0 50 3R8 A 1 5 8 22BB012 240 2 2 3 0 50 3R12 A 1 25 12 22BB017 240 3 7 5 0 50 3R18 A 0 8 18 22BB024 240 5 5 7 5 100 3R25 A 0 5 25 22BB033 240 7 5 10 0 150 3R35 A 0 4 35 22BD1P4 480 0 4 0 5 15 3R2 B 20 2 22BD2P3 480 0 75 1 0 30 3R4 C 9 4 22BD...

Page 31: ... 11 15 N A N A N A N A 22CD030 480 15 20 N A N A N A N A 22CD038 480 18 5 25 N A N A N A N A 22CD045 480 22 30 N A N A N A N A 22CD060 480 30 40 N A N A N A N A 22CD072 480 37 50 N A N A N A N A 22CD088 480 45 60 N A N A N A N A 22CD105 480 55 75 N A N A N A N A 22CD142 480 75 100 N A N A N A N A 22CD170 480 90 125 N A N A N A N A 22CD208 480 110 150 N A N A N A N A 1 Shaded rows identify drive ra...

Page 32: ...25 B 1 2 25 20AD027 480 15 20 400 3R35 B 0 8 35 20AD034 480 18 5 25 750 3R35 B N A N A 20AD040 480 22 30 1000 3R45 B N A N A 20AD052 480 30 40 1000 3R55 B N A N A 20AD065 480 37 50 1000 3R80 B N A N A 20AE0P9 600 0 37 0 5 30 3R2 B 20 2 20AE1P7 600 0 75 1 50 3R2 B 20 2 20AE2P7 600 1 5 2 50 3R4 C 9 4 20AE3P9 600 2 2 3 75 3R4 C 9 4 20AE6P1 600 4 0 5 100 3R8 C 5 8 20AE9P0 600 5 5 7 5 250 3R8 B 3 8 20A...

Page 33: ... 0 1 130 20BB130 240 37 50 1000 3R130 A 0 1 130 20BB154 240 45 60 1000 3R160 A 0 075 160 20BB192 240 55 75 1000 3R200 A 0 055 200 20BB260 240 75 100 1000 3R320 A 0 04 320 20BC1P3 400 0 37 5 250 3R2 B 20 2 20BC2P1 400 0 75 1 250 3R2 B 20 2 20BC3P5 400 1 5 2 500 3R4 B 6 5 4 20BC5P0 400 2 2 3 500 3R4 B 6 5 4 20BC8P7 400 4 5 500 3R8 B 3 8 20BC011 400 5 5 7 5 750 3R12 B 2 5 12 20BC015 400 7 5 10 1000 3...

Page 34: ...125 1500 3R160 B 0 15 160 20BD180 480 110 150 1500 3R200 B 0 11 200 20BE0P9 600 0 37 0 5 250 3R2 B 20 2 20BE1P7 600 0 75 1 250 3R2 B 20 2 20BE2P7 600 1 5 2 500 3R4 B 6 5 4 20BE3P9 600 2 2 3 500 3R4 B 6 5 4 20BE6P1 600 4 0 5 500 3R8 B 3 8 20BE9P0 600 5 5 7 5 750 3R8 B 3 8 20BE011 600 7 5 10 750 3R12 B 2 5 12 20BE017 600 11 15 750 3R25 B 1 2 25 20BE022 600 15 20 750 3R25 B 1 2 25 20BE027 600 18 5 25...

Page 35: ...320 A125 240 93 125 1000 3RB320 A 0 04 320 BRF05 480 0 37 0 5 25 3R2 B 20 2 BRF07 480 0 56 0 75 30 3R2 B 20 2 BRF10 480 0 75 1 30 3R4 B 6 5 4 BRF15 480 1 2 1 5 50 3R4 B 6 5 4 BRF20 480 1 5 2 50 3R8 B 3 0 8 BRF30 480 2 2 3 75 3R8 B 3 0 8 BRF50 480 3 7 5 100 3R12 B 2 5 12 BRF75 480 5 5 7 5 200 3R18 B 1 5 18 BRF100 480 7 5 10 275 3R25 B 1 2 25 BRF150 480 11 15 300 3R25 B 1 2 25 BRF200 480 15 20 350 3...

Page 36: ... 7 45 C050 600 37 50 850 3R55 B 0 5 55 C060 600 45 60 900 3R80 B 0 4 80 C075 600 56 75 950 3R80 B 0 4 80 C100 600 75 100 1200 3R100 B 0 3 100 C125 600 93 125 1400 3R130 B 0 2 130 C150 600 112 150 1500 3R160 B 0 15 160 C200 600 149 200 2200 3R200 B 0 11 200 C250 600 187 250 2500 3R250 B 0 09 250 C300 600 224 300 3000 3R320 B 0 075 320 C350 600 261 350 3000 3R400 B 0 06 400 C400 600 298 400 4000 3R4...

Page 37: ...on one reactor 2 Add the input currents of the drives in the group 3 Multiply that sum by 125 4 Use publication 1321 2 0 to select a reactor with a maximum continuous current rating greater than the multiplied current 5 Verify that the impedance of the selected reactor is more than 0 5 0 25 for drives with internal inductors of the smallest drive in the group by using the formulas below If the imp...

Page 38: ...ublication 1321 2 0 we selected the reactor 1321 3R12 C which has a maximum continuous current rating of 18 amps and an inductance of 4 2 mh 0 0042 henries 1 54 is more than the 0 5 impedance recommended The 1321 3R12 C can be used for the 5 2 7 amp drives in this example Ohms 102 6 2 7 3 480 I 3 V Z rating input line line drive Ohms 58 1 60 2 0042 0 2 Zreactor Π Π f L 1 54 0 0154 102 6 1 58 Z Z d...

Page 39: ... continuous current path to ground Exceeding the published phase to phase phase to ground voltage or energy ratings may cause physical damage to the 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 ground voltage or when the supply ground is tied to another system or equipment that could cause...

Page 40: ...2 18 Power Distribution Notes ...

Page 41: ...he drive and the building scheme 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 with separate copper wire or wires of the appropr...

Page 42: ...s 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 ...

Page 43: ...ts cause sensitive equipment to malfunction if they are allowed to propagate L1 L2 L3 PEN or N PE R S T R S T PE PE PE AC Drive Single Phase Device Input Transformer System Cabinet Cabinet Ground Bus X0 R S T U V W PE AC DRIVE INPUT TRANSFORMER MOTOR MOTOR FRAME A B C PE SYSTEM GROUND Feed back Device C lg m C lg c Vng Path for Common Mode Current Path for Common Mode Current Path for Common Mode ...

Page 44: ...ce ground shown in Figure 3 3 provides a direct path for common mode noise current like a fully grounded scheme Designers who are concerned with minimizing ground fault currents commonly choose high resistance ground schemes Figure 3 3 Scheme with High Resistance Ground A fully grounded scheme shown in Figure 3 4 provides a direct path for common mode noise currents Allen Bradley strongly recommen...

Page 45: ... drive installation 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 Earth Ground Potential X0 R S T U V W PE PE AC DRIVE Panel Ground Bus INPUT TRANSFORMER OPTIONAL ENCLOSURE MOTOR MOT...

Page 46: ... or Armored Cable with PVC Jacket BUILDING GROUND POTENTIAL A B C PE Connection to Ground Grid Girder or Ground Rod Connection to Cabinet Ground Bus or Directly to Drive PE Terminal Connection to Drive Structure or Optional Cabinet Via Grounding Connector or Terminating Shield at PE Terminal Motor Frame Ground X0 R S T U V W PE PE AC DRIVE Panel Ground Bus INPUT TRANSFORMER OPTIONAL ENCLOSURE MOTO...

Page 47: ...sure that continuity of the shield is not interrupted Avoid splicing motor power cables when ever possible Ideally motor cables should run continuously between the drive and motor terminals The most common reason for interrupted cable shield is to incorporate an at the motor disconnect switch In these cases the preferred method of splicing is to use fully shielded bulkhead connectors Single Point ...

Page 48: ...3 8 Grounding Notes ...

Page 49: ...ple below the drive chassis ground plane is extended to the mounting panel The panel is made of zinc plated steel to ensure a proper bond between chassis and panel Figure 4 1 Drive Chassis Ground Plane Extended to the Panel Note Where TE and PE terminals are provided ground each separately to the nearest point on the panel using flat braid In an industrial control cabinet the equivalent to the cop...

Page 50: ...ns more reliable Doors For doors 2 m 78 in in height ground the door to the cabinet with two or three braided straps EMC seals are not normally required for industrial systems 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 conduc...

Page 51: ...Figure 4 2 Stud Mounting of Ground Bus or Chassis to Back Panel Back Panel Welded Stud Paint Free Area Nut Flat Washer Mounting Bracket or Ground Bus Star Washer If mounting bracket is coated with a non conductive material anodized painted etc scrape the material off around the mounting hole Flat Washer ...

Page 52: ...nants If the plate is painted use a connector that cuts through the paint and makes a high quality 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 quality joint compound when reassembling to avoid corrosion Back Panel Bolt Paint Free Area Nut Flat Washer Mou...

Page 53: ... 3 ground bushings when using a cable with 3 ground conductors Figure 4 4 Terminating the Shield with a 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 fi...

Page 54: ... 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 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 i...

Page 55: ...losure Wall Bolt Star Washer Component Grounding Conductor Ground Lug Tapped Hole Ground Bus Component Grounding Conductors Star Washer Bolt Paint Free Area Welded Stud Ground Lug Ground Lug Star Washer Star Washer Component Ground Conductor Nut Star Washer Nut Component Ground Conductor ...

Page 56: ... 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 8 Multiple Connections to Ground Stud or Bolts ...

Page 57: ...es Refer to Spacing Note 7 Control 5 115V ac dc Logic Relay Logic PLC I O Motor Thermostat 3 9 3 6 0 3 9 Refer to Spacing Note 6 Refer to Spacing Notes 1 2 and 5 115V ac Power Power Supplies Instruments 6 24V ac dc Logic PLC I O Signal Process 7 Analog Signals DC Supplies Reference Feedback Signal 5 to 24V DC 3 18 3 12 3 9 0 1 3 Refer to Spacing Notes 2 3 4 and 5 Digital Low Speed TTK 8 Digital Hi...

Page 58: ...eparate spacing 3 Level 7 through Level 11 wires must be shielded per recommendations 4 In cable trays steel separators are advisable between the class groupings 5 If conduit is used it must be continuous and composed of magnetic steel 6 Spacing of Communication cables Levels 2 through 6 is the following 7 If more than one brake module is required the first module must be mounted within 3 0 m 10 f...

Page 59: ...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 Susceptible Equipment on page 4 12 If a cabinet PE ground wire is run it should be connected from the same side of the cabinet as the conduit armor connections This keeps the common mode noise shunted away from the PLC backplane Drive Power Wiring PWM D...

Page 60: ...oops 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 modes 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 R S T ...

Page 61: ...h 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 90º bends Nicking can significantly reduce or remove the insulation Use great care when pulling nylon coated Do not use water based l...

Page 62: ...le cable sets Keep conductors within each group bundled Arrange the order of the conductors to minimize the current which induced between sets and to balance the currents This is critical on drives with power ratings of 200 hp 150 kW and higher Maintain separation between power and control cables When laying out cable tray for large drives make sure that cable tray or conduit containing signal wir...

Page 63: ...ng method The preferred method for grounding cable shields is clamping the circular section of 360º bonding as shown in Commercial Cable Clamp Heavy Duty on page 4 15 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 13 Commercial Cable Clamp Heavy Duty Plain copper saddle clamp...

Page 64: ...ld together as they leave the cable fitting Pigtail termination is the least effective method of noise containment It is not recommended if the cable length is greater than 1 m 39 in or extends beyond the panel being used in very noisy areas the cables are for very noise sensitive signals for example registration or encoder cables strain relief is required If a pigtail is used pull and twist the e...

Page 65: ...od 360o 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 electrical bonding Armored Cable Armored cable can be terminated in a similar manner to standard cable SKINTOP MS SC MS SCL cable grounding connectors and NPT PG adapters from LAPPUSA are good examples of standard cable clamp shield termin...

Page 66: ...ripping 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 connec...

Page 67: ...ctor 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 mode noise Other cable types for wet locations include continuous welded armor cables or C...

Page 68: ...4 20 Practices Notes ...

Page 69: ...he 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 d...

Page 70: ...ots in the insulation which lowers the cable s voltage withstand capability Refer to NEC Article 100 for definitions of Damp Dry and Wet locations The U S NEC 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 XHHN 2 iden...

Page 71: ...requency 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 conventi...

Page 72: ...d 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 Take care when bonding the armor or shield to the drive PE A low impedance cable or strap is recommended when making this connection as opposed to the smaller gauge ground wire either suppli...

Page 73: ...nstantly when the switch contacts open There is also stray capacitance in the wiring Interference occurs when the switch opens while it is carrying current Load and cable inductance prevents the current from immediately stopping The current continues to flow and charges the capacitance in the circuit The voltage across the switch contacts VC rises as the capacitance charges This voltage can reach ...

Page 74: ...en Bradley Bulletin 156 contactor to switch inductive AC loads These devices feature zero cross switching Putting Resistive Capacitive RC networks or Voltage Dependant Resistors Varistors across contacts will mitigate transient interference Make sure to select components rated to withstand the voltage power and frequency of switching for your application Load AC A1 A2 L1 T1 Bulletin 156 Contactor ...

Page 75: ...ng for your application These methods are not totally effective because they do not entirely eliminate arcing at the contacts The following table contains examples which illustrate methods for mitigating transient interference Load DC Load AC Load AC Examples of Transient Interference Mitigation Example 1 A contact output controls a dc control relay The relay coil requires a suppressor blocking di...

Page 76: ...ause it is an inductive device controlled by dry contacts Example 4 A contact output controls a pilot light with a built in step down transformer The pilot light requires a suppressor because its transformer is an inductive device controlled by a dry contact Example 5 A contact output controls a relay which controls a brake solenoid The contacts require RC networks or Varistors Both the relay and ...

Page 77: ...uard against EMI problems from this source as shown in the figure below install a shielding grid over the lamp use shielded cable between the lamp and its switch use a metal encased switch install a filter between the switch and the power line or shield the power line cable Filter Shielding grid over lamp Shielded cable Metel encased switch Line filter or shielded power line ac power ...

Page 78: ...6 8 Electromagnetic Interference Notes ...

Page 79: ...nterfere with proper application performance particularly on smaller drive ratings Shielded cables that do not maintain a fixed geometry but rather twist 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 c...

Page 80: ...0 182 9 600 182 9 600 30 5 100 30 5 100 91 4 300 61 0 200 182 9 600 22 9 75 182 9 600 2 2 3 2 2 3 7 6 25 12 2 40 91 4 300 91 4 300 182 9 600 182 9 600 182 9 600 Use 1204 TFB2 22 9 75 182 9 600 1 5 2 7 6 25 12 2 40 114 3 375 182 9 600 182 9 600 182 9 600 182 9 600 22 9 75 182 9 600 0 75 1 7 6 25 12 2 40 114 3 375 182 9 600 182 9 600 182 9 600 182 9 600 22 9 75 182 9 600 0 37 0 5 7 6 25 12 2 40 114 ...

Page 81: ... NR NR NA NR 182 9 600 335 3 1100 NR 61 0 200 182 9 600 1 5 2 1 5 2 NR NR NA NR 182 9 600 335 3 1100 NR 61 0 200 182 9 600 1 2 1 5 NR NR NA NR 182 9 600 335 3 1100 NR 61 0 200 182 9 600 0 75 1 NR NR 182 9 600 NR 182 9 600 335 3 1100 NR 61 0 200 182 9 600 0 37 0 5 NR NR 182 9 600 NR 182 9 600 335 3 1100 NR 61 0 200 182 9 600 2 2 3 2 2 3 NR NR NA NR 182 9 600 335 3 1100 NR 61 0 200 182 9 600 1 5 2 N...

Page 82: ...igh Line Derate Multiplier 0 85 0 85 0 55 0 55 5 5 9m 30ft 30m 100ft 121m 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 ...

Page 83: ... 300ft 121m 400ft 3 15m 50ft 182m 600ft 182m 600ft 91m 300ft 121m 400ft 99m 325ft 61m 200ft 152m 500ft 121m 400ft 2 15m 50ft 182m 600ft 182m 600ft 121m 400ft 182m 600ft 99m 325ft 61m 200ft 182m 600ft 121m 400ft 1 15m 50ft 182m 600ft 182m 600ft 121m 400ft 182m 600ft 99m 325ft 61m 200ft 182m 600ft 121m 400ft 0 5 15m 50ft 182m 600ft 182m 600ft 182m 600ft 182m 600ft 99m 325ft 61m 200ft 182m 600ft 121m...

Page 84: ... 76 2 250 1200 27 4 90 18 3 60 160 525 183 600 99 1 325 130 425 1600 160 525 152 500 160 525 183 600 160 525 183 600 1 5 kW 2 hp 1000 12 2 40 12 2 40 130 425 183 600 99 1 325 91 5 300 1200 27 4 90 18 3 60 130 425 183 600 130 425 137 450 1600 152 500 152 500 130 425 183 600 165 540 183 600 0 75 kW 1 hp 1000 16 8 55 12 2 40 99 1 325 183 600 99 1 325 107 350 1200 38 1 125 18 3 60 99 1 325 183 600 152...

Page 85: ...8 275 183 600 122 400 183 600 8 122 400 152 500 NR 122 400 152 500 1 5 kW 2 hp 2 91 5 300 168 550 83 8 275 183 600 91 5 300 183 600 4 91 5 300 168 550 83 8 275 183 600 91 5 300 152 500 8 99 1 325 152 500 NR 107 350 152 500 0 75 kW 1 hp 2 61 200 114 375 61 200 130 425 68 6 225 122 400 4 68 6 225 114 375 61 200 130 425 68 6 225 114 375 8 76 2 250 114 375 NR 68 6 225 122 400 0 55 kW 0 75 hp 2 54 9 18...

Page 86: ...reflected wave data applies to all frequencies 2 to 10 kHz For 240V ratings reflected wave effects do not need to be considered Table A F Maximum Cable Length Recommendation Reflected Wave 380 480V Ratings Motor Insulation Rating Motor Cable Only 1 1 You can extend cable lengths by installing reactors at the drive end or other reflected wave mitigation devices RWRs or Terminators at the motor end ...

Page 87: ... NA 400 550 5 2 NA 80 40 NA 280 80 NA 450 600 NA 450 600 4 NA 80 40 NA 280 80 NA 400 600 NA 400 600 6 NA 80 40 NA 280 80 NA 400 560 NA 400 600 8 NA 80 40 NA 280 80 NA 300 400 NA 300 600 10 NA 80 40 NA 280 80 NA 300 360 NA 300 580 7 5 2 NA 50 40 NA 300 60 NA 400 600 NA 400 600 4 NA 50 40 NA 300 60 NA 400 600 NA 400 600 6 NA 50 40 NA 300 60 NA 400 520 NA 400 600 8 NA 50 40 NA 300 60 NA 400 400 NA 40...

Page 88: ... 70 50 NA 400 80 NA 600 600 NA 600 600 6 NA 70 50 NA 200 80 NA 600 600 NA 600 600 8 NA 70 50 NA 160 80 NA 600 600 NA 600 600 10 NA 70 50 NA 160 80 NA 600 340 NA 600 600 60 2 NA 70 50 NA 600 80 NA 600 600 NA 600 600 4 NA 70 50 NA 400 80 NA 600 600 NA 600 600 6 NA 70 50 NA 200 80 NA 600 600 NA 600 600 8 NA 70 50 NA 160 80 NA 600 600 NA 600 600 10 NA 70 50 NA 160 80 NA 600 340 NA 600 600 75 2 NA 70 5...

Page 89: ... NA NA NA NA NA NA NA NA NA 10 NA NA NA NA NA NA NA NA NA NA NA NA 3 2 NA NA NA NA NA NA NA NA NA NA NA NA 4 NA NA NA NA NA NA NA NA NA NA NA NA 6 NA NA NA NA NA NA NA NA NA NA NA NA 8 NA NA NA NA NA NA NA NA NA NA NA NA 10 NA NA NA NA NA NA NA NA NA NA NA NA 5 2 NA NA NA NA NA NA NA NA NA NA NA NA 4 NA NA NA NA NA NA NA NA NA NA NA NA 6 NA NA NA NA NA NA NA NA NA NA NA NA 8 NA NA NA NA NA NA NA N...

Page 90: ...NA NA NA NA NA NA NA NA NA 10 NA NA NA NA NA NA NA NA NA NA NA NA 3 2 NA NA NA NA NA NA NA NA NA NA NA NA 4 NA NA 600 NA NA 600 NA NA NA NA NA NA 6 NA NA NA NA NA NA NA NA NA NA NA NA 8 NA NA NA NA NA NA NA NA NA NA NA NA 10 NA NA NA NA NA NA NA NA NA NA NA NA 5 2 NA NA NA NA NA NA NA NA NA NA NA NA 4 NA NA 600 NA NA 600 NA NA NA NA NA NA 6 NA NA NA NA NA NA NA NA NA NA NA NA 8 NA NA NA NA NA NA N...

Page 91: ...nt for more current than the 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 ...

Page 92: ...struction 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 today mil 0 001 inches MOV Metal Oxide Varistor NEC United States National Electric Code NFPA70 Peak Cable Charging Current The curre...

Page 93: ...perature 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 ...

Page 94: ...Glossary 4 UL Underwriters Laboratories ...

Page 95: ...og Signal 1 12 Armored 1 8 Connectors 4 5 Containing Common Mode Noise 6 2 Discrete Drive I O 1 11 Encoder 1 12 European Style 1 9 Exterior Cover 1 2 Length 1 11 Material 1 2 Recommended 1 5 Shielded 1 6 Shields 3 7 Trays 4 14 Types 1 1 1 8 Unshield Definition A 1 Unshielded 1 5 Cable Length Restrictions A 1 Cables Input Power 1 10 3 7 Capacitive Current Cable Length Recommendations A 7 Capacitors...

Page 96: ...rFlex 4 AC Line Impedance 2 8 PowerFlex 40 A 8 PowerFlex 40 AC Line Impedance 2 8 PowerFlex 400 A 8 PowerFlex 400 AC Line Impedance 2 9 PowerFlex 70 A 9 A 11 A 12 PowerFlex 70 AC Line Impedance 2 9 PowerFlex 700 A 9 A 11 A 12 PowerFlex 700 AC Line Impedance 2 11 E Electromagnetic Interference EMI Causes 6 3 Mitigating 6 4 Preventing 6 4 EMC Installation 4 2 Encoder Cable 1 12 Ethernet 1 13 Europea...

Page 97: ...e Drives Line Impedance 2 15 Reactor 2 15 N Noise Brake 6 3 6 4 Common Mode 6 1 Contacts 6 3 6 4 Enclosure Lighting 6 7 Inductive Loads 6 4 Lighting 6 7 Mitigating 6 4 Motor Brake 6 3 6 4 Motor Starters 6 3 6 4 Motors 6 3 6 4 Preventing 6 4 Related Grounds 3 3 Relays 6 3 6 4 Solenoids 6 3 6 4 Switch Contacts 6 3 6 4 Transient Interference 6 3 6 4 P Power Wire 1 10 1 11 1 12 3 7 4 14 4 18 6 2 Power...

Page 98: ... 6 4 Relays 6 4 Solenoids 6 4 Suppressor 2 17 6 5 Surge Protection MOV 2 17 Switch Contacts Noise 6 3 6 4 System Configuration Delta Delta with Grounded Leg 2 2 Delta Wye with Grounded Wye 2 1 High Resistance Ground 2 3 TN S Five Wire System 2 4 Ungrounded Secondary 2 3 T TB Terminal Block Control 4 18 Power 4 18 Signal 4 18 Temperature 1 3 Termination Conductor 4 18 Control Terminal 4 18 Power Te...

Page 99: ...d Cable 1 8 Conductors 1 3 European Style Cable 1 9 Exterior Cover 1 2 Gauge 1 3 Geometry 1 4 Insulation Thickness 1 4 Material 1 2 Reflected Wave Effects 5 1 Shielded Cable 1 6 Temperature Rating 1 3 Unshielded Cable 1 5 Wiring Category Definitions 4 9 Routing 4 9 Spacing 4 9 Spacing Notes 4 10 Z Zero Cross Switching 6 3 6 4 ...

Page 100: ...Index 6 ...

Page 101: ......

Page 102: ...d du Souverain 36 1170 Brussels Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Power Control and Information Solutions Headquarters Publication DRIVES IN001D EN P October 2005 Supersedes DRIVES IN001C EN P March 2005 Copyright 2005 Rockwell Automation Inc All rights reserved P...

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