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Complying with IEC/EN 61800-3 Good EMC

Engineering Practices in the Installation of Power
Drive Syst

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 Complying with IEC/EN 61800-3
Good EMC Engineering Practices in the
Installation of Power Drive Systems

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Business Park, Craven Arms Shropshire SY7 8NT
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Email: [email protected] Website: www.reo.co.uk
 1

Complying with IEC/EN 61800-3

—
Good EMC Engineering Practices in the
Installation of Power Drive Systems
—
Keith Armstrong
Cherry Clough Consultants, www.cherryclough.com

Contents
1. Introduction 2
2. What is not covered in this Guide 7
3. Cost implications 9
4. Emissions 17
5. Immunity 54
6. EMC suppression products from REO 56
7. References and further reading 57

Front and back cover pictures © Jorgen Udvang - istockphoto.com

2 3
1. Introduction and will also help increase customer %NCLOSUREPORT
confidence and market share. 0ROCESS
This Guide is for what EN/IEC 61800- MEASUREMENTAND
3 [1] calls “Power Drive Systems” CONTROLPORT
1.1. The definition of a PDS /THERPART
(PDSs), which are AC or DC motor "$- 3IGNAL OF
speed control units more usually According to EN/IEC 61800-3 [1], a INTERFACE
ORPARTOF #$-OR0$3
called variable speed drives (VSDs) PDS is an adjustable speed AC or
or adjustable speed drives (ASDs). DC motor drive, consisting of a basic -AINPOWERPORT #$- /THERPARTOF
VSDs for AC motors only are often drive module (BDM), which is part of 0$3
0OWERINTERFACE EGMOTOR
called variable frequency drives the complete drive module (CDM), !UXILIARYPOWERPORT
(VFDs), adjustable frequency drives which – when connected to its motor Copied from Figure 2 of
(AFDs), or just inverter drives. – becomes a PDS, which in turn is %ARTHPORT EN/IEC 61800-3:2004 IEC 924/04
part of a system or installation, as
EN 61800-3 is listed under the EMC Figure 2: Definitions of PDS, CDM and BDM, showing the PDS’s “ports”
shown in Figure 1.
Directive [2], and so may be used for IEC 61800-1, IEC 61800-2 and IEC Propulsion of ships, etc. (but not
e.g. a system within
declaring PDSs in conformity with it. an installation 61800-4 provide the details for the traction drives or electric vehicles);
At the time of writing, the EMC definitions used in Figures 1 and 2. Pumps, fans, etc.
Installationor part of installation If the PDS has its own dedicated
Directive has been applying its 2004 The PDSs may be connected to
version [1] since the 1st October Power Drive Systems (PDS) transformer, this transformer is either industrial or public mains power
2007, which means that all PDSs included as a part of its CDM. distribution networks. An “industrial
CDM (Complete Drive Module)
supplied in the EU since then should System control A non-exhaustive list of PDS network” is considered to be one
and sequencing
list EN 61800-3:2004 on their EU BDM (Basic Drive Module) applications includes: that is supplied by a dedicated high
Control voltage (HV) distribution transformer,
Declarations of Conformity, and converter
and protection Machine tools, robots, test
provide the appropriate test evidence or its own generator, which supplies
Feeding section equipment in production, test
in their “Technical Documentation File” Field supply
only industrial customers or, for
dynamic braking benches; example a ship or offshore drilling rig.
– if they are following the “standards
Auxilliaries, others .....
route to conformity” (see [3]). Paper machines, textile production
machine, calenders in the rubber A public power distribution network is
EN 61800-3:2004 is identical to IEC Motor and Sensors one that operates at low voltages (e.g.
industry;
61800-3:2004, so this Guide is equally 115/230/400V) and supplies domestic
Process lines in plastic industries
applicable outside of the European Driven equipment premises. These networks usually
or in metal industries, rolling mills;
Union (EU) where the IEC version have an earthed (grounded) neutral.
Cement crushing machines, Where an industrial site is powered
– or some national standard based Copied from Figure 1 IEC 923/04
cement kilns, mixers, centrifuges, from a low voltage mains power
upon it – is applied. of EN/IEC 61800-3:2004
extrusion machines; distribution, as sometimes happens,
Even where there are no legal EMC Figure 1: Definitions of PDS, CDM and BDM
Drilling machines; the mains distribution network on that
requirements, complying with EN/IEC Figure 2 shows another view of a Conveyors, material handling site is treated as a public network.
61800-3 is good engineering practice PDS, this time identifying the various machines, hoisting equipment
that will help improve profits overall, (cranes, gantries, etc.); As Figure 1 shows, a PDS may drive
“ports” that are tested by [1].
over the medium and long term, some equipment (e.g. a winch, pump,
4 5
fan, etc.), and/or be part of a system, premises, and establishments directly Environment, is intended to be engineering practices, the entire
and/or be part of an installation, but connected without intermediate installed and commissioned only by a system or part of an installation may
only the PDS is covered by EN/IEC transformers to a low-voltage power “professional”. be covered by other EMC standards
61800-3 (see 1.3). supply network which supplies – most likely the generic standards:
A professional is defined as a
buildings used for domestic purposes.
person or an organisation having EN/IEC 61000-6-1, immunity
1.2. The requirements of Houses, apartments, commercial necessary skills in installing and/or requirements for residential,
EN/IEC 61800-3 premises or offices in a residential commissioning PDSs, including their commercial and light industrial
[1] includes requirements for PDSs building are examples of First EMC aspects. environments
with BDM input and/or output Environment locations. EN/IEC 61000-6-2, immunity
voltages (line-to-line) of up to 35 kV 1.2.5. Category C3 requirements for the industrial
AC rms, rated from a few hundred 1.2.2. The Second environment
This applies to PDSs of rated voltage
watts to hundreds of MW, installed in Environment less than 1,000 V, intended for use EN/IEC 61000-6-3, emissions
residential, commercial or industrial in the Second Environment and requirements for residential,
This environment includes all
locations. not intended for use in the First commercial and light industrial
establishments other than those
Environment, permitted to be installed environments
It claims to achieve EMC for such directly connected to a low voltage
by anyone. EN/IEC 61000-6-4, emissions
applications (but see 1.3) but warns mains power supply network which
requirements for the industrial
that it cannot cover extreme cases supplies buildings used for domestic
1.2.6. Category C4 environment
that could occur (but which are purposes.
assumed to have an extremely low In this case, it is possible for a PDS
Industrial areas, and technical areas This applies to PDSs of rated voltage that is compliant with [1] to cause
probability). It also warns that it does
of any building that are fed from equal to or above 1,000V, or rated the system or installation that it is
not cover the EMC performance in the
their own dedicated transformer are current equal to or above 400A, or part of to fail to comply with the EMC
case of faults occurring, which is very
examples of Second Environment intended for use in complex systems standards that apply to it. There are
relevant for section 2.4 later in this
locations. in the Second Environment, permitted two reasons why this could occur:
Guide.
to be installed by anyone.
[1] specifies emissions limits, a) The emissions permitted by [1] for
1.2.3. Category C1
immunity levels, and test methods the PDS might exceed the emissions
1.3. Emissions and immunity
for a PDS according to its intended This category is for PDSs with rated limits permitted by other standards for
voltage less than 1,000V, intended of PDSs as part of systems or the system or installation containing
application and the competency of
for use in the First Environment, installations the PDS. For example, some limits
its installer. It does this by defining
two different electromagnetic permitted to be installed by anyone. As mentioned above, a PDS may that are permitted by [1] for some
“environments” or locations, and be a part of a system, or part of an PDS Categories exceed the limits
four different “Categories” of installer 1.2.4. Category C2 installation, but EN/IEC 61800-3 [1] permitted by the appropriate generic
competency, as discussed below. only covers the PDS itself. standard for the same type of
This category is for PDSs with rated
environment by more than 20dB.
voltage less than 1,000V, which is However, for compliance with
1.2.1. The First Environment neither a plug-in device nor a movable the EMC Directive, customer b) There may be several PDSs in one
device and, when used in the First specifications, or just good EMC system (e.g. the sausage machine in
This environment includes domestic
6 7
Figure 3), and since their emissions Bodies and changed the compliance 2. What is not covered 2.3. Human Health and
will add up they could exceed the methods, see [3]) complained to the in this Guide Safety
limits for the overall system or European Commission (EC) about 2.1. Testing to The very high voltages and currents
installation. the listing of EN 61800-3 under the associated with high-power PDSs
EN/IEC 61800-3
EMC Directive, and asked that it be can cause a variety of problems for
It was because of a) that the
removed from that list. It was not This Guide is only concerned with health and safety. EN 61800-5-1 [l]
European Association of Competent
removed, but shortly afterwards the the use of good EMC engineering covers electrical, thermal and energy
Bodies (ECACB, disbanded
EC employed an EMC Consultant with installation practices to help PDSs hazards of PDSs, but does not cover
since 2004/108/EC, has replaced
the aim of ensuring they did not make comply with EN/IEC 61800-3 [1], human health effects due to exposure
Competent Bodies with Notified
such embarrassing mistakes again. it does not cover the actual testing to electric and/or magnetic fields
techniques that are used by [1]. (EMFs).
REO have seventeen Guides [4] that All PDSs that declare compliance with
detail how to actually perform the the Low Voltage Directive [9] must
various tests required by [1], including also now declare compliance with the
the situation where the test cannot EMF Regulations [10]. While there
be carried out at a “controlled EMC are no EMF standards specifically for
site”, such as inside a test laboratory’s PDSs, it will probably be best to apply
anechoic chamber. the “generic EMF standard” EN 62311
[1] also includes guidance on what [11].
to do when testing has to be done A workplace Health and Safety
on-site, or when the mains current Directive on EMF also exists [12],
required by a PDS exceeds 100A. If but at the time of writing is not fully
further guidance is required on on-site in force. Like all Health and Safety
testing, [5] may prove useful. directives, it applies to the owners/
users of a site or the equipment on it,
2.2. Complying with the EMC and not to manufacturers who supply
Directive them with equipment.
It is not the aim of this Guide to Neither of these issues are discussed
discuss how a manufacturer should go further in this Guide.
about legally complying with the EMC
Directive [2] [6], as implemented in the
various national laws of the European
Union’s (EU’s) Member States, such
Figure 3: Example of a machine with a number of PDSs as [7] [8] for the United Kingdom (UK).
Part of a complex installation....
The control cubicle for the sausage machine installed at Stork Townsend B.V., The The compliance methods that are
Netherlands, in 2006. 10 metres long; 60 variable speed drives 18 multi-axis servo drives available are discussed in [3].
8 9
2.4. Functional Safety 2.5. Machinery Safety 3. Cost implications Such good EMC design increases
the bill-of-materials (BOM) cost of the
It is also not the aim of this Guide A PDS as defined by the EN 61800 BDM, and most manufacturers would
to discuss the Functional Safety series of standards is not a machine 3.1. The EMC of PDSs,
assume that they must therefore sell
issues of PDSs, other than to as defined by the Machinery Safety financial risks, and the perils
it for a higher price. But this is not
say that since electromagnetic Directive [18], and so this directive of short-termism necessarily the case, because (for
interference (EMI) can cause PDSs does not apply to PDSs. example) their product could have
It is quite practical to design a BDM
to suffer errors or malfunctions (e.g. lower warranty costs, and/or might win
Of course, system integrators and (see 2.6) so that any PDS using it is
uncommanded changes in speed, a much larger market share because
owners of fixed installations (using the guaranteed to comply with EN/IEC
torque, direction, etc.) – where these of its ease of use [23]. So they might
definition in [2] and [7]) will often use 61800-3 (and the EMC Directive)
could have consequences for safety make as much or more profit even
a PDS to provide the motive power regardless of how it is installed
risks, complying with EN 61800-3 when selling it for the same price as
for a machine that does come under and how the PDS that employs it is
or any other EMC test standards, a more typical BDM that does not
the Machinery Directive, or one of the configured. However, such BDMs will
even military or aerospace ones, is control EMC so well and so requires
Health and Safety at Work Directives, almost certainly cost more.
insufficient for establishing a defence any PDS it is used in to go through
in which case it is important that they
of due diligence. When using such a BDM, a costly tests to EN/IEC 61800-3, to
understand the points made in 2.3 and
manufacturer who integrates it into be able to show due diligence in
EN 61800-5-2 [13] applies the basic 2.4. They will find helpful information
a PDS that he sells to an end-user complying with the EMC Directive.
standard on Functional Safety EN on EMC in [19] [20] and [17].
(or their main contractor) will be able
61508 [14] to PDSs, but – like [14] This all sounds good, but it rarely
to demonstrate compliance with the
– does not prescribe what to do about 2.6. Electronic and happens in real life because of short-
EMC Directive [2] [7] without having
the possibility of EMI. EMI can cause mechanical design of basic termism – managers usually only look
to test to EN/IEC 61800-3. All they
a variety of problems for motor drives, ahead as far as the next quarter’s
drive modules (BDMs) will need to do is to include a few
which might be costly (e.g. downtime) financial figures – so even very
verified EMC documents from the
or have safety risks, as shown by This Guide does not cover the significant possibilities for medium and
BDM manufacturer, in their Technical
some of the real-life anecdotes in [15]. electronic and mechanical design long-term financial gains, improving
Documentation File [3].
and assembly of the BDM section profitability and return-on-investment
To cover EMI it is necessary to
of PDSs, or its cabinet or other Such PDSs will be largely unaffected (ROI) are ignored. Sometimes the
apply the basic standard on EMC
enclosure. But well-proven techniques by EMI in their operational benefits of investing in good EMC
for Functional Safety [16], for which
do exist for these EMC aspects of environment, and so will generally engineering are discounted because
the IET have produced a helpful
BDMs, see [21] [22] and [20]. operate with greater precision. When of a lack of appreciation of EMC
and practical 9-step management
used in manufacturing processes they issues.
procedure [17]. EMC tests have a role
often improve yields and quality, and
to play in due diligence for safety, but Short-termism means that buyers are
they often prove to be more reliable.
they cannot be sufficient on their own. looking for the cheapest BDM, and
All this will reduce their overall cost-
of-ownership for their users, and also often decide solely on the basis of
generally reduce the warranty costs crude “kW versus £” comparisons.
for their manufacturers, sometimes For this reason, and others, most
very significantly. BDM manufacturers’ salesmen feel
10 11
may be unwilling or unable to sell 3.2. Mains filters and reckon that as many as one-third of all involved a serious injury or death (see
a more costly product on the basis industrial PDSs PC software “crashes” are caused by 2.4).
of lower overall cost-of-ownership, EMI. We have all experienced these
According to clause D.1.2.2 in Annex In any area where electronic
especially in regions of the world recoverable crashes on our PCs but
D of [1], the common practice for technologies are used, the past is not
where EMC regulations are not how many of us have identified the
many years has been to install PDSs a reliable guide to the future.
mandatory or strictly enforced. It isn’t crash as an EMI incident and brought
helped by the fact that most engineers without mains filters. It claims that the it to the attention of the people who The fact that there is no evidence
have difficulty in presenting technical general lack of complaints about radio sit on the IEC committee for computer of a problem should never be taken
arguments for improved profitability interference from such installations EMC standards? as proving that therefore there is
and ROI in a financial manner that indicates that they achieve EMC – but no problem. Although it sounds at
this is a very risky assumption to Another issue is that there is a rapid
can be understood by the people who first like a reasonable argument, it
make. increase in electronic instrumentation,
run their companies. Some remedies has been known since the late 18th
control and communications in all
for this latter problem will be found in There are many reasons why people century that is not a logical conclusion
areas of human activity, including
[24]. might not complain about interference, to make (see [25]). It is very
safety-related systems, all brought
why they might not be able to identify disappointing to find such an obvious
The inevitable result of this is that, about by the continual reduction in the
where it came from, why enforcement error in an IEC standard.
in general, BDM manufacturers costs of semiconductors (transistors).
aim to make the cheapest products authorities might not have the
resources or expertise to investigate, Also, the reduction in costs of 3.3. Output filters and
they possibly can, which increases
or why such investigations were not semiconductors is brought about by industrial PDSs
the cost and time burdens for the
reported to (or remembered by) the making them physically smaller and
system integrators and owners of Very few PDSs use output filters
people who wrote [1]. Also, there is operating them on lower voltages.
fixed installations (as defined in [2], because of their cost, but even if
often an element of (bad) luck in many A state-of-the-art microprocessor
see [3]), who use their products to we ignore EMC issues, we have to
EMI incidents, which tends to make (a “silicon chip” on a printed
construct PDSs. These companies acknowledge that – without output
them hard to reproduce at will, often circuit board) at the end of 2008
have to use design and installation filters – high-power VSDs suffer from
making EMI hard to “prove” after an could contain as many as 1 billion
techniques as described in this Guide, high levels of common-mode (CM)
incident. semiconductors and operate from
and perform costly testing to EN/IEC current (see 4.2) flowing through their
0.9V DC power. It is unfortunate
61800-3 on each PDS they make I find that many people who claim bearings, which can shorten their life
but unavoidable that these trends
(sometimes testing on-site), to be able their systems or installations don’t by as much as tenfold.
inevitably make them more
to declare compliance to the EMC have EMI problems, actually don’t susceptible to EMI. Another problem is that where long
Directive. This increases their overall understand how to identify an EMI
costs and so significantly increases This rapid increase in electronic motor cables are used, the “Faraday
problem anyway (if they have even
the price that they have to charge complexity, plus the worsening of Effect” causes the motor’s drive
heard of it). They may have suffered
to their customers, above what they electronic immunity, might reveal that voltages to rise significantly higher
(or be suffering) from problems that
would have to charge if they could PDSs previously thought to be EMC than those output by the VSD, which
are decreasing yields or increasing
buy BDMs that had been designed compliant (because of no complaints) can degrade the insulation materials
downtime – but they never recognised
appropriately. were not so, in fact. It would be a in the cables and motor windings,
them as being caused by EMI.
great pity if the first time this was again leading to early failure and
For example, some computer experts discovered was an incident that increased downtime.
12 13
So filtering a VSD’s motor output can study of solving a high-power VSD
be an excellent financial investment! EMI problem that had been very Phase-neutral noise is approx. 15Vp-p
For example, the majority of electrical costly for the drive user. at between 10 and 30 kHz
(Phase-earth is same, but only 4Vp-p)
submersible pumps (ESPs) rated up
This first example also shows that Figure 5: A closer view of the
to around 900-1100kW serving the oil 10-30kHz noise, about 15V
actual compliance with the test limits
industry offshore, would not function peak-to-peak
and levels in EN/IEC 61800-3 does
unless output filters were installed.
not automatically ensure compliance
with the EMC Directive [2] [7], or
3.4 An example of the ensure low financial risks.
financial risks of inadequate
It concerns a UK factory that had
EMC engineering EN/IEC 61800-3 only specifies frequencies, sometimes as much as
a new (and very large and costly)
limits for conducted emissions over ten times higher than would normally
[15] has many examples of costly programmable machining centre
the frequency range 150kHz to be expected. [15] includes some
problems caused by EMI from, or installed. This used a 50kW PDS
30MHz, and the machining centre examples of serious problems that
to, PDSs, including industrial ones, (actually a VFD) that complied with
met these limits, but since its drive’s occurred because noise was amplified
and I must say that over the last EN/IEC 61800-3, so was assumed
switching frequency was 2kHz it in mains filters or mains distribution
20 years, almost all of my work as to comply with the EMC Directive [2]
emitted significant levels of switching networks.
in independent EMC consultant in [7]. But when it was operated it put
harmonic noise into its mains supply
solving EMI problems in industrial about 15V peak-to-peak at between It can come as a big surprise to
from 2kHz at 2kHz intervals all the
sites has been caused by two 10 and 30kHz on the factory’s mains find that a mains filter is giving
way up to 150kHz and beyond. At
electronic technologies – variable supply, causing some packaging gain instead of attenuation, often
150kHz and above the mains filter
speed motor drives (i.e. PDSs) and machines to malfunction elsewhere in contradiction to the suppliers
fitted to the PDS attenuated the noise
personal wireless communications on the site. Figures 4 and 5 show attenuation versus frequency curves!
emissions to meet the specification,
(e.g. private mobile radio, Walkie- the mains voltage I measured on the This is due to the fact that mains
but it did not provide significant
talkies, cellphones). Here and in site when the machining centre was filters are not tested in situations that
attenuation below 150kHz.
3.5 are just two examples of costly running. When it was not running, the correspond to real-life operation.
EMI concerning PDSs, which do not mains supply was a nice clean 50Hz All mains filters resonate at some However, in this example, if the
appear in [15]. [37] is another case sinewave. frequency (see 3.2.9 of [21], 8.1.3.1 mains filter was resonating and giving
of [26] or 5.10 of [19]) and so do all amplification, it was below 150kHz.
Peak of mains waveform, showing mains distribution networks, due to
noise caused by operation of new The solution was very simple – the
machining centre the combination of predominantly
machining centre manufacturer
Figure 4: inductive wiring with predominantly
One peak of the mains cycle,
replaced the original mains filter on
capacitive electronic loads (e.g.
showing the 10-30kHz noise their PDS with one that provided
due to the capacitors in their EMI
reliable attenuation down to below
filters of power factor correction
10kHz. This filter was much the same
banks, see C.1.3.4 of [1]). Noise
size as the original, but weighed a lot
currents flowing in them will cause
more and was more costly. It was also
amplified voltages at these resonant
less efficient, dropped a few more
14 15
volts and ran hotter. (Incidentally, it did not actually comply with the safety standards. The site could not Figure 6 shows some of the noises
the replacement filter was the EMC Directive [2] [7] because it be operated until the problem was created by these powerful drives,
one recommended by the VFD caused unacceptable interference to fixed, which took several months with before their mains emissions were
manufacturer, so the fault lay with the other equipment when installed as the cost of lost production running at suppressed.
machining centre manufacturer, not recommended by its manufacturer, about £100,000 per week.
the VFD manufacturer.) and so did not comply with the
Directive’s Essential Requirements, 600.0
The manufacturer of the machining
see [3]. 400.0
centre had saved a few £ by
using a cheaper filter than the one 200.0
recommended, but this caused 3.5. A second example of the
significant financial losses for their financial risks of inadequate V 0.000
customer, and they also had to spend EMC engineering -200.0
a considerable amount themselves
This example concerns heavy
on field service visits to deal with -400.0
industry, with a company that built,
the customer’s complaints over
owned and operated installations that -600.0
several months, and eventually fix the
used PDSs rated at nearly 1MW. The V1 Waveform
problem when I showed them what 346.38 Vrms, 13.35% THD
BDMs they purchased were not fitted
it was. Overall, it would have been
with mains filters, and since they had 40 Red, blue and black are the three phases,
much more cost-effective to have
never suffered from any significant and the green trace is the earth/ground
shipped the product with the better 30
problems, which were identified
filter. 20 All of them suffering over 100V p-p of
as being caused by EMI, in their noise at the 2kHz chopping frequency
Since the machining centre itself installations, they felt that ignoring the 10 of the nearly 1MW VFD
sold for over £1 million, why take costs of suppressing the emissions
0
such a risk just to save one or two from these very powerful motor drives 1 5 10 15 20 25 30 35 40 45 50
hundred £ on the cheaper mains was justified.
filter? Unfortunately, that is how
If they even knew that this was not Figure 6:
most manufacturing companies Voltage noises on the site’s 3-phase mains supply, due to one PDS
good EMC engineering practice, they
are managed these days, with
nevertheless ignored it because it was
good engineering practices made
apparently saving them money.
subservient to crude analyses of BOM
cost [23], often resulting in significant But recently (at the time of writing),
financial risks, as proved by this one of their new installations did suffer
example. from EMI with its control electronics,
with potentially lethal safety risks for
It is interesting to note that although
anyone near to the machinery being
the machining centre with the
controlled. Also, the ground noise
original filter met the emissions limits
voltages exceeded those allowed by
when tested to EN/IEC 61800-3,
16 17
It turned out that the cost of the low-power VFD (<10kW), the chopper
4. Emissions
lost production on this one new site might use “PowerFET” devices, but
was many times larger than the almost all higher power choppers
company would have incurred if it had
4.1. The basic structure of a
use IGBTs (Insulated Gate Bipolar
always installed PDSs using good BDM
Transistors) instead.
EMC engineering practices (which Figure 7 shows the basic “block
means using mains filters, see later). Any DC or AC waveform can be
diagram” of the BDM for a VFD for an
This is still true even when using a synthesised by chopping at a higher
AC motor. It is basically just a mains
discounted cash-flow analysis that frequency (must be at least twice
rectifier that produces a DC supply
takes the cost of borrowing the extra the wanted frequency) by varying
(often called a “DC-Link”), followed
money for the earlier, apparently its mark:space (i.e. on:off) ratio.
by a pulse-width-modulated (PWM)
trouble-free installations into account. Chopping doesn’t waste much energy
power switching circuit (often called
as heat, which is why PWM drives
This just goes to show that we can’t a chopper, switcher or inverter).
are much smaller and less costly, and
beat Murphy’s Law – “If a thing can go Sometimes the terms chopper,
more efficient, than previous motor
wrong, it will”. We might think we are switcher or inverter are applied to the
speed control technologies, and why it
getting away with poor engineering whole BDM including the rectifier. In a
is so popular.
and saving money as a result, but
(just like gambling) our luck cannot Rectifier Chopper
Mains DC AC
6-Pulse type also called switcher
hold for ever. In the end we will be Supply Link Motor
shown here or inverter
worse off than if we had always done
good engineering. For more on why
Murphy’s Law is actually true (at least
in part), see [27].
The only situation where this “rule” L1
doesn’t apply, is if your company L2
M
L3
3
has no brand image and is happy
to supply people with rubbish and
then “disappear” (e.g. by changing
names) so as not to have to deal with
the resulting high warranty costs.
There is always someone willing to Figure 7:
buy from an unknown manufacturer, Block diagram of a VFD for an AC motor
if they have the lowest price, so
there is always a market for such
manufacturers. I’m sure it will come
as no surprise that this Guide is not
intended for use by such companies.
18 19
Figure 8 is copied from [28], and frequency required to drive the AC The sharper the edges of the PWM, numbered harmonics, for example at:
shows a simple example of generating motor at the rotational speed required. the higher the frequency range of
a sinewave using PWM. The idea the emissions. Figure 10 shows 48kHz (3rd harmonic)
Figure 9 shows an example of a PWM
is that when averaged over a few an example of the waveform and 80kHz (5th harmonic)
motor output measured with a power
switching cycles, the rapid chopping frequency spectrum of a 16kHz
quality meter, on a 900kW VFD. 112kHz (7th harmonic)
of the waveform becomes a smooth squarewave (i.e. a very simple, 1:1
Because the measuring instrument
AC waveform. So when used to drive mark-space ratio PWM) with 2μs rise 144kHz (9th harmonic)
that was used has a bandwidth of only
a motor, the high inductance in its and fall times. The analysis of the
about 5kHz, the PWM voltage signals 176kHz (11th harmonic)
windings causes the motor current to squarewave in terms of frequency
in Figure 9 are “averaged” to some
follow the average value of the PWM shows that most of its energy is at the ...etc., all the way to at least
extent and do not appear as square or
voltage. In the example of Figure 16kHz switching rate, and that it also 1.616MHz (the 101st harmonic) and
sharp-edged as they really are.
8, this results in a sinewave at the has significant energy at all the odd- beyond
1.5
V B
1.0
Figure 8:
0.5 Example of PWM used to
create a sinewave 16kHz square-wave PWM with 2μs rise/fall times
0 dB
(when measured with an oscilloscope)
0
-0.5

B(T), V(v)
-10
-1.0
-20 The same waveform
-1.5 when measured
0 5 10 15 (ms) 20 -30 with a spectrum analyser

4HEMEASUREDMOTORCURRENT -40
 ISAREASONABLE QUALITYSINEWAVE
ATTHEDESIREDFREQUENCY -50
etc...

Fundamental (16kHz)
5th Harmonic of 16kHz

3rd Harmonic of 16kHz

7th Harmonic
9th Harmonic
11th Harmonic


-60
kHz

20 50 100 200 500 1,000 2,000

Figure 10:
6  Example of frequency content of a 16kHz squarewave PWM with
! 2μs rise and fall times


 A squarewave is a special case of of their chopping frequency (e.g. 2nd,

 a chopper output waveform, and 4th, 6th, etc.). It also means that the
 typical PWM waveforms are generally levels of the various harmonics do
rectangular (i.e. their mark:space not show the simple gradual fall-

4HEMEASUREDMOTORVOLTAGE MSDIVISION ratios are usually not 1:1). This off with increasing frequency that
07-FROMACHOPPER
means that their frequency spectra we see in Figure 10. Some high
Figure 9:Example of PWM output of a 900kW VFD, measured with a 5kHz bandwidth also contain even-order harmonics frequency harmonics may have higher
20 21
amplitudes than lower frequency frequencies at up to 50% of the mains A
ones. supply frequency (these are called
cycloconverters).
A DC motor drive can use PWM just
like a VFD, it only requires the PWM Rectifiers, whether plain or phase- 50 Hz mains supply
waveform to be such that the motor angle controlled, or cycloconverters,
current averages to a DC current generate harmonics of their switching
instead of to an AC one. frequency – which is the mains – and The current waveform of a
linear load, supplied from a Hz
so they generate what we call “mains sinewave voltage 50 150 250 350 450
But some types of powerful AC and
harmonics” to distinguish them from
DC motor drives use thyristor or triac ... and its frequency spectrum
other switching harmonics.
devices switched on and off at the A
frequency of the mains power, instead Figure 11 shows the first few
of plain rectifiers. They don’t need to harmonics of the current in a single-
use a DC-Link or a chopper. Phase- phase bridge rectifier, whilst Figure 50 Hz mains supply

angle-controlled triacs are used to 12 shows those for a phase-angle-

generate a variable DC voltage, controlled single-phase rectifier (which
etc
and appropriate on/off switching could be a VSD for a DC motor).
of thyristors can generate AC at Hz
The non-linear current waveform typical
of a single-phase phase-angle-controlled 50 150 250 350 450
A
triac, supplied from a sinewave voltage
... and an example spectrum

50 Hz mains supply Figure 12:

Harmonic currents in a single-phase phase-angle-controlled triac bridge

The current waveform of a

linear load, supplied from a Hz
sinewave voltage 50 150 250 350 450 In three-phase (often called 6-pulse) secondary windings results in triplens
... and its frequency spectrum rectifiers and phase-angle controlled and other unwanted noise emissions
A triacs supplied from a good quality being produced.
sinewave voltage, the “triplen”
50 Hz mains supply
harmonics (3rd, 9th, 15th, etc.) cancel 4.2. The unwanted noise
out almost entirely in the circuit. sources in a BDM
However, if there is any imbalance
etc in the supply voltages, triplens The above discussion has shown
are produced. Similarly, for multi- that, in a BDM, rectifiers generate
Hz
The non-linear current waveform typical 50 150 250 350 450 pulse systems (e.g. 12 pulse) any currents at the mains frequency and
of a single-phase rectifier-capacitor input
AC-DC power converter, imbalances in the paralleled 6 pulse its harmonics, and choppers generate
supplied from a sinewave voltage ... and an example spectrum
rectifiers, phase shift transformer voltages at kHz frequencies plus their
Figure 11: Harmonic currents in a single-phase bridge rectifier harmonics – even up to tens of MHz.
22 23
The generators used to provide mains respond to kHz chopping frequencies, VFD, the motor draws its electrical was made on the current spectrum of
power only generate at 50Hz (or never mind their harmonics – but they power at the AC frequency that a 700kW VFD, and shows significant
60Hz), so mains harmonic currents can suffer increased downtime due to is synthesised by the PWM of its current levels at, for instance 24A
are a nuisance. They circulate widely their insulation failure, motor bearing chopper, and as a result the current at 103.75Hz, which is six times the
in the mains distribution network problems and cables being degraded in the DC-Link and the mains current mains frequency (near to 50Hz) minus
causing excess heating of the cables, by the high frequencies. In addition, demand both follow this frequency. five times the motor frequency of
induction motors, transformers, fuses induction motors with deep bar or For example, if a VFD is set to 39Hz, 39.4Hz.
and circuit-breakers, and as they double cage design can overheat then when driving its loaded motor
flow in the impedances of the supply significant on heavily distorted it draws current from the mains at
network they cause voltage drops that supplies. On explosion proof (EExd) 39Hz. And because mains rectifiers
distort the mains waveform so that it motors with these types of rotor are switching circuits and not linear
is not a clean sinewave anymore. We design, the flameproof seals on the ones, they generate harmonics of this
say that it is harmonically distorted, shaft, which are designed to contain frequency too.
and when voltage distortion levels any internal explosion, can become
These low-frequency non-
rise too high, many kinds of electronic degraded, possibly allowing any
fundamental-related (50Hz in Europe)
equipment can malfunction. For more internal explosion to be transmitted
mains currents are called mains
on the problems of mains harmonics, outside the motor carcass with
“interharmonics”, and just like mains
see [29] and [30], and also the REO possibly disastrous consequences.
harmonics they circulate widely
Guides on EN 61000-3-2 and EN
If the chopping frequencies and/or in the mains distribution network,
61000-4-13, from the list at [4].
their harmonics couple with other causing excess heating and distorting
Since mains harmonics do not equipment (via conduction, induction the voltage waveform. DC drives
contribute to delivered power (they or radiation) they can interfere can also generate interharmonics
are called “wattless power”, worsening with its operation. So it is good to some degree, when the load on
the True Power Factor – combination engineering practice to treat the their motors, or their motor speed,
of the displacement power factor and chopping frequency and its harmonics fluctuates repetitively and rapidly.
the distortion factor of harmonics), as potential source of noise or
Just as for mains harmonics, [1] and
and since they cause many problems, degradation that should be controlled.
other standards specify tests and
we consider them to be an unwanted
[1] specifies tests and sets limits for limits for interharmonic emissions.
noise emission. EN/IEC 61800-3 [1]
the amount of conducted and radiated
defines tests and sets limits for the Interharmonic emissions are made
emissions, in common with many
emissions of mains harmonics from more complex by intermodulation
other EMC standards, such as the
a PDS, as do EN/IEC 61000-3-2 (for within the mains rectifier. The mains
generic emissions standards EN/IEC
ratings up to 15A/phase) and EN/IEC voltage frequency and its harmonics
61000-6-3 and EN/IEC 61000-6-4.
61000-3-12 (for ratings up to 75A/ (distorted waveform) intermodulates
phase). So, we have to limit our PDS’s with the AC motor drive frequency
emissions of mains harmonics, and its harmonics, to create a huge
Motors have too much mechanical
and chopper frequencies and their number of “Intermodulation Products”.
inertia and electrical inductance to
harmonics. But this is not all. In a Figure 13 shows a measurement that
24 25
and voltage fluctuations due to load Variable speed motor drives are also
From Figure 13 of: “Power System Harmonics, Part 4: Interharmonics” current changes; so this Guide will used to drive various kinds of motors
R. Yacamini, IEE Power Journal, August 1966 describe the techniques that are used in servo systems, and to drive stepper
The motor drive frequency is 39.4Hz
to control noise emissions for VFDs motors. These use the same DC or
that use PWM. The same techniques AC PWM motor drive technologies
also work for thyristor and triac described above, so their EMC should
drives, which will probably need more be treated the same way.
attention paying to suppressing noise
Figure 14 shows how the noise
emissions in the lower frequency
currents flow in the BDM example
range (i.e. below 150kHz).
previously used in Figure 7.

Rectifier Chopper
Mains DC AC
6-Pulse type also called switcher
Supply Link Motor
shown here or inverter

CM noise due CM noise due

to the rectifier to the chopper
L1
L2
Mains harmonics and DM PWM output (very M
noise in the power supply noisy) to the motor 3
L3

Figure 13:
Example of intermodulation increasing the interharmonic levels in a VFD
The remainder of this Guide will Thyristors and triacs switch much
focus on VFDs and VSDs that use more slowly than PowerFETS and
CM noise from rectifier and chopper
PWM, because these are the worst IGBTs, and their switching rate is no that also flows through the DC Link This symbol indicates intentional and/or stray
capacitances to thesite’s earth/ground structure
for creating high-frequency noise higher than the mains frequency. As (whether external cases/frames are earthed/grounded for safety reasons or not) from internal components, heatsinks, windings etc.

emissions. This is because their a result they produce significantly

Figure 14:
choppers use very fast-switching lower levels of high-frequency noise How the noise currents flow in a BDM
PowerFETS or IGBTs, which are emissions than a PWM drive of the
To understand Figure 14, we have to currents flow out and back along the
operated at kHz switching rates – as same power rating. However, since
understand that there are two kinds three mains phase conductors, and
low as 1kHz for MW power ratings; they are often used at very high
of noise currents – differential-mode they also flow out and back along the
as high as 50kHz for ratings around powers, their high-frequency noise
(DM) and common-mode (CM). All three motor phase conductors.
1kW. We can expect to have to emissions can be significant and
currents flow in loops, and DM noise
control noise at frequencies of up to should not be ignored. However, CM noise flows out along all
currents flow in loops within a single
1,000 times the switching rate (e.g. of the conductors in a cable or cable
All types of VSDs create low cable (or cable bundle). In the case
1MHz for a 1kHz chopper, 50MHz for bundle at the same time, and returns
frequency emissions at harmonics of a three-phase delta connected
50kHz). via a different path to complete its
of the mains supply, interharmonics, VFD like that shown in Figure 14, DM
26 27
loop. Any path will do, but the one that consisting of the set motor frequency 13) the ratios of currents between the from a PDS to flow all over the earth/
always exists is via the earth/ground and its harmonics, plus the chopper loops is frequency-dependent. Simply ground structure of a site or a vessel.
structure of the site or vessel the frequency and its harmonics – flowing put, we should expect the CM noise
PSD is installed in. Even where no in the three-phase motor cable’s Mains Mains Filter Output Inductor
Rectifier Chopper
Inductor very close DC and/or Filter very AC
conductive path exists, high-frequency conductors. harmonic 6-Pulse type also called switcher
to rectifier Link close to chopper Motor
suppression noise suppression shown here or inverter
noise suppression
currents can easily flow through the kHz - MHz kHz - MHz
Figure 14 shows – as red ellipses
air or insulators, via stray mutual
– the CM noise current loop
inductances and stray capacitances.
associated with the rectifier and mains
Figure 14 indicates some of the stray supply, and the loop associated with
L1
capacitances that exist in a typical the chopper and the motor. It also L2
DC noise in the PWM output M
mains supply (very noisy) 3
PDS, which can carry CM currents. shows a larger ellipse indicating that L3
rectifier CM noise also flows in a loop
CM currents are caused by
that comprises the motor, chopper Filter must
imbalances between stray be RF-bonded Filter must be
and DC-Link; and that chopper noise to the rectifier’s RF-bonded to the
capacitances and stray inductances, metal enclosure chopper’s metal
also flows in a loop that comprises the Rectifier and chopper metal enclosure
for example, the stray capacitance enclosures must be RF-bonded
mains supply, rectifier and DC-Link. Now much reduced harmonics, Most CM noises now flow Now much reduced DM
of Phase 1 to earth/ground, versus DM and CM noises flow in much smaller loops and CM noises flow in
in the long mains cable within the filter/drive/filter assembly the long mains cable
that of Phase 2. These imbalances I’m sure the reader will appreciate that
are small, so CM noise currents are Figure 14 is a gross simplification for
Figure 15: Using inductors and filters to suppress noise emissions
small when compared with the DM the purpose of illustration, and that its
noise currents, but since CM currents simplified analysis can equally well be Most filters also add inductors and
4.3. Suppressing the noise
travel in very large loops, which can applied to VFDs using single-phase, chokes to increase the impedance
encompass a whole site or vessel, or six (or more) phase rectifiers. sources
of the mains or motor cables on “the
they have the potential to cause as Figure 15 shows the use of filters at other side” after the provision of the
Currents flow according to the
much (or more) interference as DM the BDM’s rectifier’s input, and at its low-impedance return path, to help
impedance that they experience
currents. chopper’s output, to suppress the DM encourage most of the noise currents
around their entire loop, and where
Figure 14 shows (as a double- there is more than one alternative and CM noise emissions. to flow in the new path provided
headed arrow) the DM noise path they will take all of them, dividing The best way to understand how a by the filter and not out into the
currents associated with the rectifier between them in a ratio that depends filter suppresses DM and CM noise installation’s cables where it might
– consisting of mains harmonics and upon the impedances of each, and the emissions, is to regard it as a means cause interference.
interharmonics plus high-frequency frequency concerned. of providing a return path for the noise Figure 15 shows the mains harmonic
switching noises from the rectifiers current loops that has a much lower emissions from the rectifier being
Stray capacitance ensures that there
themselves – flowing in the three- impedance than the other loops. The suppressed by a three-phase inductor,
are always many alternative loops
phase mains cable’s conductors. noise current will then automatically a common technique often called a
for CM currents to flow in, and since
It also shows (also as a double- there are very many noise frequencies split so that most of it flows in the path line reactor (or just reactor). Other
headed arrow) the DM noise currents associated with rectifiers and provided by the filter. Filters generally methods are discussed later.
associated with the chopper – choppers (see Figures 10, 11, 12 and use capacitors to provide these low-
impedance loops.
28 29
Note that Figure 15 shows line reactor RF-bond the metal bodies of the Figure 16 shows an example of a of the filter, rectifier and chopper
fitted to the supply side of the mains inductors or filters to the metal 50kW VFD assembled in an industrial units are all multi-point bonded to
filter, not to its BDM side, because body of the unit whose noise it cabinet with its mains filter. Note the cabinet’s conductively-plated
this helps prevent resonances in the is to suppress. how close the mains filter is to the backplate, to provide good RF-
mains power distribution network. (Even though an inductor has no VFD’s rectifier, and also how both bonding up to several 10s of MHz.
Connecting capacitors directly to intentional path to earth/ground, like the conductively-plated metal bodies
a supply network, without series the capacitors in a filter, its windings
reactors between them and the have significant stray capacitance 50kW VSD Rectifier
supply, has been seen to cause Mains Isolator
which will help control CM currents,
resonances that caused costly providing the inductor is RF-bonded.)
damage to equipment, with even 50kW VSD Chopper
Mains Filter
higher costs due to its downtime. “RF-bonding” means providing a
conductive path that has a very
Providing a low-impedance path for low impedance, <<100mΩ, at the
DM noise currents is easy – simply frequency concerned. Ideally, the
connect capacitors between the conductive path should have an
phase conductors in each cable. impedance of 1mΩ or less at the
These will tend to “short out” the DM Filter, inductor, rectifier and chopper all have metal
highest frequency that it is desired enclosures, are all close together, and are all multi-point RF-
currents, so they don’t get out into the to control. Remember that this is the bonded to one conductively-plated metal back-plate
supply or motor cable, but of course impedance of a bond, not simply its
no capacitor is perfect so the noise resistance.
current redirection is not perfect either
Wires or braid straps are ineffective Mains
and some DM noise current will still Inductors Screened motor cable’s screen
flow in the long cables. for RF-bonding purposes, because termination at chopper
their impedance is too great. The
Redirecting the CM currents also inductive impedance of a straight wire
uses capacitors, but they have to is 2ƒL, where ƒ is the frequency to
be connected to the earth/ground be suppressed in Hertz (Hz) and L is Figure 16:
structure, so to be effective the the inductance of the wire in Henries Example of a 50kW drive with filtered mains and screened motor cable
impedance in the earth/ground (H). We can assume about 1μH/metre
structure between the filter and the for a long wire and about 0.3μH/metre Figure 15 shows how this approach motor cables.
rectifier or chopper must be very small for a wide braid strap, so, for example, reduces PDS emissions, by showing
See 4.4.4 for using an isolating
indeed. This essentially means: at 1MHz a 25mm wide braid strap that the double-headed arrows of
transformer to improve the CM
just 100mm long that might have a the DM noise currents, and the red
Locate the inductors and/or performance of mains filters, and –
resistance of 1mΩ has an impedance ellipses of the CM noise currents, are
filters physically as close as where CM noise is the only significant
of nearly 0.2Ω at 1MHz – 20 to 200 all now contained within the assembly
practicable to the unit whose problem – possibly replacing the
times too high to be a good RF-bond. comprising the mains filter, VFD and
noise it is to suppress (i.e. the mains filter entirely.
output filter. They are not showing as
rectifier or the chopper)
flowing in either the mains supply or
30 31
I don’t have a real-life photograph of 961. Figure 15 does not show it, but of high-frequency noises. is because the impedance of the CM
an output filter installed on a VFD, but CM + DM output filters like the CNW loop path down the inside of the cable
Even where the chopper does not
the principles are exactly the same 961 generally require a connection to screen is so much lower than the
cause interference problems, there is
as for the mains filter in Figure 16. the DC-Link as well. alternative CM loops that exist in the
the problem of bearing life, and of the
The output filter should be one that, earth/ground structure.
Figure 17 shows some real-life degradation of the insulation in motor
like the mains filter, redirects both the
measurements on a VFD fitted with cables and windings when long motor For example, when a number of
DM and CM noise currents that would
series inductors to limit emissions cables are used (see 3.3).Figure 18 resistors are connected in parallel,
otherwise flow in the motor cable and
of mains harmonics, then with an shows an alternative to the output it is the one(s) with the lowest value
motor, such as the REO “Sinus ++”,
additional filter to suppress emissions filter shown in Figure 15 – a screened that carry the bulk of the current.
otherwise known as filter type CNW
motor cable. As this figure shows, The impedance of the CM loops at
if the screened motor cable has its frequencies above a kHz or so are
VFD mains voltage And adding a filter reduces the
screen correctly RF-bonded at both dominated by inductive and capacitive
showing RF noise RF noise on the mains voltage
ends, the CM current loops associated reactances, rather than resistance,
with the VFD’s motor output prefer but the same principle applies – the
to flow inside the cable screen. This bulk of the CM current automatically

Mains Mains Filter Screened cable,

Rectifier Chopper
Inductor very close DC or unscreened cable AC
harmonic 6-Pulse type also called switcher
to rectifier Link with an overbraid, Motor
suppression noise suppression shown here or inverter
or with a shielding
kHz - MHz conduit and/or
cable armour

VFD mains current L1

REO components are L2
DC noise in the PWM noise contained M
showing harmonic noise mains supply
available that combine within cable 3
L3
series inductors with
mains filters
Filter must “RF bonded”: to the
be RF-bonded chopper’s metal enclosure
to the rectifier’s at one end; and to the
metal enclosure motor frame at the
Rectifier and chopper metal
terminal box at the other end
enclosures must be RF-bonded
Now much reduced harmonics, Most CM noises now flow The DM and CM noises
DM and CM noises flow in much smaller loops flowing in the long motor
in the long mains cable within the filter/drive/cable assembly cable mostly stay inside it

Figure 18:
Suppression with mains inductors and filters, and screened motor cables

Adding a series inductor reduces

the mains harmonic currents

Figure 17:
Examples of suppressing mains noises
32 33
takes the loop that presents the least problems, is to make the motor
overall impedance. cable very short indeed – less than 50kW VSD
one-tenth of the wavelength at the Chopper
To achieve the low impedance
highest significant chopper harmonic
necessary to control the motor
frequency (e.g. 1m for 30MHz, 10m
output’s CM currents:
for 3MHz, 100m for 300kHz). The
At the chopper end, the motor very best is to combine the BDM with
cable screen must be RF- the motor, with their metal frames
bonded to the chopper’s metal multi-point RF-bonded together,
enclosure, chassis or frame. or combined in a common casting,
At the motor end, the motor so there is no external motor cable
cable screen must be RF- at all. This technique has been
bonded to the motor’s metal very successfully used by some
terminal box, which in turn must manufacturers, including Danfoss.
be RF-bonded to the motor’s All VFD and VSD manufacturers
enclosure or frame (e.g. by should provide detailed EMC
seam-welding or multiple spot or instructions for their products. I do not Braid-screened motor cable’s screen
tack welds). recommend using any manufacturer termination at chopper
who does not (or will not) provide Uses a metal saddleclamp that bonds
Note: Figure 18 does not show an them. They will often be different for to a wide flange extending from the
earth/ground cable between the motor different models and ratings of drives, chassis of the chopper’s electronics
body and the chopper, although one and for example, higher rated drives
will almost certainly be required. This will generally require different filter
is because some VFD manufacturers specifications. Figure 19:
require it to be contained within the Detail of the motor cable connection to the chopper in Figure 16
screen of a screened motor cable, Cable screen RF-bonding is
whereas other manufacturers require sometimes called 360° termination
or 360° bonding, because it should Figure 19 shows an amplified detail
it to be routed outside the screen (but of Figure 16, where the motor cable
still close to the motor cable along ideally make electrical connection all
around the circumference or periphery connects to the 50kW VFD’s chopper
its route). These requirements come unit. It shows that the cable’s braid is
from the electronic design of the of the braid screen. Alternatives, such
as multi-point bonding, may be used clamped to a flange protruding from
VFD, so it is important to obtain the the chopper’s chassis, using a metal
manufacturer’s EMC instructions for providing the bonding points surround
the cable. saddleclamp.
the exact model of motor drive, and
follow them.
A good way to prevent noise from
the chopper which is causing EMC
34 35
Figure 20 shows the other end of the types of EMC gland, the top left-hand
motor cable in the system driven by one being the preferred type. Where
the VFD in Figure 16. Here the motor connectors are used instead, they
cable’s braid uses an “EMC Gland” should terminate the cable screen in
to 360° bond to the motor’s terminal 360° just like an EMC gland.
box. Figure 21 shows a variety of
A high quality cable gland from
KEC
(uses an iris spring to make an
excellent RF-bond

An EMC Gland from

Lapp Kabel
(multi-point shield
connection)

A low-cost EMC Gland from Hummel

(requires the shield to be cut and
carefully spread out, so is not generally
applicable and is also susceptible to
Braid-screened motor cable’s screen quality of workmanship
termination at motor
Uses a 360O screen-bonding cable
gland Figure 21:
Examples of three kinds of EMC cable gland

Figure 20:
Detail of the cable connection to the motor driven by the VFD of Figure 16
36 37

Figure 23:
Example of a suitable 360° bond for solid conduit

Figure 22:
Examples of screened flexible conduit and overbraid
Figures 15 and 18 show the DM and associated with a VSD are installed
CM currents flowing entirely within ([37] records some difficulties with
Where it is difficult to source high- for a motor cable, but the usual the VSD assembly, which includes this). So, in practice, the electrical
current cables with good quality “banjo” washers are useless for any mains chokes or filters, and any installation of a VSD and/or its
screens, or when suppressing the suppression purposes because they output filters and/or motor cable associated components (chokes,
noise from a legacy system that rely on lengths of wire to bond them to screen bonds (at the chopper end). filters, isolating transformers, motor
used an unscreened motor cable, an earth/ground terminal, and so have However, electrical installers often cable screen bonds, etc.) might not
overbraids or shielded flexible conduit too high an impedance at RF. Figure seem to be of the opinion that all be compact, and its earth/ground
can be used, as shown in Figure 22. 23 shows one manufacturer’s solution earths or grounds are equivalent, and conductors may connect all over the
When choosing either, make sure that – a conduit nut that makes a multi- also that it does not matter exactly place.
appropriate 360° glands or connectors point 360° bond between the solid where the various components
are available for it. conduit and a metal enclosure at the
point of penetration of the enclosure.
Solid conduit makes the best screen
38 39
It is however very important indeed engineers involved will be blamed for structure, using very short 4.4. More details on
that the following two general getting it wrong, when the problem is electrical bonds. Follow all the suppressing PDS emissions
installation rules are followed: incorrect installation. necessary safety codes taking
the earth/ground leakage A little Guide like this cannot be a
a) All of the component parts of I strongly recommend to all EMC textbook and provide everything one
current from each into account
a VSD, plus its associated engineers associated with such might need to know, but at least it can
(could be several amps, due to
suppression components projects, that they write down provide the basics, and this has been
the mains filtering).
(chokes, filters, isolating mandatory requirements for the done above. This section provides
transformers, motor cable installation of their suppression a few additional notes, and many
screen bonds, etc.) must be in devices, using as much detail as references, on suppressing PDS
very close proximity, ideally needed to communicate with the emissions.
all contained within one metal electrical installers in terms that they
enclosure. will clearly understand – and insisting
4.4.1. Obtain manufacturer’s
that the contract with the customer
b) All of the earth/ground EMC instructions and follow
includes an item covering their
conductors associated with them
inspection and approval of the final
the component parts in a)
electrical installation. VFD and VSD manufacturers EMC
above must connect to one
point, ideally the chassis, Some readers might contrast point b) design/installation guides should
frame, backplate or surface above with other REO Guides, books always be obtained, and their advice
of the metal cabinet they are and articles I have written (e.g. [19] followed accurately. However, they
all contained within. This one [26]) in which the virtues of meshed may not aim to achieve the degree of
point must then connect to common-bonding networks (MESH- noise suppression that is needed (for
the site’s or vessel’s safety CBNs) are extolled at length. Note example when installing many PDSs
earth/ground structure via one that these also allow the possibility in one system, such as the example of
conductor – following all the of combining single-point bonded Figure 3).
necessary safety codes taking systems with mesh-bonded ones, There are many general guides and
the earth/ground leakage so there is no conflict. However, if a textbooks on suppressing emissions
current into account (it could MESH-CBN or MESH-IBN (see [19] or from motor drives, including [31], [32],
be several amps, due to the [26] for definitions) that can control up [33], [34], [35] and [36], and these
mains filtering). to 30MHz, at least, exists in the area might provide sufficient information
where the VSD and its suppression to overcome any shortcomings in the
I make no apology for repeating some
components are located, then b) can drive manufacturer’s EMC installation
of the points already emphasised in
be modified to read as follows: instructions. If even more information
the earlier text. Electrical installers
must be controlled very carefully to b*) All of the earth/ground is required, see the following
ensure that these rules are met in conductors associated with subsections.
full – otherwise all the time and cost the component parts in a)
of determining how to suppress the above must connect to their
drives will be wasted, and the EMC local meshed CBN or IBN
40 41
4.4.2. Filtering Where RF interference is suspected phase CM choke components can be filters on their own, so great care
from a mains or output cable, it will connected in series. should be taken when a VFD is fitted
The specifications for the filters usually be the CM currents that are with an internal mains filter, but its
should be obtained from the VFD or When trying to specify your own
to blame. Clamping a ferrite toroid performance is not enough and you
VSD manufacturer’s detailed EMC mains filter in the absence of guidance
around all of the phase and neutral are tempted to add another filter in
instructions for exactly the model of from the drive manufacturer (or when
conductors in the cable or bundle, with series with it.
drive being used. When not using an that information proves inadequate)
or without including their associated
output filter, longer motor cables – or it is important to understand that, However, multi-stage filters are
protective earthing (safety grounding)
screened or armoured motor cables in real life, mains filters operate available that have excellent
conductor, can sometimes be enough
– will have more stray capacitance, with “mismatched” input and output performance, although the more
to stop the interference, and is
causing an increase in the magnitude impedances – i.e. they are not both stages they have, the larger, heavier
especially effective at frequencies
of the chopper’s CM currents, and 50Ω, or even both the same. All and more costly they tend to be. But
above 30MHz. At frequencies below
may therefore need to use higher- mains filters resonate and provide the author knows custom-engineering
30MHz two or more ferrite toroids may
specification mains filters for the same gain rather than attenuation at their control cubicle manufacturers who
be needed in series on the cable.
level of emissions (all else being the resonant frequencies, and especially automatically fit a 100A 3-phase
same). Distributors stock many suitable so when operated mismatched 5-stage mains filter to the incoming
ferrite toroids, and the split versions – as they always are in real-life. But supply of their cabinets. Although
So the mains filter specifications in a are better for retrofitting (all EMC attenuation data from most distributers over-specified in most cases, they
properly documented EMC installation engineers carry many kilograms of and some manufacturers do not show reckon that it saves them time and
guide should show how the filter various types of ferrite when visiting this, because they only show the cost overall, by avoiding the need
specifications depend on the length of a site to try to solve a problem). It results of “matched” tests (i.e. 50Ω to spend time choosing and proving
the motor cable, and in some cases is important to ensure that all of input and output). which is the most cost-effective filter
on the type of cable too (e.g. screened the power conductors associated for each cabinet.
cable, or cable routed in conduit, will How to deal with the problems of filter
with a mains supply or motor load
have higher stray capacitance than resonance is discussed in detail in Most standard mains filters sold as
pass through the ferrite toroid, and
the same length of unscreened). section 5.10.1 of [19], 4.7.1 of [20] ‘EMC filters’ will not provide much
it may be necessary to wind those
and Chapter 8.1.3.1 of [26]. These attenuation for the VSD’s emissions
For more information on EMC filtering, conductors two or even three times on
all basically recommend getting below 150kHz (see the case study in
and how to assemble it in cabinets, the toroid. Always check that – when
all the CM and DM, matched and 3.4). Filters suitable for VSDs must
systems and installations to get maxi- installed on a cable – the ferrites do
mismatched test data from the filter provide good attenuation down to the
mum benefits, see section 5.10 of not get too hot to hold your hand on
supplier (6 curves in all), drawing the chopper’s fundamental frequency (i.e.
[19], 4.7 of [20] and Chapter 8 of [26]. for several minutes, when the drive
worst case of all of the attenuation switching frequency) for both the DM
is running at full power. Ideally, they
Mains harmonics can be filtered, curves, and assuming that a filter’s and CM noise emissions. The CM
would hardly get warm at all, and if
instead of simply reduced by line real-life performance will be no better attenuation is especially important.
they do it usually means that a much
inductors. However, because of their than that.
larger ferrite is required. CM + DM output filters convert the
low frequencies special passive and/ Cascading mains filters is generally PWM output into a relatively “clean”
or active filtering techniques are used, For even better performance from a
a bad idea. Resonances can occur DC or AC waveform, that can be sent
and these are discussed in pages 51 ferrite CM filter at low frequencies,
that make the attenuation of the significant distances, over perfectly
through 55 of [29]. wound single-phase and three-
combination worse than any of the ordinary cables to the motor, without
 42 43
causing interference problems – able to tell you which VFDs or VSDs Ships and other vessels generally or when it is “corner-grounded” (one
incidentally improving cable and motor they are suitable for. use mains supplies that do not have phase connected to earth/ground,
life as mentioned earlier. But because their neutral directly bonded to their rather than the neutral), all capacitors
In between low-cost ferrite toroids
they are costly, such output filters earth/ground structure [35], and some connected to the earth/ground (e.g.
and expensive CM + DM motor output
will probably not even be mentioned land-based installations also use this in a filter) should be safety-rated for
filters, there are various medium-cost
in most drive manufacturers’ EMC practice. This situation is discussed in the full phase-to-phase voltage, rather
alternatives. So-called dV/dt filters
instructions. Section 4.5. than phase-to-neutral.
“round off” the edges of the motor
Where using screened motor cables output PWM waveforms, which – in
is impractical for some reason, the frequency domain – attenuates 4.4.3. Safety issues with 4.4.4. Benefits of isolating
CM+, DM filters like REO’s Sinus ++ the higher frequency noise spectrum. filtering transformers
series may be the only solution. The Figure 24 shows the effect of applying Filters contain capacitors from the Where a BDM is not powered from
manufacturers of the filters should be a REO dV/dt output filter to a VFD. phase conductors (mains or motor) a co-located dedicated step-down
to the earth/ground, and these isolating mains transformer, and
The same VFD output increase the current in the protective where the mains power supply that
Rising edge of PWM output earthing conductor (the green/yellow feeds it is shared with other electronic
waveform from a VFD waveform with a REO
striped wire in the mains supply). equipment (which may include other
CNW 811 “dV/dt filter” fitted
Safety standards and electrical BDMs) that are not co-located with
wiring codes set quite low limits on the BDM concerned – then a number
this current, to help prevent electric of EMC issues arise that may be
shock hazards, but they will allow best dealt with by fitting the BDM
any amount of earth/ground leakage with a dedicated co-located isolating
current when high-integrity earthing/ transformer.
grounding systems are used with a
Isolating transformers are large and
fixed VSD installation (i.e. one that
costly components, especially for
does not have a flexible mains lead or
high-power BDMs, but omitting them
mains plug, sometimes called “non-
or trying to use less costly alternatives
pluggable” equipment.).
can prove to be more costly overall
The high earth/ground leakage (see section 3).
currents caused by filters can also
6OLTAGERISE K6› S 6OLTAGERISE K6› S In situations where a mains power
make it impossible to use residual-
-EASUREDWITHMOFMOTORCABLE -EASUREDWITHMOFMOTORCABLE supply feeds two or more items of
current circuit breakers (RCCBs),
equipment spread over a site or
earth leakage circuit breakers
vessel, the DM impedances of the
Figure 24: (ELCBs) or ground-fault interrupters
“Rounding off” the PWM waveform with a dV/dt filter
phases can become different from
(GFIs).
each other due to unequal loading,
Where the mains system is isolated and the CM impedance between the
from the safety earth/ground (see 4.5), phases and the earth/ground can
44 45
become quite low due to the stray mains filter. But all chokes cause However, there are techniques 4.4.5. More detail on
capacitances of the long cables and some voltage drop and so this might available for decreasing the stray
RF-bonding techniques
the CM filters in other equipment. cause an increased rate of tripping primary-secondary interwinding
These impedance effects negatively due to sags or dips in the supply. capacitance, and for adding Figure 25 shows the basics of the
affect the performance of a BDM’s Another possibility is to fit an earth/ interwinding screens. These can ideal method of RF-bonding two
mains filter (see [36]). Fitting an ground choke to the BDM, which of be used to provide better isolation metal items together (e.g. RF-bonding
isolating transformer restores the course will only work if it is fitted to performance and higher CM source the metal bodies of the mains filter,
balance to the DM impedances, and the single conductor that connects impedance, from DC to radio rectifier and chopper to the backplate
also restores a high CM impedance, the BDM’s earth/ground to the earth/ frequencies, which may be needed on in Figure 16).
helping the mains filter achieve its ground structure of the site or vessel occasion, for example when a mains But there are many more details
designed potential. (see item b in Section 4.3). filter is not fitted at all. that could be important, and in
Earlier, I discussed how a BDM’s But an isolating transformer dedicated some cases alternatives might be
CM return currents were ‘steered’ by to the BDM and co-located with it appropriate, so the information in
capacitors in its input and/or output (see item a in section 4.3) will provide
filters and their low-impedance much better control of CM currents Any insulating finishes Anti-vibration device,
bonding to the BDM’s chassis/frame, than any chokes. removed from entire e.g. Anti-vibration washer
bonding area or other method
so that they flowed mostly in the But never use chemical
A mains isolating transformer might (e.g. paint, anodising,
BDM’s assembly. But when the CM polymer passivation) ‘thread-lock’
also prove to be sufficient, on its own
impedance of the mains supply
without a mains filter, for preventing
is low the ratio between the path Note: this RF-bond
the CM noise from a BDM’s mains is shown partially
impedances provided by the mains
input from circulating widely. It would disassembled
filter and that provided by the mains
do little or nothing for the BDM’s DM
supply might not be as high as we
noise emissions, or the resulting
would like. For example, where there
waveform distortion, but this is often
are two or more equipments fitted with
not as much of a problem as the CM
mains filters connected to a mains
noise emissions anyway.
supply, their low CM impedances
Metal components to
encourage the CM currents of each Where a BDM is fitted with a mains be RF-bonded
item of equipment to flow in the filter that deals with CM noise as Conductive gaskets
could be inserted here
other’s mains filter – encouraging CM well as DM, the majority of problems
currents to flow widely, which is not with widely-circulating CM currents Do not rely on screw
what we want. occur at lower frequencies, below Reliable RF-bonds re created by pressing
threads of any type to
together highly-conductive metal surfaces
150kHz. In this case experience make the RF-bonds
Where a BDM’s mains filter does not Materials should be chosen to prevent
seems to show that the normal oxidation or corrosion over the lifecycle,
include a CM choke on the supply taking the real-life environment into account
type of construction for an isolating
side of its CM capacitors, this problem
transformer is adequate for controlling
can be reduced by fitting a CM choke
CM currents in this frequency range.
in that position, co-located with the Figure 25: RF-bonding two metal surfaces
46 47
section 5.7 of [19], 2.2 through 2.5 the DIY screen-bonding technique of 4.4.7. Screened (shielded) but is now EN/IEC 61000-6-4). Each
of [20] and Chapter 5 of [26] may be Figure 26. enclosures VFD complied on its own, but when all
useful. the drives in the cabinet were running,
However, where a screened enclosure EN/IEC 61800-3 is rather dismissive their aggregate emissions were
4.4.6. More detail on cable (e.g. cabinet, room, etc.) is used (see of the potential of PDSs to interfere significantly above the limit line.
screening (shielding) 4.4.5), “proper” glands like the top with radio reception through
left-hand side on in Figure 21 should radiated emissions. However, VFDs As PowerFETs and IGBTs develop,
techniques always be used (or connectors with they are designed to switch faster
– especially low-power ones switching
This will be found in sections 5.7.6 similar screened braid terminations). at over 20kHz – have been known to to reduce heat losses and increase
through 5.7.10 and 5.11 of [19], 3.7 of interfere with radiocommunications, efficiency, so the prospects for
[20] and Chapter 7.2 of [26]. as some items in [15] show (e.g. No. radiated interference can only worsen.
24). And as mentioned in section 3, more
Screen bonding need not be costly, radiocommunications are being used
especially where there are number As long ago as the early 1990s I everywhere, which also increases the
of cables screens to be bonded (e.g. have had to improve the shielding potential for radiated interference from
to a cabinet backplate) as shown by of industrial control cabinets that PDSs.
contained several VFDs, to pass the
Metal clamping plate radiated emission tests to the generic Designing and/or installing shielded
Cable screens exposed emissions standard for the industrial enclosures requires a lot of attention
to make good contact environment (which was EN 50082-1, to detail, but the basic principles are
Screened cables entering/leaving the BDM with the gaskets
(Strain relief and environmental sealing not shown) outlined in Figure 27, which shows

Screened BDM enclosure

Screened cables must Motor

Chopper
have 360O RF-bonding
connectors or glands
at both ends

Filters

Two strips of soft conductive gasket create 360O

RF-bonds between the cables’ screens and the
highly-conductive surface of the chopper’s metal
enclosure, chassis or frame - when the clamping Unshielded cables All cables
The Parallel Earth Conductor
plate is tightened down. must all be filtered by routed close
‘PEC’ (e.g. a cable tray)
through-bulkhead filters to the PEC

Figure 27:
The basic principles of employing a screened enclosure
Figure 26:
A low-cost way to RF-bond multiple cable screens
48 49
that no conductor of any type (even A great deal of detail on the whines and whistles if routed too close 4.4.10. Mains harmonics and
a mechanical push-rod or metal pipe) design and installation of shielded to cables associated with a drive, and interharmonics
can enter/exit a screened enclosure enclosures, of all sizes from just large are a matter of some concern to EN/
without either: enough for one small VFD, up to IEC 61800-3 (see 6.2.5 in [1]). For a These are typically suppressed by
screening an entire room or even a real-life example of serious telephone using a “3% inductor” in series with
a) Being RF-bonded to the the rectifier, as shown in Figures 15
building, will be found in the following: interference from a high-power drive,
enclosure’s metal wall at the point of and 16. The 3% refers to the fact that
section 5.12 of [19], section 5 of [20] see Item 1 in [15].
entry/exit, or when carrying its full rated current, its
and Chapter 6 of [26].
Cable classification and segregation internal impedance reduces the mains
b) Being filtered to an appropriate
is covered in section 4.8 of [19] (4.4 voltage by 3%. This is considered
specification, with the filter RF-bonded 4.4.8. Other EMC techniques is also important); 3.3 of [20] and to be a cost-effective compromise,
to the enclosure’s metal wall at the
The above discussion has not Chapter 7.4 of [26]. but sometimes it is necessary to go
point of entry/exit, or
addressed all the EMC techniques as high as a 4% inductor. Increasing
c) Being a screened cable with an that will probably be required, for 4.4.9. Commutation notches the impedance even further is not
appropriate specification, the screen which read [31] [32] [33] [34] [36] and advised, so if series inductors have
being RF-bonded (i.e. 360° bonded) Voltage “notching” is an emission
[19] [20] and [26]. not managed to reduce the harmonic
to the enclosure’s metal wall at the problem caused by naturally
For example, most (if not all) VFD commutated thyristors/triacs in DC and interharmonic emissions by
point of entry/exit. enough, other techniques must be
manufacturer’s EMC installation drives. The cross-conduction when
No alternatives are ever permitted, for instructions, as well as [33] [34] and one thyristor or triac turns on before used instead of, or as well as, series
any reason. I am often asked to solve [36] will include the requirement to another has finished turning off, inductors.
real-life problems in which expensive classify the cables associated with momentarily shorts-out their phases Single-phase VSDs and VFDs
shielded cabinets are found to be a PDS according to some rules, and causing a dip with a depth of 100%. suffer from emitting all of the odd-
“leaking”, and the usual problem is then to route these “cable classes” numbered mains harmonics, including
that some conductor assumed to Although this is a low-frequency
separately from each other, with triplens as mentioned earlier. On
be insignificant (e.g. hydraulic pipe, noise, it is very severe and can
certain minimum spacings to be four wire systems (i.e. 3 phase + N)
mouse cable, etc.) has been allowed interfere with other equipment that
maintained between cable classes the triplens add arithmetically in the
to enter/exit the enclosure without is using those phases. However,
where they are routed in parallel. neutral conductor causing significant
one of the above three methods being a “3% inductor” such as is often
This acknowledges the fact that no fitted to reduce emissions of mains problems with localised power quality
applied. and equipment operation. However,
cable screens or filters are perfect, harmonics and interharmonics (see
However, sometimes the problem has so it helps to reduce the crosstalk 4.4.8), will generally provide adequate three-phase (6 pulse) drives running
been that the system integrator has between the cables, especially from suppression. from reasonably low-distortion mains
simply cut a large hole in the wall or the motor output to the mains supply supplies have very low levels of
door of the screened enclosure, to [1] calls this series inductor a “triplen” harmonics, of which the most
or control cables. It also helps ensure
mount their human-machine interface, “decoupling reactance” and requires important are the 3rd and 9th. Losing
low crosstalk to cables that are not
destroying the screening effectiveness that its size be specified. the 3rd makes it easier to use series
associated with the drive, such as
in the process. telephone cables, which can suffer inductors to get good levels of mains
dramatically from audio-frequency harmonic reduction.
50 51
Phase-shifting mains transformers ships and vessels often use special is really a chopper that is controlled filters up to almost 3,000kW for both
can be used to create six-phase harmonic suppression techniques that to source or sink mains currents in AC and DC drives. Being passive
(often called 12-pulse) rectifiers, are not commonly used in land-based antiphase to those that are causing and linear, they do not cause EMI
which has the effect of causing the 5th installations, see [35] for details. problems, and – despite its name – is emissions.
and 7th harmonics to be substantially not a filtering technique at all. Passive
A reasonably new design technique, Cost-effectiveness calculations may
cancelled out in the rectifier’s circuits, and active harmonic filters are often
at the time of writing, is the “active show that it costs less to allow all
so that its first significant mains used where it is desired to deal with
front end” (AFE), which uses IGBTs the PDSs on a site or in a vessel to
harmonic is the 13th. Increasing the harmonics of all the equipment
instead of plain old rectifiers. These emit their harmonics, and to clean
multiples of three phases (or six on one floor of a building, or even an
are switched at a high rate, just like them up with a single filter (passive or
pulses) attenuates even higher-order entire building, site or vessel, instead
a chopper that drives PWM into a active) so that they do not cause too
harmonics, but the specification on of dealing with them at the level of
motor, but control software arranges much distortion of the mains voltage
the purity of the mains supply’s sine individual items of equipment.
the sequencing and timing so that, waveform.
waveform and equipment and phase
after passing through a series inductor Active filters, introduced some 10
shift transformer quality (internal These and other “installation level”
to average out the PWM, the result is years ago, are expensive but widely
imbalance tolerance levels) must techniques are discussed in pages
a rectifier that appears to the mains used. These electronic ‘filters’ provide
increase with the number of phases 42-62 of [29], and [35].
supply as a substantially linear (i.e. a very low impedance source (<1%)
for this to be effective. However,
resistive) load, which as a direct for the harmonic currents. Therefore,
using large or multiple-phase-shift 4.4.11. Mains voltage
consequence is claimed to achieve if rated correctly, the load(s) draw the
transformers, as is typical of oil fluctuations
low emissions of mains harmonics harmonic currents from the active
production platforms, can still reduce
(<5% Ithd). filter whilst the source provides only [1] sets limits for the generation of
this excessive voltage distortion,
the fundamental current. Depending mains voltage fluctuations, for which
especially at higher order where they However, AFEs achieve this at the
on the type, active filters can reduce there are only a few installation-
are both most problematic and difficult cost of significant harmonic currents
harmonic emissions to below 5%. level mitigation techniques, such as
to treat. in the supply at the switching
Active filters are parallel devices, Dynamic Voltage Restorers (DVRs)
frequency of the AFE bridge, higher
Ships and other vessels often have and so only need to be rated for the see pages 36-49 of [30].
EMI emissions between 10kHz and
very distorted mains supplies because harmonic current.
100kHz, and other a number of other At the level of the motor drive, the
their electricity generators have much
issues. AFE rectifiers, being series The other type of harmonic filter major benefit comes from using “soft-
higher (about 3 times) the source
devices, have to be dimensioned which is very popular is worldwide starting”, especially for AC motors
impedance of a landlubber’s HV
for the total load. This, of course, is the passive “wide spectrum filter”. because they can draw very large
transformer of the same VA rating, and
a matter of drive selection, and is These are multi-limbed reactors magnetising currents when switched
also because of the increased use of
not otherwise under the control of a wound on a common core, fitted Direct-On-Line (DOL) near the
powerful VFDs in “electric thrusters”
system integrator or installer. with a small capacitor bank (not like zero-crossings of the mains voltage.
and even electrical propulsion. For
traditional passive filters). They are Using VFDs solves this problem
this reason, 6-phase and higher Filtering was mentioned earlier
connected in series with the load(s) automatically.
(12-pulse and higher) rectifiers are as a means of suppressing mains
and – depending on manufacturer
often unsuitable for ships, because harmonics, using passive filters such Where high-powered drives have a
– can also reduce the Ithd to around
they rely on low-distortion mains for as resonant traps. Another technique rapidly fluctuating load, the fluctuating
5%. One manufacturer supplies these
their harmonic improvements. So is the so-called “active filter”, which
52 53
motor currents can also give rise to in a steel mill, often the only solutions necessary) either filtered or screened. from ground, and says that in
significant mains voltage fluctuations. are either to make sure that sensitive When filtering techniques are used, such situations the only mitigation
This may be able to be cured by equipment is located far enough away filters may be needed at both ends, possible is to ensure that all the other
adding inertial energy storage (e.g. a not to be effected, use equipment because the DC-Link carries noises equipment on the site is immune
larger flywheel) or by installing a DVR that is not sensitive (e.g. use plasma generated by both the rectifier and the enough to the noise emitted by the
with an adequate rating, see 5.3.9 on or LCD computer screens instead of chopper. PDS. But this ignores the possibility of
page 48 of [30]. cathode ray tube (CRT) types), or fit interference with equipment off-site,
localised screening to the affected 4.4.14. Neutral shift can and with radio receivers, so is not a
4.4.12. Radiated EM items of equipment. stress motor insulation complete solution.
disturbances – low frequency Screening for very low frequencies Section 4-12 of [36] discusses the However, if filters are fitted to
H-fields can be passive (e.g. using problems of increasing neutral- individual BDMs as recommended
MuMetalTM); or active, in which metal earth/ground voltage caused by in this Guide, all that is necessary
These are suppressed by the filtering
frameworks are driven with currents VSDs with Wye-connected inputs. It is to “float” the chassis, frame or
and cable screening methods
to create magnetic fields that “cancel also discusses solutions that can be enclosure of the BDM. Since the
discussed earlier, and by ensuring
out” the local ambient magnetic field. used when a Delta connected mains mains and output filters (if used) will
that all conductors carrying DM loops
input cannot be used. These include be RF-bonded directly to the BDM’s
are in close proximity, preferably Where there are powerful currents
using an isolation transformer at the chassis, frame or enclosure they will
twisted together, along their entire there is always the possibility that
mains input and floating the neutral not increase the leakage current into
route, see section 4.4 of [19]. human exposure to the resulting
connection to the VSD. the earth/ground. Of course, this will
magnetic fields could be too high, see
Where cables carry currents that are mean protecting the BDM from being
[10] and [11] for limits, and methods
too large to permit them to be twisted touched, to prevent personnel from
for testing and calculation. 4.5. Insulated Neutral,
or placed close together, because suffering electric shocks if there is
of the physical damage that would “floating” mains power a phase-to-earth/ground fault in the
occur to their insulation due to the 4.4.13. Emissions from the systems system.
electro-motive forces acting on their DC-Link
Ships and other vessels generally use When using cable screens and/or
conductors, it may be possible to DC-Link conductors can carry as mains supplies that do not have the armour instead of output filters, a
arrange for external shielding around much noise as the output cables. neutral of their mains power supply capacitive RF-bond could be used at
the bundle of conductors to protect Figure 14 shows that there is some directly bonded to their earth/ground one end of the motor cable, either at
nearby equipment from the magnetic stray capacitance to earth/ground structure [35], and some land-based the BDM or in the motor’s terminal
fields (see 5.12 in [19]). from the DC-Link conductors, so the installations also use this practice. box. This will not be as effective as
But shielding can be very costly, noise voltages and currents on the This is known as an IT power network a proper 360° RF-bond, but may be
especially in the case of very low DC-Link can couple noise into other (nothing to do with Information good enough if their lead lengths
frequencies – say below 1kHz – equipment and radio receivers by Technology!). are kept very short. For safety, such
where it can also be very difficult to do induction or radiation. screen-bonding capacitors should
EN/IEC 61800-3 [1] assumes
at all. Where problems arise with low- The DC-Link should therefore be (D.1.2.2 and D.2.2) that filtering is be safety-rated for the full phase-to-
frequency magnetic field emissions, treated like a motor cable: made an unsuitable technique where the phase voltage, and of course their
for instance in a ±8kA DC drive I saw as short as practicable, and then (if mains power network is isolated effect on the amount of earth/ground
54 55
leakage current must be taken into 5. Immunity 5.1. Power quality issues high frequencies.
account.
As well as dealing with emissions, Section 5 of [30] is the most relevant A technique that attenuates an
Another technique for reducing the EN/IEC 61800-3 [1] specifies test reference for installation-level equipment’s emissions of a particular
earth/ground leakage of filters and methods and test levels for immunity. methods for dealing with poor power electromagnetic disturbance,
cable screen/armour bonds, is to fit The issues it is concerned with are: quality, and 4.2 of [19] will also be generally provides a similar level
a co-located isolating transformer useful. of attenuation when protecting
to the PDS so that it can be bonded Power quality issues, including: equipment from interference by that
directly to the earth/ground without Distorted mains supplies Part 6.5 of [21] describes a number same type of disturbance.
compromising the rest of the system. (including harmonic distortion of ways of designing equipment to
Of course, if the PDS is powered from and commutation notches) improve its immunity to power quality
issues, and some of those techniques
5.3. Surge transients
a dedicated and co-located step- Supply voltage deviations,
down isolating mains transformer, can also be applied “stand-alone” to a Series inductors used for suppressing
variations, changes, fluctuations, PDS, system or installation.
a separate isolating transformer is emissions of harmonics or
dips, dropouts and short
not required – its EMI suppression commutation notches also help
interruptions And the techniques for dealing with
function is provided by the step-down increase a drive’s immunity to surge
commutation notching and other
transformer. Three-phase voltage unbalance transients. Other techniques are
low-frequency emissions such as
galvanic isolation and surge protection
Mains frequency variations harmonics and interharmonics
devices (SPDs), which are discussed
described in section 4 above, may
Magnetic fields in sections 4.3 and 5.13 of [19],
also be able to be used to improve
Conducted continuous EM respectively.
immunity to those electromagnetic
disturbances (150kHz to 80MHz) disturbances. These techniques can be used
Fast transients individually, or together in any
Radiated continuous EM 5.2. Magnetic fields, combination.
disturbances (80MHz to 1GHz)
conducted/radiated
Surge transients 5.4. Electrostatic discharge
disturbances, fast transients
Electrostatic discharge (ESD)
Most of these are best dealt with Where a PDS has problems
by the design of the equipment, as complying with the tests for immunity ESD techniques for equipment are
described in [21] and [22], and so not to magnetic fields; conducted covered in part 6.1 of [21], and they
in the scope of this Guide. continuous EM disturbances can be applied to a complete BDM
(150kHz to 80MHz); fast transients, by enclosing it in either a plastic
To discuss what can be done to and/or radiated continuous EM enclosure (to prevent ESD from
improve the immunity of a PDS by disturbances (80MHz to 1GHz) occurring at all) or in a shielded
using installation techniques, the – the usual solutions are to use the enclosure (to divert ESD disturbances
immunity problems can be broken filtering and screening techniques away from the BDM’s electronics
down into four groups, see below. discussed in section 4 above for within).
suppressing emissions of low and Plastic enclosures do not protect
56 57
from the radiated fields of a nearby 6. EMC suppression 7. References Conformity, March 2008, pages
discharge, so it may turn out that a products from REO and further reading 12-22, http://www.conformity.
shielding solution is better. This is com/PDFs/0803/0803_F1.pdf.
then just a matter of applying the Figure 28 shows the range of products [1] EN 61800-3:2004, “Adjustable Also published in a slightly
shielding techniques briefly introduced that REO provides for suppressing Speed Electrical Power Drive amended form in Conformity’s
in 4.4.5 above, usually aiming for the and/or protecting motor drives. Systems – Part 3: EMC 2009 Annual Reference Guide.
upper frequency to be controlled to be requirements and specific test
methods”. Identical to IEC [4] Seventeen EMC Guides on EM
at least 1GHz, ideally 3GHz.
61800-3:2004. phenomena, legal compliance
To suppress ESD within an installation and EMC testing have been
means preventing it from happening [2] European Union Directive written by Keith Armstrong
by using static control measures: 2004/108/EC (as amended) on and published by REO (UK)
dissipative flooring and other surfaces, Electromagnetic Compatibility Ltd. They are very readable
dissipative clothing, ionising blowers, (2nd Edition) in English: http:// and practical, and can be
control of relative humidity etc., all eur-lex.europa.eu/LexUriServ/ downloaded from www.reo.co.uk/
very familiar to anyone who has site/en/oj/2004/l_390/l_ knowledgebase.
worked in semiconductor manufacture 39020041231en00240037.pdf
They are also available from
or light electronic assembly. – in any EU language: http:// REO (UK) Ltd and Cherry
DC Converter PWM Inverter ec.europa.eu/enterprise/electr_ Clough Consultants as a CD-
equipment/emc/directiv/dir2004_ ROM that contains all 17 of them
108.htm plus two other REO EMC Guides
The Directive’s official and a great deal of other useful
L1
L2
M
EU homepage includes a information on EMC.
L3
3
downloadable version of the [5] “On-Site EMC Test Methods”,
Line Inductor Input Filter Output Filter current EMC Directive and its Keith Armstrong, EMC Test Labs
successor; a table of all the Association (www.emctla.co.uk)
dV/dt EN standards listed under
Filter
Technical Guidance Note No.
Braking Resistor
the Directive; a guidance TGN 49, also available from the
document on how to apply the “Publications and Downloads”
Directive; lists of appointed EMC pages at www.cherryclough.com.
Motor
Inductor
Competent Bodies; etc., all
DC Link Choke at: http://europa.eu.int/comm/ [6] The EC’s official Guide to
enterprise/electr_equipment/ 2004/108/EC can be downloaded
emc/index.htm. from: http://ec.europa.eu/
Combined Filter Inductor
Sinusoidal
enterprise/electr_equipment/
Filter [3] Keith Armstrong, “Complying emc/directiv/dir2004_108.
with the EMC Directive htm#guide
Figure 28: REO’s motor drive products
(2004/108/EC), Second Edition”,
58 59
[7] The EMC Regulations 2006, [12] 2004/40/EC, “On the minimum More “Banana Skins” are [19] REO Guide on “Good EMC
United Kingdom Statutory health and safety requirements published 6 times a year in “The Engineering Practices in the
Instrument 2006 No. 3418: http:// regarding the exposure of EMC Journal”, available free at Design and Construction
www.opsi.gov.uk/si/si2006/uksi_ workers to the risks arising from www.theemcjournal.com or www. of Fixed Installations”, free
20063418_en.pdf, implementing physical agents (electromagnetic compliance-club.com. download from: www.reo.co.uk/
2004/108/EC in UK law. fields) (18th individual Directive knowledgebase
[16] IEC TS 61000-1-2, basic safety
within the meaning of Article
[8] The official guide to the UK’s publication, draft second edition, [20] REO Guide on “Good EMC
16(1) of Directive 89/391/EEC)”,
2006 EMC Regulations is posted January 2008, “Electromagnetic Engineering Practices in the
dated 29 April 2004. From:
under “Related Documents” Compatibility (EMC) – Part 1-2: Design and Construction
http://www.hse.gov.uk/radiation/
at: http://www.berr.gov.uk/dius/ General – Methodology for the of Industrial Cabinets”,
nonionising/l184emf.pdf
innovation/regulations/ecdirect/ achievement of the functional available from www.reo.co.uk/
page12469.html [13] EN/IEC 61800-5-2, “Adjustable safety of electrical and electronic knowledgebase
speed electrical power drive equipment with regard to
[9] The consolidated version of the [21] Keith Armstrong, “Design
systems – Part 5-2: Safety electromagnetic phenomena.”
Low Voltage Directive, 2006/95/ Techniques for EMC” in six
requirements – Functional”
EC, replaces 73/23/EEC and its [17] The IET, “Guide on EMC for parts, The EMC Journal, Issue
amendment by 93/68/EEC, http:// [14] IEC 61508: “Functional Safety Functional Safety”, August 2008, 62 through Issue 77 (January
europa.eu.int/comm/enterprise/ of Electrical, Electronic and ISBN 978-0-9555118-2-0 2006 through July 2008), www.
electr_equipment/lv/index.htm Programmable Electronic theemcjournal.com, (search by
Cost £27 plus p&p from http://
Systems” (seven parts) “Keith Armstrong”)
[10] 1999/519/EC, “Council www.emcacademy.org/books.
recommendation 1999/519/EC [15] The First 500 “Banana Skins”, asp or free download from www. [22] Keith Armstrong, “EMC for
on the limitation of exposure Nutwood UK, 2007, 500 reports theiet.org/factfiles/emc/index. Printed Circuit Boards – Basic
of the general public to and anecdotes concerning cfm. and Advanced Design and
electromagnetic fields (0 Hz electromagnetic interference Layout Techniques”, Nutwood/
[18] The “Machinery Safety Directive”:
to 300 GHz)”, from: http:// (EMI). Read it at www. Armstrong, February 2007, £47
“Directive 98/37/EC of the
ec.europa.eu/enterprise/electr_ theemcjournal.com, or buy plus p&p.
European Parliament and of
equipment/lv/emf.htm from [email protected]
the Council of 22 June 1998 on Perfect bound (with titled spine):
(approximately £10) or via http://
[11] EN 62311:2008, “Generic the approximation of the laws of ISBN 978-0-9555118-1-3
www.emcacademy.org/books.
standard to demonstrate the Member States relating to
asp. Spiral bound (lays flat):
the compliance of electronic machinery”
ISBN 978-0-9555118-0-6
and electrical apparatus Numbers: 1, 18, 50, 101, 162,
The new Machinery Safety
with the basic restrictions 168, 233, 274, 278, 279, 282, Order via http://www.
Directive: “Directive 2006/42/EC
related to human exposure to 324, 433, 438, 455, 469, 483 emcacademy.org/books.asp
of the European Parliament and
electromagnetic fields (0 Hz - concern incidents associated
of the Council of 17 May 2006 [23] Keith Armstrong, “BOM Cost and
300 GHz)” (a modified version of with switch-mode power
on machinery, and amending Profitability”, The EMC Journal,
IEC 62311:2007, it replaces EN conversion, including variable
Directive 95/16/EC (recast)” Issue 82, May 2009, pages 32-
50392:2004). speed motor drives.
34, www.theemecjournal.com
60 61
[24] Keith Armstrong, “Getting What [32] “Variable Speed Drives – A Guide International EMC Symposium,
You Want”, The EMC Journal, to Supply Harmonics and Other Austin Texas, USA, 17-22 August
Issue 77, July 2008, pages 19- Low-Frequency Disturbances”, 2009, ISBN: 978-1-4244-4285-0
21, www.theemcjournal.com Emerson Industrial Automation,
free download from: www.
[25] Keith Armstrong, “Absence of
controltechniques.com/guides EN and IEC standards may be
Proof is Not Proof of Absence
purchased from British Standards
(and the “proven in use” fallacy)”, [33] “A Guide to Electromagnetic
Institution (BSI) at: orders@bsi-global.
The EMC Journal, Issue 78, Compatibility (EMC) for
com. To enquire about a product or
September 2008, pages 16-20, Variable Speed Drives”,
service call BSI Customer Services
www.theemcjournal.com Emerson Industrial Automation,
on +44 (0)20 8996 9001 or e-mail
free download from: www.
[26] Tim Williams and Keith them at [email protected].
controltechniques.com/guides
Armstrong, “EMC for Systems IEC standards can also be purchased
and Installations”, Newnes, [34] “Control Techniques Drives and with a credit card, in English and
2000, ISBN: 0-7506-4167- Controls Handbook, 2nd Edition”, many other languages, from http://
3, www.bh.com/newnes, RS Bill Drury, IET publishers, 2009, [email protected].
Components 16/No. 377-6463, ISBN 978-1-84919-013-8, www.
(approximately £47, paperback) theiet.org/publishing/books/
pow-en/control-techniques-2nd-
[27] Keith Armstrong, “The Truth Acknowledgement
ed.cfm
of Murphy’s Law”, The EMC
Journal, Issue 79, November [35] American Bureau of Shipping, Many thanks to Ian Evans of Harmonic Solutions Co.UK, for reviewing this text
2008, pages 16-18, www. “Guidance Notes on Control of and making many very useful suggestions.
theemcjournal.com Harmonics in Electrical Power
Systems”, May 2006, free
[28] Pulse-Width Modulation (PWM),
download from: www.eagle.
see: http://en.wikipedia.org/wiki/
org/absdownloads/getpub.
Pulse-width_modulation
cfm?pub=150
[29] REO (UK) Ltd Guide on
[36] EPRI, “Trouble-Shooting Guide
“Harmonics”, available from
for Low-Voltage ASD/Motor
www.reo.co.uk/knowledgebase.
Systems”, TR-11097, final report
[30] REO Guide on “Power Quality”, November 1998, free download:
available from www.reo.co.uk/ http://mydocs.epri.com/docs/
knowledgebase. public/TR-111097.pdf
[31] REO Guide on “Power Quality [37] K O Phipps, P F Keebler and
for Variable Speed Drives”, free R F Arritt, “Real World ASD
download from: www.reo.co.uk/ Interference Case Study with
knowledgebase Modeled Solutions”, IEEE 2009
62
and has written and presented a
great many papers and articles on
EMC. He is a past chairman of the
IEE’s Professional Group (E2) on
Electromagnetic Compatibility, is a
member of the IEEE’s EMC Society,
the EMC Test Labs Association [59],
the EMC Industries Association
(www.emcia.org), and chairs the
IEE’s Working Group on ‘EMC and
Functional Safety’.
Contact: Keith Armstrong by email at
[email protected]
or visit the Cherry Clough website
www.cherryclough.com.

Keith Armstrong from Cherry Clough

Consultants
Keith Armstrong graduated in
electrical engineering with a B.Sc
(Hons.) from Imperial College London
in 1972, majoring in analogue circuit
design and electromagnetic field
theory, with a Upper Second Class
Honours (Cum Laude). Much of his
life since then has involved controlling
real-life interference problems in
high-technology products, systems,
and installations, for a variety of
companies and organisations in a
range of industries.
Keith has been a Chartered Electrical
Engineer (UK) since 1978, a Group
1 European Engineer since 1988,