Edmund Wan

Electrimec Asia Pacific Pte Ltd

30 September 2019

27/09/2019 1c
 Power Quality Solutions

Agenda

 Introduction
 Capacitor Design
 Harmonics
 Power factor compensation
 Radio frequency interferences RFI
 Motor protection

27/09/2019 2
 Power Quality Solutions

Introduction

27/09/2019 3
Our History

1999 Terasaki subsidary in Singapore. Handle agency products from

Europe (Germany, France, Spain, Italy & Switzerland) and America.
Mainly export to S.E Asia countries.

1999 German brand with office in Berlin and office/manufacturing

facility in Wuxi, China. Manufacture LV, MV & HV Capacitor from
230V up to 550kV.
1991 Italian commercial brand with location, technical support and
EMC laboratory in Italy. The manufacture company of EMC filter,
high frequency inductance and harmonic filter for industry, military
and medical.
1992 EMC laboratory with anechoic chamber located in
Milan – Italy. Three mobile laboratory vans travel throughout
Europe.

2007 Worldwide commercial brand with locations, technical

support and Emc laboratories in United States, Germany and
Switzerland.

2011 Acquisition based merger with over 40 years experience in

safety transformers & electronic ignition systems
 FRANKE Capacitor Design

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 FRANKE Capacitor Design

27/09/2019 6
 FRANKE Capacitor Design

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 FRANKE Capacitor Design

27/09/2019 8
 FRANKE Capacitor Design

27/09/2019 9
Power Target Areas

Harmonics
PFC Motor Protection
Voltage stabilizers

Radio Frequency interferences

10
 Harmonics

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 Harmonics

• Voltage generators has sinusoidal shape

– V(t)=VM sin (2pft+F0)

• Linear loads give sinusoidal current:

– I(t)=(VM/R) sin (2pft+F0)
• R is the load resistance
V(t)=Vm sin (2pft + F0)

I(t)=(Vm/R ) sin (2pft + F0)

Harmonics

• When the load is nonlinear load the current has distortion, this means
current harmonics.
• The current is not sinusoidal

|V|

I
Fourier series

A generic periodical wave shape can be represented by a sum of

sinusoidal waves with frequency multiple of the fundamental

V, I 40, 000
v(t)=Vm sin (2pft + F0)

I1, I3, I5, i(t)=I0 + S Cn sin (nwt + Fn)

25, 000

I7 n from 1
10, 000

1 51 101 151 201

- 5, 000

- 20, 000

- 35, 000

- 50, 000
Harmonics

• Normally the power supplies don’t have an input transformer so the

loads is a high nonlinear load
• Typical diagram 6 poles drive input

L1
L2 Vdc
L3
Vac
Harmonics

• Number of harmonic generated:

– h=N p +/- 1
• h= number of harmonics
• N= progressive number starting from 1
• p= number of pulses per period equivalent to the
number of diodes

• Example:
– 3 phase drives means 6 diodes bridge
– p= 6
– h= (1x6)-1=5 5x50 = 250 Hz
– h= (1x6)+1=7
– h= (2x6)-1=11
– h= (2x6)+1=13
 Harmonics

(I22+ I32 + I42 + I52…+ In2

THD=
I1 n= typically up to 50

• THD Total Harmonic Distortion

•I1: fundemental current

27/09/2019 17
 Harmonics

(I22+ I32 + I42 + I52…+ In2

TDD=
Ir n= typically up to 50

• TDD Total Demand Distortion

•Ir: rated current or full load current
•Gives a better idea referring to the absolute value of the current
• THD and TDD are the same at the full load current
•Example:
• Full load current 100 A 100 A
• Instantenous current 20 A 50 A
• Current distorted 10 A 25 A
• THD around 50% 50 %
• TDD around 10 % 25 %
27/09/2019 18
Harmonics – The Problem

A non-linear electrical load creates distortion on the electrical current. This

results in harmonics on the power line.

19
Harmonics – The Problem

Can create high current on neutral line

Decrease motor and transformers life

Vibrations and mechanical stress

Resonance of Capacitor bank

Disturbances in other buildings

Generate Harmonics and RFI

20
 Harmonic Filters application

Three phase plus neutral single phase loads

single phase drives means 4 diodes bridge

p= 4
h= (1x4)-1=3 3x50 = 150 Hz
h= (1x4)+1=5
h= (2x4)-1= 7
h= (2x4)+1=9

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 Harmonic Filters application

Three phase plus neutral single phase loads

In this configuration the 3rd harmonic will sum in the neutral.
It means that I can have on the neutral 3 times the current harmonic that
is present on the phase
To solve this problem the active filter must have the possibility to
compensate on the neutral a current 3 times than on the phase

L1
L2
L3
N

Drive Drive Drive

Example 3rd harmonic

Will sum in the neutral line
Active
Filter

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Problems due to the Harmonics

• Motors:
– Vibrations and mechanical stress due to the
torque created by harmonic currents.
– Loss on iron increase so increase the temperature
and decrease the life
Problems due to the Harmonics

• The bank capacitor for PFC correction can have

resonance at the harmonic frequencies, in this case
the current on these capacitor can be very high and
can damage them
Problems due to the Harmonics

• Transformers:

– Distortion in current increases the loss in the

copper
– Distortion in voltage increases the loss in the
iron
– It means to increase the cost of energy
– Increasing the temperature and decrease the life
or it is necessary to design the transformer for
higher power
Problems due to the Harmonics

• Distribution on low voltage:

– Overloads due to peak current
– Create disturbance to other building
– Voltage distortion so the effect of current
distortion is increased
harmonics
harmonics
 Harmonics and RFI

• Harmonics :

L1
L2
L3
N

Drive Drive Drive

Harmonics current go always to the

lowest impedance.
PFC Typically at low frequency the lowest
Correction impedance is the transformer or the
capacitor bank, in any case is very
difficult that the impedance of one
machine or drive can be lower than the
network impedance. It means current
harmonics affect the network

27/09/2019 29
 Harmonics and RFI

• RFI:

L1
L2
L3
N

Drive Drive Drive

At high frequency the impedance of a

machine or the impedance of a drive
PFC
can be easily lower than the network
Correction impedance, it means RFI can affect also
other equiptments.

27/09/2019 30
Problems due to the Harmonics

• Standards

– EN61000-3-2 (up to 16 A)
– EN61000-3-12 (up to 75 A)

– IEEE 519 most common in this moment

– ER G5/4
 Problems due to the Harmonics

• Standards
– IEEE 519 limits

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FIN HRM

Passive Filter

• Based on LCL circuit

• Is in series to the load, so must be considered the total current
for the choose of the product
• Can achieve up to 5% THDi
• Best attenuation at full load, the attenuation is fixed and
normally can guarantee the TDD demand
• Can introduce drop voltage
• Cheaper solution
• Easy to install
FIN HRMA

Active Filter

- The active filter is an inverter, able to create the harmonic

current in opposite to the existing, so the result is a
compensation of the harmonic
- Same attenuation at different currents
- Can compensate reactive power
- Need normally a simple commissioning
FIN HRMA

Active Filter: principle of operation

240 100
240 100

80
180 80
180

60
60
120
120
40
40

60
20 60
20

Current (A)
Voltage (V)

0 0 V 0 0 I
-20 -20
-60 -60

-40 -40
-120 -120
-60 -60

-180 -180
-80 -80

-240 -100 -240 -100

Supply
LOAD

FIN HRMA
Harmonic Filters application

Passive filters:
normally used on the inverter, where the load is quite stable, in this
situation the passive filter is convenient

Passive Passive Passive

Filter Filter Filter

Inverter Inverter Inverter

36
Harmonic Filters application

Active filter:
in this application the use of an active filter is more convenient, the load
can change with the insertion of the machine. Normally in this application
the current is big but the THD don’t exceed 30%.
For example with a current of 1000 A could be enough a filter of 300 A.

Machine Machine Machine

Active
Filter

37
FINHRM Passive Filter

Series solution: The machine is

independent from the network
impedance. The results obtained at
the manufacturer will be the same at
the customer
THDi reduced up to 15%

june 2008 38
FIN HRM
FIN HRM5

FINHRM5: NEW Passive Filter

 Very low drop voltage

 THDi reduction less then 5% at full load
 TDD reduction less then 5% all over the current range
 Low capacitive power at no load (less then 20%)
 Connection in series and not in parallel so the attenuation
doesn’t depend from network impedance
 The series connection allows to protect the machine by
external harmonics
FIN HRM5

FIN HRM5 filters NEW SERIES

 Current: up to 750 A at the moment

 Open frame solution available
 690VAC series available soon
 50 and 60 Hz solution
 Application with the main drive manufacturers
 Competitive price
FIN HRM5

Typical 6 poles drive distortion

 FINHRM5

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 FINHRM5
380

380
310

310
360 360

155 185
115 Ø8 145 Ø8
H5R.080.060.1170 H5D.080.1170 THD reduced up to 5%
400 Vac-480 Vac (available 690 Vac)

260

260
50 or 60 Hz
5
Up to 750 A

120
135
FINC.0250.M
130 130
overload 150% for 60 s every 10
350
minutes
Reactive power less than 20% on no
load condition

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FIN HRMA

FINHRMA: Active Filter

- Digitally controlled generates current in opposition to the
harmonic currents
- Displays all the information (V, I, THD, Power, Power factor,
waveform of Voltage and current.

Current transformer

Supply
LOAD
FINHRMA New compact Active Filter

• modular system
• module 25 A, 50 A, 75 A, 100 A, 150 A
• Distortion correction ability: <5％ TDD
• rack and wall mounting
• Operation voltage: 400 , 480 and 690 Vac
• Frequency: 50Hz and 60 Hz
• Harmonic order: 2nd~50th
• Output ability: 100％,self-limited;
• IGBT Switch frequency: 20kHz
• Full response time: 10ms
• Display/interface: LCD
• Extension: up to 10 units in parallel
• 3 phase plus neutral product with compensation
on neutral 3 times than phase compensation
FINHRMA New compact Active Filter

• Remote control RS485 standard

• Modbus-Profibus optional
•external HMI in modular system
FRANKE Active Filter Application
FRANKE Active Filter Application
FRANKE Active Filter Application
 POWER FACTOR COMPENSATION

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PF Power Factor – The Problem

Large inductive loads cause low power factor.

Others devices with non-linear load : rectifiers, fluorescent lamps, electric

welding or arc furnaces create

Reactive
75kvar
Power

100kW
Real power used

𝑃,𝑟𝑒𝑎𝑙 𝑝𝑜𝑤𝑒𝑟
P𝑜𝑤𝑒𝑟 𝐹𝑎𝑐𝑡𝑜𝑟 𝑐𝑜𝑠Ɵ = 𝑆,𝑎𝑝𝑝𝑎𝑟𝑒𝑛𝑡 𝑝𝑜𝑤𝑒𝑟

52
PF Power Factor – The Problem

Very high cost of reactive power

Penalty and fee from utility company

PF in non linear loads create unbalanced power which

damages equipment

53
Static Var Generator

Reactive
Apparent power Power

Real power used Real power used

Supply
LOAD

Compensate current

FINSVG
Why improve your Power factor?

• Your utility bill will be smaller. Low power factor requires an increase
in the electric utility’s generation and transmission capacity to handle the
reactive power component caused by inductive loads. Utilities usually
charge a penalty fee.

• Your electrical system’s branch capacity will increase. Uncorrected

power factor will cause power losses in your distribution system. You may
experience voltage drops as power losses increase. Excessive voltage
drops can cause overheating and premature failure of motors and other
inductive equipment.
FINSVG Active VAR Generator

• modular system
• module 25 A, 50 A, 75 A, 100 A, 150 A
• Distortion correction ability: <5％ TDD
• rack and wall mounting
• Operation voltage: 400 , 480 and 690 Vac
• Frequency: 50Hz and 60 Hz
• Harmonic order: 2nd~50th
• Output ability: 100％,self-limited;
• IGBT Switch frequency: 20kHz
• Full response time: 10ms
• Display/interface: LCD
• Extension: up to 10 units in parallel
Capacitor bank VS Active Var Generator

Capacitor banks are typically grouped by switch. Output current Active VAR generator is controlled by a current transformer (CT)
is step style, which often leads to over/under compensation. thus obtaining compensation effect with the level of PF 0.99
Conventional compensation is 20ms Dynamic response time is less than 50uS – Total response time is
less than 15ms.
Reactive power is compensated mainly by SCR and capacitors. Filter does not require installation of a filter bank resulting in no
This system may be affected by harmonic resonance which concerns with resonant amplification
causes challenges and prematurely failure.
Only compensates inductive reactive power Compensates both inductive reactive power and capacitive
reactive power
Capacitors provide capacitive reactive power. The output of System is active; Voltage from the grid has little influence on the
reactive power is subject to the voltage of the grid. Reactive compensation capacity
compensation will be low if voltage is low; This causes
inadequate compensation
To have a better compensation, conventional capacitor banks The compensation capacity is the same as the installed capacity
require an installed capacity larger than required
 EMC
RFI NOISE
RFI FILTERS

27/09/2019 58
Interferences

Example

Electrical components inside a machine create disturbances at

high frequencies. These disturbances can affect other electrical
devices such as other machines, PC, telephone lines, FAX, etc.

59
Noise vs Frequency

Harmonics Various noise Electromagnetic Interference

disturbances
CISPR-16
IEEE-519 EN 61000-6-4
EN 61000-3-11 FCC-15

50-60Hz 3KHz 150KHz 30MHz

Sources of Disturbances

What can create disturbances:

Switched power supplies
Drives
Inverters
Soft starters
SCR
In general – any electrical device with high power commutation

61
Power drive system full concept scheme

L1 L2 L3
PWM

1500 V

500 V

200 ns
CE Compliance

In Europe, CE Compliance Is Not Optional

89/336/CEE Directive
Mandatory since January 1st 1996

2004/108/EC Directive
Mandatory since July 1st 2007

2014/30/EU Directive
Mandatory since July 20th 2016
CE Compliance

DIRECTIVE 2014/30/EU
Minimum requirements

1) Does Not Effect Other 2) Is Not Effected By Other

Machines Machines

EMISSIONS IMMUNITY
Standards

Why do we have standards?

To prevent problems of interference and allow compatibility in the
environment
What Standards do we use and where?
EUROPE: CE mark is mandatory, one of the directives regarding the CE
mark covers the EMC aspects, so it is mandatory for all the manufacturers to
comply with this directive, also for the US manufacturer that export in
Europe.
AUSTRALIA & NEW ZEALAND : EMC Directive as Europe with CE
Mark.
USA: The FCC standard part 15 has the same limits of European emission.
(Not mandatory).
JAPAN : EMC Directive as Europe with CE Mark with some restrictions.
CHINA : CCC Mark report 90% of the International Standard IEC included
the EMC Directive.
Emission

Conducted Emission

Required Instrumentation:
Receiver
Reference impedance: Line Impedance
Stabilization Network (L.I.S.N.)
Voltage probe (High current)
Emission (set up)

Conducted Emission – Less than 25 Amps

Network
E.U.T. L.I.S.N. Line

Voltage between Receiver

phase and the
reference (ground)
in the frequency
band from 150 KHz
up to 30 MHz
Emission (set up)

Conducted Emission – More than 25 Amps

Network
E.U.T.
Line

Probe

Voltage between
phase and the Receiver
reference (ground)
in the frequency
band from 150 KHz
up to 30 MHz
What does this disturbance look like?

Noise from a Variable Frequency Drive

* Note red limit lines
Filters

Filters attenuation

71
What does this disturbance look like?

Disturbance coming from a drive after installation of filter

Filters application

Where the filter is connected matters

Solution 1: Filter for each source

73
Filters application

Where the filter is connected matters

Solution 2: one single central filter (Enerdoor solution)

74
 CE Has More Than One Limit

What works for VFDs may not work for the panel!

RBW 9 kHz
MT 100 ms
Att 10 dB PREAMP OFF

dBµV 120 1 MHz 10 MHz

110
SGL
1 PK 618003QP
100
CLRWR

90

55011QP
80

70
PRN

60

6DB
50

40

30

20

10

150 kHz 30 MHz

Comment: Sample Company Model ABC SN:1234

Comment: Machine Cycling, Difference Between 61800 & 55011
Date: [Link].2012 [Link]
 Filters application

 Coupling on the measurement

L1
L2
L3

Filter
Measure here

Inverter

Motor Motor

settembre 2010
Filters

Advantages of central filter

•Less leakage current, less current to ground
•Less cost: one filter of 100 Amps is less expensive than 10
filters of 10 Amps
•Better results of measurement due to the better position of
the filters, means less problems due to coupling
•Requires less space in the panel.
•Reduced time for wiring multiple filters.
•Protect the entire panel (PLC, PC, other components inside
in the cabinet), not only the drives

77
Filters

Advantages of Enerdoor
5 Year Warranty
UL/CSA up to 600Vac for three-phase filter and three-phase
plus neutral
Only manufacturer with parallel filter for low frequency
attenuation.
Complies with UL508A.
25 years of experience dealing with EMC interference.
Can provide EMC and FCC testing of customers machine on-
site.

78
Filter Applications

Filters are not a cure all!

Grounding Practice
Length of Cable
Diameter of Cable
Bare Metal Contact
Cable Practices
Length of Cable
Shielded Cable
Grounding of Shielded Cable

79
 Grounding - Filter

Example: Original Configuration

Panel Layout
Test Results

80
 Grounding - Filter

Example: Shorter Ground Cable

Panel Layout
Test Results

81
Filter Installation

Motor cables should be separated from line filtered cables

L1 L2 L3

L1
L2
L3
YES Filter
Filter

0.5 – 0.6 m

Drive
Drive
NO

82
Filter Installation

Power cables radiate! Use shielded cable

< 0.3 V/m

0.5 V/m - 2 V/m

Filter
Filter

20 - 100 V/m SHIELDED

UN- Drive
SHIELDED CABLES
Drive
CABLES

200 - 300 V/m 10 - 20 V/m

Motor Motor

83
Filters application

Main switch

3 phase
series filter

PLC

Servodrives / VDF
 Filters application

Main switch

3-phase
parallel filter
3 phase
series filter

Servodrives

Servodrives
PLC

Servomotors Servomotors
Filters application

Main switch

3-phase parallel
filter

Servodrives 30Amps
PLC

3 phase
series
filter

Motors pump 100Amps Servomotors

Filters application

Main switch

3 phase series filter

Spindle and Servodrives

PLC Energy line reactor

3-phase
parallel filter Servomotors
EMI Solution

FIN538S1
FIN230SP FIN1500 FIN3755
FIN730 FIN1900 FIN1740ESM
FIN1240
 Three Phase Filter – Parallel Filter

Application

L1
L2 Filter
L3

Parallel High attenuation in the low

Inverter Inverter Inverter frequency band 30 kHz – 5 MHz,
Filter
Normally this range of frequency
can be reduced by the series filter
but at high noises generated by the
servodrive, the parallel filter can
help to reduce the disturbances in
this band.

Motor Motor Motor

june 2008 89
Three Phase Filter – Parallel Filter

FIN130SP – FIN230SP – FIN730 – FIN740 Independent of the current, the

customer can use the same model
for different current rating.
DIN RAIL mounting
The competitors don’t have a
similar product
Economical, especially when the
current is high
UL approved UL (also for Canada)
FIN740: 3 phase with neutral
application

90
 Three Phase Filter – Parallel Filter

Application In this example the parallel filter helps

to reduce the disturbance in the band
which can create problems of
L1
Filter coupling. The big advantage is that we
L2
don’t have to use a large filter on the
L3 30 A mains: the parallel filter is independent
of the current. Voltage specific only up
to 600Vac
Parallel
Filter

Inverter Inverter Inverter

10 A 10 A 10 A

Motor
100A
Motor Motor Motor

91
Single Phase Filter

FIN26 Nominal Voltage 0 – 250 Vac

Terminal blocks connection
DIN Rail mounting
UL approved (also for Canada)
Short circuit test passed
Current from 3 to 20 Amps in the same
mechanical dimensions
Stainless steel box

june 2008 92
Three Phase Filter (FIN538S1)

Voltage 600 Vac

7 to 3000 Amps
Terminal blocks, screws and bus bar
connections, book style
Medium leakage current (less then 15
mA in standard condition)
Regenerating systems
Very good compromise cost /quality
General purpose: good results with
different types of drive manufacturer
UL approved at 600 Vac also for
Canada (S.C.C.R. on label)

93
Three Phase + Neutral Filter (FIN1740ESM)

Voltage 500 Vac

Current 5 to 180 Amps
Terminal blocks connection
Very low leakage current (less then
15 mA in worst condition
Compact style
Application: textile machine,
packaging machine,
UL approved also for Canada
(S.C.C.R. on label)
Low cost solution

94
 EMC
RFI NOISE
MOTOR PROTECTION

27/09/2019 95
Power Target Areas

Harmonics
PFC Motor Protection
Voltage
stabilizeers

Radio Frtequency interferences

96
Motor Protection

How does motor protection help?

Motor Protection Reduces:

Premature Bearing Failure

Winding Insulation Failure

Energy Loss (temperature)

Downtime Production

Loss of Precision

97
Solutions

• Output reactor
• Sine wave filter
• Snubber
• High frequency inductance
Output reactors

Application Chokes can be used to reduce overvoltage

at the output of the drive
Filter Common mode: often used in
combination with shielded cables.
Does not add voltage drop
Drive Differential mode: used to separate
the drive from multiple motors or long
cable runs.
Choke
Reducing overvoltage increases the life of
the insulation in the motor

Without choke

Motor With choke and

shielded cable
Output reactors

Voltage 500 Vac

Current 5 to 300 Amps
Terminal blocks connection
50 and 60 Hz motor frequency
long motor cables application

100
Sinus filter

Application Sinus filter converts the PWM output

signal into a sinusoidal wave with residual
Filter < 5%
No overvoltage transient occurring at
the motor winding
Drive Low motor noise due to low presence
of harmonics
No need for motor shielding power
cables
EMC testing, conducted and radiated
emission
Sinus filter

Motor
Motor Protection – How Does it Work

Measurement between VFD and motor without filtering

Measurement between VFD and motor with load reactor

Measurement between VFD and motor with sine wave filter

*Grid Power Typical

Best for Motors

102
 Sinus filters

FIN905SF up to 690 Vac available

up to 880 A
available also with high frequency
material (FIN915SFH)
VERY COMPETITIVE

103
Motor protection Solution

Snubber reduces dV/dt spikes, improving motor life and reducing stress to
the components.

Application Example of spikes reduction

2500

2000

Voltage
1500
Drive Motor
1000
No snubber
Snubber 500 Enerdoor snubber
0
0 400 800 800
(L-PE) (L-PE) (L-PE) (N-PE)
Speed
Solutions - Snubber

No snubber filter
Max: 1104 V
Min: -480 V
dv/dt: ~ 3.04 kV/us

With snubber filter

Max: 800 V
Min: -176 V
dv/dt: ~ 1.93 kV/us

105
Motor protection

No choke or wrong material

Initial condition

27/09/2019 06-2014 Meeting Agenti 106

Motor protection

FIN960F with snubber

27/09/2019 06-2014 Meeting Agenti 107

Solutions - Snubber

Connects in Parallel to the motor cable

Reduce overvoltage spikes

Work in differential mode and common

mode noise

108
Solutions - Snubber

Connection on star point available

Work in differential mode and common

mode noise

109
 High frequency reactors

FIN960F Motor frequency up to 3 KHz

PWM frequency up to 30 KHz
Application with synchronous
electropindle
Very different models custom made
Very low heating
very high linearity in current and
frequency

110
 High frequency reactors
Setup
2ft 20ft

Load
Reactor

High Frequency Rated Motor

Transformer High Frequency VFD (HP? details)
480Vac 3-phase (Freq range? Details)

PRODUCT A PRODUCT B
3-phase high frequency
3-phase load reactor load reactor
V = 480Vac V = 480Vac
L = 2.4mH L = 2.4mH
I = 25 A I = 25 A
Core Material: Core Material:
Iron laminate high frequency material
 LABORATORY TEST

Temperature Testing
• Wire Temperature
• Laminate Temperature

Laminated Inductor & High Frequency Inductor at 300Hz

Note: Ambient Temperature =

73ºF
112
 THANK YOU

27/09/2019 113