EMC Cable classes

In order to properly segregate cables, these can be split into six classes, depending upon
their application, voltage or current levels, frequency of signals these carry, types of
signals these carry (like analogue or digital), components these connect to and so on.
These classes are as follows:

Class 1. These are cables that carry highly-sensitive signals like low-level analogue
signal (in mV) from transducers, instrument lines, radio receiver antenna cables, and
cables carrying high-frequency digital signals such as Ethernet. Such cables are highly
susceptible to noise and interference.

Class 2. These carry slightly-sensitive signals that are somewhat susceptible such as
ordinary analogue signals under 1MHz and of the order of 1-10V and 4-20mA. These
also include low-frequency digital signals like RS232 or RS485 and digital inputs/outputs
(I/Os) like those from limit switches, encoders and control signals.

Class 3. These are cables carrying the noise source that is slightly interfering such as low-
voltage AC distribution less than 1kV or DC power, linear power cables, control cables
for inductive loads (such as relay coils, motor brakes and contactors) where proper
transient suppression techniques like RC snubbers have been employed to control
transients at the load. These also include motor cables from output of inverter drives but
fitted with output filters as per manufacturer’s specifications.

Class 4. These are cables carrying signals from strong noise sources that are highly
interfering. These include output cables from frequency converters, inputs to and outputs
from adjustable speed motor drives, inputs to and outputs from SMPS or DC-DC
converters, cables associated with electrical welders or RF equipment (like induction
welders, wood gluers, microwave equipment and diathermy apparatus) and cables to DC
motors, to RF transmitting antennae and to unsuppressed inductive loads.

Classes 5 and 6. Class 5 cables are those that carry medium voltage, while class 6 are
those that carry high voltage.

Cable segregation
During their run in a system, cables of different classes have to be properly segregated,
that is, separated by certain minimum distance. This separation distance not only depends
on class but also on cable length. Fig. 27 shows recommended minimum segregation
distance for different classes of cables based upon a run of 30 metres, and assuming that
the cables run in close proximity to the protective earth conductor that can be a wire, a
metal tray or mounting plate that forms a local RF reference.

Fig. 27: Cable classes (dimensions in millimetres)

Accordingly, class 1 and class 2 cables must be separated by a minimum distance of
150mm (ditto for class 3 and class 4). While class 1 and class 3 and class 2 and class 4
should be separated by at least 450mm, and class 1 and class 4 by at least 600mm,
separation between class 4 and class 5 and class 5 and class 6 should be 150mm. Now,
these distances are for a cable run of less than 30 metres. For longer cables, separation
distance is multiplied by the length and divided by 30.

When cables run within a product, these must be physically segregated depending upon
their class at all times, and long parallel runs should be avoided. If that is not possible,
these should be more than 150mm apart; cable classes—as far as possible—must not
cross. If at all these have to cross, these should do so at right angles. And cables should
run as close as possible to their local RF reference or to cables carrying return signals.
Cables of the same class, when routed through the same tray or duct, should not be
twisted around one another.

Reducing common-mode coupling

When cables are routed away from the ground plane or earth, a ground loop is formed as
shown in Fig. 28. This loop acts as an antenna for stray fields causing common-mode
EMI to be coupled into the system. By the same token, the loop can also cause radiated
emission.
Fig. 28: Reducing common-mode coupling

Coupling or radiation is directly proportional to the area of the loop. In order to reduce it,
area of the loop must be reduced. This is done by routing the cable as close as possible to
the ground reference, which, in case of control panels, is the mounting plate.
Reducing differential-mode coupling

This type of coupling occurs when send and return cables are routed away from each
other. As shown in Fig. 29(a), a loop is formed between send and return paths, causing
differential-mode coupling and radiation proportional to the area of the loop.

Fig. 29: Reducing differential-mode coupling

This can be reduced by reducing the area of the loop, that is, by routing send and return
cables close to each other. Further reduction can be achieved by twisting the cables
around one another, whereby the loop area is reduced dramatically.

Cable routing in electronic control panel

Fig. 30 shows cable trunking for a control panel used for controlling a typical machine.
All components should be mounted on an unpainted mounting plate for proper grounding
connections for the modules as well as their cables. The three-phase mains comes from a
very hostile environment, which is a characteristic of shop floors, and carries signals that
can be strongly interfering. Such cables are therefore classified as class 4.
Fig. 30: Cable routing in an electronics cabinet
It is essential that these signals are filtered immediately after entering the cabinet, which
is normally achieved by a suitable line filter. The filtered cable is classified as class 3,
which then goes to the SMPS and the drive. Output of the SMPS is again classified as
class 4 since it can carry strong interference. Filter at PLC I/P converts this into a class 3
cable, which then goes to the PLC. I/O lines of PLC carry control signals that can be
slightly sensitive and, hence, are classified as class 2. Some class 2 lines from PLC go as
control cables to the drive.
As a rule, shielded cables must be used for such lines with the shield exposed and bonded
to the mounting plate through 360-degree saddle clamps. Moreover, proper distance has
to be maintained between these and nearby class 3 and class 4 cables. In Fig. 30, this
distance is shown as 300mm and 450mm, respectively; although it may be less
considering small cable lengths (remember the 300mm distance is for lines in excess of
30m).

Some I/O cables of the PLC go to the relay and contactor section, while some can also go
to MMI usually mounted on panel doors. These also must be preferably shielded, with the
shield bonded to the mounting plate at a point nearest to the PLC. For cables going to
MMI, pigtails can be used for grounding, although saddle clamps are better.

Such cables should be very close to RF reference (that is, mounting plate) as these cross
over to the front-panel door. This can be achieved only if the crossover happens along the
bonding point of the panel to the door, that is, along the bond straps that connect the
panel to the door. If possible, bond straps should be mounted along these cables or
additional bond straps should be provided along these cables. Many a time, it is observed
that these cables crossover along door hinges, which is not a good practice, since hinges
cannot be relied upon to provide a good bond.

Motor drives are the most notorious components as far as generation of conducted and
radiated emission is concerned, and are the main reasons for non compliances observed in
control panels. Most drive manufacturers give fairly-detailed information regarding the
type of cables to be used for input mains supply, drive output cable going to the motor,
frequency input cable and I/O and control cables. All these cables must be invariably
shielded.
Drive manuals also discuss cable routing to be followed, how cables are installed and
how saddle clamps and pigtails are to be used to ground the shields. Some even go to the
extent of suggesting how much tightening torque has to be applied to the screws for
proper bonding. Machine manufacturers who casually ignore these guidelines eventually
face a daunting task while complying with EMC tests.

Now, output cables of motor drives can carry strongly-interfering signals and therefore
classified as class 4. It is imperative that output and control cables of a drive are shielded
with the shield bonded to the mounting plate by a 360-degree connector or saddle clamp
at a point nearest to the drive. The shield must also be grounded at the motor end,
preferably through a 360-degree bulkhead connector at the motor terminal box.

Drive control cable, which is class 2, must be separated from output cable (class 4) by a
distance of more than 450mm and from mains cable (class 3) by more than 300mm. The
mains cable to the drive should preferably be a shielded cable with the shield bonded to
the mounting plate by a saddle clamp, and the power earth wire of the mains cable should
also be fastened under this clamp. Analogue and digital signals must have their own
separate cables; there cannot be a bigger blunder than running these as wires through the
same cable, even though these are of the same class (class 2).

Conclusion
Cable selection and routing is generally a subject of system-level EMC design, where a
large number of components are assembled to make a system. It is generally observed
that assembling all EMC-compliant components does not automatically result in a
compliant system. This is because although the components that make up the system have
been tested individually, their manufacturers do not know in what way their products
would be assembled in a system. It is the final system assembler who has to ensure
correct assembly of all components to make a compliant system. Cable selection and
routing plays a vital part in this endeavor.