VFD CABLES

Variable frequency adjustable speed motor drives (VFDs) usually employ a method of motor control called PWM (pulse width modulation) using semiconductor devices called IGBTs. IGBT stands for insulated gate bi-polar transistor for those of you who want to impress your friends at your next cocktail party! VFDs are also often referred to as adjustable speed drives (ASDs) or as AC (alternating current) drives. AC drives, as opposed to older DC (direct current) types, are used for most new installations as well as for replacement in many industrial applications. An electrical diagram of a typical VFD system is shown at left. In practice, the 3- phase, full wave rectifier and the PWM inverter are usually mounted within a single metal enclosure. VFD technology reduces the size and increases the efficiency of ASDs and at the same time improves control of the motors speed and torque along with other advantages. However, VFD technology also has a few undesirable side effects that must be managed. Due to the laws of physics, the fast switching speeds of the semiconductor devices used in VFDs (see table below) inherently create EMI (electromagnetic interference) which can be radiated by the inverter-to-motor power cable. With todays fastest devices, the electrical energy flowing in the cable contains components with frequencies as high as 30 MHz (megahertz). If this RF (radio frequency) energy is not contained, the radiated energy can interfere with the proper operation of nearby electronic equipment. The more electronics in a facility, the greater the risk of problems. The design of the cable used with VFDs, along with proper installation, plays a key role in controlling these side effects.

VFD CABLES

What Are the Issues? About a dozen industry studies have been conducted regarding the role that power cables play in the safe and reliable operation of VFD systems. In one of the larger studies, extensive testing of 150-foot lengths of eight different cable constructions was performed on a 50 horsepower VFD system installed at a test laboratory in Helsinki, Finland.1 In another major study, the magnitude and effect of reflected waves in the cable were studied extensively.2 Overall, the studies focused primarily on the following VFD cable concerns: EMI radiated by the VFDs inverter-to-motor power cable which might interfere with the proper operation of other nearby electronic equipment Stray electrical currents which can flow through both the drives grounding system and the motors bearings and cause premature bearing failure through a process called fluting (see photo at right) High voltage reflections that can occur with certain drive system configurations and that might cause early failure of the inverter-to-motor power cable The last item, high voltage reflections, has caused a significant number of in-service motor failures. These failures have lead to the development of motors that are specifically designed for use with VFDs. On the other hand, very few cable failures have been confirmed but there is concern over possible long-term cable damageespecially on VFDs operating at 575 volts and above.

VFD CABLES
EMI The fast switching speeds of the solid-state (semiconductor) devices used in VFDs increase the potential for EMI (electromagnetic interference). The drives solid-state electronics generate RF energy, which can be radiated by the drives inverter-to-motor power cable and picked up by nearby circuits. This interference can cause malfunctions in sensitive electronics. As a result, VFD manufacturers usually recommend the use of a shielded power cable between the drive electronics and the drive motor to contain this RF energy. Fortunately, adequate shielding can be obtained with existing cable technology using impervious corrugated aluminum armor as the shield. This type of armor is often called CCW for continuously corrugated and welded. Other shield types such as copper tape, copper braid or aluminum/polyester foils can also be used with slightly reduced effectiveness. The effectiveness of cable shields is typically determined by measuring the transfer impedance using NEMA test method WC61.1 A cable shield with a transfer impedance of less than 100 m/m (milliohms per meter) is generally considered to be a good shield and one with less than 10 m/m an excellent shield. Impervious corrugated aluminum armor typically has transfer impedance in the range of 1 to 10 m/m from DC to 30 MHz, the frequency range of interest for VFD applications. Most other common shield types provide transfer impedance in the range of 10 to 100 m/m. Stray Ground Currents A second concern is that stray electrical currents in the VFDs grounding system may flow though the drive motors main bearings. It is well known that the flow of electrical current through motor bearings in the milliamp range can cause premature bearing failure. Motor bearing currents can be minimized by using an inverter-to-motor power cable with three symmetrically positioned grounding conductors in combination with a low impedance shield. Such a design minimizes the total current that is induced in the grounding system by current flowing in the phase conductors and, ultimately, the amount of stray current that flows through the motor bearings. High Voltage Reflections A third concern is that the high frequencies generated by the VFD, coupled with long cable runs between the VFD and the drive motor, can result in reflected waves in the cable. Reflected waves can produce abnormally high voltages in the cable. Peak voltages of up to 2.5 times the nominal system voltage have been measured on VFD power cables. Because of these high voltage pulses, the use of 2000 volt rated cables is recommended on some 600 volt drive systems. For most VFDs operating at 480 volts or below, the recommended cable rating is 600 volts. However, 575 volt VFDs sometimes require a cable with a higher voltage rating depending on cable length and drive switching time. To determine the recommended cable voltage rating for a 575 volt drive system, refer to the graph below to determine if

VFD CABLES

Recommended Cables The winner of the sweepstakes for best overall cable for VFD applications is a threeconductor, impervious corrugated aluminum armor (CCW) cable with three symmetrically positioned grounding conductors as illustrated below. (In small sizes such as 10, 12, and 14 AWG cables, only one ground wire is required because the effect of stray ground currents is small.) Southwires Armor-X cable with three grounds is such a cable when installed with appropriate armor fittings in accordance with the NEC.2 Anixters catalog numbers for this and other VFD cable types are given in Anixters VFD cable brochure # 251921.