Challenges of EMC Compliance

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 Challenges of EMC Compliance

TABLE OF CONTENTS
EMC Defined 2

The Importance of EMC 2

Power Line Filter as One Solution 2

Choosing a Filter 3

Estimation of Filter Attenuation (Insertion Loss) 3

Real Testing Examples 4

Successful Ground Connections 5

Cabinet Before Redesign: Power & Data Cables 5

How Slight Changes Can Affect Emission Levels 6

Good and Bad Installation Practices 7

Final Thoughts 8

Copyright © 2022 Schaffner EMC Inc.

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 Challenges of EMC Compliance
CHALLENGES OF EMC COMPLIANCE
EMC Defined
EMC, or electromagnetic compatibility, is defined as the
ability of equipment or a system to function in a particular
environment. A piece of equipment must not interfere with
neighboring pieces of equipment, and nearby equipment
must not interfere with it.
You may see EMC also referred to in any of the following
terms:
• EMC Compliance
• Electromagnetic Compliance
• Radio Frequency Interference (RFI)
• Electromagnetic Interference (EMI)
In a military environment, you may also see it called
Electromagnetic Environmental Effects (E3), Electromagnetic
Emissions (EME), or Electromagnetic Susceptibility (EMS).
The Importance of EMC
It cannot be denied that in today’s world, there is an in-
creased dependency on our electronics. Therefore, it’s more
important than ever to ensure the electronics we rely on,
work as intended.
Because of the sheer number of electronics in regular use
at any given time, the chances of interference also increase.
Interference can fall into one of several types:
• Natural – Cosmic or weather-related such as solar
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flares or lightning
• Intentional – TV and radio broadcasts, telephones,
radio transceivers, radar
• Unintentional – Generators, power tools, industrial
(such as motors or drives), consumer electronics
(computers, appliances)
Typically, it’s the unintentional EMC which causes the most
problems. If a problem with another electronic device occurs,
it’s difficult to determine the cause, as there is no obvious
source. It’s essential to consider EMC in systems and installa-
tions for several key reasons:
• Reduce the risks of interference to the other systems
• Fulfill regulations around the world, (ie: the CE mark
in Europe, the FCC in America, the VCCI in Japan)
• A good solid system improves the reliability, safety,
and quality of operation
• Ensure equipment will work as intended and does
not pose risks of damage to neighboring equipment
or people
Power Line Filter as One Solution
In simplistic terms, the filter helps ensure compliance by
blocking the noise from a particular device, keeping it from
getting back onto the power grid or a neighboring piece
of equipment. They also work in reverse by improving
immunity; any noise that’s already on that power grid can be
mitigated, allowing the equipment to function as intended.
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 Challenges of EMC Compliance

Fig. 1 – Filters assure compliance by blocking or redirecting noise back to the source, allowing product to comply with regulations and function as intended.

through with the filter is compared to the unfiltered signal.

Choosing a Filter As a standard, the filters are measured according to CISPR17
The most important factors for choosing a filter are as follows: with an impedance of 50 Ohms. This should be kept in mind
when applying to real-world scenarios.
Electrical Parameters
• Attenuation performance – How much attenuation
are you going to get at a particular frequency?
• Rated current – Must be observed due to safety.
Also need to ensure the filter doesn’t get too hot
and lose all its performance characteristics.
• Maximum voltage – Again, due to safety, a filter
must be rated for the voltage that is expected in
your design.
• Grid/Line Frequency – 50 Hz, 60 Hz, 400 Hz, etc.?
• Leakage current – This factor is especially important
in military and medical applications.

Installation Parameters
• Mounting form – Any mounting form or function,
the shape of the filter, etc.
• Terminal type – How to connect the filter to the
piece of equipment. Ensure the terminal is large
enough to accept mating wires and not cause
excess heating. Fig. 2 –
• Environmental condition – Do any environmental • Curve A shows the symmetrical (differential-mode) attenuation
conditions need to be met? • Curve B shows the asymmetrical (common-mode) attenuatio
• Protection category
• Standards and Approvals – What kind of safety In the Fig. 2 example, note the frequencies from 10 kHz to 30
standards and approvals must be met to comply MHz across the X axis, and the decibels or dB of attenuation
with end product safety regulations? that can be expected at that frequency on the Y axis. 100
kHz would result in about 60 dB of attenuation for common-
mode noise, and around 43 dB of attenuation for differential-
Estimation of Filter Attenuation (Insertion Loss) mode noise.
Insertion loss, or attenuation, is one of the key functions of
the filter. To determine the attenuation curve (Fig. 2), a known To put this information into practice, let’s look at a typical
signal is put through the filter; how much of the signal gets emission profile for a piece of equipment (Fig. 3).

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 Challenges of EMC Compliance

Capacitors from line to ground provide a path for energy

to flow back to the noise source. If there is impedance in
that ground or the flow of energy is restricted, the filter
performance will be greatly affected. A resistance, or more
appropriately an impedance measurement, at 1MHz will be
much higher than at 1kHz.

The first example is a setup with a 30 cm long ground lead

tied to the filter (Fig. 5).

Fig. 3 – Typical emission profile and need for filter: Reduction of the conducted
emissions to comply with EMC standards.

The traces in this particular case, shown in blue and purple,

show average and quasi-peak conducted emissions of an
unfiltered application. These traces must be under the limit
lines of the given specification. In this case, the limit lines are
the pink and red lines, starting out slanted at 68 to 58 dBuV.

In the example above, about 60 dB of attenuation is needed

at 300 kHz. Therefore, the filter needed must provide more
than 60 dB of attenuation. Theoretically, simply installing
the filter represented in Fig. 2 would allow for a passing test
grade – see Fig. 4 below.
Fig. 5 – Filter with long ground connection (30 cm)

In this case, the scan is from about 150 kHz to 30 MHz; around
1 MHz it goes above the limit line, then begins to tail off again.

But keeping an eye on 1 MHz to about 10 MHz, if the ground

wire is reduced from 30 cm of the filter to 5 cm (Fig. 6), there
is a decrease in the emissions.

Fig. 4 – Emission profile with filter installed, displaying reduced emissions.

Unfortunately, real world scenarios do not always work out

so easily – let’s look at a few examples.

Real Testing Examples

This particular case looks at how the grounding of the filter
is affected. Grounding is one of the key aspects both of how Fig. 6 – Filter with short ground connection (5 cm)
the filter performs, and of the overall system, especially for
common-mode attenuation. Everything else in the system has stayed the same, and it

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 Challenges of EMC Compliance

is operating the same. All wires and grounds to the system Of course, the filter cannot always be bonded directly to
itself have been maintained. The only change is the actual the housing. What can be done in this situation for high
grounding of that filter. frequency and impedance?

To improve this even further, the metal housing of the filter A ground wire such as a 14-gauge or 12-gauge will not work
can be bonded to the metal enclosure, which will achieve an as well, especially if it is long, so the solution is a ground braid
additional reduction in emission levels (Fig. 7). (Fig. 9). A ground braid provides a large surface area, allowing
for more efficient high frequency connection.

Fig. 9 – Ground connection with braids

Basic design rules for ground braids are as follows:

• Maximum 5:1 for the length-to-width ratio

• Keep in mind routing of wire and its proximity to
Fig. 7 – Filter with proper ground connection
other conductors/components – this energy is
traveling on the wires and ground braids, and can
The first example achieved about 10 dB additional
still couple onto nearby components.
attenuation; the additional ground achieved another 5 for a
• If the ground braid is taken to a ground bar or a bus
total of 15 dB attenuation. All that needed to happen was an
bar, the bus bar must also be properly grounded;
improvement of the ground of the filter.
it should not just be grounded by screws into the
metal housing.
Successful Ground Connections • Just as with a wire, with a screw it’s the outer surface
area that’s conducting, which limits how much
To ground a filter, ideally the paint or lacquer should be ground effect is obtained through that system.
removed, and the metal housing should be bonded to the
metal enclosure (Fig. 8).
Cabinet Before Redesign: Power & Data Cables
Now let’s look more at wires and how they can radiate
internal to the system, as shown in Fig. 10.

Fig. 8 – Grounding connections of filters

This also goes to whatever device is making the noise. For

example, the drive should be mounted to the metal housing
as well – remember, it’s all about the return path of the noise.
If one element of that return path is interrupted, the proper
setup of one area will be defeated by the lack of grounding
in another area. Fig. 10

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 Challenges of EMC Compliance

This example is on the more extreme end, with wires running

and crossing in multiple places as well as improper routing,
but it gives a good idea of what can be expected if one can
control and route the wires effectively for EMC management.

First, let’s look at the conducted emissions with just the

system in general – this is with no filter and wires running all
over the place (Fig. 11).

Fig. 13A Fig. 13B

Cabinet After Redesign

Note the lower right-hand corner of Fig. 13B. If wires must

be crossed, they should be crossed perpendicular to one
another. Running them perpendicular as opposed to parallel
means they cannot couple as easily.

Fig. 14 shows the measurement result post-redesign, with

everything else in the system remaining the same. With the
Fig. 11 – Original cabling, measurement without filter improved wire routing, the system achieves a passing result.

Once a filter is put in, there is a slight reduction, but emission

levels are still over the limit lines (Fig. 12). This is because the
energy is bypassing the filter, the system design has limited
how much the filter can affect the emission results.

Fig. 14 – Redesign, measurement with filter

How Slight Changes Can Affect Emission Levels

Fig. 12 – Original wiring, measurement with filter
The next step is to re-route the power lines, signal lines and
ground wires appropriately, limiting the coupling that can
occur (Figures 13A and 13B).
Even minor changes can make the difference between failing
or passing results. Next we will evaluate what happens to
different filters used in different applications.
The first example is a motor drive with a 20m output cable,
using a Schaffner FN258 filter (Fig. 15).

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 Challenges of EMC Compliance

Another variation that effects emissions is to use a different

filter. If we look at the same system again – the motor drive
with the 20m output cable (Fig. 16) – but this time change the
filter to a low leakage version with reduced capacitance-to-
ground, the emission level is also going to change (Fig. 17).

Fig. 15 – FN258 used on drive with 20m output cable

Using the exact same filter and the exact same operating
conditions, but increasing the cable to a 100m cable (Fig. 16),
the emission levels increase – particularly from 150 kHz to
around 300 kHz.
Fig.17 – FN258P (only change is Y cap from 2.2uF to 0.22uF) Same drive with
same 20 meter cable

Keep in mind that since one of the return paths for the com-
mon-mode noise is through those capacitors-to-ground, if
the amount of capacitance-to-ground is limited, other com-
ponents in the filter must be able to compensate effective-
ly. This is especially important for medical and military ap-
plications, where capacitance to ground is typically limited.
A higher inductance or multistage filter can be used as an
alternative to still provide the required attenuation.

Good and Bad Installation Practices

Finally, we’ll examine a few simple examples of good and bad
installation practices, starting with an incorrect installation
shown in Fig. 18.

Fig. 16 – FN258 used on same drive with output cable increased from 20 meters
to 100 meters

These significant differences mean the engineer must always

bear in mind worst-case operating conditions, whether it’s
no load, full load, small cable, long cable, etc. These possible
variations must be taken into consideration when working
to optimize the required filter performance. Using shielded
output cable can also help reduce emissions. Fig. 18 – Filter Position in Standard Equipment, Incorrect

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 Challenges of EMC Compliance
The filter should be placed in the optimum position for the
system.
In this case, a PCB is creating noise and radiating. The filter
itself is at the lower right-hand side, but to get there, the
wires have to run back across the PCB. This means not only
filtering the energy originally on the wires, but now filtering
additional energy that’s coupling to those wires.
The ideal placement for the filter is in the upper left-hand
location (Fig. 19), as close as possible to the AC connection.
This way, the only noise being filtered is that which is on the
wires themselves, eliminating the additional noise coupling
to the wires and allowing for a smaller filter to be used.
Fig. 19 – Filter Position in Standard Equipment, Correct
Similarly, if working with a control panel or a big cabinet, the
filter must be placed in a position where the noise cannot
find an alternative path to escape. In the example shown
below (Fig. 20), the filter is effectively filtering the noise, but
the noise is finding a radiating path and coupling onto the
wire exiting the unit, ultimately negating the filter’s work.
Fig. 20 – Filter Position in Control Panels, Incorrect
The best installation in this case is to take the power straight
from the top (Fig. 21).
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Fig. 21 – Filter Position in Control Panels, Correct
Final Thoughts
The use of a filter is just one way to help mitigate your
emission levels but an effective way and typically a very
cost-effective way. There are many other topics and things
to consider regarding EMC design, which we will touch on in
future discussions.
It can be difficult to convince management to spend money
that they may not easily see return for, but achieving
compliance will be substantially easier with more evaluation
and mitigation components designed early into the
development process. For example, it is much easier to
change a PCB or a layout on a computer than it is to change
on a completed production unit. Or allocate room for a filter
than trying to move everything around later.
Testing during development and during pre-compliance
will make final compliance testing go much more easily and
quickly, and will prevent stress and headaches later on in the
application.
If you need assistance, Schaffner can provide off the shelf
EMC filter solutions as well as support with EMC layout from
the early stages of new product ideas or designs. Schaffner
can also offer custom made solutions to help manufacturers
meet any unique electrical, mechanical or EMC challenge.
Contact your nearest Schaffner representative for assistance.
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