ITG Electronics, Inc.
Mitigating EMI Problems
&
Filter Selection
By
Rafik Stepanian
Engineering Electronic Partnerships since 1963 www.ITG-Electronics.com
ITG Electronics, Inc.
EMI Noise Generators
A change of state (On/Off ) in an Electronic component has the potential to
generate EMI. Typical examples are Electronic Switchers, Clocks, Electronic
controls, Power Supplies, Inverters, Fluorescent lights, Motor Brushes, etc.”
EMI noise could;
Conduct through the power lines and it could be;
Common Mode, between Line or Neutral to Ground
Differential Mode, between Line and Neutral
Radiate through Air
Engineering Electronic Partnerships since 1963 www.ITG-Electronics.com
ITG Electronics, Inc.
Curtesy of EMC consultant, France
Engineering Electronic Partnerships since 1963 www.ITG-Electronics.com
ITG Electronics, Inc.
How to mitigate EMI?
EMI is known as “Black Magic”. No one wants to deal with it because it
has no perceived market value, it is an economical burden which is ignored
until one starts reading the paragraphs in fine print which reads;
“The system must meet the
EMI requirements of …”
Which means it is
“TIME FOR 911 CALL”
Most of the times the engineer is in a lab and the unit failed EMI test
and the most common question is
“Do you have a filter which passes MIL-STD-461 or …”
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ITG Electronics, Inc.
MIL-STD’s and EN’s Provide:
EMI limits
Detail test methods
Test procedures
Test apparatus
What they don’t or can’t provide obviously is how much noise the DUT generates
EMI filters are application specific and they provide:
“X” dB at certain frequency
Off the shelf (OTS) filters are designed to attenuate CM noise above 150KHz for commercial
applications
The OTS filters are not suitable for most military applications because the EMI test frequency
starts at 10KHz
CM components have little effective below 100KHz, therefore DM components are necessary to
suppress the lower frequency noise
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ITG Electronics, Inc.
TYPICA EMI FILTERS
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ITG Electronics, Inc
Power Line Filters Components
Common Mode Coil Differential Mode Coil
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ITG Electronics, Inc
“X”, “Y” or By-Pass Capacitors “F/T” Capacitor
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ITG Electronics, Inc.
Following are the minimum information required to
start a filter design/selection
Filter application Military, industrial or Commercial
Voltage rating, DC or AC
Power line frequency, 50/60/400Hz
Current rating
Leakage current
Single or three phase
Three phase Delta or WYE
Required attenuation (dB VS frequency)
Or results from EMI test w/o a filter installed
Available volume
Mounting means
Termination (fast-on, screw, Mil connectors, etc.)
Environmental requirements
Engineering Electronic Partnerships since 1963 www.ITG-Electronics.com
ITG Electronics, Inc.
Things to know when choosing an EMI filter
1. In commercial world the conducted emissions measurement starts from 150KHz to
30MHz, the radiated Emissions starts from 30MHz to 300KHz, and up.
2. In military world the conducted emissions measurement starts from 10KHz to
10MHz, the radiated Emissions starts from 10MHz to 1GHz and up.
3. Whether in an EMI lab or in house performing EMI test if you are lucky the DUT
will pass, but if it fails save/print the results.
4. Perform a Common Mode noise test save/print the results.
5. Record the failed frequency starting from the lowest frequency and corresponding
dB values above the limit line.
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ITG Electronics, Inc.
Continued;
6. If the failed frequencies are at 150KHz and up you may start with a simple LC or PI
configuration filter.
7. Use the recorded data dB Vs frequency and compare with data sheets provided by filter
manufacturer and choose a filter and repeat EMI test.
8. If EMI test results are better but not quite there yet, what you need to know is each filter
component in theory provide:
6dB additional attenuation when its value is doubled
6dB less attenuation when its value is cut in half
6dB additional attenuation per octave (every time the frequency is doubled)
20dB additional attenuation per decade (every time the frequency is multiplied by 10)
Additional component increases the filters attenuation by 20 dB
Note: you may use the above during system simulation.
Engineering Electronic Partnerships since 1963 www.ITG-Electronics.com
ITG Electronics, Inc.
Typical filter circuit and it’s attenuation response in ideal situation
6dB attenuation per Octave 20dB attenuation per Decade
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ITG Electronics, Inc.
2L 6dB more attenuation 1/2L, 6dB less attenuation
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ITG Electronics, Inc.
2xL & 2xC, 12dB more attenuation 1/2xL 1/2xC, 6dB less attenuation
Engineering Electronic Partnerships since 1963 www.ITG-Electronics.com
ITG Electronics, Inc.
Case Study
EMI Filter Design based on EMI test results
480VAC 60Hz 200A Inverter
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ITG Electronics, Inc.
MIL STD-461, CE102 test results without EMI filter
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ITG Electronics, Inc.
Initial open frame prototype
500uH 10uF 500uH 10uF 0.01uF
Phase A Phase A
Phase B Phase B
INPUT OUTPUT
Phase C Phase C
Case GND
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ITG Electronics, Inc.
MIL STD-461, CE102 test results with prototype filter
Engineering Electronic Partnerships since 1963 www.ITG-Electronics.com
ITG Electronics, Inc.
750uH 20uF 750uH 20uF 0.01uF
Phase A Phase A
Phase B Phase B
INPUT OUTPUT
Phase C Phase C
Case GND
Engineering Electronic Partnerships since 1963 www.ITG-Electronics.com
ITG Electronics, Inc.
MIL STD-461, CE102 test results with final EMI filter installation
Engineering Electronic Partnerships since 1963 www.ITG-Electronics.com
ITG Electronics, Inc.
Does and don’ts during electronic design
Where possible:
Use multilayer PCB design with ground planes in between layers
Short traces where possible to reduce antenna affect
Place noisy components in one area
Avoid sharp (90 degree) trace bends, round off the trace edges and corners
Use wire harness
Separate noisy cables from power line cables
If using shielded cables connect shield to ground at least one end
Do not daisy chain ground wires, have one common ground and ground wires as short as
possible
Use shielding material around the covers and doors
Make sure areas where shielded materials are used are not painted
Read fine prints on your spec and if there is an EMI requirements make sure to leave
space for an EMI filter.
Perform EMI test during prototype design phase
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ITG Electronics, Inc.
Military and Commercial EMI test are performed in a 50 ohms system using LISN’s (Line Impedance
Stabilization Network)
Conducted emissions testing is performed on power cables entering the equipment. The reason is to
prevent EMI noise generated by electronics switches is contained in the chassis and will not transmit
through the power cables and adversely effect the performance of other equipment connected to the
same power line
Military and commercial EMI spec provide limits and test procedures not solution guide lines
If emissions measured exceeds the allowable limits EMI filters are required
EMI Filters are bi-directional and they mitigate conducted emissions. They are most effective at lower
frequencies and their harmonics at higher frequency spectrum
To enhance the performance of the EMI filters they should be installed at the power line entering the
equipment, preferably input terminals protruding out of the enclosure isolated from filter output
terminals
The isolation will prevent cross talk between input (dirty) and output (clean) terminals and will
positively effects the radiated emissions test results
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ITG Electronics, Inc.
1. While in the EMI lab doing EMI test if the product fails, the very first thing to do is print
the results.
2. Perform a Common Mode noise test (most labs know how to perform this test) and print
the results.
3. Write down the failed frequency and corresponding dB margin above the limit line.
4. In the commercial world the conducted emissions measurement starts from 150KHz to
30MHz, the radiated Emissions starts from 30MHz to 300KHz, or 1GHz depending on the
product under test.
5. In the military world the conducted emissions measurement starts from 10KHz to 10MHz,
the radiated Emissions starts from 10MHz to 1GHz and up depending on the product
under test.
6. If the failed frequencies are at 150KHz and up you may start with a simple LC filter. Here
is what you need to know, every element initially provides 6dB attenuation, an LC filter
will provide total 12db attenuation above the cut off frequency. If the L or C or both
component values are doubled, each will provide 6dB additional attenuation per element.
7. Each filter component element provides:
a) 6dB attenuation per octave (every time the frequency is doubled)
b) 20dB attenuation per decade (every time the frequency is multiplied by 10)
c) 6dB attenuation when the value of a component is doubled
d) 6dB less attenuation when the value of a component is cut in half
e) Additional component adds 20dB attenuation
Engineering Electronic Partnerships since 1963 www.ITG-Electronics.com
ITG Electronics, Inc.
Conclusion
The EMI solution once designed will work for years, as long as the filter
components are properly selected for voltage fluctuation and maximum operating
current and environmental requirements. EMI solutions do not need regularly
scheduled maintenance. What is important is the manufacturing consistency of
the system the EMI solutions are designed for. Any changes no matter how
insignificant the they are it is recommended to repeat EMI test to prevent future
costly field recalls because of EMI failure. As you can see EMI solution is not
“Black Magic” it is based on a technology from past, which is reliable and most
importantly it still works
Engineering Electronic Partnerships since 1963 www.ITG-Electronics.com
ITG Electronics, Inc.
Cost of Incorporating EMI solution
Engineering Electronic Partnerships since 1963 www.ITG-Electronics.com
ITG Electronics, Inc.
Worldwide Support Team:
We work closely with customers on new design activity as well as
supplies and demand management.
Inventory in LA, Elmsford NY, Hong Kong and Shanghai, China to
support regional demand.
Our global help hotline:
USA: 1-914-347-2474 (NY Office)
USA: 1-914-806-8063 (PA Office)
Japan: 81-568-85-2830
Taipei: 886-2-2698-8669
Kaohsiung: 886-7-350-2275
Hong Kong: 852-9688-9767
ShenZhen: 86-755-8418-6263
Shanghai: 86-21-5424-5141
E-mail:
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