Application Paper AP043001EN Effective September 2014

Applying dV/dT filters with AFDs

Written by: Introduction Another factor that affects the reflected wave is
Gerry Feldmeier, the carrier frequency of the AFD. In today’s AFDs,
Eaton A dV/dT filter is a device that controls the voltage the carrier frequency can be as high as 20 kHz,
spikes generated by adjustable frequency drives which helps to control audible noise at the motor.
Dan Kupersmith, (AFDs) and long motor lead lengths. This voltage Typically, if the carrier frequency can be set
Eaton spike event is generally known as the reflected between 3 kHz and 12 kHz, the short lead length
wave phenomenon [1]. This resulting reflected applications will see a reflected wave that is less
Edited by: wave can cause very high voltages on the motor than the insulation rating of a standard inverter
Neil Wood,TCI leads, which can lead to damage and premature duty rated motor.
failure of the motor winding insulation (even with
inverter duty rated motors), particularly within the
first few turns. IGBT switching time
As a general rule, the reflected wave is twice The driving factor behind the voltage of the
the DC bus voltage, where the DC bus can be reflected wave is the speed at which the IGBT
calculated at 1.41 (square root of 2) times the turns on (the dV/dT), which can be as high as
line voltage. Therefore, for a 480 V service, the 8000 V per microsecond for an IGBT. The system
maximum reflected wave will be 480 x 2 x 1.41, impedance and/or capacitance will affect the
or 1353 V. Even though AFD rated motors and measured rise time of the IGBT. For smaller
cables are designed to handle higher voltages, this hp loads, the rise time may be 150 ns (more
voltage level can contribute to a reduced service capacitance than inductance), and a larger hp
life for the motor. Likewise, the lower the service load would be closer to 200 ns (more inductive).
voltage, the lower the peak value for the reflected With the increased impedance in the load, time
wave. For a 240 V motor, the reflected wave increases as the AFD becomes larger. Figure 1
would be closer to 680 V, so a dV/dT filter would shows the representation of the service voltage
not be required; however, a load reactor is always and the reflected wave versus distance and the
recommended. The motor hp is also a factor when rise time of the IGBT.
determining reflective wave because a smaller
hp motor appears more like a capacitor, while
a larger hp motor appears more like an inductor.
To illustrate this idea, think of a wave as it crashes
into shore; if the shore is a brick wall, the wave
splashes high into the air, which simulates the
reflected wave of a smaller hp motor. When the
wave comes onto the beach, it slowly dies out,
simulating a larger hp motor. For this reason, a
dV/dT filter may need to be applied on a shorter
lead length motor when the hp is smaller than
when the hp is larger. Generally, for a 20 hp or
lower motor, the maximum lead length is 60 feet,
while for a greater than 25 hp motor, the threshold
is 100 feet. Eaton motor control centers (MCCs)
apply a standard 3% load reactor to add extra Figure 1. Cable Length Versus Overvoltage [2]
impedance, which helps to match the impedance
of the motor and control the reflected wave
voltage until these thresholds are met. The switching speed for standard IGBT technology
is in the range of 8000 V per microsecond, which
puts the rise time of the IGBT of a 690 Vdc bus at
86 ns rise time (690 Vdc bus / [8000 V/μs] = 86 ns).
Taking into account the impedance of the system,
the measured rise time will be between 150 ns
(smaller motors) and 200 ns (larger motors). From
Figure 1, one can see that for a smaller motor the
maximum lead length is closer to 60 feet, while
for a larger motor it would be closer to 100 feet.
Application Paper AP043001EN Applying dV/dT filters with AFDs
Effective September 2014

Sizing of a dV/dT filter Upsizing the dV/dT filter can be beneficial in that the lugs typically
get larger so that the filter can accept a larger gauge wire; the core
Depending on the frame size of the dV/dT filter, the terminals are is larger and can dissipate the heat generated from common mode
designed to connect to a range of wire gauges. There is an urge to currents. However, upsizing the filter can reduce the expected
oversize the motor cables to minimize voltage losses, which may performance of the dV/dT filter, making it less effective in reducing
appear to be a positive action; however, this ends up increasing the reflected wave. Very simply, the filter works by an inductor that
capacitive coupling, leading to an increased common mode current. is good at removing high frequency components and a resistor in
A high common mode current can lead to higher motor bearing parallel that is used to dampen the voltage spikes. As the dV/dT filter
currents as well as heating of the dV/dT filter core, potentially gets larger, the value for the inductor gets smaller, which will not
leading to premature failure of the dV/dT filter. When it is necessary remove as many of the high frequency components because the
to use a wire that is too large for the dV/dT filter, see if it is possible current is less than what the filter is designed for per V=L(dI/dT). The
to move to the next largest dV/dT filter that will accept that wire reflected wave will be reduced, but it may or may not be reduced as
gauge. Table 1 shows the minimum and maximum wire sizes for a much as it would be for a filter rated for the exact motor operating
given dV/dT filter/AFD combination, as well as a calculated voltage current. When the filter is used this way, the application should be
drop at 1000 feet for the maximum terminal size. Voltage drop is evaluated to verify that the desired filtering effect is achieved.
calculated using E=K*P*L*I/A, where K=12 (specific resistivity),
P=1.73 (phase constant), L=wire length (feet), I=amperes, and
A=circular mills of the wire.
The common mode current (stray current that leaks to ground from
all phases at the same time) causes heating of the dV/dT filter core
because the dV/dT filter is tuned for a specific system impedance.
When oversized cables are used, it may also be necessary to oversize
the dV/dT filter to accept the larger cables. At times, oversizing the
dV/dT filter is the right choice, in that a larger core will have less
impedance and is capable of handling larger amounts of common
mode current, thereby dissipating the heat that the common mode
current produces. However, oversizing the dV/dT filter decreases
the effectiveness of the dV/dT filter because it is tuned for a specific
current and motor impedance. There will be times that simply Figure 2. dV/dT Filter Schematic [3]
changing the switching frequency to 2 kHz will solve heating issues.
Other times, an added inductor will be required in front of the dV/dT
filter to tune the system so that the excess capacitance is tuned out.
For extremely long runs, it is not unheard of to add another 3% or
5% inductance after the AFD and before the dV/dT filter, or to move
to a sine wave filter instead of a dV/dT filter.

Table 1. AFD to dV/dT Filter Cross [3]

Maximum Wire Size at
SVX DG1 Frame dV/dT Filter Wire Size of Voltage Drop 1000 Feet at
High OL High OL Amperes Terminal Ranges dV/dT Filter at 1000 Feet 4% Voltage Drop
FR4 FR1 2.2 12–14 AWG 12 1.5% 16
FR4 FR1 3.3 12–14 AWG 12 2.3% 14
FR4 FR1 4.3 12–14 AWG 12 3.0% 12
FR4 FR1 5.6 12–14 AWG 12 3.9% 12
FR4 FR1 7.6 12–14 AWG 12 5.3% 10
FR1 9.0 12–14 AWG 12 6.2% 10
FR5 FR2 12 12–14 AWG 12 8.3% 8
FR5 FR2 16 4–12 AWG 4 1.7% 8
FR5 FR2 23 4–8 AWG 4 2.5% 6
FR6 FR3 31 1–6 AWG 2 2.1% 4
FR6 FR3 38 1–6 AWG 2 2.6% 4
FR6 FR3 46 1–4 AWG 1 2.5% 2
FR7 FR4 72 1–3 AWG 1 3.9% 1
FR7 FR4 87 2/0–1/0 AWG 2/0 2.3% 0
FR8 FR5 105 2/0–1/0 AWG 2/0 2.8% 1/0
FR8 FR5 140 250 kcmil–3/0 AWG 250 2.5% 2/0
FR8 FR5 170 2 by 2/0 2/0 2.3% 3/0
FR8 FR6 205 2 by 2/0 2/0 2.8% 3/0
FR9 — 245 2 by 2/0 2/0 5.2% 350
FR9 FR6 261 600 kcmil or 2 by 500 kcmil or 3/0 600 1.0% 350
FR10 — 330 2 by 350 kcmil or 4/0 2 x 350 2.1% 2 x 200
FR10 — 385 2 by 600 kcmil–2 by 300 2 x 600 1.4% 400
FR10 — 460 2 by 600 kcmil–2 by 350 2 x 600 1.7% 500
FR11 — 520 2 by 600 kcmil–2 by 500 kcmil 2 x 600 2.0% 600

2 EATON www.eaton.com
Applying dV/dT filters with AFDs Application Paper AP043001EN
 Effective September 2014

Six application tuning factors Cable types
There are six factors that come into play when tuning a system. There are many types of cables that can be used to connect to the
These factors will provide positive and negative effects in many motor. The most common are AFD cables and standard stranded
cases, and must be balanced to achieve the desired outcome. cables. When a standard stranded cable is used (such as THWN or
THHN), all of the cables are loose (not bundled or twisted) and there
1. Common mode current is a significant amount of cross talk due to EMI/RFI. In essence,
2. Carrier frequency each wire is an antenna that broadcasts all switching frequencies
to adjacent wires. To solve the issue of cross talk, AFD rated cables
3. System voltage were created. AFD rated cable twists the leads and then inserts a
4. Load size ground per lead to space out the cables from one another to control
EMI/RFI. With this type of cable, the cross talk is eliminated or at
5. Lead length
least greatly reduced. However, all of the added ground wires can
6. Cable diameter add more capacitance, and this will add some common additional
mode current.
Common mode current is created mostly by capacitance due to
oversized cables combined with increased lead length. One way to In today’s applications, most motors that are connected to AFDs
control this effect is to take care not to oversize the cables to the are inverter duty rated, as are the motor cables. An inverter rated
AFD. Depending on the lead length, a dV/dT filter may not be the motor is designed with higher voltage insulation on the windings to
best choice, and a sine wave filter may need to be used. An effect counter the reflected wave, and is also designed to operate at lower
of lead length is that as the cable becomes longer, common mode frequencies without overheating.
current is bled off across the length of the wire, making the common
mode current at the motor less than a shorter cable. Shorter cables Cable splices
will have less common mode current; however, the current at both
ends of the cable will be very similar because less current is bled off, If at all possible, splicing of the cable between the dV/dT filter and
which will lead to higher common mode currents at the motor and the motor should be avoided. If a large cable is used going to the
increased current across the bearings. When the current across the motor, first look at upsizing the dV/dT filter to accept the cable if
bearings is high it can lead to premature bearing failure, which is that is the reason for the splice. A splice in the cable will introduce
why some motors are designed with insulated bearings. an impedance change, causing an impedance bump that is an
additional reflection point for the reflected wave. Also, even though
Carrier frequency, as well, controls dV/dT filter heating, because the shield may be carried through, it is not protecting the conductors
dV/dT filters are designed to operate between 2 kHz and 4 kHz. and intrudes a place where EMI and RFI can be both induced and
Most AFDs come out of the box at 12 kHz, so it is important that radiated. When a splice cannot be avoided, place that splice as close
the carrier frequency is set to the recommendation of the dV/dT to the dV/dT filer as possible to keep the leads to that splice short.
filter for the given size.

System voltage greatly affects the reflected wave, because the Shielding and grounding
reflected wave can reach about twice the system voltage. Due to
A typical AFD cable has three conductors, three grounds, and a
this effect, a 480 V or 575 V system will be much more susceptible
shield that runs the length of the cable. The cable ground should be
to the effects of the reflected wave, while a 230–380 V system will
tied to the motor ground lug, then tied to the ground lug of the AFD
have maximum reflected waves far below the insulation rating of the
unit or MCC structure on the other end. Placing the ground as close
wire and motor windings.
as possible to the AFD helps reduce the impedance of the ground
Load size affects the length as well. Small hp loads are more path, thereby reducing system common mode voltages. The shield
susceptible to common mode current, because the motor itself has should only be tied to the ground at one location to eliminate ground
more capacitance. Therefore, small hp loads will have to move to a loops, either at the motor or at the AFD.
dV/dT filter or a sine wave filter before larger hp loads will.
Summary
Lead length affects filter performance. The shorter the lead, less
common mode current is generated, and less core heating occurs. To control the effects of the reflected wave created by IGBTs in
certain applications, a dV/dT filter will need to be applied as noted
Cable diameter has an effect on the amount of capacitance and in this paper. The design of a dV/dT filter is based on a number of
resistance that the cable produces. A larger diameter cable will have factors, including IGBT switching time, load ampacity, cable length,
more surface area and more capacitance, leading to higher common and cable diameter. It is always best to use a dV/dT filter with an
mode currents, and less resistance, leading to reduced dampening ampacity matched to the motor, and cable sizes (AWG) that are
of the reflected wave. appropriate for the distance between the motor and the AFD while
resisting the urge to oversize the cable. When an oversized cable
must be used, upsizing the filter is an option if the lugs are not
large enough for the cable. However, there is a risk when upsizing
the filter too much; this is because the performance of the filter is
reduced when the amperage of the filter is too large for the load. In
these situations, it is advisable to add a terminal block at the dV/dT
filter to step the cable down to the filter lug size. When applying a
dV/dT filter, always remember to reduce the AFD carrier frequency
to 2–4 kHz. Taking these factors into account will assist in the
performance of the dV/dT filter in the application and the protection of
the motor from dangerous reflected wave voltages up to 1000 feet
from the AFD.

EATON www.eaton.com 3
Application Paper AP043001EN Applying dV/dT filters with AFDs
Effective September 2014 

References
[1] For more on reflected waves, search the Eaton.com website for
“Reflective Wave Phenomenon.”

[2] “Riding the Reflected Wave—IGBT Drive Technology Demands

New Motor and Cable Considerations.” Presented at IEEE IAS
Petroleum and Chemical Industry Conference 1996.

[3] Information based upon Eaton standard dV/dT filters.

Non-standard dV/dT filters may have different physical features.

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Publication No. AP043001EN / Z15630 All other trademarks are property
September 2014 of their respective owners.