How To Use A Grounded Neutral System

Transcription

1 Installation Instructions Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives

2 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. Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required to be carried out by suitably trained personnel in accordance with applicable code of practice. If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired. In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment. The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams. No patent liability 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. WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss. ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence. IMPORTANT Identifies information that is critical for successful application and understanding of the product. Labels may also be on or inside the equipment to provide specific precautions. SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may be present. BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may reach dangerous temperatures. ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE). Allen-Bradley, Rockwell Software, PartnerNetwork, PowerFlex, and Rockwell Automation are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies.

3 Summary of Changes The information below summarizes the changes to this manual since the last release. New and Updated Information Topic Added PowerFlex 55, PowerFlex 753, and PowerFlex 755 drives to the motor cable length cross reference table. Added motor cable length restriction tables for PowerFlex 55 drives. Table 3, 00V (frames A E) 90 Table, 80V (frames A E) 91 Table 5, 600V (frames A E) 9 Updated motor cable length restriction tables for PowerFlex 700H drives. Table 3, 600V (frames 9 13) 100 Table 33, 690V (frames 9 13) 100 Updated motor cable length restriction tables for PowerFlex 700S drives. Table, 600V (frames 3 13) 107 Table 5, 690V (frames 5 13) 108 Added motor cable length restriction tables for PowerFlex 753 and 755 wall mount drives. Table 6, 00V (frames 1 and ) 109 Table 7, 80V (frames 1 and ) 111 Table 8, 600V (frames 3 7) 11 Table 9, 690V (frames 6 and 7) 117 Added motor cable length restriction tables for PowerFlex 755 floor mount drives. Table 50, 00V (frames 9 and 10) 118 Table 51, 80V (frames 9 and 10) 10 Table 5, 600V (frames 8 10) 11 Table 53, 690V (frames 8 10) 13 Page 83 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01 3

4 Summary of Changes Notes: Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

5 Table of Contents Preface About This Publication Intended Audience Additional Resources Recommended Cable/Wire General Precautions Chapter 1 Wire/Cable Types General Material Exterior Cover Temperature Rating Gauge Number of Conductors Insulation Thickness and Concentricity Geometry Unshielded Cable Shielded Cable Armored Cable European Style Cable Input Power Cables Motor Cables Cable for Discrete Drive I/O Analog Signal and Encoder Cable Communication DeviceNet ControlNet Ethernet Remote I/O and Data Highway Plus (DH+) Serial (RS-3 and RS-85) Chapter Power Distribution System Configurations Delta/Wye with Grounded Wye Neutral Delta/Delta with Grounded Leg, or Four-wire Connected Secondary Delta Three-phase Open Delta with Single-phase Center Tapped Ungrounded Secondary High Resistance Ground TN-S Five-wire System AC Line Voltage AC Line Impedance Multi-drive Protection Surge Protection MOVs and Common Mode Capacitors Use PowerFlex Drives with Regenerative Units Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01 5

6 Table of Contents DC Bus Wiring Guidelines Drive Lineup DC Bus Connections Chapter 3 Grounding Grounding Safety Grounds Building Steel Grounding PE or Ground RFI Filter Grounding Grounding Motors Grounding and TN-S Five-wire Systems Noise Related Grounds Acceptable Grounding Practices Effective Grounding Practices Optimal Recommended Grounding Practices Cable Shields Isolated Inputs Chapter Best Practices Mounting Standard Installations EMC Specific Installations Layout Hardware Conduit Entry Entry Plates Cable Connectors/Glands Shield Termination via Pigtail (lead) Ground Connections Wire Routing General Within A Cabinet Within Conduit Loops, Antennas, and Noise Conduit Cable Trays Shield Termination Termination via Circular Clamp Shield Termination via Pigtail (lead) Shield Termination via Cable Clamp Conductor Termination Power TB Control TB Signal TB Moisture Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

7 Table of Contents Chapter 5 Reflected Wave Description Effects On Wire Types Length Restrictions For Motor Protection Chapter 6 Electromagnetic Interference What Causes Common Mode Noise Containing Common Mode Noise With Cabling Conduit Shielded or Armored Power Cable How Electromechanical Switches Cause Transient Interference How to Prevent or Mitigate Transient Interference from Electromechanical Switches Enclosure Lighting Bearing Current Appendix A Motor Cable Length Restrictions Overview Tables Motor Cable Length Restrictions Tables Cross Reference PowerFlex Drives PowerFlex M Drives PowerFlex 0 Drives PowerFlex 00 Drives PowerFlex 55 Drives PowerFlex 70 and 700 Drives PowerFlex 700H PowerFlex 700L PowerFlex 700S PowerFlex 753 and 755 Wall Mount Drives PowerFlex 755 Floor Mount Drives PLUS II and IMPACT Drives Drives Drives Reflected Wave Reduction Guidelines (for catalog number 131-RWR) Glossary Index Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01 7

8 Table of Contents Notes: 8 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

9 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. Resource Safety Guidelines for the Application, Installation and Maintenance of Solid State Control, publication SGI-1.1 Don t Ignore the Cost of Power Line Disturbance, publication 131-TD001 IEEE Guide for the Installation of Electrical Equipment to Minimize Electrical Noise Inputs to Controllers from External Sources, publication IEEE 518. Available from IEEE Xplore Digital Library. Recommended Practice for Powering and Grounding Electronic Equipment - IEEE Emerald Book, publication IEEE STD Available from IEEE Xplore Digital Library. IEEE Recommended Practice for Grounding of Industrial and Commercial Power Systems, publication IEEE Std Available from IEEE Xplore Digital Library. Cable Alternatives for PWM AC Drive Applications, publication IEEE Paper No. PCIC Available from IEEE Xplore Digital Library. EMI Emissions of Modern PWM AC Drives IEEE Industry Applications Magazine, Nov./Dec Electromagnetic Interference and Compatibility, Volume 3, by Donald R. J. White Grounding, Bonding, and Shielding for Electronic Equipment and Facilities (Military Handbook 19) Noise Reduction Techniques in Electronic Systems by Henry W. Ott Grounding for the Control of EMI by Hugh W. Denny EMC for Product Designers by Tim Williams National Electrical Code (ANSI/NFPA 70) Articles 50, 75-5, 75-15, 75-5 and ( Application Guide for AC Adjustable Speed Drive Systems, NEMA ( IEC Selection and Erection of Electrical Equipment - Wiring systems, IEC ( Description Provides general guidelines for the application, installation, and maintenance of solid-state control devices or assemblies. Provides technical data on Allen-Bradley power conditioning products. Provides techniques for installing controllers and control systems so that proper operation can be achieved in the presence of electrical noise. Provides the recommended practices for powering and groundiing electronic equipment. Provides recommended practices to ground power systems. Describes an alternative solution for cables used with IGBT variable frequency drives (VFDs). Provides an understanding of EMI issues and with pre-installation and post-installation guidelines. This book provides information EMI control methods and techniques. Provides grounding, bonding, and shielding applications for communication electronics equipments and facilities. This book provides information on controlling emissions from electronic systems, and techniques for providing electromagnetic compatibility (EMC). This book provides grounding guidelines for the control of EMI. This book provides the information needed to meet the requirements of the latest EMC directive. Provides information on the installation of electrical components, signaling and communication conductors and grounding. Provides a NEMA application guide for AC drive systems. IEC wiring systems. You can view or download publications at To order paper copies of technical documentation, contact your local Allen-Bradley distributor or Rockwell Automation sales representative. Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01 9

10 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 rockwellautomation/sales-partners/complementary-products/ overview.page.. Under Find an Encompass Referenced Product, click FIND NOW. 3. In the Product Category pull-down list, choose Drive - Cables.. Click SEARCH. General Precautions ATTENTION: To avoid an electric shock hazard, verify that the voltage on the bus capacitors has discharged before performing any work on the drive. Measure the DC bus voltage at the +DC and DC terminals of the power terminal block. The voltage must be zero. 10 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

11 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. Mechanical needs such as geometry, shielding, flexibility, and crush resistance. Electrical characteristics such as cable capacitance/charging current, resistance/voltage drop, current rating, and insulation. Insulation can be the most significant of these. Because drives can create voltages in excess of line voltage, the industry standard cables that were used in the past are not the best choice for variable speed drives. Drive installations benefit from cable that is significantly different than cable used to wire contactors and push buttons. Safety issues such as electrical code requirements, grounding needs, and others. Choosing incorrect cabling can be costly and can adversely affect the performance of your installation. General Material Use only copper wire. The wire clamp-type terminals in Allen-Bradley drives are made for use with copper wire. If you use aluminum wire, the connections can loosen and cause premature equipment failure. Wire gauge requirements and recommendations are based on 75 C (167 F) rating. Do not reduce wire gauge when you use higher temperature wire. Exterior Cover Whether shielded or unshielded, the cable must meet all of the application requirements. Consider insulation value and resistance to moisture, contaminants, corrosive agents, and other invasive elements. Consult the cable manufacturer and Figure 1 on page 1 for cable selection criteria. Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01 11

12 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 WET (per NEC Article 100) Insulation Thickness PVC Conductor Insulation 0 mil or > (1) XLPE XLPE (XHHW-) Insulation for < 600V AC System No RWR or Terminator Required 15 mil 30V 00/60V Reflected Wave Reducer? No RWR or Terminator 575V Reflected Wave Reducer? OK for < 600V AC System No RWR or Terminator Required Cable Length > 15. m (50 ft) RWR or Terminator < 15. m (50 ft) Single Drive, Single Conduit or Wire Tray Number of Drives in Same Conduit or Wire Tray Multiple Drives in Single Conduit or Wire Tray 15 mil PVC in Not Recommended. Use XLPE or > 0 mil No RWR or Terminator 15 mil PVC is Not Recommended. Use XLPE or > 0 mil RWR or Terminator (1) The minimum wire size for PVC cable with 0 mil or greater insulation is 10 gauge. See NEC Guidelines (Article 310 Adjustment Factors) for Maximum Conductor Derating and Maximum Wires in Conduit or Tray Temperature Rating In general, follow these temperature ratings for installations: In surrounding air temperature of 50 C (1 F), use 90 C (19 F) wire (required for UL) In surrounding air temperature of 0 C (10 F), use 75 C (167 F) wire (required for UL) Refer to the user manual of the drive for other restrictions. IMPORTANT The temperature rating of the wire affects the required gauge. Verify that your installation meets all applicable national, state, and local codes. 1 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

13 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. Generally, these configurations are recommended: Figure shows cable with a single ground conductor that is recommended for drives up to and including 00 Hp (150 kw). Figure 3 shows cable with three ground conductors that is recommended for drives larger than 00 Hp (150 kw). Space the ground conductors symmetrically around the power conductors. Verify that the ground conductors are rated for full drive ampacity. Figure - Cable with One Ground Conductor One Ground Conductor W R G B Figure 3 - Cable with Three Ground Conductors Three Ground Conductors Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01 13

14 Chapter 1 Wire/Cable Types Insulation Thickness and Concentricity Wire must have an insulation thickness of 15 mil (0. mm/0.015 in.). The wire insulation must not have significant variations of concentricity around the wire. Figure - Insulation Concentricity Acceptable Unacceptable Geometry The physical relationship between individual conductors is important in drive installations. Individual conductors in conduit or cable trays have no fixed relationship and are subject to cross coupling of noise, induced voltages, excess insulation stress, and other possible interference. Fixed geometry cable (cable that keeps the spacing and orientation of the individual conductors constant) offers significant advantages over individual loose conductors, including reduced cross-coupling noise and insulation stress. Three types of fixed geometry, multi-conductor cables are discussed in this section. See Unshielded Cable on page 15, Shielded Cable on page 16, and Armored Cable on page 17. Table 1 - Recommended Cable Design Type Max Wire Size Where Used Rating/Type Description Type 1 AWG Standard installations 100 Hp or less Type AWG Standard installations 100 Hp or less with brake conductors Type MCM AWG Standard installations 150 Hp or more Type 500 MCM AWG Water, caustic chemical, crush resistance 600V, 90 C (19 F) XHHW/RHW- 600V, 90 C (19 F) RHH/RHW- Tray-rated 600V, 90 C (19 F) RHH/RHW- Tray-rated 600V, 90 C (19 F) RHH/RHW- Four tinned copper conductors with cross-linked polyethylene (XLPE) insulation Four tinned copper conductors with XLPE insulation plus one shielded pair of brake conductors. Three tinned copper conductors with XLPE insulation and three bare copper grounds and polyvinyl chloride (PVC) jacket. Three bare copper conductors with XLPE insulation and three copper grounds on 10 AWG and smaller. Acceptable in Class I and II, Division I and II locations. Type MCM AWG 690V applications Tray-rated 000V, 90 C (19 F) Three tinned copper conductors with XLPE insulation. Three bare copper grounds and PVC jacket. IMPORTANT: If terminator network or output filter is used, connector insulation must be XLPE, not PVC. 1 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

15 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. Verify that the installation does not require shielded cable to meet specific electromagnetic compatibility (EMC) standards for CE, C-Tick, or FCC requirements. Cable specifications depend on the installation type. Type 1 and Type Installation Type 1 or Type installations require 3-phase conductors and a fully rated individual ground conductor with or without brake leads. Refer to Table 1 on page 1 for detailed information and specifications on these installations. Figure 5 - Type 1 Unshielded Multi-conductor Cable without Brake Leads Type 1 Installation, without Brake Conductors Filler W B PVC Outer Sheath R G Single Ground Conductor Type 3 Installation Type 3 installation requires three symmetrical ground conductors whose ampacity equals the phase conductor. Refer to Table 1 on page 1 for detailed information and specifications on this installation. Figure 6 - Type 3 Unshielded Multi-Conductor Cable Filler W G B PVC Outer Sheath G R G Multiple Ground Conductors Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01 15

16 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. Use shielded cable for installations with sensitive equipment, such as weigh scales, capacitive proximity switches, and other devices that can be affected by electrical noise in the distribution system. Applications with large numbers of drives in a single location, imposed EMC regulations, or a high degree of communication/networking, are also good candidates for shielded cable. Shielded cable can also help reduce shaft voltage and induced bearing currents for some applications. In addition, the increased size of shielded cable can help extend the distance that the motor can be from the drive without the addition of motor protective devices, such as terminator networks. Refer to Chapter 5 for information regarding reflected wave phenomena. Consider all of the general specifications dictated by the environment of the installation, including temperature, flexibility, moisture characteristics, and chemical resistance. In addition, include a braided shield specified by the cable manufacturer as having coverage of at least 75%. An additional foil shield can greatly improve noise containment. Type 1 Installation An acceptable shielded cable for Type 1 installations has four XLPE insulated conductors with a 100% coverage foil and an 85% coverage copper braided shield (with drain wire) surrounded by a PVC jacket. For detailed specifications and information on Type 1 installations, refer to Table 1 on page 1. Figure 7 - Type 1 Installation Shielded Cable with Four Conductors Drain Wire Shield W R G B 16 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

17 Wire/Cable Types Chapter 1 Type Installation An acceptable shielded cable for Type installations is essentially the same cable as Type 1, plus one shielded pair of brake conductors. For more information on Type installations, refer to Table 1 on page 1. Figure 8 - Type Installation Shielded Cable with Brake Conductors Drain Wire for Brake Conductor Shield W R G B Shield for Brake Conductors Type 3 Installation These cables have 3 XLPE insulated copper conductors, 5% minimal overlap with helical copper tape, and three bare copper grounds in PVC jacket. TIP Other types of shielded cable are available, but the selection of these types can limit the allowable cable length. Particularly, some of the newer cables twist four conductors of THHN wire and wrap them tightly with a foil shield. This construction can greatly increase the cable charging current required and reduce the overall drive performance. Unless specified in the individual distance tables as tested with the drive, these cables are not recommended and their performance against the lead length limits supplied is not known. For more information about motor cable lead restrictions, refer to, Conduit on page 67, Moisture on page 7, Effects On Wire Types on page 73, and Appendix A. Armored Cable Cable with continuous aluminum armor is often recommended in drive system applications or specific industries. Armored cable 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 (electrical metallic tubing [EMT]) in the installation. It can also be directly buried or embedded in concrete. Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01 17

18 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 ). 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 00 Hp (150 kw). Cable with three ground conductors is recommended for drive sizes larger than 00 Hp (150 kw). Space the ground conductors symmetrically around the power conductors. Verify that the ground conductors are rated for full drive ampacity. Cable with a Single Ground Conductor Cable with Three Ground Conductors W B W G B R G G R G Figure 9 - Armored Cable with Three Ground Conductors Armor Conductors with XLPE Insulation Optional PVC Outer Sheath Optional Foil/Copper Tape and/or Inner PVC Jacket A good example of cable for Type 5 installation is Anixter 7V G. This cable has three XLPE insulated copper conductors, 5% minimal overlap with the helical copper tape, and three bare copper grounds in PVC jacket. IMPORTANT If a terminator network or output filter is used, the connector insulation must be XLPE, and not PVC. 18 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

19 Wire/Cable Types Chapter 1 European Style Cable Cable used in many installations in Europe must conform to Low Voltage Directive (LVD) 006/95/EC. Generally recommended are flexible cables with a bend radius of 0 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. The number and color of individual conductors can vary, but the recommendation is for three phase conductors (customer-preferred colors) and one ground conductor (green/yellow). Ölflex Classic 100SY, or Ölflex Classic 110CY, are examples. Figure 10 - European Style Multi-conductor Cable Filler PVC Outer Sheath W R B Stranded Neutral Input Power Cables In general, the selection of cable for AC input power to a drive has no special requirements. Some installations suggest shielded cable to prevent coupling of noise onto the cable (see Chapter ), and in some cases shielded cable can be required to meet noise standards, such as CE for Europe, C-Tick for Australia/ New Zealand, and others. This can be especially true if an input filter is required to meet a standard. The user manual for the drive has the requirements for meeting these types of standards. Additionally, individual industries can have required standards due to environment or experience. For AC variable frequency drive applications that must satisfy EMC standards for CE, C-Tick, FCC, or others, we recommend the same type of shielded cable that is specified for the AC motors be used between the drive and transformer. Check the individual user manuals or system schematics for specific additional requirements to meet EMC standards. Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01 19

20 Chapter 1 Wire/Cable Types Motor Cables 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. Consider these factors when choosing a cable: The effects of the drive output once the cable is installed. The need for the cable to contain noise caused by the drive output. The amount of cable charging current available from the drive. Possible voltage drop (and subsequent loss of torque) for long wire runs. All examples represent motor cable length of m (600 ft) Keep the motor cable lengths within the limits set in the user manual for the drive. Various issues, including cable charging current and reflected wave voltage stress, can exist. If the cable restriction is listed because of excessive coupling current, apply the methods to calculate total cable length, as shown in Figure 11. If the restriction is due to voltage reflection and motor protection, refer to Appendix A for exact distances allowed. Figure 11 - Motor Cable Length for Capacitive Coupling 15. (50) 16 (550) 15. (50) 15. (50) IMPORTANT For multi-motor applications, review the installation carefully. Consult your distributor drive specialist or Rockwell Automation when considering a multi-motor application with greater than two motors. In general, most installations have no issues. However, high peak cable charging currents can cause drive over-currents or ground faults. 0 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

21 Wire/Cable Types Chapter 1 Cable for Discrete Drive I/O 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. Separate control wires from power wires by at least 0.3 m (1 ft) Table - Recommended Control Wire for Digital I/O Type (1) Wire Type(s) Description Minimum Insulation Rating Unshielded Per US NEC or applicable national or local code 300V, 60 C Shielded Multi-conductor shielded cable mm (18 AWG), (10 F) 3-conductor, shielded. (1) The cable choices shown are for -channel (A and B) or 3-channel (A,B, and Z) encoders. If high resolution or other types of feedback devices are used, choose a similar cable with the correct gauge and number of conductor pairs. Analog Signal and Encoder Cable Always use shielded cable with copper wire. We recommend wire with an insulation rating of 300V or greater. Separate analog signal wires from power wires by at least 0.3 m (1 ft). Run encoder cables in a separate conduit. If signal cables must cross power cables, cross at right angles. Terminate the shield of the shielded cable as recommended by the manufacturer of the encoder or analog signal device. Table 3 - Recommended Signal Wire Signal Type/ Where Used Wire Type(s) Description Standard analog I/O mm (18 AWG), twisted pair, 100% shield with drain (1) Remote pot mm (18 AWG), 3-conductor, shielded Encoder/Pulse I/O < m (100 ft) Encoder/Pulse I/O m ( ft) Encoder/Pulse I/O 59.1 m ( ft) Combined Signal mm ( AWG), individually shielded mm ( AWG), individually shielded Power mm (18 AWG) Combined mm or mm Signal Power Combined mm ( AWG), individually shielded mm (18 AWG) mm (18 AWG), individually shielded pair Minimum Insulation Rating 300V, C ( F) (1) If the wires are short and contained within a cabinet that has no sensitive circuits, the use of shielded wire is not always necessary, but is recommended. Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01 1

22 Chapter 1 Wire/Cable Types Communication This section provides cable recommendations for these communication protocols: DeviceNet on page ControlNet on page 3 Ethernet on page 3 Remote I/O and Data Highway Plus (DH+) on page Serial (RS-3 and RS-85) on page 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-UM07. In general, the four cable types for DeviceNet media meet these criteria: Round (thick) cable with an outside diameter of mm (0.8 in.); normally used for trunk lines, but can also be used for drop lines. Round (thin) cable with an outside diameter of 6.9 mm (0.7 in.); normally used for drop lines, but can also be used for trunk lines. Flat cable, normally used for trunk lines. KwikLink drop cable, used only in KwikLink systems. Round cable contains these five wires: One twisted pair (red and black) for V DC power. One twisted pair (blue and white) for signal. One drain wire (bare). Flat cable contains these four wires: One pair (red and black) for V DC power. One pair (blue and white) for signal. Drop cable for KwikLink is a -wire, unshielded, gray cable. The distance between points, installation of terminating resistors, and chosen baud rate are significant to the installation. For more information, refer to the DeviceNet Media Design and Installation Guide, publication DNET-UM07. Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

23 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-IN00. 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. Country, state, or local codes, such as the U.S. NEC, govern the installation. Installation Environment Use this Cable Type Light industrial Standard PVC CM-CL Heavy industrial Lay-on armored Light interlocking armor High/Low temperature or corrosive (harsh chemicals) Plenum-FEP CMP-CLP Festooning or flexing High flex Moisture: direct burial, with flooding compound, fungus resistant Flood burial The allowable length of segments and installation of terminating resistors play a significant part in the installation. Refer to the ControlNet Coax Media Planning and Installation Guide, publication CNET-IN00, for details. Ethernet Ethernet communication interface wiring is very detailed for the type of cable, connectors, and routing. In general, Ethernet systems use shielded twisted pair (STP) cable, or unshielded twisted pair (UTP) cable, with RJ5 connectors that meet the IP67 standard and are appropriate for the environment. Use cables that meet Telecommunications Industry Association/Electronic Industries Alliance (TIA/EIA) standards at industrial temperatures. Shielded cable is recommended when the installation can include welding, electrostatic processes, drives over 10 Hp, motor control centers (MCCs), high power RF radiation, or devices carrying current in excess of 100 A. Shield handling and single-point grounding, also discussed in this document, are also important for the proper operation of Ethernet installations. There are also important distance and routing limitations published in detail. Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01 3

24 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 5 Kbps 308 m (10,000 ft) 115. Kbps 15 m (5000 ft) 30. Kbps 76 m (500 ft) All three connections (blue, shield, and clear) must be connected at each node. IMPORTANT Do not connect in a star topology. Only two cables can be connected at any wiring point. Use either series or daisy chain topology at all points. Serial (RS-3 and RS-85) Follow these recommended standard practices for serial communications wiring: One twisted pair and one signal common for RS-3. Two twisted pair, with each pair individually shielded, for RS-85. Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

25 Chapter 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. Delta/Wye with Grounded Wye Neutral Delta/Wye with Grounded Wye Neutral is the most common type of distribution system. It provides a 30 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 recommends the use of grounded neutral systems for these reasons: Controlled path for common mode noise current Consistent line-to-ground voltage reference that minimizes insulation stress Accommodation for system surge protection schemes Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01 5

26 Chapter 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. Three-phase Open Delta with Single-phase Center Tapped Single-phase Loads Three-phase Loads Single-phase Loads Three-phase Open Delta with Single-phase Center Tapped is a configuration providing a Three-phase delta transformer with one 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 0V, single-phase transformer rating. Closing the delta with a third single-phase, 0V transformer provides full rating for the two single-phase, 0V transformers. The phase leg opposite the midpoint has an elevated voltage when compared to earth or neutral. The hottest high leg must be positively identified throughout the electrical system. Make the hottest high leg the center leg in any switch, motor control, three-phase panel board, and so on. The NEC requires orange color tape to identify this leg. 6 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

27 Power Distribution Chapter 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. If the system is ungrounded, other general precautions, such as a system level ground fault detector or system level line to ground suppressor, can be necessary. Or consider an isolation transformer with the secondary of the transformer grounded. Refer to local codes regarding safety requirements. Also refer to Surge Protection MOVs and Common Mode Capacitors on page 5. 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 do not exceed the normal line-to-line voltage. This is within the rating of the MOV input protection devices on the drive. The resistor is often used to detect ground current by monitoring the associated voltage drop. Because high frequency ground current can flow through this resistor, be sure to properly connect the drive motor leads by using the recommended cables and methods. In some cases, multiple drives (that can have one or more internal references to ground) on one transformer can produce a cumulative ground current that can trigger the ground fault interrupt circuit. Refer to Surge Protection MOVs and Common Mode Capacitors on page 5. Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01 7

28 Chapter Power Distribution TN-S Five-wire System L1 L 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 00V) powers three-phase loads. Leg-to-neutral voltage (commonly at 30V) powers single-phase loads. Neutral is a current conducting wire, and connects through a circuit breaker. The fifth wire is a separate ground wire. There is a single connection between ground and neutral, typically in the distribution system. Do not make connections between ground and neutral within the system cabinets. AC Line Voltage In general, all Allen-Bradley drives are tolerant to a wide range of AC line voltage. Check the individual specifications for the drives you are installing. Incoming voltage imbalances >% can cause large unequal currents in a drive. Use an input line reactor when line voltage imbalances are >%. AC Line Impedance To prevent excess current that can damage drives during events such as line disturbances or certain types of ground faults, provide a minimum amount of impedance in front of the drives. In many installations, this impedance comes from the supply transformer and the supply cables. In some cases, an additional transformer or reactor is recommended. If any of these conditions exist, consider adding impedance (line reactor or transformer) in front of the drive: Installation site has switched power factor correction capacitors. Installation site has lightning strikes or voltage spikes in excess of 6000V peak. Installation site has power interruptions or voltage dips in excess of 00V AC. The transformer is too large in comparison to the drive. See impedance recommendations on Table on page 30 through Table 13 on page 1. IMPORTANT Tables through 13 define the largest transformer size for each product and rating based on specific differences in construction, and is the preferred method to follow. 8 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

29 Power Distribution Chapter 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%. For drives with built-in inductors add line impedance whenever the transformer kva is more than 0 times larger than the drive kva, or the percent source impedance relative to each drive is less than 0.5%. To identify drives with built-in inductors, see the product specific information in Table on page 30 through Table 13 on page 1. The shaded rows identify products ratings without built-in inductors. Use these equations to calculate the impedance of the drive and transformer: Drive Impedance (in ohms) Z drive = V line-line 3 * I input-rating Transformer Impedance (in ohms) Z xfmr = V line-line 3 * I xfmr-rated or * % Impedance Z xfmr = (V line-line ) VA * % Impedance % impedance is the nameplate impedance of the transformer. Typical values range from 0.03 (3%) to 0.06 (6%). Transformer Impedance (in ohms) Z xfmr = V line-line 3 * I xfmr-rated * % Impedance % impedance is the nameplate impedance of the transformer. Typical values range from 0.03 (3%) to 0.06 (6%). Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01 9

30 Chapter Power Distribution EXAMPLE The drive is rated 1 Hp, 80V,.7A input. The supply transformer is rated 50,000 VA (50 kva), 5% impedance. Z drive = V line-line 80V = = 10.6 Ohms 3 * I input-rating 3 *.7 Z xfmr = (V line-line ) VA 80 * % Impedance = * 0.05 = 0.30 Ohms 50,000 Note that the percent (%) impedance has to be in per unit (5% becomes 0.05) for the formula. Z xfmr Z = 0.30 drive 10.6 = 0.00 = 0.% 0.% is less than 0.5%. Therefore, this transformer is too big for the drive. Consider adding a line reactor. IMPORTANT Grouping multiple drives on one reactor is acceptable; however, the reactor percent impedance must be large enough when evaluated for each drive separately, not evaluated for all loads connected at once. These recommendations are advisory and do not address all situations. Site specific conditions must be considered to assure a quality installation. Table - AC Line Impedance Recommendations for Bulletin 160 Drives Bulletin Drive Catalog Volts kw (Hp) Max Supply 3% Line Reactor Reactor Inductance Reactor Current Number Number (1) kva () Open Style 131- (mh) Rating (amps) 160 -AA (0.5) 15 3R-B 6.5 -AA (0.75) 0 3R-A 3 -AA (1) 30 3R-A 3 -AA () 50 3R8-A AA1 0. (3) 75 3R1-A AA (5) 100 3R18-A BA (0.5) 15 3R-B 0 -BA (0.75) 0 3R-A 1 -BA (1) 30 3R-A 1 -BA () 50 3R-B 6.5 -BA (3) 75 3R8-B 3 8 -BA (5) 100 3R18-B (1) Shaded rows identify drive ratings without built-in inductors. () Maximum suggested KVA supply without consideration for additional inductance. 30 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

31 Power Distribution Chapter Table 5 - AC Line Impedance Recommendations for Bulletin 1305 Drives Bulletin Drive Catalog Volts kw (Hp) Max Supply 3% Line Reactor Reactor Inductance Reactor Current Number Number (1) kva () Open Style 131- (mh) Rating (amps) AA0A (0.5) 15 3R-A 3 -AA03A (0.75) 0 3R-A -AA0A (1) 30 3R8-A AA08A () 50 3R8-A AA1A 0. (3) 75 3R18-A BA01A (0.5) 15 3R-B 0 -BA0A (0.75) 0 3R-B 0 -BA03A (1) 30 3R-B 6.5 -BA0A () 50 3R-B 6.5 -BA06A 80. (3) 75 3R8-B 3 8 -BA09A (5) 100 3R18-B (1) Shaded rows identify drive ratings without built-in inductors. () Maximum suggested KVA supply without consideration for additional inductance. Table 6 - AC Line Impedance Recommendations for PowerFlex Drives Drive PowerFlex Drive Catalog Number (1) Volts kw (Hp) Max Supply kva 3% Line Reactor Open Style 131- Reactor Inductance (mh) AB1P (0.5) 15 3R-A 1 ABP (0.5) 5 3R-B 6.5 ABP (1.0) 50 3R8-B 3 8 AB8P (.0) 100 3R8-A AB01 0. (3.0) 15 3R1-A AB (5.0) 150 3R18-A Reactor Current Rating (amps) AD1P (0.5) 15 3R-B 0 ADP (1.0) 30 3R-C 9 ADP (.0) 50 3R-B 6.5 AD6P0 80. (3.0) 75 3R8-C 5 8 AD8P (5.0) 100 3R8-B 3 8 (1) Shaded rows identify drive ratings without built-in inductors. Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01 31

32 Chapter Power Distribution Table 7 - AC Line Impedance Recommendations for PowerFlex 0 Drives Drive PowerFlex 0 Drive Catalog Number (1) Volts kw (Hp) Max Supply kva () 3% Line Reactor Open Style 131- Reactor Inductance (mh) BBP (0.5) 5 3R-B 6.5 BB5P (1.0) 50 3R8-B 3 8 BB8P (.0) 50 3R8-A BB01 0. (3.0) 50 3R1-A BB (5.0) 50 3R18-A BB (7.5) 100 3R5-A BB (10.0) 150 3R35-A Reactor Current Rating (amps) BD1P (0.5) 15 3R-B 0 BDP (1.0) 30 3R-C 9 BDP (.0) 50 3R-B 6.5 BD6P0 80. (3.0) 75 3R8-C 5 8 BD (5.0) 100 3R8-B 3 8 BD (7.5) 10 3R1-B.5 1 BD (10.0) 150 3R18-B BD (15.0) 00 3R5-B 1. 5 BE1P (1.0) 0 3R-B 0 BE3P (.0) 30 3R-B 6.5 BEP 600. (3.0) 50 3R-B 6.5 BE6P (5.0) 75 3R8-C 5 8 BE9P (7.5) 10 3R1-B.5 1 BE (10.0) 150 3R1-B.5 1 BE (15.0) 00 3R18-B (1) Shaded rows identify drive ratings without built-in inductors. () Maximum suggested KVA supply without consideration for additional inductance. 3 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

33 Power Distribution Chapter Table 8 - AC Line Impedance Recommendations for PowerFlex 00 Drives Drive PowerFlex 00 Drive Catalog Number (1) Volts kw (Hp) Max Supply kva () 3% Line Reactor Open Style 131- Reactor Inductance (mh) CB01 0. (3.0) 50 3R1-A N/A N/A CB (5.0) 50 3R18-A N/A N/A CB (7.5) 00 3R5-A CB (10.0) 75 3R35-A CB (15.0) 350 3R5-A CB (0.0) 5 3R55-A CB (5.0) 550 3R80-A CB090 0 (30.0) 600 3R100-A CB (0.0) 750 3R130-A CB (50.0) 800 3R160-A Reactor Current Rating (amps) CD6P0 80. (3.0) N/A N/A N/A N/A CD (5.0) N/A N/A N/A N/A CD (7.5) N/A N/A N/A N/A CD (10) N/A N/A N/A N/A CD (15) N/A N/A N/A N/A CD (0) N/A N/A N/A N/A CD N/A N/A N/A N/A CD05 80 (30) N/A N/A N/A N/A CD N/A N/A N/A N/A CD (50) N/A N/A N/A N/A CD N/A N/A N/A N/A CD (75) N/A N/A N/A N/A CD N/A N/A N/A N/A CD (15) N/A N/A N/A N/A CD N/A N/A N/A N/A (1) Shaded rows identify drive ratings without built-in inductors. () Maximum suggested KVA supply without consideration for additional inductance. Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01 33

34 Chapter Power Distribution Table 9 - AC Line Impedance Recommendations for PowerFlex 55 Drives Drive PowerFlex 55 Drive Catalog Number (1) Volts kw (Hp) Max Supply kva () 3% Line Reactor Open Style 131- Reactor Inductance (mh) 5BBP (0.5) 5 3R-B 6.5 5BB5P (1.0) 50 3R8-B 3 8 5BB8P (.0) 50 3R8-A BB01 0. (3.0) 50 3R1-A BB (5.0) 50 3R18-A BB (7.5) 100 3R5-A BB (10.0) 150 3R35-A BB (15.0) 150 3R55-B BB (10.0) 150 3R80-B Reactor Current Rating (amps) 5BD1P (0.5) 15 3R-B 0 5BDP (1.0) 30 3R-C 9 5BDP (.0) 50 3R-B 6.5 5BD6P0 80. (3.0) 75 3R8-C 5 8 5BD (5.0) 100 3R8-B 3 8 5BD (7.5) 10 3R1-B.5 1 5BD (10.0) 150 3R18-B BD (15.0) 00 3R5-B BD (0.0) 00 3R35-B BD (5.0) 500 3R5-B BD03 80 (30.0) 500 3R5-B BE0P (0.5) 0 3R-B 0 5BE1P (1.0) 0 3R-B 0 5BE3P (.0) 30 3R-B 6.5 5BEP 600. (3.0) 50 3R-B 6.5 5BE6P (5.0) 75 3R8-C 5 8 5BE9P (7.5) 10 3R1-B.5 1 5BE (10.0) 150 3R1-B.5 1 5BE (15.0) 00 3R18-B BE (0.0) 00 3R5-B BE (5.0) 500 3R35-B BE (30.0) 500 3R35-B (1) Shaded rows identify drive ratings without built-in inductors. () Maximum suggested KVA supply without consideration for additional inductance. 3 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

35 Power Distribution Chapter Table 10 - AC Line Impedance Recommendations for PowerFlex 70 Drives Drive PowerFlex 70 Drive Catalog Volts kw (Hp) Max Supply Number (1) kva () 3% Line Reactor Open Style 131- Reactor Inductance (mh) 0ABP (0.5) 5 3R-D 6 0ABP (1) 50 3R-A 3 0AB6P () 50 3R8-A AB9P6 0. (3) 50 3R1-A AB (5) 00 3R18-A AB (7.5) 50 3R5-A AB (10) 300 3R35-A AB (15) R5-A AB (0) R80-A AB R80-A AC1P (0.5) 30 3R-B 0 0ACP (1) 50 3R-B 0 0AC3P () 50 3R-B 6.5 0AC5P0 00. (3) 75 3R-B 6.5 0AC8P (5) 100 3R8-B 3 8 0AC (7.5) 50 3R1-B.5 1 0AC (10) 50 3R18-B AC (15) 300 3R5-B AC (0) 00 3R35-B AC R35-B AC03 00 (30) R5-B AC R55-B AC (50) R80-B Reactor Current Rating (amps) (3) 0AD1P (0.5) 30 3R-B 0 0ADP (1) 50 3R-B 0 0AD3P () 50 3R-B 6.5 0AD5P0 80. (3) 75 3R-B 6.5 0AD8P (5) 100 3R8-B 3 8 0AD (7.5) 50 3R1-B.5 1 0AD (10) 50 3R18-B AD (15) 300 3R5-B AD (0) 00 3R35-B AD R35-B N/A N/A 0AD00 80 (30) R5-B N/A N/A 0AD R55-B N/A N/A 0AD (50) R80-B N/A N/A continued 0AE0P (0.5) 30 3R-B 0 0AE1P (1) 50 3R-B 0 0AEP () 50 3R-C 9 0AE3P (3) 75 3R-C 9 0AE6P (5) 100 3R8-C 5 8 0AE9P (7.5) 50 3R8-B 3 8 0AE (10) 50 3R1-B.5 1 0AE (15) 300 3R18-B AE (0) 00 3R5-B AE R35-B Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01 35

36 Chapter Power Distribution Table 10 - AC Line Impedance Recommendations for PowerFlex 70 Drives (Continued) Drive PowerFlex 70 Drive Catalog Volts kw (Hp) Max Supply Number (1) kva () 3% Line Reactor Open Style 131-0AE (30) R35-B AE R5-B AE (50) R55-B (1) Shaded rows identify drive ratings without built-in inductors. () Maximum suggested KVA supply without consideration for additional inductance. (3) N/A = not available at time of printing. Reactor Inductance (mh) Reactor Current Rating (amps) (3) Table 11 - AC Line Impedance Recommendations for PowerFlex 700/700S Drives Drive PowerFlex 700/700S For PowerFlex 700S, replace 0B with 0D. Drive Catalog Number Volts kw (Hp) Max Supply KVA (1) 3% Line Reactor Open Style 131- Reactor Inductance (mh) 0BBP (0.5) 100 3R-D 6 0BBP (1) 15 3R-A 3 0BB6P () 00 3R8-A BB9P6 0. (3) 300 3R1-A BB (5) 00 3R18-A BB (7.5) 500 3R5-A BB (10) 750 3R35-A BB (15) R5-A BB (0) R80-A BB R80-A BB080 0 (30) R100-A BB R130-A BB (50) R130-A BB R160-A BB (75) R00-A BB R30-A Reactor Current Rating (amps) continued 0BC1P (5) 50 3R-B 0 0BCP (1) 50 3R-B 0 0BC3P () 500 3R-B 6.5 0BC5P0 00. (3) 500 3R-B 6.5 0BC8P7 00 (5) 500 3R8-B 3 8 0BC (7.5) 750 3R1-B.5 1 0BC (10) R18-B BC (15) R5-B BC (0) R35-B BC R5-B BC03 00 (30) R5-B BC R55-B BC (50) R80-B BC R130-B BC (75) R130-B BC (75) R130-B BC R160-B BC (15) R00-B BC R00-B BC (175) 000 3RB30-B Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

37 Power Distribution Chapter Table 11 - AC Line Impedance Recommendations for PowerFlex 700/700S Drives (Continued) Drive PowerFlex 700/700S For PowerFlex 700S, replace 0B with 0D. Drive Catalog Number Volts kw (Hp) Max Supply KVA (1) 3% Line Reactor Open Style 131- Reactor Inductance (mh) 0BD1P (0.5) 50 3R-B 0 0BDP (1) 50 3R-B 0 0BD3P () 500 3R-B 6.5 0BD5P0 80. (3) 500 3R-B 6.5 0BD8P (5) 500 3R8-B 3 8 0BD (7.5) 750 3R1-B.5 1 0BD (10) 750 3R18-B BD (15) 750 3R5-B BD (0) 750 3R35-B BD R35-B BD00 80 (30) R5-B BD R55-B BD (50) R80-B BD R80-B BD (75) R100-B BD R130-B BD R160-B BD (15) R160-B BD R00-B Reactor Current Rating (amps) 0BE0P (0.5) 50 3R-B 0 0BE1P (1) 50 3R-B 0 0BEP () 500 3R-B 6.5 0BE3P (3) 500 3R-B 6.5 0BE6P (5) 500 3R8-B 3 8 0BE9P (7.5) 750 3R8-B 3 8 0BE (10) 750 3R1-B.5 1 0BE (15) 750 3R5-B BE (0) 750 3R5-B BE R35-B BE (30) R35-B BE R5-B BE (50) R55-B BE R80-B BE (75) R80-B BE R100-B BE (15) 100 3R130-B BE R160-B (1) Maximum suggested KVA supply without consideration for additional inductance Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01 37

38 Chapter Power Distribution Table 1 - AC Line Impedance Recommendations for PowerFlex 753/755 Drives Drive PowerFlex 753/755 For PowerFlex 753, replace 0G with 0F. Drive Catalog Number Volts kw (Hp) Max Supply KVA (1) 3% Line Reactor Open Style 131- Reactor Inductance (mh) 0G_RCP (1) 50 3R-B 0 0G_RC3P () 500 3R-B 6.5 0G_RC5P0 00. (3) 500 3R-B 6.5 0G_RC8P7 00 (5) 500 3R8-B 3 8 0G_RC (7.5) 750 3R1-B.5 1 0G_RC (10) R18-B G_CP (1) 50 3R-B 0 0G_C3P () 500 3R-B 6.5 0G_C5P0 00. (3) 500 3R-B 6.5 0G_C8P7 00 (5) 500 3R8-B 3 8 0G_C (7.5) 750 3R1-B.5 1 0G_C (10) R18-B G_C (15) R5-B G_C (0) R35-B G_C R5-B G_C03 00 (30) R5-B G_C R80-B G_C (50) R80-B G_C R130-B G_C (75) R130-B G_C (75) R130-B G_C R160-B G_C (15) R00-B G_C R00-B G_C (175) 500 3RB30-B G_C (1) 500 3RB30-B G_C (68) RB00-B G_C (335) R500-B G_C (335) R500-B G_C () 000 3R600-B G_C (76) 500 3R750-B G_C (536) 500 3R750-B G_C (536) R850-B G_C1K (670) R1000-B G_C1K (750) 5000 x 3R750-B G_C1K (175) 5000 x 3R750-B G_C1K (1070) 5000 x 3R850-B G_C1K x 3R850-B G_CK (1675) 5000 x 3R1000-B Reactor Current Rating (amps) continued 0G_RDP (1) 50 3R-B 0 0G_RD3P () 500 3R-B 6.5 0G_RD5P0 80. (3) 500 3R-B 6.5 0G_RD8P0 80 (5) 500 3R8-B 3 8 0G_RD (7.5) 750 3R1-B.5 1 0G_RD (10) R18-B G_DP (1) 50 3R-B 0 0G_D3P () 500 3R-B Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

39 Power Distribution Chapter Table 1 - AC Line Impedance Recommendations for PowerFlex 753/755 Drives (Continued) Drive PowerFlex 753/755 For PowerFlex 753, replace 0G with 0F. Drive Catalog Number Volts kw (Hp) Max Supply KVA (1) 3% Line Reactor Open Style 131- Reactor Inductance (mh) 0G_D5P0 80. (3) 500 3R-B 6.5 0G_D8P (5) 500 3R8-B 3 8 0G_D (7.5) 750 3R1-B.5 1 0G_D (10) 750 3R18-B G_D (15) 750 3R5-B G_D (0) 750 3R35-B G_D R35-B G_D00 80 (30) R5-B G_D R55-B G_D (50) R80-B G_D R80-B G_D (75) R100-B G_D R130-B G_D R160-B G_D (15) R160-B G_D R00-B G_D RB30-B G_D (50) 500 3RB30-B G_D RB00-B G_D R500-B G_D R500-B G_D R600-B G_D (50) 000 3R600-B G_D R750-B G_D R750-B G_D (650) 500 3R750-B G_D R850-B G_D R1000-B G_D1K R1000-B G_D1K x 3R750-B G_D1K (1100) 5000 x 3R750-B G_D1K x 3R850-B G_D1K (1350) 5000 x 3R850-B G_DK (1750) 5000 x 3R1000-B Reactor Current Rating (amps) continued 0G_E1P (1) 50 3R-B 0 0G_EP () 500 3R-B 6.5 0G_E3P (3) 500 3R-B 6.5 0G_E6P (5) 500 3R8-B 3 8 0G_E9P (7.5) 750 3R8-B 3 8 0G_E (10) 750 3R1-B.5 1 0G_E (15) 750 3R5-B G_E (15) 750 3R5-B G_E (0) 750 3R5-B G_E R35-B G_E R35-B G_E R35-B G_E R35-B G_E (30) R35-B Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01 39

40 Chapter Power Distribution Table 1 - AC Line Impedance Recommendations for PowerFlex 753/755 Drives (Continued) Drive PowerFlex 753/755 For PowerFlex 753, replace 0G with 0F. Drive Catalog Number Volts kw (Hp) Max Supply KVA (1) 3% Line Reactor Open Style 131- Reactor Inductance (mh) 0G_E (30) R35-B G_E R5-B G_E R5-B G_E (50) R55-B G_E (50) R55-B G_E R80-B G_E (75) R80-B G_E R100-B G_E (15) 100 3R130-B G_E R160-B G_E R00-B G_E (50) 000 3RB30-B G_E RB30-B G_E RB30-B G_E RB00-B G_E RB00-B G_E (50) R500-B G_E R500-B G_E R600-B G_E R600-B G_E R750-B G_E R850-B G_E R850-B G_E (950) R1000-B G_E R1000-B G_E1K (1100) 5000 x 3R600-B G_E1K x 3R750-B Reactor Current Rating (amps) continued 0G_F (10) 750 3R1-B.5 1 0G_F (15) 750 3R5-B G_F (0) 750 3R5-B G_F R5-B G_F (30) R35-B G_F R35-B G_F (50) R55-B G_F R55-B G_F (75) R80-B G_F R100-B G_F (15) 100 3R100-B G_F R130-B G_F (177) R160-B G_F (15) R00-B G_F (68) 000 3RB30-B G_F (335) 000 3RB30-B G_F (335) 500 3RB30-B G_F () 500 3RB00-B G_F (76) 500 3RB00-B G_F (536) 500 3R500-B G_F R500-B Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

41 Power Distribution Chapter Table 1 - AC Line Impedance Recommendations for PowerFlex 753/755 Drives (Continued) Drive Drive Catalog Number Volts kw (Hp) Max Supply KVA (1) 3% Line Reactor Open Style 131- Reactor Inductance (mh) PowerFlex 0G_F (670) R500-B /755 0G_F (750) R600-B For 0G_F (85) 500 3R750-B PowerFlex 753, 0G_F (95) 500 3R750-B replace 0G 0G_F (1006) R850-B with 0F. 0G_F (1073) R850-B G_F (107) R1000-B G_F1K (131) R1000-B G_F1K (1877) 5000 x 3R750-B (1) Maximum suggested KVA supply without consideration for additional inductance. Reactor Current Rating (amps) Table 13 - AC Line Impedance Recommendations for Bulletin 1336 Drives Drive 1336 PLUS, PLUS II IMPACT FORCE Drive Catalog Volts kw (Hp) Max Supply Number (1) kva ()(3) 3% Line Reactor Open Style, 131- Reactor Inductance (mh) AQF (0.5) 5 3R-A 3.0 AQF (0.75) 5 3R-A 3.0 AQF (1) 50 3R8-A AQF (1.5) 75 3R8-A AQF () 100 3R1-A AQF30 0. (3) 00 3R1-A AQF (5) 75 3R5-A AQF (7.5) 300 3R5-A A (7.5) 300 3R5-A A (10) 350 3R35-A A (15) 600 3R5-A A (0) 800 3R80-A A R80-A A30 0 (30) 950 3R80-A A R130-A A (50) R160-A A R00-A A (75) RB50-A A RB30-A A (15) RB30-A Reactor Current Rating (amps) () continued BRF (0.5) 5 3R-B 0 BRF (0.75) 30 3R-B 0 BRF (1) 30 3R-B 6.5 BRF (1.5) 50 3R-B 6.5 BRF () 50 3R8-B BRF (3) 75 3R8-B BRF (5) 100 3R1-B.5 1 BRF (7.5) 00 3R18-B BRF (10) 75 3R5-B 1. 5 BRF (15) 300 3R5-B 1. 5 BRF (0) 350 3R5-B 1. 5 B (15) 350 3R5-B 1. 5 B (0) 5 3R35-B Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01 1

42 Chapter Power Distribution Table 13 - AC Line Impedance Recommendations for Bulletin 1336 Drives (Continued) Drive 1336 PLUS, PLUS II IMPACT FORCE Drive Catalog Volts kw (Hp) Max Supply Number (1) kva ()(3) 3% Line Reactor Open Style, 131- Reactor Inductance (mh) B R35-B B (30) 600 3R5-B B R55-B B (50) 800 3R80-B B R80-B B (75) R100-B B R130-B B (15) 100 3R160-B B R00-B 0.11 N00 B RB50-B B (50) 500 3RB30-B B RB00-B B R500-B B R500-B B (50) 500 3R600-B B R600-B B R750-B B R850-B B R1000-B BP/BPR (50) N/A N/A N/A N/A BP/BPR N/A N/A N/A N/A BP/BPR N/A N/A N/A N/A BP/BPR N/A N/A N/A N/A BP/BPR (50) N/A N/A N/A N/A BX N/A N/A N/A N/A BX N/A N/A N/A N/A BX N/A N/A N/A N/A BX (50) N/A N/A N/A N/A Reactor Current Rating (amps) () continued CWF (1) 5 3R-C 9 CWF () 50 3R-C 9 CWF (3) 75 3R8-C 5 8 CWF (5) 100 3R8-B 3 8 CWF (7.5) 00 3R8-B 3 8 CWF (10) 00 3R1-B.5 1 CWF (15) 300 3R18-B CWF (0) 350 3R5-B 1. 5 C (15) 300 3R18-B C (0) 350 3R5-B 1. 5 C R5-B 1. 5 C (30) 600 3R35-B C R5-B C (50) 850 3R55-B C R80-B C (75) 950 3R80-B C R100-B C (15) 100 3R130-B C R160-B C R00-B Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

43 Power Distribution Chapter Table 13 - AC Line Impedance Recommendations for Bulletin 1336 Drives (Continued) Drive 1336 PLUS, PLUS II IMPACT FORCE Drive Catalog Volts kw (Hp) Max Supply Number (1) kva ()(3) 3% Line Reactor Open Style, 131- C (50) 500 3R50-B C R30-B C R00-B C R00-B C (50) 500 3R500-B C R500-B C R600-B C (650) R750-B C R850-B FN C R850-B FN CP/CPR N/A N/A N/A N/A CP/CPR N/A N/A N/A N/A (1) Shaded rows identify drive ratings without built-in inductors. () Maximum suggested KVA supply without consideration for additional inductance. (3) 000 KVA represents MVA and greater. () N/A = not available at time of printing. Reactor Inductance (mh) Reactor Current Rating (amps) () Multi-drive Protection Use a separate line reactor for each drive that shares a common power line. Individual line reactors provide filtering between each drive to provide optimum surge protection for each drive. However, if it is necessary to group more than one drive on a single AC line reactor, use this process to verify that the AC line reactor provides a minimum amount of impedance: In general, up to five drives can be grouped on one reactor. Add the input currents of the drives in the group. Multiply that sum by 15%. Refer to 131 Power Conditioning Products Technical Data, publication 131-TD001, to select a reactor with a maximum continuous current rating greater than the multiplied current. Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01 3

44 Chapter Power Distribution Use the formula below to verify that the impedance of the selected reactor is more than 0.5% (0.5% 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. Z drive = V line-line 3 * I input-rating Z reactor = L * * 3.1 * f L is the inductance of the reactor in henries and f is the AC line frequency. EXAMPLE There are five drives. Each drive is rated 1 Hp, 80V,.7 A. These drives do not have internal inductors. Total current is 5 x.7 A = 13.5 A 15% x Total current is 15% x 13.5 A = 16.9 A From 131 Power Conditioning Products Technical Data, publication 131- TD001, we selected the catalog number 131-3R1-C reactor. This reactor has a maximum continuous current rating of 18 A and an inductance of. mh (0.00 henries). Z drive = V line-line 80V 3 * I input-rating 3 *.7 = = 10.6 Ohms Z reactor = L * ( * 3.1) * f = 0.00 * 6.8 * 60 = 1.58 Ohms Z reactor Z = 1.58 drive 10.6 = = 1.5% 1.5% is more than the 0.5% impedance recommended. The catalog number 131-3R1-C reactor can be used for the five.7 A drives in this example. Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

45 Power Distribution Chapter Surge Protection MOVs and Common Mode Capacitors 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. MOV Circuitry Most drives are designed to operate on three-phase supply systems with symmetrical line voltages. To meet IEEE C6.1, these drives are equipped with MOVs that provide voltage surge protection as well as phase-to-phase and phaseto-ground protection. The MOV circuit is designed only for surge suppression (transient line protection), not for continuous operation. Figure 1 - Typical MOV Configuration 3-phase AC Input Ground R S T 1 3 Phase-to-phase MOV rating includes two phase-to-phase MOVs. Phase-to-ground MOV rating includes one phase-to-phase MOV and one phase-to-ground MOV. With ungrounded distribution systems, the phase-to-ground MOV connection can become a continuous current path to ground. Exceeding the published phase-to-phase voltage, phase-to-ground voltage, or energy ratings can damage the MOV. Suitable isolation is required for the drive when there is potential for abnormally high phase-to-ground voltages (in excess of 15% of nominal line-to-line voltage), or when the supply ground is tied to another system or equipment that could cause the ground potential to vary with operation. We recommend an isolation transformer when this condition exists. Common Mode Capacitors Many drives also contain common mode capacitors that are referenced to ground. In installations with ungrounded or high resistive ground systems, the common mode capacitors can capture high frequency common mode or ground fault currents. This can cause bus overvoltage conditions that can cause damage or drive faults. Systems that are ungrounded or have one phase grounded (commonly called B-phase grounded) apply higher than normal voltage stresses directly to the common mode capacitors and can lead to shortened drive life or damage. Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01 5

46 Chapter Power Distribution Use PowerFlex Drives with Regenerative Units 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 Guidelines DC bus wiring refers to connecting the DC bus of an AC drive to the DC connections on another piece of equipment. That equipment can include any or all of these items: Additional AC drive Non-regenerative DC bus supply Regenerative DC bus supply Regenerative braking module Dynamic braking module Chopper module For more information on the types of common DC bus configurations and applications, refer to PowerFlex AC Drives in Common Bus Configurations, publication DRIVES-AT00. Drive Lineup Generally, it is desirable for the drive lineup to match the machine layout. However, if there is a mix of drive frame sizes used in the lineup, the general system layout places the largest drives closest to the rectifier source. The rectifier source does not need to be at the end of the system lineup. Many times it is advantageous to put the rectifier in the middle of the lineup, minimizing the distances to the farthest loads. This is needed to minimize the energy stored in the parasitic inductance of the bus structure and thus lower peak bus voltages during transient operation. The system must be contained in one contiguous lineup. The bus cannot be interrupted to go to another cabinet for the remainder of the system drives. A contiguous lineup is needed to maintain low inductance. 6 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

47 Power Distribution Chapter 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. Figure 13 - Star Configuration of Common Bus Connections L1 Bus Supply L L3 DC+ DC+ DC- DC- Power Distribution Terminal Block DC+ BR1 BR DC- DC+ BR1 BR DC+ BR1 BR DC- DC- L1 L1 L1 L L L L3 L3 L3 AC Drive AC Drive AC Drive M1 M M3 Bus Bar Versus Cable Follow these recommendations for using a bus bar versus a cable: A DC bus bar is recommended versus a cable. When a DC bus bar cannot be used, follow these guidelines for DC bus cables: Use twisted cable where possible, approximately one twist per inch. Use cable rated for the equivalent AC voltage rating. The peak AC voltage is equivalent to the DC voltage. For example, the peak AC voltage on a 80V AC system no load is 80 x 1.1 = 679V peak. The 679V peak corresponds to 679V DC at no load. Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01 7

48 Chapter 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. ft) of the chopper module. Refer to the respective braking product documentation for details. An RC snubber circuit is required when you use Allen-Bradley catalog number 1336-WA, 1336-WB, or 1336-WC brake choppers in the configurations listed below: A non-regenerative bus supply configuration that uses a PowerFlex diode bus supply. A shared AC/DC bus configuration containing a PowerFlex 700/700S Frame 0 drive, or PowerFlex 0P drive. A shared DC bus (piggy back) configuration when the main drive is a PowerFlex 700/700S Frame 0, or PowerFlex 0P drive. The RC snubber circuit is required to prevent the DC bus voltage from exceeding the 100V maximum brake chopper IGBT voltage. The 1336 brake chopper power-up delay time is 80 ms. During this time, the IGBT does not turn on. The RC snubber circuit must always be connected to the DC bus (found close to the braking chopper) to absorb the power-on voltage overshoot (see Figure 1). The specifications for the RC snubber are described here: R = 10 Ω, 100 W, low inductance (less than 50 μh) C = 0 μf, 000V Figure 1 - Configuration Example of Diode Bus Supply with PowerFlex 700 Frame 0, PowerFlex 0P, 1336-W Braking Chopper and RC Snubber Circuit. 3-phase Source 3-phase Reactor L1 Diode Bus Supply DC+ L DC- L3 PowerFlex DC+ DC- DC+ BR1 BR DC- DC+ BR1 BR DC+ DC- DC- DC+ BR+ BR- BR+ BR- DC- Braking Unit 1336-W* Frame 0 Frame 0 L1 L1 L L L3 L3 L1 L L3 PowerFlex 0P L1 L L3 PowerFlex 0P BR1 BR PowerFlex 700 PowerFlex 700 BR M1 M M3 M 8 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

49 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). Grounding of a drive or drive system is done for two basic reasons: safety (as defined above), and noise containment or reduction. While the safety ground scheme and the noise current return circuit can sometimes share the same path and components, they are considered different circuits with different requirements. Grounding Safety Grounds The object of safety grounding is to make sure that all metalwork is at the same ground (or earth) potential at power frequencies. Impedance between the drive and the building scheme ground must conform to the requirements of national and local industrial safety regulations or electrical codes. These regulations and codes vary based on country, type of distribution system, and other factors. Periodically check all ground connections and verify that the connections are secure and correct. General safety requires that all metal parts are connected to earth with separate copper wire, or wires of the appropriate gauge. Always follow any specific directions for connecting a safety ground or protective earth (PE) directly to any piece of equipment. Building Steel If intentionally bonded at the service entrance, the incoming supply neutral or ground is bonded to the building ground. Building steel is typically the best representation of ground or earth. The structural steel of a building is generally bonded together to provide a consistent ground potential. If other means of grounding are used, such as ground rods, you must understand the voltage potential between ground rods in different areas of the installation. The type of soil, ground water level, and other environmental factors can greatly affect the voltage potential between ground points if they are not bonded to each other. Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01 9

50 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. Global drive systems requires the PE ground to be connected to the transformer ground feeding the drive system. RFI Filter Grounding The use of an optional radio frequency interference (RFI) filter can result in relatively high ground leakage currents. Therefore, use an RFI filter only in installations with grounded AC supply systems and RFI filters that are permanently installed and solidly grounded to the building power distribution ground. Make sure the incoming supply neutral is solidly connected to the same building power distribution ground. Some codes require redundant ground connections and periodic examination of connection integrity. Refer to the instructions supplied with the filter. IMPORTANT Do not use flexible cables or any plug or socket that can be accidentally disconnected. Grounding Motors The motor frame or stator core must be connected directly to the drive PE connection with a separate ground conductor. We recommended that each motor frame be grounded to building steel at the motor. Refer to Cable Trays on page 68 for more information. Grounding and TN-S Five-wire Systems IMPORTANT Do not connect ground to neutral within a system cabinet if you use a TN-S Five-wire distribution system. The neutral wire is a current conducting wire. There is a single connection between ground and neutral, typically in the distribution system. 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 00V) powers three-phase loads. Leg-to-neutral voltage (commonly at 30V) powers single-phase loads. 50 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

51 Grounding Chapter 3 Figure 15 - Cabinet Grounding with a TN-S Five-wire System Input Transformer L1 System Cabinet L L3 PEN or N PE R S T AC Drive R S T PE PE PE Single- Phase Device Cabinet Ground Bus Noise Related Grounds 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. Input Transformer AC Drive Path for Common Mode Current Motor Frame X 0 A B R S U V Motor Feedback Device PE C T W PE C lg-m Path for Common Mode Current Path for Common Mode Current C lg-c Path for Common Mode Current V ng System Ground Path for Common Mode Current Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01 51

52 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. Figure 16 - Ungrounded Scheme Earth Ground Potential A scheme with a high resistance ground (Figure 17) provides a direct path for common mode noise current, like a fully grounded scheme. Designers that are concerned with minimizing ground fault currents commonly choose high resistance ground schemes. Figure 17 - Scheme with High Resistance Ground Earth Ground Potential A fully grounded scheme (Figure 18) provides a direct path for common mode noise currents. The use of grounded neutral systems is recommended for these reasons: Controlled path for common mode noise current. Consistent line-to-ground voltage reference that minimizes insulation stress. Accommodation for system surge protection schemes. 5 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

53 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. Acceptable Grounding Practices PE The scheme shown below is an acceptable ground layout for a single drive installation. However, conduit does 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 offers a lower impedance path and causes noise to inhabit the ground grid. Connection to Drive Structure or Optional Motor Frame Cabinet Via Conduit Input Transformer AC Drive Conduit Connector X0 A B C R S T U V W PE PE Strap Motor Connection to Ground Grid, Girder, or Ground Rod Connection to Cabinet Ground Bus or Directly to Drive PE Terminal Panel Ground Bus Optional Enclosure Building Ground Potential Incidental Contact of Conduit Strap Motor Frame Ground Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01 53

54 Chapter 3 Grounding Effective Grounding Practices PE Input Transformer X0 Connection to Ground Grid, Girder, or Ground Rod A B C 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. R S T AC Drive U V W PE PE Panel Ground Bus Shielded or Armored Cable with PVC Jacket PVC Connection to Drive Structure or Optional Cabinet Via Grounding Connector or Terminating Shield at PE Terminal Motor Frame Motor Connection to Cabinet Ground Bus or Directly to Drive PE Terminal Optional Enclosure Motor Frame Ground Building Ground Potential Optimal Recommended Grounding Practices PE Input Transformer X0 Connection to Ground Grid, Girder or Ground Rod A B C Connection to Drive Structure or Optional Cabinet Via Grounding Connector or Terminating Shield at PE Terminal The fully grounded scheme provides the best containment of common mode noise. It uses PVC jacketed, shielded cable on both the input and the output to the drive. This method also provides a contained noise path to the transformer to keep the ground grid as clean as possible. Shielded or Armored Cable with PVC Jacket PVC R S T AC Drive U V W PE PE Panel Ground Bus Optional Enclosure Connection to Cabinet Ground Bus or Directly to Drive PE Terminal Building Ground Potential Shielded or Armored Cable with PVC Jacket PVC Connection to Drive Structure or Optional Cabinet Via Grounding Connector or Terminating Shield at PE Terminal Motor Frame Ground Motor Frame Motor 5 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

55 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. The shield for a cable from a cabinet to an external device must be connected at the cabinet end, unless specified by the manufacturer of the external device. IMPORTANT Never connect a shield to the common side of a logic circuit (doing so introduces noise into the logic circuit). Connect the shield directly to a chassis ground. Shield Splicing Figure 19 - Spliced Cable That Uses a Shieldhead Connector If the shielded cable needs to be stripped, strip it back as little as possible so the continuity of the shield is not interrupted. Avoid splicing motor power cables whenever possible. Ideally, run the motor cables continuously between the drive and motor terminals. The most common reason for interrupted PE cable/shield is to install a disconnect switch at the motor. In these cases, the preferred method of splicing is to use fully shielded bulkhead connectors. Single Point Connect a single safety ground point or ground bus bar directly to the building steel for cabinet installations. Ground all circuits, including the AC input ground conductor, independently and directly to this point/bar. Isolated Inputs If the analog inputs of the drive are from isolated devices and the output signal is not referenced to the ground, the inputs of the drive do not need to be isolated. An isolated input is recommended to reduce the possibility of induced noise if the signal from the transducer is referenced to ground and the ground potentials are varied (see Noise Related Grounds on page 51). An external isolator can be installed if the drive does not provide input isolation. Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01 55

56 Chapter 3 Grounding Notes: 56 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

57 Chapter 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. The panel is made of zinc-plated steel that helps to create a proper bond between chassis and panel. Figure 0 - Drive Chassis Ground Plane Extended to the Panel Drive Ground Plane (chassis) Bonded to Panel IMPORTANT Where TE and PE terminals are provided, ground each separately to the nearest point on the panel with flat braid. Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01 57

58 Chapter 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. The disadvantage with painted panels, apart from the cost in labor to remove the paint, is the difficulty in making quality control checks to verify if the paint has been properly removed, and any future corrosion of the unprotected mild steel can compromise noise performance. Plain stainless steel panels are also acceptable but are inferior to zinc-plated mild steel due to their higher ohms-per-square resistance. Though not always applicable, a plated cabinet frame is also highly desirable because it makes a high frequency bond between panel and cabinet sections more reliable. Doors For doors 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 to help guard against radiated noise to meet EMC standards. If the enclosure door has a viewing window, a laminated screen or a conductive optical substrate can block EMC. Do not rely on the hinge for electrical contact between the door and the enclosure. Install a grounding wire. For doors m (78 in.) in height, use two or three braided grounding straps between the door and the cabinet. EMC gaskets are not normally required for industrial systems. Layout Plan the cabinet layout so that drives are separated from sensitive equipment. Choose conduit entry points that allow any common mode noise to remain away from programmable logic controllers (PLCs) and other equipment that can be susceptible to noise. Refer to Moisture on page 7 for additional information. 58 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

59 Best Practices Chapter Hardware You can mount the drive and/or mounting panel with either bolts or welded studs. Figure 1 - Stud Mounting of Ground Bus or Chassis to Back Panel Mounting Bracket or Ground Bus Back Panel Welded Stud Star Washer Flat Washer Paint-free Area 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. Figure - Bolt Mounting of Ground Bus or Chassis to Back Panel Back Panel Mounting Bracket or Ground Bus Star Washer Bolt Nut Star Washer Star Washer Flat Washer Paint-free Area Nut Flat Washer If the mounting bracket is coated with a non-conductive material (anodized, painted, or other), scrape the material off around the mounting hole. If the drive chassis does not lay flat before the nuts/bolts are tightened, use additional washers as shims so that the chassis does not bend when you tighten the nuts. Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01 59

60 Chapter 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. Grind down the paint on the top and bottom surfaces. Use a high quality joint compound when reassembling to help prevent corrosion. Cable Connectors/Glands Choose cable connectors or glands that offer the best cable protection, shield termination, and ground contact. Refer to Shield Termination on page 69 for more information. Shield Terminating Connectors The cable connector must provide good 360 o 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. SKINTOP MS-SC/MS-SCL cable grounding connectors and NPT/PG adapters from LAPPUSA are good examples of this type of shield terminating glands. Figure 3 - Terminating the Shield with a Connector Metal connector body makes direct contact with the braid wires. Braid wires pulled back in a 360 pattern around the ground cone of the connector. U (T1) Ground Bushing V (T) W (T3) PE One or More Ground Leads Metal locknut bonds the connector to the panel. Drain wires pulled back in a 360 pattern around the ground cone of the connector. IMPORTANT This is mandatory for CE compliant installations, to meet requirements for containing radiated electromagnetic emissions. 60 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

61 Best Practices Chapter 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. Figure - Terminating the Shield with a Pigtail Lead Exposed Shield U (T1) V (T) W (T3) One or More Ground Leads PE PE Flying Lead Soldered to Braid IMPORTANT This is an acceptable industry practice for most installations to minimize stray common mode currents. Pigtail termination is the least effective method of noise containment, and is not recommended for these conditions: If the cable length is greater than 1 m (3. ft) or extends beyond the panel If used in very noisy areas If the cables are for noise-sensitive signals (for example, registration or encoder cables) If strain relief is required If a pigtail is used, pull and twist the exposed shield after separation from the conductors. Solder a flying lead to the braid to extend its length. Ground Connections Make sure that ground conductors are properly connected to assure safe and adequate connections. For individual ground connections, use star washers and ring lugs to make connections to mounting plates or other flat surfaces that do not provide proper compression lugs. If a ground bus system is used in a cabinet, follow the bus bar mounting diagrams. Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01 61

62 Chapter Best Practices Figure 5 - Connections to Ground Bus Ground Bus Tapped Hole Component Grounding Conductors Ground Lug Bolt Star Washer Component Grounding Conductor Figure 6 - Ground Connections to Enclosure Wall Area Without Paint Bolt Ground Lug Star Washer Welded Stud Star Washer Star Washer Nut Component Ground Conductor Nut Component Ground Conductor Ground Lug Do not lay one ground lug directly on top of the other. This type of connection can become loose due to compression of the metal lugs. Sandwich the first lug between a star washer and a nut with another star washer following. After tightening the nut, sandwich the second lug between the first nut and a second nut with a captive star washer. 6 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

63 Best Practices Chapter Figure 7 - Multiple Connections to Ground Stud or Bolts Wire Routing General Category Wiring Level 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. Signal Definition Signal Examples Minimum Spacing (in inches) between Levels in Steel Conduits (cable trays) 1 /3/ 5/6 7/8 9/10/11 Power 1 AC power (600V or greater).3kv 3-phase AC lines 0 3 (9) 3 (9) 3 (18) Refer to spacing note 6 AC power (less than 600V) 60V 3-phase AC lines 3 (9) 0 3 (6) 3 (1) Refer to spacing 3 AC power AC motor note 6 Dynamic brake cables Refer to spacing note 7 Control 5 115V AC/DC logic Relay logic/plc I/O motor thermostat Signal (process) Signal (comm) 115V AC power 6 V AC/DC logic PLC I/O Power supplies, instruments 7 Analog signals, DC supplies Reference/Feedback signal, 5 V DC Digital (low speed) TTK 8 Digital (high speed) I/O, encoder, counter pulse tach 9 Serial communication RS-3, to terminals/printers 11 Serial communication (greater than 0k total) ControlNet, DeviceNet, remote I/O, Data Highway 3 (9) 3 (6) 0 3 (9) Refer to spacing note 6 Spacing Notes on page 6 Refer to spacing notes 1,, and 5 Refer to spacing notes 1,, and 5 Refer to spacing notes 1,, and 5 3 (18) 3 (1) 3 (9) 0 1 (3) Refer to spacing notes, 3,, and 5 Refer to spacing note 6 1 (3) 0 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01 63

64 Chapter Best Practices EXAMPLE Spacing relationship between 80V AC incoming power leads and V DC logic leads: 80V AC leads are Level ; V 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 15 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.. These cable levels can be grouped together: a. Level 1: Equal to or above 601V. b. Levels, 3, and can have respective circuits pulled in the same conduit or layered in the same tray. c. Levels 5 and 6 can have respective circuits pulled in the same conduit or layered in the same tray. IMPORTANT The cable bundle must not exceed conditions of NEC 310. d. Levels 7 and 8 can have respective circuits pulled in the same conduit or layered in the same tray. IMPORTANT Encoder cables run in a bundle can experience some amount of EMI coupling. The circuit application dictates separate spacing. e. Levels 9, 10, and 11 can have respective circuits pulled in the same conduit or layered in the same tray. IMPORTANT Communication cables run in a bundle can experience some amount of EMI coupling and corresponding communication faults. The application dictates separate spacing. 3. Level 7 through level 11 wires must be shielded per recommendations.. 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. This table lists the spacing of communication cables, levels through 6. Conduit Spacing 115V = 5. mm (1 in.) 30V = 38.1 mm (1.5 in.) Through Air Spacing 115V = 50.8 mm ( in.) 30V = mm ( in.) 60/575V = 76. mm (3 in.) 60/575V = 03. mm (8 in.) 575V = proportional to mm (6 in.) per 1000V 575V proportional to mm (1 in.) per 1000V 6 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

65 Best Practices Chapter 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 8. Separate any PLC or other susceptible equipment cabling to the opposite side of the enclosure to minimize the effects of drive-induced noise currents. Figure 8 - Separating Susceptible Circuits Programmable Logic Controller and Other Control Circuits PWM Drives Sensitive Equipment Drive Power Wiring Drive Control and Communications Wiring Ground Bus Power Distribution Terminals Common mode noise current returning on the output conduit, shielding, or armor can flow into the cabinet bond and most likely exit through the adjacent input conduit/armor bond near the cabinet top, well away from sensitive equipment (such as the PLC). Common mode current on the return ground wire from the motor flows to the copper PE bus and back up the input PE ground wire, also away from sensitive equipment (Refer to Proper Cabinet Ground - Drives and Susceptible Equipment on page 66). If a cabinet PE ground wire is used, connect the wire from the same side of the cabinet as the conduit/armor connections. This keeps the common mode noise shunted away from the PLC backplane. Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01 65

66 Chapter Best Practices Common Mode Current on Cabinet Backplane/Subpanel Figure 9 - Proper Cabinet Ground - Drives and Susceptible Equipment Output Conduit or Armor (bonded to cabinet) U V W PE U V W PE 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. If possible, avoid running incoming power leads and motor leads in the same conduit for long runs. IMPORTANT Do not run power or motor cables with control or communications cables in the same conduit. 66 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

67 Best Practices Chapter 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). Figure 30 - Avoid Loops in Wiring Not Recommended Good Solution Better Solution Conduit Magnetic steel conduit is preferred. This type of conduit provides the best magnetic shielding. However, not all applications allow the use of magnetic steel conduit. Stainless steel or PVC can be required. Conduit other than magnetic steel does not provide the same level of shielding for magnetic fields induced by the motor and input power currents. Install the conduit so it provides a continuous electrical path through the conduit itself. This path can become important in the containment of high frequency noise. Pull the wire gently and carefully through the conduit. Do not nick the wire insulation when pulling the wires through the conduit. Insulation damage can occur when nylon coated wiring, such as thermoplastic high heat-resistant nylon-coated (THHN) or thermoplastic heat and water-resistant nylon-coated (THWN), is pulled through conduit, particularly 90 bends. Nicking can significantly reduce or remove the insulation. Do not use water-based lubricants with nylon coated wire such as THHN. Do not route more than three sets of motor cables in one conduit. Maintain the proper fill rates per the applicable electrical codes. Do not rely on the conduit as the ground return for a short circuit. Route a separate ground wire inside the conduit with the motor or input power wires. Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01 67

68 Chapter 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. Figure 31 - Recommended Cable Tray Practices Bundled and Anchored to Tray Recommended Arrangements for Multiple Cable Sets T PE T PE T PE R S R S R S R S T PE PE T S R IMPORTANT Carefully arrange the geometry of multiple cable sets. Keep conductors within each group bundled. Arrange the order of the conductors to minimize the current that is induced between sets and to balance the currents. This is critical on drives with power ratings of 00 Hp (150 kw) and higher. Maintain separation between power and control cables. When laying out a cable tray for large drives, make sure that the cable tray or conduit containing the signal wiring is separated from the conduit or trays containing power or motor wiring by 1 m (3. ft) or more. Electromagnetic fields from power or motor currents can induce currents in the signal cables. Dividers also provide excellent separation. 68 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

69 Best Practices Chapter Shield Termination 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. The preferred method for grounding cable shields is clamping the circular section of 360 bonding (see Figure 3). This method has the advantage of covering a wide variety of cable diameters and drilling/ mounting is not required. The disadvantages are cost and availability in all areas. Figure 3 - Commercial Cable Clamp (heavy duty) Plain copper saddle clamps (see Figure 33) are sold in many areas for plumbing purposes, but are very effective and available in a range of sizes. They are low cost and offer good strain relief as well. You must drill mounting holes to use them. Figure 33 - Plain Copper Saddle Clamp Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01 69

70 Chapter 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. Pigtail termination is not recommended for these conditions: If the cable length is greater than 1 m (3. ft) or extends beyond the panel If used in very noisy areas If the cables are for noise sensitive signals (for example, registration or encoder cables) If strain relief is required If a pigtail is used, pull and twist the exposed shield after separation from the conductors. To extend the length, solder a flying lead to the braid. Shield Termination via Cable Clamp Standard Cable Grounding cable glands are a simple and effective method for terminating shields while offering excellent strain relief. They are applicable only when entry is through a cabinet surface or bulkhead. The cable connector must provide good 360 contact and low transfer impedance from the shield or armor of the cable to the conduit entry plate at both the motor and the drive (or drive cabinet) for electrical bonding. SKINTOP MS-SC/MS-SCL cable grounding connectors and NPT/PG adapters from LAPPUSA are good examples of standard cable clamp shield terminating gland. 70 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

71 Best Practices Chapter 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. Use a connector with three ground bushings when you use a cable with three ground conductors. Follow applicable electric codes when bending radii minimums. Power TB Power terminals are normally fixed (non pull apart) and can be cage clamps, barrier strips, or studs for ring-type crimp lugs depending on the drive style and rating. Cage clamp styles can require a non-standard screwdriver. Crimp lugs require a crimping tool. On smaller sizes, a stripping gauge is sometimes provided on the drive to assist in the amount of insulation to remove. Normally the three-phase input is not phase sensitive. That is, the sequence of the A, B, and C phases has no effect on the operation of the drive or the direction of motor rotation. Control TB Control terminal blocks are either pull apart or fixed (non pull apart). Terminals are either spring clamp type or barrier strip. A stripping gauge is sometimes provided on the drive to assist in the amount of insulation to remove. Some control connections, such as analog input and output signals, are sensitive to polarity. Consult the applicable user manual for correct connection. Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01 71

72 Chapter 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. Some shields can be terminated at the terminal block, and other shields are terminated at the entry point. Moisture 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 ). However, PVC insulation material is more susceptible to absorbing moisture than XLPE insulation material (XHHW-) identified for use in wet locations. Because the PVC insulating material absorbs moisture, the corona inception voltage (CIV) insulation capability of the damp or wet THHN was found to be less than ½ of the same wire when dry. For this reason, certain industries where water is prevalent in the environment do not use THHN wire with IGBT drives. Based on Rockwell Automation research, tests have determined that the cable type described below is superior to loose wires in dry, damp, and wet applications and can significantly reduce capacitive coupling and common mode noise: PVC jacketed, shielded type TC with XLPE conductor insulation designed to meet NEC code designation cross-linked polyethylene high heat-resistant water-resistant (XHHW-) (use in wet locations per the U.S. NEC, Table ). Other cable types for wet locations include continuous welded armor cables or CLX-type cables. 7 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

73 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. If the voltage reflection is combined with another subsequent pulse, peak voltages can be at a destructive level. A single IGBT drive output can have reflected wave transient voltage stresses of up to twice ( pu, or per unit) the DC bus voltage between its own output wires. Multiple drive output wires in a single conduit or wire tray further increase output wire voltage stress between multi-drive output wires that are touching. One drive can have a (+) pu stress, while another drive can simultaneously have a (-) pu stress. Effects On Wire Types Wires with dielectric constants greater than cause the voltage stress to shift to the air gap between the wires that are barely touching. This electric field can be high enough to ionize the air surrounding the wire insulation and cause a partial discharge mechanism (corona) to occur. The electric field distribution between wires increases the possibility for corona and greater ozone production. This ozone attacks the PVC insulation and produces carbon tracking, leading to the possibility of insulation breakdown. Based on field and internal testing, Rockwell Automation has determined conductors manufactured with poly-vinyl chloride (PVC) wire insulation are subject to a variety of manufacturing inconsistencies that can lead to premature insulation degradation when used with IGBT drives. Flame-retardant heatresistant thermoplastic insulation is the type of insulation listed in the NEC code for the THHN wire designation. This type of insulation is commonly referred to as PVC. In addition to manufacturing inconsistencies, the physical properties of the cable can change due to environment, installation, and operation that can also lead to premature insulation degradation. Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01 73

74 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. Ozone attacks the PVC insulation leading to a breakdown in cable insulation. Asymmetrical construction of the insulation has also been observed for some manufacturers of PVC wire. A wire with a 15 mil specification was observed to have an insulation thickness of 10 mil at some points. The smaller the insulation thickness, the less voltage the wire can withstand. THHN jacket material has a relatively brittle nylon that lends itself to damage (for example, nicks and cuts) when pulled through conduit on long wire runs. This issue is of even greater concern when the wire is being pulled through multiple 90 bends in the conduit. These nicks can be a starting point for CIV leading to insulation degradation. During operation, the conductor heats up and a coldflow condition can occur with PVC insulation at points where the unsupported weight of the wire can stretch the insulation. This has been observed at 90 bends where wire is dropped down to equipment from an above wireway. This coldflow condition produces thin spots in the insulation that lowers the voltage withstand capability of the cable. 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 ). However, PVC insulation material is more susceptible to absorbing moisture than XLPE insulation material (XHHN-) identified for use in wet locations. Because the PVC insulating material absorbs moisture, the Corona Inception Voltage insulation capability of the damp or wet THHN was found to be less than ½ of the same wire when dry. For this reason, certain industries where water is prevalent in the environment do not use THHN wire with IGBT drives. Rockwell Automation strongly suggests the use of XLPE insulation for wet areas. Length Restrictions For Motor Protection To protect the motor from reflected waves, limit the length of the motor cables from the drive to the motor. The user manual for each drive lists the lead length limitations based on drive size and the quality of the insulation system in the chosen motor. If the distance between drive and motor must exceed these limits, contact the local office or factory for analysis and advice. Refer to Appendix A for complete tables. 7 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

75 Chapter 6 Electromagnetic Interference This chapter discusses types of electromagnetic interference and its impact on drive systems. What Causes Common Mode Noise 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. Input Transformer AC Drive Path for Common Mode Current Motor Frame X 0 A B R S U V Motor Feedback Device PE C T W PE C lg-m Path for Common Mode Current Path for Common Mode Current V ng C lg-c Path for Common Mode Current System Ground Path for Common Mode Current Electrical noise from drive operation can interfere with adjacent sensitive electronic equipment, especially in areas where many drives are concentrated. Generating common mode currents by varying frequency inverters is similar to the common mode currents that occur with DC drives, although AC drives produce a much higher frequency then DC drives (50 khz 6 MHz). Inverters have a greater potential for exciting circuit resonance because of very fast turn on switches causing common mode currents to look for the lowest impedance path back to the inverter. The dv/dt and di/dt from the circulating ground currents can couple into the signal and logic circuits, causing improper operation and possible circuit damage. When conventional grounding techniques do not work, you must use high frequency bonding techniques. If installers do not use these techniques, motor bearing currents increase and system circuit boards have the potential to fail prematurely. Currents in the ground system can cause problems with computer systems and distributed control systems. Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01 75

76 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. The AC resistance characteristics of earth are generally variable and unpredictable, making it difficult to know how noise current is divided between wire, conduit, or the ground grid. Shielded or Armored Power Cable The predominant return path for common mode noise is the shield or armor itself when you use shielded or armored power cables. Unlike conduit, the shield or armor is isolated from accidental contact with grounds by a PVC outer coating. The coating makes the majority of noise current flow in the controlled path and very little high frequency noise flows into the ground grid. Noise current returning on the shield or safety ground wire is routed to the drive PE terminal, down to the cabinet PE ground bus, and then directly to the grounded neutral of the drive source transformer. When bonding the armor or shield to the drive PE, use a low impedance cable or strap, as opposed to the smaller gauge ground wire supplied as part of the motor cable or supplied separately. Otherwise, the higher frequencies associated with the common mode noise can find this cable impedance higher and look for a lower impedance path. The radiated emissions of the cable are minimal because the armor completely covers the noisy power wires. Also, the armor prevents EMI coupling to other signal cables that are routed in the same cable tray. Another effective method of reducing common mode noise is to attenuate the noise before it can reach the ground grid. Install a common mode ferrite core on the output cables to reduce the amplitude of the noise to a level that makes it relatively harmless to sensitive equipment or circuits. Common mode cores are most effective when multiple drives are in a relatively small area. For more information, refer to 131-M Common Mode Chokes Instructions, publication Follow these guideline as a general rule for installing common mode chokes: If the distance between the drive and motor, or the drive and input transformer, is greater than.8 m (75 ft), and If sensitive circuits with leads greater then.8 m (75 ft), such as encoders, analog or capacitive sensors, are routed in or out of the cabinet near the drive or transformer, then Install common mode chokes. 76 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

77 Electromagnetic Interference Chapter 6 How Electromechanical Switches Cause Transient Interference 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. Both the load and the wiring have inductance that prevents the current from stopping instantly when the switch contacts open. There is also stray capacitance in the wiring. V C Power Wiring Capacitance Load Inductance Load Wiring Inductance 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 very high levels. When the voltage exceeds the breakdown voltage for the space between the contacts, an arc occurs and the voltage returns to zero. Charging and arcing continues until the distance between the contacts is sufficient to provide insulation. The arcing radiates noise at an energy levels and frequencies that disturb logic and communication circuits. If the power source is periodic (like AC power), you can reduce the interference by opening the contact when the current waveform crosses zero. Opening the circuit farther from zero elevates the energy level and creates more interference. How to Prevent or Mitigate Transient Interference from Electromechanical Switches The most effective way to avoid this type of transient interference, is to use a device like an Allen-Bradley Bulletin 156 contactor to switch inductive AC loads. These devices feature zero cross switching. A1 A L1 T1 AC Bulletin 156 Contactor Load Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01 77

78 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. AC Load AC Load 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. Be sure to select components rated to withstand the voltage, power, and frequency of switching for your application. IMPORTANT These methods are not totally effective at stopping transient interference, because they do not entirely eliminate arcing at the contacts. + DC Load - AC Load AC Load 78 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

79 Electromagnetic Interference Chapter 6 This table contains examples that illustrate methods for mitigating transient interference. Examples of Transient Interference Mitigation Digital Contact Output V DC 1CR Example 1 A contact output controls a DC control relay. The relay coil requires a suppressor (blocking diode) because it is an inductive device controlled by a dry contact. Digital DC Output Solid-state Switch L1 1MS L L1 L L1 1MS 1MS 1MS Suppressor Suppressor Suppressor 1M Example 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. An inductive device controlled by a solid state switching device (like the starter coil in this example) typically does not require a suppressor. Digital AC Output Solid-state Switch L1 1CR 1CR Suppressor 1S L Example 3 An AC output controls an interposing relay, but the circuit can be opened by dry contacts. Relay contacts control a solenoid coil. The contacts require RC networks or varistors. The relay coil requires a suppressor because it is an inductive device controlled by dry contacts. The solenoid coil also requires a suppressor because it is an inductive device controlled by dry contacts. Suppressor Digital Contact Output L1 Pilot Light with Built-in Step-down Transformer L Example 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. Suppressor Digital Contact Output 115V AC 1CR Suppressor 1CR 80V AC Brake Solenoid 1CR Example 5 A contact output controls a relay that controls a brake solenoid. The contacts require RC networks or varistors. Both the relay and the brake solenoid require suppressors because they are both inductive devices controlled by dry contacts. Suppressor Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01 79

80 Chapter 6 Electromagnetic Interference Enclosure Lighting Fluorescent lamps are also sources of EMI. If you must use fluorescent lamps inside an enclosure, follow these precautions to help guard against EMI problems: 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 AC Power Shielding Grid Over Lamp Shielded Cable Metal-encased Switch Line Filter or Shielded Power Line Bearing Current The application of pulse-width modulated (PWM) inverters has led to significant advantages in terms of the performance, size, and efficiency of variable speed motor controls. However, the high switching rates used to obtain these advantages can also contribute to motor bearing damage due to bearing currents and electric discharge machining (EDM). Bearing damage on motors supplied by PWM inverters is more likely to occur in applications where the coupling between the motor and load is not electrically conductive (such as belted loads), when the motor is lightly loaded, or when the motor is in an environment with ionized air. Other factors, such as the type of grease and the type of bearings used, can also affect the longevity of motor bearings. Motor manufacturers that design and manufacture motors for use with variable frequency drives can offer solutions to help mitigate these potential problems. 80 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

81 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. Unshielded Cable Tray cable fixed geometry without foil or braided shield but including an exterior cover Individual wires not routed in metallic conduit Shielded Cable Individual conductors routed in metallic conduit Fixed geometry cables with foil or braided shield of at least 75% coverage Continuous weld or interlocked armored cables with no twist in the conductors (can have an optional foil shield) IMPORTANT Certain shielded cable constructions can cause excessive cable charging currents and can interfere 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, can 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 can be considerably less. Type A Motor No phase paper or misplaced phase paper Lower quality insulation systems Corona inception voltages between V Type B Motor Properly placed phase paper Medium quality insulation systems Corona inception voltages between V 188V Motor Meets NEMA MG section 31 standard Insulation can withstand voltage spikes of 3.1 times rated motor voltage due to inverter operation 139 R/L Motor AC variable speed motors are control-matched for use with Allen-Bradley drives Motor designed to meet or exceed the requirements of the Federal Energy Act of 199 Optimized for variable speed operation and include premium inverter grade insulation systems that meet or exceed NEMA MG1 (Part ) Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01 81

82 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 10-TFA1/10-TFB) and/or reflected wave reduction device with common mode choke (catalog number 10-RWC-17) or without choke (catalog number 10-RWR). Follow these guidelines for terminators and reflected wave reduction devices: For the terminator, the maximum cable length is m (600 ft) for 00/80/600V drives (not 690V). The PWM frequency must be khz. Catalog number 10-TFA1 can be used only on low Hp (5 Hp and below), while catalog number 10-TFB can be used from 800 Hp. 10 reflected wave reduction device (all motor insulation classes): Catalog number 10-RWR-09 khz: m (600 ft) at 00/80V and m (00 ft) at 600V. khz: m (300 ft) at 00/80V and m (00 ft) at 600V. Catalog number 10-RWC-17 khz: m (100 ft) at 00/80/600V. khz: 3.8 m (800 ft) at 00/80V and m (00 ft) at 600V. For both devices, power dissipation in the damping resistor limits maximum cable length. Catalog number 131-RWR is a complete reflected wave reduction solution available for many of the PowerFlex drives. If available, a 131-RWR catalog number is indicated in the Reactor/RWR column. When not available, use the reactor and resistor information provided in the tables in this section to build a solution. For this Cat. No. 131-RWR, 131-3Rxx Refer to this Publication 131 Power Conditioning Products Technical Data, publication 131-TD RWR 10 Reflected Wave Reduction Device Instructions, publication RWC 10-TFxx 10 Reflected Wave Reduction Device with Common Mode Choke Instructions, publication 10-IN Terminator Instructions, publication 10-IN00 8 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

83 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. Drive Voltage Table Page Drive Voltage Table Page PowerFlex PowerFlex 700S PowerFlex M PowerFlex PowerFlex 753 and 755 (wall mount) PowerFlex PowerFlex 755 (floor mount) PowerFlex PowerFlex 70 (standard/enhanced) PowerFlex 700 (standard/vector) PLUS II IMPACT (no external devices) PowerFlex 700 (standard/vector) (external devices at motor) PowerFlex 700H PowerFlex 700L with PowerFlex 700VC Control PowerFlex 700L with PowerFlex 700S Control (cable charging current) 0 and Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01 83

84 Appendix A Motor Cable Length Restrictions Tables PowerFlex Drives This section lists motor cable length restrictions, reactors, and available options for PowerFlex Drives. Table 1 - PowerFlex Drives, 00V Shielded/Unshielded Cable Meters (Feet) Rating No Solution Reactor Only Reactor and Damping Resistor or 131-RWR Reactor/RWR (see page 19) Resistor kw khz 1000V 100V 188V 1600V 1000V 100V 188V 1600V 1000V 100V 188V 1600V Cat. No. Ohms Watts 0. / 0.75 / 1.5 /. / 3.7 / 53.3 (175) (75) (75) 137. (50) 137. (50) 53.3 (175) (75) (75) (175) (75) (75) RWR8-DP 131-RWR1-DP Available Options TFA1 TFB RWR RWC Table 15 - PowerFlex Drives, 80V Shielded/Unshielded Cable Meters (Feet) Rating No Solution Reactor Only Reactor and Damping Resistor or 131-RWR Reactor/RWR (see page 19) Resistor Hp khz 1000V 100V 188V 1600V 1000V 100V 188V 1600V 1000V 100V 188V 1600V Cat. No. Ohms Watts 0.5 / 1 / / 3 / 5 / 53.3 (175) (75) (75) 19.5 (5) 137. (50) 53.3 (175) (75) (75) 19.5 (5) RWR8-DP 131-RWR1-DP Available Options TFA1 TFB RWR RWC 8 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

85 Motor Cable Length Restrictions Tables Appendix A PowerFlex M Drives This section lists motor cable length restrictions, reactors, and available options for PowerFlex M Drives. Table 16 - PowerFlex M Drives, 00V Shielded/Unshielded Cable Meters (Feet) Rating No Solution Reactor Only Reactor and Damping Resistor or 131-RWR Reactor/RWR (see page 19) Resistor kw khz 1000V 100V 188V 1600V 1000V 100V 188V 1600V 1000V 100V 188V 1600V Cat. No. Ohms Watts 0. / 0.75 / 1.5 /. / 3.7 / 5.5 / 7.5 / 11 / 53.3 (175) (75) (75) 137. (50) 137. (50) 137. (50) 137. (50) 137. (50) 53.3 (175) (75) (75) (175) (75) (75) RWR8-DP 131-RWR1-DP 131-RWR1-DP 131-RWR18-DP 131-RWR5-DP Available Options TFA1 TFB RWR RWC Table 17 - PowerFlex M Drives, 80V Shielded/Unshielded Cable Meters (Feet) Rating No Solution Reactor Only Reactor and Damping Resistor or 131-RWR Reactor/RWR (see page 19) Resistor Hp khz 1000V 100V 188V 1600V 1000V 100V 188V 1600V 1000V 100V 188V 1600V Cat. No. Ohms Watts 0.5 / 1 / / 3 / 5 / 7.5 / 10 / 15 / 53.3 (175) (75) (75) 19.5 (5) 137. (50) 137. (50) 137. (50) 137. (50) 53.3 (175) (75) (75) 19.5 (5) RWR8-DP 131-RWR1-DP 131-RWR1-DP 131-RWR18-DP 131-RWR5-DP Available Options TFA1 TFB RWR RWC Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01 85

86 Appendix A Motor Cable Length Restrictions Tables PowerFlex 0 Drives This section lists motor cable length restrictions, reactors, and available options for PowerFlex 0 Drives. Table 18 - PowerFlex 0 Drives, 00V Shielded/Unshielded Cable Meters (Feet) Rating No Solution Reactor Only Reactor and Damping Resistor or 131-RWR Reactor/RWR (see page 19) Resistor kw khz 1000V 100V 188V 1600V 1000V 100V 188V 1600V 1000V 100V 188V 1600V Cat. No. Ohms Watts 0. / 0.75 / 1.5 /. / / 5.5 / 7.5 / 11 / 53.3 (175) (75) (75) 137. (50) 137. (50) 137. (50) 137. (50) 137. (50) 53.3 (175) (75) (75) (175) (75) (75) RWR8-DP 131-RWR1-DP 131-RWR1-DP 131-RWR18-DP 131-RWR5-DP Available Options TFA1 TFB RWR RWC Table 19 - PowerFlex 0 Drives, 80V Shielded/Unshielded Cable Meters (Feet) Rating No Solution Reactor Only Reactor and Damping Resistor or 131-RWR Reactor/RWR (see page 19) Resistor Hp khz 1000V 100V 188V 1600V 1000V 100V 188V 1600V 1000V 100V 188V 1600V Cat. No. Ohms Watts 0.5 / 1 / / 3 / 5 / 7.5 / 10 / 15 / 53.3 (175) (75) (75) 19.5 (5) 137. (50) 137. (50) 137. (50) 137. (50) 53.3 (175) (75) (75) 19.5 (5) RWR8-DP 131-RWR1-DP 131-RWR1-DP 131-RWR18-DP 131-RWR5-DP Available Options TFA1 TFB RWR RWC 86 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

87 Motor Cable Length Restrictions Tables Appendix A Table 0 - PowerFlex 0 Drives, 600V Shielded/Unshielded Cable Meters (Feet) Rating No Solution Reactor Only Reactor and Damping Resistor or 131-RWR Reactor/RWR (see page 19) Resistor Hp khz 188V 1850V 188V 1600V 188V 1600V Cat. No. Ohms Watts 1 / / 3 / 5 / 7.5 / 10 / 15 /.7 (10).7 (10).7 (10).7 (10).7 (10).7 (10).7 (10) RWR8-DP 131-RWR1-DP 131-RWR18-DP 131-RWR5-DP Available Options TFA1 TFB RWR RWC Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01 87

88 Appendix A Motor Cable Length Restrictions Tables PowerFlex 00 Drives This section lists motor cable length restrictions, reactors, and available options for PowerFlex 00 Drives. Table 1 - PowerFlex 00 Drives, 00V Shielded/Unshielded Cable Meters (Feet) Rating No Solution Reactor Only Reactor and Damping Resistor or 131-RWR Reactor/RWR (see page 19) Resistor kw khz 1000V 100V 188V 1600V 1000V 100V 188V 1600V 1000V 100V 188V 1600V Cat. No. Ohms Watts.,, 5.5, 7.5, 11, 15, 18.5,, 30, 37, 5, 55, 75, 90, 110, 13, 160, 00, 50, (550) 16 (550) (50) 76. (50) 76. (50) 76. (50) 76. (50) 76. (50) RWR8-DP 131-RWR1-DP 131-RWR1-DP 131-RWR18-DP 131-RWR5-DP 131-RWR35-DP 131-RWR5-DP 131-RWR5-DP 131-RWR55-DP 131-RWR80-DP 131-RWR100-DP 131-RWR100-DP 131-RWR160-DP 131-RWR00-DP 131-RWR00-DP 131-RWR50-DP 131-RWR30-DP 131-3RB00-B R500-B 0 95 Available Options TFA1 TFB RWR RWC 88 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

89 Motor Cable Length Restrictions Tables Appendix A Table - PowerFlex 00 Drives, 80V Shielded/Unshielded Cable Meters (Feet) Rating No Solution Reactor Only Reactor and Damping Resistor or 131-RWR Reactor/RWR (see page 19) Resistor Hp khz 1000V 100V 188V 1600V 1000V 100V 188V 1600V 1000V 100V 188V 1600V Cat. No. Ohms Watts 3, 5, 7.5, 10, 15, 0, 5, 30, 0, 50, 60, 75, 100, 15, 150, 00, 50, 300, 350, 137. (50) 137. (50) 137. (50) 137. (50) 137. (50) 137. (50) 137. (50) 137. (50) 137. (50) 137. (50) 137. (50) 137. (50) 137. (50) 137. (50) 16 (550) 16 (550) 16 (550) 137. (50) 137. (50) 76. (50) 76. (50) 76. (50) 76. (50) 76. (50) (50) 76. (50) RWR8-DP 131-RWR1-DP 131-RWR1-DP 131-RWR18-DP 131-RWR5-DP 131-RWR35-DP 131-RWR5-DP 131-RWR5-DP 131-RWR55-DP 131-RWR80-DP 131-RWR100-DP 131-RWR100-DP 131-RWR160-DP 131-RWR00-DP 131-RWR00-DP 131-RWR50-DP 131-RWR30-DP 131-3RB00-B R500-B 0 95 Available Options TFA1 TFB RWR RWC Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01 89

90 Appendix A Motor Cable Length Restrictions Tables PowerFlex 55 Drives This section lists motor cable length restrictions, reactors, and available options for PowerFlex 55 Drives. Table 3 - PowerFlex 55 Drives, 00V Shielded/Unshielded Cable Meters (Feet) Drive No Solution Reactor Only Reactor and Damping Resistor or 131-RWR Reactor/RWR (see page 19) Resistor Frame kw khz 1000V 100V 188V 1600V 1000V 100V 188V 1600V 1000V 100V 188V 1600V Cat. No. Ohms Watts A 0. / 0.75 / 1.5 /. / B / C D E (115) 35.1 (115) (75) (75) (75) 35.1 (115) 35.1 (115) (75) (75) (75) (115) 35.1 (115) (75) (75) (75) 131-RWR8-DP 131-RWR1-DP 131-RWR18-DP 131-RWR18-DP 131-RWR5-DP 131-RWR35-DP 131-RWR5-DP 131-RWR5-DP Available Options TFA1 TFB RWR RWC 90 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

91 Motor Cable Length Restrictions Tables Appendix A Table - PowerFlex 55 Drives, 80V Shielded/Unshielded Cable Meters (Feet) Drive No Solution Reactor Only Reactor and Damping Resistor or 131-RWR Reactor/RWR (see page 19) Resistor Frame kw khz 1000V 100V 188V 1600V 1000V 100V 188V 1600V 1000V 100V 188V 1600V Cat. No. Ohms Watts A 0.5 / 1 / / 3 / B 5 / C D E (115) 35.1 (115) (75) (75) (75) 35.1 (115) 35.1 (115) (75) (75) (75) 137. (50) 137. (50) 137. (50) 137. (50) 137. (50) 137. (50) 137. (50) 137. (50) 137. (50) 137. (50) 137. (50) 137. (50) 131-RWR8-DP 131-RWR1-DP 131-RWR18-DP 131-RWR18-DP 131-RWR5-DP 131-RWR35-DP 131-RWR5-DP 131-RWR5-DP Available Options TFA1 TFB RWR RWC Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01 91

92 Appendix A Motor Cable Length Restrictions Tables Table 5 - PowerFlex 55 Drives, 600V Shielded/Unshielded Cable Meters (Feet) Drive No Solution Reactor Only Reactor and Damping Resistor or 131-RWR Reactor/RWR (see page 19) Resistor Frame HP khz 188V 1850V 188V 1850V 188V 1850V Cat. No. Ohms Watts A 0.5 / 1 / / 3 / B 5 / C D E (75).9 (75).9 (75).9 (75) 35.1 (115) 35.1 (115) (75) (75) (75) 76. (50) 76. (50) 76. (50) 76. (50) 76. (50) 76. (50) 76. (50) 76. (50) 76. (50) 76. (50) 76. (50) 76. (50) 76. (50) 76. (50) 76. (50) 76. (50) 76. (50) 131-RWR8-EP 131-RWR8-EP 131-RWR1-EP 131-RWR1-EP 131-RWR5-EP 131-RWR5-EP 131-RWR35-EP 131-RWR35-EP Available Options TFA1 TFB RWR RWC 9 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

93 Motor Cable Length Restrictions Tables Appendix A PowerFlex 70 and 700 Drives This section lists motor cable length restrictions, reactors, and available options for PowerFlex 70 and 700 Drives. Table 6 - PowerFlex 70 (standard/enhanced) and 700 (standard/vector) Drives, 00V Shielded/Unshielded Cable Meters (Feet) Drive Frame A B C D 0 1 Rating No Solution Reactor Only Reactor and Damping Resistor or 131-RWR Reactor/RWR (see page 19) Resistor kw khz 1000V 100V 188V 1600V 1000V 100V 188V 1600V 1000V 100V 188V 1600V Cat. No. Ohms Watts D 18.5 D E continued 53.3 (175) 53.3 (175) (75) 76. (50) (75) 76. (50) 137. (50) 137. (50) 137. (50) 137. (50) 137. (50) 137. (50) 137. (50) 137. (50) 137. (50) 137. (50) 137. (50) 53.3 (175) 53.3 (175) (75) 76. (50) (75) 76. (50) (175) 53.3 (175) (75) 76. (50) (75) 76. (50) RWR8-DP 131-RWR8-DP 131-RWR1-DP 131-RWR1-DP 131-RWR18-DP 131-RWR18-DP 131-RWR5-DP 131-RWR5-DP 131-RWR35-DP 131-RWR35-DP 131-RWR35-DP 131-RWR35-DP 131-RWR5-DP 131-RWR5-DP 131-RWR55-DP 131-RWR55-DP 131-RWR80-DP 131-RWR80-DP 131-RWR80-DP 131-RWR80-DP Available Options TFA1 TFB RWR RWC Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01 93

94 Appendix A Motor Cable Length Restrictions Tables Table 6 - PowerFlex 70 (standard/enhanced) and 700 (standard/vector) Drives, 00V Shielded/Unshielded Cable Meters (Feet) (continued) Drive Frame Rating No Solution Reactor Only Reactor and Damping Resistor or 131-RWR (1) Requires two parallel cables. () Requires three parallel cables (50) 137. (50) 137. (50) 137. (50) 137. (50) (50) 137. (50) (850) 59.1 (850) (550) (550) 76. (50) (10) (10) (10) (10) (10) (10) 5.7 (10) 5.7 (10) 5.7 (10) (10) (10) (10) (10) (650) 16 (550) 16 (550) 16 (550) 16 (550) (750) (750) 8.6 (750) 8.6 (750) (650) 76. (50) (650) 76. (50) (50) (50) Reactor/RWR (see page 19) 131-RWR100-DP 131-RWR100-DP 131-RWR130-DP 131-RWR130-DP 131-RWR160-DP 131-RWR160-DP 131-RWR00-DP 131-RWR00-DP 131-RWR50-DP 131-RWR50-DP Resistor kw khz 1000V 100V 188V 1600V 1000V 100V 188V 1600V 1000V 100V 188V 1600V Cat. No. Ohms Watts 131-3RB30-B RB30-B RB30-B RB30-B RB00-B (1) RB00-B (1) R00-B (1) RB00-B (1) R500-B (1) R500-B (1) R600-B (1) R600-B (1) R600-B (1) R600-B (1) R750-B () R750-B () R850-B () R850-B () Available Options TFA1 TFB RWR RWC 9 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

95 Rockwell Automation Publication DRIVES-IN001M-EN-P - March Motor Cable Length Restrictions Tables Appendix A Table 7 - PowerFlex 70 (standard/enhanced) and 700 (standard/vector) Drives, 80V Shielded/Unshielded Cable Meters (Feet) Drive Frame Rating No Solution Reactor Only Reactor and Damping Resistor or 131-RWR Reactor/RWR (see page 19) Resistor Available Options Hp khz 1000V 100V 188V 1600V 1000V 100V 188V 1600V 1000V 100V 188V 1600V Cat. No. Ohms Watts TFA1 TFB RWR RWC A (175) 53.3 (175) 53.3 (175) 53.3 (175) 1 (75) (75) 76. (50) 76. (50) (75) (75) 76. (50) 76. (50) B (5) 19.5 (5) (50) RWR8-DP RWR8-DP C (50) 131-RWR1-DP 131-RWR1-DP (50) 131-RWR18-DP 131-RWR18-DP D (50) 131-RWR5-DP 131-RWR5-DP (50) 131-RWR35-DP 131-RWR35-DP (50) 76. (50) 131-RWR35-DP RWR35-DP (50) 76. (50) 131-RWR5-DP RWR5-DP E (50) 76. (50) 131-RWR55-DP 8.6 (750) RWR55-DP (50) 131-RWR80-DP 8.6 (750) RWR80-DP (50) 137. (50) 131-RWR80-DP 8.6 (750) 76. (50) RWR80-DP continued

96 Appendix A Motor Cable Length Restrictions Tables Table 7 - PowerFlex 70 (standard/enhanced) and 700 (standard/vector) Drives, 80V Shielded/Unshielded Cable Meters (Feet) (continued) Drive Frame Rating No Solution Reactor Only Reactor and Damping Resistor or 131-RWR 600 (1) Requires two parallel cables. () Requires three parallel cables (50) 137. (50) 137. (50) 137. (50) 137. (50) 137. (50) 137. (50) 16 (550) 16 (550) (10) (650) (650) 137. (50) 137. (50) 137. (50) 137. (50) 59.1 (850) 59.1 (850) (650) (650) 137. (50) 137. (50) 137. (50) 76. (50) 137. (50) (50) (50) (50) (50) (50) (50) (50) (50) (50) (50) (50) (50) 76. (50) (550) 16 (550) 16 (550) 16 (550) (850) 59.1 (850) 59.1 (850) Reactor/RWR (see page 19) 131-RWR100-DP 131-RWR100-DP 131-RWR130-DP 131-RWR130-DP 131-RWR160-DP 131-RWR160-DP 131-RWR00-DP 131-RWR00-DP 131-RWR50-DP 131-RWR50-DP Resistor Hp khz 1000V 100V 188V 1600V 1000V 100V 188V 1600V 1000V 100V 188V 1600V Cat. No. Ohms Watts 131-3RB30-B RB30-B RB30-B RB30-B RB00-B (1) RB00-B (1) R00-B (1) RB00-B (1) R500-B (1) R500-B (1) R600-B (1) R600-B (1) R600-B (1) R600-B (1) R750-B () R750-B () R850-B () R850-B () Available Options TFA1 TFB RWR RWC 96 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

97 Motor Cable Length Restrictions Tables Appendix A Table 8 - PowerFlex 70 (standard/enhanced) and 700 (standard/vector) Drives, 600V Shielded/Unshielded Cable Meters (Feet) Drive Frame A B C D E Rating No Solution Reactor Only 131-RWR RWR (see page 19) Hp khz 188V 1850V 188V 1850V 188V 1850V Cat. No. Available Options 1.7 (10).7 (10) 137. (50) (10) 137. (50) 5.7 (10) RWR8-EP 137. (50) RWR8-EP (10) 131-RWR1-EP 137. (50) 131-RWR1-EP (10) 131-RWR1-EP 137. (50) 131-RWR1-EP 15.7 (10) 131-RWR18-EP 137. (50) 131-RWR18-EP 0.7 (10) 131-RWR5-EP 137. (50) 131-RWR5-EP 5.7 (10) 131-RWR35-EP 137. (50) 131-RWR35-EP 30.7 (10) 131-RWR35-EP 137. (50) (10) 131-RWR35-EP (10) 131-RWR5-EP 137. (50) (10) 131-RWR5-EP 50.7 (10) 131-RWR55-EP (10) 137. (50) RWR55-EP 60.7 (10) 131-RWR80-EP (10) 137. (50) RWR80-EP.7 (10) 131-RWR80-EP 75 (10) 137. (50) RWR80-EP (10) 131-RWR100-EP.7 (10) 137. (50) RWR100-EP.7 (10) 131-RWR130-EP 15.7 (10) 137. (50) (750) 131-RWR130-EP (10) 131-RWR160-EP.7 (10) 137. (50) (650) 131-RWR160-EP TFA1 TFB RWR RWC Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01 97

98 Appendix A Motor Cable Length Restrictions Tables Table 9 - PowerFlex 700 (standard/vector) Drives, 690V Shielded/Unshielded Cable Meters (Feet) Drive No Solution Reactor Only Reactor and Damping Resistor Reactor Resistor Available Options Frame kw khz 1850V 000V 1850V 000V 1850V 000V Cat. No. Ohms Watts R80-C (50) (10) R80-C R80-C (50) (10) R80-C R100-C (50) (10) R100-C R130-C (50) (10) R130-C R160-C (50) (10) 99.1 (35) R160-C R00-C (50) (10) (75) R00-C TFA1 TFB RWR RWC PowerFlex 700H This section lists motor cable length restrictions, reactors, and available options for PowerFlex 700H drives. Table 30 - PowerFlex 700H Drives, 00V Shielded/Unshielded Cable Meters (Feet) Drive No Solution Reactor Only Reactor and Damping Resistor or 131-RWR Reactor/RWR (see page 19) Resistor Frame kw khz 1000V 100V 188V 1600V 1000V 100V 188V 1600V 1000V 100V 188V 1600V Cat. No. Ohms Watts (1) () 710 () 800 () 8.8 (160) 8.8 (160) 8.8 (160) 8.8 (160).7 (10).7 (10).7 (10).7 (10).7 (10).7 (10) 76. (50) 76. (50) 76. (50) 99.1 (35) 99.1 (35) 99.1 (35) 137. (50) 137. (50) 16 (550) 16 (550) 16 (550) (10) (10) (10) 8.8 (160) 8.8 (160) 8.8 (160) 8.8 (160).7 (10).7 (10).7 (10).7 (10).7 (10).7 (10) (650) (650) (650) (1) Frame 1 drives have dual inverters and require two output reactors. The resistor ratings are per phase values for each reactor. () Some Frame 13 drives require two output reactors to match drive amp rating. The resistor ratings are per phase values for each reactor. (3) Resistor specification is based on two cables per phase. () Resistor specification is based on three cables per phase. (5) Resistor specification is based on four cables per phase. 131-RWR30-DP 131-RWR30-DP 131-3R500-B 0 95 (3) 131-3R500-B 0 95 (3) 131-3R600-B 0 95 (3) 131-3R750-B 0 95 (3) 131-3R750-B () x 131-3RB00-B x 131-3R500-B x 131-3R500-B x 131-3R600-B x 131-3R750-B x 131-3R750-B Available Options TFA1 TFB RWR RWC () () 0 55 (5) 0 55 (5) 0 55 (5) 0 55 (5) 98 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

99 Motor Cable Length Restrictions Tables Appendix A Table 31 - PowerFlex 700H Drives, 80V Shielded/Unshielded Cable Meters (Feet) Drive No Solution Reactor Only Reactor and Damping Resistor or 131-RWR Reactor/RWR (see page 19) Resistor Frame Hp khz 1000V 100V 188V 1600V 1000V 100V 188V 1600V 1000V 100V 188V 1600V Cat. No. Ohms Watts (1) () 100 () 150 ().7 (10).7 (10).7 (10).7 (10) (10) (10) (10) (10) (10) (10) 76. (50) 76. (50) 76. (50) 76. (50) (50) 76. (50) (550) (1) Frame 1 drives have dual inverters and require two output reactors. The resistor ratings are per phase values for each reactor. () Some Frame 13 drives require two output reactors to match drive amp rating. The resistor ratings are per phase values for each reactor. (3) Resistor specification is based on two cables per phase. () Resistor specification is based on three cables per phase. (5) Resistor specification is based on four cables per phase. 131-RWR30-DP 131-RWR30-DP 131-3RB00-B 0 95 (3) 131-3R500-B 0 95 (3) 131-3R500-B 0 95 (3) 131-3R750-B 0 95 (3) 131-3R750-B () x 131-3RB00-B x 131-3R500-B x 131-3R500-B x 131-3R600-B x 131-3R750-B x 131-3R750-B Available Options TFA1 TFB RWR RWC () () 0 55 (5) 0 55 (5) 0 55 (5) 0 55 (5) Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01 99

100 Appendix A Motor Cable Length Restrictions Tables Table 3 - PowerFlex 700H Drives, 600V Shielded/Unshielded Cable Meters (Feet) Drive No Solution Reactor Only Reactor and Damping Resistor or 131-RWR Table 33 - PowerFlex 700H Drives, 690V Shielded/Unshielded Cable Meters (Feet) Reactor/RWR (see page 19) Resistor Frame Hp khz 188V 1850V 188V 1850V 188V 1850V Cat. No. Ohms Watts Available Options (650) 131-RWR00-EP RWR50-EP (550) 131-3RB50-B (550) 131-3RB350-B (3) (550) 131-3RB00-B (3) (550) 131-3R500-B (3) (550) 131-3R500-B (3) R600-B (3) x 131-3RB30-B (3) 1 (1) x 131-3RB00-C 0 80 () x 131-3R00-B 0 80 () x 131-3R500-C 0 80 () 13 () (50) x 131-3R500-B 0 70 (5) (50) x 131-3R600-B 0 70 (5) (1) Frame 1 drives have dual inverters and require two output reactors. The resistor ratings are per phase values for each reactor. () Frame 13 drives require two output reactors to match drive amp rating. The resistor ratings are per phase values for each reactor. (3) Resistor specification is based on two parallel cables per phase. () Resistor specification is based on three parallel cables per phase. (5) Resistor specification is based on four parallel cables per phase. Drive No Solution Reactor Only Reactor and Damping Resistor Reactor Resistor Available Options Frame kw khz 1850V 000V 1850V 000V 1850V 000V Cat. No. Ohms Watts (50) 131-3RB50-C (50) 131-3RB50-C (50) 131-3RB00-C RB00-C (3) R500-C (3) R500-C (3) R750-C (3) R750-C (3) R850-C (3) 630 x131-3r600-c 0 80 () 1 (1) 710 x131-3r600-c 0 65 () 800 x131-3r750-c 0 65 () 900 x131-3r600-c 0 65 () () x131-3r600-c 0 80 (5) 1100 () x131-3r750-c 0 80 (5) (1) Frame 1 drives have dual inverters and require two output reactors. The resistor ratings are per phase values for each reactor. () Some Frame 13 drives require two output reactors to match drive amp rating. The resistor ratings are per phase values for each reactor. (3) Resistor specification is based on two parallel cables per phase. () Resistor specification is based on three parallel cables per phase. (5) Resistor specification is based on four parallel cables per phase. TFA1 TFB RWR RWC TFA1 TFB RWR RWC PowerFlex 700L This section lists motor cable length restrictions, reactors, and available options for PowerFlex 700L drives. 100 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

101 Motor Cable Length Restrictions Tables Appendix A Table 3 - PowerFlex 700L Drives with 700VC Control, 00V Input Shielded/Unshielded Cable Meters (Feet) Drive No Solution Reactor Only Reactor and Damping Resistor Reactor Resistor Available Options Frame kw khz 1000V 100V 188V 1600V 1000V 100V 188V 1600V 1000V 100V 188V 1600V Cat. No. Ohms Watts 00 3A 370 3B 715 (1) Requires two parallel cables. () Requires four parallel cables. 76. (50) 76. (50) 19.5 (5) (55) 76. (50) 76. (50) 76. (50) 76. (50) 76. (50) 76. (50) 8.6 (750) 137. (50) 8.6 (750) 137. (50) Table 35 - PowerFlex 700L Drives with 700VC Control, 80V Input Shielded/Unshielded Cable - Meters (Feet) Table 36 - PowerFlex 700L Drives with 700VC Control, 600V Input Shielded/Unshielded Cable Meters (Feet) 8.6 (750) 76. (50) 76. (50) 76. (50) (50) (50) (50) R00-B (1) R00-B (1) R750-B (1) R750-B (1) x 131-3R600-B () 0 55 x () R600-B TFA1 TFB RWR RWC Drive No Solution Reactor Only Reactor and Damping Resistor Reactor Resistor Available Options Frame Hp khz 1000V 100V 188V 1600V 1000V 100V 188V 1600V 1000V 100V 188V 1600V Cat. No. Ohms Watts 300 3A 600 3B 1150 (1) Requires two parallel cables. () Requires four parallel cables. (75) (75) (75) (75) 11.3 (375) 11.3 (375) 11.3 (375) 11.3 (375) (10) (10) 99.1 (35) (75) 99.1 (35) (75) (75) 137. (50) 11.3 (375) 137. (50) 11.3 (375) 11.3 (375) 137. (50) 137. (50) 137. (50) R00-B (1) R00-B (1) R750-B (1) R750-B (1) x 131-3R600-B () Drive No Solution Reactor Only Reactor and Reactor Resistor Available Options Damping Resistor Frame Hp khz 188V 1850V 188V 1850V 188V 1850V Cat. No. Ohms Watts 3A 65 3B 870 (1) Requires two parallel cables. () Requires three parallel cables. (3) Requires four parallel cables. 3B 175 (75) (75) 76. (50) 53.3 (175) 137. (50) (65) (50) R500-B (1) R500-B (1) R850-B () R850-B () x 131-3R600-B (3) x () R600-B TFA1 TFB RWR RWC TFA1 TFB RWR RWC Rockwell Automation Publication DRIVES-IN001M-EN-P - March

102 Appendix A Motor Cable Length Restrictions Tables Table 37 - PowerFlex 700L Drives with 700VC Control, 690V Input Shielded/Unshielded Cable Meters (Feet) Drive No Solution Reactor Only Reactor and Damping Resistor Reactor Resistor Available Options Frame kw khz 188V 1850V 188V 1850V 188V 1850V Cat. No. Ohms Watts 3A 355 3B 657 (1) Requires two parallel cables. () Requires three parallel cables. (3) Requires four parallel cables. 3B (750) 76. (50) 76. (50) 8.6 (750) 8.6 (750) 131-3R500-C (1) R500-C (1) R850-C () R850-C () x 131-3R600-C (3) 0 80 TFA1 TFB RWR RWC Table 38 - PowerFlex 700L Drives with 700S Control, 00V Input Shielded/Unshielded Cable Meters (Feet) Drive No Solution Reactor Only Reactor and Damping Resistor Reactor Resistor Available Options Frame kw khz 1000V 100V 188V 1600V 1000V 100V 188V 1600V 1000V 100V 188V 1600V Cat. No. Ohms Watts 00 3A 370 3B 715 (1) Requires two parallel cables. () Requires four parallel cables (5) 68.6 (5) 68.6 (5) 68.6 (5) 68.6 (5) 68.6 (5) 99.1 (35) 99.1 (35) 99.1 (35) 99.1 (35) 99.1 (35) 99.1 (35) 16 (550) 16 (550) 16 (550) 16 (550) 16 (550) 16 (550) (10) (10) (10) (10) (10) (10) 68.6 (5) 68.6 (5) 68.6 (5) 68.6 (5) 68.6 (5) 68.6 (5) (1100) (1100) (1100) (1100) (1100) (1100) Table 39 - PowerFlex 700L Drives with 700S Control, 80V Input Shielded/Unshielded Cable Meters (Feet) R00-B (1) R00-B (1) R750-B (1) R750-B (1) x 131-3R600-B () 0 55 x 131-3R600-B () TFA1 TFB RWR RWC Drive No Solution Reactor Only Reactor and Damping Resistor Reactor Resistor Available Options Frame Hp khz 1000V 100V 188V 1600V 1000V 100V 188V 1600V 1000V 100V 188V 1600V Cat. No. Ohms Watts 300 3A 600 3B 1150 (1) Requires two parallel cables. () Requires four parallel cables R00-B (1) R00-B (1) R750-B (1) R750-B (1) x 131-3R600-B () 0 55 x () R600-B TFA1 TFB RWR RWC 10 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

103 Motor Cable Length Restrictions Tables Appendix A Table 0 - PowerFlex 700L Drives with 700S Control, 600V Input Shielded/Unshielded Cable Meters (Feet) Drive No Solution Reactor Only Reactor and Damping Resistor Reactor Resistor Available Options Frame Hp khz 188V 1850V 188V 1850V 188V 1850V Cat. No. Ohms Watts 3A 65 3B 870 (1) Requires two parallel cables. () Requires three parallel cables. (3) Requires four parallel cables. 3B (50) 76. (50) (50) 76. (50) (750) 8.6 (750) 8.6 (750) 131-3R500-B (1) R500-B (1) R850-B () R850-B () x 131-3R600-B (3) 0 70 TFA1 TFB RWR RWC Table 1 - PowerFlex 700L Drives with 700S Control, 690V Input Shielded/Unshielded Cable Meters (Feet) Drive No Solution Reactor Only Reactor and Reactor Resistor Available Options Damping Resistor Frame kw khz 188V 1850V 188V 1850V 188V 1850V Cat. No. Ohms Watts 3A 355 3B 657 (1) Requires two parallel cables. () Requires three parallel cables. (3) Requires four parallel cables. 3B (750) 8.6 (750) 8.6 (750) 8.6 (750) 8.6 (750) 131-3R500-C (1) R500-C (1) R850-C () R850-C () x 131-3R600-C (3) 0 80 TFA1 TFB RWR RWC Rockwell Automation Publication DRIVES-IN001M-EN-P - March

104 Appendix A Motor Cable Length Restrictions Tables PowerFlex 700S This section lists motor cable length restrictions, reactors, and available options for PowerFlex 700S drives. Table - PowerFlex 700S Drives, 00V Shielded/Unshielded Cable Meters (Feet) Drive No Solution Reactor Only Reactor and Damping Resistor or 131-RWR Reactor/RWR (see page 19) Resistor Frame kw khz 1000V 100V 188V 1600V 1000V 100V 188V 1600V 1000V 100V 188V 1600V Cat. No. Ohms Watts / 1.5 /. / / 5.5 / 7.5 / 11 / 15 / 18.5 / / 30 / 37 / 5 / continued 55 / 75 / 90 / 110 / 13 / (75) 76. (50) 76. (50) 68.6 (5) 68.6 (5) 68.6 (5) (75) (35) 99.1 (35) 99.1 (35) 99.1 (35) (75) (550) 16 (550) 16 (550) 16 (550) 76. (50) 76. (50) (10) (10) (10) (10) (10) (50) 68.6 (5) 68.6 (5) 68.6 (5) (750) 8.6 (750) 8.6 (750) 8.6 (750) (1100) (1100) RWR8-DP 131-RWR1-DP 131-RWR18-DP 131-RWR5-DP 131-RWR5-DP 131-RWR35-DP 131-RWR5-DP 131-RWR55-DP 131-RWR80-DP 131-RWR80-DP 131-RWR100-DP 131-RWR130-DP 131-RWR160-DP 131-RWR00-DP 131-RWR50-DP 131-RWR30-DP 131-RWR30-DP 131-3R500-B 0 95 (3) 131-3R500-B 0 95 (3) 131-3R600-B 0 95 (3) 131-3R750-B 0 95 (3) 131-3R750-B () Available Options TFA1 TFB RWR RWC 10 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

105 Motor Cable Length Restrictions Tables Appendix A Table - PowerFlex 700S Drives, 00V Shielded/Unshielded Cable Meters (Feet) (continued) Drive No Solution Reactor Only Reactor and Damping Resistor or 131-RWR 1 (1) () 710 () 800 () 68.6 (5) 68.6 (5) 68.6 (5) 99.1 (35) 99.1 (35) 99.1 (35) 99.1 (35) 99.1 (35) 99.1 (35) 16 (550) 16 (550) 16 (550) 16 (550) 16 (550) 16 (550) (10) (10) (10) (10) (10) (10) 68.6 (5) 68.6 (5) 68.6 (5) 8.6 (750) (650) (650) (650) (650) (650) (1) Frame 1 drives have dual inverters and require two output reactors. The resistor ratings are per phase values for each reactor. () Some Frame 13 drives require two output reactors to match drive amp rating. The resistor ratings are per phase values for each reactor. (3) Resistor specification is based on two cables per phase. () Resistor specification is based on three cables per phase. (5) Resistor specification is based on four cables per phase. Reactor/RWR (see page 19) x 131-3RB00-B x 131-3R500-B x 131-3R500-B x 131-3R600-B x 131-3R750-B x 131-3R750-B Resistor Frame kw khz 1000V 100V 188V 1600V 1000V 100V 188V 1600V 1000V 100V 188V 1600V Cat. No. Ohms Watts () () 0 55 (5) 0 55 (5) 0 55 (5) 0 55 (5) Available Options TFA1 TFB RWR RWC Table 3 - PowerFlex 700S Drives, 80V Shielded/Unshielded Cable Meters (Feet) Drive No Solution Reactor Only Reactor and Damping Resistor or 131-RWR Reactor/RWR (see page 19) Resistor Frame Hp khz 1000V 100V 188V 1600V 1000V 100V 188V 1600V 1000V 100V 188V 1600V Cat. No. Ohms Watts / / 3 / 5 / 7.5 / 10 / 15 / 0 / 5 / 30 / 0 / 50 / 60 / 5 continued 75 / 100 / (75) (75) (75) (75) 137. (50) 76. (50) 76. (50) 76. (50) RWR8-DP 131-RWR1-DP 131-RWR18-DP 131-RWR5-DP 131-RWR5-DP 131-RWR35-DP 131-RWR5-DP 131-RWR55-DP 131-RWR80-DP 131-RWR80-DP 131-RWR100-DP 131-RWR130-DP Available Options TFA1 TFB RWR RWC Rockwell Automation Publication DRIVES-IN001M-EN-P - March

106 Appendix A Motor Cable Length Restrictions Tables Table 3 - PowerFlex 700S Drives, 80V Shielded/Unshielded Cable Meters (Feet) (continued) Drive No Solution Reactor Only Reactor and Damping Resistor or 131-RWR (1) / 150 / 00 / () 100 () 150 () 137. (50) 137. (50) 137. (50) (750) 76. (50) 76. (50) (1) Frame 1 drives have dual inverters and require two output reactors. The resistor ratings are per phase values for each reactor. () Some Frame 13 drives require two output reactors to match drive amp rating. The resistor ratings are per phase values for each reactor. (3) Resistor specification is based on two cables per phase. () Resistor specification is based on three cables per phase. (5) Resistor specification is based on four cables per phase. Reactor/RWR (see page 19) 131-RWR160-DP 131-RWR00-DP 131-RWR50-DP 131-RWR30-DP 131-RWR30-DP 131-3RB00-B 0 95 (3) 131-3R500-B 0 95 (3) 131-3R500-B 0 95 (3) 131-3R750-B 0 95 (3) 131-3R750-B () x 131-3RB00-B x 131-3R500-B x 131-3R500-B x 131-3R600-B x 131-3R750-B x 131-3R750-B Resistor Frame Hp khz 1000V 100V 188V 1600V 1000V 100V 188V 1600V 1000V 100V 188V 1600V Cat. No. Ohms Watts () () 0 55 (5) 0 55 (5) 0 55 (5) 0 55 (5) Available Options TFA1 TFB RWR RWC 106 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

107 Motor Cable Length Restrictions Tables Appendix A Table - PowerFlex 700S Drives, 600V Shielded/Unshielded Cable Meters (Feet) Drive No Solution Reactor Only Reactor and Damping Resistor or 131-RWR Reactor/RWR (see page 19) Resistor Frame Hp khz 188V 1850V 188V 1850V 188V 1850V Cat. No. Ohms Watts Available Options TFA1 TFB RWR RWC 1 / / 3 / 1 5 / RWR8-EP 7.5 / 131-RWR8-EP 10 / 131-RWR1-EP 15 / (10) 131-RWR18-EP 0 / (10) 131-RWR5-EP 5 / RWR5-EP 30 / RWR35-EP 3 0 / 137. (50) RWR5-EP 50 / 137. (50) RWR55-EP 60 / 137. (50) RWR80-EP 5 75 / 137. (50) RWR80-EP 100 / 137. (50) RWR100-EP 6 15 / 137. (50) (650) 131-RWR130-EP 150 / 137. (50) (650) 131-RWR160-EP (50) (650) 131-RWR00-EP (50) (650) 131-RWR50-EP (50) (650) 16 (550) 131-3RB50-B (550) 131-3RB350-B (3) (550) 131-3RB00-B (3) (550) 131-3R500-B (3) (550) 131-3R500-B (3) R600-B (3) 700 x 131-3RB30-B (3) 1 (1) 800 x 131-3RB00-C 0 80 () 900 x 131-3R00-B 0 80 () 1000 x 131-3R500-C 0 80 () 13 () (175) 137. (50) 137. (50) x 131-3R500-B 0 70 (5) (175) 137. (50) 137. (50) x 131-3R600-B 0 70 (5) (1) Frame 1 drives have dual inverters and require two output reactors. The resistor ratings are per phase values for each reactor. () Frame 13 drives require two output reactors to match drive amp rating. The resistor ratings are per phase values for each reactor. (3) Resistor specification is based on two parallel cables per phase. () Resistor specification is based on three parallel cables per phase. (5) Resistor specification is based on four parallel cables per phase. Rockwell Automation Publication DRIVES-IN001M-EN-P - March

108 Appendix A Motor Cable Length Restrictions Tables Table 5 - PowerFlex 700S Drives, 690V Shielded/Unshielded Cable Meters (Feet) Drive No Solution Reactor Only Reactor and Damping Reactor Resistor Available Options Resistor Frame kw khz 1850V 000V 1850V 000V 1850V 000V Cat. No. Ohms Watts (1) 13 5 / R80-C / / R80-C / / R100-C / / R130-C / / (50) R160-C / / (50) R00-C / RB50-C RB50-C RB00-C RB00-C (3) R500-C (3) R500-C (3) R750-C (3) R750-C (3) (50) R850-C (3) (50) 3.8 x 131-3R600-C 0 80 () (50) 3.8 x 131-3R600-C 0 65 () (50) 3.8 x 131-3R750-C 0 65 () (50) 3.8 x 131-3R600-C 0 65 () 1000 () x 131-3R600-C 0 80 (5) 1100 () x 131-3R750-C 0 80 (5) (1) Frame 1 drives have dual inverters and require two output reactors. The resistor ratings are per phase values for each reactor. () Some Frame 13 drives require two output reactors to match drive amp rating. The resistor ratings are per phase values for each reactor. (3) Resistor specification is based on two parallel cables per phase. () Resistor specification is based on three parallel cables per phase. (5) Resistor specification is based on four parallel cables per phase. TFA1 TFB RWR RWC 108 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

109 Motor Cable Length Restrictions Tables Appendix A PowerFlex 753 and 755 Wall Mount Drives This section lists motor cable length restrictions, reactors, and available options for PowerFlex 753 and 755 wall mount drives. Table 6 - PowerFlex 753 and 755 Wall Mount Drives, 00V Shielded/Unshielded Cable Meters (Feet) Drive Rating No Solution Reactor Only Reactor and Damping Resistor or 131-RWR Reactor/RWR (see page 19) Resistor Frame kw khz 1000V 100V 188V 1600V 1000V 100V 188V 1600V 1000V 100V 188V 1600V Cat. No. Ohms Watts continued (75) (75) (75) (75) (75) (75) (75) (75) 3.8 (75) (75) RWR1-DP 131-RWR1-DP 131-RWR18-DP 31-RWR1-DP 31-RWR1-DP 131-RWR18-DP 131-RWR5-DP Available Options TFA1 TFB RWR RWC Rockwell Automation Publication DRIVES-IN001M-EN-P - March

110 Appendix A Motor Cable Length Restrictions Tables Table 6 - PowerFlex 753 and 755 Wall Mount Drives, 00V Shielded/Unshielded Cable Meters (Feet) (continued) Drive Rating No Solution Reactor Only Reactor and Damping Resistor or 131-RWR continued (50) 137. (50) 137. (50) 137. (50) 137. (50) 137. (50) 137. (50) 137. (50) 137. (50) 137. (50) (50) (10) (650) Reactor/RWR (see page 19) 131-RWR35-DP 131-RWR35-DP 131-RWR5-DP 131-RWR55-DP 131-RWR80-DP 131-RWR80-DP 131-RWR100-DP 131-RWR130-DP 131-RWR160-DP 131-RWR00-DP Resistor Frame kw khz 1000V 100V 188V 1600V 1000V 100V 188V 1600V 1000V 100V 188V 1600V Cat. No. Ohms Watts Available Options TFA1 TFB RWR RWC 110 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

111 Motor Cable Length Restrictions Tables Appendix A Table 6 - PowerFlex 753 and 755 Wall Mount Drives, 00V Shielded/Unshielded Cable Meters (Feet) (continued) Drive Rating No Solution Reactor Only Reactor and Damping Resistor or 131-RWR (1) Requires two parallel cables (50) (850) (10) (10) (10) 5.7 (10) 5.7 (10) 16 (550) 16 (550) (750) (750) 8.6 (750) Reactor/RWR (see page 19) 131-RWR50-DP 131-3RB30-B Resistor Frame kw khz 1000V 100V 188V 1600V 1000V 100V 188V 1600V 1000V 100V 188V 1600V Cat. No. Ohms Watts RB00-B (1) R500-B (1) R600-B (1) Available Options TFA1 TFB RWR RWC Table 7 - PowerFlex 753 and 755 Wall Mount Drives, 80V Shielded/Unshielded Cable Meters (Feet) Drive Rating No Solution Reactor Only Reactor and Damping Resistor or 131-RWR Reactor/RWR (see page 19) Resistor Frame Hp khz 1000V 100V 188V 1600V 1000V 100V 188V 1600V 1000V 100V 188V 1600V Cat. No. Ohms Watts continued (75) (75) (75) (75) (75) (75) (75) (75) RWR8-DP 131-RWR1-DP 131-RWR18-DP Available Options TFA1 TFB RWR RWC Rockwell Automation Publication DRIVES-IN001M-EN-P - March

112 11 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01 Appendix A Motor Cable Length Restrictions Tables 1.0 (75) (75) (75) (75).0 (75) (75) (75) (75) RWR8-DP RWR1-DP RWR18-DP RWR5-DP (50) 131-RWR35-DP (50) 76. (50) 131-RWR35-DP (50) 76. (50) 131-RWR5-DP (50) 76. (50) 131-RWR55-DP 8.6 (750) (50) 131-RWR80-DP 8.6 (750) (50) 137. (50) 131-RWR80-DP 8.6 (750) 76. (50) (50) (50) 131-RWR100-DP 76. (50) continued Table 7 - PowerFlex 753 and 755 Wall Mount Drives, 80V Shielded/Unshielded Cable Meters (Feet) (continued) Drive Rating No Solution Reactor Only Reactor and Damping Resistor or 131-RWR Reactor/RWR (see page 19) Resistor Available Options Frame Hp khz 1000V 100V 188V 1600V 1000V 100V 188V 1600V 1000V 100V 188V 1600V Cat. No. Ohms Watts TFA1 TFB RWR RWC

113 Motor Cable Length Restrictions Tables Appendix A Table 7 - PowerFlex 753 and 755 Wall Mount Drives, 80V Shielded/Unshielded Cable Meters (Feet) (continued) Drive Rating No Solution Reactor Only Reactor and Damping Resistor or 131-RWR (50) 137. (50) 137. (50) 137. (50) 137. (50) 16 (550) 16 (550) (1) Resistor specification is based on two parallel cables per phase (650) (650) 137. (50) 137. (50) 137. (50) 59.1 (850) 59.1 (850) 137. (50) 76. (50) (50) (50) 137. (50) (50) (50) (50) (50) (50) (50) Reactor/RWR (see page 19) 131-3R130-DP 131-3R160-DP 131-3R00-DP 131-RWR50-DP 131-3RB30-B 131-3RB00-B 131-3RB00-B 131-3R500-B Resistor Frame Hp khz 1000V 100V 188V 1600V 1000V 100V 188V 1600V 1000V 100V 188V 1600V Cat. No. Ohms Watts (1) (1) 0 95 (1) (1) 0 95 (1) (1) Available Options TFA1 TFB RWR RWC Rockwell Automation Publication DRIVES-IN001M-EN-P - March

114 Appendix A Motor Cable Length Restrictions Tables Table 8 - PowerFlex 753 and 755 Wall Mount Drives, 600V Shielded/Unshielded Cable Meters (Feet) Drive Rating No Solution Reactor Only Reactor and Damping Resistor or 131-RWR Reactor/RWR (see page 19) Resistor Available Options Frame HP khz 188V 1850V 188V 1850V 188V 1850V Cat. No. Ohms Watts TFA1 TFB RWR RWC 3 5 continued (50) 137. (50) (10) (10) (10) (10) RWR8-EP 131-RWR1-EP 131-RWR1-EP 131-RWR18-EP 131-RWR5-EP 131-RWR35-EP 131-RWR35-EP 131-RWR5-EP 131-RWR55-EP 11 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

115 Motor Cable Length Restrictions Tables Appendix A Table 8 - PowerFlex 753 and 755 Wall Mount Drives, 600V Shielded/Unshielded Cable Meters (Feet) (continued) Drive Rating No Solution Reactor Only Reactor and Damping Resistor or 131-RWR Reactor/RWR (see page 19) Resistor Available Options Frame HP khz 188V 1850V 188V 1850V 188V 1850V Cat. No. Ohms Watts TFA1 TFB RWR RWC RWR1-EP 15 (10) (10) 131-RWR18-EP 0 (10) (10) 131-RWR5-EP RWR35-EP RWR35-EP (50) 137. (50) RWR5-EP 131-RWR55-EP (50) RWR80-EP (50) RWR80-EP (50) RWR100-EP (50) (650) RWR130-EP (50) (650) RWR160-EP continued Rockwell Automation Publication DRIVES-IN001M-EN-P - March

116 Appendix A Motor Cable Length Restrictions Tables Table 8 - PowerFlex 753 and 755 Wall Mount Drives, 600V Shielded/Unshielded Cable Meters (Feet) (continued) Drive Rating No Solution Reactor Only Reactor and Damping Resistor or 131-RWR (50) 137. (50) 137. (50) (650) 16 (550) 16 (550) 16 (550) (650) (650) (650) Reactor/RWR (see page 19) 131-RWR00-EP 131-RWR50-EP 131-3RB350-B Resistor Available Options Frame HP khz 188V 1850V 188V 1850V 188V 1850V Cat. No. Ohms Watts TFA1 TFB RWR RWC 116 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

117 Motor Cable Length Restrictions Tables Appendix A Table 9 - PowerFlex 753 and 755 Wall Mount Drives, 690V Shielded/Unshielded Cable Meters (Feet) Drive Rating No Solution Reactor Only Reactor and Damping Resistor Reactor Resistor Available Options Frame kw khz 188V 1850V 188V 1850V 188V 1850V Cat. No. Ohms Watts TFA1 TFB RWR RWC 6 continued (10) (10) (10) (10) (10) (10) (10) (10) (10) (10) (10) (10) (50) 76. (50) 76. (50) 76. (50) 76. (50) 76. (50) (50) 76. (50) 76. (50) 76. (50) 76. (50) R18-C 131-3R5-C 131-3R35-C 131-3R35-C 131-3R5-C 131-3R5-C 131-3R55-C 131-3R80-C 131-3R80-C 131-3R100-C 131-3R130-C 131-3R160-C 131-3R00-C Rockwell Automation Publication DRIVES-IN001M-EN-P - March

118 Appendix A Motor Cable Length Restrictions Tables Table 9 - PowerFlex 753 and 755 Wall Mount Drives, 690V Shielded/Unshielded Cable Meters (Feet) (continued) Drive Rating No Solution Reactor Only Reactor and Reactor Resistor Available Options Damping Resistor Frame kw khz 188V 1850V 188V 1850V 188V 1850V Cat. No. Ohms Watts TFA1 TFB RWR RWC R00-C 131-3RB50-C 131-3RB30-C PowerFlex 755 Floor Mount Drives This section lists motor cable length restrictions, reactors, and available options for PowerFlex 755 floor mount drives. Table 50 - PowerFlex 755 Floor Mount Drives, 00V Shielded/Unshielded Cable Meters (Feet) Drive Rating No Solution Reactor Only Reactor and Damping Resistor Reactor Resistor Available Options Frame kw khz 1000V 100V 188V 1600V 1000V 100V 188V 1600V 1000V 100V 188V 1600V Cat. No. Ohms Watts 8 continued (50) 59.1 (850) 59.1 (850) (550) 5.7 (10) 5.7 (10) 5.7 (10) (10) (10) 16 (550) 16 (550) 16 (550) (750) 8.6 (750) 8.6 (750) (650) 76. (50) (50) R500-B 131-3R600-B 131-3R750-B 0 95 () () 0 95 () () 0 95 () () 131-3R850-B (3) (3) TFA1 TFB RWR RWC 118 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

119 Motor Cable Length Restrictions Tables Appendix A Table 50 - PowerFlex 755 Floor Mount Drives, 00V Shielded/Unshielded Cable Meters (Feet) (continued) Drive Rating No Solution Reactor Only Reactor and Damping Resistor Reactor Resistor Available Options Frame kw khz 1000V 100V 188V 1600V 1000V 100V 188V 1600V 1000V 100V 188V 1600V Cat. No. Ohms Watts 9 (1) 10 (1) (50) (50) (50) 137. (50) 137. (50) 137. (50) 137. (50) 137. (50) 137. (50) (10) (10) (10) (10) (10) (10) (10) (10) x x x x x x x 3 x 131-3R500-B 131-3R600-B 131-3R600-B 131-3R600-B 131-3R750-B 131-3R750-B 131-3R850-B 131-3R750-B (1) Frame 9 and Frame 10 drives require two or three parallel reactors to match drive amp rating. The resistor ratings are per phase values for each reactor. () Resistor specification is based on two parallel cables per phase. (3) Resistor specification is based on three parallel cables per phase. () Resistor specification is based on four parallel cables per phase. (5) Resistor specification is based on five parallel cables per phase. (6) Resistor specification is based on six parallel cables per phase (3) (3) 0 55 () () 0 55 () () 0 55 () () 0 55 () () 0 55 () () (5) (5) (6) (6) TFA1 TFB RWR RWC Rockwell Automation Publication DRIVES-IN001M-EN-P - March

120 Appendix A Motor Cable Length Restrictions Tables Table 51 - PowerFlex 755 Floor Mount Drives, 80V Shielded/Unshielded Cable Meters (Feet) Drive Rating No Solution Reactor Only Reactor and Damping Resistor Reactor Resistor Available Options Frame Hp khz 1000V 100V 188V 1600V 1000V 100V 188V 1600V 1000V 100V 188V 1600V Cat. No. Ohms Watts 8 9 (1) continued (50) 76. (50) 76. (50) 76. (50) 76. (50) 76. (50) 76. (50) 76. (50) (50) 137. (50) 137. (50) 76. (50) 76. (50) 76. (50) 76. (50) 76. (50) 76. (50) 76. (50) 76. (50) (50) (50) (50) (50) (50) (50) (50) x x x x x x 131-3R500-B 131-3R500-B 131-3R600-B 131-3R750-B 131-3R750-B 131-3R850-B 131-3RB500-B 131-3R600-B 131-3R600-B 131-3R750-B 131-3R750-B 131-3R850-B TFA1 TFB 0 95 () () 0 95 () () 0 95 () () 0 95 () () (3) (3) (3) (3) (3) (3) () () 0 55 () () 0 55 () () 0 55 () () (5) (5) RWR RWC 10 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

121 Motor Cable Length Restrictions Tables Appendix A Table 51 - PowerFlex 755 Floor Mount Drives, 80V Shielded/Unshielded Cable Meters (Feet) (continued) Drive Rating No Solution Reactor Only Reactor and Damping Resistor Reactor Resistor Available Options Frame Hp khz 1000V 100V 188V 1600V 1000V 100V 188V 1600V 1000V 100V 188V 1600V Cat. No. Ohms Watts 10 (1) (50) (50) (50) 76. (50) (50) 76. (50) (50) x 3 x 131-3R850-B 131-3R850-B (1) Frame 9 and Frame 10 drives require two or three parallel reactors to match drive amp rating. The resistor ratings are per phase values for each reactor. () Resistor specification is based on two parallel cables per phase. (3) Resistor specification is based on three parallel cables per phase. () Resistor specification is based on four parallel cables per phase. (5) Resistor specification is based on five parallel cables per phase. (6) Resistor specification is based on six parallel cables per phase (5) (5) (6) (6) TFA1 TFB RWR RWC Table 5 - PowerFlex 755 Floor Mount Drives, 600V Shielded/Unshielded Cable Meters (Feet) Drive Rating No Solution Reactor Only Reactor and Reactor Resistor Available Options Damping Resistor Frame HP khz 188V 1850V 188V 1850V 188V 1850V Cat. No. Ohms Watts TFA1 TFB RWR RWC 8 continued (50) 16 (550) 16 (550) 16 (550) 16 (550) 16 (550) (650) RB00-B 131-3RB00-B 131-3R500-B 131-3R500-B 131-3R600-B () () () () () () () () Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01 11

122 Appendix A Motor Cable Length Restrictions Tables Table 5 - PowerFlex 755 Floor Mount Drives, 600V Shielded/Unshielded Cable Meters (Feet) (continued) Drive Rating No Solution Reactor Only Reactor and Reactor Resistor Available Options Damping Resistor Frame HP khz 188V 1850V 188V 1850V 188V 1850V Cat. No. Ohms Watts TFA1 TFB RWR RWC (1) 950 (1) 1000 (1) 1100 (1) 100 (1) 53.3 (175) 53.3 (175) 53.3 (175) 53.3 (175) 53.3 (175) 53.3 (175) 137. (50) 137. (50) 137. (50) 137. (50) 131-3R750-B R850-B R850-B 13. X R500-B X R500-B X R600-B x R750-B x R850-B () () (3) (3) (3) (3) 0 80 (3) (3) 0 80 (3) (3) 0 80 (3) (3) 0 70 () 0 10 () (5) (5) (1) Some Frame 9 and all Frame 10 drives require two reactors to match drive amp rating. The resistor ratings are per phase values for each reactor. () Resistor specification is based on two parallel cables per phase. (3) Resistor specification is based on three parallel cables per phase. () Resistor specification is based on four parallel cables per phase. (5) Resistor specification is based on five parallel cables per phase. 1 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

123 Motor Cable Length Restrictions Tables Appendix A Table 53 - PowerFlex 755 Floor Mount Drives, 690V Shielded/Unshielded Cable Meters (Feet) Drive Rating No Solution Reactor Only Reactor and Damping Resistor Reactor Resistor Available Options Frame kw khz 188V 1850V 188V 1850V 188V 1850V Cat. No. Ohms Watts TFA1 TFB RWR RWC 8 9 continued (1) 800 (1) 900 (1) (50) 76. (50) 76. (50) 76. (50) 76. (50) 76. (50) 76. (50) 76. (50) 76. (50) 76. (50) 76. (50) 76. (50) RB00-C RB00-C R500-C R500-C R500-C R600-C R750-C R750-C R850-C 3.8 x 131-3R500-C 3.8 x 131-3R500-C 3.8 x 131-3R600-C () () () () () () () () () () () () (3) (3) 0 65 (3) (3) 0 65 (3) (3) 0 65 (3) (3) Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01 13

124 Appendix A Motor Cable Length Restrictions Tables Table 53 - PowerFlex 755 Floor Mount Drives, 690V Shielded/Unshielded Cable Meters (Feet) (continued) Drive Rating No Solution Reactor Only Reactor and Reactor Resistor Available Options Damping Resistor Frame kw khz 188V 1850V 188V 1850V 188V 1850V Cat. No. Ohms Watts TFA1 TFB RWR RWC (1) 100 (1) (50) 76. (50) 3.8 x 131-3R600-C 3.8 x 131-3R750-C 0 80 () () 0 80 () () (1) Some Frame 9 and all Frame 10 drives require two reactors to match drive amp rating. The resistor ratings are per phase values for each reactor. () Resistor specification is based on two parallel cables per phase. (3) Resistor specification is based on three parallel cables per phase. () Resistor specification is based on four parallel cables per phase PLUS II and IMPACT Drives Table PLUS II/IMPACT Drives, V Meters (Feet) Drive Frame A1 Drive kw (Hp) Motor kw (Hp) 0.37 (0.5) 0.37 (0.5) 0.75 (1) 1. (1.5) 0.75 (1) 0.37 (0.5) 1. (1.5) 0.75 (1) 0.37 (0.5) To increase the distance between the 1336 PLUS II and IMPACT drives and the motor, some device (RWR or terminator) needs to be added to the system. Shaded distances are restricted by cable capacitance charging current. No External Devices (1) with 10-TFB Term. (1) with 10-TFA1 Terminator (1) Reactor at Drive (1)() Motor Motor Motor Motor A B R/L (1600V) A or B 139 A B 139 A B or 139 Any Cable Any Cable 33.5 (110) 33.5 (110) 33.5 (110) 33.5 (110) 33.5 (110) 33.5 (110) Any Cable 11.3 (375) Any Shld (3) Unshld Any Cable () Cable Use 10-TFA1 Shld.(3) Unshld Shld.(3) Unshld Any Cable Any Cable.9 (75).9 (75).9 (75).9 (75).9 (75).9 (75) Any Cable 1 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

125 Motor Cable Length Restrictions Tables Appendix A Table PLUS II/IMPACT Drives, V Meters (Feet) (continued) Drive Frame A 1.5 (). (3) A3 3.7 (5) A B C D E F G Drive kw (Hp) (7.5-0) 11- (15-30) 30-5 (X0-X60) 5-11 (60-X150) (150-50) (50-50) (X50-600) Motor kw (Hp) 1.5 () 1. (1.5) 0.75 (1) 0.37 (0.5). (3) 1.5 () 0.75 (1) 0.37 (0.5) 3.7 (5). (3) 1.5 () 0.75 (1) 0.37 (0.5) (7.5-0) 11- (15-30) 30-5 (0-60) 5-11 (60-150) (150-50) (50-50) (50-600) No External Devices (1) with 10-TFB Term. (1) with 10-TFA1 Terminator (1) Reactor at Drive (1)() Motor Motor Motor Motor A B R/L (1600V) A or B 139 A B 139 A B or 139 Any Cable Any Cable 53.3 (175) 53.3 (175) 53.3 (175) Any Cable 11.3 (375) 11.3 (375) 11.3 (375) 11.3 (375) 11.3 (375) 11.3 (375) 11.3 (375) 11.3 (375) 11.3 (375) 11.3 (375) 11.3 (375) 11.3 (375) 11.3 (375) 11.3 (375) 11.3 (375) 11.3 (375) 11.3 (375) 11.3 (375) Any Shld (3) Unshld Any Cable () Cable Shld.(3) Unshld Shld.(3) Unshld Any Cable Use 10-TFB Any Cable.9 (75).9 (75).9 (75).9 (75).9 (75).9 (75).9 (75).9 (75).9 (75).9 (75).9 (75).9 (75).9 (75) 76. (50) (1) Values shown are for nominal input voltage, drive carrier frequency of khz or as shown and surrounding air temperature at the motor of 0 C. Consult factory regarding operation at carrier frequencies above khz. Multiply values by 0.85 for high line conditions. For input voltages of 380, 00 or 15V AC, multiply the table values by 1.5, 1.0 or 1.15, respectively. () These distance restrictions are due to charging of cable capacitance and can vary from application to application. (3) Includes wire in conduit. () A 3% reactor reduces motor and cable stress but can cause a degradation of motor waveform quality. Reactors must have a turn-turn insulation rating of 100V or higher. Any Cable Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01 15

126 Appendix A Motor Cable Length Restrictions Tables Table PLUS II/IMPACT Drives, 600V Meters (Feet) Drive Frame A C D E F G Drive kw (Hp) 0.75 (1) 1.5 (). (3) 3.7 (5) (7.5-0) (5-60) (75-15) 11- (150-X300) (350-00) -8 ( ) Motor kw (Hp) No External Devices (1) with 10-TFB Terminator (1) with 10-TFA1 Terminator (1) Reactor at Drive (1) (3) Motor (NR = not recommended) Motor (NR = not recommended) Motor (NR = not recommended) Motor A B 139R/L () A B 139R/L () A B 139R/L () A B 139R/L () Any Cable Any Cable Any Cable 0.75 (1) NR NR NA NR 0.37 (0.5) NR NR NA NR 1.5 () NR NR NA NR 1. (1.5) NR NR NA NR 0.75 (1) NR NR NR 0.37 (0.5) NR NR NR. (3) NR NR NA NR 1.5 () NR NR NA NR 0.75 (1) NR NR NR 0.37 (0.5) NR NR NR 3.7 (5) NR NR NA NR. (3) NR NR NA NR 1.5 () NR NR NR 0.75 (1) NR NR NR 0.37 (0.5) NR NR NR (7.5-0) (5-60) (75-15) 11- (150-X300) (350-00) -8 ( ) NR NR NR NR NR NR 9.1 (30) 9.1 (30) 9.1 (30) 9.1 (30) 9.1 (30) 9.1 (30) Any Cable Any Cable (1) Values shown are for nominal input voltage and drive carrier frequency of khz. Consult factory regarding operation at carrier frequencies above khz. () When used on 600V systems, 139R/L motors have a corona inception voltage rating of approximately 1850V. (3) A 3% reactor reduces motor and cable stress but can cause a degradation of motor waveform quality. Reactors must have a turn-turn insulation rating of 100V or higher. Any Cable (1100) NR (1100) NR (1100) NR (1100) NR (1100) NR (1100) NR (1100) NR (1100) NR (1100) NR (1100) NR (1100) NR (1100) NR (1100) NR (1100) NR (1100) NR NR NR NR NR NR NR Any Cable Any Cable Any Cable Any Cable Any Cable Any Cable Not Recommended 16 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

127 Motor Cable Length Restrictions Tables Appendix A 1305 Drives This section lists motor cable data for 1305 drives. Table Drives, 80V, No External Devices at Motor Meters (Feet) Drive Hp (80V) Motor Hp (80V) (80V) Using a Motor with Insulation V P-P Type A Type B 139R/L Any Cable Any Cable Shielded Cable Unshielded Cable Maximum Carrier Frequency khz khz khz khz High-line Derate Multiplier (30) (30) (30) (30) (30) (30) (30) (30) (30) 9.1 (30) 76. (50) (30) (30) (30) 68.6 (5) (30) (30) 5.7 Table Drive, 80V with Devices at Motor Meters (Feet) Drive Hp (60V) Motor Hp (60V) Reactor at the Drive (1) Using a Motor with Insulation V P-P With 10-TFB Terminator Using a Motor with Insulation VP-P (NR = not recommended) With 10-TFA1 Terminator Using a Motor with Insulation VP-P (NR = not recommended) Type A Type B or 139R/L Type A or Type B Type A Type B Any Cable Shielded Unshielded Shielded Unshielded Shielded Unshielded Shielded Unshielded Maximum Carrier Frequency khz khz khz khz khz khz khz khz khz High-line Derating Multiplier (50) NR NR (50) 99.1 (35) (50) 99.1 (35) (50) 99.1 (35) (50) 99.1 (35) (50) NR NR (50) 99.1 (35) (50) 99.1 (35) (50) 99.1 (35) 15. (50) 76. (50) 16 (550) NR NR (50) 99.1 (35) (50) 99.1 (35) (50) 68.6 (5) NR NR (50) (50) NR NR 76. (50) 76. (50) (50) 5.7 NR NR NR NR NR NR (1) IMPORTANT: A 3% reactor reduces motor stress but can cause a degradation of motor waveform quality. Reactors must have a turn-to-turn insulating rating of 100V or higher. Reactors are not recommended for lightly loaded applications because over voltage trips can result at low output frequencies. Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01 17

128 Appendix A Motor Cable Length Restrictions Tables 160 Drives This section lists motor cable data for 160 drives. Table Drives, 80V Meters (Feet) V Ratings.0 kw (5 Hp). kw (3 Hp) 1.5 kw ( Hp) 0.75 kw (1 Hp) 0.55 kw (0.75 Hp) 0.37 kw (0.5 Hp) Motor Insulation Rating - Motor Cable Only RWR at Drive Reactor at Motor VoltsP-P Shielded Unshielded Shielded Unshielded Shielded Unshielded (5) 6.1 (0) (55) 99.1 (35) (90) (55) (55) 19.5 (5) (55) 1.8 (75) (55) (55) (55) 68.6 (5) 76. (50) (90) (55) 99.1 (35) 19.5 (5) (55) (55) (55) (5) 99.1 (35) (90) 19.5 (5) 19.5 (5) 137. (50) (5) 16.6 (50) (55) 99.1 (35) 99.1 (35) (15) 99.1 (35) 137. (50) (35) (5) (15) (5) 7. (90) 19.5 (5) 19.5 (5) (15) 5.9 (180) 19.5 (5) (5) Table Drive, 0V and 80V Cable Charging Current Meters (Feet) 80V Ratings.0 kw (5 Hp). kw (3 Hp) 1.5 kw ( Hp) 0.75 kw (1 Hp) 0.55 kw (0.75 Hp) 0.37 kw (0.5 Hp) khz Motor Cable Only RWR at Drive (NR = not recommended) Reactor at Motor Shielded (1) Unshielded Shielded (1) Unshielded Shielded (1) Unshielded 19.5 (5) 137. (50) (75) NR NR 137. (50) (360) 85.3 (80) 11.3 (375) (75) 8 NR NR 16 (550) (75) 16 (550) (75) (35) NR NR 11.3 (375) 19.5 (5) 68.6 (5) 68.6 (5) 11.3 (375) 19.5 (5) 68.6 (5) 11.3 (375) (50) 11.3 (375) NR NR 68.6 (5) 5.9 (180) 5.9 (180) 11.3 (375) 5.9 (180) 5.9 (180) 5.9 (180) 11.3 (375) 5.9 (180) (180) NR NR 5.9 (180) 99.1 (35) 99.1 (35) (35) NR 0V Ratings No Reactor RWR at Drive Reactor at Motor 0.37 to.0 kw Shielded (1) Unshielded Shielded (1) Unshielded Shielded (1) Unshielded (0.5 to 5 Hp) through 8 khz (55) NR NR (55) (1) When you use shielded cable at lightly loaded conditions, cable length recommendations for drives rated 0.75 kw (1 Hp) and below are 61 m (00 ft). 18 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

129 Motor Cable Length Restrictions Tables Appendix A Reflected Wave Reduction Guidelines (for catalog number 131-RWR) Follow these guidelines for catalog number 131-RWR reflected wave reduction solution: Figure 3 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 1). Figure 36 is for single inverter drives that require parallel reactors because the drive amp rating exceeds the rating of the largest available reactor (PowerFlex 700S Frame 13). Configurations shown in Figure 3 and Figure 36 can be used for single inverter drives with single or parallel cables, and single-motor or multimotor applications. The configuration shown in Figure 35 is used with dual inverter drives with single or parallel cables, and single-motor or multi-motor applications. Filter (RWR or L-R) must be connected at drive output terminals, less than m (5 ft) from the drive. See the lead length tables for output reactor and resistor selection. The resistor specification is based on the number of parallel cables used. For PowerFlex 700H and 700S Frame 1 drives and some PowerFlex 700S Frame 13 drives, two reactors are required. In this case, the resistor ohms and watts ratings are values per phase for each reactor (see lead length tables for output reactor selection). Resistor must be connected to reactor with 150 C (30 F) wire. Select wire gauge based on rated resistor power from the lead length tables. Recommended cables include XLPE, EPR, and Hypalon. Maximum total cable distance for resistor wires is 6.1 m (0 ft) or 3 m (9.8 ft) per side. Figure 3 - Filter Wiring for Single Inverter Drive AC Drive Catalog Number 131-RWR Output Reactor U V W Cable Motor R Damping Resistor Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01 19

130 Appendix A Motor Cable Length Restrictions Tables Figure 35 - Filter Wiring for Dual Inverter Frame 1 Drive L-R Filter Output Reactor AC Drive U1 R V1 W1 U Damping Resistor Cable Motor V L-R Filter W Output Reactor R Damping Resistor 130 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

131 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 V W Damping Resistor L-R Filter Output Reactor Cable Motor R Damping Resistor Rockwell Automation Publication DRIVES-IN001M-EN-P - March

132 Appendix A Motor Cable Length Restrictions Tables Notes: 13 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

133 Glossary Ambient Air Armored Capacitive Coupling CIV (Corona Inception Voltage) Common Mode Core Common Mode Noise Conduit Damp Discrete Dry dv/dt EIA Fill Rates Fixed Geometry Air around any equipment cabinet. See surrounding air for more detail. A fixed geometry cable that has a protective sheath of continuous metal. Current or voltage that is induced on one circuit by another because of their close physical proximity. For drive installations it is generally seen in two areas: Coupling between motor leads of two drives, such that the operating drive induces voltage onto the motor leads (and thus the motor) of a nonoperating drive. Coupling between the conductors or shields of motor leads that creates a requirement for more current than the motor itself demands. 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. A ferrite bead or core that can be used to pass control, communications or motor leads through to attenuate high frequency noise. Catalog number/part number 131-Mxxx. Electrical noise, typically high frequency, that is imposed on the ground grid, carriers in an electrical system. Conductive ferrous electrical metal tubing used to contain and protect individual wires. Wet locations per U.S. NEC or local code. Individual, hard-wired inputs or outputs, typically used for control of the drive (start, stop, and so on). Dry locations per Per NEC Article 100 or local code. The rate of change of voltage over time. Electronic Industries Alliance The maximum number of conductors allowed in a conduit, as determined by local, state or national electrical code. Cable whose construction fixes the physical position of each conductor within the overall coating, usually with filler material that prevents individual conductors from moving. Rockwell Automation Publication DRIVES-IN001M-EN-P - March

134 Glossary IGBT mil MOV NEC Peak Cable Charging Current PVC RC Network RC Snubber Circuit RWR Shielded Signal STP Cable Surrounding Air Temperature TIA Terminator THHN Insulated gate bi-polar transistor. The typical power semi conductor device used in most PWM AC drives today inches Metal oxide varistor United States National Electric Code NFPA70 The current required to charge capacitance in motor cable. This capacitance has various components: conductor to shield or conduit conductor to conductor motor stator to motor frame Polyvinyl chloride (typically thermoplastic) An electric circuit composed of resistors and capacitors driven by a voltage or current source. RC circuits can be used to filter a signal by blocking certain frequencies and passing others. Resistor-capacitor snubber circuit (see RC Network) Reflected waver reducer, an RL network mounted at or near the drive, used to reduce the amplitude and rise time of the reflected wave pulses. Catalog number 10-RWR-09-B or 10-RWR-09-C. Cable containing a foil or braided metal shield surrounding the conductors. Usually found in multi-conductor cable. Use a shield coverage of at least 75%. Individual hard wired analog inputs or outputs, typically used to issue reference commands or process information to or from the drive. Shielded twisted-pair cable. 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. Telecommunications Industry Association A resistor capacitor (RC) network mounted at or near the motor, used to reduce the amplitude and rise time of the reflected wave pulses. Catalog number 10-TFxx. Thermoplastic high heat-resistant nylon-coated. A U.S. a designation for a specific insulation material, temperature rating, and condition of use (suitable for dry and damp locations) for electrical wire and cable. 13 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

135 Glossary THWN Unshielded UTP Wet XHHW- XLPE UL 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. Cable containing no braided or foil sheath surrounding the conductors. Can be multi-conductor cable or individual conductors. Unshielded twisted-pair cable. Locations with moisture present see Damp. Cross-linked polyethylene high heat-resistant water-resistant. A U.S. designation for a specific insulation material, temperature rating, and condition of use (wet locations) for electrical wire and cable. Cross-linked polyethylene. Underwriters Laboratories Rockwell Automation Publication DRIVES-IN001M-EN-P - March

136 Glossary Notes: 136 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

137 Index Numerics drive Impact PLUS II Plus II/Impact drive PLUS II/Impact drive, 600V drive, cable charging current 18 A AC line 8 AC line impedance recommendations Bulletin 1305 drives 31 Bulletin 1336 drives 1 Bulletin 160 drives 30 PowerFlex drives 31 PowerFlex 0 drives 3 PowerFlex 00 drives 33 PowerFlex 55 drives 3 PowerFlex 70 drives 35 PowerFlex 700/700S drives 36 PowerFlex 753/755 drives 38 analog signal cable 1 antiphase grounded (neutral) system 6 arching between contacts 77 armored cable 17 containing common mode Noise 76 B bearing current 80 best practices, grounding 57 B-phase grounded 5 brake module mounting distance 65 brake solenoid, noise 77 braking chopper 8 built-in inductors 9 C cable analog signal 1 armored 17 charging current 81 connectors 60 containing common mode noise 76 discrete drive I/O 1 encoder 1 European-style 19 exterior cover 11 inductance 77 input power 19, 55 length 0 length restrictions 81 material 11 recommended 10, 1 shielded 16 shields 55 trays 68 types 11, 17 unshielded 15 unshielded definition 81 capacitive current cable length recommendations 18 capacitors, common mode 5 chopper modules 8 circuit resonance 75 clamp, shield termination 69 coldflow condition 7 common DC bus configurations 6 common mode noise armored cable 76 attenuate 76 capacitors 5 causes 75 chokes 76 conduit 76 containing 76 ferrite core 76 motor cable length 76 return path 76 shielded cable 76 communications ControlNet 3 Data Highway DeviceNet Ethernet 3 remote I/O RS-3/RS-85 serial concentricity, insulation 1 conductor, termination 71 conductors 13 Rockwell Automation Publication DRIVES-IN001M-EN-P - March

138 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 5 control terminal 71 control wire 1 ControlNet 3 corona 73 corona inception voltage 7 cumulative ground current 7 D Data Highway DC bus wiring guidelines 6 Delta/Delta with Grounded Leg 6 Delta/Wye with Grounded Wye 5 DeviceNet DH+ dielectric constants 73, 7 discrete drive I/O, cable 1 distribution Delta/Delta with Grounded Leg 6 Delta/Wye with Grounded Wye 5 high resistance ground 7 TN-S five-wire system 8 ungrounded secondary 7 documentation 9 E electrical noise 75 electromagnetic interference (EMI) causes 77 mitigating 77 preventing 77 EMC, installation 58 EMI caused by fluorescent lamps 80 EMI coupling 76 encoder cable 1 Encompass partners 10 website 10 European-style cable 19 F filter, RFI 50 fluorescent lamps and EMI 80 G gauge 13 geometry 1 glands 60 ground current, cumulative 7 Grounded Delta/Delta 6 Delta/Wye 5 grounding 9 acceptable practices 53 best practices 57 building steel 9 connections 61 effective practices 5 fully grounded system 53 high resistance system 5 motors 50 optimal practices 5 PE 50 practices 53 RFI filter 50 safety 9 TN-S fivewwire 50 ungrounded 5 grounding practices 5 grounds, noise related 51 I I/O cable, discrete drive 1 impedance 8 equations 9 multiple drives 3 reactor 8 inductive loads, noise 77 inductors, built in 9 input power cables 19 inputs, isolated 55 installation best practices 57 EMC-specific 58 layout 58 insulation 11, 1, 19, 0, 1, 67, 71, 73 insulation degradation 73 intended audience 9 isolation transformer 5 L layout, installation 58 leg-to-leg voltage 50 leg-to-neutral voltage 50 length common mode noise 76 motor cable 0 restrictions 7 length restrictions 81 lighting, noise Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

139 Index line impedance AC line impedance 8 adding line reactor or transformer for lightning strikes 8 power interruptions 8 transformer is too large 8 voltage dips 8 voltage spikes 8 for drives with built-in inductors 9 for drives without built-in inductors 9 multiple drives 3 M material, cable 11 mitigating transient interference examples 79 mode capacitors, common 5 moisture 1, 7, 7 motor 139R/L V 81 brake solenoid noise 77 grounding 50 type A 81 type B 81 motor bearing damage due to bearing currents 80 due to electric discharge machining 80 motor brake solenoid, noise 77 motor cable length 0 motor cable length restrictions Drive, 80V with devices at motor Drive, 80V, no devices at motor PLUS II/IMPACT Drive, V PLUS II/IMPACT Drive, 600V Drive, 0V and 80V Drive, 80V 18 cross reference table 83 PowerFlex, 00V 8 PowerFlex, 80V 8 PowerFlex 0, 00V 86 PowerFlex 0, 80V 86 PowerFlex 0, 600V 87 PowerFlex 00, 00V 88 PowerFlex 00, 80V 89 PowerFlex M, 00V 85 PowerFlex M, 80V 85 PowerFlex 55, 00V 90 PowerFlex 55, 80V 91 PowerFlex 55, 600V 9 PowerFlex 70 (standard/enhanced), 00V 93 PowerFlex 70 (standard/enhanced), 80V 95 PowerFlex 70 (standard/enhanced), 600V 97 PowerFlex 700 (standard/vector), 00V 93 PowerFlex 700 (standard/vector), 80V 95 PowerFlex 700 (standard/vector), 600V 97 PowerFlex 700 (standard/vector), 690V 98 PowerFlex 700H, 00V 98 PowerFlex 700H, 80V 99 PowerFlex 700H, 600V 100 PowerFlex 700H, 690V 100 PowerFlex 700L with 700S Control, 00V 10 PowerFlex 700L with 700S Control, 80V 10 PowerFlex 700L with 700S Control, 600V 103 PowerFlex 700L with 700S Control, 690V 103 PowerFlex 700L with 700VC Control, 00V 101 PowerFlex 700L with 700VC Control, 80V 101 PowerFlex 700L with 700VC Control, 600V 101 PowerFlex 700L with 700VC Control, 690V 10 PowerFlex 700S, 00V 10 PowerFlex 700S, 80V 105 PowerFlex 700S, 600V 107 PowerFlex 700S, 690V 108 PowerFlex 753 and 755, 00V 109, 118 PowerFlex 753 and 755, 80V 111, 10 motor starters, noise 77 motors, noise 77 mounting 57 MOV circuit 5 MOV surge protection 5 multiple drives line impedance 3 reactor 3 multiple equipment in common enclosure 65 Rockwell Automation Publication DRIVES-IN001M-EN-P - March

140 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 7 ozone production 73 P parasitic inductance 6 pigtail termination 70 power wire 19, 1, 55, 68, 71, 76 power cables, input 19 power distribution 5 Delta/Delta with Grounded Leg 6 Delta/Wye with Grounded Wye 5 high resistance ground 7 TN-S five-wire system 8 ungrounded secondary 7 power distribution schemes 5 power scheme types fully grounded 5 high resistance ground 5 ungrounded 5 power terminals 71 barrier strip 71 barrier strips 71 cage clamps 71 crimp lugs 71 studs 71 precautions 10 protection MOV surge 5 R radiated noise 58 RC networks 78 RC snubber circuit 8 reactor, multiple drives 3 recommended cable design 1 recommended documentation 9 redundant ground paths 50 reflected wave 73 effects on wire types 73 length restrictions 7 motor protection 7 reflected wave phenomenon 73 reflected wave transient voltage 73 regenerative unit 6 relays, noise 77 remote I/O resistance, ground 7 RFI filter grounding 50 routing 63 S safety grounding 9 safety grounds building steel 9 grounding PE or ground 50 safety grounds, grounding 9 secondary, ungrounded 7 serial (RS3/85) shielded cables grounding 69 splicing 55 shields cable 16, 55 termination 69 signal analog cable 1 terminals 7 wire 1 sinusoidal voltage 73 solenoids, noise 77 spacing wiring 63, 6 spacing notes 6 splice shielded cables 55 standard installation 57 stray capacitance 77 suppression, noise contracts 77 inductive loads 77 motor starters 77 motors 77 relays 77 solenoids 77 suppressor 5 surge protection MOV 5 surge suppression 5 switch contacts noise Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

141 Index system configuration Delta/Delta with Grounded Leg 6 Delta/Wye with Grounded Wye 5 high resistance ground 7 TN-S five-wire system 8 ungrounded secondary 7 T TB (terminal block) control 71 power 71 signal 7 temperature 1 termination conductor 71 control terminal 71 power terminals 71 shield 69 shield via pigtail (lead) 61 signal terminals 7 via cable clamp 70 via circular clamp 69 via pigtail (lead) 70 TN-S five-wire systems 8, 50 transient interference 77 causes 77 mitigate with diode 78 mitigate with suppressor 78 mitigating 78 suppression 77 transient line protection 5 wire/cable types 11 armored cable 17 conductors 13 European-style cable 19 exterior cover 11 gauge 13 geometry 1 insulation thickness 1 material 11 reflected wave effects 73 shielded cable 16 temperature rating 1 unshielded cable 15 wiring category definitions 63 routing 63 spacing 63 spacing notes 6 Z zero cross switching 77 U ungrounded secondary 7 ungrounded system example 5 unshielded cable 15 V varistors 5, 78 voltage reflection 73 voltage surge protection 5 W wire control 1 insulation 11, 1, 19, 0, 1, 67, 71, 73 power 19, 1, 55, 68, 71, 76 signal 1 wire routing antennas 67 loops 67 noise 67 within a cabinet 65 within conduit 66 wire, recommended 10 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01 11

142 Index 1 Rockwell Automation Publication DRIVES-IN001M-EN-P - March 01

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144 Rockwell Automation Support Rockwell Automation provides technical information on the Web to assist you in using its products. At you can find technical and application notes, sample code, and links to software service packs. You can also visit our Support Center at for software updates, support chats and forums, technical information, FAQs, and to sign up for product notification updates. In addition, we offer multiple support programs for installation, configuration, and troubleshooting. For more information, contact your local distributor or Rockwell Automation representative, or visit Installation Assistance If you experience a problem within the first hours of installation, review the information that is contained in this manual. You can contact Customer Support for initial help in getting your product up and running. United States or Canada Outside United States or Canada Use the Worldwide Locator at or contact your local Rockwell Automation representative. New Product Satisfaction Return Rockwell Automation tests all of its products to help ensure that they are fully operational when shipped from the manufacturing facility. However, if your product is not functioning and needs to be returned, follow these procedures. United States Outside United States Contact your distributor. You must provide a Customer Support case number (call the phone number above to obtain one) to your distributor to complete the return process. Please contact your local Rockwell Automation representative for the return procedure. Documentation Feedback Your comments will help us serve your documentation needs better. If you have any suggestions on how to improve this document, complete this form, publication RA-DU00, available at Rockwell Automation maintains current product environmental information on its website at Rockwell Otomasyon Ticaret A.Ş., Kar Plaza İş Merkezi E Blok Kat:6 375 İçerenköy, İstanbul, Tel: +90 (16) Publication DRIVES-IN001M-EN-P - March 01 Supersedes Publication DRIVES-IN001L-EN-P - February 013 Copyright 01 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.