Rockwell Automation Allen-Bradley 160-AA02 User manual

Installation Instructions
Wiring and Grounding
Guidelines for
Pulse Width Modulated
(PWM) AC Drives

Important User Information Solid state equipment has operational characteristics differing from those of
electromechanical equipment. Safety Guidelines for the Application,
Installation and Maintenance of Solid State Controls (Publication SGI-1.1
available from your local Rockwell Automation sales office or online at http://
www.rockwellautomation.com/literature) describes some important differences
between solid state equipment and hard-wired electromechanical devices.
Because of this difference, and also because of the wide variety of uses for solid
state equipment, all persons responsible for applying this equipment must
satisfy themselves that each intended application of this equipment is
acceptable.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect
or consequential damages resulting from the use or application of this
equipment.
The examples and diagrams in this manual are included solely for illustrative
purposes. Because of the many variables and requirements associated with any
particular installation, Rockwell Automation, Inc. cannot assume responsibility
or liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use
of information, circuits, equipment, or software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without
written permission of Rockwell Automation, Inc. is prohibited.
Throughout this manual, when necessary we use notes to make you aware of
safety considerations.
Important: Identifies information that is critical for successful application and
understanding of the product.
PowerFlex is a registered trademark of Rockwell Automation, Inc.
DriveExplorer, DriveExecutive, and SCANport are trademarks of Rockwell Automation, Inc.
PLC is a registered trademark of Rockwell Automation, Inc.
!
WARNING: Identifies information about practices or
circumstances that can cause an explosion in a hazardous
environment, which may lead to personal injury or death, property
damage, or economic loss.
!
ATTENTION: Identifies information about practices or
circumstances that can lead to personal injury or death, property
damage, or economic loss. Attentions help you:
•identify a hazard
•avoid the hazard
•recognize the consequences
Shock Hazard labels may be located on or inside the equipment
(e.g., drive or motor) to alert people that dangerous voltage may be
present.
Burn Hazard labels may be located on or inside the equipment
(e.g., drive or motor) to alert people that surfaces may be at
dangerous temperatures.

Summary of Changes
The information below summarizes the changes to the Wiring and
Grounding Guidelines for Pulse Width Modulated AC Drives, publication
DRIVES-IN001, since the last release.
Manual Updates
Change Page
Revised guidelines for AC line impedance. 2-5
Revised guidelines for multi-drive protection 2-15
Revised guidelines for MOVs and common mode
capacitors
2-17
Added footnote 4. A-10

ii Summary of Changes
Notes:

Table of Contents
Important User Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Summary of
Changes
Preface Overview
Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1
Recommended Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1
Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-2
General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-2
Chapter 1 Wire/Cable Types
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Input Power Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Motor Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Cable for Discrete Drive I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Analog Signal and Encoder Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Chapter 2 Power Distribution
System Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
AC Line Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
AC Line Impedance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Surge Protection MOVs and Common Mode Capacitors . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Chapter 3 Grounding
Grounding Safety Grounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Noise Related Grounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Chapter 4 Practices
Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Conduit Entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Ground Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Wire Routing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Cable Trays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Shield Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Conductor Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Moisture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Chapter 5 Reflected Wave
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Effects On Wire Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Length Restrictions For Motor Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

ii
Chapter 6 Electromagnetic Interference
What Causes Common Mode Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Containing Common Mode Noise With Cabling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
How Electromechanical Switches Cause Transient Interference . . . . . . . . . . . . . . . . . . . 6-3
How to Prevent or Mitigate Transient Interference from Electromechanical Switches . . 6-4
Enclosure Lighting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Appendix A Motor Cable Length Restrictions Tables
PowerFlex 4 and 40 Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8
PowerFlex 400 Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8
Glossary
Index

Preface
Overview
The purpose of this manual is to provide you with the basic information
needed to properly wire and ground Pulse Width Modulated (PWM) AC
drives.
Who Should Use This
Manual
This manual is intended for qualified personnel who plan and design
installations of Pulse Width Modulated (PWM) AC drives.
Recommended
Documentation
The following publications provide general drive information.
Title Publication Available…
Installing, Operating and
Maintaining Engineered Drive
Systems (Reliance Electric)
D2-3115-2
Safety Guidelines for the
Application, Installation and
Maintenance of Solid State Control
SGI-1.1 www.rockwellautomation.com/
liiterature
IEEE Guide for the Installation of
Electrical Equipment to Minimize
Electrical Noise Inputs to
Controllers from External Sources
IEEE 518
Recommended Practice for
Powering and Grounding
Electronic Equipment - IEEE
Emerald Book
IEEE STD 1100
Electromagnetic Interference and
Compatibility, Volume 3
N/A RJ White - publisher
Don White Consultants, Inc., 1981
Grounding, Bonding and Shielding
for Electronic Equipment and
Facilities
Military Handbook 419
IEEE Recommended Practice for
Grounding of Industrial and
Commercial Power Systems
IEEE Std 142-1991
National Electrical Code (ANSI/
NFPA 70)
Articles 250, 725-5,
725-15, 725-52 and
800-52
Noise Reduction Techniques in
Electronic Systems
N/A Henry W. Ott
Published by Wiley-Interscience
Grounding for the Control of EMI N/A Hugh W. Denny
Published by Don White Consultants
Cable Alternatives for PWM AC
Drive Applications
IEEE Paper No.
PCIC-99-23
EMI Emissions of Modern PWM
AC Drives
N/A IEEE Industry Applications
Magazine, Nov./Dec. 1999
EMC for Product Designers N/A Tim Williams
Published by Newnes

p-2 Overview
Manual Conventions The following words are used throughout the manual to describe an action:
General Precautions
Application Guide for AC
Adjustable Speed Drive Systems
N/A NEMA
www.nema.org
IEC 60364-5-52 Selection &
Erection of Electrical Equipment -
Wiring systems
N/A IEC
www.iec.ch
Don’t Ignore the Cost of Power
Line Disturbance
1321-2.0 www.rockwellautomation.com/
liiterature
Title Publication Available…
Word Meaning
Can Possible, able to do something
Cannot Not possible, not able to do something
May Permitted, allowed
Must Unavoidable, you must do this
Shall Required and necessary
Should Recommended
Should Not Not recommended
!
ATTENTION: To avoid an electric shock hazard, verify that the
voltage on the bus capacitors has discharged before performing
any work on the drive. Measure the DC bus voltage at the +DC &
–DC terminals of the Power Terminal Block. The voltage must be
zero.

Chapter 1
Wire/Cable Types
AC drive installations have specific requirements for cables. Wire or cable
selection for a drive application must consider a variety of criteria.
The following section covers the major issues and proper selection of cable.
Recommendations are made to address these issues. Cable materials and
construction must consider the following:
•Environment including moisture, temperature and harsh or corrosive
chemicals.
•Mechanical needs including geometry, shielding, flexibility and crush
resistance.
•Electrical characteristics including cable capacitance/charging current,
resistance/voltage drop, current rating and insulation. Insulation may be
the most significant of these. Since drives can create voltages well in
excess of line voltage, the industry standard cables used in the past may
not represent the best choice for customers using variable speed drives.
Drive installations benefit from using cable that is significantly different
than cable used to wire contactors and push buttons.
•Safety issues including electrical code requirements, grounding needs
and others.
Choosing incorrect cable can be costly and may adversely affect the
performance of your installation.

1-2 Wire/Cable Types
General Material
Use Copper wire only. The wire clamp type terminals in Allen-Bradley
drives are made for use with copper wire only. If you use aluminum wire the
connections may loosen.
Wire gauge requirements and recommendations are based on 75 degrees C.
Do not reduce wire gauge when using higher temperature wire.
Exterior Cover
Whether shielded or unshielded, the cable must be chosen to meet all of the
application requirements. Consideration must be given to insulation value
and resistance to moisture, contaminants, corrosive agents and other
invasive elements. Consult the cable manufacturer and the chart below for
proper selection.
Figure 1.1 Wire Selection Flowchart
Selecting Wire to Withstand Reflected Wave Voltage for New and Existing Wire Installations
in Conduit or Cable Trays
Conductor
Environment
Conductor
Insulation
Insulation
Thickness
XLPE
PVC
OK for < 600V AC
System
No RWR or
Terminator required
20 mil or > (1)
230V 400/460V
15 mil
RWR or
Terminator
No RWR or
Terminator
Cable
Length
# of
Drives in Same
Conduit or Wire
Tray
> 50 ft.
< 50 ft.
Single Drive,
Single Conduit
or Wire Tray
Multiple Drives
in Single Conduit
or Wire Tray
575V
No RWR
or Terminator
Reflected Wave
Reducer?
Reflected Wave
Reducer?
RWR or
Terminator
XLPE (XHHW-2)
Insulation for
<600V AC
System
No RWR or
Terminator
Required
15 mil PVC
Not
Recommended
USE XLPE
or > 20 mil
15 mil PVC
Not
Recommended
USE XLPE
or > 20 mil
See NEC Guidelines (Article 310
Adjustment Factors) for Maximum
Conductor Derating and Maximum
Wires in Conduit or Tray
(1) The mimimum wire size for PVC cable with 20 mil or greater insulation is 10 gauge.
DRY (Per
NEC Article 100)
WET (Per
NEC Article 100)

Wire/Cable Types 1-3
Temperature Rating
In general, installations in surrounding air temperature of 50ºC should use
90ºC wire (required for UL) and installations in 40ºC surrounding air
temperature should use 75ºC wire (also required for UL). Refer to the drive
user manual for other restrictions
The temperature rating of the wire affects the required gauge. Be certain to
meet all applicable national, state and local codes.
Gauge
The proper wire size is determined by a number of factors. Each individual
drive user manual lists a minimum and maximum wire gauge based on the
amperage rating of the drive and the physical limitations of the terminal
blocks. Local or national electrical codes also set the required minimum
gauge based on motor full load current (FLA). Both of these
requirements should be followed.
Number of Conductors
While local or national electrical codes may determine the required number
of conductors, certain configurations are recommended. Figure 1.2 on
page 1-3 shows cable with a single ground conductor, which is
recommended for drives up to and including 200 hp (150 kW). Figure
1.3 on page 1-4 shows cable with three ground conductors, which is
recommended for drives larger than 200 hp (150 kW). The ground
conductors should be spaced symmetrically around the power conductors.
The ground conductor(s) should be rated for full drive ampacity.
Figure 1.2 Cable with One Ground Conductor
B
R
G
W
One Ground Conductor

1-4 Wire/Cable Types
Figure 1.3 Cable with Three Ground Conductors
Insulation Thickness and Concentricity
Selected wire must have an insulation thickness of equal to or more then 15
mils (0.4 mm / 0.015 in.). The quality of wire should not have significant
variations on concentricity of wire and insulation.
Figure 1.4 Insulation Concentricity
Geometry
The physical relationship between individual conductors plays a large role
in drive installation.
Individual conductors in conduit or cable tray have no fixed relationship and
are subject to a variety of issues including: cross coupling of noise, induced
voltages, excess insulation stress and others.
Fixed geometry cable (cable that keeps the spacing and orientation of the
individual conductors constant) offers significant advantages over
individual loose conductors including reducing cross coupling noise and
insulation stress. Three types of fixed geometry multi-conductor cables are
discussed below: Unshielded, shielded, and armored.
Three Ground Conductors
ACCEPTABLE UNACCEPTABLE

Wire/Cable Types 1-5
Table 1.A Recommended Cable Design
Unshielded Cable
Properly designed multi-conductor cable can provide superior performance
in wet applications, significantly reduce voltage stress on wire insulation
and reduce cross coupling between drives.
The use of cables without shielding is generally acceptable for installations
where electrical noise created by the drive does not interfere with the
operation of other devices such as: communications cards, photoelectric
switches, weigh scales and others. Be certain the installation does not
require shielded cable to meet specific EMC standards for CE, C-Tick or
FCC. Cable specifications depend on the installation Type.
Type 1 & 2 Installation
Type 1 or 2 installation requires 3 phase conductors and a fully rated
individual ground conductor without or with brake leads. Refer to Table 1.A
on page 1-5 for detailed information and specifications on these
installations.
Figure 1.5 Type 1 & 2 Unshielded Multi-Conductor Cable without and with Brake
Leads
Type Max. Wire Size Where Used Rating/Type Description
Type 1 2 AWG Standard Installations
100 hp or less
600V, 90oC (194oF)
XHHW2/RHW-2
Four tinned copper conductors with XLPE insulation
Type 2 2 AWG Standard Installations
100 hp or less with Brake
Conductors
600V, 90oC (194oF)
RHH/RHW-2
Four tinned copper conductors with XLPE insulation plus
one (1) shielded pair of brake conductors.
Type 3 500 MCM AWG Standard Installations
150 hp or more
Tray rated 600V, 90oC (194oF)
RHH/RHW-2
Three tinned copper conductors with XLPE insulation
and (3) bare copper grounds and PVC jacket.
Type 4 500 MCM AWG Water, Caustic Chemical,
Crush Resistance
Tray rated 600V, 90oC (194oF)
RHH/RHW-2
Three bare copper conductors with XLPE insulation and
three copper grounds on 10 AWG and smaller.
Acceptable in Class I & II, Division I & II locations.
Type 5 500 MCM AWG 690V Applications Tray rated 2000V, 90oC (194oF) Three tinned copper conductors with XLPE insulation. (3)
bare copper grounds and PVC jacket.
Note: If terminator network or output filter is used,
connector insulation must be XLPE, not PVC.
Type 2 Installation, with Brake Conductors
Type 1 Installation, without Brake Conductors
G
R
B
W
Filler PVC Outer
Sheath
Single Ground
Conductor
Brake
Conductors
G
R
B
W
Filler PVC Outer
Sheath
Single Ground
Conductor

1-6 Wire/Cable Types
Type 3 Installation
Type 3 installation requires 3 symmetrical ground conductors whose
ampacity equals the phase conductor. Refer to Table 1.A on page 1-5 for
detailed information and specifications on this installation.
Figure 1.6 Type 3 Unshielded Multi-Conductor Cable
The outer sheathing and other mechanical characteristics should be chosen
to suit the installation environment. Consideration should be given to
surrounding air temperature, chemical environment, flexibility and other
factors as necessary in all installation 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. Strong consideration for shielded
cable should be given for installations with sensitive equipment such as
weigh scales, capacitive proximity switches and other devices that may be
affected by electrical noise in the distribution system. Applications with
large numbers of drives in a similar location, imposed EMC regulations or a
high degree of communications / networking are also good candidates for
shielded cable.
Shielded cable may also help reduce shaft voltage and induced bearing
currents for some applications. In addition, the increased size of shielded
cable may help extend the distance that the motor can be located from the
drive without the addition of motor protective devices such as terminator
networks. Refer to Chapter 5 for information regarding reflected wave
phenomena.
Consideration should be given to all of the general specifications dictated by
the environment of the installation, including temperature, flexibility,
moisture characteristics and chemical resistance. In addition, a braided
shield should be included and specified by the cable manufacturer as having
coverage of at least 75%. An additional foil shield can greatly improve
noise containment.
G
R
B
W
G
G
Filler
PVC Oute
r
Sheath
Multiple Ground
Conductors

Wire/Cable Types 1-7
Type 1 Installation
A good example of acceptable shielded cable for Type 1 installation is
Belden®295xx (xx determines gauge) or Anixter B209500-B209507.
These cables have 4 XLPE insulated conductors with a 100% coverage foil
and an 85% coverage copper braided shield (with drain wire) surrounded by
a PVC jacket. For detailed specifications and information on these
installations, refer to Table 1.A on page 1-5.
Figure 1.7 Type 1 Installation — Shielded Cable with Four Conductors
Type 2 Installation
A good example of acceptable shielded cable for Type 2 installation is
Anixter OLF-7xxxxx. This is essentially the same cable as Type 1, plus one
(1) shielded pair of brake conductors. For more information on this
installation, refer to Table 1.A on page 1-5.
Figure 1.8 Type 2 Installation — Shielded Cable with Brake Conductors
B
R
G
W
Shield
Drain Wire
B
R
G
W
Shield for
Brake
Conductors
Drain Wire for
Brake Conductor
Shield

1-8 Wire/Cable Types
Type 3 Installation
These cables have 3 XLPE insulated copper conductors, 25% minimal
overlap with helical copper tape and three (3) bare copper grounds in PVC
jacket.
TIP: Other types of shielded cable are available, but the selection of these
types may limit the allowable cable length. Particularly, some of the newer
cables twist 4 conductors of THHN wire and wrap them tightly with a foil
shield. This construction can greatly increase the cable charging current
required and reduce the overall drive performance. Unless specified in the
individual distance tables as tested with the drive, these cables are not
recommended and their performance against the lead length limits supplied
is not known. For more information, about motor cable lead restrictions
refer Appendix A, Conduit on page 4-13, Moisture on page 4-18 and
Effects On Wire Types on page 5-1 on THHN wire.
Armored Cable
Cable with continuous aluminum armor is often recommended in drive
system applications or specific industries. It offers most of the advantages
of standard shielded cable and also combines considerable mechanical
strength and resistance to moisture. It can be installed in concealed and
exposed manners and removes the requirement for conduit (EMT) in the
installation. It can also be directly buried or embedded in concrete.
Because noise containment can be affected by incidental grounding of the
armor to building steel (see Chapter 2) when the cable is mounted, it is
recommended the armored cable have an overall PVC jacket.
Interlocked armor is acceptable for shorter cable runs, but continuous
welded armor is preferred.
Cable with a single ground conductor is sufficient for drive sizes up to and
including 200 HP (150 kW). Cable with three ground conductors is
recommended for drive sizes larger than 200 HP (150 kW). The ground
conductors should be spaced symmetrically around the power conductors.
The ground conductor(s) should be rated for full drive ampacity.
Cable with Three Ground Conductors
Cable with a Single Ground Conductor
G
R
B
W
G
G
G
R
B
W

Wire/Cable Types 1-9
Figure 1.9 Armored Cable with Three Ground Conductors
A good example of acceptable cable for Type 5 installation is Anixter
7V-5003-3G, which has three (3) XLPE insulated copper conductors, 25%
minimal overlap with the helical copper tape and three (3) bare copper
grounds in PVC jacket. Please note that if a terminator network or output
filter is used, connector insulation must be XLPE, not PVC.
European Style Cable
Cable used in many installations in Europe should conform to the CE Low
Voltage Directive 73/23/EEC. Generally recommended are flexible cables
with a recommended bend radius of 20 times the cable diameter for
movable cable and 6 times the cable diameter for fixed installations. The
screen (shield) should be between 70 and 85% coverage. Insulation for both
conductors and the outer sheath is PVC.
The number and color of individual conductors may vary, but the
recommendation is for 3 phase conductors (customer preferred color) and
one ground conductor (Green / Yellow)
Ölflex® Classic 100SY or Ölflex Classic 110CY are examples.
Figure 1.10 European Style Multi-Conductor Cable
Optional PVC Outer Sheath
Armor
Conductors with XLPE
Insulation
Optional Foil / Copper Tape
and / or inner PVC Jacket
R
B
W
Filler
PVC Outer
Sheath
Stranded
Neutral

1-10 Wire/Cable Types
Input Power Cables In general, the selection of cable for AC input power to a drive has no
special requirements. Some installations may suggest shielded cable to
prevent coupling of noise onto the cable (see Chapter 2) and in some cases,
shielded cable may be required to meet noise standards such as CE for
Europe, C-Tick for Australia / New Zealand, and others. This may be
especially true if an input filter is required to meet a standard. Each
individual drive user manual will show the requirements for meeting these
types of standards. Additionally, individual industries may have required
standards due to environment or experience.
For AC variable frequency drive applications that must satisfy EMC
standards for CE, C-Tick, FCC or other, Rockwell Automation may
recommend that the same type of shielded cable specified for the AC motors
be used between the drive and transformer. Check the individual user
manuals or system schematic note sheets for specific additional
requirements in these situations.
Motor Cables The majority of recommendations regarding drive cable address issues
caused by the nature of the drive output. A PWM drive creates AC motor
current by sending DC voltage pulses to the motor in a specific pattern.
These pulses affect the wire insulation and can be a source of electrical
noise. The rise time, amplitude, and frequency of these pulses must be
considered when choosing a wire / cable type. The choice of cable must
consider:
1. The effects of the drive output once the cable is installed
2. The need for the cable to contain noise caused by the drive output
3. The amount of cable charging current available from the drive
4. Possible voltage drop (and subsequent loss of torque) for long wire runs
Keep the motor cable lengths within the limits set by the drive's user
manual. Various issues, including cable charging current and reflected wave
voltage stress may exist. If the cable restriction is listed because of
excessive coupling current, apply the methods to calculate total cable
length, as shown in Figure 1.11 on page 1-11. If the restriction is due to
voltage reflection and motor protection, tabular data is available. Refer to
Appendix A for exact distances allowed.

Wire/Cable Types 1-11
Figure 1.11 Motor Cable Length
Important: For multi motor applications review the installation carefully.
Consult your distributor drive specialist or Rockwell
Automation directly, when considering a multi motor
application with greater than two motors. In general most
installations will have no issues. However high peak cable
charging currents can cause drive over-currents or ground
faults.
Cable for Discrete Drive I/O Discrete I/O such as Start and Stop commands can be wired to the drive
using a variety of cabling. Shielded cable is recommended, as it can help
reduce cross-coupled noise from power cables. Standard individual
conductors that meet the general requirements for type, temperature, gauge
and applicable codes are acceptable if they are routed away from higher
voltage cables to minimize noise coupling. However, multi-conductor cable
may be less expensive to install. Control wires should be separated from
power wires by at least 0.3 meters (1 foot)
Table 1.B Recommended Control Wire for Digital I/O
182.9 (600)
91.4 (300) 91.4 (300)
15.2 (50)
167.6 (550) 152.4 (500)
15.2 (50)15.2 (50)
All examples represent motor cable length of 182.9 meters (600 feet)
Type (1)
(1) The cable choices shown are for 2 channel (A&B) or three channel (A,B & Z) encoders. If high resolution or
other types of feedback devices are used, choose a similar cable with the correct gauge and number of
conductor pairs.
Wire Type(s) Description
Minimum
Insulation Rating
Unshielded Per US NEC or applicable national
or local code
–300V,60
º C
(140 º F)
Shielded Multi-conductor shielded cable
such as Belden 8770(or equiv.)
0.750 mm2(18AWG),
3 conductor, shielded.

1-12 Wire/Cable Types
Analog Signal and Encoder
Cable
Always use shielded cable with copper wire. Wire with insulation rating of
300V or greater is recommended. Analog signal wires should be separated
from power wires by at least 0.3 meters (1 foot). It is recommended that
encoder cables be run in a separate conduit. If signal cables must cross
power cables, cross at right angles. Terminate the shield of the shielded
cable as recommended by manufacturer of the encoder or analog signal
device.
Table 1.C Recommended Signal Wire
Communications DeviceNet
DeviceNet cable options, topology, distances allowed and techniques used
are very specific to the DeviceNet network. Refer to DeviceNet Cable
System Planning and Installation Manual, publication DN-6.72.
In general, there are 4 acceptable cable types for DeviceNet media. These
include:
1. Round (Thick) cable with an outside diameter of 12.2 mm (0.48 in)
normally used for trunk lines but can also be used for drop lines
2. Round (Thin) cable with an outside diameter of 6.9 mm (0.27 in)
normally used for drop lines but may also be used for trunk lines
3. Flat cable normally used for trunk lines
4. KwikLink drop cable used only in KwikLink systems.
Signal Type/
Where Used Wire Type(s) Description
Minimum
Insulation Rating
Standard Analog I/O Belden 8760/9460(or equiv.) 0.750 mm2(18AWG),
twisted pair, 100% shield
with drain (5).
(5) If the wires are short and contained within a cabinet which has no sensitive circuits, the use of shielded wire may
not be necessary, but is always recommended.
300V,
75-90 ºC
(167-194 ºF)
Remote Pot Belden 8770 (or equiv.) 0.750 mm2(18AWG), 3
cond., shielded
Encoder/Pulse I/O
Less 30.5 m (100 ft.)
Combined: Belden 9730 (or
equivalent) (1)
(1) Belden 9730 is 3 individually shielded pairs (2 channel plus power). If 3 channel is required, use Belden 9728 (or
equivalent).
0.196 mm2(24 AWG),
individually shielded.
Encoder/Pulse I/O
30.5 m (100 ft.) to
152.4 m (500 ft.)
Signal: Belden 9730/9728
(or equivalent) (1)
0.196 mm2(24 AWG),
individually shielded.
Power: Belden 8790 (2)
(2) Belden 8790 is 1 shielded pair.
0.750 mm2(18 AWG)
Combined: Belden 9892 (3)
(3) Belden 9892 is 3 individually shielded pairs (3 channel), 0.33 mm2(22 AWG) plus 1 shielded pair 0.5 mm2(20
AWG) for power.
0.330 mm2or 0.500 mm2 (3)
Encoder/Pulse I/O
152.4 m (500 ft.) to
259.1 m (850 ft.)
Signal: Belden 9730/9728
(or equivalent) (1)
0.196 mm2(24 AWG),
individually shielded.
Power: Belden 8790
(2) 0.750 mm2(18 AWG)
Combined: Belden 9773/9774
(or equivalent) (4)
(4) Belden 9773 is 3 individually shielded pairs (2 channel plus power). If 3 channel is required, use Belden 9774 (or
equivalent).
0.750 mm2(18 AWG),
individually shielded pair.