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VFD Cable Selection Single Phase to Three Phase VFD

(VFD is shorted for Variable Frequency Drive, also refer to adjustable speed drive, frequency inverter, variable speed drive...) Wiki
Manufacturers of medium and large VFDs typically provide information on the requirements for power cables Case study
connecting the variable frequency drive to the AC motor and from the VFD isolation transformer to the VFD Market
converter. Cable and panel grounding recommendations are also included. Cable supplier catalogs and Web
Troubleshooting
sites provide detailed information, but not necessarily everything needed to determine if the VFD
manufacturer's recommendations are being met. This paper provides typical requirements, reasons for those
requirements, and some useful insights to help the reader bridge the gap between VFD supplier Featured Articles
requirements and cable supplier published data.
What is VFD, How it works? - VFD ...
Background VFD is shorted for Variable
The availability of cost-effective thyristor- and transistor-based power devices made Pulse Width Modulated Frequency Drive (also
(PWM) power conversion practical. As is the case with most advances in technology, issues not seen in known as AC Drives and
previous generations of VFDs came to light. These included motor insulation problems, bearing failures, Inverters) -- that's used to
interference with or destruction of existing VFD systems, and interference with unrelated plant equipment. make an AC motor working
Most, if not all, of these phenomena are attributable to switching speeds on the order of 10–100 times faster in ...
than the thyristors used in conventional DC power conversion.
VFD: Insulated Gate Bipolar Transistor ...
Thyristors are line-commutated devices; that is, a gate current applied when the device voltage is of one
IGBT (insulated gate
polarity causes the device to conduct current. Conduction is stopped when the AC line voltage polarity is
bipolar transistor) provides
reversed and the current is decreased to zero. The IGBT (Insulated Gate Bipolar Transistor), GCT (Gate
a high switching speed
Commutated Turn-off thyristor) and IEGT (Injection-Enhanced Gate Transistor) devices used in PWM power
necessary for PWM VFD
converters do not have this design limitation and are turned on and off by gate voltage or current.2 Power
operation. IGBTs are
converters using these devices not only operate at high switching frequencies, but they also are independent
capable of ...
of the incoming power system frequency. The resulting harmonics of switching frequencies are well beyond
the fifth, seventh, 11th and 13th line frequency harmonics generally the concern when conventional DC Three phase inverters
drives are employed (Figure 1). In the variable frequency
drive rectifier paper, it
explains how to go from
three phase alternating
current voltage to a direct
...

Variable frequency drive Rectifier

To understand variable
frequency drive (VFD)
better, it's necessary to
explain some of the main
parts of the variable
frequency ...

Variable Frequency Drive Harmonics and ...

A discussion of the benefits of variable
frequency drives often leads to a question
regarding electrical harmonic distortion ...

Fig. 1 Typical harmonic spectrum of PWM variable frequency drive

Cable Concerns
The widespread use of PWM variable frequency drives in the 1990s and the early associated problems VFD manufacturers
referenced above required new cable types not generally available at the time. VFD and cable [email protected]

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manufacturers conducted tests of various cable configurations, resulting in various recommendations and [email protected]
the availability of new cable types.

The referenced IEEE paper3 identifies some of the basic concerns as they apply to the inverter-duty-motor
combination:

The introduction of additional harmonic currents in the equipment grounding circuits.

Common mode currents require proper grounding to avoid premature bearing failures.
Cross-talk between adjacent motor circuits.

It should be remembered that PWM variable frequency drives are also often applied as converters,
converting AC to DC for use by the inverters, which then supply variable voltage and frequency power to the
motors. Therefore, similar cable recommendations also apply to the transformer-converter circuit.

Equipment Grounding Circuits - The analog regulators and power conversion equipment of the 1960s and
later required separate ground circuits for proper operation. With analog signals as low as 5 V, offsets of a
few millivolts difference between the various control platforms could cause hundreds of unwanted amperes
to flow in the motor and generator circuits.

Separate grounding circuits might be classified as follows:

Personnel Safety: Includes electrical equipment cases, motor frames and so forth.
Control System 1: Ties all control circuit grounds within separate enclosures in a designated area.
Power Conversion Equipment: Separate grounding circuits may be used for static power conversion
equipment, depending on local codes and manufacturer. This may be tied to the Personnel Safety
ground but not the Control System ground.
Control System 2: Multiple control grounding circuits may exist, especially as additional lines are
added to existing facilities.

Control of Common Mode Currents - A simplistic view of common mode is that any difference in potential
between two points will cause a current to flow through the path of least resistance. Since the potential
difference can consist of many different frequencies, the mathematical solution can be extremely complex.
The basic solution is to ensure that all potentials are equidistant to ground, with the path of least resistance
determined by the installation to not be through equipment components that can fail due to unwanted ground
currents.

The primary concern here is that improper installation can introduce the motor terminals to much higher
voltages than the insulation is design to accommodate. In addition, the path of least resistance to common
mode current may well be the motor bearing, which generally shortens bearing life. In cases where both
motor bearings are insulated, the path of least resistance may be passed to the driven equipment bearing.
Note that sensors attached to the motor shaft, such as tachometers, must be properly protected to avoid
their bearings becoming the path of least resistance.

A related cause of high voltage at the motor terminals is the standing wave concept. The combination of high
device switching speeds and PWM control that allows a high-frequency string of voltage pulses being sent
from the variable frequency drive can cause motor voltages many times nominal. For a particular cable type,
there is some cable length that maximizes this voltage component. The PWM control algorithm can mitigate
this issue.

Circuit Cross-Talk - Physical separation of power cables and control cables is generally recommended by
VFD manufacturers and may also be required by personnel safety codes. Multiple inverter-motor cables in
the same raceway for long distances can have electromagnetic and/or electrostatic coupling. This could
result in one system interfering with another's operation. Personnel safety is another concern, in that an
individual may be doing maintenance on an un-energized power circuit that has voltage/current induced from
an operating VFD.

Electromagnetic coupling from power cables can also interfere with other equipment, such as radios, control
circuits and instrumentation.

Thyristor and Diode Converters

Power cables between VFD isolation transformers and thyristor or diode converters follow the same
guidelines used for DC drives. Special cable is not required.

PWM Converters and Inverters

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As noted previously, PWM AC-DC converters and DC-AC inverters operate at high switching frequencies,
producing harmonics well beyond the fifth, seventh, 11th and 13th associated with thyristor and diode AC-DC
converters. The basic requirements for properly installed power cabling that minimizes the undesirable
effects include:

Three symmetrically arranged phase conductors.

Three symmetrically arranged ground conductors.
High-integrity overall cable sheath.
Individual phase conductor shields when RMS voltages above 2,400 VAC are recommended.

The following cable configurations are prioritized from 1 to 4, or best practice to less desirable alternatives.

Priority 1 Cable - The arrangement shown in Figure 2, when properly terminated, meets the above criteria.
The cable does not introduce phase unbalance and minimizes high-frequency emissions. This cable type is
designated Priority 1 because it results in the minimum common mode currents in the grounding circuit and
minimum interference with other equipment in the facility.

Fig. 2 Priority 1 VFD cable

Overall cable sheaths or shields may be implemented using several methods. These include:

Continuous, welded corrugated aluminum sheath. Generally considered the best technical solution for
grounding high-frequency emissions, it also provides very good mechanical protection and is
sometimes referred to as "armored." This type is also the most expensive and difficult to install due to
the rigidity of the sheath.
Corrugated and longitudinally applied sheath with overlap. The material is usually copper and provides
a good grounding path. The corrugated sheath flattens when the cable is bent, providing an unbroken
sheath.
Circumferentially wrapped flat copper tape with 133–150% overlap. The level of overlap ensures
coverage if the bend radius is not too severe. Separation or gaps in the sheath allow some level of
unwanted emissions.
Weaved sheaths are found on some cables advertised as VFD. Weaves do not provide a 100%
emission shield due to gaps in the weave.

Priority 2 Cable - Priority 2 cable has a single, centrally placed ground conductor. Although shown for
completeness and technically a solution, it has proved difficult to confirm that the ground conductor is
centrally placed. It seems to be more common for the ground conductor to be just one of four randomly
placed cables in the bundle and not centered as shown in Figure 3. Unsymmetrical cable should be avoided.

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Fig. 3 Priority 2 VFD cable

Priority 3 Cable - Priority 3 cable (Figure 4) has no separate ground conductor and relies solely on the
overall cable sheath for grounding and emission control.

Fig. 4 Priority 3 VFD cable

Priority 4 Cable - Priority 4 cables (Figure 5) have three individual cables symmetrically placed. In all
arrangements, symmetrical main phase conductors are required to keep the phase currents balanced, with
the goal of minimizing common mode ground currents and high-frequency emissions. Some manufacturers
allow the use of Priority 4 cables when Priority 1–3 cables are not available. Special care should be taken to
ensure symmetrical placement of the three single-phase cables.

Fig. 5 Priority 4 VFD cable

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In the event Priority 4 cable is used, a separate ground conductor should be run in a separate path (conduit)
to avoid the Priority 2 case of unbalanced electromagnetic effects. There will be phase unbalance with
Priority 4 cables regardless of the care taken during VFD installation. Also note that since there is no overall
three-phase sheath, all three individual cable sheaths should be grounded per the manufacturers
recommendation.

Multiple Cables
When multiple cables are required for ampacity purposes, each cable should contain all three phases, as
shown in Figure 6 for Priority 1 cables. Cables are routed through buried conduits or placed in cable trays, or
both. The ampacity de-rating rules recommended by the cable manufacturer should be observed.

Fig. 6 Priority 1 multiple cables configuration

Should it be necessary to use multiple single-phase cables, there are two possibilities. The Priority 4 case
can be followed, or the cable runs are placed in individual phase conduits to minimize common mode
currents. However, this second case requires point-to-point buried conduit with no proximity to other power
or control cables. In the case where cables are randomly run without regard to phase, cable sheath
terminations may burn off due to excessive currents. In this case, the voltage driving the current is relatively
high and may be considered a personnel hazard.

Cable Voltage Rating

All VFD cables must meet local codes and be rated for the RMS circuit voltage in which they are installed.
Some suggested cable ratings available in North America are given in Table 1.

Table 1. Cable Voltage Ratings

Nominal converter/inverter voltage Cable voltage rating

460 600 VAC with 2,000-volt insulation withstand

575/690 1,000 VAC with 2,000-volt insulation withstand

1,250 3 kV

3,300 8 kV

Cable Grounding
Always refer to the equipment manufacturer's documentation for proper handling and installation, including
grounding. Figure 7 illustrates the grounding method for the case of a PWM converter connection to a
transformer with a single Priority 1 cable.

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Fig. 7 Transformer and converter cable grounding diagram

Note that the cable sheath/shield is grounded at both ends of the cable. The three symmetrical ground
conductors are also grounded at each end of the cable. VFD isolation transformers are generally provided
with an electrostatic shield between the primary and secondary windings which is connected to the system
grounding circuit. The cable sheath/shield and ground conductors are also connected to the system
grounding circuit.

Converters are generally provided with an internal ground (earth) bus for cable grounding purposes, and
perhaps a separate control ground bus. As noted earlier, separate external ground buses for control and
power are not generally used in new installations. Therefore, all grounds eventually terminate to the same
system grounding circuit, designated "frame ground" in Figure 7.

In Figure 8, the variable frequency drive connection to the motor uses Priority 4 cables and includes a motor
disconnect. This case requires careful grounding of the individual shields/sheaths, plus the separately run
ground cable to mediate the common mode ground currents that this installation will incur. All cables used
have the shield/sheath grounded at both ends. Again, please consult the manufacturer's documentation to
confirm their recommendations.

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Fig. 8 Variable frequency drive and motor cable grounding diagram

Note that Figure 8 does not attempt to illustrate the cable physical arrangement. Priority 4 guidelines are
implied and should be followed.

Case Study of Individual Cables

Figure 9 shows the main power and grounding circuits of a medium-voltage IEGT main VFD applied in a
rolling mill. The main power cables between the variable frequency drive and motor are Priority 4 type; that
is, three individually shielded cables. Each cable has a sheath used as a shield and grounded at both ends.
There are multiple paths for ground currents to flow, including the intended ground wires and stray
capacitance. The ground current flows as follows:

As an initial condition, all of the variable frequency drive output voltages are zero.
The U-phase power devices Q1 and Q2 are turned on, applying +2,345 V to the U-phase output.
Ground current flows as indicated by the arrows in Figure 9.

Fig. 9 Variable frequency drive grounding and ground current paths

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When the motor load current is zero, the U-phase current flows from the U-phase cable through the sheath
and returns to the variable frequency drive SE point. The current return to the variable frequency drive main
power circuit is mainly through two paths. One path is the neutral grounding point, and the other through the
V-phase and W-phase sheaths and cables.

Figure 10 shows the ground currents Ias, Ibs and Iie as measured in the actual installation. The Ias peak
current is 120 A with a frequency of more than 100 Hz.

Fig. 10 Measured ground currents

Simulation - A simulation was run using PSCAD/EMTDC version 3.0.8 to confirm the model against the field
measurements. The parameters are shown in Table 2.

Table 2 Parameters for Model Simulation

DC bus voltage 2,345 VDC

Dv/dt of switching 2,345 V/microsecond

Motor load No load, no current

Cable length 90 m

Cable parallel number 2 parallel

Cable layout Priority 4 (Figure 11)

Cable model EMTDC cable (Figure 12)

Fig. 11 One possible arrangement of two parallel Priority 4 cables

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When single cables are used in place of three-phase cables, the physical arrangement possibilities are
endless. Since these tests were on a mill in Japan, we can be certain that care was taken that the Priority 4
guidelines were followed as much as practical. The arrangement for each phase might look as shown in
Figure 11, with three single-core cables twisted as triplex sets. The cable model used in the simulation is
shown in Figure 12.

Fig. 12 Cable modeled in the simulation

The simulation results are shown in Figure 13. The simulated ground currents Ias, Ibs and Iie are similar to
the measured values of Figure 8, verifying the simulation results.

Fig. 13 Results of the ground current simulation: (left) VFD ground currents and (right) other ground
currents.

The ground currents Iem, Iem2 and Ien of Figure 9 were also simulated. The impedance to earth of the
motor side currents, Iem and Iem2, is higher than the impedance to ground of the neutral point established in
the variable frequency drive, and little or no current is observed. The ground path of the Ien and Iie currents
are nearly the same, and so the simulated ground currents are practically the same. The intention of the
neutral point grounding resistor is to control the ground current, so the simulation confirms the desired result.
Keeping the unwanted currents within the variable frequency drive and cable sheaths mitigates the amount
of unwanted electrical noise introduced into the plant ground grid. It is important to note that the cable sheath
can carry significant repetitive pulse-shaped currents and must be rated and properly terminated to carry
these currents.

Conclusions
Differences in PWM VFD designs may result in different cable recommendations between manufacturers. In
some countries, the recommended cables may not be available. However, the manufacturer's

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recommendations should be followed as closely as possible. Proper cabling installation of high-performance
PWM VFDs will avoid interference with the operation of other plant equipment, as well as ensure proper
operation and life of the connected equipment.

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