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Part 6 — ESD, Electromechanical Devices, Power Factor Correction Another EMC resource from EMC Standards EMC techniques in electronic design Part 6 - ESD, electromechanical devices, power factor correction Helping you solve your EMC problems 9 Bracken View, Brocton, Stafford ST17 0TF T:+44 (0) 1785 660247 E:[email protected] Design Techniques for EMC Part 6 — ESD, electromechanical devices, power factor correction, voltage fluctuations, immunity to supply dips and dropouts and other power quality issues Originally published in the EMC Compliance Journal in 2006-9, and available from http://www.compliance-club.com/KeithArmstrong.aspx Eur Ing Keith Armstrong CEng MIET MIEEE Partner, Cherry Clough Consultants, www.cherryclough.com, Member EMCIA, EMCTLA Phone/Fax: +44 (0)1785 660247, Email: [email protected] This is the sixth and final article in this series on basic good-practice electromagnetic compatibility (EMC) techniques in electronic design, published during 2006-8. It is intended for designers of electronic modules, products and equipment, but to avoid having to write modules/products/equipment throughout – everything that is sold as the result of a design process will be called a ‘product’ here. This series is an update of the series first published in the UK EMC Journal in 1999 [1], and includes basic good EMC practices relevant for electronic, printed-circuit-board (PCB) and mechanical designers in all applications areas (household, commercial, entertainment, industrial, medical and healthcare, automotive, railway, marine, aerospace, military, etc.). Safety risks caused by electromagnetic interference (EMI) are not covered here; see [2] for more on this issue. These articles deal with the practical issues of what EMC techniques should generally be used and how they should generally be applied. Why they are needed or why they work is not covered (or, at least, not covered in any theoretical depth) – but they are well understood academically and well proven over decades of practice. A good understanding of the basics of EMC is a great benefit in helping to prevent under- or over-engineering, but goes beyond the scope of these articles. The techniques covered in these six articles will be: 1) Circuit design (digital, analogue, switch-mode, communications), and choosing components 2) Cables and connectors 3) Filtering and suppressing transients 4) Shielding (screening) 5) PCB layout (including transmission lines) 6) ESD, electromechanical devices, power factor correction, voltage fluctuations, immunity to power quality issues Many textbooks and articles have been written about all of the above topics, so this magazine article format can do no more than introduce the various issues and point to the most important of the basic good-practice EMC design techniques. References are provided for further study and more in-depth EMC design techniques. Table of contents for this article 6. ESD, electromechanical devices, power factor correction, voltage fluctuations, immunity to power quality issues..............................................................................................................................................2 6.1 Electrostatic Discharge (ESD) ......................................................................................................... 2 6.1.1 ESD threats ......................................................................................................................... 2 6.1.2 Prevent ESD by preventing electrostatic charge from building up...................................... 7 6.1.3 Prevent the discharge from happening with insulation........................................................ 7 6.1.4 Control the discharge with shielding.................................................................................. 10 6.1.5 Protecting signal, data, control or power conductors ........................................................ 14 6.1.6 ‘Earth lift’ problems for interconnected items of equipment .............................................. 17 6.1.7 Protecting data and signals from errors ............................................................................ 19 6.1.8 Use all the other EM design techniques too...................................................................... 20 6.1.9 Software techniques.......................................................................................................... 20 6.2 Electromechanical devices and spark ignition............................................................................... 20 6.2.1 Important safety note......................................................................................................... 20 6.2.2 Introduction to arcs and sparks ......................................................................................... 21 Design Techniques for EMC – Part 6 Cherry Clough Consultants May 2009 Page 1 of 71 6.2.3 A problem with emissions and immunity standards .......................................................... 22 6.2.4 Suppressing arcs and sparks............................................................................................ 22 6.2.5 Suppressing commutator motors and generators............................................................. 25 6.2.6 Suppressing sliprings ........................................................................................................ 27 6.2.7 Suppressing spark ignition ................................................................................................ 28 6.2.8 Electric bells and buzzers.................................................................................................. 28 6.3 Power factor correction (emissions of mains harmonic currents).................................................. 28 6.3.1 The particular problem of rectifiers with capacitive loads ................................................. 28 6.3.2 Using smaller values of unregulated DC smoothing capacitor ......................................... 33 6.3.3 Filtering mains harmonics ................................................................................................. 33 6.3.4 Passive harmonic reduction with a series inductor ........................................................... 35 6.3.5 Charge-pump PFC in a switch-mode converter................................................................ 36 6.3.6 ‘Active’ PFC techniques ....................................................................................................37 6.3.7 Reducing emissions from 3-phase (3I) equipment........................................................... 39 6.3.8 ‘Active Front End’ (AFE) three-phase ‘boost’ rectifiers ..................................................... 40 6.3.9 Anti-harmonic injection (‘active filtering’)........................................................................... 41 6.3.10 Other methods .................................................................................................................. 41 6.4 Emissions of voltage fluctuations and flicker ................................................................................. 41 6.4.1 Causes of emissions of voltage fluctuations and flicker.................................................... 41 6.4.2 The standards and their limits ........................................................................................... 42 6.4.3 Background to the suppression techniques ...................................................................... 43 6.4.4 Reducing inrush current at switch-on................................................................................ 43 6.4.5 Reducing emissions of voltage fluctuations caused by varying AC loads ........................ 47 6.4.6 Reducing emissions of voltage fluctuations caused by varying electronic loads.............. 48 6.5 Immunity to Power Quality issues.................................................................................................. 48 6.5.1 Introduction to power quality ............................................................................................. 48 6.5.2 Important Safety Considerations for Mains Circuits.......................................................... 49 6.5.3 Overvoltages (swells) .......................................................................................................50 6.5.4 Frequency variations ......................................................................................................... 52 6.5.5 3-phase unbalance............................................................................................................ 53 6.5.6 DC in AC supplies ............................................................................................................. 53 6.5.7 Common-mode (CM) low-frequency voltages................................................................... 53 6.5.8 Undervoltages (sags, brownouts, dips, dropouts and interruptions)................................ 55 6.5.9 Voltage fluctuations ........................................................................................................... 61 6.5.10 Waveform distortion (harmonic and/or interharmonic) .................................................... 61 6.5.11 Improving the quality of the mains supply itself ................................................................ 64 6.5.12 Tripping-out techniques .................................................................................................... 69 6.6 Conclusion to the series ...............................................................................................................
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