Measurement and Instrumentation
Technical
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
applications ranging from motion control to
commercial flow/pumping. VFDs, also known
as adjustable- speed drives or variable-speed
drives, require special considerations to properly
install and operate the drive system, and for
nearby systems to properly operate. The VFD’s
operation impacts these systems’ longevity and
reliability. This article will examine the motor-
supply cable’s impact on VFDs and surrounding
equipment, and provide fundamental guidelines
for their installation and design.
Evaluation of cable types used for VFDs
To better understand the variables and develop
a guide for cable selection, we studied the
most commonly recommended cables for
VFD applications in both a lab and working
application. We didn’t examine some wiring
methods, such as THHN building wire in conduit,
because their use has been shown in other
studies to have detrimental effects [1, 2].
The exception was PVC-nylon insulated and
PVC-jacketed tray cables. These cables are
the most commonly installed industrial control
cables, and they are often misapplied in VFD
applications. The PVC-Nylon designs (see
Fig. 1: PVC-nylon/PVC foil shield type TC cable designs
(top) and PVC-nylon/PVC type TC cable designs
(bottom) were evaluated in a study of the most
commonly recommended cables for
variable-frequency drives.
EngineerIT - July 2009 29
How to evaluate
VFD cable parameters
by Brandon L Phillips and Eric J Bullington, Belden, USA
Fig. 1) were evaluated in both unshielded and were available. In addition to other benefits,
foilshielded versions. Other cables evaluated such as reduced capacitance, more closely
were: matching impedance can improve motor life.
• XLP insulated, foil/braid (85%) shielded, PVC Fig. 7 lists the observed line-to-line peak motor
jacketed cable designed for VFD applications terminal voltages and the impedance of the
(see Fig. 2). cables under test. The voltage measurements
• XLPE insulation (0,045-in.wall) 100% Foil +85%
tinned copper braid shield
• XLP insulated, continuously welded,
aluminium-armoured, PVC-jacketed cable
designed for VFD applications (see Fig. 3).
• XLP insulated, dual-copper tape shielded,
PVC-jacketed cable designed for VFD
applications (see Fig. 4).
Fig. 5 illustrates the application. The cables
were used to interconnect the VFD to the AC
motor(s). All testing was conducted using
Fig. 2: XLP insulated, foil/braid shielded, PVC-jacketed
a current generation, IGBT-based, 480 V,
cables for VFD applications were also
5 hp (3,5 kW), AC VFD; an inverter duty-rated AC
part of the study.
motor; and relevant lab equipment, such as
an LCR meter used to characterise the cables
and an oscilloscope used to make voltage
measurements.
Cable design impact on motor and cable life
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
impedance. A cable with such high characteristic
impedance would require conductor spacing
Fig. 4: The fifth type of cable examined in the study
in excess of several metres; such a cable would was XLP insulated, dual-copper tape shielded,
be both impractical and very expensive, if it PVC-jacketed cable.
were taken using approx. 40 m. cable lengths.
Fig. 7 lists typical impedance values for #12
AWG circuit conductors and is based on actual
data. Impedance is influenced by the geometry
and materials used to manufacture the cable.
The characteristic impedance of the cable is
calculated using the formula:
ZC = √L/C
Fig. 5: This schematic shows the application used for the study. The cables are used to interconnect the
Note the inversely proportional relationship VFD to the AC motor(s). All testing used a current generation, IGBT-based, 480 V, 3,68 kW,
between the cable’s impedance and the peak AC VFD; an inverter duty-rated AC motor; and relevant lab equipment.
motor terminal voltage. The cables with higher
impedance tended to result in lower peak
motor terminal voltages. The cable design for
impedance also impacts the cable’s useful life.
Lower voltages across the motor terminals also
expose the cable to lower voltages, increasing
the life expectancy of the cable. This also
reduces the likelihood of reaching the cable
or motor’s corona inception voltage (CIV). CIV
is the point at which the air gap between two
conductors in the cable or two windings on the
motor breaks down. If the CIV level is reached,
insulation failure can occur in the motor
windings [3]. Fig. 6: Note that the cable impedance for 0,7 kW motor/drive combinations would need to be
approximately 1000 Ω to match the corresponding motor’s impedance.
The corona discharge occurring between cable
conductors can reach very high temperatures.
If the cable’s insulation system is a plastic
As cable lengths grow, so does the magnitude In addition, users should limit the use of
material, such as PVC, corona inception
of reflected voltage. This transient overvoltage unshielded cables in conduits because the
can cause premature failure because of the
combined with the high amplitudes of current conduit is an uncontrolled path to ground for
insulation’s gradual, localised melting. For this
associated with VFDs creates a source of the noise it captures. Any equipment near the
reason alone, thermoplastic insulations should
significant radiated noise. Noise can be conduit or conduit hangers may be subject to
not be used for VFD applications.
controlled by shielding the VFD cable. an injection of this captured, common-mode
Thermoset insulation systems such as XLP noise. Therefore, unshielded cables in conduit
Relative shielding effectiveness was observed
are ideal materials for such small localised
in the study by noting the magnitude of noise aren’t a recommended method for connecting
temperature extremes because of the high
coupled to ±3 m of parallel, unshielded VFDs to motors. If radiated noise is an issue in
temperature stability they exhibit. The heat
instrumentation cable for each VFD cable an existing VFD installation, take care when
generated from possible corona forms a
type. Fig. 8 shows the results of the shielding routing instrumentation/control cables in the
thermally isolating charred layer on the insulation
effectiveness testing. The pale green/blue area. Maintain as much separation as possible
surface, preventing further degradation. All
trace in Fig. 8 shows that foil shields simply between instrumentation cables and VFD
cables used for VFDs should use a thermoset
aren’t robust enough to capture the volume of cables/ leads. We recommend a minimum of
insulation system as a precautionary measure.
30 cm for shielded instrumentation and ±1 m
noise generated by VFDs. Unshielded cables
Understanding radiated noise in VFD for unshielded instrumentation cables.
between VFDs and motors can radiate noise in
applications If the cables must cross paths, try to minimise the
excess of 80 V to unshielded communication
Radiated noise is proportional to the amount wires/cables, and in excess of 10 V to shielded amount of parallel cable in the runs, preferably
of varying electric current within the VFD cable. instrumentation cables. crossing the instrument cable perpendicularly

30 July 2009 - EngineerIT


Fig. 7: These are the observed line-to-line peak motor terminal voltages and the
impedance of the ables studies. More closely matching impedance
can improve motor life.
Fig. 8: The pale green/blue trace shows that foil shields aren’t robust enough to
capture the volume of noise generated by variable-frequency drives. Unshielded
cables between VFDs and motors can radiate noise in excess of 80 V to
unshielded communication wires/cables, and in excess of 10 V to
shielded instrumentation cables.
Fig. 9: Tests were conducted across a broad frequency spectrum above on the five
cable types to determine the ground path impedance of the shield and grounding
system of each cable. Lower impedance implies a more robust ground path and
therefore relatively lower noise coupled to the building ground. Lower-building
ground noise means reduced troubleshooting of nearby adjacent
systems and components.
32 July 2009 - EngineerIT
with the power/VFD cable. If noise issues persist, use a nonmetallic, vertical-
tray, flame-rated fibre-optic cable and media-converters or direct-
connect fibre coammunication equipment for the instrumentation circuit.
Other mitigation techniques also may be required, such as band-pass
filters/chokes, output reactors, motor terminators, and metallic barriers in
cable trays or raceways.
Impact of common mode noise in VFD applications
Noise radiating from the cable is one method for interference of
adjacent systems, but it is often easier to identify and rectify. Common-
mode noise is more difficult to diagnose because of the point of failure
in adjacent systems, but it’s often the cause and most difficult situation
to rectify. High noise levels across a broad frequency range, often from
60 Hz to 30 MHz, can capacitively couple from the motor windings to
the motor frame, and then to ground. Common-mode noise also can
capacitively couple from unshielded motor leads in a conduit to ground
via the conduit ground straps, supports or other adjacent and unintentional
grounding paths. This common-mode ground current is troublesome
because digital systems are susceptible to the high-frequency noise
generated by VFDs.
Components and systems susceptible to common-mode noise are
capacitive sensors such as proximity sensors, thermocouples signals, low-
level communication signals and encoders. Because this noise takes
the path of least resistance, it finds unpredictable grounding paths that
change and often are intermittent as humidity, temperature and load
change over time. One way to control common-mode noise is to provide
a known path to ground for the noise captured at the motor’s frame.
A low-impedance path, such as a properly designed cable ground/
shield system, can provide this noise with an easier way to get back to
the drive, other than using the building ground grid, steel, equipment,
etc. We conducted tests on the five cable types mentioned previously
to determine the ground path impedance of the shield and grounding
system of each cable. These tests were conducted across a broad
frequency spectrum (see Fig. 9). Lower impedance implies a more robust
ground path and therefore relatively lower noise coupled to the building
ground. Lower-building ground noise means reduced troubleshooting of
nearby adjacent systems and components.
The right cable is crucial
Selecting an appropriate VFD cable can improve overall drive system
longevity and reliability by mitigating the impact of reflected waves on
the overall drive system. Pay special attention to the cable’s insulation
type, impedance and shield/ground system. Cables employing a heavy
wall of thermoset insulation are recommended because of the proven
electrical benefits and improved high-temperature stability they exhibit.
Shielding systems including copper tape, combination foil/braid, and
continuous armouring types are the most appropriate shielding systems
for VFD applications because of the low impedance path they provide
for common-mode noise to return to the drive. When VFD cables are
installed in close proximity to low-level communications cables and other
susceptible devices, shielded instrumentation cable should be used. Also,
limit parallel runs of VFD cable with instrumentation cables to ±3 m or less
to reduce the likelihood of experiencing radiated noise issues.
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
Drive Technology Demands New Motor and Cable Considerations,” IEEE
Petroleum and Chemical Industry Conference, Sept.,1996.
Belden is a Rockwell Automation Encompass Partner.
Contact Jeff Sandison, Rockwell Automation, Tel 011 654-9700,
jksandison@ra.rockwell.com