www.schaffner.

com
E M C E n g in e e rin g
C u sto m P ro d u c t D e ve lo p m e n t
A d va n c e d Te stin g C a p a b ilitie s
SERVICES & SOLUTIONS
COMPONENTS
SCHAFFNER A UNIQUE ORGANIZATION
No one needs reminding, that we live
in the age of electronics. But our
enjoyment of the benefits of electrical
energy depends entirely on the
success of manufacturers in ensuring
the electromagnetic compatibility of
each new product they develop.
For over 35 years, Schaffner has
worked with the international
electronics manufacturing
community to ensure that success.
Our business is the development and
delivery of highly effective EMC
solutions to electrical and electronic
equipment manufacturers,
world-wide. This is our sole focus -
and it makes us unique. No other
company has the breadth of skills,
products and resources, or the depth
of expertise that we can offer.
Our solutions serve the world-wide
electronics community, from the
smallest manufacturer seeking type
approval for the first time, to the
multinational building a full in-house
EMC test facility.
We design and manufacture the
filters and chokes which prevent
equipment from generating EMI, and
protect it from its effects.
We develop the advanced test
instruments and systems required to
check the effectiveness of product
designs. We provide the expertise
and resources to help our customers
deploy our products effectively.
And we put at their disposal some of
the most sophisticated test and
calibration facilities in the world, to
certify their sustained compliance
with EMC standards.
G L O B A L P R E S E N C E L O C A L S U P P O R T
As the number 1 in EM C, Schaffner is in a unique position to assist
manufacturers with every aspect of EM C, at every stage of the product
development cycle, everywhere. With a global network of subsidiaries
and distributors, several production facilities in Europe and Asia and
sophisticated test and evaluation laboratories at seven strategic
positions around the world, Schaffner is always very close to you.
Each of these laboratories is staffed by specialist EM C engineers and
equipped with advanced instrumentation for fast and accurate
assessment of electromagnetic interference (EM I) and electromagnetic
immunity or susceptibility (EM S).
Available services at these locations include:
Semi-anechoic chamber and open field testing
Harmonics instrumentation for current and voltage to the
49th harmonic
Emission and immunity tests according to European and
international standards (EN, IEC, FCC, CISPR, M il)
Additional services available at the accredited testing facility in
Switzerland:
Full load test set-up for motor drives (see also Advanced testing
under real-life conditions )
Safety testing and environmental simulation for passive components
for electromagnetic interference suppression according to European,
international and North American standards
U N S U R P A S S E D C A P A B I L I T I E S
For initial prototype development work and investigation of products
that fail early compliance testing, conducted emission tests to 30M Hz
or above will be performed, and near-field probes and spectrum
analyzers allow radiated field strength to be measured down to board
or component level at frequencies as high as 1 GHz.
D E D I C AT E D P R O P R I E TA R Y E Q U I P M E N T
Some of our larger EM C test laboratories can perform radiated power
testing using broad-spectrum power meters to measure up to
1 GHz and radiated EM I testing, using proprietary state-of-the-art
pulse and noise generators.
S TAT E -O F -T H E -A R T E XP E R I E N C E
Each EM C test laboratory maintains close links with the main
laboratory at our headquarter in Switzerland and is able to call upon
this additional source of expertise whenever needed.
EMC ENGINEERING SERVICES AND
CUSTOM PRODUCT DESIGN
WH Y U S E A C U S T O M P R O D U C T ?
Schaffners standard products satisfy an extremely diverse range of
requirements. However, invariably there will be occasions when
application-specific products offer a better technical and economical
solution. Some of the key reasons for choosing custom products
include:
M eeting special mechanical layout, size, installation or connection
requirements
Ensuring conformance with overall application specifications
Satisfying specific filtration requirements by fine-tuning parameters
O ptimizing cost/performance to exactly match the application
The decision to use a custom product should always be backed by a
full technical and economic analysis.
B A L A N C I N G T H E E Q U AT I O N
Electronics equipment manufacturers often view the use of custom
filters with some caution. A common concern is that they will some-
how lose control of the costs or the process, and possibly risk delaying
the introduction of a new product to market, or end up using a poorly
designed filter.
S E L E C T I N G T H E B E S T S U P P L I E R
All these issues can be satisfactory resolved from the beginning by
careful choice of supplier. A prudent first step would be to check the
companys credentials.
It is vital that the filter supplier is willing to work with you as a partner
preferably in the language of your choice and has the skills,
willingness, applications-awareness and necessary resources to ensure
timely project completion.
I n a d d i ti o n to o ffe ri n g o n e o f th e w o rld s m o s t c o m p re h e n s i v e ra n g e s
o f s ta n d a rd E M C fi lte rs , li n e -c o n d i ti o n i n g p ro d u c ts , R F I s u p p re s s i o n
c h o k e s a n d p u ls e tra n s fo rm e rs , S c h a ffn e r o ffe rs th e fu ll c o m p le m e n t
o f e n g i n e e ri n g s e rv i c e s a n d c u s to m p ro d u c t d e s i g n to s u p p o rt
e q u i p m e n t m a n u fa c tu re rs a n d u s e rs .
S E C U R I N G L O N G -T E R M S U P P O R T
The ideal supplier will have the capability of simulating designs to help
speed development, together with comprehensive test and
measurement facilities to verify the performance of the filter and its
overall effect upon the product that incorporates it.
The supplier must also be able to provide high-quality prototypes as
quickly as possible and maintain this quality when the filter goes into
volume production.
T H E I D E A L P A R T N E R
Schaffner is well-positioned to help on all these fronts. The company
has over 35 years experience in producing high quality EM C
components for the world market. Schaffner has the most
comprehensive portfolio of power line filters and suppression products
in the world. It produces custom AC and DC power line filters, line-
conditioning products, chokes and pulse transformers for an extremely
diverse range of industrial, telecommunication, power supply, medical,
office, defence, aerospace and transportation applications.
B E N C H M A R K I N G T H E E XP E R I E N C E
Schaffners products and experience encompass everything from
miniature 100mA filters weighing less than 3g to high-current 3500A
industrial systems that tip the balance at well above 100kg. There is no
application too large or too small for consideration.
A U N I Q U E S O U R C E O F H E L P A N D S U P P O R T
Schaffners wide-ranging expertise in EM C issues enables it to provide
the most cost-effective products. O ur ability to recognize EM C
problems and accurately identify their origins allows us to propose
solutions very fast. O ur overall intention is one of long-term partnership
we want to build the best solution for you, to ensure that your own
goals are met.
WO R L D WI D E P R E S E N C E
Schaffner is renowned for the quality and responsiveness of its custom
product services. The company has custom filter design and
prototyping facilities at seven strategic locations world-wide. At each
location, experts are available to provide help and guidance with every
aspect of custom products from initial costing and technical analysis,
through design and prototype building, to test and evaluation.
L O C A L E XP E R T I S E
Extensive knowledge of the EM C regulations that apply in each country
enables our engineers to provide support at every stage of the
process. Custom products can be developed directly from customers
mechanical and electrical specifications, or from investigation of the
end-equipment and the compliance regulations of its intended market.
T O TA L C A P A B I L I T I E S
Schaffners custom products are subjected to the same rigorous
performance checks as standard, high-volume products. The custom
design facilities are equipped with:
Powerful simulator workstations and leading-edge test and
measurement instrumentation for full evaluation and quantification of
filter performance.
High voltage and high current sources to verify isolation voltage and
current-carrying capacity up to 6kV and 600A.
Broad-spectrum signal generators and power meters for insertion
loss measurements to above 3 GHz.
Special high-accuracy measurement instruments to certify that the
filters temperature rise is in accordance with international safety
standards such as UL, CSA and EN.
A C L E A R P AT H T O S U C C E S S
Schaffner is uniquely able to help customers move efficiently and easily
from the prototype phase to volume production. Each custom design
facility maintains close links with Schaffners ISO 9001:2000 -approved
manufacturing plants in Thailand, Hungary and Switzerland; customers
can consequently benefit from both Far East manufacture for very
high-volume applications and European manufacture for small- to
medium-volume applications.
Whichever route you choose, our ultimate goal is the
same as yours the efficient production and delivery
of cost-effective high quality products, to help ensure
that your products comply with all appropriate EMC
regulations, and help increace the reliability and
functional security of your equipment.
ADVANCED TESTING UNDER
REAL-LIFE CONDITIONS
T E S T I N G P O WE R D R I VE S YS T E M S WI T H M A I N S F I LT E R S
The standard that controls the compliance of PDS with the EM C
Directive is EN 61800-3. This standard specifies the conducted
emissions limits of EN 55011 for drives which are connected to a
network that supplies domestic premises. It allows light loading for the
tests on the grounds that the main emissions source is the dV/dt
associated with the edges of the switched voltage waveform, which
doesn t change significantly with load. Is this practice justified?
When a filter is used in the supply line, it must pass the full current
taken by the drive. If the filter is necessary for compliance, then its
attenuation must be guaranteed over the whole current range. There
are two important parameters which relate the input current to the
attenuation: these are saturation of the magnetic material due to
supply current and operating temperature.
S U P P LY C U R R E N T
You might be tempted to specify a filter against the RM S current
drawn by the drive at full power. This is normally inadequate. A typical
three-phase bridge capacitor-input rectifier can draw more than twice
its rated RM S current at the peaks of the input waveform. But, the
ferrite core of an input EM I filter is
designed so that the common
mode inductance retains 80% of
its nominal value at the filters
rated current. To protect the
common mode inductance
against saturation, the 80%
point should occur at the peak.
Fig.1 shows the saturation curve of a
manganese-zinc ferrite core, rated for
80% inductance at 21A. Testing a PDS
under light load condition, as accepted
by EN 61800-3, will see the fastest
rise time of the switched DC voltage
but core saturation at the maximum
input current peak will not occur.
Although the supply current magnetic field is compensated inside a common mode ferrite core, the
stray inductance (around 1% of nominal) still leads to saturation at the peak current. The effect of a
choke in saturation is mainly felt at the bottom end of the spectrum near 150kHz, where >10dB
reduction in attenuation can be found.
I n a d d i ti o n to o ffe ri n g th e m e a s u re m e n t a n d te s ti n g s e rv i c e s m e n ti o n e d i n th e
i n tro d u c ti o n p a rt o f th i s b ro c h u re , S c h a ffn e r a ls o o p e ra te s a fu ll lo a d te s t s e t-u p fo r
m o to r d ri v e s . A lth o u g h s p e c i fi e d b y th e E M C d i re c ti v e , p e rfo rm i n g c o n d u c te d
e m i s s i o n te s ts w i th li g h t lo a d s o n ly d o e s n o t n e c e s s a ri ly s i m u la te p ro b le m s w h i c h
c a n o c c u r i n re a l li fe s i tu a ti o n s .
M o d e rn p o we r
d rive syste m s
P D S ) u se
h ig h -fre q u e n c y
switc h in g
te c h n iq u e s fo r
m a x im u m
e ffic ie n c y a n d
th is m a k e s th e m
p rim e so u rc e s o f
R F c o n d u c te d
e m issio n s.
To re d u c e th e
le ve l o f th e se
e m issio n s, a
m a in s filte r m u st
b e u se d .
80%@21A
saturation
@>35A
O P E R AT I N G T E M P E R AT U R E
When the full rated (RM S) load current is drawn through the filter,
inevitably there are losses in the core and in the winding wires. These
lead to a temperature rise of the choke which can be several tens of
degrees between light load and full load, and will be greatest in the
core itself. The effect of this temperature rise on the ferrites
magnetization curve is shown in Fig.2.
The winding is designed for, e.g. 300
mT flux density at room temperature
(25C). Again, testing a PDS at light
loads will not generate these
temperatures in the filter.
CONCLUSION
I f th e c o n d u c te d e m issio n p e rfo rm a n c e o f a P D S re lie s o n th e
p re se n c e o f a m a in s in p u t filte r, te stin g th e syste m o n ly a t lig h t
lo a d s a s a llo we d in E N 6 1 8 0 0 -3 will se rio u sly u n d e re stim a te th e
e m issio n s, e sp e c ia lly a t th e lo w fre q u e n c y e n d . Te stin g u p to th e
fu ll lo a d c u rre n t d ra wn th ro u g h th e filte r is a d visa b le .
F o r e ve ry n e w filte r we d e ve lo p , S c h a ffn e r e n g in e e rs c o n sid e r
th e se p a ra m e te rs to m a k e su re , th e filte r will k e e p its
sp e c ific a tio n s u n d e r lo a d c o n d itio n s. With th e e q u ip m e n t
a va ila b le to u s, th is is n o t o n ly d o n e b y c a lc u la tio n o r sim u la tio n
b u t a lso b y te stin g u n d e r th e c o n d itio n s th e filte r will o p e ra te in
th e fin a l a p p lic a tio n . F o r yo u a s o u r p a rtn e r, th is m e a n s n o
u n p le a sa n t su rp rise s a fte r th e in sta lla tio n o r e x p e n sive d e la ys o f
yo u r p ro d u c t s tim e to m a rk e t. With o u r te ste d a n d a p p ro ve d ,
fit-a n d -fo rg e t filte r so lu tio n s, yo u c a n sa tisfy yo u r c u sto m e rs with
e q u ip m e n t, wh ic h m e e ts th e la te st in te rfe re n c e a n d im m u n ity
sta n d a rd s e ve n u n d e r fu ll lo a d c o n d itio n s.
Design target level
Te stin g th e
filte rs u p to
th e fu ll lo a d
c u rre n t d ra wn
b y th e
in ve rte r
is a d visa b le
www.schaffner.com
2001 Schaffner EMV. Specifications
subject to change without notice.
All trademarks recognised.
Schaffner is an ISO-registered company.
Its products are designed and manufac-
tured under the strict quality requirements
of the ISO 9001 standard.
This catalogue is a sales and promotion
document. It has been carefully checked.
However, Schaffner does not assume any
liability for errors or inaccuracies.
To obtain the latest technical datasheets,
contact your local sales office.
China
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E-mail: chinasales@ schaffner.com
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E-mail: switzerlandsales@ schaffner.com
SALES SUBSIDIARIES
Finland
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E-mail: finlandsales@ schaffner.com
J apan
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Tel: [+81] 3 3418 5822
E-mail: japansales@ schaffner.com
UK
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USA
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Germany
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Sweden
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HEADQUARTERS
S c h a ffn e r E M V A G
CH-4542 Luterbach
Switzerland
Tel: [+41] 32 6816 626
Fax: [+41] 32 6816 641
E-mail: sales@ schaffner.com
E U R O L O G I S T I C S C E N T E R
S c h a ffn e r E M C S . A . S .
F-68311 Illzach
France
Tel: [+33] 3 89 31 04 00
Fax: [+33] 3 89 31 04 01
690-695A
Benteli Hallwag Druck AG / O ctober 2001