EMC: How to handle
large machinery
Prof. dr. ir. Johan CATRYSSE
FMEC, KHBO, Oostende (BE)
MICAS/ESAT, KULeuven (BE)
1
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2
Overview
•
•
•
•
•
•
•
•
•
Large Machinery
EMC Directive and Harmonised Standards
TEMCA2 project
Conducted Emission
Radiated Emission
Immunity Testing
Practical Example
Conclusions
Questions
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3
Introduction: the actual ambient
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4
Overview
•
•
•
•
•
•
•
•
•
Large Machinery
EMC Directive and Harmonised Standards
TEMCA2 project
Conducted Emission
Radiated Emission
Immunity Testing
Practical Example
Conclusions
Questions
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5
Large Machinery
Emergency stop
Machinery
electronics
Input / output of materials
Access by operator
PDS
Motor
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Mains
PS
6
Large Machinery
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7
Overview
•
•
•
•
•
•
•
•
•
Large Machinery
EMC Directive and Harmonised Standards
TEMCA2 project
Conducted Emission
Radiated Emission
Immunity Testing
Practical Example
Conclusions
Questions
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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
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D.o.C.
Name of :
manufacturer
importer
Type : xxx-yyy
S/N : 123456
9
EMC Directive 2004/108 and
Harmonised Standards for machinery
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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)
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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
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12
Overview
•
•
•
•
•
•
•
•
•
Large Machinery
EMC Directive and Harmonised Standards
TEMCA2 project
Conducted Emission
Radiated Emission
Immunity Testing
Practical Example
Conclusions
Questions
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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
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14
Overview
•
•
•
•
•
•
•
•
•
Large Machinery
EMC Directive and Harmonised Standards
TEMCA2 project
Conducted Emission
Radiated Emission
Immunity Testing
Practical Example
Conclusions
Questions
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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
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16
Conducted Emission
•
LISN used as a voltage probe (or “LISN in parallel”)
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17
Conducted Emission
•
CISPR 11 voltage probe 1500/50 Ohm
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18
Conducted Emission
•
Capacitive Voltage Probe (CVP)
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19
Conducted Emission
•
EFT Capacitive clamp used as capacitive voltage probe
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20
Conducted Emission
•
Capacitive Foil Probe (CFP)
Foil
Crocodile clamp
Cable duct
(GRP)
Measurement wire
GRP connection
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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)
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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)
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(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
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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
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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
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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
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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)
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(ONERA)
analysis & simulation
27
Overview
•
•
•
•
•
•
•
•
•
Large Machinery
EMC Directive and Harmonised Standards
TEMCA2 project
Conducted Emission
Radiated Emission
Immunity Testing
Practical Example
Conclusions
Questions
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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.
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29
Radiated Emission
Definition of the problem
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Radiated Emission
Definition of the problem - Basic concept by use of GTO
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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)
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300
1000
32
Radiated Emission
Definition of the problem - Basic concept by wire simulation
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33
Radiated Emission
Definition of the problem - Basic concept by wire simulation
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34
Overview
•
•
•
•
•
•
•
•
•
Large Machinery
EMC Directive and Harmonised Standards
TEMCA2 project
Conducted Emission
Radiated Emission
Immunity Testing
Practical Example
Conclusions
Questions
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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
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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
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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
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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
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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.
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40
Immunity Testing: radiated immunity
•
Bulk Current Injection instead of Radiated immunity testing, in
the range from 1 MHz upto 1 GHz: Measuring setup
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