Several items need to be considered in order to properly install and wire an

electric motor drive and motor circuit. The motor controlled by the electric
motor drive, system power quality, safety, installation factors, and both
power and control wiring all need to be checked for compatibility with the
motor and drive. A properly installed electric motor drive can function cor-
rectly and safely for a long time without introducing any problems into an
existing electrical distribution system.

INSTALLATION CONSIDERATIONS EFFECTIVE PULSE WIDTH MODULATION

Special considerations are necessary when install- RMS VOLTAGE
ing an electric motor drive and motor circuit. These
considerations involve motors, power quality, safety, SCOPE METER
+650 VDC REQUIRED TO DISPLAY
and engineered applications. The items that need to be EFFECTIVE VOLTAGE
addressed to ensure that the motor and electric motor +325 VDC AND SINE WAVE PULSES
drive function properly are the electrical distribution 0
system, the electric motor drive, the motor connected to
the drive, and the load connected to the motor. −325 VDC

−650 VDC

ELECTRIC MOTOR CONSIDERATIONS

SHORTER "ON" DURATION,
Electric motors connected to AC drives receive a simu- LOWER VOLTAGE
lated AC sine wave known as pulse width modulation
(PWM). The PWM waveform is created by the AC drive
SIMULATED SINE WAVE
rapidly pulsing the DC bus ON and OFF using insulated +650 VDC IS RMS VOLTAGE
+600 VDC
gate bipolar transistors (IGBTs). The height of each pulse (EFFECTIVE VOLTAGE)
SENT TO MOTOR
is equal to the DC bus voltage. The width of the pulses
is controlled to provide an effective rms voltage, similar 0
to that of a pure sine wave. See Figure 9-1. The number
of pulses in the PWM waveform is controlled to vary the
output frequency of the voltage to the motor. The carrier −600 VDC
−650 VDC
frequency or pulse frequency (PWM frequency) of an
electric motor drive determines how quickly the IGBTs LONGER "ON" DURATION,
must turn ON and OFF. The carrier frequency is constant HIGHER VOLTAGE
and independent of the voltage frequency applied to the
motor. The carrier frequency is selectable and can vary Figure 9-1. The width of the pulses determines the
from 2 kHz to 20 kHz. The higher the carrier frequency, voltage to the motor; the wider the pulse, the higher the
the quieter a motor runs. voltage.

233
234 ELECTRIC MOTOR DRIVE INSTALLATION AND TROUBLESHOOTING

Inverter Duty Motors power from an electric motor drive to a standard motor,
An inverter duty motor is an electric motor specifically contact the manufacturer to verify compatibility of the
designed to work with electric motor drives. A PWM motor in a drive circuit.
waveform creates insulation problems for standard Service Factor. Service factor (SF), is a multiplier
electric motors because the leading edge of each PWM that represents the percentage of extra load that can
pulse begins with a voltage spike. A voltage spike is be placed on a motor for short periods of time without
due to the rapid rise time of the IGBTs. A voltage damaging the motor. A motor with a service factor of
spike is typically twice the DC bus voltage of the AC 1.25 can be overloaded by 25% for a short time. Motors
drive. See Figure 9-2. Voltage spikes create damage that are NEMA MG-1, Section IV, Part 31 compliant
insulation and shorten the life expectancy of standard have a service factor of 1.0 per NEMA requirements.
electric motors. Inverter duty motors are designed to A motor that is used with an electric motor drive that is
withstand voltage spikes. not NEMA MG-1, Section IV, Part 31 compliant must
not be operated beyond a service factor of 1.0 regardless
of the nameplate rating.
Lead Length. Lead length is the length of the conduc-
PWM VOLTAGE SPIKES tors (motor leads) between the electric motor drive and
the motor. The motor leads T1, T2, and T3 have a line-
SPIKE ON LEADING to-line capacitance and a line-to-ground capacitance.
EDGE OF PULSE
DAMAGES STANDARD Capacitance increases the magnitude of the voltage spikes
MOTOR INSULATION
+1300 V at the motor terminals. The longer the motor leads, the
greater the capacitance and the greater the magnitude of
+650 V

NORMAL
the voltage spikes.
0
Long lead lengths also cause reflected waves, known
−650 V as standing waves or voltage ring-up. Reflected waves are
dependent on lead length and carrier frequency. The longer
−1300 V
SPIKE the lead length and the higher the carrier frequency, the
more pronounced the problem. Reflected waves are the
SPIKE TYPICALLY result of a portion of the voltage waveform being reflected
TWICE ELECTRIC MOTOR
DRIVE BUS VOLTAGE back from the motor terminal due to an impedance mis-
match. The reflected portion combines with the voltage
from the AC drive, increasing the voltage at the motor ter-
Figure 9-2. The spike on the leading edge of each pulse is
caused by the rapid rise time of the IGBTs.
minals. The voltage can be as high as 1500 V at the motor
terminals when fed from a 480 V electric motor drive.
The easiest way to avoid problems caused by lead
The National Electrical Manufacturers Associa- length is to keep the lead lengths as short as possible.
tion (NEMA) has developed a set of specifications for Typically, lengths less than 100 ft should not pose a
electric motors used with electric motor drives. The problem. It is not always possible to avoid long lead
NEMA standard MG-1, Section IV, Part 31 provides lengths. Electric motors may be located in harsh envi-
an enhanced insulation requirement for electric motors, ronments with the electric motor drive located a long
allowing compatibility with electric motor drives. Most distance away in a clean, air-conditioned control room.
motor manufacturers produce motors to comply with In this case an output reactor, also referred to as a load
NEMA MG-1, Motors and Generators, Section IV, Part reactor, can be installed at the electric motor drive. A
31; these motors are referred to as “inverter rated” or load reactor helps eliminate voltage spikes by slowing
“inverter duty” motors. down the rate of change in the output voltage.
Standard motors that are not compliant with the Load reactors are installed as close as possible to
NEMA MG-1, Section IV, Part 31 standard, and are the output of the electric motor drive. Load reactors are
used with electric motor drives may fail prematurely. sized based on the electric motor drive input voltage and
The speed at which a standard motor fails depends frequency, the drive horsepower, and the impedance of
upon the specific motor application. Before connecting the reactor. See Figure 9-3.
 Chapter 9 — Electric Motor Drive Installation Procedures 235

LOAD REACTORS

OUTPUT REACTOR
ELECTRIC MOTOR DRIVE

Jog

EACH COIL
P

WOUND ON
SEPARATE CORE
TERMINAL STRIP FOR
INPUT AND OUTPUT
WIRING
THREE COILS
(ONE FOR
EACH PHASE)

MTE C
Corporation 3φ
MOTOR

PE PE DC DC T1/U T2/V T3/W

T1 T2 T3

REACTORS INSTALLED CLOSE TO

OUTPUT OF ELECTRIC MOTOR DRIVE

Figure 9-3. Output reactors are installed as close as possible to the output of an electric motor drive to reduce the level of
voltage spikes at the motor.

Electric motor drive manufacturers may recommend AC drives are often used in industrial and commercial
output filters instead of load reactors. Output filters are HVAC systems, and are increasingly used in residential
also referred to as motor terminators. Output filters HVAC systems.
consist of inductance, capacitance, and resistance. An Electric motor drive manufacturers provide speci-
output filter may be installed at the output of the electric fications for maximum lead lengths for various carrier
motor drive or at the motor. See Figure 9-4. frequencies and for shielded or unshielded cable with
Another method to diminish the effects of lead output reactors or output filters.
length is to lower the carrier frequency. The result is Bearing Currents. A bearing current is the result of
fewer voltage pulses per unit of time and less stress induced voltage in the motor rotor created by the electric
on the motor insulation. At lower carrier frequencies, motor drive. Bearing current causes premature failure
motors make more audible noise. Noise can be a prob- of motor bearings. The spikes on the leading edge of
lem for people working near the motor or if an HVAC the PWM waveform are induced into the rotor, and a
fan motor transmits the noise through the ductwork. voltage potential is developed between the rotor and the
stator. The bearing race and balls or rollers serve as the
current path for the voltage potential, and a continuous
TECH FACT flow of current through the bearing occurs. The current
Follow manufacturer installation guidelines on motor lead flow causes atoms of metal to be removed. Over time,
length to avoid premature failure of motors. roughness, known as fluting, develops in the race, which
eventually destroys the bearing.
236 ELECTRIC MOTOR DRIVE INSTALLATION AND TROUBLESHOOTING

OUTPUT FILTERS

ELECTRIC MOTOR DRIVE

OUTPUT FILTER

Jog
P

GROUND PER
LOCAL CODES

MTE C
Corporation

PE PE DC DC T1/U T2/V T3/W CABLE FROM TERMINATOR

TO MOTOR TERMINALS T3

3φ
T2 MOTOR

T1

PE (MOTOR FRAME)

Figure 9-4. An output filter/terminator installed at the motor termination box reduces reflected waves.

Electric motor manufacturers have developed shaft electric motor drive through a relay. The leads of a tempera-
grounding systems to eliminate the problem. A shaft ture sensor are labeled J1 (P1) and J2 (P2). When internal
grounding system is a system that connects (shorts) temperatures of a motor exceed safe limits, the temperature
the rotor voltage to ground via a brush or other de- sensor opens, de-energizing the relay, shutting down the
vice in contact with the shaft to discharge unwanted electric motor drive and motor. See Figure 9-6.
voltage. See Figure 9-5. Another method to reduce Operating Temperature. NEMA has standardized the
or eliminate bearing currents is to lower the carrier maximum ambient temperature for motors as 104°F
frequency of the electric motor drive. Bearing currents (40°C). Ambient temperature is the temperature of the
are common in HVAC fan applications. Bearings are air surrounding an object. Electric motors operated at
the only path for the potential to discharge to ground a higher than ambient temperature must be derated.
in fan applications. NEMA has also standardized altitude ratings for motor
Low-Speed Operation. The cooling effect of a fan at- operation. Electric motors are designed to operate up to
tached to the motor shaft, and/or fins that are part of the 3300′ (1000 m). Electric motors operated above 3300′
rotor end ring, is reduced when a motor is operated at low must be derated. The derating is requried because at
speeds. Electric motors that are continuously operated at higher altitudes, air is thinner and does not dissipate
low speeds must be derated or provided with auxiliary cool- heat as quickly. Consult the charts provided by motor
ing. Auxiliary cooling is accomplished by using a separate manufacturers for specific derating tables.
blower and motor mounted to the motor to provide cooling.
Auxiliary blower motors operate on fixed voltages, and are TECH FACT
either ON or OFF. The blower motor must be connected to
Failure to derate or provide auxiliary cooling to
a power source independent of the variable voltage output motors operating at low speeds results in premature
of an electric motor drive. Temperature sensors are installed failure of motors.
in the stator windings of a motor and are connected to an
 Chapter 9 — Electric Motor Drive Installation Procedures 237

SHAFT GROUNDING SYSTEMS

MOTOR BEARING
RACE SECTION

FLUTING PATTERN FROM

BEARING CURRENTS

TOTALLY ENCLOSED
NON-VENTILATED
(TENV) MOTOR

SHAFT GROUNDING SYSTEM

CONNECTS (SHORTS) SHAFT
TO MOTOR FRAME

UNWANTED VOLTAGE FROM

ROTOR DISCHARGED TO GROUND Siemens

Figure 9-5. A shaft grounding system eliminates bearing currents that lead to bearing failures.

TEMPERATURE SENSOR

RELAY CONTACT
FROM EXTERNAL CONNECTED TO
VOLTAGE SOURCE ELECTRIC MOTOR
ELECTRIC MOTOR DRIVE DRIVE CONTACT
Jog TERMINAL STRIP
P

TEMPERATURE
SENSOR
CR1

RELAY ISOLATES
ELECTRIC MOTOR
DRIVE FROM EXTERNAL
VOLTAGE SOURCE
PE PE DC DC T1/U T3/W The
hermik Corporation
TEMPERATURE
T2 J1 (P1)
T3 SENSOR LEADS
T1
3φ J2 (P2)
MOTOR

NORMALLY CLOSED TEMPERATURE SENSOR

EMBEDDED IN MOTOR STATOR HOUSING

Figure 9-6. When excessive motor heat is detected, the temperature sensor opens, de-energizing the relay and sending
a signal to the electric motor drive to stop the motor.
 238 ELECTRIC MOTOR DRIVE INSTALLATION AND TROUBLESHOOTING

Voltage and current are not proportional because nonlinear

loads draw current in short pulses, even when the source
voltage is a sine wave. It is important that the power source
for an electric motor drive has sufficient current capacity.
If the power supply cannot deliver enough current, volt-
age flat-topping occurs. Flat-topping is the lowering of
the peaks of the voltage sine wave. Flat-topping results in
lower supply voltage to an electric motor drive. The lower
supply voltage causes undervoltage faults and undepend-
able motor operation. See Figure 9-8.
Input Reactors. Input reactors or isolation transformers
are recommended for AC drives in a variety of situations.
Input reactors are sized based on the electric motor drive
input voltage and frequency, the drive horsepower, and the
impedance of the input reactor. Input reactors are used in
the following situations:
ASI Robicon
Power quality cabinets contain transformers, reactors, power factor correction • When line impedance is too low. A reactor raises the line
capacitors, and filters to prepare electrical distribution power for electric impedance and protects an electric motor drive from volt-
motor drive use. age spikes in the electrical distribution system caused by
large loads or lighting being switched ON and OFF.
Power Quality • When power factor correction capacitors are installed.
Electric motor drives are adversely affected by poor • When the electric motor drive causes harmonics in the
power quality. Electric motor drives can also intro- electrical distribution system. Harmonics produce power
duce power quality problems into a power distribution quality problems on the electrical distribution system. The
system. Power quality is affected by voltage and fre- effects of harmonics are cumulative; the greater the number
quency variations, and by whether a system is grounded of electric motor drives installed in a facility, the greater
or ungrounded. the harmful effects. Harmonics can be either voltage
Voltage and Frequency. Electric motor drives are harmonics or current harmonics.
designed to operate over a wide range of input voltages. Input reactors may also be used as output reactors. Input
Most electric motor drives are designed to operate with reactors should be part of every drive installation because
input frequencies of either 50 Hz or 60 Hz. Operating they provide multiple benefits and add little to the overall
outside the specified frequency range can result in motor system installation costs.
damage to an electric motor drive or cause various Power Factor Correction Capacitors. A power factor cor-
drive faults. rection capacitor is a capacitor used to improve a facility’s
Grounded and Ungrounded Systems. Electric motor power factor by improving voltage levels, increasing
drives are intended to be powered from grounded systems system capacity, and reducing line losses. Power factor is
with 3φ power lines that are electrically symmetrical with the ratio of true power to apparent power. True power is
the power that actually performs work. Apparent power
respect to ground. The NEC® permits ungrounded distri-
is the total power delivered. Utility companies penalize
bution systems in a limited number of instances. Electric
customers with low power factors. Facilities with many
motor drives contain metal oxide varistors (MOVs) to
inductive loads have a poor power factor because voltage
provide phase-to-phase and phase-to-ground protection
is leading the current. The common practice is to install
from voltage surges. In an ungrounded system, there is
power factor correction capacitors to improve the power
no path back to the power source to activate an overcur-
factor of a facility because capacitors cause the current
rent device. The phase-to-ground MOV can become a to lead voltage.
continuous path for current, resulting in damage to the
Power factor correction capacitors can be placed ahead of
electric motor drive. See Figure 9-7.
an electric motor drive in the AC supply lines but not between
Current. An electric motor drive is a nonlinear load. A the drive and motor. Power factor correction capacitor units
nonlinear load is any load where the instantaneous load with automatic switching must not be used unless specifically
current is not proportional to the instantaneous voltage. recommended by the manufacturer. See Figure 9-9.
 Chapter 9 — Electric Motor Drive Installation Procedures 239

METAL OXIDE VARISTOR (MOV) VOLTAGE SURGE PROTECTION

ELECTRIC
EARTH GROUND MOTOR
PER NEC® DRIVE
L1
Jog
P

L3 L2

DELTA-WYE
TRANSFORMER L1/R L2/S L3/T PE PE

OVERCURRENT
PROTECTION
AND DISCONNECT

GROUNDED 4-WIRE DELTA-WYE SYSTEM

EARTH GROUND METAL ELECTRIC

PER NEC® OXIDE MOTOR
L1 VARISTORS DRIVE
Jog
P

WYE PATH FOR DESTRUCTIVE

TRANSFORMER CURRENT TO RETURN TO
POWER SOURCE
L3 L2

L1/R L2/S L3/T PE PE

OVERCURRENT
PROTECTION
AND DISCONNECT

GROUNDED 4-WIRE WYE SYSTEM

ELECTRIC
METAL MOTOR
OXIDE DRIVE
L1 VARISTORS
Jog
P

L3 L2
NO PATH FOR DESTRUCTIVE
CURRENT TO RETURN TO
POWER SOURCE

DELTA
TRANSFORMER
L1/R L2/S L3/T PE PE

OVERCURRENT
PROTECTION
AND DISCONNECT

UNGROUNDED 3-WIRE DELTA SYSTEM

Figure 9-7. Electric motor drives are intended to be powered from 3φ lines with a common ground.
240 ELECTRIC MOTOR DRIVE INSTALLATION AND TROUBLESHOOTING

VOLTAGE AND CURRENT POWER SUPPLY

VOLTAGE MAY BE SINUSOIDAL

+VOLTS
CURRENT DRAW
IN SHORT PULSES

-VOLTS

ASI Robicon

VOLTAGE AND CURRENT WAVEFORM

SUFFICIENT CURRENT CAPACITY

TO MEET ELECTRIC MOTOR SCR
DRIVE POWER DRAW
+ VOLTS DC BUS
INDUCTOR T1
PHASE A L1

PHASE B OR T2
0 L2 CAPACITOR
T3
PHASE C L3

- VOLTS

IGBT

AC SINE WAVE WITHOUT FLAT-TOPPING

INSUFFICIENT CURRENT CAPACITY

TO MEET ELECTRIC MOTOR SCR
MAX DRIVE POWER DRAW
+VOLTS DC BUS
+VOLTS INDUCTOR T1
PHASE A L1

PHASE B OR T2
0 L2 CAPACITOR
T3
PHASE C L3
-VOLTS
MAX
-VOLTS
FLAT-TOPPING IGBT
REDUCES CAPACITY

AC SINE WAVE WITH FLAT-TOPPING

Figure 9-8. In nonlinear loads, instantaneous load current is not proportional to the instantaneous voltage, allowing flat-
topping to occur and causing electric motor drive faults.
 Chapter 9 — Electric Motor Drive Installation Procedures 241

POWER FACTOR CORRECTION CAPACITORS

FROM POWER SUPPLY

ELECTRIC
L1 L2 L3 MOTOR DRIVE

MAIN
DISCONNECT Jog
P

AUTOMATICALLY SWITCHED POWER

FACTOR CAPACITORS MUST NOT BE USED
IN ELECTRIC MOTOR DRIVE CIRCUITS
SYSTEM
FUSES

L1/R L2/S L3/T PE PE DC DC T1/U T2/V T3/W

FIXED POWER FACTOR

CORRECTION CAPACITORS

LINE
REACTOR

ABB Inc., Drives & Power Electronics

Figure 9-9.. The effects of inductive and nonlinear loads can be compensated using properly sized power factor capacitors.

SAFETY The brake is mounted on the end of the motor opposite

Electric motor drives are part of a system that includes a the shaft. When power is applied (solenoid energized),
motor, a driven load, and possibly external controls. Care the brake disengages and allows the motor and load to
must be taken to ensure that all items are compatible, and rotate. When power is removed (solenoid de-energized),
that any item or combination of items does not introduce a springs cause the brake to engage and hold the motor
safety hazard. Electric motor drive control circuits are not and load. The brake operates on an ON or OFF fixed
to be used as emergency stops. An emergency stop is used voltage. The brake must be connected to a power source
where accidental contact with moving equipment, or the independent of the variable voltage output of the electric
unintended flow of product, can result in physical injury motor drive.
or property damage. If an emergency stop is required, an
additional hard-wired stop circuit that removes AC line
power to the electric motor drive is necessary. When AC WARNING
line power is removed, the braking effect of the electric
DC injection braking and dynamic braking are auxiliary
motor drive is lost and the motor coasts to a stop. The braking functions and are not intended to take the place of
motor may require an auxiliary electromechanical brake electromechanical brakes.
to stop quickly or to stop and hold a load. See Figure 9-10.
242 ELECTRIC MOTOR DRIVE INSTALLATION AND TROUBLESHOOTING

AUXILIARY ELECTROMECHANICAL BRAKES

FROM DISCONNECT

L1 L2 L3 DRUM MOUNTED
FROM SEPARATE (R) (S) (T) ON MOTOR SHAFT
VOLTAGE SOURCE
CONVERTER
L1 N SECTION SOLENOID
FILTER ENERGIZED,
OPENS BRAKE,

C
SECTION

L
CONTROL LOGIC LOAD ROTATES
CR2
BUS
DC
INVERTER
SECTION
SOLENOID
DE-ENERGIZED,
ELECTRIC SPRING CLOSES,
MOTOR LOAD HELD
BRAKE SOLENOID T1 T2 T3 DRIVE
RELAY CONTROLLED BY (U) (V) (W)
ELECTRIC MOTOR DRIVE BRAKE SHOES

3φ
MOTOR

ELECTRICAL SCHEMATIC MECHANICAL OPERATION

Figure 9-10. An electromechanical brake is used to hold a motor shaft stationary after voltage is removed from the motor.

ENGINEERED APPLICATIONS the point where full armature voltage is applied with
An engineered application is an electric motor drive full rated field excitation. Operation of a motor above
base speed is governed by the mechanical limits of the
application that requires a licensed engineer to be
rotor, armature, and bearings.
safely implemented. A licensed engineer provides
drawings, answers questions, and oversees the in-
stallation to ensure that it conforms to all applicable ELECTRIC MOTOR DRIVE INSTALLATION
codes. Engineered applications include those where a
motor is operated above its rated base speed, where an An electric motor drive installation process requires
emergency stop button is required, or where a drive is receiving shipment of a drive from a manufacturer,
controlling people-moving equipment. Base speed is selecting a suitable location and enclosure, mounting
the nameplate speed (rpm) at which a motor develops the drive (taking into account derating factors), and
rated horsepower at rated load and voltage. When minimizing electromagnetic interference. Paying close
using an AC motor, base speed is typically the point attention to all installation factors results in a smooth
where nameplate voltage and nameplate frequency start-up and years of trouble-free service.
are applied. When using a DC motor, it is typically
Receiving Drive and Hardware
Upon receipt of an electric motor drive and any associ-
ated hardware, there are several steps to follow:
• Thoroughly inspect the items for any damaged or
WARNING missing parts. Immediately report any problems to
Always consult the electric motor drive manufacturer or the freight company.
licensed engineer regarding drive application questions.
• Verify the size, rating, configuration, etc., of the
Incorrect application of an electric motor drive can result
in serious personal injury or damage to the drive and/or items ordered.
driven load. • Remove the instructions and other documentation,
and store in a safe location for future reference.
 Chapter 9 — Electric Motor Drive Installation Procedures 243

• Store the electric motor drive and related hardware Mounting

in a clean, dry, and secure location that conforms An electric motor drive should be mounted on a
to the operating manufacturer specifications. smooth, nonflammable vertical surface, with the name
• Do not store an electric motor drive for longer than of the manufacturer facing out and right side up. Small
a year. Electric motor drives contain electrolytic electric motor drives are mounted in rack slots or on
capacitors, which deteriorate if not powered for a DIN rail. Medium-size electric motor drives may
long periods of time. be mounted directly to a motor or in a cabinet using
mounting holes. Larger electric motor drives have
separate mounting holes for individual fasteners. See
Location Figure 9-12. The fastening method should be adequate
Electric motor drives should be mounted in a clean to support the weight of the electric motor drive.
and dry location. High temperatures, high humid- Heat is generated during the normal operation
ity, dust, particles or fibers in the air, corrosive or of an electric motor drive. An electric motor drive
explosive vapors, constant vibration, and direct is mounted to allow the free flow of air across the
sunlight should be avoided. The location should have heat sink(s), possibly aided by integral cooling fans.
sufficient lighting and sufficient working space to Adequate clearances must be maintained around the
facilitate the installation, start-up, and maintenance electric motor drive for the free flow of air. Follow
of the electric motor drive. manufacturer specifications for mounting an electric
motor drive.

Enclosures
Derating
NEMA rates enclosures based on use and service.
Most electric motor drives are delivered from a Electric motor drives are designed for specific op-
manufacturer in NEMA Type 1 enclosures. An elec- erating ranges of temperature, voltage, altitude, and
tric motor drive in a NEMA Type 1 enclosure may humidity. Derating is required if an electric motor
be placed in a suitable environment or in another drive is operated outside the normal operating ranges
encosure. Other NEMA rated enclosures are available specified by the manufacturer. Electric motor drives
for installing electric motor drives in hostile environ- operated above the normal temperature range, from a
ments. See Figure 9-11. 1φ power source or from a power source with reduced
voltage, or at a high altitude, or higher carrier frequen-
An electric motor drive in a NEMA Type 1 enclo-
cies, must be derated. Manufacturers supply charts and
sure may require a NEMA Type 3R enclosure if the
derating multipliers for each particular condition.
enclosure is subjected to falling rain, ice, or other
damaging environments. The enclosure that is to house
the electric motor drive should be mounted, and any
metal debris must be discarded before the drive is in-
stalled in the enclosure. All precautions must be taken
to prevent debris from falling into an electric motor
drive and causing a problem. The person responsible
for installing the electric motor drive must decide
whether the drive can be installed as is or whether it
requires installation in another enclosure.
When an electric motor drive is installed in an
enclosure, heat buildup can be a problem. The elec-
tric motor drive radiates heat and the enclosure may
not be able to dissipate the heat. The heat may cause
electric motor drive faults, or premature component
failure. Extra cooling may be required to supplement
the fan(s) that are integral to the electric motor drive.
Omron IDM Controls
The additional cooling can be in the form of a fan or Cabinets with multiple electric motor drives require extra attention to mounting
a cooling unit. positions, airflow, and derating to avoid heat buildup and drive failures.
244 ELECTRIC MOTOR DRIVE INSTALLATION AND TROUBLESHOOTING

ENCLOSURE SELECTION

ENCLOSURES
Type Use Service Conditions Tests Comments Type
1 Indoor No unusual Rod entry, rust resistance

3 Outdoor
Windblown dust, rain, sleet, and ice Rain, external icing, dust, Do not provide protection against 1
on enclosure and rust resistance internal condensation or internal icing
Rod entry, rain, external Do not provide protection against dust,
3R Outdoor Falling rain and ice on enclosure
icing, and rust resistance internal condensation, or internal icing
Windblown dust and rain, splashing
Hosedown, external icing, Do not provide protection against 4
4 Indoor/outdoor water, hose-directed water, and ice
and rust resistance internal condensation or internal icing
on enclosure
Corrosion, windblown dust and rain,
Hosedown, external icing, Do not provide protection against
4X Indoor/outdoor splashing water, hose-directed
water, and ice on enclosure
and corrosion resistance internal condensation or internal icing 4X
Occasional temporary submersion at
6 Indoor/outdoor
a limited depth
Prolonged submersion at a limited
6P Indoor/outdoor
depth
Withstand and contain an internal Enclosed heat-generating devices shall
Indoor locations classified as explosion of specified gases, contain not cause external surfaces to reach
7 Class I, Groups A, B, C, or D, an explosion sufficiently so an
Explosion, hydrostatic, and
temperature
temperatures capable of igniting 7
as defined in the NEC ® explosive gas-air mixture in the explosive gas-air mixtures in the
atmosphere is not ignited atmosphere
Enclosed heat-generating devices shall
Indoor locations classified as Dust penetration, not cause external surfaces to reach
9 Class II, Groups E or G, as Dust temperature, and gasket temperatures capable of igniting 9
defined in the NEC ® aging explosive gas-air mixtures in the
atmosphere
Dust, falling dirt, and dripping Drip, dust, and rust Do not provide protection against
12 Indoor
noncorrosive liquids resistance internal condensation
Dust, spraying water, oil, and Oil explosion and rust Do not provide protection against
12
13 Indoor
noncorrosive coolant resistance internal condensation

DESIGNED ENCLOSURE WITH

WASHDOWN RESISTANCE
AMBIENT ADDITIONAL COOLING
OUTSIDE AIR
HEAT PIPE CORE

COOLED WASTE HEATED

ENCLOSED OUTSIDE AIR
AIR

HEATED
AIR OUT

ELECTRIC MOTOR
DRIVE ENCLOSURE Baldor Motors and Drives

ENCLOSURE WITH COOLING UNIT TYPE 4X ENCLOSURE

Figure 9-11. Depending on the application, an enclosure with a cooling unit may be required.
 Chapter 9 — Electric Motor Drive Installation Procedures 245

ELECTRIC MOTOR DRIVE MOUNTS

MOUNTING HOLES
FOR SCREWS
MODULAR ELECTRIC MOTOR DRIVE
MOUNTED IN RACK SLOTS
LARGE
ELECTRIC
MOTOR DRIVE

SMALL ELECTRIC
MOTOR DRIVES
DIN RAIL

Control Techniques
RACK SLOT MOUNT

Omron IDM Controls

Kebco Power Transmission SCREW MOUNT
DIN RAIL MOUNT

Danfoss Drives
MEDIUM ELECTRIC MOTOR
DRIVE MOUNTED ON MOTOR MOTOR MOUNT

Figure 9-12. Mounting methods vary with the size of electric motor drive.

An electric motor drive model may have multiple out- High frequency electric-field EMI can emanate from
put ratings, depending on the type of load and the carrier equipment as electromagnetic radiation, also known
frequency used. Constant torque loads require the same as radio frequency interference (RFI). EMI can be re-
current from zero to base speed. Variable torque loads re- ceived by other equipment and interfere with its proper
quire less current at lower speeds. Consequently, an electric operation. EMI problems range from corrupted data
motor drive model typically has higher output ratings for transmissions to electric motor drive damage.
a variable torque load than for a constant torque load. All electrical and electronic equipment should have
Power losses occur when the IGBTs of an electric mo- some level of immunity to EMI. Electromagnetic com-
tor drive are between states (neither ON nor OFF). The patibility (EMC) is a comparison of how different pieces
higher the carrier frequency, the more pulses per unit of of equipment work together with varying levels of in-
time, and the more loss of power the IGBTs create. An terference. As use of electronic equipment in industrial
electric motor drive has lower output ratings at higher environments has increased, manufacturers have taken
carrier frequencies because of IGBT power losses. steps to both minimize emissions and maximize EMI
immunity in the design of equipment.
Electromagnetic Interference Regulations regarding EMC/EMI are very complicat-
Electromagnetic interference (EMI), also known as electri- ed and vary from country to country. A properly installed
cal noise, is the unwanted signals generated by electrical electric motor drive minimizes potential problems from
and electronic equipment. All electrical and electronic EMI. Installation techniques and supplemental devices
equipment generate EMI. Low frequency magnetic-field that minimize emissions and maximize immunity in-
EMI can be emitted from the cables connected to equip- clude wiring techniques, grounding, shielding, and
ment, or from inductive loads in proximity to equipment. isolation of power and signal or control cable.
246 ELECTRIC MOTOR DRIVE INSTALLATION AND TROUBLESHOOTING

Power Wiring. The drive output power wiring (load grounding conductors contained in the cable need to be
conductors) contains high-voltage switching wave- connected at each end.
forms which can affect the line conductors. The line Control Wiring. Control wiring is all external wiring con-
and load conductors of an electric motor drive need to nected to an electric motor drive, excluding the line and
be installed in separate metal conduits. Metal conduit load conductors. Electric motor drives have control wiring
serves as a shield, preventing conductors from radiating that communicate signals to start and stop the drive, com-
EMI and protecting conductors from any radiated EMI. municate sensor conditions to the drive, and carry output
Nonmetallic conduit does not provide the shielding ef- signals from drive auxiliary contacts. See Figure 9-13.
fect. A separate grounding conductor must be installed Control wiring can communicate four types of signals: AC
in each conduit and connected at each end. In the event digital signals, DC digital signals, DC analog signals, and
that multiple electric motor drives feed multiple motors, serial communication signals. Digital signals are signals
the line and load conductors of each drive need to be that have only two states, ON or OFF like a momentary
installed in separate metal conduits. pushbutton. Analog signals are signals that vary over a
When cable trays are used, armored metal cable with range of values such as 0 VDC to 10 VDC for speed refer-
a separate grounding conductor, or shielded power cable ence. Serial communication signals are digital data signals
with a separate grounding conductor, must be used. The from an external source such as a PLC or PC.

ELECTRIC MOTOR DRIVE CONTROL WIRING

D SHELL CONNECTOR
FOR SERIAL COMMUNICATION

Jog OUTPUT RELAY (NORMALLY OPEN)

P 110 VAC MAX, 1 A/30 VDC MAX, 1 A
(RESISTIVE RATING)

1 2 3 4 5 6 7 8 9 10 11
P10 0V AIN AIN DIN1 DIN2 DIN3 P15 0V RL1B RL1C

OUTPUT RELAY
(NORMALLY OPEN)
110 VAC MAX,
POWER ANALOG 1 A/30 VDC MAX, 1 A
SUPPLY INPUTS (RESISTIVE RATING)
DIGITAL INPUTS
(+10 V MAX, (0 V – 10 V)
(7.5 V – 33 V MAX, 5 mA)
10 mA) (2 V – 10 V)
OUTPUT RELAY (NORMALLY OPEN)
110 VAC MAX, 1 A/30 VDC MAX, 1 A
T1/U T2/V T3/W (RESISTIVE RATING)
MOTOR TERMINALS
POTENTIAL
EARTH 12 13 14 15 16 17 18 19 20
(GROUND) DC DC DIN4 DIN5 DIN6 P15 0V AIN AIN RL2B RL2C
DC BUS
TERMINALS
L1/R L2/S L3/T
ANALOG INPUTS
MAIN POWER PE PE (0 V – 10 V) OR
SUPPLY TERMINALS POTENTIAL EARTH (2 V – 10 V)
(GROUND)
POWER SUPPLY FOR P1
DIGITAL INPUTS FEEDBACK TRANSDUCER
(7.5 V – 33 V MAX, 5 mA) OR OTHER LOAD
(+15 V MAX, 50 mA)

Figure 9-13. Power wiring and control wiring are terminated at separate locations on an electric motor drive.
 Chapter 9 — Electric Motor Drive Installation Procedures 247

The harmful effects of EMI from control wiring can protective devices (OCPDs). Equipment grounding
be minimized by the following procedure: also aids in containing EMI. All equipment grounds
• Control and power wiring should be separated as much should be brought back to a single point at the elec-
as possible inside an electric motor drive enclosure. If tric motor drive. The connections should be tight and
control and power wiring must cross, they should cross mechanically sound to guarantee a good electrical
at a 90° angle. connection. When making a grounding connection to
• Control wiring should not be installed in the same the interior of a metal enclosure, scrape away any pro-
conduit as power wiring. Control wiring should be tective coating to ensure bare metal-to-metal contact.
installed in a separate metal conduit. See Figure 9-14.
• Install each category of control wiring in its own Control wires carry analog signals and serial com-
metal conduit. munication signals using twisted shielded pair cable. A
• DC analog signals and serial communication signals shield is constructed of metal foil or mesh and a bare
should run in twisted shielded pair cable. wire wrapped around the twisted conductors. The bare
Grounding. Proper grounding is required for the safe and wire is also referred to as the drain wire. The shield/drain
reliable operation of electric motor drives, motors, and wire and the twisting of the conductors provide en-
related equipment. Grounding requirements can be divided hanced noise protection. The shield/drain wire is only
into equipment grounding and signal wire grounding. grounded at the electric motor drive end. A shield/drain
Equipment grounding is an equal potential between wire that is grounded at both ends introduces EMI into
all metal components of an installation and a low-im- the signal circuit because of the difference of potential
pedance path for fault currents to operate overcurrent between the two points of grounding.

ELECTRIC MOTOR DRIVE AND MOTOR CIRCUIT GROUNDING

ELECTRIC MOTOR DRIVE

ELECTRIC
MOTOR
GROUND
PER NEC® AND
LOCAL CODES Jog
P

L1
AC MAIN SUPPLY

L2
CONNECT ALL WIRES
CON
T1, T2, T3, AND
T1
EQUIPMENT GROUND INSIDE

L3 L1/R L2/S L3/T PE PE DC DC T1/U T2/V T3/W

4-WIRE DELTA-WYE
TRANSFORMER

LINE REACTOR LOAD REACTOR

ROUTE ALL WIRES L1, L2, L3, ROUTE ALL WIRES T1, T2, T3,
AND EQUIPMENT GROUND AND EQUIPMENT GROUND
TOGETHER IN ONE CONDUIT TOGETHER IN ONE CONDUIT

Figure 9-14. Equipment grounds for line and load conductors are terminated at the electric motor drive.
 248 ELECTRIC MOTOR DRIVE INSTALLATION AND TROUBLESHOOTING

Inductive Loads. Inductive loads such as solenoids or INDUCTIVE LOAD EMI SUPPRESSION
the coils of relays and contactors are a source of EMI.
When inductive loads are de-energized, a large counter
FROM
electromotive force (CEMF) is generated. CEMF is OUTPUT POWER SOURCE
DEVICE COIL
a voltage spike created by the inductive loads when

CONTROL CIRCUIT
de-energized that can cause electric motor drive faults.

TO
Coils in the same enclosure as an electric motor drive
or coils controlled by relay contacts of a drive need to
suppress voltage spikes.
Devices are installed across the coils to dissipate
CAPACITOR RESISTOR
the CEMF and suppress EMI. Resistor-capacitor net-
works (RC snubber networks) or MOVs are connected SMALL AC LOADS
across the AC coils. Diodes are connected across DC OUTPUT
FROM
POWER SOURCE
coils to suppress EMI. The diodes are connected in re- DEVICE COIL

CONTROL CIRCUIT
verse bias across the DC coils in the same way fly-back
diodes are used with transistors. See Figure 9-15.

TO
Other EMI/RFI Reducing Devices. Other devices
and techniques are used for reducing EMI/RFI. An
output reactor or an output choke may be used to reduce
interference with sensitive equipment. An RFI filter
installed at the input of an electric motor drive reduces
RFI interference. Lowering the PWM frequency also METAL OXIDE
reduces EMI. See Figure 9-16. VARISTOR

LARGE AC LOADS

WIRING FROM
OUTPUT POWER SOURCE
The National Electrical Code (NEC ) must be followed
® DEVICE COIL
CONTROL CIRCUIT

when connecting an electric motor drive. The wiring

process of an electric motor drive is divided into NEC®
TO

and manufacturer requirements.

DIODE

DC LOADS

Figure 9-15. A snubber circuit can be used to suppress EMI.

NEC® and Electric Motor Drives

The NEC® refers to drives as adjustable speed drive
systems or conversion equipment. NEC® Article 430,
Motors, Motor Circuits and Controllers, is the principal
code source for drives. Part X of Article 430, Adjustable-
Speed Drive Systems, contains specific requirements for
the installation of electric motor drives. Other sections
of Article 430 apply as well, as an electric motor drive
is a controller that powers a motor. Other portions of the
Kebco Power Transmission
EMI filters installed across EMI-producing devices suppress EMI and prevent NEC®, even when not specifically named, also apply to
it from disrupting control signals. drives. See Figure 8-17.
 Chapter 9 — Electric Motor Drive Installation Procedures 249

OTHER EMI/RFI REDUCING DEVICES

ELECTRIC MOTOR DRIVE

CONDUCTORS FROM ELECTRIC
LINE TERMINALS GROUND LOAD TERMINALS MOTOR DRIVE TO MOTOR
WRAP AROUND AND
L1/R L2/S L3/T PE PE DC DC T1/U T2/V T3/W PASS THROUGH CHOKE

OUTPUT CHOKE
ASSEMBLY
T2
T1

MOTOR CONDUCTORS
GROUND TO MOTOR

T1 T2
MOTOR
T3

CHOKE
T3
CONDUCTORS
T1 T2 T3 FROM ELECTRIC
MOTOR DRIVE WRAPPED WIRE

SCHEMATIC DEVICE
OUTPUT CHOKE
ELECTRIC MOTOR DRIVE AND
RFI FILTER MOUNTED TO COMMON
BACK PLATE WITH POSITIVE
ELECTRICAL BOND AND IN CLOSE
PROXIMITY TO EACH OTHER

IRON TERMINAL
3 POWER SUPPLY CORE BLOCK
ELECTRIC
MOTOR DRIVE

g
Jo P

PHASE C
RFI FILTER PHASE A COIL
INSTALLED AT COIL
ELECTRIC MOTOR
DRIVE INPUT

PHASE B
COIL

CABLE SUPPLIED
WITH RFI FILTER
RFI FILTER OUTPUT REACTOR

Figure 9-16. Output chokes, RFI filters, and output reactors are used to reduce EMI.

Manufacturer Instructions. NEC® Section 110.3(B) information on wire size, recommended mounting
states, “Listed or labeled equipment shall be installed location, and the size and type of overcurrent devices.
and used in accordance with any instructions included in Electric motor drives may us fuses or circuit breakers
the listing or labeling.” NEC® Section 110.3(B) makes as circuit overcurrent protection. Electric motor drive
the instructions of the manufacturer the primary refer- manufacturers specify the type of overcurrent protection
ence for installation. Manufacturer instructions provide to be used with particular drives.
250 ELECTRIC MOTOR DRIVE INSTALLATION AND TROUBLESHOOTING

ELECTRIC MOTOR DRIVE SYSTEMS – NEC ® REFERENCES

FROM POWER SOURCE

NEC® ARTICLE 430 FUSED DISCONNECT SERVES

PART IV AS OVERCURRENT PROTECTION
AND DISCONNECTING MEANS
FUSES AND CIRCUIT
BREAKERS ARE USED
FOR OVERCURRENT MOTOR NAMEPLATE USED
FOR SETTING PARAMETERS
PROTECTION

MANUFACTURER
TM
PE 21 PLUS PREMIUM EFFICIENCY
®
NEC ARTICLE 430 ORD. NO. 1LA02864SE41 MAG. 21.8
PART III TYPE RGZESD I FRAME 286T
SERVICE
HP 30.00 FACTOR 1.0 3 PH
CONTROLLER MAY AMPS 34.9 VOLTS 460
PROVIDE OVERLOAD Square D Company RPM 1765 HERTZ 60
PROTECTION

51-770-642
o DATE
DUTY CONT 40 C AMB. CODE
CLASS NEMA KVA NEMA
INSUL H DESIGN B CODE G NOM. EFF. 93.6
SH. END
BRG. 50BC03JPP3 OPP. END
BRG. 50BC03JPP3

Inverter Duty AC Induction Motor made in

U.S.A.

OVERLOAD CURRENT
PARAMETERS AND
OVERLOAD MODE
PARAMETERS MAY
BE USED TO MEET
CODE REQUIREMENTS

ABB Inc., Drives & Power Electronics

NEC® ARTICLE 430 Square D Company

PART IX
DISCONNECTING MEANS
MAY BE REQUIRED MOTOR RATED Rockwell Automation/Reliance Electric
DISCONNECT
AT THE MOTOR

Figure 9-17. NEC® Article 430 contains several parts that apply to electric motor drives.

Wire Size. In the event the instructions do not specify Disconnects. A disconnect is a device that isolates
wire size, NEC® Section 430.122(A) states, “Circuit an electric motor drive and/or motor from the voltage
conductors supplying power conversion equipment source to allow safe access for maintenance or repair.
included as part of an adjustable-speed drive system NEC® Article 430 Part IX contains general requirements
shall have an ampacity not less than 125% of the rated for disconnects. Article 430 Part X contains specific
input to the power conversion unit.” The wire size can requirements for the disconnect located in the incoming
be calculated using the electric motor drive (power line to the electric motor drive. NEC® Section 430.128
conversion equipment) nameplate current and NEC® states “The disconnecting means shall be permitted to
Table 310.16. be in the incoming line to the conversion equipment
 Chapter 9 — Electric Motor Drive Installation Procedures 251

and shall have a rating of not less than 115 percent of motor. See Figure 9-18. NEC® Section 430.124(A) states,
the rated input current of the conversion unit.” Circuit “Where the power conversion equipment is marked to
breakers and motor-circuit switches rated in horsepower indicate that overload protection is included, additional
are devices used as disconnecting means. A circuit overload protection shall not be required.” In order for
breaker or fused motor-rated disconnect can serve as the electric motor drive to provide overload protec-
both a disconnecting means and overcurrent device. A tion, the nameplate information of the motor must be
motor-circuit switch is commonly referred to as a mo- programmed into the drive. The electric motor drive
tor-rated disconnect. control board provides the overload protection based
NEC® Article 430 Part IX has specific rules regard- on the information entered.
ing disconnects for various applications. One of the If an electric motor drive is not approved for use as an
more commonly applied sections, NEC® 430.102(B) overload, or if multiple motors are fed from the drive, an
exception, allows a controller disconnect that is capable external overload relay(s) must be provided. See Figure 9-
of being locked open to also serve as the motor discon- 19. NEC® Article 430 contains information on selecting
necting means. Articles and exceptions in the NEC® and sizing overcurrent devices and overload protection.
may be superseded by other building codes such as a The normally closed contacts of the overload relays are
mechanical code requiring a disconnect be located at connected in series and terminate at the control terminal
all HVAC equipment. strip of the electric motor drive. An overload in any mo-
Overload Protection. In a majority of electric motor drive tor opens the circuit and causes the electric motor drive
applications, the drive provides overload protection for the to stop outputting voltage to the motors.

ELECTRIC MOTOR DRIVE AS OVERLOAD PROTECTION

ELECTRIC MOTOR DRIVE PROGRAMMED

WITH MOTOR NAMEPLATE INFORMATION
TO PROVIDE OVERLOAD PROTECTION

ELECTRIC MOTOR DRIVE

MANUFACTURER
Jog
TM
P
PE 21 PLUS PREMIUM EFFICIENCY
ORD. NO. 1LA02864SE41 MAG. 21.8
NUMBER
HORSEPOWER TYPE RGZESD I FRAME 286T OF PHASES
SERVICE
HP 30.00 FACTOR 1.0 3 PH
FULL LOAD AMPS 34.9 VOLTS 460
CURRENT
RPM 1765 HERTZ 60
SUPPLY
51-770-642

o DATE
DUTY CONT 40 C AMB. VOLTAGE
SPEED CLASS NEMA KVA NEMA
CODE

INSUL H DESIGN B CODE G NOM. EFF. 93.6

SH. END
BRG. 50BC03JPP3 OPP. END
BRG. 50BC03JPP3 FREQUENCY

Inverter Duty AC Induction Motor made in

U.S.A.

PE PE DC DC T1/U T2/V T3/W

3φ MOTOR
MOTOR
NAMEPLATE

Figure 9-18. Motor nameplate information is entered into an electric motor drive and the information is processed by the
CPU to calculate overload protection levels.
252 ELECTRIC MOTOR DRIVE INSTALLATION AND TROUBLESHOOTING

OVERLOAD PROTECTION PROVIDED BY OVERLOAD RELAY

ELECTRIC MOTOR DRIVE CONTACT OPENS ON

THERMAL OVERLOAD
SIGNALING ELECTRIC
MOTOR DRIVE TO
SHUT DOWN MOTOR

NORMALLY CLOSED
27 OVERLOAD RELAY
CONTACT
25

23
22
21

3φ
MOTOR

PE PE DC DC T2/V T3/W

OVERLOAD BOX

SINGLE MOTOR PROTECTION

CONTACT OPENS ON
ELECTRIC
THERMAL OVERLOAD
MOTOR NORMALLY CLOSED
SIGNALING ELECTRIC
DRIVE OVERLOAD RELAY
MOTOR DRIVE TO
SHUT DOWN MOTOR CONTACT

27
Jog
P

26

24
23
22 3φ
MOTOR
21

PE PE DC DC T1/U T2/V T3/W

3φ
MOTOR

FUSES PROVIDE OVERCURRENT

PROTECTION FOR EACH MOTOR OVERLOAD BOX

MULTIPLE MOTOR PROTECTION

Figure 9-19. External fuses and overload relays may be required along with the electric motor drive in certain applications.
 Chapter 9 — Electric Motor Drive Installation Procedures 253

Clearances. NEC® Article 110 Part II lists requirements safety and enhanced EMI reduction, electric motor drive
for dedicated working space and dedicated electrical manufacturers require an equipment grounding conductor
space. The working space requirements are intended to in addition to the metal raceway containing the power and
protect the technician who must adjust or service the control conductors of the drive. Grounding requirements
equipment by providing minimum working spaces, and and the sizing of equipment grounding conductors are
include illumination requirements. The equipment space covered in NEC® Article 250.
requirements are intended to protect the electrical equip-
ment by limiting nonelectrical piping systems above CAUTION
electrical equipment. Electric motor drive installations Consult the electric motor drive manufacturer before powering
must comply with NEC® Article 110 Part II requirements. a drive from an ungrounded system or a 3φ supply whose line
See Figure 9-20. voltages are not symmetrical to ground to avoid injuries to
personnel and avoid damaging the drive.
Grounding. Proper grounding of an electric motor drive
provides equal potential between all metal surfaces, a
low-impedance path to activate overcurrent devices, and Power Wiring
EMI reduction. NEC® Article 100 defines an equipment Power wiring for an electric motor drive consists of the con-
grounding conductor as “The conductor used to con- ductors supplying power to the drive (line conductors) and the
nect the non-current-carrying metal parts of equipment, conductors supplying power to the motor (load conductors).
raceways, and other enclosures to the system grounded A variety of wiring methods are available, depending upon
conductor, the grounding electrode conductor, or both, at installation considerations. The load conductors may power
the service equipment or at the source of a separately de- a single motor or multiple motors. Certain applications use a
rived system.” The NEC® permits certain metal raceways line bypass contactor to provide standard 60 Hz power to the
to be used as equipment grounding conductors. For added motor in the event the electric motor drive fails.

NEC ® EQUIPMENT SPACE REQUIREMENTS

EXHAUST DUCTS
LIGHTING

SPRINKLER
HEADS
DEDICATED
ELECTRICAL SPACE

6′ DEDICATED
WORKING SPACE

6¹⁄₂′
6′

DIMENSION
VARIES WITH
STATE AND
LOCAL CODES

Figure 9-20. The NEC® requires a dedicated working space and a dedicated electrical space for indoor installations of
electrical equipment.
254 ELECTRIC MOTOR DRIVE INSTALLATION AND TROUBLESHOOTING

Power Terminal Strip. The power terminal strip and R, S, and T for line; and U, V, W for load. Care must be
the control wiring terminal strip are separated from one taken to ensure the line conductors are connected at the
another to reduce EMI. The line conductors and load line terminals, and the load conductors are connected at
conductors are terminated at the power terminal strips. the load terminals. The DC bus connection is designated
Many electric motor drives have a location on the power by DC+, DC–. Some drive manufacturers denote the DC
terminal strip to connect an auxiliary braking unit direct- bus with B+ and B–. This is done to indicate the location
ly to the DC bus. The North American designations for where a dynamic braking resistor can be installed. The
conductors are L1, L2, and L3 for line; and T1, T2, T3 ground terminal is designated by potential earth (PE),
for load. The European designations for conductors are or the ground symbol ( ). See Figure 9-21.

ELECTRIC MOTOR DRIVE TERMINAL STRIPS

CLAMPING SCREW STRIPPED WIRE

L1(R) L2(S) L3(T) PE PE DC DC T1(U) T2(V) T3(W)

TERMINAL STRIP CONSISTING OF CLAMPING SCREWS

STRIPPED WIRE
SCREW WASHER CLAMP

PE PE DC DC L1(R) L2(S) L3(T) T1(U) T2(V) T3(W)

TERMINAL STRIP CONSISTING OF SCREWS, WASHERS, AND CLAMPS

THREADED STUD NUT

DC
THREADED STUD BRAKE
RING
LUG

PRESSURE
PLATE DC
BRAKE

L1(R) L2(S) L3(T) T1(U) T2(V) T3(W)

TERMINAL STRIP CONSISTING OF NUTS, WASHERS, AND THREADED STUDS

FLAT BUSBAR WASHER BUSBAR LUG

BOLT

DC DC L1(R) L2(S) L3(T) PE PE T1(U) T2(V) T3(W)

FLAT BUSBAR CONSISTING OF BOLTS AND WASHERS

Figure 9-21. Power terminal strips use various termination methods according to horsepower requirements and have
multiple designations for the line and load terminations.
 Chapter 9 — Electric Motor Drive Installation Procedures 255

The type of terminal strip required varies depend-

ing on the horsepower rating of the electric motor
drive. Small electric motor drives have screws with
pressure plates. Large electric motor drives have
threaded studs or busbars with nuts and washers.
Ring lugs are also used to terminate conductors onto
threaded studs. Ring lugs are used instead of fork lugs
because they do not fall off the threaded stud if the
nut and washer become loose. Always use the lugs
recommended by the electric motor drive manufac-
turer. The terminals need to be tightened for a secure
electrical connection.

TECH FACT
Nonmetallic conduits and raceways must not be used for
power wiring and control wiring when nonshielded cable
(wiring) is used.

Wiring Methods. The NEC® permits conductors 1/0

AWG and larger to be paralleled. Conductors may
be paralleled for ease of installation, or where wire-
bending space for large conductors is limited. Where
conductors are paralleled, conductors must be kept
together in sets with T1(1), T2(1), T3(1) in one conduit,
and T1(2), T2(2), T3(2) in another conduit. NEC ®
Section 310.4 contains the specific requirements for Control wiring and power wiring must be in separate metal conduits. Control
wiring should also be separated by voltage into separate metal conduits.
paralleling conductors.
Commonly used wiring conduit for power conduc-
Single-Motor Installation. The most common electric
tors include armored cable (Type AC), metal-clad cable
motor drive application involves a single motor pow-
(Type MC), rigid metal conduit, electrical metallic
ered by a drive. The overcurrent device that protects
tubing (EMT), intermediate metal conduit (IMC), and
the electric motor drive also protects the load conduc-
shielded power cable. The specific location and applica-
tors and motor. The electric motor drive provides the
tion determines the wiring conduit to be used, such as in
overload protection to the motor if it is approved for
commercial HVAC installation, industrial installation,
this purpose. An electric motor drive controlling an
or an original equipment manufacturer (OEM) piece of
HVAC fan motor is a common single-motor installation.
machinery. See Figure 9-22. Plastic raceways are not
See Figure 9-24.
recommended because plastic raceways do not provide
shielding to limit EMI.
The final connection to the motor should be made
with a short length of flexible conduit (6′ or less) and WARNING
stranded wire. Either flexible metal conduit (flex) or Always follow the instructions and recommendations of
liquidtight flexible metal conduit (Sealtite™) can be electric motor drive manufacturers and applicable federal,
used. Each method allows the motor to be moved for state, and local codes. Failure to do so can result in serious
physical injury and/or equipment damage. Only qualified
minor adjustments and prevents vibration from the mo- personnel are allowed to install, start up, and troubleshoot
tor and driven load from damaging a solid raceway or electric motor drives.
solid conductor. See Figure 9-23.
256 ELECTRIC MOTOR DRIVE INSTALLATION AND TROUBLESHOOTING

ELECTRIC MOTOR DRIVE TO MOTOR WIRING METHODS

ELECTRIC MOTOR DRIVE 3 MOTOR

DISCONNECT

EMT WITH
Jog INDIVIDUAL
CONDUCTORS
P

NEMA® RATED PUMP

ENCLOSURE

SEALTITE™ Siemens
CONDUCTOR CONDUIT
PULL BOX

PUMP MOTOR

ELECTRIC MOTOR DRIVE SHIELDED POWER CABLE

CABLE TRAY DROP

CABLE TRAY
Jog
P

ELECTRIC MOTOR
DRIVE CABINET

CONVEYOR
MOTOR

Siemens
CONVEYOR MOTOR

SHIELD

INSULATION CONDUCTOR

BOX FITTING
GROUND

CONDUCTORS

SHIELDED POWER CABLE FOR CABLE TRAY APPLICATIONS

Figure 9-22. A wide variety of wiring methods are available for installing an electric motor drive and motor.
 Chapter 9 — Electric Motor Drive Installation Procedures 257

FLEXIBLE MOTOR CONDUIT

POWER FROM
ELECTRIC MOTOR DRIVE
MACHINE PULLEY
(DRIVEN PULLEY)
3 MOTOR
MOTOR
DISCONNECT

FLEXIBLE CONNECTION V BELTS

TO MOTOR USING
STRANDED
CONDUCTORS
Siemens MOTOR PULLEY
(DRIVER PULLEY)

ADJUSTMENT

ADJUSTABLE
PIVOT BASE

Figure 9-23. A flexible connection to a motor allows motor adjustment and negates the effects of vibration from the motor
or building.

ELECTRIC MOTOR DRIVE AND SINGLE-MOTOR SYSTEM INSTALLATION

FROM
POWER SOURCE

FUSED MOTOR
RATED DISCONNECT
HVAC FAN

MOTOR-RATED
DISCONNECT

Square D Company

RIGID CONDUIT

ELECTRIC MOTOR
DRIVE PROVIDES
OVERLOAD
PROTECTION
FOR MOTOR

ASI Robinson RIGID

CONDUIT HVAC FAN FLEXIBLE
MOTOR CONDUIT

Figure 9-24. A basic electric motor drive application involves a single motor powered by a drive.
258 ELECTRIC MOTOR DRIVE INSTALLATION AND TROUBLESHOOTING

Multiple-Motor Installation. A multiple-motor instal- motor drive controlling an exhaust fan that removes
lation involves multiple motors being fed from a single fumes from a parking garage is a common application
electric motor drive. An electric motor drive controlling requiring a bypass contactor. Speed control is not pos-
a conveyor with multiple motors that operate at the sible when operating in bypass mode.
same speed is a common multiple-motor installation. The bypass contactor works in conjunction with an
Each motor has its own set of conductors. Supplemen- input contactor, output contactor, overload relay, and
tal overcurrent devices and overload protection must
other control components. See Figure 9-26. When in the
be installed, as the rating of the individual motors is
electric motor drive mode, the bypass contactor is open,
less than the electric motor drive rating. A multiple-
motor installation requires that all the motors have the the input contactor and output contactor are closed, and
same NEMA design letter. Open-loop or closed-loop the motor is powered by the drive. In the bypass mode,
vector drives cannot be fed from a single electric mo- the bypass contactor is closed, the input and output
tor drive. See Figure 9-25. NEC® Article 430 contains contactors are open, and the motor is powered by the
information on sizing overcurrent devices and overload line voltage, not the electric motor drive.
protection for multiple-motor installations. The bypass contactor is mechanically interlocked to
Bypass Contactor. A bypass contactor is a contactor the output contactor and electrically interlocked to the
that allows line power to a motor that is normally con- input contactor. The interlocking ensures that both the
trolled by an electric motor drive. A bypass contactor output contactor and input contactor are de-energized
allows a critical load to operate during electric motor (open) when the bypass contactor is closed. Isolating the
drive maintenance, or when a drive fails. An electric electric motor drive prevents line power from reaching

MULTIPLE-MOTOR INSTALLATION
FROM
POWER SUPPLY
FUSES PROVIDE
OVERCURRENT
PROTECTION FOR
INDIVIDUAL MOTORS
JUNCTION BOX
FUSE
MOTOR-RATED EXTERNAL
DISCONNECT EXTERNAL OVERLOAD OVERLOAD
AND FUSE ENCLOSURE AND FUSE
ENCLOSURE

OVERLOAD RELAY
OVERLOAD RELAY ENCLOSURE
ENCLOSURE
General Electric Company
General Electric Company
General Electric Company
3 MOTORS

OVERLOAD ON EITHER MOTORS CONTROLLED FROM ONE

MOTOR SENDS SIGNAL ELECTRIC MOTOR DRIVE MUST
TO ELECTRIC MOTOR DRIVE HAVE SAME NEMA DESIGN LETTER
TO STOP MOTORS

Square D - Schneider Electric

Figure 9-25. Multiple motors fed from a single electric motor drive require supplemental overcurrent and overload protection.
 Chapter 9 — Electric Motor Drive Installation Procedures 259

the drive output. The overload relay is provided to The input contactor and output contactor do not control
protect the motor when the electric motor drive with stopping and starting of an electric motor drive. The start-
its integral overload protection is bypassed. The con- ing and stopping of an electric motor drive is controlled
trols to initiate the bypass function may be manual or by inputs to the drive. The output contactor must be closed
automatic. Other bypass control systems are found in prior to starting an electric motor drive, and the drive must
industry for specific applications. be OFF before opening the output contactor.

BYPASS CONTACTOR CIRCUIT

FROM ELECTRIC
POWER SUPPLY MOTOR DRIVE
SELECTOR SWITCH CONDITIONS
L1 L2 L3
Jog
CONTACTOR DRIVE OFF BYPASS
FUSED MOTOR P

RATED DISCONNECT INPUT CLOSED OPEN OPEN

OUTPUT CLOSED OPEN OPEN
BYPASS OPEN OPEN CLOSED

OUTPUT CONTACTOR

LINE EXTERNAL
REACTOR L1/R L2/S L3/T PE PE DC DC T1/U T2/V T3/W OVERLOADS
IC OC

INPUT
CONTACTOR

F1
BYPASS BYP
F2 CONTACTOR
TRANSFORMER 3φ
MOTOR
LADDER
2 1 F3 DIAGRAM
BYPASS
CONTACTOR
OC
SELECTOR
1
SWITCH

DRIVE – OFF – BYPASS OC

IC
BYP OL
2 3 4 5
2

ELECTRICAL IC
INTERLOCK BYP MECHANICAL
IC
2 6 INTERLOCK
3

BYP

BYPASS
2 BYP 7 5
4
ELECTRIC Square D -
MOTOR DRIVE Schneider Electric
LINE NUMBER WIRE-REFERENCE NUMBER

Figure 9-26. A bypass contactor provides line power to a motor if the electric motor drive fails.
260 ELECTRIC MOTOR DRIVE INSTALLATION AND TROUBLESHOOTING

Control Wiring The outputs can control devices related to the electric
Control wiring consists of inputs and outputs con- motor drive or provide metering and annunciation func-
nected to the electric motor drive, excluding the power tions. A digital output such as a relay can be used to start
wiring. The inputs and outputs are connected to the and stop an external electromechanical motor brake. An
electric motor drive at the control terminal strips. analog output can be used with an external meter that
The type of inputs and outputs determine the wiring displays frequency or motor current. See Figure 9-27.
method. Various wiring schemes are used, depending Wiring Methods. Digital inputs and outputs are
upon the specific application. connected to an electric motor drive with individual
Control Terminal Strips. Digital inputs, analog inputs, conductors. Analog inputs and outputs are connected
digital outputs, and analog outputs are connected to the to an electric motor drive with twisted shielded pair
control terminal strips. The number and type of inputs cables. See Figure 9-28. The following items must be
and outputs varies with the complexity of the electric mo- considered when installing control wiring:
tor drive. The functionality of an input or output may be • Control wiring and power wiring should be installed
controlled by the programming parameters of an electric in separate metal conduits.
motor drive. The functionality of a relay output (digital • Wiring for digital signals, analog signals, and serial
output) may be programmed to indicate motor over-cur- communication signals should be installed in separate
rent, motor overload, or an electric motor drive fault. metal conduits.
Electric motor drive inputs control the starting, • Do not mix wiring for AC and DC control signals in
stopping, and speed of a motor. Digital inputs consist the same conduit.
of control devices that provide an on/off signal such • Inside an electric motor drive enclosure, control and
as a selector switch or pushbutton. Analog inputs con- power wiring should be separated as much as pos-
sist of signals that vary over a range of values, such sible. If control and power wiring must cross, they
as a potentiometer with a 0 VDC–10 VDC signal. A should cross at a 90° angle.
combination of digital and analog inputs can control an • Care must be taken when terminating the twisted shield-
electric motor drive by using a selector switch to start ed pair cables to ensure the shield is terminated only at
a motor and a 4 mA–20 mA signal to control the speed the electric motor drive end, and the pairs should be
of the motor. twisted as close as possible to the terminals.

TERMINAL STRIP FUNCTIONALITY

DRAIN WIRE
GND 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

DRAIN
WIRE
POTENTIOMETER

0 VDC – 10 VDC
INPUT

4 mA – 20 mA
INPUT

PROGRAMMABLE
ANALOG OUTPUT

DIGITAL
INPUT 1

DIGITAL
INPUT 2
DIGITAL
INPUT3

PROGRAMMABLE
OUTPUT RELAY

DRAIN WIRES OF SHIELDED TWISTED PAIR CABLES

TERMINATE AT CONTROL TERMINAL STRIP GROUND

Figure 9-27. Programming the parameters of an electric motor drive allows the functions of the inputs and outputs to
be modified.
 Chapter 9 — Electric Motor Drive Installation Procedures 261

CABLE DRAIN AND SHIELD CONNECTIONS

SIGNAL WIRES
DRAIN SHIELD/DRAIN WIRE COVERED TERMINATE
WIRE WITH SHRINK TUBING TO ALLOW AT DEVICE
GROUNDING AT ONE POINT

SIGNAL WIRES
TERMINATE
AT ELECTRIC
MOTOR DRIVE SHRINK
MESH SHIELD TRIMMED BACK TUBING
AND SHRINK TUBING ADDED
TO PREVENT SHIELD TOUCHING
GROUNDED SURFACES

ELECTRIC MOTOR DRIVE END DEVICE END

SIGNAL WIRES

DRAIN WIRE SIGNAL

WIRE
COVERED WITH SHRINK TUBING
SHRINK TUBING

Figure 9-28. The termination of twisted shielded pair cable requires that shrink tubing be added correctly.

Control Wiring Schemes. Wiring schemes involving Wiring schemes involving analog signals fall into two
digital inputs fall into two categories, 2-wire control and categories, 2-wire control and 3-wire control. Certain ana-
3-wire control. Two-wire control is the simplest. Two-wire log signals only require a two-conductor twisted shielded
control consists of two wires to an electric motor drive from pair cable with a 4 mA–20 mA or a 0 VDC–10 VDC
a single digital input such as a selector switch. Opening signal. Other analog signals require a three-conductor
and closing the digital input stops and starts the electric twisted shielded pair cable as with a potentiometer.
motor drive operation. Three-wire control consists of Many electric motor drives have the capability to
three wires from two digital inputs. One of the inputs is communicate with PLCs, other drives, building automa-
a normally open start and the other is a normally closed tion systems, HMIs, and PCs via serial communication.
stop. The scheme is similar to the 3-wire control used The serial communication may be RS-232 or RS-485.
with magnetic motor starters. See Figure 9-29. The serial communication may be integral to the electric
motor drive or require an interface board. An electric
TECH FACT motor drive is connected to other devices with twisted
shielded pair cables. The advantages of serial commu-
Electric motor drives on HVAC fans include a bypass
contactor that is used to power the fan with utility power nication include less wiring between control equipment,
when drive failure occurs. and the electric motor drive can be monitored and con-
trolled from a central location.
262 ELECTRIC MOTOR DRIVE INSTALLATION AND TROUBLESHOOTING

CONTROL WIRING SCHEMES

1 2 3 14 15 16 17 18 19

Jog
P

S
START/STOP

2-WIRE CONTROL

1 2 3 14 15 16 17 18 19

Jog
P

NO
NORMALLY
N CLOSED
(STOP)
NORMALLY OPEN
(START)
3-WIRE CONTROL

1 2 3 14 15 16 17 18 19

Jog
P

DRAIN OF TWISTED
SHIELDED CABLE
POTENTIOMETER 4 mA – 20 mA
ANALOG INPUT
ANALOG CONTROL

INPUT &
STATUS OUTPUT INPUT OUTPUT SPARE

D SHELL
POWER
PC RUN
CPU FAULT

CONNECTOR FORCED I/O

BATTERY LOW

Jog
P

COMMUNICATIONS CABLE
SERIAL COMMUNICATION

Figure 9-29. Electric motor drive control wiring schemes include 2-wire control, 3-wire control, analog control, and serial
communication.