EMC: How to handle large machinery Prof. dr. ir. Johan CATRYSSE FMEC, KHBO, Oostende (BE) MICAS/ESAT, KULeuven (BE) 1 Created with novaPDF Printer (www.novaPDF.com). Please register to remove this message. 2 Overview • • • • • • • • • Large Machinery EMC Directive and Harmonised Standards TEMCA2 project Conducted Emission Radiated Emission Immunity Testing Practical Example Conclusions Questions Created with novaPDF Printer (www.novaPDF.com). Please register to remove this message. 3 Introduction: the actual ambient Created with novaPDF Printer (www.novaPDF.com). Please register to remove this message. 4 Overview • • • • • • • • • Large Machinery EMC Directive and Harmonised Standards TEMCA2 project Conducted Emission Radiated Emission Immunity Testing Practical Example Conclusions Questions Created with novaPDF Printer (www.novaPDF.com). Please register to remove this message. 5 Large Machinery Emergency stop Machinery electronics Input / output of materials Access by operator PDS Motor Created with novaPDF Printer (www.novaPDF.com). Please register to remove this message. Mains PS 6 Large Machinery Created with novaPDF Printer (www.novaPDF.com). Please register to remove this message. 7 Overview • • • • • • • • • Large Machinery EMC Directive and Harmonised Standards TEMCA2 project Conducted Emission Radiated Emission Immunity Testing Practical Example Conclusions Questions Created with novaPDF Printer (www.novaPDF.com). Please register to remove this message. 8 EMC Directive 2004/108 and Harmonised Standards for machinery Application of HS Apparatus EMC assessment Optional report from notified body Product type Installation Technical Documentation Application of protection requirements Created with novaPDF Printer (www.novaPDF.com). Please register to remove this message. D.o.C. Name of : manufacturer importer Type : xxx-yyy S/N : 123456 9 EMC Directive 2004/108 and Harmonised Standards for machinery Created with novaPDF Printer (www.novaPDF.com). Please register to remove this message. 10 EMC Directive 2004/108 and Harmonised Standards for machinery EN 50370-1 Electromagnetic Compatibility (EMC) – Product family standard for machine tools – Part 1: Emission EN 50370-2 Electromagnetic Compatibility (EMC) – Product family standard for machine2 tools – Part 2: Immunity If a specific product standard exists, it overrules the use of EN 50370-X Examples: PDS: PLC: Power Supply: IT EN EN EN EN 61800-3 61131-2 62041 55022 (CISPR 22) Note: All of them refer to the basic standards for test setups (e.g. CISPR) Created with novaPDF Printer (www.novaPDF.com). Please register to remove this message. 11 EMC Directive 2004/108 and Harmonised Standards for machinery CHOICE OF PROCEDURE Procedure A Procedure B Procedure C Prepare Machine Prepare entire electrical set Divide into EM relevant modules Type Test Type Test Type Test Visual inspection Visual inspection Additional test on machine END Created with novaPDF Printer (www.novaPDF.com). Please register to remove this message. 12 Overview • • • • • • • • • Large Machinery EMC Directive and Harmonised Standards TEMCA2 project Conducted Emission Radiated Emission Immunity Testing Practical Example Conclusions Questions Created with novaPDF Printer (www.novaPDF.com). Please register to remove this message. 13 TEMCA2 project • TEMCA2, “Alternative EMC testing methods for large machines”, No. G6RD-CT-2002-00865 for the 5th European Framework Program, GROWTH, Objective 6.2.1. (Methodologies to support standardisation) • The three main objectives of TEMCA2 were: • development of new methodologies and methods for the evaluation of conducted and radiated emission, generated by large machinery, as an alternative to the existing harmonized standards • development of new methodologies and methods for the evaluation of immunity of large machinery, as an alternative to the existing harmonized standards • expertise transfer by means of a guideline for machine manufacturers Created with novaPDF Printer (www.novaPDF.com). Please register to remove this message. 14 Overview • • • • • • • • • Large Machinery EMC Directive and Harmonised Standards TEMCA2 project Conducted Emission Radiated Emission Immunity Testing Practical Example Conclusions Questions Created with novaPDF Printer (www.novaPDF.com). Please register to remove this message. 15 Conducted Emission • The main problem for large machinery is related to two items: – the current consumption, and the current handling capacity of a LISN – the fact that it is nearly impossible to insert a measuring probe in the power mains cabling • If possible, to develop measuring setups, with a non-contacting probe for the power mains • Therefore, a number of possible alternative methodologies have been analysed, and an example of measuring results is given in the next sections Created with novaPDF Printer (www.novaPDF.com). Please register to remove this message. 16 Conducted Emission • LISN used as a voltage probe (or “LISN in parallel”) Created with novaPDF Printer (www.novaPDF.com). Please register to remove this message. 17 Conducted Emission • CISPR 11 voltage probe 1500/50 Ohm Created with novaPDF Printer (www.novaPDF.com). Please register to remove this message. 18 Conducted Emission • Capacitive Voltage Probe (CVP) Created with novaPDF Printer (www.novaPDF.com). Please register to remove this message. 19 Conducted Emission • EFT Capacitive clamp used as capacitive voltage probe Created with novaPDF Printer (www.novaPDF.com). Please register to remove this message. 20 Conducted Emission • Capacitive Foil Probe (CFP) Foil Crocodile clamp Cable duct (GRP) Measurement wire GRP connection Created with novaPDF Printer (www.novaPDF.com). Please register to remove this message. 21 Conducted Emission • Capacitive Foil Probe (CFP) - calibration setup KHBO CALIBRATION CAPACITIVE FOIL PROBE (CFP) (Injected signal: 0 dBm) 0 Received signal (dBm) -10 -20 -18 dBm +20 dB/dec -30 -40 -38 dBm -50 -60 -58 dBm -70 0,1 1 10 Frequency (MHz) Created with novaPDF Printer (www.novaPDF.com). Please register to remove this message. 100 22 Conducted Emission • Capacitive Foil Probe (CFP) - CRYPTE 30 cm 1 mm 7.807 mm 0.5 mm 3 2 50 mm 1 4 Z1=50Ohm (receiver) Created with novaPDF Printer (www.novaPDF.com). Please register to remove this message. (ONERA) analysis & simulation 23 Conducted Emission • Capacitive Foil Probe (CFP) - CRYPTE (ONERA) analysis & simulation L11 L3 250uH L4 50uH L10 2mH L30 2mH 2.5uh V4 C9 2uf C4 C5 C6 8uf 1uf 2.2uf R18 2 L1 250uH L8 C1 8uf T34 16uh R1 C3 1uf 2uf C7 C10 R100 K K2 K_Linear 2.2uf 220000 COUPLING= 0.99 R6 50 2mH L20 L40 2mH C8 1uf V6 in1 out1 in2 out2 in3 out3 T3coupledX R9 R10 C12 R11 R2 L5 1.7mh 5 1.7mh C11 R12 4.7nf 50 4.7nf 6 C20 RECEIVER C19 1n 2n 0 LISN V5 1uf L6 5 50 6 K_Linear COUPLING= 0.99 in1 out1 in2 out2 in3 out3 T3coupledX L2 50uH C2 L9 16uh T19 K K1 L7 C15 MACHINE TOOL 500pF 100nH POWER NETWORK 0 0 Simulation of the LISN Created with novaPDF Printer (www.novaPDF.com). Please register to remove this message. R4 R5 50 50 24 Conducted Emission • Capacitive Foil Probe (CFP) - CRYPTE (ONERA) analysis & simulation CAPACITIVEFOILPROBE (CFP) L11 L10 2mH L30 2mH 2.5uh V4 C9 L12 2.2uf R18 1.5uH 2 T19 C21 0.1uf R19 50 L8 K_Linear COUPLING = 0.99 in1 out1 in2 out2 in3 out3 T3coupledX C25 K K1 C10 R100 K K2 K_Linear 2.2uf 220000 COUPLING = 0.99 R6 50 2mH L20 L40 2mH L9 16uh T34 16uh R1 R2 6 6 in1 out1 in2 out2 in3 out3 T3coupledX L13 1.5uH 1.5uH 0 POWERNETWORK V6 C23 0.1uf R20 50 L14 100pf 0 C12 R28 50 4.7nf RECEIVER C24 0.1uf 0 C19 4.7nf 1n 2n R21 50 MACHINE TOOL 0 0 STABILISATION NETWORK Simulation of the CFP lumped model Created with novaPDF Printer (www.novaPDF.com). Please register to remove this message. C11 C20 0 V5 R4 R5 50 50 25 Conducted Emission • Capacitive Foil Probe (CFP) - CRYPTE (ONERA) analysis & simulation CAPACITIVE FOIL PROBE (CFP) L11 L10 2mH L30 2mH 2.5uh V4 C9 L12 R18 1.5uH 2 T35 C21 0.1uf L9 16uh T34 16uh R1 6 in1 out1 in2 out2 in3 out3 T3coupledX L13 1.5uH 1.5uH 0 K_Linear COUPLING = 0.99 in1 out1 in2 out2 in3 out3 T3coupledX K K2 K_Linear C10 R100 2.2uf 220000 COUPLING = 0.99 50 2mH L20 L40 0 R26 100MEG R27 50 OPEN CIRCUIT C12 4.7nf RECEIVER 0 2mH C19 C24 0.1uf R21 50 0 0 STABILISATION NETWORK Simulation of the CFP transmission line model Created with novaPDF Printer (www.novaPDF.com). Please register to remove this message. 4.7nf 1n 2n V5 C11 C20 0 MACHINE TOOL POWER NETWORK R6 V6 C23 0.1uf R20 50 L14 T19 K K1 0 R2 6 FOIL in1 out1 in2 out2 in3 out3 in4 out4 T4coupledX R19 50 L8 2.2uf R4 R5 50 50 26 Conducted Emission • Capacitive Foil Probe (CFP) - CRYPTE COMPARISON LISN - CFP Effect of CFP modeling: Transmission Line model vs. Capacitor lumped model (network impedance stabilised; MT filter installed) 150 LISN CFP: C lumped model 100 Received Voltage (dBuV) CFP: TL model 50 0 -50 -100 0,001 0,01 0,1 1 10 100 Frequency (MHz) Created with novaPDF Printer (www.novaPDF.com). Please register to remove this message. (ONERA) analysis & simulation 27 Overview • • • • • • • • • Large Machinery EMC Directive and Harmonised Standards TEMCA2 project Conducted Emission Radiated Emission Immunity Testing Practical Example Conclusions Questions Created with novaPDF Printer (www.novaPDF.com). Please register to remove this message. 28 Radiated Emission • The main problems for in-situ measurements for radiated emission are: – the lack of space to perform adequate measurements using antenna’s – the background noise in an industrial environment • Therefore, an alternative methodology has been developed, by putting a simple wire over the machine. This wire acts as an antenna, and is able to capture radiated emissions. The problem is to identify and define a correlation factor (or antenna factor or K-factor) for this “test-wire” method. Created with novaPDF Printer (www.novaPDF.com). Please register to remove this message. 29 Radiated Emission Definition of the problem Created with novaPDF Printer (www.novaPDF.com). Please register to remove this message. 30 Radiated Emission Definition of the problem - Basic concept by use of GTO Created with novaPDF Printer (www.novaPDF.com). Please register to remove this message. 31 Radiated Emission Definition of the problem - Basic concept by use of GTO ANTENNA METHOD - TEST WIRE METHOD COMPARISON: CETIM, LABEIN, SIEMENS GTO with Cu-plate not mounted, in semianechoic chamber 40 Proposed K-factor (initial) Proposed K-factor (new) LABEIN CETIM SIEMENS MEAN VALUE 30 Difference (dB/m) 20 10 0 -10 -20 -30 10 30 100 Frequency (MHz) Created with novaPDF Printer (www.novaPDF.com). Please register to remove this message. 300 1000 32 Radiated Emission Definition of the problem - Basic concept by wire simulation Created with novaPDF Printer (www.novaPDF.com). Please register to remove this message. 33 Radiated Emission Definition of the problem - Basic concept by wire simulation Created with novaPDF Printer (www.novaPDF.com). Please register to remove this message. 34 Overview • • • • • • • • • Large Machinery EMC Directive and Harmonised Standards TEMCA2 project Conducted Emission Radiated Emission Immunity Testing Practical Example Conclusions Questions Created with novaPDF Printer (www.novaPDF.com). Please register to remove this message. 35 Immunity Testing • It has been found that two different interferences are important concerning the immunity of machines – – • Effects by radio transmitters, simulated by CW signal injection Effects due to transients, simulated by EFT and external ESD Most machines have only a few outside connections: – Connection to a power mains network – Connection to a LAN or data network – Construction of the machine is normally a metal chassis or even closed cubicle, and cable layout near the metal GND reference can easily be done – EMC assessment will show that all subparts, subassemblies and components are CE marked, and that final testing is only intended for final control of the machinery • Simple alternative methods might be used Created with novaPDF Printer (www.novaPDF.com). Please register to remove this message. 36 Immunity Testing: radiated immunity • Bulk Current Injection instead of Radiated immunity testing, in the range from 1 MHz upto 1 GHz (and above) on all external cabling. This avoids also the perturbation of the spectrum. – Injected current was found to be about 1.5 mA/ 1 V/m fieldstrength Created with novaPDF Printer (www.novaPDF.com). Please register to remove this message. 37 Immunity Testing: radiated immunity P o w e r for 4 0 dB am plifier to g enera te 3V on cab ling 40 ,0 0 30 ,0 0 Pin (dBm) 20 ,0 0 EM 10 1 EF T Folie 10 ,0 0 0 ,0 0 -10 ,0 0 -20 ,0 0 1 10 10 0 1 00 0 F req ue ntie (M Hz) Comparison of BCI clamp (EM 101), EFT capacitive clamp and CFP probe for conducted immunity tests Created with novaPDF Printer (www.novaPDF.com). Please register to remove this message. 38 Immunity Testing: radiated immunity • Bulk Current Injection instead of Radiated immunity testing, in the range from 1 MHz upto 1 GHz – Injected current following MIL Std 461E Created with novaPDF Printer (www.novaPDF.com). Please register to remove this message. 39 Immunity Testing: radiated immunity • Bulk Current Injection instead of Radiated immunity testing, in the range from 1 MHz upto 1 GHz – Injected current following Ford Motor Co. Created with novaPDF Printer (www.novaPDF.com). Please register to remove this message. 40 Immunity Testing: radiated immunity • Bulk Current Injection instead of Radiated immunity testing, in the range from 1 MHz upto 1 GHz: Measuring setup Created with novaPDF Printer (www.novaPDF.com). Please register to remove this message.
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