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Technical
How to evaluate
VFD cable parameters
by Brandon L Phillips and Eric J Bullington, Belden, USA
VFD cables can improve overall drive system longevity and reliability by minimising the impact of reflected waves on the drive system.
Variable-frequency drives (VFD) are used in Fig. 1) were evaluated in both unshielded and were available. In addition to other benefits,
applications ranging from motion control to foilshielded versions. Other cables evaluated such as reduced capacitance, more closely
commercial flow/pumping. VFDs, also known were: matching impedance can improve motor life.
as adjustable- speed drives or variable-speed • XLP insulated, foil/braid (85%) shielded, PVC Fig. 7 lists the observed line-to-line peak motor
drives, require special considerations to properly jacketed cable designed for VFD applications terminal voltages and the impedance of the
install and operate the drive system, and for (see Fig. 2). cables under test. The voltage measurements
nearby systems to properly operate. The VFD’s
• XLPE insulation (0,045-in.wall) 100% Foil +85%
operation impacts these systems’ longevity and
tinned copper braid shield
reliability. This article will examine the motor-
• XLP insulated, continuously welded,
supply cable’s impact on VFDs and surrounding
aluminium-armoured, PVC-jacketed cable
equipment, and provide fundamental guidelines
designed for VFD applications (see Fig. 3).
for their installation and design.
• XLP insulated, dual-copper tape shielded,
Evaluation of cable types used for VFDs PVC-jacketed cable designed for VFD
To better understand the variables and develop applications (see Fig. 4).
a guide for cable selection, we studied the Fig. 5 illustrates the application. The cables
most commonly recommended cables for were used to interconnect the VFD to the AC
VFD applications in both a lab and working motor(s). All testing was conducted using
application. We didn’t examine some wiring Fig. 2: XLP insulated, foil/braid shielded, PVC-jacketed
a current generation, IGBT-based, 480 V,
methods, such as THHN building wire in conduit, cables for VFD applications were also
5 hp (3,5 kW), AC VFD; an inverter duty-rated AC
because their use has been shown in other part of the study.
motor; and relevant lab equipment, such as
studies to have detrimental effects [1, 2].
an LCR meter used to characterise the cables
The exception was PVC-nylon insulated and and an oscilloscope used to make voltage
PVC-jacketed tray cables. These cables are measurements.
the most commonly installed industrial control
cables, and they are often misapplied in VFD Cable design impact on motor and cable life
applications. The PVC-Nylon designs (see Reflected waves caused by a cable-to-motor
impedance mismatch are prevalent in all AC
VFD applications. They vary according to the
length of the cable, the rise-time of the pulse
width modulated (PWM) carrier wave, the VFD’s
voltage, and the magnitude of the impedance Fig. 3: The study also included XLP insulated,
difference between motor and cable. Because continuously welded, aluminium armoured,
cable length is mostly determined by the PVC-jacketed cable.
application, the rise times vary by VFD output
semiconductor, and the VFD voltage is driven by
the application. We are primarily discussing the
impedance of the cable relative to the motor.
Let us look at estimated motor impedance over
a range of horsepower settings (see Fig. 6.).
The cable impedance for 0,7 kW motor/drive
combinations would need to be approximately
1 kΩ to match the corresponding motor’s
Fig. 1: PVC-nylon/PVC foil shield type TC cable designs
impedance. A cable with such high characteristic
(top) and PVC-nylon/PVC type TC cable designs
impedance would require conductor spacing
(bottom) were evaluated in a study of the most Fig. 4: The fifth type of cable examined in the study
commonly recommended cables for in excess of several metres; such a cable would was XLP insulated, dual-copper tape shielded,
variable-frequency drives. be both impractical and very expensive, if it PVC-jacketed cable.
References
[1] E J Bartolucci, B H Finke, “Cable Design for PWM Variable Speed AC Drives,” IEEE
Petroleum and Chemical Industry Conference, Sept., 1998.
[2] E Bulington, S Abney, G Skibinski, “Cable Alternatives of PWM AC Drive
Applications, IEEE Petroleum and Chemical Industry Conference, Sept., 1999.
[3] S Evon, D Kempke, L Saunders, G Skibinski, “Riding the Reflected wave - IGBT
Fig. 9: Tests were conducted across a broad frequency spectrum above on the five Drive Technology Demands New Motor and Cable Considerations,” IEEE
cable types to determine the ground path impedance of the shield and grounding Petroleum and Chemical Industry Conference, Sept.,1996.
system of each cable. Lower impedance implies a more robust ground path and
Belden is a Rockwell Automation Encompass Partner.
therefore relatively lower noise coupled to the building ground. Lower-building
ground noise means reduced troubleshooting of nearby adjacent Contact Jeff Sandison, Rockwell Automation, Tel 011 654-9700,
systems and components. jksandison@ra.rockwell.com