Cabling Wiring Guidelines Cranes

Document:
Cabling and wiring guidelines for cranes
Date:
Revision:
2007-03-23
1.1
Cabling and Wiring Guidelines

for Cranes
RELEASE PROJECTMANAGER
Name
Function
: Gerhard Fischer
: Sales
RELEASE INTERNAL PRINCIPALS

Name
Function
: Hans Buurkes
: Quality
Revision
Date
:1.1
: 23. March 2007
The document content and the provide solutions are the intellectual property of Siemens the Netherlands NV. Copies to external parties can only be provided after a formal
release of Siemens.
Siemens AG, A&D MC CR
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TABLE OF CONTENTS
BACKGROUND .............................................................................................................................3
INTRODUCTION ............................................................................................................................4
2.1
2.2
2.3
2.4
HIGH FREQUENCY DISTURBANCE ..............................................................................................4

LONG MOTOR CABLES..............................................................................................................6
COMMON MODE OSCILLATION ...................................................................................................7
BEARING CURRENTS................................................................................................................7
SELECTION OF LOAD SIDE COMPONENTS ..............................................................................8

3.1
MAXIMUM CABLE LENGTH WITHOUT OUTPUT CHOKES .................................................................8
3.2
MAXIMUM CABLE LENGTH WITH OUTPUT CHOKES .......................................................................9
3.2.1
Iron-core reactors .............................................................................................................9
3.2.2
Ferrite-core reactors .........................................................................................................9
3.2.3
Voltage limiting (dv/dt) filters.............................................................................................9
3.2.4
Sinusoidal filters .............................................................................................................10
SIZING OF CABLE CROSS SECTIONAL AREA ........................................................................12

4.1
4.2
POWER CABLE SELECTION .....................................................................................................13

5.1
5.2
5.3
5.4
5.4.1
5.4.2
5.4.3
5.4.4
CONDUCTORS ......................................................................................................................12
PROTECTIVE CONDUCTOR......................................................................................................12
TYPES OF POWER CABLES .....................................................................................................13
INSULATION MATERIAL USED FOR POWER CABLES ....................................................................13
SIEMENS RECOMMENDED POWER CABLES ...............................................................................14
INSTALLATION GUIDELINES .....................................................................................................15
Wiring guidelines in accordance to EMC rules................................................................17
Wiring requirements as per IEC 60204-32......................................................................22
Wiring practices to be avoided........................................................................................26
Best practice screened power cable termination ............................................................28
INSTALLATION OF CONTROL CABLES ...................................................................................30

6.1
INSTALLATION OF PROFIBUS CABLES ...................................................................................30
6.2
INSTALLATION OF ENCODER CABLES .......................................................................................33
6.2.1
Installation of encoder cables at motor side....................................................................34
6.2.2
Installation of encoder cables at drive side .....................................................................36
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Background
Siemens supplies electrical components such as SIMATIC S7 programmable logic controllers, SIMOVERT
MASTERDRIVES frequency converters 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 detail cabling recommendations by Siemens.
This document summarizes recommendations from several sources as listed below. It has been
compiled by Mabel Chin of Siemens Ptd. Ltd. Singapore and proof-read by Peter Dek and Pieter
Olislagers of Siemens Nederlands N.V., The Hague, Netherlands.
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
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
Catalog DA65.10
Simovert Masterdrives Vector Control Catalogue 2003/2004
6SE7087-6QX60
Masterdrives Compendium Vector Control 1998
6SE7087-6CX87-8CE0 Installation Instructions for EMC Correct Installation of Drives

Prysmian (Pirelli) catalog BU IS 2.1 2000
Flexible Electric Cables
Implementation of these recommendations is no substitute for a risk assessment of the crane, which
needs to be made by the crane designer.
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Introduction
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 crane ratead load and crane size
has become a technical challenge. The following recommendations are intended to help the crane builder
in carrying out the electrical installation and cabling such that latest aspects of variable speed drives
parasitic effects are covered.
2.1
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.
SIMOVERT MASTERDRIVES frequency converters 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. An reasonably sinusoidal current flows in the motor.
Figure 1: Block diagram showing output voltage V and motor current I of a frequency converter
The described mode of operation in conjunction with high-performance semiconductor switching
elements have 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.
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Figure 2a: 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".
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Long motor cables
Effect of crane mechnical configurations on the length of the electrical cables:

a) Machinery on trolley (MOT)
+ Shorter wire-ropes for hoist
+ No wire-ropes for trolley
- Long electrical cables for hoist
motors
- Long electrical cables for trolley
motors
- Space constraints for hoist motors
b) Self-propelled trolley (SPT)

+ No wire-ropes for trolley
- Long electrical cables for trolley
motors
c) Rope-towed trolley (RTT)

+ short cables to hoist and trolley
motors
- long wire-ropes for hoist and trolley
d) Typical Gantry configuration

- accumulated long motor cables
From all of 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.
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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 2b: Principle circuit for common-mode oscillation

Engineering of the drive system is to carefully consider the entire power train comprising the medium
voltage transformer, drive system with line-side converters and inverters on the common DC-bus , the
motor with the insulation grade and the cabling between the different components.
2.4
Bearing currents
Asymmetrical characteristics of the motor feeder cable in conjunction with the PWM switching pattern
of the inverter leads to voltage building up 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.
As a consequence all motor feeder cables are to be screened and of symmetric design.
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Selection of load side components
The objective of the following chapters is to give a clear instruction on:1. how to select the correct load-side components
2. how to select suitable cable and type.
3. how to implement correct wiring practices.
Dimensioning of cable cross sectional area
Installation of power cables
Installation of control cables
The purpose of output chokes 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 chokes are dependant on the following parameters:1) Type of cables used ( screened or unscreened )
2) Number of motors supplied from a converter
Item 1 is reflected in Table 1.
Item 2 is when a converter/inverter supplies several motors (group drive), the capacitive charge/
discharge currents of the motor cables are added together. The total cable length is the sum of the
cable lengths for the individual motors.
3.1
Maximum cable length without output chokes
The maximum cable lengths which can be connected to the standard Simovert Masterdrive unit
without reactors are specified in table 1.
Table 1: Motor cable distance without output choke
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Maximum cable length with output chokes
3.2
In cases whereby there are longer power cables, they should be dimensioned according to Table 2.
Table 2: Motor cable distance with output choke

1)
2)
3)
4)
5)
3.2.1
o
o
3.2.2
Cannot be used.
In the case of sizes M, N and Q, 2 inverters are connected in parallel and the number of reactors for the permissible
cable lengths is therefore required for each inverter section.
Applies to sizes E, F, G, J, K, L, N and Q.
Applies to size M.
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.
Iron-core reactors
Drives with standard and non-standard induction motors with a rated motor frequency
(frequency at the start of field weakening) of up to 87 Hz and a maximum frequency of 200 Hz.
Drives with reluctance motors or permanent-magnet synchronous motors with a maximum
frequency of 120 Hz.
Ferrite-core reactors
Not relevant for cranes applications.
3.2.3
Voltage limiting (dv/dt) filters
Voltage limiting filters (output dv/dt filters for SIMOVERTMASTERDRIVES Vector Control) should be
used for motors where the voltage strength of the insulation system is not known or is inadequate.
The dv/dt filters limit the voltage rate-of-rise to values of < 500 V/s and the typical voltage spikes for
the rated supply voltage to the following values:
<1000 V at Vsupply 575 V,
<1150 V at 660V Vsupply 690 V
with a motor cable length of 150m.
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When reactors and filters are connected in series, the cable lengths can be dimensioned according to
the Table 4.
Table 3: Motor cable distance with combination of reactors and dv/dt filter
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 the case of standard units.
The voltage limiting filters can be used up to a maximum frequency of 300 Hz.
The dv/dt filters can only be used with a motor connected.
Figure 3: Arrangement of output reactor and dv/dt filter

3.2.4
Sinusoidal filters
Sinusoidal filters ensure that the motor voltage and currents are almost sinusoidal. The harmonic
distortion factor for a 50 Hz motor voltage with sinusoidal filter, for example, is approximately 5%. The
stressing levels of motors which are supplied via sinusoidal filters are lower than the values specified
in DIN VDE 0530. When engineering the drive, it should be ensured that the output voltage of
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converters and inverters with sinusoidal filters is approximately 85% of the associated supply voltage
at 380 V to 480 V and approximately 90% at 500 V to 600 V.
The sinusoidal filters for supply voltages of 380 V to 480 V are designed for a 6 kHz pulse frequency.
The maximum output frequency is:
400 Hz for Compact units (sizes A to D),
200Hz for chassis units (sizes E to G).
Note the current derating for chassis units as a result of the 6 kHz pulse frequency!
The sinusoidal filters for supply voltages of 500 V to 600 V are designed for a pulse frequency of 3
kHz.
The maximum output frequency is:
200 Hz for Compact units (sizes B to D),
100 Hz for chassis units (sizes E to G).
Sinusoidal filters are suitable for supplying Ex(d) motors. They limit the voltage stressing in the motor
terminal boxes to below 1080 V up to a supply voltage of 500 V.
For possible cable lengths, see Table 5.
Table 4: Motor cable distance with sinusoidal filter
Note
The total cable length is the sum of the cable lengths to the individual motors. From a motor current of
120 A, single-motor drives can also be operated with parallel cables (up to the maximum permissible
cable length) in the case of standard units.
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Sizing of cable cross sectional area

Conductors
4.1
Please refer to the recommended cross sectional area of the conductors for incoming and outgoing
cables of every unit sizes of Simovert Masterdrives in the operation manual.
Protective conductor
4.2
The protective conductor is to be dimensioned considering the following functions:
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 120VDC, 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.
In the event of a fault in accordance with EN 50 178, Section 8.3.3.4, it is possible that
continuous currents can flow through the protective conductor. The cross-section of the
protective conductor is therefore to be dimensioned for this continuous current.
Switchgear and motors are usually earthed separately using a local earth electrode. With this
constellation, the earth-fault current, in the event of an earth fault, flows through the parallel
earth connections and is divided up. In spite of the cross-sections of the protective conductor
as specified in the table, no non-permissible touch voltages then occur with this kind of
earthing.
Table 5: Recommended Cross section of external protective conductors
The MASTERDRIVES converters, inverters, rectifier units (>400 kW) and rectifier/
regenerative units limit the current to an effective value in accordance with the rated current,
thanks to their rapid control.
Given these facts, we recommend that the cross section of the protective conductor is
generally the same as the cross-section of the outer conductor for earthing the control cubicle
and the motor.
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5.1
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Power cable selection

Types of power cables
Table 6: Overview power cable types
5.2
Insulation material used for power cables
In view of minimizing the capacitance between the motor phase conductors and ground (see section
2.1 capacitance CP) it is advicable to choose cables with an as low as possible specific capacitance
(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.
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Siemens recommended power cables
In general, we highly recommend Protoflex EMV 3 Plus due to the fact that:1. it can reduce the high frequency noise emission
2. it can reduce the bearing current effects
3. It has a minimal effective capacitance per unit length which is comparable to that of a standard
unscreened cable. (eg: 3X70+3X10 has capacitance of 290nF/km)
4. 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.
L1
PE
PE
L2
L3
PE
Figure 4: Principle cross-sectional view of screened symmetric motor feeder cable

However, its important to check at the cable specifications with the suppliers! It is good to know that
different cable suppliers used different material for their cable sheaths, different quality with
geometrical properties and so on. Therefore, it is critical to compare the capacitance value/ unit length
of all these cables and select the one with the lowest value.
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Typical power cable electrical and mechanical characteristics:

Electrical Characteristics:-
Table 7: Electrical specification PROTOFLEX EMV
Cable Design Specifications:-
Table 8: Mechanicall specification PROTOFLEX EMV
5.4
Installation guidelines
Typical wiring to the drive for the recommended power cable type
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Figure 5: Earthing and screening for connection 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 cranes 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 6 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.
The figure below illustrates the best wiring practices within as well as outside the panel enclosure
following the 16 EMC rules in the next section which ensure minimum disturbances to other electrical
components.
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Figure 7: Overview of best wiring practice adhering to EMC rules

5.4.1
Wiring guidelines in accordance to EMC rules
Design of drives must be in conformance with EMC regulations. Rules 1 to 13 are generally
applicable. Rules 14 to 16 are particularly important for limiting noise emission.
Rule 1
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.
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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Rule 2 and 3
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.
Group 1: very susceptible (eg: analogue signals)

Group 2: Susceptible (eg: digital signals)
Group 3: Noise source (eg: control cables)
Group 4: Strong noise source (eg: output cables from drives)
Note:
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.
Rule 4
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.
Rule 5
Eliminate any unnecessary cable lengths to keep coupling capacitances and inductances low.
Rule 6
Connect the reserve cables/conductors to ground at both ends to achieve an additional shielding
effect.
Rule 7
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.
Rule 8
Encoders must be connected through a shielded cable. The shield must be connected to the encoder
housing and at the SIMOVERT MASTERDRIVES through a large surface area. The shield must not
be interrupted, e.g. using intermediate terminals. For chassis units (sizes E), the shields can be
additionally connected using cable ties (cable connectors) at the shield connecting locations.
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Screen connection via serrated bars:
Figure 8a: Connecting signal cable shields via 2 serrated bars in the cabinet
Screen connection via a single screen rail:
Figure 8b: Connecting signal cable shields via 2 screen rails in the cabinet
Rule 9
The cable shields of digital signal cables must be connected to ground at both ends (transmitter and
receiver) through the largest possible surface area. If the equipotential bonding is poor between the
shield connections, an additional equipotential bonding conductor with at least 10 mm must be
connected in parallel to the shield, to reduce the shield current. Generally, the shields can be
connected to ground (= cabinet housing) in several places. The shields can also be connected to
ground at several locations, even outside the cabinet.
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Figure 9: Examples of shield connections

Foil-type shields are not to be favoured. Braided shields are at least 5 times more effective.
Rule 10
The cable shields of analog signal cables can be connected to ground at both ends if the equipotential
bonding is good. Good equipotential bonding is achieved if Rule 1 is observed.
If low-frequency noise occurs on analog cables, for example: speed/measured value fluctuations as a
result of equalizing currents (hum), the shields are only connected for analog signals at one end at
the SIMOVERT MASTERDRIVES. The other end of the shield should be grounded through a
capacitor (e.g. 10 nF/100 V type MKT). However, the shield is still connected at both ends to ground
for high frequency as a result of the capacitor.
Rule 11
If possible, the signal cables should only enter the cabinet at one side.
Rule 12
If SIMOVERT MASTERDRIVES are operated from an external 24 V power supply, this power supply
must not feed several consumers separately installed in various cabinets (hum can be coupled-in!).
The optimum solution is for each SIMOVERT MASTERDRIVE to have its own power supply.
Rule 13
Prevent noise from being coupled-in through the supply. SIMOVERT MASTERDRIVES 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.
Rule 14
In order to limit the noise emitted, all variable-speed motors have to be connected-up using shielded
cables, with the shields being connected to the respective housings at both ends in a low-inductive
manner (through the largest possible surface area). The motor feeder cables also have to be shielded
inside the cabinet or at least shielded using grounded partitions. Suitable motor feeder cable e.g.
Siemens PROTOFLEX-EMV-CY with Cu shield. Cables with steel shields are unsuitable.
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Figure 10a: Connecting power cable shields on strain relief bar in cabinet
A suitable metallic gland with shield connection must be used at the motor to connect the shield. It
should also be ensured that there is a low impedance connection between the motor terminal box and
the motor housing. If required, connect-up using an additional grounding conductor.
Do not use plastic motor terminal boxes and plastic cable glands!
Figure 10b: Shield connection at the motor

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 picture 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, Hckeswagen
- HUGRO Armaturen GmbH
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Rule 15
The line supply cable has to be spatially separated from the motor feeder cables, e.g. by grounded
partitions.
Figure 11: Side view of the incoming and outgoing cables

Rule 16
The shield between the motor and SIMOVERT MASTERDRIVES must not be interrupted by the
installation of components such as output reactors, sinusoidal filters, dv/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.
5.4.2
Wiring requirements as per IEC 60204-32
- All connections must be securely fastened to prevent accidental loosening (14.1.1).

- One protective conductor must be connected to one terminal connecting point, unless, the terminal is
designed for 2 or more conductors (14.1.1).
- Terminals on terminal blocks must be identified according to the markings in the drawing and clearly
visible (14.1.1).
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Figure 12: Side view of the incoming and outgoing cables

- For aluminium conductors consideration shall be given to the problem of electrolythic corrosion
(14.1.1)
Figure 13: 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.
(exceptions see 14.4.2)
Figure 14: Examples for routing of cable on cable ladders in sillbeam
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- Terminations of cable must be adequately supported to prevent mechanical stresses at the

terminations of the conductors.
- Flexible conduit or flexible multiconductor cable shall be used for connections involving small or
infrequent movements. They shall be installed in a manner which avoid excessive flexing and straining
at the connection points (14.4.3)
Figure 15: Example of routing cable from main structure to boom across boom hinge
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- All exposed conductive parts of the electrical equipment and structure must be connected to the
protective bonding circuit to protect against electric shock.
Figure 16: Protective bonding for junction boxes

- Continuity of protective bonding circuit must be observed. Removal of any equipment due to
maintenance reason should not interrupt the protective bonding circuit (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 (8.2.1)
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5.4.3
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Wiring practices to be avoided

Wiring examples to be avoided at all times!
Explanation
Violation of IEC60204-32,
clause 14.2.2 requiring the PE
conductor to be identified by
colour green-yellow.
- signal cables (purple colour

PROFIBUS bus communication
cables) are mixed with power
cables
- incoming power cables and
outgoing motor feeder cables
are not separated
- No EMC cable glands are

used
- Screens are connected to
junction box PE via long pig
tails
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Violation of IEC60204-32 clause

14.1.1 requiring that only one
protective conductor shall be
connected to one terminal
connecting point.
Violation of IEC60204-32,
clause 14.1.1
The bolt fastening the cable
shoe must be tightly fasten to
the terminal connecting point.
Serrated washers are to be
used id the frame is painted.
- Connection of cable screens

via pigtails.
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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.
5.4.4
Date:
Revision:
Best practice screened power cable termination
The following section shows best practices for terminating screened power cable at the drive panel
end and the motor terminal box end.
5.4.4.1
Termination in Drive Panel
Figure 17: An example of terminating screened cable at drive panel end

The above pictures shows several interesting details:
- the colour 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 clamp.
Page 28 of 36
Document:
5.4.4.2
Date:
Revision:
2007-03-23
1.1
Termination in Motor junction box
PE cable
connected to
PE terminal
Point.
Only Metal
Cable gland and
Metal terminal
box used
Figure 13: Screened Power at the motor terminal box end
Figure 14: Internal view of the terminal box with cable entry
The above examples shows how 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.
Page 29 of 36
Document:
6.1
Date:
Revision:
2007-03-23
1.1
Installation of control cables

Installation of PROFIBUS cables
When you are laying the bus cable, you must not:
- twist it
- stretch it
- or 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 may 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 7: Allowable baud rate as function of cable length
Figure 15: Termination resistor settings in PROFIBUS connectors
Shielding of the bus cable / EMC measures

In order to ensure interference-free operation of the PROFIBUS-DP, especially in the case of data
transmission with RS485, the following measures are imperative:
For the PROFIBUS bus cable, the shield in the bus connector should be connected to the
drives CBP card. 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.
Page 30 of 36
Document:
Date:
Revision:
2007-03-23
1.1
Figure 16: Connecting the signal cable shields for SIMOVERT MASTERDRIVES
Please ensure that the shield of each bus cable is connected to protective earth, both
where it enters the cabinet as well as at the converter housing.
Bus cables are to be laid at an angle of 90 to power cables if they are to intersect.
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 to the
shielding of the bus cable between the PROFIBUS-DP master and the converters.
Page 31 of 36
Document:
Date:
Revision:
2007-03-23
1.1
Figure 17: Installation with separate cable ducts
Page 32 of 36
Document:
6.2
Date:
Revision:
2007-03-23
1.1
Installation of encoder cables
Siemens crane duty motors (see catalog HE1 N 2007) generally are equipped with incremental pulse
encoders sourced from Huebner Berlin.
Self-ventilated motors normally features hollow-shaft encoders type HOG. Non-ventilated motors are
equipped with flange-mounted encoders type POG.
Figure 18a: Combination of HOG 10DN

with FSL centrifugal overspeed switch
Figure 18b: HOG 10DN
Figure 18c: POG 10DN
It is recommended that a pre-fabricated encoder cable is installed. For example, Hbner 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 20a: HEK 8 cable at motor side
Figure 20b: HEK 8 cable at drive side
Page 33 of 36
Document:
6.2.1
Date:
Revision:
2007-03-23
1.1
Installation of encoder cables at motor side
Figure 21: Encoder cable termination (plug-type)
Page 34 of 36
Document:
Date:
Revision:
2007-03-23
1.1
Figure 21: Encoder cable termination (terminal type)
Page 35 of 36
Document:
6.2.2
Date:
Revision:
2007-03-23
1.1
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 Figure 15, the cables can be
connected to the detachable terminal strips of either the CUVC or SBP of the drives.
____________________ end of document
Page 36 of 36

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Cabling and wiring guidelines for cranes

Cabling and Wiring Guidelines

RELEASE INTERNAL PRINCIPALS

Siemens AG, A&D MC CR

Cabling and wiring guidelines for cranes

HIGH FREQUENCY DISTURBANCE ..............................................................................................4

SELECTION OF LOAD SIDE COMPONENTS ..............................................................................8

SIZING OF CABLE CROSS SECTIONAL AREA ........................................................................12

POWER CABLE SELECTION .....................................................................................................13

INSTALLATION OF CONTROL CABLES ...................................................................................30

Siemens AG, A&D MC CR

Cabling and wiring guidelines for cranes

Safety of machinery - Electrical equipment of machines - Part 32:

Safety of machinery - Safety-related parts of control systems - Part 1:

DIN VDE 0660 Part 12 Protective conductor terminals

Limits and methods of measurement of radio disturbance characteristics of industrial,

COUNCIL DIRECTIVE of 3 May 1989 on the approximation of the laws of

Council Directive of 19 February 1973 on the harmonization of the laws of

Simovert Masterdrives Vector Control Catalogue 2003/2004

Masterdrives Compendium Vector Control 1998

6SE7087-6CX87-8CE0 Installation Instructions for EMC Correct Installation of Drives

Flexible Electric Cables

Siemens AG, A&D MC CR

Cabling and wiring guidelines for cranes

High frequency disturbance

Cabling and wiring guidelines for cranes

Siemens AG, A&D MC CR

Cabling and wiring guidelines for cranes

Long motor cables

Effect of crane mechnical configurations on the length of the electrical cables:

b) Self-propelled trolley (SPT)

c) Rope-towed trolley (RTT)

d) Typical Gantry configuration

Siemens AG, A&D MC CR

Cabling and wiring guidelines for cranes

Common mode oscillation

Figure 2b: Principle circuit for common-mode oscillation

Siemens AG, A&D MC CR

Cabling and wiring guidelines for cranes

Selection of load side components

Maximum cable length without output chokes

Table 1: Motor cable distance without output choke

Siemens AG, A&D MC CR

Cabling and wiring guidelines for cranes

Maximum cable length with output chokes

Table 2: Motor cable distance with output choke

Voltage limiting (dv/dt) filters

Cabling and wiring guidelines for cranes

Figure 3: Arrangement of output reactor and dv/dt filter

Cabling and wiring guidelines for cranes

Table 4: Motor cable distance with sinusoidal filter

Siemens AG, A&D MC CR

Cabling and wiring guidelines for cranes

Sizing of cable cross sectional area

The protective conductor is to be dimensioned considering the following functions:

Table 5: Recommended Cross section of external protective conductors

Siemens AG, A&D MC CR

Cabling and wiring guidelines for cranes

Power cable selection

Table 6: Overview power cable types

Insulation material used for power cables

Siemens AG, A&D MC CR

Cabling and wiring guidelines for cranes