Introduction to Proper Variable Frequency Drive Installation Practices. Copyright 2012 Rockwell Automation, Inc. All rights reserved.

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2 Field Installations Do These Look Familiar To You? Spacing above drive half as much as recommended High Power, signal wire, unshielded Ethernet cable and 24VDC were mixed together throughout this panel Option module with and without corrosion Magnetic dust found inside drive enclosure Motor Winding Failures PUBLIC 35% of escalated issues are preventable installation or environment related! 2

3 Poor Installation Practices What Type of Problems Can Occur? PUBLIC Unintentional machine stopping Errors and accuracy issues in products produced Registration errors in printing, poor quality print job Dimension errors in machining, poor quality products Inconsistent batches or mixes Inconsistent control of an process systems Network communication errors and slow downs Unable to listen to telephone, radio, residential or commercial Damage to electronic equipment Others

4 Poor Installation Practices Overall Impacts PUBLIC Overall a loss in functionality of a system which could mean Loss in production Loss of revenue Increased costs associated with poor quality of manufactured goods Time delays in commissioning Increased costs

Guidelines/rules/recommendations documented throughout our manuals Not unique

5 5 Why Are We Talking About This? A little work upfront saves a lot of work on the back end Guidelines/rules/recommendations documented throughout our manuals Not unique to Rockwell drives Compliance requirements (RoHS) have changed electronics Proper Installation and Drive Environment will help prevent issues

6 Rockwell Automation Resources Installation and environmental recommendations are stated in user manuals Available for purchase at time of order Available on the web via Literature Library Wiring

6 6 Rockwell Automation Resources Installation and environmental recommendations are stated in user manuals Available for purchase at time of order Available on the web via Literature Library Wiring and grounding recommendations are stated in our guidelines DRIVES-IN001 Wiring and Grounding Guidelines for PWM AC Drives DRIVES-AT003 Industry Installation Guidelines for PWM AC drives Applies to all drives (Rockwell & competitor)

7 7 Rockwell Automation Resources Installation/Environment recommendations are stated in manuals 750-IN001 PowerFlex 750 Drives Installation Instructions 520-UM001 PowerFlex 520 Drives User Manual

8 8 Rockwell Automation Resources Installation/Environment recommendations are stated in manuals DRIVES-IN001 Wiring and Grounding Guidelines for PWM AC Drives DRIVES-AT003 Industry Installation Guidelines for PWM AC Drives

9 9 Drive Installation 1. Drive Input Power Distribution Source Impedance Grounding Scheme 2. Drive Panel Environmental Minimum Clearances/Environmental Specifications Atmosphere Drive Configuration Power Jumper Configuration Ground Practices 3. Drive Output Cabling Type (Length, Properties, Routing)

10 10 Drive Input Power Distribution - Chapter 2 of Drives-IN001 Source Impedance Symptoms: Input Failures, Overvoltage/Undervoltage Faults Max Supply KVA Line Reactor helps with line sags and spikes

11 F05 DC Bus Overvoltages Event Details/Waveforms 1000 500 Volts 0-500 -1000 D V A-B V B-C V C-A V 20 10 Amps 0-10 -20 A I B I C I 11:02:33.55 06/30/2010 Wednesday 11:02:33.60 11:02:33.65 11:02:33.

11 11 F05 DC Bus Overvoltages Event Details/Waveforms Volts D V A-B V B-C V C-A V Amps A I B I C I 11:02: /30/2010 Wednesday 11:02: :02: :02:33.70 Event #188 at 06/30/ :02: B-CV Wave window D A B C A- B B- C C - A V rms V Pea k Irms IPe ak

13 Line Transient with Line Reactor PUBLIC 13 Vbus = 637Vdc Vbus = 653Vdc Ipk = 10A Ipk = 19A

14 14 Drive Input

15 15 Drive Input Power Distribution - Chapter 2 of Drives-IN001 Source Impedance When to add Line Reactor Low line impedance (Less than 1% line reactance) Supply transformer KVA rating 10 times than drive for without DC link choke, 20 times for drives with DC link choke Line has power factor correction capacitors Line has frequent power interruptions Line has intermittent noise spikes in excess of 6KV Incoming voltage imbalances greater than 2% (cause large unequal currents in a drive)

16 16 Drive Input Power Distribution - Chapter 2 of DRIVES-IN001 Grounding Symptoms: Equipment Damage, Overvoltage Faults, Ground Faults Solid Ground High Resistance Ground Ungrounded Rockwell can support all three schemes Some competitors only support solidly grounded

17 17 Drive Input Power Distribution - Chapter 2 of DRIVES-IN001 Solid Ground Wye Recommended Controlled path for common mode noise current Consistent line-to-ground voltage reference that minimizes insulation stress Accommodation for system surge protection schemes Fewer Technical Support Calls when this scheme is used The only system allowed for CE compliance

18 18 Drive Input Power Distribution - Chapter 2 of DRIVES-IN001 High Resistance Ground Wye Potential nuisance ground fault trips causes drive overvoltage Potential equipment damage 1 Power Distribution

19 19 Drive Input Power Distribution - Chapter 2 of DRIVES-IN001 Ungrounded System level ground fault detection or suppression may be required (use of zig-zag transformer for ground fault detection) High voltages can be present between the chassis of the drive and the internal power structure components causing undue stress on insulation Dangerous ground faults on the primary will show primary voltage potential to ground on the secondary side 1 Power Distribution

20 20 Drive Input Drive Configuration 750-IN001 or 520-UM001 Power Jumper Configuration Symptoms: Equipment Damage, Ground Faults

21 21 Drive Input Drive Configuration 750-IN001 or 520-UM001 Power Jumper Configuration

22 23 Drive Panel Drive Configuration DRIVES-IN001 Grounding Practices Symptoms: Ground Faults, Communication Faults Motor Ground directly back to drive, then from drive to panel ground Motor Cable shield directly back to drive (either PE or drive chassis), then from drive to panel ground

23 24 Grounding and Bonding to Panel

24 25 Panel Build

25 Grounding & Bonding Inside the panel Remove Paint Remove Paint

26 28 Drive Panel Environmental 520-UM001 Minimum Clearances/Environmental Specifications Symptoms: Reduced Life & Over Temperature Faults 2 VFD

Drive Panel Heat Dissipation B A A B B B Maximum Ambient Temperature Outside Enclosure The rated or desired temperature for the electronics inside the enclosure.

27 Drive Panel Heat Dissipation B A A B B B Maximum Ambient Temperature Outside Enclosure The rated or desired temperature for the electronics inside the enclosure. < > A A IF ELECTRONICS TEMPERATURE MUST BE LOWER THAN AMBIENT TEMPERATURE Then air conditioners, air-to-water heat exchangers, thermoelectric coolers or vortex coolers are selected. IF ELECTRONICS TEMPERATURE CAN BE HIGHER THAN AMBIENT TEMPERATURE Then filter fans, axial fans, fan trays or air-to-air heat exchangers are chosen. *Manufacture of cabinet and cabinet cooling solutions have calculation tools*

28 30 Drive Panel Environmental Atmosphere DRIVES-AT003 Symptoms: Drive Failures, Nuisance Faults RoHS Changed Materials Heavy Metals no longer allowed Stable Low reactivity to many corrosive gasses Environment requirements have not changed, but current materials react differently Electronics smaller and closer in proximity 3 rd parties (Purafil) can evaluate corrosion and offer solutions Conformal Coating implemented to improve reliability 2 VFD

29 31 Drive Panel Environmental DRIVES-AT003 Atmosphere Rockwell Atmospheric Requirements

30 Manual Overview - Environment PUBLIC 32

31 Manual Overview - Environment PUBLIC 33

32 Copyri Reflective Wave at VFD and at Motor V Drive V Motor 300 Ft of cable

33 35 Drive Output Cabling Appendix A of Drives-IN001 Length Symptoms: Motor Failures, Overcurrent Faults

34 Electro-Magnetic Interference Common Mode Current

35 Copyri Creation of Common Mode Current Switching Pattern (PWM) of Output IGBT Common Mode Voltage pattern

36 38 Grounding Recommended Grounding Practices The fully grounded scheme provides the best containment of common mode noise. It uses PVC jacketed, shielded cable on both the input and the output to the drive. This method also provides a contained noise path to the transformer to keep the ground grid as clean as possible.

Maintain fill rates per applicable electrical codes.

37 39 Wire/Cable Types Individual Conductors in Conduit Use Under 12 AWG use XPLE ( XHHW) insulated conductors Do not route more than three sets of motor leads (three drives) in the same conduit. Maintain fill rates per applicable electrical codes. If possible, avoid running incoming power leads and motor leads in the same conduit for long runs. IMPORTANT! Do not run power or motor cables with control or communications cables in the same conduit.

38 40 Wire/Cable Types

39 41 Wire/Cable Types Unshielded Cable Multi-conductor cable Superior performance in wet environments Reduce cross coupling between other drive cables < 200HP > 200HP

40 42 Wire/Cable Types Shielded Cable Shielded cable contains all of the general benefits of multi-conductor cable with the added benefit of a copper-braided shield that can contain much of the noise generated by a typical AC drive. Shielded cable can also help reduce shaft voltage and induced bearing currents for some applications. Armored Cable Cable with continuous aluminum armor is often recommended in drive system applications or specific industries. Armored cable offers most of the advantages of standard shielded cable and also combines considerable mechanical strength and resistance to moisture. Space the ground conductors symmetrically around the power conductors. Verify that the ground conductors are rated for full drive ampacity < 200HP > 200HP

41 43 Drive Output Cabling Chapter 1 of Drives-IN001 Properties Symptoms: Overcurrent Faults, Ground Faults

42 Drive Output Cable Charging Currents PUBLIC Short Cable between drive and motor - 3m Longer Cable between drive and motor - 30m

43 45 Drive Output Cabling Chapter 6 of Drives-IN001 Other hardware Common Mode Cores

44 Common Mode Noise What Do Common Mode Chokes Do? PUBLIC V L di Vground Lground di dt dt

45 47 What Else to Watch Out For Cabling Inside and outside of the panel Encoder cable routing and shielding EtherNet/IP cable selection and routing Common Mode Cores

46 48 Drive Output Cabling Chapter 4 of Drives-IN001 Routing Symptoms: Comm Faults, I/O Loss of Signal

47 Panel Layout- Solutions Space between top and bottom of VFD to allow proper cooling

48 Panel Layout- Solutions Space between top and bottom of VFD to allow proper cooling

49 51 What Can You Do? New installs, migrations, switching to a new drive product review the entire drive system from line to load Download latest manuals DRIVES-IN001 (Wiring and Grounding Guidelines for PWM AC Drives) DRIVES-AT003 (Industry Installation Guidelines for PWM AC Drives) 750-IN001 (PowerFlex 750 Installation Instructions) 520-UM001 (PowerFlex 520 User Manual)

To start, scan the QR Code below: Then fill in the required information on the

50 Copyright 2012 Rockwell Automation, Inc. All rights reserved. Like what you saw? Request Follow-up from a Rockwell Representative! To start, scan the QR Code below: Then fill in the required information on the survey screen: 1. Your Session Code (i.e. T200) 2. Your Short Code Located on your Badge 3. Select YES 4. Hit Continue

T107 - Installation Considerations for AC drives

T107 - Installation Considerations for AC drives PUBLIC Field Installations Do These Look Familiar To You? High Power, signal wire, unshielded Ethernet cable and 24VDC were mixed together throughout this