Screened SUBCAB Cable Connection Recommendations and EMC Guideline PDF

Screened SUBCAB & EMC
Screened SUBCAB cable connection

recommendations and EMC guideline
Overview:
This document will give you some recommendations about Screened SUBCAB cable handling
as well as giving some guidance in having a good installation from an EMC perspective regarding
interference/problems that arise from VFD converters.
Xylem Inc. adopts a policy of continuous improvement and whilst every effort has been made to
provide accurate and up to date information, the information contained in this document should
be used for guidance purposes only and does not form the part of any contract.
H:\Genuine Parts Package\Cables\Cables General\Cable connection recommendations and EMC
Guideline.docx
Prepare and connect Screened SUBCAB cable

The table below shows the different types of Screened SUBCAB cables and the associated part
numbers.
Denomination
SUBCAB
S3x1,5+3x1,5/3+S(2x0,5)
S3x2,5+3x2,5/3+S(4x0,5)
S3x6+3x6/3+S(4x0,5)
S3x10+3x10/3+S(4x0,5)
S3x16+3x16/3+S(4x0,5)
S3x25+3x16/3+S2(2x0,5)
S3x35+3x16/3+S2(2x0,5)
S3x50+3x25/3 +S2(2x0,5)
S3x70+3x35/3+S2(2x0,5)
S3x95+3x50/3+ S2(2x0,5)
S3x120+3x70/3+S2(2x0,5)
S6x95+95+S(4x0,5)
Conductor
Size
Number
mm2
1,5
3+2+1
2,5
3+4+1
6
3+4+1
10
3+4+1
16
3+4+1
25
3+4+1
35
3+4+1
50
3+4+1
70
3+4+1
95
3+4+1
120
3+4+1
190
6+1+4+1
Dy
Part number
mm
16,0-17,0
18,022,0
20,022,0
24,0 26,0
24,0 26,0
29,0 31,0
32,0 34,0
38,0 40,0
42,0 44,0
44,0 47,0
50,0 52,0
57,0-60,0
94 19 89
94 19 90
94 19 91
94 19 92
94 19 93
94 19 94
94 19 95
94 19 96
94 19 97
94 19 98
94 19 99
94 20 00
The Screened SUBCAB is a cable developed for submersible applications, used primarily for
VFD applications.
The cable has a concentric screen around each power core (no green/yellow earth ground
core), the screen works both as earth ground core and as EMC screen.
The control element is also screened with a copper coated foil and drain wire
The use of the screen as an earth (ground) core is in accordance with IEC 60364, HD 384 and
Xylem Flygt standard A3216.01.
Guideline.docx

Peel and prepare the cable
1.
Peel off the outer sheath at the end of the cable.
2. Untwist the screen around each main core, and then remove the Al-foil around each
power core.
3. Let a longer piece of each screen remain twisted, each screen should be at least 10cm
longer then the power cores, due to PE ground core regulation.
4. Twist all three power cores screens together to create an earth (ground) core use a cable
terminal at the end.
5. Put a yellow/green shrink hose over the earth (ground) core. Leave a short piece
uncovered nearest to the unpeeled cable, see Figure 1.
6. If the connection to earth (ground) is made by a screw, fit a cable lug to the earth
(ground) core. If the connection is made by a terminal block, leave the core end as it is.
Make sure that the earth (ground) core is longer (at least 10%) than the phase cores. For
the correct length, see the Installation, Operation and Maintenance manual for the
pump.
7. The control element must also be peeled, keep the element as long as possible unpeeled
until it reaches the control terminals (to keep the screen as long as possible). Remove the
jacket and the copper foil. Put a white shrink hose over the open drain wire (cable lug),
twist T1+T2 and T3+T4 and connect to the terminals.
Figure 1: Peeled and prepared Screened SUBCAB cable
Guideline.docx
Figure 2 Peeling the control element and its accessories.
Figure 3 Handling the control element when no sensors
Guideline.docx

Recommendable EMC connection for our Screened SUBCAB.
When operating a pump or a system with a VFD (Variable Frequency Drive), the level of
disturbance in proximity of the VFD is rapidly increasing due to the nature of a VFD.
A VFD emits a high degree of harmonic disturbances both on the cables and in the air.
The level of disturbances is related to the installation in relation to EMC prevention
EMC Gland
It is very important to obtain a good ground system to avoid interference/emission from the
VFD to the surrounding electrical system. A well grounding system also reduces the risk of
functional disruption and damage to the equipment caused by lightning.
Connect the Screened SUBCAB with incoming EMC gland/conduit entry, if the VFD have metal
flange joint. Otherwise use short pig tales for the ground PE earth screen. Connect control cores
T1+T2 and T3+T4 twisted together to the terminal of the VFD, the drain wire to signal ground
(potential compensation terminal). Separate the control cores from the power cores as much as
possible.
Try to use special EMC glands, for the outgoing cable to the pump. Those glands assure 360
grounding around the screen and control screen, the EMC glands reduce the interference
emission from the VFD via the cable. See to that cabinet inlet plate is well grounded (without
paint and rubber gasket, use EMC copper bonded gasket if so).
Figure 4 EMC gland
Toroid Cores
Install toroid cores so they cover the three motor phase cores, but not PE-core.
Guideline.docx

The toroids attenuates high frequency mains-borne interference that is produced by VFD:s,
placing them around the three phase cores reduces such disturbance.
Toroids can get warm/hot, make sure they do not touch cable insulation by using
a heat insulating tape or shrink tube around the cable cores. (toroid part.no: 83 95 06-07)
Figure 5 Toroid wiring with three toroids in

parallel
Figure 7 Schematic
connection of Screened
SUBCAB in VFD
applications
Guideline.docx

Filters
These filters can be used to suppress noise.
Grounding
Make sure that the Earthing Rod is sufficiently long to meet moisten ground.
Recommendable EMC connection in general.

Guideline.docx

To avoid EMC problems such as radiation (emission) from VFD or surrounding interference
(immunity) from external sources the connection to the earth (ground) core must be done in a
proper way. Examine the site and see to that there is a good ground connection around the
pump station. The Main Earth Terminal must be connected to a ground rod (at least 1-2m deep
in ground) outside or in close connection to control panel, use a copper wire (25-50mm)
between the ground rod and the panel/pump house main earth terminal.
4
4
3
3
2
2
5
11
No. Description
Connect each main core screen to the mounting plate by an EMC gland
1
(grounding). Make the connection directly after the cable inlet.
Follow the instruction for twisting the control element cores, see How to peel and
2
prepare the cable on page 1.
3
Use a screened cable between the VFD filter and the terminal block.
If possible, exchange the rubber seal on the cabinet door to a conductive seal to
4
make a good EMC connection between the door and the cabinet.
5
Optional, place a toroid core around the three power cores. [Part no. 83 95 06-07]
Guideline.docx

Connection of the screen to the mounting plate if no EMC glands are
available
No.
1
Description
Connect the core including screen with a cable clamp to the mounting plate to
get a good EMC grounding. See to scratch of the paint on the plate so the screen
connection is good to PE..
Guideline.docx

Proper grounding and cable routing
Always use screened monitoring cables when extending SUBCAB Screened Control Cable
conductors. The following practices shall be used when terminating the screens:
The motor cable should be screened and grounded at both ends (Screened SUBCAB
where screen also acts as protected earth) to prevent undesired electrical interference
from the VFD (range between 1MHz and 10MHz).
Use EMC cable gland and assure that the screen is connected 360 in the gland or
connect the screen pigtail as short as possible in the panel.
Ensure that the control conductors are twisted together, and do not separate the
conductors when cable is peeled until reaching the connection point. If possible place
the control conductors in separate cable channel in the control panel to avoid coupling
to other interference sources.
Conductor Screens to connect to a signal ground (potential compensation terminal) and

not the protective ground. Protective ground and signal ground should be separated.
They are then connected together only once at the main supply point. Parallel grounding
is not allowed.
If ground loops, current or magnetic disturbances occur in the cable screen open the
screen connection in the control panel and connect a capacitor in series between the
screen and ground (e.g. 0.5f, 1kV). The ground system must have one system ground,
where all ground connections should be connected from the control panel and various
control units. Avoid ground loops through gland plates and cable gland bonding and
ensure that there is no potential difference in the ground system.
Control cables must be segregated from all mains cables by at least 30 cm by use of separate
metal conduits / cable trays grounded.
Control cables must be segregated from all motor cables by at least 50 cm by use of separate
metal conduits / cable trays grounded.
Control cables should not cross power cables unless absolutely necessary and then only at 90
degree angles.
Guideline.docx
10

General advice how to avoid EMC problems at VFD installations.
Wiring inside a control panel:
Separate as much as possible VFD motor cables from control cores dont let them go in
parallel
Place sensitive control cores as close as possible to the mounting plate, twist them
together. Bend those 90 towards the VFD power cores if they are close to the power
cores.
Avoid locating the control terminals close to the power line terminals. Peel of a long
piece of the SUBCAB cable so the control element including its screen comes away from
the power line terminals. When separated, twist the T1+T2 and T3+T4 cores together,
connect to the terminals and then the drain wire to system earth (PE).
Additional recommendations:
Supply relay and contactor with interference suppression device at the coil.
For AC coils use RC-protections or varistors, for DC coils use protection diode
e.g. 1N4007 (cathode to +).
Use Flygt noise suppression filter part.no:604 68 00-4 to reduce induces interference on
sensor wires that comes from inside the pump and motor windings. Ground the filter
well, use short pigtails.
Those filters can also be used in other applications to suppress noise in control
circuits.
Use good noise protective 24 Volt DC power supply as auxiliary supply.
Use ferrite core around control cores that are affected by leakage current in the screen
(material 43 or 77)
Use decoupling capacitor for interfered control cores at the control panels terminals.
(e.g. 0,01f 250 V). Connect one end of the capacitor to ground (mounting plate) the
other end to control terminal.
No: 604 68 04
No:604 68 01
Figure 8 Various noise suppression components
Guideline.docx
11
Varistor
Gas discharge tube

lightning
Conductive joint
RC-comp.
Ferrite cores
Y-capacitor.
0,1f capacitor.
choke coil.
choke coil.
Revision History
Version
Comments
1.0
First Release
2.0
Second Release
4,7nf 3kV cap.
Author
GT
GT
Guideline.docx
Date
19/9/12
121012
12

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