High Frequency Electromagnetic Noise of Modern PWM Adjustable Speed Drives 2014-09-16 (Final) MF

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Harmonic and Energy Saving Solutions
High Frequency Electromagnetic Noise of
Modern PWM Adjustable Speed Drives
Marek Farbis
Private and Confidential | Mirus International
Scope of Presentation
EMI Emissions
PWM Adjustable Speed Drives
Problems Associated with PWM Inverter Operation
Long leads/cables
Overvoltage at motor terminals and reflective wave phenomenon
Motor Anti-resonance issue
Common-mode voltage issues, shaft voltage and bearing
currents
Output Filters for AC Adjustable Speed Drives
Summary
The Federal Communications Commission (FCC)
regulates the use of radio frequencies from 9 kHz to
3000 GHz (FCC Part 15)
Any electronic system with digital circuits using clock
signals or other signals over 9 kHz must comply with
the FCC limits for radiated and conducted emissions
FCC Part 15 regulations on allowable EMI emissions
became Defacto Standard for all SMPS (Switch Mode
Power Supply) manufacturers
There is no North American EMI standard for
Adjustable Speed Drives
Only CE standards cover ASDs

EMI Emissions
Common Mode (CM) noise is a type of EMI noise
introduced on signals with respect to a reference
ground
Common Mode noise problems
Source of noise
Means of coupling noise, by conduction or radiation
Circuits / Equipment susceptible to the magnitude,
frequency, and repetition rate of the noise impressed
CM noise issues increase with susceptible
equipment present, high system-input voltage,
large quantity of ASD, and long length of motor
leads, also ground system and layout
2014 Mirus International | All Rights Reserved
What is Common Mode noise?
Applications with potential EMI issues
Higher system AC line voltages have higher DC
bus voltages (V DC bus)
Higher output switching dV/dt (change of voltage
with time) increases peak Common-Mode ground
current, =

Increasing drive quantity increases sum total of
transient CM noise current to ground
Higher drive carrier frequency (f
c
) increases the
number of switch transitions and sum total of CM
noise current
Risk factors
Motor cable lengths < 20 ft (6.1m) exhibit low cable
line-to-ground capacitance and low Common-Mode
risk from capacitive dV/dt ground currents
As cable lengths increase, cable capacitance
increases and CM charging current to ground
increases
At long cable lengths, the high frequency
oscillations of reflected wave voltage transients (~
2 x VDC bus) also appear on motor terminals, to
create CM ground noise current through the stator
winding and cable capacitance
Risk factors cntd.
PWM Adjustable Speed Drives
Conventional ASD System
M
Utilize Pulse Width Modulation (PWM)
Inverters with high frequency switching of
Insulated Gate Bipolar Transistors (IGBTs)
2 to 8 kHz switching frequencies typical,
Voltage rise time (dV/dt) rates of 6,000 V/s typical,
(dV/dt of up to 20kV/s is possible).
Motors are designed to withstand stress of
1,000V/ s.
ASD Inverters and Generation of EMI
Reference: An Evaluation of Mitigation Techniques for Bearing Currents, EMI and Overvoltages in ASD Applications, IEEE IA Vol. 34, No.5 Sept/Oct. 1998
200 HP ASD Normal Output Waveforms
2 ms/Div
ASD Normal Mode Output Voltage:
Typical PWM for 600V inverter at 2 kHz
Voltage rise time ratio (dV/dt) = 4,400 V/s
Peak voltage = 853 V (603V AC supply)
Pulse rise and fall time between pulses
V
DC_bus
pulse width (T)
t
rise
t
fall
f
c
f
n
= 1 / ( * t
rise
)

V
U-V
dV / dt magnitude (~ V
DC_bus
/ t
rise
)
Simplified drive-conduit-motor system
ASD phase current
- Fundamental sinewave
- Ripple current
- Line-to-line cable charge current due to dV/dt (I_ll)
- Line-to-ground transient current due to dV/dt (I_lg)
Transient line-to-line cable charge current (I_ll) is
determined by the DC bus voltage magnitude and surge
impedance of the cable parameters
Cable resistance (R_01)
Self inductance (L_01)
Line-to-line capacitance (C_ll)
R_02
L_02
I_ll is confined to the drive terminals and cable loop area
I_ll does not interfere with other plant equipment,
interference possible only by radiated noise from the power
leads
I_ll may reach 12 Amps peak and become problems for
small HP drives and current sensors used within them
Transient line-to-line cable charge current
Transient line-to-ground current (I_lg) is determined by the
DC bus voltage magnitude and surge impedance of the
cable parameters
Cable resistance (R_01)
Self inductance (L_01)
Line-to-ground wire (PE) capacitance (C_lg)
Line-to-conduit ground capacitance (C_lg-c)
Motor stator winding capacitance to ground (C_lg-m)
I_lg is sourced from to the drive output terminals, but does
not have a return path directly back to the output terminals
I_lg can interfere with other plant equipment referenced to
ground
I_lg is Common-mode or zero-sequence current
I_lg may reach 20 Amps peak and is a predominant EMI
problems generator
Transient line-to-ground current
Common-Mode Noise Current Path in a
Solidly Grounded ASD System
I
lg
~(C
lg-c
+ C
lg-m
)*(dv/dt)

Noise source
I_lg magnitudes are highest for:
ASDs with long output cables (C_lg-c is greater)
High HP ASDs with higher motor capacitance (C_lg-m is
greater)
ASDs with faster output voltage rise times (dV/dt is greater)
ASDs with higher system voltages (dV/dt is greater)
RMS magnitude of I_lg CM noise current increases
with higher carrier frequency, since repetition rate is
faster
Higher quantities of ASD may increase the RMS
magnitude of CM noise and EMI, due to increased I_lg
in the ground circuit
I_lg current returns to ASD through lower impedance
path at the I_lg transient oscillation frequency
Induced line-to-gnd CM current
ASD PWM Inverter
Inverter zero-sequence switching pattern
and Common-Mode Voltage generation
Switching state 1
GND
Vdc/2
Vdc/2
V(N-GND) = - Vdc/2
0 GND
-Vdc/6
-Vdc/2
Vdc/6
Vdc/2
Stator neutral to
Ground Voltage
Switching state 2
Vdc/2
Vdc/2
V(N-GND) = - Vdc/6
- Vdc/2 x 1/3
-Vdc/6
-Vdc/2
Vdc/6
Vdc/2
GND
0 GND
Stator neutral to
Ground Voltage
Switching state 3
Vdc/2
Vdc/2
V(N-GND) = Vdc/6
Vdc/2 x 1/3
-Vdc/6
-Vdc/2
Vdc/6
Vdc/2
GND
0 GND
Stator neutral to
Ground Voltage
Switching state 4
Vdc/2
Vdc/2
V(N-GND) = Vdc/2
-Vdc/6
-Vdc/2
Vdc/6
Vdc/2
GND
0 GND
Stator neutral to
Ground Voltage
Switching state 5
Vdc/2
Vdc/2
V(N-GND) = Vdc/6
Vdc/2 x 1/3
-Vdc/6
-Vdc/2
Vdc/6
Vdc/2
GND
0 GND
Stator neutral to
Ground Voltage
Switching state 6
GND
Vdc/2
Vdc/2
V(N-GND) = - Vdc/6
- Vdc/2 x 1/3
-Vdc/6
-Vdc/2
Vdc/6
Vdc/2
GND
0 GND
Stator neutral to
Ground Voltage
Switching state 1
GND
Vdc/2
Vdc/2
V(N-GND) = - Vdc/2
0 GND
-Vdc/6
-Vdc/2
Vdc/6
Vdc/2
Stator neutral to
Ground Voltage
Switching state 7
Vdc/2
Vdc/2
V(N-GND) = - Vdc/6
- Vdc/2 x 1/3
-Vdc/6
-Vdc/2
Vdc/6
Vdc/2
GND
0 GND
Stator neutral to
Ground Voltage
Switching state 8
Vdc/2
Vdc/2
V(N-GND) = Vdc/6
- Vdc/2 x 1/3
-Vdc/6
-Vdc/2
Vdc/6
Vdc/2
GND
0 GND
Stator neutral to
Ground Voltage
Switching state 4 again
Vdc/2
Vdc/2
V(N-GND) = Vdc/2
-Vdc/6
-Vdc/2
Vdc/6
Vdc/2
GND
0 GND
Stator neutral to
Ground Voltage
Common-Mode Voltage
The motor neutral voltage on a balanced 60Hz or
50Hz utility sine-wave system is zero.
The motor neutral on ASD due to rectangular
PWM pulses at high frequency is never zero.
Although sum of average 3-ph voltages is zero an
instantaneous sum of 3-ph voltages is not zero
resulting in neutral point shift voltage (Common-Mode
Voltage).
Common-Mode voltage induces shaft voltage and
generates bearing currents in motor.
Common-mode currents cause motor bearing
failures and other motor issues.
Reference: Inverter Driven Induction Motor Bearing Current Solutions IEEE PCIC-2002-08
Measured ASD neutral-to-ground voltage
V
ng
neutral-to-
ground
voltage
I
lg
CM
current
Expanded Neutral-to-GND Voltage
Frequency Characteristics of the
Differential Mode (DM) Voltage Spectrum
Spectrum normalised to the DC bus voltage value

Duty cycle = 50%

Carrier frequency
f
c
=500 Hz

Pulse rise time
t
rise
=200 ns

- 20 dB/decade
- 40 dB/decade
IGBT rise times range from 50 ns to 200 ns,
corresponding to noise coupling frequencies of 6.4
MHz and 1.6 MHz, respectively
BJT trise range from 1 to 2 us, corresponding to
320 kHz and 160kHz, respectively
Slow pulse rise time has a significant effect on the
total noise energy coupled into a circuit, because
the 40 dB/decade attenuation factor is occurring
at a higher frequency
Rise times
Frequency Characteristics of the Common
Mode (CM) Voltage Spectrum
Spectrum normalised to the DC bus voltage value

Duty cycle = 50%

Carrier frequency
f
c
=500 Hz

Pulse rise time
t
rise
=200 ns

- 20 dB/decade
- 40 dB/decade
High EMI and RFI
Motor problems:
Motor terminal overvoltage (spikes) due to
reflected wave phenomenon, and
motor anti-resonance
Excessive harmonic losses
Excessive noise
Stressed insulation leading to failures
Shaft voltage and Bearing currents leading to bearing
failures
Problems Associated with PWM Inverter
Operation
What is it?
Inverter section of adjustable speed drive does not
produce sinusoidal output voltage wave forms but
generates a continuous series of pulses (PWM)
The reflected wave phenomenon
PWM pulses travel between
inverter and motor behaving like
traveling waves on transmission
lines
Lead to reflected wave
phenomenon and result in
overvoltage at motor terminals
Can be up to 2 x DC bus voltage of
the drive (nearly 3 x system voltage)
Caused by high dV/dt of PWM
pulse and mismatch between
cable and motor surge
impedance (characteristic
impedance Z
0
)
Reflected Wave Phenomenon
Motor Terminal Voltage
Voltage Oscillation
Characteristic impedance
Z
0
,
Ratio of the amplitudes of
voltage and current of a
single wave propagating
along the line

lossless
Surge Impedance
properly terminated, Z
L
= Z
0
, the end of a
transmission line produces no reflections
Transmission line model
Transmission line
Sending end
Receiving end
Reflected wave transients occur at every drive
switching instant determined by the ASD carrier
frequency
Reflected wave transients are independent of ASD
fundamental output frequency
Determined by:
dV/dt
Magnitude of drive pulse (V DC bus)
Voltage rise time of drive pulse
Cable transmission line characteristic impedance
(surge impedance),
Motor surge impedance
Spacing of PWM pulses (switching frequency)
Cable length
Variables Affecting Reflected Wave
Phenomenon
Motor and cable surge impedance mismatch are
primarily responsible for the magnitude of peak over-
voltage
The rise time of the PWM pulse primarily determines a
critical cable length where the peak over-voltage
develops
Worse with long cable runs, PWM pulse rise time, and
higher switching frequency
Higher surge impedance of smaller HP (kW) motors
also makes problem worse
Most of the excessive peak voltage is impressed upon
the first turns of the motor windings and can cause
premature failure
Variables Affecting Reflected Wave
Phenomenon (cont.)
IGBTs allow for higher
switching frequencies
Even relatively short cable
runs can cause problems:
Critical cable length for
dV/dt=500V/s is in the 100m
range (328 ft),
1000 V/s is in the 50m range
(164 ft),
and for 10,000 V/s in the 5m
range (16 ft).
Reflected wave phenomenon
appears at some cable length
regardless of the type of output
switching device used
Critical Cable length
Reference: AB App Note, Effective Motor Protection
Against Reflected Wave Phenomenon
0
20
40
60
80
100
120
140
3 6 9 12
m
a
x
.

c
a
b
l
e

l
e
n
g
t
h

[
f
t
]

Carrier frequency [kHz]
Carrier frequency impact on
critical cable length
460V motors
575V motors
Causes insulation stress
Voltages can be higher than
magnetic wire insulation
rating
Higher voltage at shorter
rise time on the motor coils
creates higher volt/turn
stress on the insulation
High dV/dt can ionize air in
insulation voids causing
partial discharges, corona
and lead to breakdown
Insulation stress
Reference: Eaton App Note, The Reflective Wave
Phenomena
When frequency of
voltage oscillation
matches internal anti-
resonance frequency
of motor
Can cause overvoltages
within motor windings
even with relatively
short cable runs
Motor Anti-Resonance
Phenomenon
Reference: A Failure Mode for PWM Inverter-Fed AC
Motors Due to the Anti-Resonance Phenomenon
Voltage Ratios within
Motor Windings
Motor Winding Measurement Points
High EMI and RFI
Motor problems:
Motor terminal overvoltage (spikes) due to
reflected wave phenomenon, and
motor anti-resonance
Excessive harmonic losses
Excessive noise
Stressed insulation leading to failures
Shaft voltage and Bearing currents leading to bearing failures
Higher cost, inverter duty motors required
NEMA MG-1 Part 31
Special cables required to reduce leakage currents, deal
with overvoltage, etc
Problems Associated with PWM Inverter
Operation
Low pass filter with cutoff
frequency well below the
lowest harmonic frequency
of the inverter voltage
resulting from PWM.
Filters out high frequency currents
while allowing lower frequency
fundamental currents to pass
Prevents
Transient overvoltages at motor
terminals
Additional motor losses
Excessive motor noise

INVERSINE Advanced Universal Sine-Wave
Filter (AUSF)
Motor does not have adequate insulation for ASD duty.
Number of parallel motors.
Motor cable length is long.
Step-up/Step-down transformer is used.
There are specific requirements for peak voltage level and dV/dt
rise time ratio.
Motor noise needs to be reduced.
Maximum safety and reliability is needed in e.g. EX applications.
Submersible pumps with long motor cables e.g. in the oil & gas
industry.
INVERSINE (AUSF) Applications

INVERSINE AUSF Performance (Voltage)
V
THD
= 1.9%
< 3% VTHD Typical
INVERSINE AUSF Performance (Current)
I
THD
= 2.3%
< 8% ITHD Typical
The filter capacitor
compensates a part of the
reactive power of the motor.
Power Factor improved
close to 1.0
The resulting RMS current
of the inverter is smaller
with filter than without filter.
Voltage drop of the filter
choke is kept as low as
possible.

INVERSINE and the inverter current
V
inv
V
L
I
inv
I
C
I
0
V
M
I
MN
Low insertion loss
< 2% of rated voltage.
(inverter voltage needs to be
2% higher than normal to
deliver the same shaft power)
No damping resistors
required
Much higher efficiency than
competitors filters, > 98%.
Power delivered to the
motor
> 96%.
Standard LC filter
insertion loss is 10% of
rated voltage.
This translates to power
delivered to the motor
81%.
INVERSINE and the inverter power
Rated for Full-Load Current of the motor as per
NEC Table 430.250
For motors 5 HP to 500 HP (shaft power)
Rated for NEMA motors efficiency levels
Rated for power factor 0.8
Motor rated voltage 460V, or 575V, (660V also
available)
Rated motor frequency 60Hz, max. 90Hz
Inverter carrier frequency > 1 kHz.
INVERSINE design criteria
The use of PWM Drives can lead to motor problems, cable issues
and high EMI/RFI
Mirus INVERSINE Advanced Universal Sine-Wave Filter will
eliminate or reduce these problems by:
Substantially reducing voltage rise time (dV/dt)
Converting output voltage to near sinewave (<3% VTHD)
Lowering harmonic losses in motor
Reducing motor and cable insulation stress
Reducing motor noise
Available common-mode blocking option will:
Reduce shaft voltage and bearing currents
Reduce cable leakage currents
Reduce common-mode voltages throughout power system

Summary
Thank you
Questions

High Frequency Electromagnetic Noise of Modern PWM Adjustable Speed Drives 2014-09-16 (Final) MF

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