Benefits of VFD Cables Over THHN:

Extending the Life of Your Automated Equipment

A Voice From The Field: A Quick Guide to Selecting
HELUKABEL Products For Process Automation and Material
Handling Applications
The race is on as it relates to process automation in material handling
and other industrial applications that rely on automated equipment to
maximize output. With cyclical economic impacts, budget crunches, and
project deadlines, selecting the right products are more critical now than James Moorman
ever. This guide will help design engineers and procurement specialists V.P. of Sales
james.moorman@helukabel.com
better understand why VFD cable is becoming such a key piece to extend
the life of your automated equipment.
The current version of NFPA 79 (ed. 2018) made a change to Chapter 4,
Article 4.4.2.8 - Circuits Supplied from Power Conversion Equipment that
states, “Electrical conductors and equipment supplied by power conversion
NFPA-79
equipment as part of adjustable speed drive systems and servo drive systems
Chapter 4,
shall be listed flexible motor supply cable marked type RHH, RHW, RHW-2,
Article 4.4.2.8
XHH, XHHW, or XHHW-2 or selected based on equipment manufacturer’s
instruction.” To date no motor manufacturers have specifically required XLPE
“Electrical
insulation for general VFD wiring applications. The general interpretation
conductors
of the current 2018 NFPA for wiring with regards to Chapter 4, Article
and equipment
4.4.2.8 is that cables using these insulation types are intended for use inside
supplied by
the panel where the wiring is contained between the drives and protection
power conversion
equipment (of the panels) that may experience unusual overload and/or a
equipment as part
fault condition. The reason behind this belief is because this requirement is
of adjustable speed
not included in Chapter 12 - Conductors, Cables and Flexible Cords, where
drive systems
THHN and TFFN insulation are still approved.
and servo drive
However, HELUKABEL does believe that the requirement for thermoset systems shall be
(common to RHH, RHW, RHW-2, XHH, XHHW and XHHW-2) conductors listed flexible
in VFDs under Chapter 12, which applies to cables used for external wiring, motor supply cable
or outside of the control panel, will be in the next NFPA. This potential code marked type RHH,
change would be the result of a shift in the market rather than a safety RHW, RHW-2,
concern when comparing the benefits of thermoset over thermoplastic XHH, XHHW, or
insulation in terms of premature insulation failure. This is because electrical XHHW-2”
systems are safeguarded by properly sized cables (using 125 percent FLA),
and/or the system’s circuit protection device (circuit breaker or fuses) Source: NFPA.org
that would trip or blow before any conductors would be exposed to such NFPA79 Ed. 2018
extreme currents as to degrade the insulation.
So why should such a critical component use a cable specifically made to
extend a motor’s life cycle within a VFD system? Three areas where VFD
cables set themselves apart over traditional tray-rated power cables are:

Address high and low frequency noise issues with proper shielding
Shielding on cables is what prevents systems from interacting with each other. In short, a
cable’s shield is its defense against noise. THHN and most generic control/tray cable are
constructed using either an aluminum shield or they are unshielded. HELUKABEL’s VFD
cables are constructed using either a foil (100% coverage) + tinned copper braid (85%
coverage), or a triple shield comprising of a semi-conductive fleece + foil + braid shield
(80% coverage). Cables with the proper shielding prevent the VFD system from radiating
electrical noise that can interfere with surrounding networking, instrumentation, wireless
communication, and industrial devices.

Ability to withstand voltage spikes/reflected wave voltage

A cable combats voltage spikes with insulation material and wall thickness. HELUKABEL’s
VFD cables use XLPE insulation as its conductor insulation. XLPE has a much lower
capacitance (higher corona inception voltage) than THHN and generic control/tray cable
which just use PVC. This is particularly important in wet or damp environments as PVC
is more susceptible to absorbing moisture, which results in less than half the insulation
capability of XLPE. The wall thickness of a VFD cable tends to be thicker allowing it to
withstand voltage spikes significantly better.
High temperature resistance
A cable’s type of insulation plays a significant role in how it responds to thermal stress.
Thermoset insulation won’t melt or drip in higher temperatures like the thermoplastic
insulation found in THHN and generic control/tray cables. If thermoplastic insulation is
used, you run the risk that it will melt, drip, or simply deform, which reduces the insulation
properties, and can cause damage to critical and expensive equipment/machinery.
Our technical sales team hear a variety of “responses” from our customers when discussing
our TOPFLEX® VFD cables for their automated applications. While the new requirements
from NFPA 79 are rewriting the standard, its enforcement is slowly rolling out as it becomes
the new norm. This has left many unanswered questions for contractors as they try to
compete on this new playing field.
Here are a few real-world examples from voices in the field:
From the Field – We’ve always used THHN and to our knowledge, have not had any issues
• Response – Typically, you would not see immediate issues, and troubleshooting
impacted components, if there is an issue, might overlook the installation and type
of cable. Legacy VFD inverters typically used switching components (BJTs/SCRs) to
accommodate fluctuating power output. Older VFDs also performed slower than
VFDs being manufactured today. THHN cable is typically only rated for 600V or
850V at its peak. Today’s drives can see peaks up to 1,300V, which can not only
damage the motors, but also the cable and connection points. PVC insulation and
thermoplastic jacket degradation could occur as well.

From the Field – Why should I use a shielded cable? The rigid conduit acts as my shield.
• Response – Utilizing the conduit as your only shield may result in increased EMI/
noise concerns to both the VFD and the entire electrical system.

From the Field – We typically run a ground conductor inside the conduit to the motor
ground and then the VFD ground.
• Response – Unless the cable is shielded, an install using this technique may cause
the motor to seize up. Ground faults will find the path of least resistance, which will
typically cause the motor windings and bearings to pay the price.

From the Field – Using individual conductors makes it easier to pull in case one line fails.
• Response – Original installs are pulled with all four conductors. A re-pull of only
one conductor may cause unseen damage to the other conductors.

From the Field – Lower DC resistance results in increased performance

• Response – Higher conductor stranding counts allows for greater distances
without as much voltage drop.
While NFPA 79 requirements slowly merge with legacy installation and inspection practices,
it is critical to address the environment our customers face to stay competitive, win projects,
and remain aware of potential risks as we adapt to an advancing industry!
TOPSERV® 600 VFD

UL 1277 & 2277 Motor Supply cable · T

 emperature range -40°C to +105°C (application dependent)· I nsulation ·A
 pprovals
·N ominal voltage XLPE
Available Sizes TC 600 V & WTTC / Flexible Motor Supply 1000 V ·O  uter Jacket
Gauge size / # of cond.: Special TPE
18 — 2 AWG / 4 *For control pairs: TOPSERV® 650 VFD

TOPFLEX® 600 VFD

UL 1277 & 2277 Motor Power Cable· T

 emperature range -40°C to +105°C (application dependent) · I nsulation ·A
 pprovals
Available Sizes ·N ominal voltage XLPE
Gauge size / # of cond.: TV 600 V / WTTC & Flexible Motor Supply 1000 V ·O
 uter Jacket
18 - 2 AWG / 4
*For control pairs: TOPFLEX 650 VFD
® Special PVC

TOPFLEX® 1000 VFD

UL 44, 1277 & 2277 Motor Power Cable · T

 emperature range -40°C to +105°C (application dependent) · I nsulation ·A
 pprovals
Available Sizes ·N ominal voltage XLPE
Gauge size / # of cond.: TC 600 V / WTTC & Flexible Motor Supply 1000 V ·O
 uter Jacket
8 AWG — 500 kcmil / 3 PWR + 3 GRD Special TPE

TOPGEBER 512 PUR

UL 20233 & 20236 Feedback Cable · T

 emperature range -40°C to +80°C (application dependent) · I nsulation ·A
 pprovals
Available Sizes ·N ominal voltage Special PP
Gauge size / # of cond.: 30V - 300 V ·O
 uter Jacket
26 - 20 / 2 - 12 PUR

TOPSERV® PUR

UL (CSA) AWM Style 21223 (20234) ·T

 emperature range -40°C to +90°C (application dependent) · I nsulation ·A
 pprovals
Servomotor Cable ·N
 ominal voltage Halogen-Free PP
Available Sizes VDE U0 / U 600 / 1000 V ·O  uter Jacket
Gauge size / # of cond.: UL/CSA 1000 V PUR
V DE

17 — 1 AWG / 4 PWR + 1 or 2 control pairs *For PVC Jacket: TOPSERV® PVC

HELUKABEL® USA - 1201 Wesemann Dr. West Dundee, IL 60118 · Phone: 847-930-5118 · Fax: 847-622-8766 · Email: sales@helukabel.com