Grounding and Cabling of the Drive System Variable Speed Drives

A
L3

L1 L2

B
PE

L1 L3
PE

PE

C
Separate protective grounding wire

L1 L3 L2

L2

Concentric Cu-shield Frequency converter PE U V W

Concentric Al/Cu-shield Frequency converter PE U V W

Fe-armour

Transformer PE

Transformer PE

Transformer PE

Frequency converter PE U V W

Factory main grounding bus

U PE

M 3~

Factory main grounding bus

U PE

M 3~

Factory main grounding bus Separate protective conductor

U PE

M 3~

Variable Speed Drives

Grounding and Cabling of the Drive System

3AFY61201998 REV B EFFECTIVE: 23.6.2005 SUPERSEDES: 11.3.1998

2005 ABB Oy. All rights reserved.

Table of contents

Table of contents .................................................................................................................................................i Chapter 1 Introduction..................................................................................................................................1-1 What this manual contains.......................................................................................................................1-1 Target audience .......................................................................................................................................1-1 General ....................................................................................................................................................1-1 Objectives of grounding ...........................................................................................................................1-1 Availability ................................................................................................................................................1-2 Bearing currents................................................................................................................1-2 The grounding structure...........................................................................................................................1-3 Chapter 2 Grounding of drive modules ......................................................................................................2-1 General ....................................................................................................................................................2-1 Chapter 3 Cabling of variable speed drives ...............................................................................................3-1 General ....................................................................................................................................................3-1 Supply ......................................................................................................................................................3-1 Transformer ...................................................................................................................................3-1 Grounded secondary (TN, TN-S)......................................................................................3-1 Floating secondary (IT) ....................................................................................................3-1 Cabling...........................................................................................................................................3-1 Low-power supply .............................................................................................................3-1 High-power supply ............................................................................................................3-3 Motor cables ............................................................................................................................................3-5 Recommended AC drive cable types for general applications ......................................................3-5 Availability ......................................................................................................................................3-6 AC drive cable types for limited use ..............................................................................................3-6 Cable routes ..................................................................................................................................3-6 Cabling of high-power frequency converter drives ........................................................................3-7 Additional grounding of motors ......................................................................................................3-8 Cable connections to be avoided.................................................................................................3-10 DC drives .....................................................................................................................................3-12 Signal cables..........................................................................................................................................3-13 PE (protective ground) vs. FE (functional ground) .....................................................................3-13 Interfacing problem of systems with dissimilar grounding ...........................................................3-14 Control cable shielding ................................................................................................................3-15 Analogue and low- voltage (SELV) digital I/O signals.....................................................3-15 Serial communication .....................................................................................................3-16 115/230 VAC digital signals ............................................................................................3-16 Shield connection............................................................................................................3-16 Cabling and insulation of tachometers, pulse encoders ..............................................................3-17 Examples of cabling system drives .............................................................................................3-18 Galvanic isolation.........................................................................................................................3-20 Cable routes ................................................................................................................................3-20 Common mode inductor ..............................................................................................................3-20 Chapter 4 Interference coupling, informative annex .................................................................................4-1 Common impedance coupling .................................................................................................................4-1 Capacitive coupling ..................................................................................................................................4-2 Inductive coupling ....................................................................................................................................4-3

Grounding and cabling of the drive system

Grounding of drive modules Electromagnetic coupling.........................................................................................................................4-4 Chapter 5 Terms and literature ....................................................................................................................5-1 Terms.......................................................................................................................................................5-1 Armour ...........................................................................................................................................5-1 Availability ......................................................................................................................................5-1 GND...............................................................................................................................................5-1 EMI ................................................................................................................................................5-1 FB ..................................................................................................................................................5-1 FE ..................................................................................................................................................5-1 PE ..................................................................................................................................................5-1 Shield.............................................................................................................................................5-1 TE ..................................................................................................................................................5-1 Literature..................................................................................................................................................5-2 EMC...............................................................................................................................................5-2 Bearing currents ............................................................................................................................5-2

ii

Grounding and cabling of the drive system

Chapter 1 Introduction
What this manual contains
This manual describes the grounding and cabling principles of variable speed drive systems. The system may be composed of parts such as a transformer, mains cable, converter, motor cable and motor. The converter may be a single drive or system drive a.c. frequency converter or a d.c. converter. Examples of proper cabling and grounding practices for low voltage systems are given. A short description of interference phenomena, terms and literature references are included at the end of the manual.

Target audience General

The manual is intended for persons involved in drive system installations and assembly. When the principles given in this manual are followed, the installation will fulfil the appropriate personal safety, electromagnetic compatibility (EMC) and availability requirements concerning grounding and cabling. Product specific instructions are given in the product manuals. The installation must always be designed and made according to applicable local laws and regulations. ABB does not assume any liability whatsoever for any installation which breaches the local laws and/or other regulations. Furthermore, if the recommendations given by ABB are not followed, the drive may experience problems that the warranty does not cover.

Objectives of grounding

Traditional grounding is based on electrical safety. It ensures personal safety in all circumstances and limits material damages due to electrical faults. For interference-free operation and long-term availability of the drive, more profound methods are needed: highfrequency grounding and equipotential ground planes on building floor, equipment enclosure and circuit board levels.

Grounding and cabling of the drive system

1-1

Grounding of drive modules

Availability
Bearing currents

Proper cabling and grounding strongly attenuates motor shaft and frame voltages that may cause high-frequency bearing currents and lead to premature bearing replacements. Two types of bearing currents are shown schematically below: highfrequency circulating current (5) and shaft grounding current (7).

INVERTER 2 1 MOTOR CABLE MOTOR 4 7 GEAR LOAD

Common mode voltage pulse

+DC

-DC

2 1 3

High frequency common mode current

High frequency shaft voltage

High frequency circulating current

PE-current

High frequency frame voltage

Shaft grounding current

1-2

Grounding and cabling of the drive system

Introduction

The grounding structure

Interference-free operation of electronics is facilitated by establishing equipotential areas on all structural levels. Building floors, equipment enclosures and circuit boards are using local ground planes on each level. The ground planes can also be mesh structures. The best result is achieved by means of a well structured grounding. It begins with ground electrodes connected to each other reliably to form a network. The electrical equipment is connected to the network of electrodes through a short wiring to minimise the impedance (Figure 1-1).
1

~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~
3

Figure 1 - 1.

Recommended configuration for ground electrodes and grounding networks. 1 Power and communications ground, as needed 2 Soil 3 Multiple, bonded ground electrodes

In buildings where the ground plane model is not carried out, a radial conductor system is used for potential equalization. This is the practice in many old buildings. A cabinet PE busbar shall be connected to factory ground only at one point if the ground electrode system is of a single electrode type and not well structured (Figure 1-2).

Grounding and cabling of the drive system

1-3

Grounding of drive modules

Figure 1 - 2.

Grounding of the single-electrode drive system.

1-4

Grounding and cabling of the drive system

Chapter 2 Grounding of drive modules

General
When assembling drive modules into a cabinet, they must be grounded for personal safety to prevent dangerous voltages under any circumstances. Connection to ground through fixing screws and the cabinet chassis is not always good enough. To ensure the continuity of the protective bonding circuit, modules must be connected to the cabinet PE busbar by a copper busbar or cable. The cross-sections must be in accordance with local regulations. From the EMC standpoint, low impedance highfrequency grounding (0.1 , 25 A) is recommended. The best result can be achieved with a flat copper braid.

Grounding and cabling of the drive system

2-1

Grounding of drive modules

2-2

Grounding and cabling of the drive system

Chapter 3 Cabling of variable speed drives

General
Cables are dimensioned on a case-by-case basis in accordance with the local regulations concerning short-circuit protection, operating voltage, permissible touch voltage appearing under fault conditions and current-carrying capacity of the cable. In addition, the cable type must support the EMC protection and availability of installed equipment. This chapter describes examples of proper cabling and grounding practices. It is necessary to follow the instructions when selecting cables with the local vendor and implementing the grounding of the system.

Supply
Transformer
Grounded secondary (TN, TN-S) A variable speed drive-dedicated transformer with static shielding between the primary and secondary is recommended. If no frequency converter input filter is used, the grounding impedance of the transformer secondary must be especially low: a at least 70 mm x 0.75 mm copper plate or at least two separate 2 50 mm cables. The distance between the cables must be at least 150 mm. If the installation specific drawings specify larger crosssections for grounding, they must be followed. The length of the grounding conductor should be as short as possible. All frequency converter input filters are not suitable for use on IT (ungrounded) systems. With unsuitable EMC filters, the system will be connected to earth potential through the EMC filter capacitors of the drive. This may cause danger or damage the unit.

Floating secondary (IT)

Cabling
Low-power supply At low currents (< 300 A) when one cable is sufficient, a shielded symmetrical multicore cable is recommended. The shield is connected to PE at both ends. When the converter incorporates an input filter, also unshielded cable can be used.

Grounding and cabling of the drive system

3-1

Cabling of variable speed drives

L1 L2 L3 N Transformer PE

L1 L2 Converter L3 N PE
Short Low inductance

L1 L2

N L3

L1 L2 L3

Factory main grounding bus

Figure 3 - 1.

Low-power supply with cable.

The reactance of a multicore cable is low enabling the longest supply cabling. With parallel multicore cables, also high currents are possible.

3-2

Grounding and cabling of the drive system

Cabling of variable speed drives

High-power supply

High-current (> 300 A) variable speed drives can be supplied either with a busbar or cable bus system. The metal conduit (shield) of the busbar system shall be connected to PE (Figure 3-2) at either one or both ends.
Metal conduit (shield) L1 L2 L3 Trans- N former PE L1 L2 Converter L3 N PE L1 L2 L3 N

Factory main grounding bus

Figure 3 - 2.

Power supply with busbars.

A cable bus system consists of parallel single-core cables for phase leads. Compared to a corresponding busbar system, a cable bus system has: better cooling due to separe conductors -> less concuctor material is needed lower reactance -> longer distances are allowed.
L1 L2 L3 Trans- N former PE L1 L2 Converter L3 N PE

Factory main grounding bus

Figure 3 - 3.

Power supply with cable bus system.

Grounding and cabling of the drive system

3-3

Cabling of variable speed drives

It is recommended to arrange the cables as shown in Figure 3-4 to achieve as equal a current distribution as possible.

L1

L2

L3

L1

L2

L3

L1

L2

L3

Figure 3 - 4.

Cable bus arrangement.

In single-core cables equipped with concentric protective shield (armour), the phase current induces voltage to the cable shield. If the shields are connected to each other at both ends of the cable, current will flow in the cable shield. In order to prevent this current and to ensure personal safety, the cable shield must be connected to PE at the feeder side only and insulated at the converter side (Figure 3-5).
L1 L2 L3 Trans- N former
PE

L1 L2 Converter L3 N PE
Concentric shield

Factory main grounding bus

Figure 3 - 5.

Shield connection of single-core cables.

3-4

Grounding and cabling of the drive system

Cabling of variable speed drives

Motor cables
Recommended AC drive cable types for general applications
To meet the EMC and availability requirements, only shielded, symmetrical, multicore cables shall be used. Exceptions to this rule are given in the product specific manuals. To be effective at high frequencies, the shield conductivity shall be at least 1/10 of the phase conductor conductivity. The effectiveness of the shield can be evaluated based on the shield inductance, which must be low and only slightly dependent on frequency. The requirements are easily met with a copper or aluminium shield/armour. The cross-section of a steel shield has to be ample and the shield helix low gradient. Galvanizing increases the highfrequency conductivity. Aluminium and copper shields are connected to PE at both ends. 360 bonding of the shield utilizes the full high-frequency capability to comply with the EMC and availability requirements. To operate as a protective conductor, the shield conductivity must be at least 50% of the phase lead conductivity. Three alternative cable types can be recommended. The first cable type is a three-core cable equipped with concentric protective copper shield. The phase wires are at an equal distance from each other and the shield, and the shield is used as a protective conductor. The cross-section of the protective copper braid or strand must be sufficient according to safety regulations. Figure 3-6. A.

Figure 3 - 6. Approved motor cable connections (A, B and C for general use. D for limited use.).

Grounding and cabling of the drive system

3-5

Cabling of variable speed drives

An equally suitable cable type, 3+3+Cu/Al-shield + possible armour, has three symmetrical conductors for protective grounding. The shield is typically a solid corrugated aluminium armour. The shield is connected to the PE bar on the frequency converter side and to the PE terminal on the motor side. Figure 3-6. B. The third cable type has a galvanized iron, coarse-pitch, stranded armour shield. The shield is connected to PE at both ends. However, a separate high-conductivity PE conductor is needed unless sufficient cross-section of copper is incorporated in the strand, as in some cables from some manufacturers. Figure 3-6. C. The length of the unshielded part of the cable should be as short as possible on the frequency converter side and at the motor junction box as specified in the drive and motor specific documentation.

Availability

The bearing current risk depends on voltages affecting across the motor bearings. Three basic types of voltages can be measured in AC drive applications: shaft end-to-end voltage, shaft voltage to ground or motor frame voltage to ground. On medium and high power motors, improper motor cabling strongly increases these voltages, thus reducing the lifetime of the motor, gearbox and driven machine bearings. On the other hand, proper cabling and 360 termination of the cable shield at both ends effectively reduce these voltages. Symmetrical, shielded cables reduce the motor frame voltage, the effect being more significant at high motor currents.

AC drive cable types for limited use

2 Cable sizes up to 10 mm and motor powers up to 30 kW 2 Unsymmetrical cables can be used up to 10 mm cable size and up to 30 kW motor power, but a shielded cable is always recommended. Foil shield is common in this power range.

Note: Using a non-shielded cable even in this motor power range may cause interference of other equipment. Motor power up to 100 kW Well-shielded (copper or aluminium shield) 4-core or 3+1 core cables can be used for up to 100 kW motor power rating (Figure 3-6. D) with potential equalization according to Figure 3-8a.

Cable routes

Cable trays shall have good electrical bonding to each other and to the grounding electrodes. Aluminium tray systems can be used to improve local equalization of potential.

3-6

Grounding and cabling of the drive system

Cabling of variable speed drives

Cabling of highpower frequency converter drives

When cabling a high-power frequency converter and motor, several conductor elements have to be used in parallel. In this case, the cabling shall be done according to Figure 3-7. Always use symmetrical cabling.

DC bus

=
U V

~
W
123

123 123

123 123

123

M 3~
Figure 3 - 7.

Symmetrical cabling of the high-power frequency converter and motor.

Grounding and cabling of the drive system

3-7

Cabling of variable speed drives

Additional grounding of motors

With motors from 100 kW upwards, a potential equalization connection between the motor frame and the machinery is sometimes needed due to the grounding conditions of the driven machinery. Potential equalization is typically needed in applications such as pumps (grounded by water) and gearboxes with central lubrication (grounded by oil pipes). As low inductance is the objective, a copper plate or strip with a cross-section of at least 70 mm x 0,75 mm is required between the motor frame and the gearbox/pump 2 frame. Alternatively, at least two separate 50 mm cables can be used. The distance between the cables must be at least 150 mm. Install the potential equalization through the shortest possible route. If protection from dirt is needed, use a plastic tube, not a metal conduit. Potential equalization has no electrical safety function. The purpose of it is purely to equalize the potentials. When the motor and the gearbox are mounted on a common steel fundament, no potential equalization is needed.
Potential equalization
Plate/strip
Cables/wires

0.75 mm 70 mm

> 150 mm min 50 mm

2

V1 U1 PE W1 3~M

Driven machinery

Figure 3-8a.

Potential equalization between the motor frame and the machinery. The purpose of this connection is to equalize the potentials. It has no electrical safety function. When the motor and the gearbox are mounted on a common steel fundament, there is no need to make the connection.

3-8

Grounding and cabling of the drive system

Cabling of variable speed drives

Large motors may have additional grounding terminals outside the terminal box. Connect them to the PE on the motor frame (Figure 38b) to ensure a proper connection between the terminal box and the frame.

Cu-cable 2 50 mm

Figure 3 - 8b.

Equalization of the potential of the motor frame and the terminal box of large motors.

Grounding and cabling of the drive system

3-9

Cabling of variable speed drives

Cable connections to be avoided

If other than the recommended cable types are used, the following rules are mostly useful. Complying with them does, however, not exclude effects of improper cabling and may void warranty. In four-core cables (one is ground), three cores are not at an equal distance from the ground wire. The ground wire must not be used as a protective conductor. The ground wire shall be connected to PE only on the frequency converter side, and it shall be isolated at the motor end. Use a separate protective conductor with a crosssectional area of at least half of the phase conductor cross-section. The power cable and the protective conductor shall be placed at least 300 mm apart (not on the same cable tray) in order to prevent inductive disturbance currents in the protective conductor (Figure 39A). This lay-out can in some countries violate the regulations. In this case, use other cable types. When a fine-pitch interlaced steel plate armour is provided, the highfrequency capability of the armour is insufficient. The armour can be terminated to PE at both ends if its conductivity is at least 1/10 of the conductivity of the phase conductor. If the conductivity is less than 1/10, leave the motor end open. Do not use the internal unsymmetrical ground wire (fourth conductor) as a protective conductor (figures 3-9.B and 3-9.C). Apply the same rules also to three-core cables. Make the potential equalization connection between the motor frame and the machinery as described on page 3-8.

Single-core cables are not suitable for motor cables!

3-10

Grounding and cabling of the drive system

Cabling of variable speed drives

A
Separate protective grounding wire PE

L1 L3 L2

B
Separate protective grounding wire PE

L1 L3 L2

C
Separate protective grounding wire PE

L1 L3 L2

Tape Fe-armour Frequency converter PE U V W Frequency converter PE U V W

Tape Fe-armour Frequency converter PE U V W

Transformer PE

Transformer PE

Transformer PE

Factory main grounding bus Separate protective conductor

U PE

M 3~

Factory main grounding bus Separate protective conductor

U PE

M 3~

Factory main grounding bus Separate protective conductor

U PE

M 3~

Low armour conductivity <10%

High armour conductivity >10%

Figure 3 - 9.

Motor cable connections to be avoided.

Grounding and cabling of the drive system

3-11

Cabling of variable speed drives

DC drives

The same basic rules apply as for AC motors. The most economical power cable has an even number of conductors. Also three-core cables with shield can be used. For larger motors, where several cables are needed, power sharing of three-core cables is made based on the 2+1 / 1+2 principle (Figure 3-10). The excitation cable is a heavy source of interference because of the abrupt commutation. Therefore, always use shielded excitation cables. Single-core cables shall be rejected for DC drives. Motors with stator serial winding must have a grounding brush on the shaft to avoid bearing problems.

AC bus

+
123

123

+ 123

123

123

123

Figure 3 - 10.

Symmetrical cabling between the DC converter and the motor

3-12

Grounding and cabling of the drive system

Cabling of variable speed drives

Signal cables
PE (protective ground) vs. FE (functional ground)
The ABB policy is to use uniform, equipotential PE grounding with drive systems. The principle is extended to all structural levels of installations in large buildings containing electrical equipment. Example levels are floor, equipment cubicle and circuit board levels. It is not possible to keep all levels of a large system at the same highfrequency potential, but applying uniform PE grounding at all levels will ensure electromagnetic compatibility. The end users also apply other installation philosophies, for example, systems with PE and FE (former TE). This is usual in electronic equipment of other manufactures and several previous ABB products. The FE system of co-operating equipment can be either general or partial (only part of the equipment is built using FE ground, Figure 3-11). In the sense that the PE and FE grounds are connected together at one point only, the PE/FE structure resembles a one ground-level uniform PE system. Therefore, a large FE system may also need an effective local figh-frequency ground and becomes more like the uniform PE system (Figure 3-12).

Figure 3 - 11.

PE and FE system

Grounding and cabling of the drive system

3-13

Cabling of variable speed drives

Figure 3 - 12.

Uniform PE system

Interfacing problem of systems with dissimilar grounding

Many existing installations today have been made by applying other grounding principles than those given in this manual, specially concerning low-frequency EMC, even starting from the ground electrodes. New deliveries, which employ the uniform PE system, are usually additions which have to operate together with the old equipment. Existing systems, implemented with a different philosophy, usually operate well, and making changes in them is out of the question. The mismatching may create problems, which have to be solved case by case. Physically large installations (dimensions, power) normally need some kind of matching. The matching is done to obtain sufficient compatibility. Sometimes, it is reasonable to accept a lower immunity level. The legal requirements concerning emissions and immunity must, however, be fulfilled. Matching elements between the systems are usually transformers, optocouplers, optical fibre links, galvanic analogue isolation and common mode interference filters and inductors. All these methods can improve signal transmission. Isolation transformers are used for power supply. This guide will not go deep into the interfacing practice. It is, however, important to be aware of the interfacing problem areas before implementing signal cables.

3-14

Grounding and cabling of the drive system

Cabling of variable speed drives

Control cable shielding

It is very important to use correct cable types to meet the EMC compatibility. A wrong cable type can cause severe interference problems. A shielded control cable will reduce disturbances. Always use a shielded cable for safety low-voltage (SELV) control signals.

Analogue and lowvoltage (SELV) digital I/O signals

Twisting the signal wire with its return wire reduces disturbances caused by inductive coupling. Pairs should be twisted as close to terminals as possible. A double-shielded twisted pair cable shall be used for analogue signals. Employ one individually shielded pair for each signal. Do not use common return for different analogue signals (Figure 3-13). A double-shielded cable is the best alternative for low-voltage digital signals but single-shielded twisted pair cable is also possible (Figure 3-14). Never mix 24 VDC and 115/230 VAC signals in the same cable.

Figure 3 - 13.

Double-shielded twisted pair cable

Figure 3 - 14.

Single-shielded twisted pair cable

Grounding and cabling of the drive system

3-15

Cabling of variable speed drives

Serial communication

There are several alternatives depending on the type of communication. The communication systems employ either doubleshielded (Figure 3-13) or coaxial cables in internal communication. A part of the serial communication is implemented with optical cables (figures 3-17 and 3-18). A communication system may also have its own cable specification. Note that serial communications will operate properly only with correct terminating resistors. See the system-specific instructions.

115/230 VAC digital signals

A shielded cable with proper voltage rating is the best alternative but an unshielded multi-core cable can also be used. (Figure 3-15).

Figure 3 - 15.

Unshielded multi-core cable

Shield connection

Always connect the shield of a control cable to a ground terminal on the converter side. A ground terminal can be a special clamp, screw or terminal block marked with PE, FE, GND or one of the following symbols:

The unshielded part of the cable shall be minimized. The ground connection of the shield shall be kept as short as possible.

3-16

Grounding and cabling of the drive system

Cabling of variable speed drives

A signal cable shield left unconnected (ungrounded) at both ends does not suppress disturbances. Grounding a signal cable shield at one end only suppresses the electromagnetic field and inductive disturbances enough in most cases. Grounding a signal cable shield at both ends improves disturbance suppression above a certain frequency, but forms also a loop where low-frequency current will flow if the ends of the cable shield are at different potentials. Therefore, if high-frequency grounding is needed, the other end of the shield should be grounded via a capacitor. In some equipment the capacitor is incorporated. (Figure 3-16).

Figure 3 - 16.

Grounding of signal cables

Cabling and insulation of tachometers, pulse encoders

A tachometer shall be insulated electrically from the motor stator or rotor to prevent the forming of a current path through the tachometer. The usual coupling-type encoder must have an electrically insulating coupling. When a hollow-shaft type tachometer is used, the insulation can be implemented by insulating the ball joints of the engaging arm, or insulating the bar of the engaging arm. The shield of the tachometer cable should be insulated from the tachometer frame. The other end of the shield should be grounded at the converter PE, see figures 3-17 and 3-18. Always use a double-shielded cable for the pulse encoder. In case of high-frequency interference problems, the cable shield can be grounded at the encoder end via a capacitor. Single-shielded cables can be used with analogue tachometers. In hollow-shaft encoders with electrical insulation between the hollowshaft and the tachometer frame, the cable shield can be connected to the tachometer frame also.

Grounding and cabling of the drive system

3-17

Cabling of variable speed drives

Examples of cabling system drives

Typical examples of cabling in AC and DC drive systems are shown in figures 3-17 and 3-18.

INCOMER SECTION
230V PE (110V)

DRIVE SECTION

DRIVE SECTION DRIVE SECTION

~ =
24V

+24V 0V

This wire is connected to boardrack housing in the first drive section only
2)
X2
1 2

TE X3 1

2) SERIAL LINK UNIT X2 FREQUENCE 0 CONVERTER TE

GND

X3 1
1 2

24V

MB90 BUS INTERFACE

24V

2) X2 1 X3 1
2

OPTICAL DISTRIBUTOR

Fibre-optic pair cable

APPLICATION CONTROLLER (APC)

+5VP 1) A B GND 24V

MB90 BUS INTERFACE APPLICATION CONTROLLER (APC)

+5VP

0VP

ADVANCED, COMPACT OPERATOR STATION B (AOS,COS) +24V

A 0V

1)

0VP GND

MB90 BUS INTERFACE

Fibre-optic pair cable

24V

GND

APPLICATION CONTROLLER (APC) EXTENDED I/O

A TE B +24V 0V 0VP

EXTENDED I/O

0V +24V B GND

GND
TE

ADVANCED, COMPACT OPERATOR STATION (AOS,COS)

TE TE TAI TERMINAL BLOCK

A B +24V 0V 0VP

APC TE TERMINAL BLOCK

RED LINE 1 BLUE LINE 2

EXTENDED I/O

TAI TERMINAL BLOCK TE

TE

TE TE

MB90 BUS ADMINISTATOR

INVERTER
PE TE

TAI TERMINAL BLOCK

24V CHA1 CHA2 PE

INVERTER
PE

INVERTER

3~ PE

3~

3~

MEB

1) A = Positive signal conductor

B = Negative signal conductor

2) Boardrack

Figure 3 - 17.

Typical example of AC drive system grounding

3-18

Grounding and cabling of the drive system

Cabling of variable speed drives

INCOMER SECTION
230V PE (110V)

DRIVE SECTION

DRIVE SECTION

DRIVE SECTION

~ =
24V

+24V 0V

This wire is connected to boardrack housing in the first drive section only
2)
X2
1 2

TE X3 1

2) SERIAL LINK UNIT PULL-OUT UNIT

0 TE
X2
X3 1
1 2

24V

MB90 BUS INTERFACE

FREQUENCE CONVERTER

2) X2 1 X3 1
2

OPTICAL DISTRIBUTOR

Fibre-optic pair cable

APPLICATION CONTROLLER (APC)

Fibre-optic pair cable

MB90 BUS INTERFACE

24V

APPLICATION CONTROLLER (APC)

+5VP

+5VP 1) A B GND 24V A +24V 0V

GND

0VP

ADVANCED, COMPACT OPERATOR STATION (AOS,COS)

1)

0VP GND

24V

MB90 BUS INTERFACE

GND

APPLICATION CONTROLLER (APC) EXTENDED I/O

A TE B +24V 0V 0VP

EXTENDED I/O

0V A +24V B GND

GND
TE

ADVANCED OPERATOR STATION (AOS)

TE TE TE

A B +24V 0V 0VP

APC TE TERMINAL BLOCK

RED LINE 1 BLUE LINE 2

EXTENDED I/O

DIGITAL TERMINAL BLOCK

ANALOGUE TERMINAL BLOCK

DIGITAL TERMINAL BLOCK

ANALOGUE TERMINAL BLOCK

MB90 BUS ADMINISTATOR

CONVERTOR

ANALOGUE TERMINAL BLOCK

24V CHA1 CHA2 TE
TE

CONVERTOR

CONVERTOR

DIGITAL TERMINAL BLOCK

TE TE

PE

MEB

1) A = Positive signal conductor

B = Negative signal conductor

2) Boardrack

Figure 3 - 18.

Typical example of DC drive system grounding

Grounding and cabling of the drive system

3-19

Cabling of variable speed drives

Galvanic isolation

Galvanic isolation of control signals improves the interference immunity and is recommended specially at long distances. Isolation prevents interference caused by common impedance coupling (ground loop) and suppresses inductive coupling interference. Weak signals are isolated and amplified at the source, normal signals can also be isolated at the receiving end.

Cable routes

Avoid parallel running of power cables and signal cables. The distance between power and control cables should be at least 500 mm. When control cables must cross power cables, make sure they are arranged at an angle as near to 90 degrees as possible. The cable trays shall have good electrical bonding to each other and to the grounding electrodes. Aluminium tray systems can be used to improve local equalization of potential.

Common mode inductor

In applications of high emission level such as trains, trams and moving machines, common mode inductors can be used in signal cables to avoid interfacing problems between different systems. Common mode disturbances can be suppressed by wrapping the signal conductors through a common mode inductor ferrite core (Figure 3-19). The ferrite core increases inductance of conductors and their mutual inductance so that common mode disturbance signals above a certain frequency are suppressed. An ideal common mode inductor does not suppress differential mode signals.

Figure 3 - 19.

Common mode inductor

3-20

Grounding and cabling of the drive system

Chapter 4 Interference coupling, informative annex

Common impedance coupling
Common impedance coupling appears, if interference source circuits have a common current path (Figure 4-1), e.g. in the grounding or power supply circuit. Current changes in the interfering circuit cause potential changes in the common impedance: u = R * i - L * di/dt. Coupling via a ground loop can be reduced as follows: Low-frequency coupling can be prevented by using onepoint grounding. For high frequency, it is most essential to keep inductance as low as possible. To achieve lowest impedance, the relation between the length and width of a conductor should be less than five. In practice, this rule is implemented by multi-point grounding.

Figure 4 - 1.

Common impedance coupling

Grounding and cabling of the drive system

4-1

Capacitive coupling

Capacitive disturbance is coupled by changing electric field. Capacitive coupling appears in circuits that have stray capacitance with each other. Interference current (IN) is proportional to frequency (f), voltage level of the interfering conductor (V1) and stray capacitance between conductors (C12).

V N = j2 f V1 C12 R (Figure 4-2)

Capacitive coupling can be reduced by: reducing stray capacitances between circuits reducing the impedance level of the victim circuit limiting the frequency level of the interfering circuit limiting voltage level of the interfering circuit.

Stray capacitance can be reduced by: using metal casings for devices using shielded conductors increasing the distance between conductors using a ground plane between conductors.

Figure 4 - 2.

Capacitive coupling

4-2

Grounding and cabling of the drive system

Cabling of variable speed drives

Inductive coupling

Inductive disturbance is coupled via magnetic field. Current in the interfering circuit will generate magnetic flux around the conductor. When a changing magnetic flux perforates a closed loop, an alternative voltage will be induced to the victim circuit and interference current will flow in the closed loop. Interference voltage (VN) is proportional to frequency (f), current (I1) of the interfering conductor, mutual inductance of circuits (M12). Mutual inductance can be calculated by the area of the loop perpendicular to the magnetic lines (Acos) and the distance between conductors (r).

VN = j 2 f M 12 I 1
M 12 = Acos 2 r

(Figure 4-3) (long, straight conductors)

Inductive coupling can be reduced by: reducing mutual inductance between circuits filtering the high frequency content of the interfering circuit reducing the current of the interfering circuit.

Mutual inductance can be reduced by: using twisted pairs as signal cables increasing the distance between conductors reducing the loop area by galvanic isolation avoiding parallel conductors and coils.

By shielding the victim conductor with a material that has high permeability, some extra suppression will be achieved. (Highpermeability material "short-circuits" magnetic circuits, so most of the flux flows through this material.) High-frequency disturbance is reduced by using a metal enclosure or shield. Highly-conductive metals such as aluminium and copper are good shield materials.

Figure 4 - 3.

Inductive coupling

Grounding and cabling of the drive system

4-3

Electromagnetic coupling

Electromagnetic energy can propagate in free space as a wave motion. Each conductor carrying a changing current is a potential transmitter antenna of electromagnetic waves. Reciprocally, all conductors can operate as receiver antennas. In addition, each conductor, whether part of the active circuit or not, will shape the fields and perhaps amplify the antenna operation. Sometimes, a solid insulator may behave in the same way. The efficiency of the antenna increases at high frequencies when the antenna dimensions exceed about 1/100 of the wave length. Therefore, the problem worsens above 10 MHz frequencies due to improved antenna function, suitable dimensions of normal digital electronics and their operation at those speeds. Also, part of the climatic interference, e.g. lightning at a long distance, lies at frequencies from 10 to 100 MHz. A stroke of lightning close to electronic equipment easily stops normal function and may damage the equipment. The coupling decreases as the distance increases. How to protect against electromagnetic waves? Use ground planes or mesh structures as local ground. Use shielded cables. Use metal enclosures for equipment (leaky doors are problematic). Openings in enclosures must be small. Prevent unintentional antenna structures. Ground systematically at short (< 1/10 wavelength) intervals. Pay attention to high-frequency grounding, i.e. capacitive grounding of coaxial cables, for instance.

Due to reciprocity, these rules apply to both sides, the source and the victim.

4-4

Grounding and cabling of the drive system

Chapter 5 Terms and literature

Terms
Armour
Some terms used in this manual or related to the subjects of this manual are described briefly below. Metal sheath commonly of woven wire, spiralled tape or solid corrugated metal covering the insulation of an electrical conducting cable and serving both as a mechanical protection and as a shield against electrostatic or electromagnetic induction. Note that sometimes a cable may contain both an electromagnetic shield and a separate armour for mechanical protection, but both are electrically bonded.

Availability GND EMI FB FE

Capability of a device or system to be used for the intended purpose. General ground Electromagnetic interference Functional bonding Functional earthing (grounding). Earthing a point or points in a system, installation or equipment, for purposes other than electrical safety. IEC 60050-195 (195-01-13) 1998. Protective earthing (grounding). Earthing a point or points in a system, installation or equipment for purposes of electrical safety. IEC 60050-195 (195-01-11) 1998. Part of an electromagnetic barrier that separates the shielded circuits from the external sources of EMI (or confines EMI effects to the shielded volume). An electromagnetic barrier is a closed surface made up of shields and other elements to exclude (or to confine) electromagnetic waves propagating in space or guided along conductors. The barrier may be made of metal, conductively coated equipment cases, interconnecting cable shields, filters or surge arresters on wires that penetrate the shield and mesh or wave guides (below cut-off frequency) at ventilation openings. In a protected system, the barrier is everywhere sufficiently impervious for guided and space waves of EMI sources outside the barrier not to degrade the performance of the protected system. Technical earth (ground). This term has been replaced with FE.

PE

Shield

TE

Grounding and cabling of the drive system

5-1

Literature
EMC
"Interference-free electronics" by Dr. Sten Benda. Ordering number ABB 3BSE 000877R0001, ISBN 91-44-3140-9, ISBN 0-86238-255-6. "High Frequency Bearing Currents in Low Voltage Asynchronous Motors" 3GZF500930-8. A New Reason for Bearing Current Damage in Variable Speed AC Drives by J. Ollila, T. Hammar, J. Iisakkala, H. Tuusa. EPE 97. The European Conference on Power Electronics and Applications 810 September 1997 Trondheim, Norway pp. 2.539 to 2.542. On the Bearing Currents in Medium Power Variable Speed AC Drives by J. Ollila, T. Hammar, J. Iisakkala, H. Tuusa. Proceedings of the IEEE IEDMC in Milwaukee, May 1997. Evaluation of Motor Power Cables for PWM AC Drives by John M. Bentley, Patric J. Link. IEEE Trans. Ind. Appl., 1997, Vol 33, pages 342358. Minimizing Electric Bearing Currents in Adjustable Speed Drive Systems by Patric J. Link. IEEE IAS Pulp & Paper Conference Portland, ME, USA June 1998. IEC 61000-5-2: 1997. Installation and mitigation guidelines Earthing and cabling. IEC 60034-17:2002 Rotating electrical machines, Cage induction motors when fed from converters Application guide. IEC 60034-25:2004. Rotating electrical machines Guide for the design and performance of cage induction motors specifically designed for converter supply. Laakerivirta ja sen minimoiminen sdettyjen vaihtovirtakyttjen moottoreissa. Ilkka Erkkil. Automaatio 1999 14.16.9. Helsinki. GAMBICA/REMA Technical Report No. 2 Motor Shaft Voltages and Bearing Currents under PWM Inverter Operation. 2002. GAMBICA/REMA User guide No. 3 Installation Guidelines for Power Drive Systems. 2003.

Bearing currents

5-2

Grounding and cabling of the drive system

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