Installation Instructions Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives
Important User Information Read this document and the documents listed in the additional resources section about installation, configuration, and operation of this equipment before you install, configure, operate, or maintain this product. Users are required to familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws, and standards.
Summary of Changes The information below summarizes the changes to this manual since the last release. New and Updated Information Topic Page Added PowerFlex 525, PowerFlex 753, and PowerFlex 755 drives to the motor cable length cross reference table. 83 Added motor cable length restriction tables for PowerFlex 525 drives. Table 23, 400V (frames A…E) 90 Table 24, 480V (frames A…E) 91 Table 25, 600V (frames A…E) 92 Updated motor cable length restriction tables for PowerFlex 700H drives.
Summary of Changes Notes: 4 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 2014
Table of Contents Preface About This Publication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Intended Audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Recommended Cable/Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 General Precautions . . . . . .
Table of Contents DC Bus Wiring Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Drive Lineup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 DC Bus Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Chapter 3 Grounding Grounding Safety Grounds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Building Steel . . . . . . . . . . . . . .
Table of Contents Chapter 5 Reflected Wave Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Effects On Wire Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Length Restrictions For Motor Protection . . . . . . . . . . . . . . . . . . . . . . . . . 74 Chapter 6 Electromagnetic Interference What Causes Common Mode Noise. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents Notes: 8 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 2014
Preface About This Publication This manual provides the basic information needed to properly install, protect, wire, and ground pulse width modulated (PWM) AC drives. Intended Audience This manual is intended for qualified personnel who plan and design installations of PWM AC drives. Additional Resources These documents contain additional information concerning related products from Rockwell Automation.
Preface Recommended Cable/Wire The recommended wire and cable referenced in this publication can be obtained from third-party companies found in our PartnerNetwork™ Encompass Program. For further information on these suppliers and their products, follow these steps to find recommended wire and cable for your drives. 1. Go to the Encompass website at http://www.rockwellautomation.com/ rockwellautomation/sales-partners/complementary-products/ overview.page. 2.
Chapter 1 Wire/Cable Types AC drive installations have specific wire and cable requirements. This section includes information about the major issues for proper selection of cable, and provides recommendations to address these issues. Consider these conditions and requirements when choosing cable material and construction for your installation: • Environment – such as moisture, temperature, and harsh or corrosive chemicals.
Chapter 1 Wire/Cable Types Figure 1 - Wire Selection Flowchart Selecting Wire to Withstand Reflected Wave Voltage for New and Existing Wire Installations in Conduit or Cable Trays DRY (per NEC Article 100) Conductor Environment Conductor Insulation PVC WET (per NEC Article 100) XLPE (XHHW-2) Insulation for < 600V AC System No RWR or Terminator Required XLPE Insulation Thickness 20 mil or > (1) 15 mil 230V 400/460V Reflected Wave Reducer? OK for < 600V AC System No RWR or Terminator Required 5
Wire/Cable Types Chapter 1 Gauge The correct wire size is determined by a number of factors. The user manual for each drive 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 full load current (FLA). Follow both of these requirements. Number of Conductors Local or national electrical codes can determine the required number of conductors.
Chapter 1 Wire/Cable Types Insulation Thickness and Concentricity Wire must have an insulation thickness of ≥ 15 mil (0.4 mm/0.015 in.). The wire insulation must not have significant variations of concentricity around the wire. Figure 4 - Insulation Concentricity Acceptable Unacceptable Geometry The physical relationship between individual conductors is important in drive installations.
Wire/Cable Types Chapter 1 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. 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 communication cards, photoelectric switches, weigh scales, and others.
Chapter 1 Wire/Cable Types Chose the outer sheathing and other mechanical characteristics to suit the installation environment. Consider the surrounding air temperature, chemical environment, flexibility, and other factors in all installation types. 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.
Wire/Cable Types Chapter 1 Type 2 Installation An acceptable shielded cable for Type 2 installations is essentially the same cable as Type 1, plus one shielded pair of brake conductors. For more information on Type 2 installations, refer to Table 1 on page 14.
Chapter 1 Wire/Cable Types Because noise containment can be affected by incidental grounding of the armor to building steel when the cable is mounted, we recommend that the armored cable has an overall PVC jacket (see Chapter 2). Interlocked armor is acceptable for shorter cable runs, but continuous welded armor is preferred. General recommendations for ground conductors are listed here: • Cable with a single ground conductor is sufficient for drive sizes up to and including 200 Hp (150 kW).
Wire/Cable Types Chapter 1 European Style Cable Cable used in many installations in Europe must conform to Low Voltage Directive (LVD) 2006/95/EC. Generally recommended are flexible cables with a bend radius of 20 times the cable diameter for movable cable, and 6 times the cable diameter for fixed installations, with a screen (shield) of 70…85% coverage. Insulation for both conductors and the outer sheath is PVC.
Chapter 1 Wire/Cable Types The majority of recommendations regarding drive cables are for 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. Consider the rise time, amplitude, and frequency of these pulses when choosing a wire/cable type.
Wire/Cable Types Cable for Discrete Drive I/O Chapter 1 Discrete I/O, such as start and stop commands, can be wired to the drive with a variety of cabling. We recommend shielded cable to reduce cross-coupled noise from power cables. Standard individual conductors that meet the general requirements for type, temperature, gauge, and applicable codes are acceptable if they are routed away from higher voltage cables to minimize noise coupling. However, multi-conductor cable can be less expensive to install.
Chapter 1 Wire/Cable Types Communication This section provides cable recommendations for these communication protocols: • DeviceNet on page 22 • ControlNet on page 23 • Ethernet on page 23 • Remote I/O and Data Highway Plus (DH+) on page 24 • Serial (RS-232 and RS-485) on page 24 DeviceNet DeviceNet cable options, topology, distances allowed, and techniques are specific to the DeviceNet network. For more information, refer to DeviceNet Media Design and Installation Guide, publication DNET-UM072.
Wire/Cable Types Chapter 1 ControlNet ControlNet cable options, topology, distances allowed, and techniques are specific to the ControlNet network. For more information, refer to the ControlNet Coax Media Planning and Installation Guide, publication CNET-IN002. Depending on the environment at the installation site, there are several types of RG-6 quad shield cables that can be appropriate. The standard cable recommended is Allen-Bradley catalog number 1786-RG6, Quad Shield coax.
Chapter 1 Wire/Cable Types Remote I/O and Data Highway Plus (DH+) IMPORTANT Only Allen-Bradley catalog number 1770-CD shielded twinaxial cabling is tested and approved for remote I/O and DH+ installations. The maximum cable length depends on the baud rate. Baud Rate Maximum Cable Length 57.6 Kbps 3048 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. IMPORTANT Do not connect in a star topology.
Chapter 2 Power Distribution This chapter discusses different power distribution schemes and factors that can affect drive performance. System Configurations The type of transformer and the connection configuration feeding the drive have an important role in drive performance and safety. This section includes a brief description of some of the more common configurations and their qualities and shortcomings.
Chapter 2 Power Distribution Delta/Delta with Grounded Leg, or Four-wire Connected Secondary Delta or Delta/Delta with Grounded Leg or Four-wire Connected Secondary Delta is a common configuration with no phase shift between input and output. The grounded center tap provides a direct path for common mode current caused by the drive output.
Power Distribution Chapter 2 Ungrounded Secondary ATTENTION: Grounding the transformer secondary is essential to the safety of personnel and safe operation of the drive. Leaving the secondary floating causes dangerous high voltages between the chassis of the drive and the internal power structure components. Exceeding the voltage rating of the drive’s input metal oxide varistor (MOV) protection devices can cause a catastrophic failure. In all cases, the input power to the drive is referenced to ground.
Chapter 2 Power Distribution TN-S Five-wire System L1 L2 L3 PEN or N PE TN-S Five-wire distribution systems are common throughout Europe, with the exception of the United Kingdom and Germany. Leg-to-leg voltage (commonly at 400V) powers three-phase loads. Leg-to-neutral voltage (commonly at 230V) powers single-phase loads. Neutral is a current conducting wire, and connects through a circuit breaker. The fifth wire is a separate ground wire.
Power Distribution Chapter 2 Otherwise, use one of the following more conservative methods: • For drives without built-in inductors – add line impedance whenever the transformer kVA is more than 10 times larger than the drive kVA, or the percent source impedance relative to each drive is less than 0.5%.
Chapter 2 Power Distribution EXAMPLE The drive is rated 1 Hp, 480V, 2.7A input. The supply transformer is rated 50,000 VA (50 kVA), 5% impedance. Zdrive = Zxfmr = Vline-line 3 * Iinput-rating (Vline-line )2 VA = 480V = 102.6 Ohms 3 * 2.7 * % Impedance = 4802 50,000 * 0.05 = 0.2304 Ohms Note that the percent (%) impedance has to be in per unit (5% becomes 0.05) for the formula. Zxfmr 0.2304 = = 0.00224 = 0.22% 102.6 Zdrive 0.22% is less than 0.5%.
Power Distribution Chapter 2 Table 5 - AC Line Impedance Recommendations for Bulletin 1305 Drives Bulletin Number Drive Catalog Volts Number (1) kW (Hp) Max Supply 3% Line Reactor Reactor Inductance Reactor Current Open Style 1321- (mH) Rating (amps) kVA (2) 1305 -AA02A 240 0.37(0.5) 15 3R4-A 3 4 -AA03A 240 0.55 (0.75) 20 3R4-A 4 4 -AA04A 240 0.75 (1) 30 3R8-A 1.5 8 -AA08A 240 1.5 (2) 50 3R8-A 1.5 8 -AA12A 240 2.2 (3) 75 3R18-A 0.8 18 -BA01A 480 0.37 (0.
Chapter 2 Power Distribution Table 7 - AC Line Impedance Recommendations for PowerFlex 40 Drives Drive Drive Catalog Volts Number (1) kW (Hp) Max Supply 3% Line Reactor Reactor Inductance Reactor Current Open Style 1321- (mH) Rating (amps) kVA (2) 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.
Power Distribution Chapter 2 Table 8 - AC Line Impedance Recommendations for PowerFlex 400 Drives Drive Drive Catalog Volts Number (1) kW (Hp) Max Supply 3% Line Reactor Reactor Inductance Reactor Current Open Style 1321- (mH) Rating (amps) kVA (2) PowerFlex 400 22CB012 240 2.2 (3.0) 50 3R12-A N/A N/A 22CB017 240 3.7 (5.0) 50 3R18-A N/A N/A 22CB024 240 5.5 (7.5) 200 3R25-A 0.5 25 22CB033 240 7.7 (10.0) 275 3R35-A 0.4 35 22CB049 240 11 (15.0) 350 3R45-A 0.
Chapter 2 Power Distribution Table 9 - AC Line Impedance Recommendations for PowerFlex 525 Drives Drive Drive Catalog Volts Number (1) kW (Hp) Max Supply 3% Line Reactor Reactor Inductance Reactor Current Open Style 1321- (mH) Rating (amps) kVA (2) PowerFlex 525 25BB2P5 240 0.4 (0.5) 25 3R4-B 6.5 4 25BB5P0 240 0.75 (1.0) 50 3R8-B 3 8 25BB8P0 240 1.5 (2.0) 50 3R8-A 1.5 8 25BB012 240 2.2 (3.0) 50 3R12-A 1.25 12 25BB017 240 3.7 (5.0) 50 3R18-A 0.8 18 25BB024 240 5.
Power Distribution Chapter 2 Table 10 - AC Line Impedance Recommendations for PowerFlex 70 Drives Drive Drive Catalog Volts Number (1) kW (Hp) Max Supply 3% Line Reactor Reactor Inductance Reactor Current kVA (2) Open Style 1321- (mH) Rating (amps)(3) PowerFlex 70 20AB2P2 240 0.37 (0.5) 25 3R2-D 6 2 20AB4P2 240 0.75 (1) 50 3R4-A 3 4 20AB6P8 240 1.5 (2) 50 3R8-A 1.5 8 20AB9P6 240 2.2 (3) 50 3R12-A 1.25 12 20AB015 240 4.0 (5) 200 3R18-A 0.8 18 20AB022 240 5.5 (7.
Chapter 2 Power Distribution Table 10 - AC Line Impedance Recommendations for PowerFlex 70 Drives (Continued) Drive Drive Catalog Volts Number (1) kW (Hp) Max Supply 3% Line Reactor Reactor Inductance Reactor Current kVA (2) Open Style 1321- (mH) Rating (amps)(3) PowerFlex 70 20AE031 600 22 (30) 1000 3R35-B 0.8 35 20AE042 600 30 (40) 1000 3R45-B 0.7 45 20AE051 600 37 (50) 1000 3R55-B 0.5 55 (1) Shaded rows identify drive ratings without built-in inductors.
Power Distribution Chapter 2 Table 11 - AC Line Impedance Recommendations for PowerFlex 700/700S Drives (Continued) Drive Drive Catalog Volts Number kW (Hp) Max Supply 3% Line Reactor Reactor Inductance Reactor Current KVA (1) Open Style 1321- (mH) Rating (amps) PowerFlex 700/700S 20BD1P1 480 0.37 (0.5) 250 3R2-B 20 20BD2P1 480 0.75 (1) 250 3R2-B 20 2 20BD3P4 For PowerFlex 20BD5P0 700S, replace 20B 20BD8P0 with 20D. 20BD011 480 1.5 (2) 500 3R4-B 6.5 4 480 2.2 (3) 500 3R4-B 6.
Chapter 2 Power Distribution Table 12 - AC Line Impedance Recommendations for PowerFlex 753/755 Drives Drive Drive Catalog Volts Number kW (Hp) Max Supply 3% Line Reactor Reactor Inductance Reactor Current KVA (1) Open Style 1321- (mH) Rating (amps) PowerFlex 753/755 20G_RC2P1 400 0.75 (1) 250 3R2-B 20 20G_RC3P5 400 1.5(2) 500 3R4-B 6.5 4 20G_RC5P0 For PowerFlex 20G_RC8P7 753, replace 20G 20G_RC011 with 20F. 20G_RC015 400 2.2 (3) 500 3R4-B 6.
Power Distribution Chapter 2 Table 12 - AC Line Impedance Recommendations for PowerFlex 753/755 Drives (Continued) Drive Drive Catalog Volts Number kW (Hp) Max Supply 3% Line Reactor Reactor Inductance Reactor Current KVA (1) Open Style 1321- (mH) Rating (amps) PowerFlex 753/755 20G_D5P0 480 2.2 (3) 500 3R4-B 6.5 4 20G_D8P0 480 4.0 (5) 500 3R8-B 3 8 20G_D011 For PowerFlex 20G_D014 753, replace 20G 20G_D022 with 20F. 20G_D027 480 5.5 (7.5) 750 3R12-B 2.5 12 480 7.
Chapter 2 Power Distribution Table 12 - AC Line Impedance Recommendations for PowerFlex 753/755 Drives (Continued) Drive Drive Catalog Volts Number kW (Hp) Max Supply 3% Line Reactor Reactor Inductance Reactor Current KVA (1) Open Style 1321- (mH) Rating (amps) PowerFlex 753/755 20G_E033 600 22 (30) 1000 3R35-B 0.8 35 20G_E041 600 30 (40) 1000 3R45-B 0.7 45 20G_E042 For PowerFlex 20G_E052 753, replace 20G 20G_E053 with 20F. 20G_E063 600 30 (40) 1000 3R45-B 0.
Power Distribution Chapter 2 Table 12 - AC Line Impedance Recommendations for PowerFlex 753/755 Drives (Continued) Drive Drive Catalog Volts Number kW (Hp) Max Supply 3% Line Reactor Reactor Inductance Reactor Current KVA (1) Open Style 1321- (mH) Rating (amps) PowerFlex 753/755 20G_F500 690 500(670) 3000 3R500-B 0.05 500 20G_F590 690 560 (750) 3500 3R600-B 0.04 600 20G_F650 For PowerFlex 20G_F710 753, replace 20G 20G_F765 with 20F. 20G_F795 690 630 (845) 4500 3R750-B 0.
Chapter 2 Power Distribution Table 13 - AC Line Impedance Recommendations for Bulletin 1336 Drives (Continued) Drive Drive Catalog Volts Number (1) 1336 PLUS, B025 PLUS II B030 IMPACT B040 FORCE B050 kW (Hp) Max Supply 3% Line Reactor Reactor Inductance Reactor Current kVA (2)(3) Open Style, 1321- (mH) Rating (amps)(4) 480 18.5 (25) 550 3R35-B 0.8 35 480 22 (30) 600 3R45-B 0.7 45 480 30 (40) 750 3R55-B 0.5 55 480 37 (50) 800 3R80-B 0.4 80 B060 480 45 (60) 900 3R80-B 0.
Power Distribution Chapter 2 Table 13 - AC Line Impedance Recommendations for Bulletin 1336 Drives (Continued) Drive Drive Catalog Volts Number (1) kW (Hp) Max Supply 3% Line Reactor Reactor Inductance Reactor Current kVA (2)(3) Open Style, 1321- (mH) Rating (amps)(4) 1336 PLUS, C250 PLUS II C300 IMPACT C350 FORCE C400 600 187 (250) 2500 3R250-B 0.09 250 600 224 (300) 3000 3R320-B 0.075 320 600 261 (350) 3000 3R400-B 0.06 400 600 298 (400) 4000 3R400-B 0.
Chapter 2 Power Distribution • Use the formula below to 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. If the impedance is too small, select a reactor with a larger inductance and same amperage, or regroup the drives into smaller groups and start over. Zdrive = Vline-line 3 * Iinput-rating Zreactor = L * 2 * 3.14 * f L is the inductance of the reactor in henries and f is the AC line frequency.
Power Distribution Surge Protection MOVs and Common Mode Capacitors Chapter 2 ATTENTION: When installing a drive on an ungrounded, high-resistance, or B-phase grounded distribution system, disconnect the phase-to-ground MOV circuit and the common mode capacitors from ground. IMPORTANT In some drives, a single jumper connects both the phase-to-ground MOV and the common mode capacitors to ground.
Chapter 2 Power Distribution Use PowerFlex Drives with Regenerative Units DC Bus Wiring Guidelines ATTENTION: If a regenerative unit (for example, 1336 REGEN line regeneration package) or other active front end (AFE) is used as a bus supply or brake, disconnect the common mode capacitors as described in the user manual for the drive. This guards against possible equipment damage. DC bus wiring refers to connecting the DC bus of an AC drive to the DC connections on another piece of equipment.
Power Distribution Chapter 2 DC Bus Connections For reliable system operation, minimize the interconnection of drives to the DC bus and the inductance levels between the drives. Use a low inductance-type DC bus (for example, 0.35 μH/m or less). IMPORTANT Do not daisy chain the DC bus connections. Configure the DC bus connections in a star configuration to allow for proper fusing.
Chapter 2 Power Distribution Braking Chopper Connect the brake unit closest to the largest drive. If all of the drives are the same rating, then connect the brake unit closest to the drive that regenerates the most. In general, mount brake units within 3 m (9.8 ft) of the drive. Resistors for use with chopper modules must be within 30 m (98.4 ft) of the chopper module. Refer to the respective braking product documentation for details.
Chapter 3 Grounding This chapter discusses various grounding schemes for safety and noise reduction. An effectively grounded scheme 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 that can result in undue hazard to connected equipment or to persons (as defined by the US National Electric Code NFPA70, Article 100B).
Chapter 3 Grounding Grounding PE or Ground The drive safety ground, PE, must be connected to scheme 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 require redundant ground paths and periodic examination of connection integrity.
Grounding Chapter 3 Figure 15 - Cabinet Grounding with a TN-S Five-wire System Input Transformer L1 System Cabinet AC Drive L2 R R S S T T L3 PEN or N PE PE PE SinglePhase Device PE Cabinet Ground Bus Use appropriate grounding schemes to reduce noise when installing PWM AC drives to reduce output that can produce high frequency common mode (coupled from output to ground) noise currents. These noise currents can cause sensitive equipment to malfunction if they are allowed to propagate.
Chapter 3 Grounding The grounding scheme can greatly affect the amount of noise and its impact on sensitive equipment. The power scheme is likely to be one of these three types: • Ungrounded scheme • Scheme with high resistance ground • Fully grounded scheme An ungrounded scheme (Figure 16) does not provide a direct path for the common mode noise current, causing the current to seek other uncontrolled paths. This causes related noise issues.
Grounding Chapter 3 Figure 18 - Fully Grounded Scheme Earth Ground Potential The installation and grounding practices to reduce common mode noise issues can be categorized into three ratings. The scheme used must consider additional costs against the operating integrity of all scheme components. If no sensitive equipment is present and noise is not an issue, the added cost of shielded cable and other components is not always justified.
Chapter 3 Grounding Effective Grounding Practices This scheme 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 can enter the ground grid.
Grounding Chapter 3 Cable Shields Motor and Input Cables Shields of motor and input cables must be bonded at both ends to provide a continuous path for common mode noise current. Control and Signal Cables Connect the shields of control cables only at one end. Cut back and insulate the other end. Follow these guidelines for connecting shields: • The shield for a cable from one cabinet to another must be connected at the cabinet that contains the signal source.
Chapter 3 Grounding Notes: 56 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 2014
Chapter 4 Best Practices This chapter discusses various installation practices. Mounting Standard Installations There are many criteria in determining the appropriate enclosure. Some of these include: • Environment • EMC compatibility/compliance • Available space • Access/Wiring • Safety guidelines Grounding to the Component Mounting Panel In the example below, the drive chassis ground plane is extended to the mounting panel.
Chapter 4 Best Practices In an industrial control cabinet, the equivalent to the copper ground layer of a printed circuit board (PCB) is the mounting panel. A panel made of zinc-plated, mild steel functions well as a ground plane. If painted, remove the paint at each mounting and grounding point. Zinc-plated steel is strongly recommended due to its ability to bond with the drive chassis and resist corrosion.
Best Practices Chapter 4 Hardware You can mount the drive and/or mounting panel with either bolts or welded studs. Figure 21 - Stud Mounting of Ground Bus or Chassis to Back Panel Back Panel Mounting Bracket or Ground Bus Welded Stud Paint-free Area Flat Washer Star Washer Nut Flat Washer If the mounting bracket is coated with a non-conductive material (anodized, painted, and so on), scrape the material off around the mounting hole.
Chapter 4 Best Practices Conduit Entry Entry Plates In most cases, the conduit entry plate is a conductive material that is not painted. Make sure that the surface of the plate is clean of oil or contaminants. If the plate is painted, follow one of these steps to make a good connection: • Use a connector that cuts through the paint and makes a high quality connection to the plate material. • Remove the paint around the holes down to the bare metal one inch in from the edge of the plate.
Best Practices Chapter 4 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 conductors and/or shields together as they leave the cable fitting.
Chapter 4 Best Practices Figure 25 - Connections to Ground Bus Ground Bus Tapped Hole Component Grounding Conductors Ground Lug Bolt Star Washer Component Grounding Conductor Figure 26 - Ground Connections to Enclosure Wall Area Without Paint Bolt Ground Lug Star Washer Welded Stud Star Washer Star Washer Nut Component Ground Conductor Nut Ground Lug Component Ground Conductor Do not lay one ground lug directly on top of the other.
Best Practices Chapter 4 Figure 27 - Multiple Connections to Ground Stud or Bolts Wire Routing General 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 dividers.
Chapter 4 Best Practices EXAMPLE Spacing relationship between 480V AC incoming power leads and 24V DC logic leads: • 480V AC leads are Level 2; 24V AC leads are Level 6. • For separate steel conduits, the conduits must be 76 mm (3 in.) apart. • In a cable tray, the two groups of leads must be 152 mm (6 in.) apart. Spacing Notes 1. Both outgoing and return current carrying conductors are pulled in the same conduit or laid adjacent in tray. 2. These cable levels can be grouped together: a.
Best Practices Chapter 4 7. If more than one brake module is required, the first module must be mounted within 3.0 m (10 ft) of the drive. Each remaining brake module can be a maximum distance of 1.5 m (5 ft) from the previous module. Resistors must be within 30 m (100 ft) of the chopper module. 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 Figure 28.
Chapter 4 Best Practices Figure 29 - Proper Cabinet Ground - Drives and Susceptible Equipment Output Conduit or Armor (bonded to cabinet) U V W PE U V W PE Common Mode Current on Cabinet Backplane/Subpanel R S T PE Common Mode Current on Armor or Conduit Incoming Power Conduit/Armor Cabinet Backplane/ Subpanel Within Conduit Do not route more than three sets of motor leads (three drives) in the same conduit. Maintain fill rates per applicable electrical codes.
Best Practices Chapter 4 Loops, Antennas, and Noise When routing signal or communication wires, do not use routes that produce loops. Wires that form a loop can form an efficient antenna. Antennas work well in both receive and transmit modes, and 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 form a loop. Twisting the pair together further reduces the antenna effects (see Figure 30).
Chapter 4 Best Practices Cable Trays When laying cable in cable trays, do not randomly distribute them. Bundle the power cables for each drive together and anchored them to the tray. Keep a minimum separation of one cable width between bundles to reduce overheating and cross-coupling. Current flowing in one 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.
Best Practices Shield Termination Chapter 4 Refer to Shield Splicing on page 55 to splice shielded cables. These 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 Use the circular section clamping method to clamp the cable to the main panel closest to the shield terminal.
Chapter 4 Best Practices 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 conductors, or shield together as they leave the cable fitting. IMPORTANT Pigtail termination is the least effective method of noise containment.
Best Practices Chapter 4 Armored Cable Armored cable can be terminated in a similar manner to standard cable. The Tek-Mate Fast-Fit cable clamp by O-Z/Gedney is a good example of an armored cable terminator. Conductor Termination Terminate power, motor, and control connections to the drive terminal blocks. User manuals list minimum and maximum wire gauges, tightening torque for terminals, and recommended lug types if stud connections are provided.
Chapter 4 Best Practices Signal TB If an encoder or tachometer feedback is used, a separate terminal block or blocks is sometimes provided. IMPORTANT Consult the user manual for these phase-sensitive connections. Improper wiring can 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 recommendations on shield termination.
Chapter 5 Reflected Wave This chapter discusses the reflected wave phenomenon and its impact on drive systems. Description 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.
Chapter 5 Reflected Wave This section provides a summary of our findings: • 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 can appear across these voids. If the corona inception voltage (CIV) for the air void is reached, ozone is produced.
Chapter 6 Electromagnetic Interference This chapter discusses types of electromagnetic interference and its impact on drive systems. 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.
Chapter 6 Electromagnetic Interference Containing Common Mode Noise With Cabling The type of cable that is used can affect the ability to contain common mode noise in a system that incorporates a drive. Conduit The combination of a ground conductor and conduit contains most capacitive current and returns it to the drive without polluting the ground grid. A conduit can still have unintended contact with grid ground structure due to straps, support, and so on.
Electromagnetic Interference How Electromechanical Switches Cause Transient Interference Chapter 6 Electromechanical contacts cause transient interference when switching inductive loads such as relays, solenoids, motor starters, or motors. Drives, as well as other devices with electronic logic circuits, are susceptible to this type of interference. Examine this circuit model for a switch controlling an inductive load.
Chapter 6 Electromagnetic Interference Putting resistor-capacitor (RC) networks or voltage-dependant resistors (varistors) across contacts can mitigate transient interference. Be sure to select components rated to withstand the voltage, power, and frequency of switching for your application. Load AC Load AC A common method for mitigating transient interference is to put a diode in parallel with an inductive DC load, or a suppressor in parallel with an inductive AC load.
Electromagnetic Interference Chapter 6 This table contains examples that illustrate methods for mitigating transient interference. Examples of Transient Interference Mitigation Solid-state Switch L1 L2 1MS L1 1MS L2 Suppressor Suppressor 1M 1MS L1 L1 Digital AC Output Example 2 A DC output controls a motor starter, contacts on the starter control a motor. The contacts require RC networks or varistors. The motor requires suppressors because it is an inductive device.
Chapter 6 Electromagnetic Interference Enclosure Lighting Fluorescent lamps are also sources of EMI.
Appendix A Motor Cable Length Restrictions Tables Overview The distances listed in each table are valid only for specific cable constructions and are not always accurate for lesser cable designs, particularly if the length restriction is due to cable charging current (indicated in the tables by shading). When choosing the proper cable, note these definitions.
Appendix A Motor Cable Length Restrictions Tables In the tables in this section, a ‘●’ in the available options columns indicates that the drive rating can be used with an Allen-Bradley terminator (catalog numbers 1204-TFA1/1204-TFB2) and/or reflected wave reduction device with common mode choke (catalog number 1204-RWC-17) or without choke (catalog number 1204-RWR2). Follow these guidelines for terminators and reflected wave reduction devices: • For the terminator, the maximum cable length is 182.
Motor Cable Length Restrictions Tables Appendix A Motor Cable Length Restrictions Tables Cross Reference Use this table to find the drive and voltage rating that you are looking for.
Appendix A Motor Cable Length Restrictions Tables This section lists motor cable length restrictions, reactors, and available options for PowerFlex 4 Drives. PowerFlex 4 Drives Table 14 - PowerFlex 4 Drives, 400V Shielded/Unshielded Cable – Meters (Feet) Reactor Only Reactor and Damping Resistor or 1321-RWR Reactor/RWR (see page 129) Resistor Available Options 1000V 1200V 1488V 1600V 1000V 1200V 1488V 1600V 1000V 1200V 1488V 1600V Cat. No. 0.4 2/4 7.6 (25) 53.3 (175) 53.3 (175) 53.
Motor Cable Length Restrictions Tables Appendix A This section lists motor cable length restrictions, reactors, and available options for PowerFlex 4M Drives. PowerFlex 4M Drives Table 16 - PowerFlex 4M Drives, 400V Shielded/Unshielded Cable – Meters (Feet) Reactor Only Reactor and Damping Resistor or 1321-RWR Reactor/RWR (see page 129) Resistor Available Options 1000V 1200V 1488V 1600V 1000V 1200V 1488V 1600V 1000V 1200V 1488V 1600V Cat. No. 0.4 2/4 7.6 (25) 53.3 (175) 53.3 (175) 53.
Appendix A Motor Cable Length Restrictions Tables This section lists motor cable length restrictions, reactors, and available options for PowerFlex 40 Drives. PowerFlex 40 Drives Table 18 - PowerFlex 40 Drives, 400V Shielded/Unshielded Cable – Meters (Feet) 0.4 2/4 0.75 2/4 1.5 2/4 2.2 2/4 4 2/4 5.5 2/4 7.5 2/4 11 2/4 7.6 (25) 7.6 (25) 7.6 (25) 7.6 (25) 7.6 (25) 7.6 (25) 7.6 (25) 7.6 (25) 53.3 (175) 83.8 (275) 83.8 (275) 137.2 (450) 137.2 (450) 137.2 (450) 137.2 (450) 137.2 (450) 53.
Motor Cable Length Restrictions Tables Appendix A Table 20 - PowerFlex 40 Drives, 600V Shielded/Unshielded Cable – Meters (Feet) 2/4 2 2/4 3 2/4 5 2/4 7.5 2/4 10 2/4 15 2/4 1850V 1488V 1600V 42.7 (140) 42.7 (140) 42.7 (140) 42.7 (140) 42.7 (140) 42.7 (140) 42.7 (140) 121.9 (400) 152.4 (500) 152.4 (500) 152.4 (500) 182.9 (600) 182.9 (600) 182.9 (600) 121.9 (400) 152.4 (500) 152.4 (500) 152.4 (500) 152.4 (500) 152.4 (500) 152.4 (500) 121.9 (400) 152.4 (500) 152.4 (500) 243.8 (800) 304.
Appendix A Motor Cable Length Restrictions Tables This section lists motor cable length restrictions, reactors, and available options for PowerFlex 400 Drives. PowerFlex 400 Drives Table 21 - PowerFlex 400 Drives, 400V Shielded/Unshielded Cable – Meters (Feet) Reactor/RWR (see page 129) Resistor Available Options RWC Reactor and Damping Resistor or 1321-RWR RWR2 Reactor Only TFB2 No Solution TFA1 Rating ● ● ● ● ● ● ● 304.8 304.8 304.8 304.8 304.8 304.
Motor Cable Length Restrictions Tables Appendix A Table 22 - PowerFlex 400 Drives, 480V Shielded/Unshielded Cable – Meters (Feet) Reactor/RWR (see page 129) Resistor Available Options RWC Reactor and Damping Resistor or 1321-RWR RWR2 Reactor Only TFB2 No Solution TFA1 Rating ● ● ● ● ● ● ● 304.8 304.8 304.8 (1000) (1000) (1000) 1321-RWR12-DP ● ● 365.8 365.8 152.4 (1200) (1200) (500) 365.8 365.8 365.8 (1200) (1200) (1200) 1321-RWR18-DP ● ● 76.2 (250) 365.8 365.8 152.
Appendix A Motor Cable Length Restrictions Tables This section lists motor cable length restrictions, reactors, and available options for PowerFlex 525 Drives. PowerFlex 525 Drives No Solution Reactor Only Reactor and Damping Resistor or 1321-RWR Reactor/RWR (see page 129) Resistor Available Options Ohms Watts RWR2 Drive TFA1 Table 23 - PowerFlex 525 Drives, 400V Shielded/Unshielded Cable – Meters (Feet) 1000V 1200V 1488V 1600V 1000V 1200V 1488V 1600V 1000V 1200V 1488V 1600V Cat. No. 0.
Motor Cable Length Restrictions Tables Appendix A No Solution Reactor Only Reactor and Damping Resistor or 1321-RWR Reactor/RWR (see page 129) Resistor Available Options Ohms Watts RWR2 Drive TFA1 Table 24 - PowerFlex 525 Drives, 480V Shielded/Unshielded Cable – Meters (Feet) 1000V 1200V 1488V 1600V 1000V 1200V 1488V 1600V 1000V 1200V 1488V 1600V Cat. No. 0.5 2/4 7.6 (25) 12.2 (40) 35.1 (115) 35.1 (115) 7.6 (25) 61.0 (200) 121.9 (400) 121.9 (400) 121.9 (400) 121.9 (400) 121.
Appendix A Motor Cable Length Restrictions Tables Table 25 - PowerFlex 525 Drives, 600V Shielded/Unshielded Cable – Meters (Feet) No Solution Reactor Only Reactor and Reactor/RWR Damping Resistor (see page 129) or 1321-RWR Resistor Ohms 1488V 1850V 1488V 1850V 0.5 2/4 12.2 (40) 35.1 (115) 76.2 (250) 121.9 (400) 121.9 (400) 121.9 (400) ● ● 1 2/4 12.2 (40) 35.1 (115) 76.2 (250) 121.9 (400) 121.9 (400) 121.9 (400) ● ● 2 2/4 12.2 (40) 83.8 (275) 76.2 (250) 152.4 (500) 152.
Motor Cable Length Restrictions Tables PowerFlex 70 and 700 Drives Appendix A This section lists motor cable length restrictions, reactors, and available options for PowerFlex 70 and 700 Drives. Table 26 - PowerFlex 70 (standard/enhanced) and 700 (standard/vector) Drives, 400V Shielded/Unshielded Cable – Meters (Feet) 4 2 A 0.75 4 2 1.5 4 0 2 2.2 4 B 2 4 4 2 5.5 4 C 2 7.5 4 1 2 11 4 D 2 15 4 2 2 D 18.5 4 2 D 22 4 2 3 30 4 E 2 37 4 2 4 45 4 53.3 (175) 53.3 (175) 83.8 (275) 76.2 (250) 83.
Appendix A Motor Cable Length Restrictions Tables Table 26 - PowerFlex 70 (standard/enhanced) and 700 (standard/vector) Drives, 400V Shielded/Unshielded Cable – Meters (Feet) (continued) 2 55 4 5 2 75 4 2 90 4 2 6 110 4 2 132 4 2 160 4 7 2 180 4 2 200 4 2 240 4 2 8 280 4 2 300 4 2 350 4 2 9 400 4 2 10 500 4 12.2 (40) 12.2 (40) 18.3 (60) 18.3 (60) 18.3 (60) 18.3 (60) 24.4 (80) 24.4 (80) 24.4 (80) 24.4 (80) 24.4 (80) 24.4 (80) 24.4 (80) 24.4 (80) 24.4 (80) 24.4 (80) 24.4 (80) 24.4 (80) 24.4 (80) 24.
Motor Cable Length Restrictions Tables Appendix A Table 27 - PowerFlex 70 (standard/enhanced) and 700 (standard/vector) Drives, 480V Shielded/Unshielded Cable – Meters (Feet) 2 A 1 4 2 2 4 0 2 3 4 B 2 5 4 2 7.5 4 C 2 10 4 1 2 15 4 2 20 4 D 2 2 25 4 2 30 4 2 3 40 4 E 2 50 4 2 4 60 4 12.2 (40) 12.2 (40) 12.2 (40) 12.2 (40) 12.2 (40) 12.2 (40) 12.2 (40) 12.2 (40) 12.2 (40) 12.2 (40) 12.2 (40) 12.2 (40) 12.2 (40) 12.2 (40) 12.2 (40) 12.2 (40) 12.2 (40) 12.2 (40) 12.2 (40) 12.2 (40) 12.2 (40) 12.
Appendix A Motor Cable Length Restrictions Tables Table 27 - PowerFlex 70 (standard/enhanced) and 700 (standard/vector) Drives, 480V Shielded/Unshielded Cable – Meters (Feet) (continued) 2 75 4 5 2 100 4 2 125 4 2 6 150 4 2 200 4 2 250 4 7 2 250 4 2 300 4 2 350 4 2 8 400 4 2 450 4 2 500 4 600 2 9 4 2 10 700 4 12.2 (40) 7.6 (25) 12.2 (40) 7.6 (25) 12.2 (40) 7.6 (25) 12.2 (40) 7.6 (25) 12.2 (40) 7.6 (25) 12.2 (40) 7.6 (25) 12.2 (40) 7.6 (25) 12.2 (40) 7.6 (25) 12.2 (40) 7.6 (25) 12.2 (40) 7.
Motor Cable Length Restrictions Tables Appendix A A 2 3 B 5 7.5 C 10 1 15 20 D 2 25 30 3 40 E 50 4 60 75 5 100 125 6 150 2 42.7 (140) 1321-RWR 1850V 1488V 1850V 1488V 1850V 121.9 (400) 121.9 (400) 121.9 (400) 121.9 (400) 121.9 (400) 4 30.5 (100) 121.9 (400) 30.5 (100) 121.9 (400) 121.9 (400) 121.9 (400) 2 42.7 (140) 152.4 (500) 152.4 (500) 152.4 (500) 152.4 (500) 152.4 (500) 4 30.5 (100) 137.2 (450) 30.5 (100) 152.4 (500) 152.4 (500) 152.4 (500) 2 42.7 (140) 152.
Appendix A Motor Cable Length Restrictions Tables 45 4 55 75 5 90 110 6 132 1850V 2000V Reactor and Damping Resistor Reactor 1850V Resistor Available Options 2000V Cat. No. Ohms Watts 365.8 (1200) 365.8 (1200) 1321-3R80-C 50 345 213.4 (700) 274.3 (900) 1321-3R80-C 50 690 365.8 (1200) 365.8 (1200) 1321-3R80-C 50 345 213.4 (700) 274.3 (900) 1321-3R80-C 50 690 365.8 (1200) 365.8 (1200) 1321-3R100-C 50 345 213.4 (700) 274.3 (900) 1321-3R100-C 50 690 365.8 (1200) 365.
Motor Cable Length Restrictions Tables Appendix A kHz 1000V 1200V 1488V 1600V 1000V 1200V 1488V 1600V 1000V 1200V 1488V 1600V Cat. No. 13 (1) (2) (3) (4) (5) Available Options Ohms Watts 2 12.2 (40) 24.4 (80) 42.7 (140) 76.2 (250) 12.2 (40) 24.4 (80) 106.7 (350) 152.4 (500) 61.0 (200) 167.6 (550) 304.8 365.8 (1000) (1200) 1321-RWR320-DP ● 250 2 12.2 (40) 24.4 (80) 42.7 (140) 76.2 (250) 12.2 (40) 24.4 (80) 91.4 (300) 121.9 (400) 61.0 (200) 152.4 (500) 304.8 365.
Appendix A Motor Cable Length Restrictions Tables Table 32 - PowerFlex 700H Drives, 600V Shielded/Unshielded Cable – Meters (Feet) 9 10 12 (1) 13(2) (1) (2) (3) (4) (5) Resistor Ohms Available Options 1850V 1488V 1850V 1488V 1850V Cat. No. 150 2 24.4 (80) 45.7 (150) 61.0 (200) 91.4 (300) 198.1 (650) 365.8 (1200) 1321-RWR200-EP ● 200 2 24.4 (80) 45.7 (150) 61.0 (200) 91.4 (300) 198.1 (600) 365.8 (1200) 1321-RWR250-EP ● 250 2 24.4 (80) 45.7 (150) 61.0 (200) 91.
Motor Cable Length Restrictions Tables Appendix A Table 34 - PowerFlex 700L Drives with 700VC Control, 400V Input Shielded/Unshielded Cable – Meters (Feet) 2 3A 3B Resistor Available Options Ohms Watts 2 24.4 (80) 91.4 (300) 152.4 (500) 213.4 (700) 30.5 (100) 76.2 (250) 228.6 (750) 365.8 152.4 (1200) (500) 274.3 (900) 365.8 365.8 (1) (1200) (1200) 1321-3R400-B 20 495 4 24.4 (80) 91.4 (300) 121.9 (400) 152.4 (500) 18.3 (60) 76.2 (250) 137.2 (450) 182.9 (600) 76.2 (250) 137.
Appendix A Motor Cable Length Restrictions Tables Table 37 - PowerFlex 700L Drives with 700VC Control, 690V Input Shielded/Unshielded Cable – Meters (Feet) 3A 3B 3B Reactor Resistor Available Options 1850V Cat. No. Ohms Watts 2 24.4 (80) 45.7 (150) 24.4 (80) 45.7 (150) 228.6 (750) 304.8 (1000) 1321-3R500-C (1) 20 960 4 24.4 (80) 45.7 (150) 24.4 (80) 45.7 (150) 76.2 (250) 121.9 (400) 1321-3R500-C (1) 20 1920 2 24.4 (80) 45.7 (150) 24.4 (80) 45.7 (150) 182.9 (600) 228.
Motor Cable Length Restrictions Tables Appendix A Table 40 - PowerFlex 700L Drives with 700S Control, 600V Input Shielded/Unshielded Cable – Meters (Feet) 3A 3B 3B Reactor Resistor Available Options 1850V Cat. No. Ohms Watts 2 18.3 (60) 76.2 (250) 18.3 (60) 76.2 (250) 182.9 (600) 304.8 (1000) 1321-3R500-B (1) 20 585 4 18.3 (60) 76.2 (250) 18.3 (60) 76.2 (250) 182.9 (600) 304.8 (1000) 1321-3R500-B (1) 20 1170 2 18.3 (60) 61.0 (200) 18.3 (60) 61.0 (200) 152.4 (500) 228.
Appendix A Motor Cable Length Restrictions Tables This section lists motor cable length restrictions, reactors, and available options for PowerFlex 700S drives. PowerFlex 700S 1 4 kHz 1000V 1200V 1488V 1600V 1000V 1200V 1488V 1600V 1000V 1200V 1488V 1600V Cat. No. 83.8 (275) 83.8 (275) 91.4 (300) 152.4 (500) 152.4 (500) 152.4 (500) 152.4 (500) 152.4 (500) 152.4 (500) 152.4 (500) ● 1.5 7.6 2/4 (25) 106.7 (350) 182.9 (600) 182.9 (600) 91.4 (300) 182.9 (600) 182.9 (600) 182.
Motor Cable Length Restrictions Tables Appendix A Table 42 - PowerFlex 700S Drives, 400V Shielded/Unshielded Cable – Meters (Feet) (continued) 12 (1) 13 (1) (2) (3) (4) (5) kHz 1000V 1200V 1488V 1600V 1000V 1200V 1488V 1600V 1000V 1200V 1488V 1600V Cat. No. Resistor Available Options Ohms Watts 450 2 18.3 (60) 68.6 (225) 99.1 (325) 167.6 (550) 36.6 (120) 68.6 (225) 304.8 365.8 228.6 (1000) (1200) (750) 274.3 (900) 365.8 365.8 2 x (1200) (1200) 1321-3RB400-B 40 375 (4) ● 500 2 12.
Appendix A Motor Cable Length Restrictions Tables 6 kHz 1000V 1200V 1488V 1600V 1000V 1200V 1488V 1600V 1000V 1200V 1488V 1600V Cat. No. 13 (1) (2) (3) (4) (5) 106 Available Options Ohms Watts 2/4 12.2 (40) 24.4 (80) 91.4 (300) 137.2 (450) 12.2 (40) 61.0 (200) 243.8 (800) 365.8 76.2 (1200) (250) 304.8 365.8 365.8 (1000) (1200) (1200) 1321-RWR160-DP ● 150 2/4 12.2 (40) 24.4 (80) 91.4 (300) 137.2 (450) 12.2 (40) 61.0 (200) 243.8 (800) 304.8 76.2 (1000) (250) 274.3 (900) 365.
Motor Cable Length Restrictions Tables Appendix A 1 2 3 4 5 6 9 10 11 12 (1) 13(2) (1) (2) (3) (4) (5) 1 2 3 5 7.5 10 15 20 25 30 40 50 60 75 100 125 150 150 200 250 350 400 450 500 600 700 800 900 1000 1100 1300 kHz 1488V 1850V 1488V 1850V Reactor and Damping Resistor or 1321-RWR 1488V 1850V 2/4 2/4 2/4 2/4 2/4 2/4 2/4 2/4 2/4 2/4 2/4 2/4 2/4 2/4 2/4 2/4 2/4 2 2 2 2 2 2 2 2 2 2 2 2 2 2 121.9 (400) 121.9 (400) 121.9 (400) 121.9 (400) 121.9 (400) 121.9 (400) 121.9 (400) 121.9 (400) 121.
Appendix A Motor Cable Length Restrictions Tables Table 45 - PowerFlex 700S Drives, 690V Shielded/Unshielded Cable – Meters (Feet) 5 6 9 10 11 12 (1) 13 (1) (2) (3) (4) (5) 108 45 55 75 90 110 132 160 200 250 315 355 400 450 500 560 630 710 800 900 1000 (2) 1100 (2) 2000V 1850V 2000V 2/4 2/4 2/4 2/4 2/4 2/4 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 45.7 (150) 45.7 (150) 45.7 (150) 45.7 (150) 45.7 (150) 45.7 (150) 45.7 (150) 45.7 (150) 45.7 (150) 45.7 (150) 45.7 (150) 45.7 (150) 45.7 (150) 45.7 (150) 45.
Motor Cable Length Restrictions Tables Appendix A This section lists motor cable length restrictions, reactors, and available options for PowerFlex 753 and 755 wall mount drives. PowerFlex 753 and 755 Wall Mount Drives Reactor and Damping Resistor Reactor/RWR or 1321-RWR (see page 129) kHz 1000V 1200V 1488V 1600V 1000V 1200V 1488V 1600V 1000V 1200V 1488V 1600V Cat. No. Resistor Available Options Ohms Watts 2 7.6 (25) 83.8 (275) 83.8 (275) 83.8 (275) 91.4 (300) 152.4 (500) 152.4 (500) 152.
Appendix A Motor Cable Length Restrictions Tables 2 7.6 (25) 137.2 (450) 365.8 365.8 91.4 (1200) (1200) (300) 365.8 365.8 365.8 365.8 365.8 365.8 365.8 (1200) (1200) (1200) (1200) (1200) (1200) (1200) 4 7.6 (25) 91.4 (300) 152.4 (500) 91.4 (300) 2 7.6 (25) 137.2 (450) 365.8 365.8 91.4 (1200) (1200) (300) 365.8 365.8 365.8 365.8 365.8 365.8 365.8 (1200) (1200) (1200) (1200) (1200) (1200) (1200) 4 7.6 (25) 91.4 (300) 152.4 (500) 91.4 (300) 2 7.6 (25) 137.2 (450) 365.8 365.8 91.
Motor Cable Length Restrictions Tables Appendix A Reactor and Damping Resistor Reactor/RWR or 1321-RWR (see page 129) kHz 1000V 1200V 1488V 1600V 1000V 1200V 1488V 1600V 1000V 1200V 1488V 1600V Cat. No. 2 24.4 (80) 137.2 (450) 274.3 (900) 365.8 61.0 (1200) (200) 182.9 (600) 365.8 365.8 243.8 (1200) (1200) (800) 365.8 365.8 365.8 (1200) (1200) (1200) 4 24.4 (80) 91.4 (300) 152.4 (500) 213.4 (700) 36.6 (120) 91.4 (300) 365.8 365.8 91.4 (1200) (1200) (300) 182.9 (600) 2 24.4 (80) 121.
Appendix A Motor Cable Length Restrictions Tables Available Options Ohms Watts 7.6 (25) 12.2 (40) 83.8 (275) 83.8 (275) 7.6 (25) 91.4 (300) 152.4 (500) 152.4 (500) 152.4 (500) 152.4 (500) 152.4 (500) 152.4 (500) ● ● 4 7.6 (25) 12.2 (40) 83.8 (275) 83.8 (275) 7.6 (25) 12.2 (40) 121.9 (400) 152.4 (500) 152.4 (500) 152.4 (500) 152.4 (500) 152.4 (500) ● ● 2 7.6 (25) 12.2 (40) 83.8 (275) 83.8 (275) 7.6 (25) 91.4 (300) 182.9 (600) 182.9 (600) 152.4 (500) 182.
Motor Cable Length Restrictions Tables Appendix A 2 12.2 (40) 24.4 (80) 137.2 (450) 182.9 (600) 12.2 (40) 61.0 (200) 243.8 (800) 365.8 137.2 (1200) (450) 365.8 365.8 365.8 (1200) (1200) (1200) 4 7.6 (25) 18.3 (60) 91.4 (300) 152.4 (500) 12.2 (40) 30.5 (100) 91.4 (300) 152.4 (500) 137.2 (450) 2 12.2 (40) 24.4 (80) 137.2 (450) 182.9 (600) 12.2 (40) 61.0 (200) 243.8 (800) 365.8 121.9 (1200) (400) 304.8 365.8 365.8 (1000) (1200) (1200) 4 7.6 (25) 18.3 (60) 91.4 (300) 152.
Appendix A Motor Cable Length Restrictions Tables Table 48 - PowerFlex 753 and 755 Wall Mount Drives, 600V Shielded/Unshielded Cable – Meters (Feet) Drive Rating Frame HP No Solution Reactor Only Reactor and Damping Resistor or 1321-RWR Reactor/RWR (see page 129) Resistor kHz 1488V 1850V 1488V 1850V 1488V 1850V Cat. No. Ohms 2 24.4 (80) 121.9 (400) 24.4 (80) 182.9 (600) 182.9 (600) 182.9 (600) ● ● ● 4 24.4 (80) 121.9 (400) 24.4 (80) 121.9 (400) 182.9 (600) 182.
Motor Cable Length Restrictions Tables Appendix A Table 48 - PowerFlex 753 and 755 Wall Mount Drives, 600V Shielded/Unshielded Cable – Meters (Feet) (continued) Drive Rating Frame HP kHz No Solution Reactor Only Reactor and Damping Resistor or 1321-RWR Reactor/RWR (see page 129) Resistor 1488V 1488V 1488V Cat. No. Ohms 1850V 1850V 1850V 2 24.4 (80) 121.9 (400) 24.4 (80) 365.8 (1200) 365.8 (1200) 365.8 (1200) 4 24.4 (80) 121.9 (400) 24.4 (80) 106.7 (350) 365.8 (1200) 365.
Appendix A Motor Cable Length Restrictions Tables Table 48 - PowerFlex 753 and 755 Wall Mount Drives, 600V Shielded/Unshielded Cable – Meters (Feet) (continued) Drive Rating Frame HP kHz No Solution Reactor Only Reactor and Damping Resistor or 1321-RWR Reactor/RWR (see page 129) Resistor 1488V 1488V 1488V Cat. No. Ohms 1850V 1850V 1850V 2 24.4 (80) 137.2 (450) 61.0 (200) 243.8 (800) 167.6 (550) 365.8 (1200) 4 24.4 (80) 106.7 (350) 61.0 (200) 121.9 (400) 121.9 (400) 198.
Motor Cable Length Restrictions Tables Appendix A Table 49 - PowerFlex 753 and 755 Wall Mount Drives, 690V Shielded/Unshielded Cable – Meters (Feet) Drive Rating Frame kW No Solution Reactor and Damping Resistor Reactor Resistor Cat. No.
Appendix A Motor Cable Length Restrictions Tables Table 49 - PowerFlex 753 and 755 Wall Mount Drives, 690V Shielded/Unshielded Cable – Meters (Feet) (continued) Drive Rating Frame kW No Solution Reactor and Damping Resistor Reactor Resistor Cat. No. Ohms Watts 50 375 50 750 50 480 50 960 50 480 50 960 kHz 1488V 1850V 1488V 1850V 1488V 1850V 2 24.4 (80) 45.7 (150) 91.4 (300) 121.9 (400) 182.9 (600) 243.8 (800) 4 24.4 (80) 45.7 (150) 91.4 (300) 106.7 (350) 152.
Motor Cable Length Restrictions Tables Appendix A Table 50 - PowerFlex 755 Floor Mount Drives, 400V Shielded/Unshielded Cable – Meters (Feet) (continued) 24.4 (80) 76.2 (250) 152.4 (500) 213.4 (700) 61.0 (200) 152.4 (500) 304.8 365.8 213.4 (1000) (1200) (700) 4 24.4 (80) 61.0 (200) 106.7 (350) 137.2 (450) 36.6 (120) 91.4 (300) 182.9 (600) 2 24.4 (80) 61.0 (200) 152.4 (500) 182.9 (600) 61.0 (200) 152.4 (500) 304.8 365.8 182.9 (1000) (1200) (600) 274.3 (900) 4 24.4 (80) 61.
Appendix A Motor Cable Length Restrictions Tables Reactor and Damping Resistor Reactor kHz 1000V 1200V 1488V 1600V 1000V 1200V 1488V 1600V 1000V 1200V 1488V 1600V Cat. No. 12.2 (40) 30.5 (100) 106.7 (350) 152.4 (500) 12.2 (40) 45.7 (150) 137.2 (450) 182.9 (600) 61.0 (200) 213.4 (700) 304.8 365.8 (1000) (1200) 4 7.6 (25) 24.4 (80) 91.4 (300) 121.9 (400) 12.2 (40) 30.5 (100) 91.4 (300) 121.9 (400) 45.7 (150) 137.2 (450) 243.8 (800) 2 12.2 (40) 30.5 (100) 106.7 (350) 152.
Motor Cable Length Restrictions Tables Appendix A Table 51 - PowerFlex 755 Floor Mount Drives, 480V Shielded/Unshielded Cable – Meters (Feet) (continued) Resistor 2 12.2 (40) 30.5 (100) 76.2 (250) 106.7 (350) 12.2 (40) 45.7 (150) 91.4 (300) 121.9 (400) 61.0 (200) 152.4 (500) 4 7.6 (25) 24.4 (80) 45.7 (150) 76.2 (250) 12.2 (40) 30.5 (100) 76.2 (250) 106.7 (350) 45.7 (150) 121.9 (400) 2 12.2 (40) 30.5 (100) 76.2 (250) 91.4 (300) 12.2 (40) 45.7 (150) 91.4 (300) 121.9 (400) 45.
Appendix A Motor Cable Length Restrictions Tables Table 52 - PowerFlex 755 Floor Mount Drives, 600V Shielded/Unshielded Cable – Meters (Feet) (continued) Drive Rating Frame HP No Solution 1488V 1850V 1488V 1850V 1488V 1850V 2 24.4 (80) 91.4 (300) 61.0 (200) 152.4 (500) 152.4 (500) 365.8 (1200) 4 24.4 (80) 91.4 (300) 61.0 (200) 121.9 (400) 121.9 (400) 213.4 (700) 2 24.4 (80) 91.4 (300) 61.0 (200) 152.4 (500) 152.4 (500) 365.8 (1200) 4 24.4 (80) 91.4 (300) 61.0 (200) 121.
Motor Cable Length Restrictions Tables Appendix A Table 53 - PowerFlex 755 Floor Mount Drives, 690V Shielded/Unshielded Cable – Meters (Feet) Drive Rating Frame kW No Solution Reactor Only Reactor and Damping Resistor kHz 1488V 1850V 1488V 1850V 1488V 1850V 2 24.4 (80) 45.7 (150) 91.4 (300) 121.9 (400) 182.9 (600) 243.8 (800) 4 24.4 (80) 45.7 (150) 91.4 (300) 106.7 (350) 152.4 (500) 182.9 (600) 2 24.4 (80) 45.7 (150) 91.4 (300) 121.9 (400) 182.9 (600) 243.8 (800) 4 24.
Appendix A Motor Cable Length Restrictions Tables Table 53 - PowerFlex 755 Floor Mount Drives, 690V Shielded/Unshielded Cable – Meters (Feet) (continued) Drive Rating Frame kW No Solution Reactor and Damping Resistor kHz 1488V 1850V 1488V 1850V 1488V 1850V 2 24.4 (80) 45.7 (150) 61.0 (200) 91.4 (300) 182.9 (600) 243.8 (800) 4 24.4 (80) 45.7 (150) 61.0 (200) 76.2 (250) 152.4 (500) 182.9 (600) 2 24.4 (80) 45.7 (150) 61.0 (200) 91.4 (300) 182.9 (600) 243.8 (800) 4 24.
Motor Cable Length Restrictions Tables Appendix A Table 54 - 1336 PLUS II/IMPACT Drives, 380…480V – Meters (Feet) (continued) Drive Drive kW Frame (Hp) Motor kW No External Devices (1) (Hp) Motor A 1329R/L (1600V) A or B 1329 Motor A B 1329 A B or 1329 Cable Any Cable Any Cable 91.4 (300) 22.9 (75) 182.9 (600) 61.0 (200) 182.9 (600) 22.9 (75) 182.9 (600) 91.4 (300) 61.0 (200) 182.9 (600) 22.9 (75) 182.9 (600) 91.4 (300) 61.0 (200) 182.9 (600) 22.9 (75) 182.9 (600) 182.
Appendix A Motor Cable Length Restrictions Tables Table 55 - 1336 PLUS II/IMPACT Drives, 600V – Meters (Feet) Drive Frame Drive kW (Hp) Motor kW (Hp) No External Devices (1) with 1204-TFB2 Terminator (1) Motor (NR = not recommended) Motor (NR = not recommended) with 1204-TFA1 Terminator (1) Reactor at Drive (1) (3) Motor (NR = not recommended) Motor A B 1329R/L (2) A B 1329R/L (2) A B 1329R/L (2) A B 1329R/L (2) Any Cable Any Cable Any Cable Any Cable Any Cable Any Cable Any Cab
Motor Cable Length Restrictions Tables Appendix A This section lists motor cable data for 1305 drives. 1305 Drives Table 56 - 1305 Drives, 480V, No External Devices at Motor – Meters (Feet) Drive Hp (480V) Motor Hp (480V) (480V) Using a Motor with Insulation VP-P Type A Type B Any Cable Any Cable Shielded Cable Unshielded Cable Maximum Carrier Frequency 4 kHz 4 kHz 2 kHz 2 kHz High-line Derate Multiplier 5 3 2 1 0.5 1329R/L 0.85 0.85 0.55 0.55 5 9.1 (30) 30.5 (100) 121.
Appendix A Motor Cable Length Restrictions Tables This section lists motor cable data for 160 drives. 160 Drives Table 58 - 160 Drives, 480V – Meters (Feet) 380…460V Ratings 4.0 kW (5 Hp) 2.2 kW (3 Hp) 1.5 kW (2 Hp) 0.75 kW (1 Hp) 0.55 kW (0.75 Hp) 0.37 kW (0.5 Hp) Motor Insulation Rating - Motor Cable Only VoltsP-P Shielded Unshielded Shielded RWR at Drive Unshielded Shielded Reactor at Motor Unshielded 1000 13.7 (45) 6.1 (20) 160.0 (525) 182.9 (600) 99.1 (325) 91.4 (300) 1200 27.
Motor Cable Length Restrictions Tables Reflected Wave Reduction Guidelines (for catalog number 1321-RWR) Appendix A Follow these guidelines for catalog number 1321-RWR reflected wave reduction solution: • Figure 34 shows wiring for single inverter drives (PowerFlex 70 Frames A…E; PowerFlex 700 Frames 0…6; PowerFlex 700H Frames 9…11; and PowerFlex 700S Frames 1…11 and 13). Figure 35 describes dual inverter drives (PowerFlex 700H/700S Frame 12).
Appendix A Motor Cable Length Restrictions Tables Figure 35 - Filter Wiring for Dual Inverter Frame 12 Drive L-R Filter Output Reactor AC Drive U1 R V1 W1 Damping Resistor U2 Cable V2 L-R Filter W2 Output Reactor R Damping Resistor 130 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 2014 Motor
Motor Cable Length Restrictions Tables Appendix A Figure 36 - Filter Wiring for Single Inverter Frame 13 Drive with Parallel Reactors L-R Filter Output Reactor R AC Drive U Damping Resistor Cable V W Motor L-R Filter Output Reactor R Damping Resistor Rockwell Automation Publication DRIVES-IN001M-EN-P - March 2014 131
Appendix A Motor Cable Length Restrictions Tables Notes: 132 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 2014
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.
Glossary 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 current required to charge capacitance in motor cable.
Glossary THWN Thermoplastic heat and water-resistant nylon-coated. A U.S. designation for a specific insulation material, temperature rating, and condition of use (wet locations) for electrical wire and cable. Unshielded Cable containing no braided or foil sheath surrounding the conductors. Can be multi-conductor cable or individual conductors. UTP Unshielded twisted-pair cable. Wet Locations with moisture present – see Damp. XHHW-2 Cross-linked polyethylene high heat-resistant water-resistant. A U.S.
Glossary Notes: 136 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 2014
Index Numerics 1305 127 1305 drive 127 1336 Impact 124 1336 PLUS II 124 1336 Plus II/Impact drive 124 1336 PLUS II/Impact drive, 600V 126 160 128 160 drive, cable charging current 128 A AC line 28 AC line impedance recommendations Bulletin 1305 drives 31 Bulletin 1336 drives 41 Bulletin 160 drives 30 PowerFlex 4 drives 31 PowerFlex 40 drives 32 PowerFlex 400 drives 33 PowerFlex 525 drives 34 PowerFlex 70 drives 35 PowerFlex 700/700S drives 36 PowerFlex 753/755 drives 38 analog signal cable 21 antiphase gro
Index conduit 67 cable connectors 60 common mode noise 76 entry 60 entry plates 60 magnetic steel 67 pulling wires 67 PVC 67 stainless steel 67 connections, ground 61 contact arcing 77 contacts 77 contained noise path 54 control terminal 71 control wire 21 ControlNet 23 corona 73 corona inception voltage 74 cumulative ground current 27 D Data Highway 24 DC bus wiring guidelines 46 Delta/Delta with Grounded Leg 26 Delta/Wye with Grounded Wye 25 DeviceNet 22 DH+ 24 dielectric constants 73, 74 discrete drive
Index line impedance AC line impedance 28 adding line reactor or transformer for lightning strikes 28 power interruptions 28 transformer is too large 28 voltage dips 28 voltage spikes 28 for drives with built-in inductors 29 for drives without built-in inductors 29 multiple drives 43 M material, cable 11 mitigating transient interference examples 79 mode capacitors, common 45 moisture 12, 72, 74 motor 1329R/L 81 1488V 81 brake solenoid noise 77 grounding 50 type A 81 type B 81 motor bearing damage due to
Index N noise brake 77 common mode 75 contacts 77 enclosure lighting 80 inductive loads 77 lighting 80 mitigating 77 motor brake 77 motor starters 77 motors 77 preventing 77 related grounds 51 relays 77 solenoids 77 switch contacts 77 transient interference 77 O ozone 74 ozone production 73 P parasitic inductance 46 pigtail termination 70 power wire 19, 21, 55, 68, 71, 76 power cables, input 19 power distribution 25 Delta/Delta with Grounded Leg 26 Delta/Wye with Grounded Wye 25 high resistance ground 27
Index system configuration Delta/Delta with Grounded Leg 26 Delta/Wye with Grounded Wye 25 high resistance ground 27 TN-S five-wire system 28 ungrounded secondary 27 T TB (terminal block) control 71 power 71 signal 72 temperature 12 termination conductor 71 control terminal 71 power terminals 71 shield 69 shield via pigtail (lead) 61 signal terminals 72 via cable clamp 70 via circular clamp 69 via pigtail (lead) 70 TN-S five-wire systems 28, 50 transient interference 77 causes 77 mitigate with diode 78 mi
Index 142 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 2014
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