Ap10 - Cranes - Cabling Guides

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Foreword

Introduction 1
Selection of load side
components 2
Cranes
Sizing of cable cross section 3

AP10: Cabling and Wiring Power cable selection 4


Guidelines SINAMICS
Installation of control cables 5
Product Information
Busbar connections
(including cable connection) 6

Appendix A

11/2012
Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.

! DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.

! WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.

! CAUTION
with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken.

CAUTION
without a safety alert symbol, indicates that property damage can result if proper precautions are not taken.

NOTICE
indicates that an unintended result or situation can occur if the relevant information is not taken into account.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.
Qualified Personnel
The product/system described in this documentation may be operated only by personnel qualified for the specific
task in accordance with the relevant documentation, in particular its warning notices and safety instructions.
Qualified personnel are those who, based on their training and experience, are capable of identifying risks and
avoiding potential hazards when working with these products/systems.
Proper use of Siemens products
Note the following:

! WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended
or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and
maintenance are required to ensure that the products operate safely and without any problems. The permissible
ambient conditions must be complied with. The information in the relevant documentation must be observed.

Trademarks
All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication
may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.

Siemens AG Copyright © Siemens AG 2012.


Industry Sector 11/2012 Technical data subject to change
Postfach 48 48
90026 NÜRNBERG
GERMANY
Foreword

General Notes

Note
The standard applications are not binding and do not claim to be complete regarding the
circuits shown, equipping and any eventuality. The standard applications do not represent
customer-specific solutions. They are only intended to provide support for typical
applications. You are responsible in ensuring that the described products are correctly used.
These standard applications do not relieve you of the responsibility in safely and
professionally using, installing, operating and servicing equipment. When using these
standard applications, you recognize that we cannot be made liable for any damage/claims
beyond the liability clause described. We reserve the right to make changes to these
standard applications at any time without prior notice. If there are any deviations between the
recommendations provided in these standard applications and other Siemens publications –
e. g. catalogs – then the contents of the other documents have priority.

Guarantee, Liability and Support


If the application is provided free of charge the following shall apply:
We shall not be liable for the information contained in this document.
Any and all further rights and remedies against Siemens AG for whatsoever legal reason,
shall be excluded; this shall refer in particular to claims for loss of production, loss of use,
loss of orders or profit and other direct, indirect or consequential damage.
The aforesaid shall not apply if liability is mandatory, e. g. in accordance with the Product
Liability Act, in cases of intent, gross negligence by directors and officers of Siemens AG or
in the case of willful hiding of a defect.
These limitations of liability shall also apply for the benefit of the Siemens AG's
subcontractors, suppliers, agents, directors, officers and employees.
This Contract shall be subject to German law if customer’s place of business is in Germany.
If customer’s place of business is outside of Germany the Contract shall be subject to Swiss
law. The application of the UN Convention on Contracts for the International Sale of Goods
(CISG) shall be excluded.
If the application is provided in return for payment the alternative shall apply which fits the
respective business case:

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Product Information, 11/20112 3
Introduction

Alternative 1: (internal business)


If not explicitly stated otherwise below, the "Terms and Conditions for Deliveries and
Services for Siemens Internal Transactions", valid at the time of sale, are applicable.
Alternative 2: (domestic business of Siemens AG)
If not explicitly stated otherwise below, the "General License Conditions for Software
Products for Automation and Drives for Customers with a Seat or registered Office in
Germany", valid at the time of sale, are applicable.
Alternative 3: (direct export business of Siemens AG)
If not explicitly stated otherwise below, the "General License Conditions for Software
Products for Automation and Drives for Customers with a Seat or Registered Office
outside of Germany", valid at the time of sale, are applicable.
It is not permissible to transfer or copy these standard applications or excerpts of them in
unmodified form without first having prior explicit authorization from Siemens Industry Sector
in writing.

Export Procedure Indicator


AL: N
ECCN: N

Background
Siemens supplies electrical components such as SIMATIC S7 programmable logic
controllers, SINAMICS frequency converters, SINAMICS infeed and regenerative units and
induction motors as components for installation on cranes in the harbour and other
industries. Safe and reliable performance of the electrical components without disturbance or
premature failure of electronic components depends on adequate installation and wiring
practices. The following chapters describe in detail cabling recommendations by Siemens.
Particularly noteworthy are aspects covered in the international standard IEC 60204-32
providing requirements and recommendations relating to the electrical equipment of hoisting
machines so as to promote safety of persons and property, consistency of control response
and ease of maintenance.

IEC 60204-32 Safety of machinery – Electrical equipment of machines –


Part 32:
Requirements for hoisting machines
EN 954-1 Safety of machinery – Safety-related parts of control
systems - Part 1:
General principles for design
DIN VDE 0660 Part 12 – Protective conductor terminals
EN 55011 Limits and methods of measurement of radio disturbance
characteristics of industrial, scientific and medical (ISM)
radio-frequency equipment
EN 61800-3 EMC product standard including special test methods for
electric drive units

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4 Product Information, 11/20112
Introduction

89/336/EWG COUNCIL DIRECTIVE of 3 May 1989 on the approximation


of the laws of the Member States relating to
electromagnetic compatibility
73/23/EWG Council Directive of 19 February 1973 on the harmonization
of the laws of Member States relating to electrical
equipment designed for use within certain voltage limits
6SE7087-6QX60 Masterdrives Compendium Vector Control 1998
6SE7087-6CX87-8CE0 Installation Instructions for EMC Correct Installation of
Drives
Prysmian (Pirelli) catalog BU IS Flexible Electric Cables
2.1 × 2000
SINAMICS catalogue D21.3 SINAMICS S120 chassis / cabinet modules
SINAMICS Engineering Manual SINAMICS G130, G150, S120 Chassis, S120 Cabinet
Modules, S150
IEEE Transactions on Industrial Article by Annette Muetze and Andreas Binder
Applications
(Vol. 42, No. 4 July/August
2006)
The implementation of these recommendations is no substitute for a risk assessment of the
crane which needs to be made by the crane builder.

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Product Information, 11/20112 5
Introduction

Table of contents

1 Introduction .................................................................................................................................. 7
1.1 High frequency disturbance ...................................................................................................... 7
1.2 Long motor cables.................................................................................................................... 8
1.3 Common-mode oscillation .......................................................................................................12
1.4 Bearing current .......................................................................................................................13
2 Selection of load side components ................................................................................................ 15
2.1 Maximum cable length, no output reactor ................................................................................15
2.2 Maximum cable length and output reactor ...............................................................................16
2.2.1 Voltage-limiting du/dt filters......................................................................................................17
2.2.2 Sine filters ...............................................................................................................................20
3 Sizing of cable cross section ........................................................................................................ 22
3.1 Conductors .............................................................................................................................22
3.2 Protective conductor................................................................................................................23
4 Power cable selection.................................................................................................................. 25
4.1 Types of power cable ..............................................................................................................25
4.2 Insulation material used for power cables ................................................................................26
4.3 Power cables recommended by Siemens ................................................................................26
4.4 Installation guidelines ..............................................................................................................28
4.4.1 Grounding and high-frequency equipotential bonding ..............................................................29
4.4.2 Wiring guidelines in accordance to EMC rules .........................................................................31
4.4.3 Digital signals / encoder ..........................................................................................................34
4.4.4 EMC-compliant cable routing on the plant side on cable racks and in cable ducts ....................36
4.4.5 Wiring requirements as per IEC 60204-32 ...............................................................................38
4.4.6 Wiring practices to be avoided .................................................................................................41
4.4.7 Best practices for screened power cable termination ...............................................................43
5 Installation of control cables ......................................................................................................... 49
5.1 Installation of PROFIBUS cables .............................................................................................49
5.2 Installation of encoder cables ..................................................................................................51
6 Busbar connections (including cable connection) ............................................................................ 57
A.1 Contact ...................................................................................................................................59

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6 Product Information, 11/20112
Introduction

Introduction 1
Variable speed drives have become an integral component of the electrical control system
for cranes. The installation of variable speed drives on cranes with increasing rated load and
crane size has become a technical challenge. The following recommendations are meant to
help the crane builder in carrying out the electrical installation and cabling in a way that latest
aspects of variable speed drives parasitic effects are covered.

1.1 High frequency disturbance


Variable-speed drives have advantages and disadvantages. One of the disadvantages is the
high switching frequency of the semiconductor (IGBT) which can cause disturbances to other
components.
Sinamics frequency converters (motor modules) operate with a voltage-source DC link. In
order to keep the power losses as low as possible the inverter switches the DC link voltage
to the motor winding in the form of voltage blocks. A reasonably sinusoidal current flows into
the motor.

Figure 1-1 Block diagram of a PWM converter with voltage-source DC link

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Product Information, 11/20112 7
Introduction
1.2 Long motor cables

The described mode of operation in conjunction with high-performance semiconductor


switching elements has made it possible to develop compact frequency converters which
now play a vital role in drive technology.
However, due to the fast switching a pulse-type noise current flows to ground through
parasitic capacitances CP at each switching edge. Parasitic capacitances exist between the
motor cable and ground and also within the motor.

Figure 1-2 Block diagram showing output voltage V and fault current Is

The source of the earth current IS is the inverter, thus this earth current must also flow back
to the inverter. Impedance ZN and ground impedance ZE act in the return flow path.
Impedance ZN forms parasitic capacitances between the supply cable and ground which is
connected in parallel with the impedance (between phase and ground) of the supply
transformer. The noise current itself and the voltage drops across ZN and ZE caused by the
noise current can also affect other electrical units. Therefore, variable-speed drives generate
high-frequency noise currents.
EMC stands for "Electromagnetic Compatibility" and, in accordance with the EMC Law §2(7),
it defines "the capability of a unit to operate satisfactorily in an electromagnetic environment,
without itself causing electromagnetic disturbances which would be unacceptable for other
electrical units in this environment".

1.2 Long motor cables


Effect of crane mechanical configurations on the length of the electrical cables of a Ship-to-
Shore (STS) type of crane:

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8 Product Information, 11/20112
Introduction
1.2 Long motor cables

Machinery on trolley (MOT)

Positive:
Shorter wire-ropes for hoist
No wire-ropes for trolley

Negative:
Long electrical cables for hoist motors
Long electrical cables for trolley motors
Space constraints for hoist motors

Self-propelled trolley (SPT)

Positive
No wire-ropes for trolley

Negative
Long electrical cables for trolley motors

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Product Information, 11/20112 9
Introduction
1.2 Long motor cables

Rope-towed trolley (RTT)

Positive:
Shorter cables to hoist and trolley motors

Negative:
Long wire-ropes for hoist and trolley

Typical Gantry configuration

Negative:
Accumulated long motor cables

From all the examples above the gantry motion has the longest motor cable. A typical STS
crane with the inverters mounted in the machinery house on the girder has accumulated
gantry motor cable lengths reaching almost 1000 m.
The industrial cranes have a large variety of designs in terms of the mechanical or electrical
aspects. Siemens has so far identified the following 7 types of application industries for
cranes:

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10 Product Information, 11/20112
Introduction
1.2 Long motor cables

1. Cranes for metallurgical plants


2. Steel mill cranes
3. Installation and workshop cranes
4. Warehouse cranes
5. Shipyard cranes
6. Power house cranes
7. Other process cranes

Figure 1-3 Some examples of industrial cranes

However, most of the industrial cranes mentioned above can be classified as STS cranes.
With this classification it can be further analyzed that two types of power cable routing
methods are used:
Festoon types
E-Chain types
E-chain types (although often not preferred by terminal operators for Harbour cranes) are
usually used in long travel applications via integrated gliding mounts or shoes that are made
from low wear polymers and plastics.

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Product Information, 11/20112 11
Introduction
1.3 Common-mode oscillation

1.3 Common-mode oscillation


On large cranes with long motor feeder cables (e. g. SPT and MOT configurations) in
combination with pulsed line-side converters, a common-mode oscillation may occur that
could lead to excessive phase-to-ground voltage stress on the motors.

Figure 1-4 Principal circuit for common-mode oscillation

Engineering of the drive system has to consider carefully the entire drive train, comprising
the medium voltage transformer
the drive system with line-side converters and inverters on the common DC bus
the motor with the insulation class
the cabling between the different components

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12 Product Information, 11/20112
Introduction
1.4 Bearing current

1.4 Bearing current


Asymmetrical characteristics of the motor feeder cable in conjunction with the PWM
switching pattern of the inverter leads to building up voltage between the rotor and the stator
of the motor. If this voltage exceeds a certain threshold value the grease film lubricating the
bearing will collapse and bring about a metal-metal contact. This leads to premature bearing
failures.

Figure 1-5 Types of bearing current in a typical crane system

The figure above shows the fundamental bearing currents which can lead to premature
bearing failures and also possible encoder failures (depending on the insulation of the
encoder from the bearing). In the following you find a brief description of the various bearing
currents shown above:

Circular current
High frequency leakage current flows between winding and housing and thus to ground
which induces a high frequency shaft voltage (VShaft). Current flows from shaft to housing in
one bearing and from housing back to shaft in the other bearing.

Electrostatic Discharge Machining (EDM) current


Phase-to-ground voltage (or referred to as "common mode voltage") charges the bearing
capacitance. When the lubricating film on the bearing breaks down due to a high VBearing
values the bearing capacitance and capacitance between winding and rotor discharges
causing a high current pulse referred to as EDM.

Rotor shaft current


When the housing of the motor is badly grounded for the purpose of high frequency currents,
this causes the leakage current (due to capacitance between winding and housing) to
encounter a high resistance between housing and grounded systems across. If the gearbox /
driven machine of the motor is grounded more effectively then the leakage current flows in
this path and can further cause damages on the gearbox or driven machine bearings apart
from the motor bearings.

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Product Information, 11/20112 13
Introduction
1.4 Bearing current

As a conclusion, all motor feeder cables have to be screened and of symmetric design.
Proper/effective grounding for the motor is to be ensured for the purpose of high frequency
currents to avoid premature bearing damages. Bearing damage may be viewed as
insignificant cost to other potential failures but it is nevertheless time consuming (especially
for Hoist motors) contributes to crane down time leading to huge losses at the expense of
terminal operators.

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14 Product Information, 11/20112
Selection of load side components 2
The objective of the following chapters is to give a clear instruction on
How to select the correct load-side components
How to select suitable cable and type.
How to implement correct wiring practices.
– Dimensioning of cable cross section
– Installation of power cables
– Installation of control cables
The purpose of output reactors is to limit capacitive recharging currents into the capacitance
of the motor feeder cable so as to protect the IGBTs in the drive.
The selection of output reactors depends on the following parameters:
Type of cables used (screened or unscreened; refer to table in the following chapter)
Number of motors supplied from a converter
When a converter/inverter supplies several motors (group drive) the capacitive charge /
discharge currents of the motor cables are added. The total cable length is the sum of the
cable lengths for the individual motors.

2.1 Maximum cable length, no output reactor


The market of cables supplies a variety of applications and defines a myriad of criteria.
However, cables can be categorized according to the following characteristics:
Electrical (which will be looked at further in detail)
Thermal
Mechanical
Chemical
Electromagnetic capability
Others (e. g. fire resistance etc.)
This guideline will look into the selection of cable lengths in terms of cable capacitance and
the remaining characteristics of the cables as mentioned above would be in favour of the
crane builder/customer.
The maximum cable lengths which can be connected to the Sinamics Motor Modules unit
without reactors are specified in the following table.

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Product Information, 11/20112 15
Selection of load side components
2.2 Maximum cable length and output reactor

Table 2- 1 Motor cable length without output reactor Sinamics G130, G150, S150, S120 (Chassis /
Cabinet Modules)

Rated voltage Non-shielded cables Shielded Cables


(e.g. Protodur NYY) (e.g. Protodur NYCWY)
3AC 380 V - 480 V 450 m 300 m
3AC 500 V – 600 V 450 m 300 m
3AC 660 V - 690 V 450 m 300 m

2.2 Maximum cable length and output reactor


Whenever there are long power cables they should be dimensioned according to the following
table.

Table 2- 2 Motor cable length when using output reactors (Sinamics G130 / G150)

Number of reactors in series 1 2 1 2


Rated Voltage Reactor Reactor
Non-shielded cables Shielded cables2)
3AC 380 V to 480 V 450 m 675 m 300 m 450 m
3AC 500 V to 600 V 450 m 675 m 300 m 450 m
3AC 660 V to 690 V 450 m 675 m 300 m 1) 450 m 1)

Table 2- 2.1 Motor cable length when using output reactors (Sinamics S120 / S150)

Number of reactors in series 1 2 1 2


Rated Voltage Reactor Reactor
Non-shielded cables Shielded cables2)
3AC 380 V to 480 V 450 m 787 m 300 m 525 m
3AC 500 V to 600 V 450 m 787 m 300 m 525 m
3AC 660 V to 690 V 450 m 787 m 300 m 525 m

1) For using Sinamics G150 (1750kW up to 2700kW) in parallel a maximum cable length of
525m (non-shielded cables) and 787m (shielded cables)

2) The effective capacitance per unit length of the PROTOFLEX EMC cable corresponds to that
of an unshielded cable. With the PROTOFLEX EMC cable, the same motor cable lengths are
therefore possible as with an unshielded cable.

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16 Product Information, 11/20112
Selection of load side components
2.2 Maximum cable length and output reactor

2.2.1 Voltage-limiting du/dt filters


Voltage limiting filters (output du/dt filters) should be used for motors if the voltage strength
of the insulation system is not known or is inadequate.
The du/dt filters limit the voltage rate-of-rise and the typical voltage spikes for the rated
supply voltage to the following values:
du/dt-Filter plus VPL
voltage rate-of-rise <500V/µs
< 1000 V at Vsupply 575 V
< 1250 V at 660 V Vsupply 690 V

du/dt-Filter compact plus VPL


voltage rate-of-rise <1600V/µs
< 1150 V at Vsupply 575 V
< 1400 V at 660 V Vsupply 690 V

Note
The maximum cable length between the motor module and the du/dt filter is limited to 5m.

The maximum motor cable length can be dimensioned according to the following tables.

Table 2- 3 Motor cable length when using du/dt filter plus VPL

Maximum motor cable length


Rated Voltage Shielded cables Non-Shielded cables
e.g. Protodur NYCWY e.g. Protodur NYY
3AC 380 V to 480 V 300 m 450 m
3AC 500 V to 600 V 300 m 450 m
3AC 660 V to 690 V 300 m 450 m

Table 2- 4 Motor cable length when using du/dt filter compact plus VPL

Maximum motor cable length


Rated Voltage Shielded cables Non-Shielded cables
e.g. Protodur NYCWY e.g. Protodur NYY
3AC 380 V to 480 V 100 m 150 m
3AC 500 V to 600 V 100 m 150 m
3AC 660 V to 690 V 100 m 150 m

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Product Information, 11/20112 17
Selection of load side components
2.2 Maximum cable length and output reactor

Note
The total cable length is the sum of the cable lengths connected to the individual motors.
From a motor current of 120 A, single-motor drives can also be supplied with parallel cables
(up to the maximum permissible cable length) in case of standard units.

Note
The voltage limiting filters can be used up to a maximum output frequency of 150 Hz.
The permanent minimum output frequency can be 0Hz with a du/dt-Filter plus VPL and
10Hz with a du/dt-Filter compact plus VPL ( <10Hz for maximum 5min)

Note
The du/dt filters can only be used with a motor connected.

Note
The maximum pulse frequency is limited to the double of the factory settings.
Factory setting 2kHz => maximum 4kHz
Factory setting 1,25kHz => maximum 2,5kHz

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18 Product Information, 11/20112
Selection of load side components
2.2 Maximum cable length and output reactor

The following principal diagram shows the voltage values at the motor output terminals of the
motor module and the voltage values at the motor connection terminals.

Figure 2-1 Arrangement of output reactor and dV/dt filter

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Product Information, 11/20112 19
Selection of load side components
2.2 Maximum cable length and output reactor

2.2.2 Sine filters


Sine filters ensure that motor voltage and motor current are almost sinusoidal.
The peak voltage and the critical rate of rise of off-state voltage are limited by the filter.
critical rate of rise of off-state voltage du/dt << 50V/µs
peak voltage < 1.1 * 2 * Usupply

The sine filters for supply voltages of 380 V to 480 V are designed for a pulse frequency of
4 kHz (2.5kHz at 3AC500V - 600V)
The maximum output frequency is limited to 150Hz.

NOTICE
The maximum cable length between the motor module and the sine filter is limited to
5m.

NOTICE

Note the current derating for chassis units as a result of the 4 kHz (2,5kHz) pulse
frequency!

ATTENTION

The sine filters can only be used with a motor connected!

Sine filters are suitable for supplying Ex (d) motors. They limit the voltage stressing in the
motor terminal boxes to a value like a direct driven motor.
The sine filters are able to run in earthed power supplies (TN/TT) and in unearthed power
supplies (IT).
For possible cable lengths see the following table.

Table 2- 5 Motor cable length with sine filter (for Sinamics G130, G150, S150, S120)

Supply voltage Maximum motor cable length


Shielded cables Non-shielded cables
(e.g. Protodur NYCWY) (e.g. Protodur NYY)
3AC 380 – 480 V 300 m 450 m
3AC 500 – 600 V 300 m 450 m

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20 Product Information, 11/20112
Selection of load side components
2.2 Maximum cable length and output reactor

Because of the increased pulse frequency (4kHz at 380-480V and 2.5kHz at 500-600V) the
maximum output power is reduced. The following table shows the maximum output power with
and without a sine filter.
Supply voltage Output power Nominal output Current-Derating- Output current
current Factor

without sine filter without sine filter with sine filter with sine filter

3AC 380V – 480V 110 kW 210 A 82% 172 A

3AC 380V – 480V 132 kW 260 A 83% 216 A

3AC 380V – 480V 160 kW 310 A 88% 273 A

3AC 380V – 480V 200 kW 380 A 87% 331 A

3AC 380V – 480V 250 kW 490 A 78% 382 A

3AC 500V – 600V 110 kW 175 A 87% 152 A

3AC 500V – 600V 132 kW 215 A 87% 187 A

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Product Information, 11/20112 21
Sizing of cable cross section

Sizing of cable cross section 3


3.1 Conductors
For information on the recommended cross-sectional area of the conductors for incoming
and outgoing cables of every size: refer to the respective operating instructions of SINAMICS
components.

With symmetrical, 3-wire, three-phase cables, the summed ampere-turns over the cable
outer diameter are equal to zero and they can be routed in conductive, metal cable ducts or
racks without any significant currents (ground current or leakage current) being induced in
these conductive, metal connections. The danger of induced leakage currents and thus of
increased cable-shield losses increases with single-wire cables.

Copper cable Aluminum


Cross-section of Single Groups of cables Single Groups of cables
3-wire-cable routing routed in parallel 1) routing routed in parallel 1)
[mm2] [A] [A] [A] [A]
3 x 2.5 22 17 17 13
3 x 4.0 30 23 23 18
3 x 6.0 37 29 29 22
3 x 10 52 41 40 31
3 x 16 70 54 53 41
3 x 25 88 69 68 53
3 x 35 110 86 84 65
3 x 50 133 104 102 79
3 x 70 171 133 131 102
3 x 95 207 162 159 124
3 x 120 240 187 184 144
3 x 150 278 216 213 166
3 x 185 317 247 244 190
3 x 240 374 292 287 224
1) maximum 9 cables routed horizontally in direct contact with one another on a cable rack

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22 Product Information, 11/20112
Sizing of cable cross section
3.2 Protective conductor

Current-carrying capacity of PVC-insulated, 3-wire copper and aluminum cables with a


maximum permissible conductor temperature of 70 °C at an ambient temperature of 40 °C
according to IEC 60364-5-52

With higher amperages, cables must be connected in parallel.

Note:
The recommendations for the North American market in AWG or MCM must be
taken from the appropriate NEC (National Electrical Code)/CEC (Canadian Electrical
Code) standards.

3.2 Protective conductor


The protective conductor has to be dimensioned considering the following aspects:
In the event of an earth fault, it must be ensured that no excessively high touch voltages
occur on the protective conductor as a result of voltage drops of the earth fault current
(<50 VAC or 120 VDC, EN 50 178 Section 5.3.2.2, IEC 60 364, IEC 60 543).
The earth fault current flowing in the protective conductor in the event of an earth fault
must not overheat the protective conductor.

Table 3- 1 Recommended cross-sectional area of external protective conductors

Cross-sectional area for phase conductors Minimum cross-sectional area of the external
supplying the equipment S [mm2] protective copper conductor SP [mm2]
S 16 S
16 < S 35 16
S > 35 S/2

Switchgear and motors are usually grounded via separate local ground connections.
When this grounding arrangement is used, the current caused by a ground fault flows
through the parallel ground connections and is divided. Despite the use of the relatively
small PE conductor cross-sections specified in the table above, no impermissible contact
voltages can develop with this grounding system. Based on experience with different
grounding configurations, however, we recommend that the ground wire from the motor
should be routed directly back to the converter. For EMC reasons and to prevent bearing
currents, symmetrical 3-wire three-phase cables should be used where possible instead
of 4-wire cables, especially on drives in the higher power range. The protective or PE
conductor must be routed separately when 3-wire cables are used or must be arranged
symmetrically in the motor cable. The symmetry of the PE conductor is achieved using a
conductor surrounding all phase conductors or using a cable with a symmetrical
arrangement of the three phase conductors and three ground conductors.

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Product Information, 11/20112 23
Sizing of cable cross section
3.2 Protective conductor

Through their controllers, the converters limit the load current (motor and ground fault
currents) to an rms value corresponding to the rated current. We therefore recommend
the use of a PE conductor cross-section analogous to the phase conductor cross-section
for grounding the converter cabinet.

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24 Product Information, 11/20112
Power cable selection 4
4.1 Types of power cable

Table 4- 1 Overview over power cable types

Construction Shield EMC evaluation


Symmetrical 3 + 3 Cu braid Optimum
(possibly with Cu fleece)

Symmetrical 3-core Cu braid Good


(single core)

Unsymmetrical 4-core Cu braid Good


(possibly with Cu fleece)

Symmetrical 3 + 3 – Satisfactory

Unsymmetrical 4-core – Mediocre

Unsymmetrical parallel Cu braid Mediocre


cores or flat cable

Unsymmetrical parallel – Poor


cores or flat cable

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4.2 Insulation material used for power cables

4.2 Insulation material used for power cables


In view of minimizing the capacitance between the motor phase conductors and ground (see
chapter High frequency disturbance (Page 7) ) it is advisable to choose cables with a
possible specific capacitance as low as possible (pF/m).
The cable capacitance is directly proportional to the dielectrical constant of the insulation
material of the cable. Material such as cross-linked polyethylene (XLPE) have a dielectric
constant of about 2, rubber in contrast may have a dielectric constant of 5.

4.3 Power cables recommended by Siemens


In general, we highly recommend PROTOFLEX EMV 3 Plus for the following reasons:
It can reduce the high frequency noise emission.
It can reduce the bearing current effects.
It has a minimal effective capacitance per unit length which is comparable to that of a
standard unscreened cable (e. g. 3 x 70 + 3 x 10 has a capacitance of 290 nF/km).
The geometric arrangement of conductors and PE conductors is chosen such as to
ensure identical coupling capacitances between phase to phase and phase to PE as
shown in the figure below.

Figure 4-1 Principal cross-sectional view of screened symmetric motor feeder cable

However, it is important to check the cable specifications with the supplier! Different cable
suppliers use different material for their cable sheaths, different quality with geometrical
properties and so on. Therefore, compare the capacitance value / unit length of all these
cables and select the one with the lowest value.

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4.3 Power cables recommended by Siemens

For typical electrical and mechanical characteristics of power cables (PROTOFLEX EMV)
see the two tables below:

Table 4- 2 Electrical specification PROTOFLEX EMV

Nominal voltage in three-phase AC operation U0 / U 0.6 / 1 kV


Test AC voltage 4 kVeff
Maximum permissible peak AC voltage U 1.7 kV
FC connection on 3 Level frequency converter with a U Max. 690 V
nominal voltage
Coupling resistance 250 /km at 30 MHz
Current carrying capacity The definitions in DIN VDE 0298 part 4
apply.

Table 4- 3 Mechanical specification PROTOFLEX EMV

Conductor according DIN VDE 0295 Copper, plain, finely stranded, class 5
Protective conductor according DIN VDE 0295 Copper, plain, finely stranded, class 5
For cross-sections > 16 mm2 the protective
conductor is divided in three cores
Insulation according DIN VDE 0207 part 2 Thermoplastic compound on the basis of
polyethylene (PE); compound 2YI1
Core identification according DIN VDE 0293 Green / yellow, black, blue, brown
Screen Multilayer screen
1. Layer Al-coated plastic tape
braid of tinned copper wires
2. Layer
Sheath according DIN VDE 0207 part 5 PVC compound YM2
colour of sheath: orange, transparent
Marking
Cables with rated cross-section up to 10 mm2 [Year of manufacture] PROTOFLEX EMV-FC
2YSLCY-J [number of cores] X [cross-section]
600/1000 V
[Year of manufacture] PROTOFLEX EMV-CY
2YSLCY-J [number of cores] X [cross-section]
600/1000 V
Cables with rated cross-section of 16 mm2 [Year of manufacture] PROTOFLEX EMV-FC
2YSLCY-J [number of cores] X [cross-section]
600/1000 V
[Year of manufacture] PROTOFLEX EMV-CY
3PLUS
2YSLCY-J [number of cores] X [cross-section]
600/1000 V

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4.4 Installation guidelines

4.4 Installation guidelines


Typical wiring to the drive for the recommended power cable type

Figure 4-2 Earthing and screening for motor connection

Using non-shielded motor cables, the noise current flows in an undefined fashion back to the
frequency converter, e. g. via the crane’s steel structure, cable ducts, cabinet frames. These
current paths have a very low resistance for currents with a frequency of 50 or 60 Hz.
However, the noise current induces a high-frequency component which can result in
problematical voltage drops.
A shielded motor cable is necessary to enable the noise current to flow back to the
frequency converter in a defined fashion. The shield must be connected to the housing of the
frequency converter and to the motor housing through a large surface area. The shield now
forms the easiest path for the noise current to take when returning to the frequency
converter.

Figure 4-3 Flow of the noise current with shielded motor cable

A shielded motor cable with a shield connected at both sides causes the noise current to
flow back to the frequency converter through the shield.

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4.4 Installation guidelines

4.4.1 Grounding and high-frequency equipotential bonding

The ground connections shown in black [0] represent the conventional grounding system for
the drive components. They are made with standard, heavy-power PE conductors without
special high-frequency properties and ensure low frequency equipotential bonding as well as
protection against injury.
The connections shown in red inside the SINAMICS cabinets [1] provide solid bonding for
high-frequency currents between the metal housings of the integrated Chassis components
and the PE busbar and the EMC shield busbar of the cabinet. These internal connections
can be made via a large area using non-isolated metal construction components of the
cabinet. In this case, the contact surface must be bare metal and each contact area must
have a minimum cross-section of several cm2. Alternatively, these connections can be made
with short, finely stranded, braided copper wires with a large cross-section ( 95 mm2).
The shields of the motor cables shown in orange [2] provide high-frequency equipotential
bonding between the Motor Modules and the motor terminal boxes. In older installations in
which unshielded cables are already installed, or where the cables used have a
shield with poor high-frequency properties, or in installations with poor grounding
systems, it is absolutely essential to install the finely stranded, braided copper cables shown
in red in parallel and as close as possible to the motor cable.

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4.4 Installation guidelines

The connections shown in red [3], [4] and [5] provide a conductive, high-frequency bond
between the terminal box of the motor and the motor housing, and also between
gearbox / driven machine and the motor housing. These connections can be omitted
if the motor is constructed in such a way that a conductive, high-frequency bond is
provided between the terminal box and the housing, and if motor, gearbox and
driven machine are all in close proximity and all conductively bonded over a large
area by means of a shared metallic structure, e.g. a metal machine bed.

The connections shown red dashed-and-dotted lines [6] provide a conductive, high-
frequency bond between the cabinet frame and the foundation ground in the form of
finely stranded, braided copper cables with large cross-section ( 95 mm2).

Note:
Grounding measures for machines are essentially a protective measure. However, in the
case of drive systems, this also has an influence on the noise emission and noise immunity.
A system can either be grounded in a star configuration or each component grounded
separately. Preference should be given to the latter grounding system in the case of drive
systems, i.e. all parts of the installation to be grounded are connected through their surface
or in a mesh pattern.

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4.4.2 Wiring guidelines in accordance to EMC rules

For example:
EMC-compliant installation of a SINAMICS G150 converter cabinet unit

Figure 4-4 Overview of best wiring practices adhering to EMC rules

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4.4 Installation guidelines

Further rules to avoid troubles caused by EMC:

The shield between the motor and SINAMICS Motor Module must not be interrupted by the
installation of components such as output reactors, sine filters, du/dt filters, fuses,
contactors. The components must be mounted on a mounting panel which simultaneously
serves as the shield connection for the incoming and outgoing motor cables. Grounded
partitions may be necessary to shield the components.

All of the metal cabinet parts must be connected through the largest possible surface areas
(not paint on paint). Serrated washers should be used to ensure a good metal-metal contact.
The cabinet door must be connected to the cabinet through grounding straps which must be
kept as short as possible.
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4.4 Installation guidelines

Contactors, relays, solenoid valves, surge arrestors, electromechanical operating hours


counters, etc. in the cabinet must be provided with surge suppressor devices, for
example, RC elements, diodes, varistors. These surge suppressor devices must be
connected directly at the coil.

Non-shielded cables associated with the same circuit (outgoing and incoming
conductor) must be twisted, or the surface between the outgoing and incoming conductors
kept as small as possible in order to prevent unnecessary coupling effects.

Connect the reserve cables/conductors to ground at both ends to achieve an additional


shielding effect.

In general, it is possible to reduce the noise being coupled-in by routing cables close to
grounded cabinet panels. Therefore, wiring should be routed as close as possible to the
cabinet housing and the mounting panels and not freely through the cabinet. The same
applies for reserve cables/conductors.

Prevent noise from being coupled-in through the supply. SINAMICS Motor Modules and PLC
/ control electronics should be connected-up to different supply networks. If there is only one
common network, the PLC / control electronics have to be de-coupled from the supply using
an isolating transformer.

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4.4 Installation guidelines

4.4.3 Digital signals / encoder

Digital signals from encoders, transmitters or other devices must be wired with shielded
cables. The shield must be connected at the source and at the target through a large surface
area. The shield must not be interrupted, e.g. using intermediate terminals.

From the EMC point of view, the use of intermediate terminals should be avoided wherever
possible because interruptions in the shield reduce its effectiveness. If it is impossible to
avoid the use of intermediate terminals in certain cases, however, the signal cable shields
must be properly bonded immediately before and after the intermediate terminals on
clamping rails. The clamping rails must be connected to the cabinet housing at both ends
with excellent electrical conductivity and with a large contact area.

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4.4 Installation guidelines

If the equipotential bonding is poor between the shield connections, an additional


equipotential bonding conductor with at least 10 mm² must be connected in parallel
to the shield, to reduce the shield current. Generally, the shields can be connected to
ground (panel housing) in several places. The shields can also be connected to ground at
several locations, even outside the cabinet.

Foil-type shields are not to be favoured. Braided shields are at least 5 times more effective.

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4.4.4 EMC-compliant cable routing on the plant side on cable racks and in cable
ducts

1) When single-wire cables (e.g. unshielded supply connection cables) are used in three-phase
systems, the three phase conductors (L1, L2, and L3) must be bundled symmetrically to minimize the
magnetic leakage fields. This is particularly important when several single-wire cables need to be
routed in parallel for each phase of a three-phase system due to high amperages. The illustration
below uses an example of a three-phase system with two single-wire cables per phase routed in
parallel.

2) When several three-phase motor cables have to be routed in parallel between the converter and
the associated motor, it has to be ensured that all three phases of the three-phase system are routed
within each motor cable. This minimizes the magnetic leakage fields. The illustration below uses an
example of three shielded, three-phase motor cables routed in parallel.

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4.4 Installation guidelines

3) When DC cables (DC link cables or connection cables between Braking Modules and the
associated braking resistors) are routed, the feed and return lines must be routed in parallel
with as little space between them as possible to minimize magnetic leakage fields.

4) Signal cables and power cables must be routed separately (to eliminate coupled-in noise).
Minimum clearance: 20 cm. If the minimum distance is not possible then partitions between
power cables and signal cables as shown in the photo should be provided.
The partitions must be grounded at several points along their length.

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4.4 Installation guidelines

4.4.5 Wiring requirements as per IEC 60204-32

Note
All entries of "chapter" in the following refer to the respective chapters in IEC 60204-32.

All connections must be securely fastened to prevent accidental loosening (chapter


13.1.1).
One protective conductor must be connected to one terminal connecting point unless the
terminal is designed for two or more conductors (chapter 13.1.1).
Terminals on terminal blocks must be identified according to the markings in the drawing
and clearly visible (chapter 13.1.1).

Figure 4-5 Terminals with proper marking

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4.4 Installation guidelines

For aluminium conductors consideration shall be given to the problem of electrolytic


corrosion (chapter 13.1.1).

Figure 4-6 Cupal plates to interface transformer aluminium conductors to copper cable shoes

Cables outside enclosures are to be protected by suitable ducts, conduits or cable


trunking systems; for exceptions refer to chapter 13.4.2.

Figure 4-7 Examples for routing of cable on cable ladders in sill beam

Terminations of cable must be adequately supported to prevent mechanical stresses at


the terminations of the conductors.

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4.4 Installation guidelines

Flexible conduit or flexible multi-conductor cable shall be used for connections involving
small or infrequent movements. Excessive flexing and straining at the connection points
has to be avoided (chapter 13.4.3).

Figure 4-8 Routing cable from main structure to boom across boom hinge

All exposed conductive parts of the electrical equipment and structure must be connected
to the protective bonding circuit to protect against electric shock.

Figure 4-9 Protective bonding for junction boxes

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4.4 Installation guidelines

Continuity of protective bonding circuit must be observed. Removal of any equipment due
to maintenance reason should not interrupt the protective bonding circuit (chapter 8.2.3).
In case of IT supply, the structure will be used as part of the protective bonding circuit in
conjunction with an earth fault supervision system (chapter 8.2.1).

4.4.6 Wiring practices to be avoided

1 Violation of IEC 60204-32, clause 14.2.2


requiring the PE conductor to be identified by
color green-yellow.

2 Signal cables (purple color PROFIBUS bus


communication cables) are mixed with power
cables.
Incoming power cables and outgoing motor
feeder cables are not separated.

3 No EMC cable glands are used.


Screens are connected to junction box PE via
long pigtails.

4 Violation of IEC60204-32 clause 14.1.1


requiring that only one protective conductor
shall be connected to one terminal connecting
point.

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4.4 Installation guidelines

5 Violation of IEC60204-32, clause 14.1.1. The


bolt fastening the cable shoe must be tightly
fastened to the terminal connecting point.
Serrated washers are to be used if the frame is
painted.

6 Connection of cable screens via pigtails.

7 The screen connection of power cables and


analog / digital signal cables on the same cable
screen bar.

8 Violation of IEC60204-32 clause 8.2.3


Metal ducts of flexible or rigid construction and
metallic cable sheaths shall not be used as
protective conductors.
Nevertheless, such metal ducts and the metal
sheathing of all connecting cables (e. g. cable
armouring, lead sheath) shall be connected to
the protective bonding circuit.

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4.4 Installation guidelines

4.4.7 Best practices for screened power cable termination


The following sections show best practices for terminating screened power cable at the
output of drive, intermediate junction box and motor junction box.

4.4.7.1 Termination in drive unit

Figure 4-10 Terminating screened cable at drive unit end

The figure above shows several interesting details:


the color of the cable is according to IEC 60204-32
the PE bar is indicated with the PE strips Green and Yellow strips.
the cable screen is electrically connected to the cable retaining bar via a cut-off section of
the cable exposing the screen braid clamped down by a galvanized steel U-clamp or
metal cable tie. The U-clamp is a preferred solution. This refer also to the picture on page
32 (Shield bonding to the EMC shield busbar in the converter using an EMC shield clip.

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4.4 Installation guidelines

Figure 4-11 Connecting power cable shields on strain relief bar in cabinet

The figure above shows the U-clamp types used to connect the screening braids of the
screened (shielded) cables. These clamps have opposite pressure sleeves which provide a
larger surface area for the screen connection, hence a better protection against
electromagnetic influences. U-clamps made from non-magnetic materials such as stainless
steel (e. g. PUK type K-AC LW) are a good choice for this type of installation.

4.4.7.2 Termination in intermediate junction box from screened power cables

Figure 4-12 Cable screen connection

The figure above shows an example of termination where the cable screen is connected to
an isolated bar via metal cable tie. Connection for the cable screen can be done in the
following way:
Cable screen is connected via an insulated bar in each junction box which means there is
no connection to ground at intermediate points. The insulated bars are connected via
intermediate points.
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4.4 Installation guidelines

4.4.7.3 Termination in motor junction box


A suitable metallic gland with shield connection must be used at the motor to connect the
shield. It should be ensured that there is a low impedance connection between the motor
terminal box and the motor housing. If required an additional grounding conductor should be
installed.

! CAUTION

Do not use plastic motor terminal boxes and plastic cable glands!

Figure 4-13 Shield connection at the motor junction box

The shield can be connected through a metallic gland made of either nickel plated brass
material for indoor usage or stainless Steel AISI 316L for harsh outdoor environment with a
strain relief bar. Degree of protection of up to IP 68 is also available and as shown in the
figure below.
EMI glands are available for example from the following suppliers:
SKINDICHT SHVE, Messrs. Lapp, Stuttgart
UNI IRIS Dicht or UNI EMV Dicht, Messrs. Pflitsch, Hückeswagen
HUGRO Armaturen GmbH

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4.4 Installation guidelines

Figure 4-14 Screened Power at the motor terminal box end

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4.4 Installation guidelines

Figure 4-15 Internal view of the terminal box with cable entry

The examples above show how the usage of EMC cable glands completely avoids pigtails of
the tinned copper braided shield connecting at the PE terminal connection. The external
shield is properly cut away at the internal view of the terminal box and the shield is
connected to the metal cable gland and to the housing of the motor terminal box.

Note for the use from 1-single Core shielded cables between Converter and Motor if it is not
possible to use symmetrical 3 Core shielded cables:
Correct bundling as described in further capters
The engine should have an antimagnetic cable inlet to minimise the induced currents in
the area of the cable inlet and the warming connected with that.
At the use of shielded 1 conductor cables the length of the Power cables should not be
larger than 20 m. At Power cables lengths > 20 m the cable screens should be
established only on the voltage system converter side and not on the Motor side to
avoid ring currents in the screens which can warm the cables inadmissibly.
If the cable screens due to motor cable lengths > 20 m are not established at the motor,
a high frequency technically suitable cable be provided for the high-frequency
potential equalization between the converter and motorcase to minimise the bearing
currents in the motor.
Because of the stray magnetic field extended opposite 3 core cables and the screen
edition at the motor be avoided because cable lengths >20m you must calculate with
an increased electromagnetic Interference emission of the drive.

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Installation of control cables 5
5.1 Installation of PROFIBUS cables
When you are laying the bus cable:
Don't twist it!
Don't stretch it!
Don't squash it!
In addition to this, you must take into account any influences on electromagnetic
compatibility (EMC).
The maximum cable length depends on the baud rate (transmission speed). The maximum
cable length can be increased by using repeaters, but no more than three repeaters should
be connected in series. The maximum cable lengths given in the following table can only be
ensured if PROFIBUS bus cables are used (e. g. Siemens PROFIBUS cable with type
number 6XV1830-0AH10).

Table 5- 1 Permissible baud rate as a function of cable length

Baud rate Maximum cable length in a Maximum distance between two


segment [m] stations [m]
9.6 to 187.5 kBd 1000 10000
500 kBd 400 4000
1.5 MBd 200 2000
3 to 12 MBd 100 1000

Figure 5-1 Termination resistor settings in PROFIBUS connectors

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Installation of control cables
5.1 Installation of PROFIBUS cables

Shielding of the bus cable / EMC measures


In order to ensure interference-free operation of the PROFIBUS-DP especially in case of
data transmission with RS485 the following measures are imperative:
For the PROFIBUS cable, the shield in the bus connector should be connected to the
drive’s CBP card (CBP: Communication Board PROFIBUS). Shielding is also provided by
the shield clamps (in the event of compact units) or by the shield clamps and cable ties
(in the event of chassis-type units) on the converter housing. The following illustrations
show you how to use the shield clamps. When removing the insulation from the various
core ends please ensure that the solid copper core is not damaged.

Figure 5-2 Connecting the signal cable shields

Ensure that the shield of each bus cable is connected to protective earth, both where it
enters the cabinet and at the converter housing.
Bus cables and power cables must not be laid parallel to each other. In case of crossing
these cables should be laid in an angle of 90 ° to each other. The bus cables must be
twisted and shielded and are to be laid separately from the power cables at a minimum
distance of 20 cm. The braided shield and, if necessary, the underlying foil shield as well
are to be connected on both sides through a large surface area so that they are highly
conductive, i. e. the shield of the bus cable between two converters is to be connected to
the converter housing at both ends of the cable. The same applies for the shielding of the
bus cable between the PROFIBUS-DP master and the converters.

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5.2 Installation of encoder cables

Figure 5-3 Installation with separate cable ducts

5.2 Installation of encoder cables


Siemens crane duty motors (see catalog HE1 N 2007) generally are equipped with
incremental pulse encoders sourced from Hübner, Berlin.
Self-ventilated motors normally features hollow-shaft encoders type HOG. Non-ventilated
motors are equipped with flange-mounted encoders type POG.

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Installation of control cables
5.2 Installation of encoder cables

Figure 5-4 Combination of HOG 10DN with FSL centrifugal overspeed switch

Figure 5-5 HOG 10DN (left) and POG 10DN (right)

It is recommended to install a pre-fabricated encoder cable. For example, Hübner sensor


cable HEK 8 is a proven industrial product designed to match high demands. It is halogen-
free and its rugged outer construction allows it to be pulled and dragged in free conditions. It
is certified to UL 20233. The cable can be supplied in any length and pre-fitted with various
mating connectors.

Figure 5-6 HEK 8 cable at motor side (left) and at drive side (right)

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5.2 Installation of encoder cables

Installation of encoder cables at motor side

Housing
Cover with o-ring
Hollow shaft with spanner flat
Support plat for torque arm
Clamping element (only version with cylinder shaft)
Earthing shaft, length approx. 230 mm
Terminal box cover
Cable fitting M20 x 1.5 for cable 5-13 mm
Connection board
SUB D connectors (male) on the encoder housing
Figure 5-7 Encoder cable termination, plug type

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Installation of control cables
5.2 Installation of encoder cables

Figure 5-8 Encoder cable termination, terminal type

Figure 5-9 Encoder cable terminal

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5.2 Installation of encoder cables

Installation of encoder cables at drive side


The encoder cable will be installed in the same manner as the PROFIBUS cable with all the
precautions mentioned. After the shield is properly connected as according to chapter
Installation of PROFIBUS cables (Page 49), the cables can be connected to the detachable
terminal strips of either the encoder interface (e.g. SMC30, SMC20) of the drives.

Figure 5-10 Encoder cable signals

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Busbar connections (including cable connection) 6
To guarantee a proper connection to a busbar you have to use a bolt with conical washer and spring washer.
The torque moment is depending on the thread size.

Table 6- 1 Connections by busbars or cables at connection busbars

Termination type Bolting


Conical spring washer With spring washer
DIN 6796

Screw: degree of firmness 8.8 (acc. ISO 898)


nut: degree of firmness 8.8 (acc. ISO 898)

Thread size Bolting with conical spring washer Bolting with spring water + washer DIN 125
Torque [Nm] Torque [Nm]
Fixing Fixing Checking
M8 20 20 14
M10 40 40 28
M12 70 70 50
Free of maintenance Maintenance necessary
Torque check value = 70 % of fixing torque

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Appendix A
A.1 Contact
Application Center
Siemens AG
Industry Sector
I DT MC CR AP
Frauenauracher Str. 80
D-91056 Erlangen
Tel.: +49 9131-98-5233
Fax: +49 9131-98-1424
mailto: applications.cranes.aud@siemens.com
www.automation.siemens.com

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