Electronics Guide

Requirements Definition

The design process begins with defining the filter requirements based on the noise characteristics and applicable limits. Conducted emission limits from standards such as CISPR 11, CISPR 32, or FCC Part 15 specify maximum noise levels at the equipment power port. The difference between the unfiltered noise level and the limit, plus appropriate margin, determines the required insertion loss.

Frequency range requirements define the span over which filtering is needed. Conducted emission limits typically apply from 150 kHz to 30 MHz, while conducted immunity requirements may extend to higher frequencies. The filter must provide adequate attenuation throughout this range, accounting for the frequency-dependent characteristics of both the noise source and the filter components.

Operating conditions including voltage, current, temperature, and environmental factors constrain component selection. Maximum continuous current determines inductor sizing and core selection. Operating voltage affects capacitor ratings and safety classification requirements. Temperature range impacts component derating and reliability.

Noise Analysis

Understanding the noise to be filtered guides topology selection and component specification. Separating common-mode and differential-mode components reveals the dominant noise modes at different frequencies. This separation can be performed using current probes measuring phase and neutral currents, with mathematical analysis extracting the mode components.

Switch-mode power supplies typically exhibit a noise spectrum with differential-mode dominance at lower frequencies (150 kHz to 1-2 MHz) transitioning to common-mode dominance at higher frequencies. This pattern reflects the physics of noise generation, with differential-mode noise arising from switching current and common-mode noise from capacitive coupling of switching voltages to ground.

Noise measurements should be performed under realistic operating conditions including various load levels, input voltage variations, and temperature extremes. The worst-case noise level, which may occur at conditions different from nominal operation, determines the filter requirements.

Basic Single-Stage Filter

The simplest practical EMI filter combines a common-mode choke with X capacitors for differential-mode filtering and Y capacitors for common-mode filtering. This topology provides first-order differential-mode filtering and second-order common-mode filtering, suitable for applications with moderate EMI requirements.

The common-mode choke inductance, typically 1 mH to 20 mH for power line applications, determines the low-frequency corner of the common-mode response. X capacitor values typically range from 0.1 uF to 2.2 uF, sized to provide adequate filtering while limiting reactive current. Y capacitor values are constrained by leakage current requirements, typically 1 nF to 4.7 nF for each line-to-ground capacitor.

Two-Stage Filter

When single-stage filtering provides insufficient attenuation, adding a second stage increases the filter order and improves high-frequency performance. Two-stage filters can achieve 80 dB or more insertion loss, addressing the most demanding EMI requirements.

The stages may be identical or optimized for different functions. A common approach uses a larger first stage for low-frequency attenuation and a smaller second stage optimized for high-frequency performance. This division of function allows efficient use of filter volume while achieving broad-spectrum attenuation.

Inter-stage coupling must be considered in two-stage designs. Without adequate separation or damping, the resonant frequencies of the two stages may interact, creating response peaks that reduce attenuation at specific frequencies. Adding resistance or placing a conductive shield between stages prevents this interaction.

Filters with Separate Differential-Mode Inductors

When differential-mode attenuation requirements exceed what can be achieved with the leakage inductance of the common-mode choke, separate differential-mode inductors are added. These inductors are placed in series with each line, before or after the common-mode choke, and provide dedicated differential-mode filtering.

Differential-mode inductor values are typically smaller than common-mode choke values, ranging from 10 uH to several hundred microhenries. The smaller inductance reflects the higher corner frequency typically needed for differential-mode filtering and the constraint that excessive inductance can affect voltage regulation under changing load conditions.

Common-Mode Choke Selection

Common-mode choke selection begins with the inductance value needed to achieve the required attenuation in conjunction with the Y capacitors. The inductance should provide low-impedance resonance with Y capacitors at a frequency below the lowest frequency requiring significant attenuation.

Current rating is determined by the maximum continuous operating current. The choke must maintain its inductance without saturating at this current level. Most common-mode chokes are designed so the differential-mode current (which cancels in the core) does not contribute to saturation, but the common-mode current (which adds) can cause saturation if excessive. For most applications, common-mode currents are small and saturation from common-mode current is not a concern.

Core material affects the frequency characteristics of the choke. High-permeability nanocrystalline and ferrite cores provide high inductance for low-frequency attenuation. The impedance versus frequency curve, provided in manufacturer datasheets, shows the useful frequency range and helps match the choke to the application requirements.

Capacitor Selection

X capacitor selection considers capacitance value, voltage rating, frequency characteristics, and safety certification. The capacitance should provide low impedance at the frequencies requiring filtering, typically in the 0.1 uF to 2.2 uF range for power line filters. Film capacitors are preferred for their low ESR and ESL, providing better high-frequency performance than electrolytics.

Y capacitor selection is primarily constrained by leakage current requirements. Equipment standards specify maximum touch current and ground leakage current, which limit the total Y capacitance that can be connected line to ground. For 60 Hz, 120 V operation with a 0.5 mA leakage limit, the maximum Y capacitance is approximately 22 nF total. Higher voltages and lower leakage limits further restrict Y capacitor size.

Both X and Y capacitors in AC mains applications must carry appropriate safety agency certifications. X capacitors are classified as X1 or X2 based on their impulse withstand capability. Y capacitors are classified as Y1 or Y2 based on their insulation rating and failure mode characteristics. The safety class required depends on the application and the location of the capacitors in the circuit.

Inductor Selection for Differential-Mode Filtering

Differential-mode inductors must handle the full line current without saturating. This typically requires gapped ferrite cores or powdered iron cores that maintain inductance under DC bias. The saturation current rating should exceed the peak operating current with appropriate margin.

Inductor self-resonant frequency should be well above the highest frequency requiring attenuation. Above self-resonance, the inductor behaves capacitively and no longer provides filtering. Distributed winding capacitance determines the self-resonant frequency; single-layer windings and sectioned windings achieve higher self-resonant frequencies than multi-layer windings.

Circuit Simulation

SPICE simulation models filter response using component values and parasitic elements. Accurate simulation requires including parasitic inductance and resistance of capacitors, parasitic capacitance of inductors, and the frequency-dependent characteristics of magnetic cores. Manufacturer-provided SPICE models capture these effects for many components.

Simulation can model the complete system including noise source, filter, and LISN to predict compliance margin. Source impedance models representing the actual equipment, rather than idealized sources, improve prediction accuracy. Sensitivity analysis identifies components whose tolerances most affect compliance margin.

Analytical Methods

Closed-form equations provide quick estimates for initial filter sizing. For a basic LC filter, the cutoff frequency f = 1/(2 pi sqrt(LC)) and the attenuation above cutoff is 40 dB per decade. These relationships allow rapid exploration of design space before detailed simulation.

Impedance mismatch effects can be estimated using transmission line concepts. Maximum insertion loss occurs when filter input impedance matches the source impedance and filter output impedance matches the load impedance. Significant deviations from this condition reduce effective attenuation.

General Layout Principles

Input and output circuits must be separated to prevent coupling around the filter. Traces carrying unfiltered signals should not run parallel to filtered signal traces. Physical barriers, including ground planes and shields, help maintain separation between filter input and output.

Component placement should follow signal flow, with filter stages arranged sequentially from input to output. This arrangement minimizes the opportunity for unfiltered signals to couple to filtered circuits. Placing the filter at the enclosure boundary takes advantage of the enclosure shielding to maintain input/output isolation.

Grounding Considerations

Y capacitor ground connections must be short and low-inductance to maintain effectiveness at high frequencies. Every nanohenry of ground inductance adds to the capacitor impedance, reducing attenuation. Direct connection to a ground plane or chassis through minimal trace length and multiple vias provides the lowest inductance.

The filter ground reference should be well-defined and consistent. Connecting filter ground to chassis at the filter location, with a single-point or very short multi-point connection to system ground, prevents ground loops that could couple noise around the filter.

PCB Design

For PCB-mounted filters, trace width must accommodate the current without excessive voltage drop or heating. Ground planes on adjacent layers provide low-impedance return paths and shielding. Via placement should minimize inductance in critical current paths, using multiple vias in parallel for high-current connections.

Keep high-frequency components such as Y capacitors on the outer board layers close to their ground plane connection. Burying these components on inner layers adds via inductance that degrades high-frequency performance. Surface-mount components generally provide better high-frequency performance than through-hole components due to shorter lead lengths.

Creepage and Clearance

Safety standards specify minimum distances between circuits at different potentials. Clearance is the shortest distance through air; creepage is the shortest distance along surfaces. These distances depend on the voltage, pollution degree of the environment, and the material group of insulating surfaces.

For 250 VAC operation in typical indoor environments (pollution degree 2), minimum clearances and creepage distances are typically 2.5 to 3 mm between line and ground, and similar distances between primary and secondary circuits. Higher voltages and more contaminated environments require greater distances.

Component Safety Requirements

Components bridging safety insulation barriers must be safety certified. X and Y capacitors require certification to IEC 60384-14 or equivalent standards. Common-mode chokes in line-to-line positions should be recognized or certified for the intended application.

Fusing of X capacitors may be required if their failure could create a hazard. A failed X capacitor short-circuiting the line could draw excessive current if not limited by a fuse. The fuse must interrupt the available fault current before the capacitor fails catastrophically.

Leakage Current

Y capacitors create a path for current flow from line to ground, contributing to equipment leakage current. Safety standards limit this current to prevent shock hazards if the ground connection is interrupted. Medical equipment has particularly stringent leakage current limits to protect patients who may be in direct electrical contact with the equipment.

Insertion Loss Measurement

Insertion loss characterizes filter attenuation as a function of frequency. The measurement compares the signal level with and without the filter in the circuit. Standards such as CISPR 17 define measurement methods using 50-ohm source and load impedances.

Separate common-mode and differential-mode insertion loss measurements characterize the filter's performance against each noise mode. Mode separation can be achieved using specialized test fixtures or mathematical analysis of mixed-mode measurements.

In-System Testing

The definitive test of filter adequacy is EMI compliance testing of the complete system. The filter is evaluated in its intended application, with the actual noise source and real-world impedances. Conducted emission measurements following CISPR procedures verify that the filtered emissions meet applicable limits.

Margin testing identifies the available design margin by either increasing noise artificially or measuring to lower limit lines. Adequate margin (typically 6 dB or more) provides confidence that production variations and field conditions will not cause compliance failures.