POWER LINE FILTERS

FOR AC, DC & SERVO MOTOR DRIVES

EFFICIENT EMC SOLUTIONS

 Rasmi Electronics Ltd.
Rasmi Electronics Ltd. has been established since 1974, designing and manufacturing a wide range of RFI
filters, chokes and power transformers.
The company is based in Stanley and operates from its two purpose designed 30,000 sq ft factories with its
skilled workforce, now totalling over 150.
Rasmi offers its customers quality products, competitive pricing and a complete design/manufacturing service.
By working closely with customers and competent body test authorities, Rasmi can be sure that its products
perform effectively, efficiently and meet all the application needs imposed on them.

POWER LINE FILTERS FOR MOTOR DRIVES

AC, DC and servo motor and are now established as the most flexible means of controlling motors in virtually all mechanical
equipment. However, they are a significant source of RF interference.

Recent European legislation on EMC imposes limits on RF emissions from such equipment. The DLC range of power line
filters has been specifically developed for use with these drives, enabling systems incorporating them to meet the European
RFI emissions standards for domestic or industrial use.
The example emission graphs in this brochure represent actual results measured by a competent body on drive equipment
using Rasmi filters. These results ensured that Rasmi's customer gained the EMC certificate and was therefore able to
mark the products.

The range comprises three types of filter in various sizes up to 990A current capacity. Although these filters are intended for
use with motor drives, their high performance makes them effective in suppressing high RF emissions in virtually any
installation.

♦ RF 1xxx DLC Series - single phase power line filters

♦ RF 3xxx DLC Series - three phase power line filters
♦ RF 4xxx DLC Series - three phase plus neutral power line filters
All filters are constructed with approved components:- self healing X and Y capacitors approved to VDE, SEMKO, NEMKO
and UL are used and all assemblies are encapsulated in stainless steel cases with resin approved to UL 94-V0 flammability
class. Input and output connections are made by shrouded terminals up to 170A bolt stud type terminals from 170A to 480A
and tag type connections above 480A.

A range of output chokes is also available, to complement the power line filters and improve EMC performance, especially
radiated emissions, where long motor cables are used.
APPLICABLE EMC STANDARDS

Generic Standard Referenced or comparable Aspects

covered basic/product standard

EN50081-1 EN55022 class B conducted & radiated emission

EN55011 group1 class B
EN55014 (conducted emission only)
IEC555-2 (household apparatus only) power harmonics

EN50081-2 EN55022 class A conducted and radiated emission

EN55011 group 1 class A

EN50082-1 IEC801-2 electrostatic discharge immunity

IEC801-3 RF field immunity
IEC801-4 fast transient burst immunity

EN50082-2 ENV50140 (similar to IEC801-3) RF field immunity

ENV50204 RF field immunity (pulse modulation)
EN61000-4-8 50Hz field immunity
EN61000-4-2 (similar to IEC801-2) electrostatic field immunity
ENV50141 (similar to IEC801-6) conducted RF immunity
EN61000-4-4 (similar to IEC801-4) fast transient burst immunity
RF 1xxx - DLC SINGLE PHASE FILTERS

Circuit Schematic

L L

LOAD

LINE
N N

E E

Rated Voltage: Line - Neutral 250V, 50-60Hz @ 40oC

Part Drive Terminal Max Leakage Power Case Weight
Number Input output Type Cable Current Loss Style
(A) (kW) (mm2) (mA) (W) (kg)
RF 1010-DLC 10 0.75 Shrouded 6 3.2 3.8 A 0.4
RF 1015-DLC 15 1.5 Shrouded 6 3.2 6.5 A 0.5
RF 1020-DLC 20 2.2 Shrouded 10 3.2 10 B 0.9
RF 1035-DLC 35 3.7 Shrouded 10 3.2 15 B 1.0

Case Dimensions (mm) X

Case L W H X Y Mount
Style
A 150 55 45 140 36 M4
B 170 80 55 160 46 M5
W Y

L H

100
Performance 90
EN 55081/1 QP

EN 55081/1 AV
80 UNFILTERED
The graph opposite shows typical improvements in conducted
emissions achieved from the fitting of an RF 1035-DLC filter 70

to a 3.7kW, single phase AC Inverter running a 3.7kW motor 60

with 25m screened motor cable. dBµV 50

40

30
FILTERED
20

10

0
0.15 0.3 0.5 1.0 2.0 5.0 10.0 20.0 30.0
Log Frequency 0.15 - 30.0 MHz
RF 3xxx - DLC THREE PHASE FILTERS
Circuit Schematic
L1 L1

L2 L2

LOAD

LINE
L3 L3

E E

Rated Voltage: Line - Line 440 - 520V, 50-60Hz @ 40oC

Part Drive Terminal Max Leakage Power Case Weight
Number Output Input Type Cable Current Loss Style
(A) (kW) (mm2) nom (mA) max (W) (kg)
RF 3006-DLC 6 1.5 Shrouded 6 0.5 27 8 C 1.5
RF 3012-DLC 12 3.7 Shrouded 6 0.5 27 10 C 1.5
RF 3020-DLC 20 5.5 Shrouded 10 0.5 27 15 D 1.7
RF 3040-DLC 40 11 Shrouded 10 0.5 27 30 D 1.8
RF 3060-DLC 60 18.5 Shrouded 16 0.5 27 51 E 3.2
RF 3070-DLC 70 22 Shrouded 25 0.5 27 44 F 4.9
RF 3100-DLC 100 30 Shrouded 35 0.75 130 69 G 6.8
RF 3120-DLC 120 37 Shrouded 35 0.75 130 45 G 6.8
RF 3170-DLC 170 55 Shrouded 95 0.75 130 80 H 9.2
RF 3230-DLC 230 75 Stud M12 1.3 150 50 J 14
RF 3280-DLC 280 90 Stud M12 1.3 150 60 J 15
RF 3400-DLC 400 132 Stud M16 1.3 150 80 J 27
RF 3480-DLC 480 160 Stud M16 1.3 150 90 J 27
RF 3660-DLC 660 230 Tag M16 1.3 150 130 N 45
RF 3880-DLC 880 315 Tag M16 1.3 150 210 N 45
RF 3990-DLC 1000 330 Tag M16 1.3 150 300 N 45

Case Dimensions (mm) X

Case L W H X Y Mount
Style
C 250 110 60 238 76 M6
D 270 140 60 258 106 M6
E 270 140 90 258 106 M6 WY
F 365 180 90 338 146 M6
G 435 200 130 408 166 M6
H 495 200 160 468 166 M6
J 587 250 205 560 170 M6
N 688 364 180 640 300 M8
L H

100
EN 55081/1 QP
90
EN 55081/1 AV
Performance 80 UNFILTERED

70
The graph opposite shows typical improvements in conducted
60
emissions achieved from the fitting of an RF 3040-DLC filter
to a 11kW, three phase AC Inverter running an 11kW motor dBµV 50

with 25m screened motor cable. 40

30 FILTERED

20

10

0
0.15 0.3 0.5 1.0 2.0 5.0 10.0 20.0 30.0
Log Frequency 0.15 - 30.0 MHz
 RF 4xxx - DLC THREE PHASE + NEUTRAL FILTERS

Circuit Schematic
L1 L1

L2 L2

LOAD

LINE
L3 L3

N N

E E

Rated Voltage: Line - Line 440 - 520V, 50-60Hz @ 40oC

Part Drive Terminal Max Leakage Power Case Weight
Number Output Input Type Cable Current Loss Style
(A) (kW) (mm2) nom (mA) max (W) (kg)
RF 4006-DLC 6 1.5 Shrouded 6 0.1 27 8 C 1.7
RF 4012-DLC 12 3.7 Shrouded 6 0.1 27 10 D 1.9
RF 4020-DLC 20 5.5 Shrouded 6 0.1 27 13 D 1.9
RF 4040-DLC 40 11 Shrouded 10 0.1 27 28 E 2.6
RF 4060-DLC 60 18.5 Shrouded 16 0.1 27 47 F 5.1
RF 4070-DLC 70 22 Shrouded 25 0.1 27 44 F 5.1
RF 4100-DLC 100 30 Shrouded 35 0.5 130 53 G 6.8
RF 4120-DLC 120 37 Shrouded 35 0.5 130 55 G 6.8
RF 4170-DLC 170 55 Shrouded 95 0.5 130 71 H 10
RF 4230-DLC 230 75 Stud M12 0.5 160 50 J 15
RF 4280-DLC 280 90 Stud M12 0.5 160 60 J 16
RF 4400-DLC 400 132 Stud M16 0.5 160 80 J 27
RF 4480-DLC 480 160 Stud M16 0.5 160 90 J 27

Case Dimensions (mm) X

Case L W H X Y Mount
Style
C 250 110 60 238 76 M6
D 270 140 60 258 106 M6
E 270 140 90 258 106 M6 WY
F 365 180 90 338 146 M6
G 435 200 130 408 166 M6
H 495 200 160 468 166 M6
J 587 250 205 560 170 M6
L H

100
EN 55081/1 QP
90
EN 55081/1 AV
Performance 80 UNFILTERED

70
The graph opposite shows typical improvements in conducted
60
emissions achieved from the fitting of an RF 4020-DLC filter
to a 4kW three phase AC Inverter running a 4kW motor with dBµV 50

25m screened motor cable. 40

30 FILTERED

20

10

0
0.15 0.3 0.5 1.0 2.0 5.0 10.0 20.0 30.0
Log Frequency 0.15 - 30.0 MHz
 OC/x - OUTPUT CHOKES

C H

YD

X
W
Dimensions in mm
Output Approx Centre Width Height Depth Mounting Mounting
Choke Motor kW Hole C W H D Dims X,Y Holes Dia
OC/1 2.2 21 85 46 22 70 - 5
OC/2 15 28.5 105 62 25 90 - 5
OC/3 45 50 150 110 50 125 x 30 5
OC/4 >45 58 200 170 65 180 x 45 6

The OC/x output chokes can be used in conjunction with the filters to improve EMC performance. They are especially
effective where radiated emissions from long drive to motor cables are a problem e.g. corruption of near by control or data
cable signals or radio / television interference. The correct fitting of an OC/x into the motor cable can eliminate these
problems.

The table above gives approximate motor kW ratings for the OC/x chokes but the selection is ultimately governed by the
type and thickness of motor cable fitted i.e. the motor cable must fit through the OC centre hole.

TERMINAL TYPES
SHROUDED TERMINALS
54 95mm2
35mm2 shrouded
2 32
23 25mm shrouded terminal -
6mm2 18 10mm2 21 16mm2 terminal -
13 shrouded strip 24mm
shrouded shrouded shrouded strip 15mm 20
8 15 terminal - 12
8 terminal - 13 terminal - terminal - strip 12mm
strip 7mm strip 10mm strip 10mm
11 16 18 27 30 46

STUDS AND TAGS M16 hole

30

40 Tag
M12 stud M16 stud terminal
terminal terminal
10

48 58 75

EARTH LEAKAGE MEASUREMENTS

The earth leakage currents mentioned in the tables are particularly relevant
when using earth leakage circuit breakers. L1
The currents mentioned are actual measured values by method of voltage drop L2 RFI Filter
L3
across a resistor. 1kΩ
E
Under normal conditions, with the three phases balanced, earth leakage currents
V
are extremely small - the max values stated are worst possible values such as
would occur momentarily during switch on or failure of one or two phases.
 INSTALLATION RECOMMENDATIONS
While these filters and chokes are particularly effective at suppressing RF emissions, to achieve maximum performance,
it is essential that they are fitted in accordance with the following recommendations. These recommendations and the
diagram overleaf should give all the information needed at the installation stage to prevent problems before they
occur and ensure compliance to the relevant emission standards.

FILTERS AND OUTPUT CHOKES

The input filter should be mounted close to the drive with the filter to drive cable being as short as
possible, this reduces the length of "noisy" unfiltered cable inside the cabinet.
Where long motor output cables are used an output choke may be required to reduce radiated emissions
from the cable. This choke should be fitted close to the exit point of the motor cable from the drive, the
three phase conductors only should pass through the choke, not the earth conductor or screen. Where
possible it is preferable to wind the phase conductors through the output choke more than once as
shown below.

WIRING CABINETS

In general, all installations including motor drives will be inside a wiring cabinet - the use of a good wiring
cabinet during installation will prevent radiated RF emissions from components and unscreened cabling
inside. The cabinet should have a closely fitting door, preferably earthed top and bottom to the main body of
the cabinet.
Usually the cabinet need not be any special or screened type, except in unusual situations where meeting
domestic radiated emission levels proves difficult. The backplate should be securely earthed to the main
cabinet body by removing paint from the mounting points.

EARTHING

Of all factors affecting EMC performance, earthing arrangements are certainly the most important. The point
here is to clearly define the paths through which high frequency earth currents flow, and thereby minimise
their harmful effect on other nearby, sensitive devices.
Paint should be removed from cabinet backplates at the mounting points of metal cased equipment All
earthing leads, including filter earth, inverter earth and screened cable earths, should be made as short as
possible and securely fastened to the bonded backplate earth post - poor connections and loops of cable will
act as antennas and can radiate or pick up stray radiated emissions.
Screened control cables entering the enclosure, however, should be earthed only at the remote end - this
helps to prevents high frequency earth currents from corrupting control signals.

CABLES

The motor output cable must be of a screened type with the screen and earth core bonded to the motor at
one end and to the wiring cabinet backplate earth at the other.

Separation of input power cables from motor output is most important - these cables should never be run
in the same trunking or conduit or come into close proximity - doing so can cause the motor output cable
to "infect" the power input with RF interference and therefore defeat the purpose of the input filter.
It is advisable to separate control cables from the motor cables for the same reasons. In general, cable
runs should be kept as short and direct as possible.

ADDITIONAL CHOKES

Occasionally EMC problems will occur within an installation when components in the same wiring enclosure affect
one another, for example, open control boards may corrupt low level sensor signals. Usually in these cases the fitting
of additional OC/x chokes into the control and sensor cables will cure the problem - a small amount of experimentation
may be required to determine the optimum configuration of these additional chokes.

Output Filter Choke Motor

L1,L2,L3
Filter Inverter
E
Screened Motor Cable
Backplate Bonded Earth
 TYPICAL INSTALLATION SHOWING USE OF AN AC INVERTER
AND FILTERING WITH SUITABLE CABLE LAYOUT AND SEPARATION

BACKPLATE HAS PAINT

CLEANED WHERE METAL CASED
COMPONENTS ARE MOUNTED
E.G. INVERTER AND FILTER

CONTROL CABLES AND

CIRCUITRY WELL POSITIONED relay relay
AND SEPARATED OF FROM
POWER CABLES
INVERTER

SHORT LENGTHS OF CABLE

FROM FILTER TO INVERTER AND control terminals
FROM INVERTER TO OUTPUT
CHOKE counter counter
L1 L2 L3 U V W

OUTPUT CHOKE HAS ONLY

PHASE CONDUCTORS PASSING
THROUGH, NOT EARTH CORE
OR SCREEN

PLC

PLC
FILTER POSITION IS RELATIVELY FILTER
CLOSE TO SUPPLY ENTRY POINT
AND HAS MINIMUM CABLE
LENGTH BACK TO ENTRY POINT

MOTOR CABLE SCREEN

contactor power
EARTHED BY COPPER SADDLE supply
CLOSE TO OUTPUT CHOKE AND
TO MOTOR BODY

MCBs

mains supply control cables

RASMI ELECTRONICS LTD., Morrison Road, Annfield Plain, Stanley,

Co. Durham DH9 7RX, England. e-mail: sales@rasmi.com
Tel: Stanley +44 (0)1207 291300 Fax: +44 (0)1207 291304