How can we Assist our customer to pass EMC

The EMC Challenge: How We Saved a Failing Single-Phase Power Filter

When an industrial automation company approached us in a panic, their situation was dire. Their single-phase power filter—a critical component for protecting sensitive medical imaging equipment—had failed EMC testing three times at a certified lab. With their product launch deadline looming and penalties mounting, they needed a miracle.

The Problem: A Filter That Couldn’t Filter

The client’s filter was designed to clean up noise from variable frequency drives (VFDs) but failed spectacularly during:

• Conducted Emissions (CE) tests (EN 55011) – Noise spikes at 150kHz–30MHz exceeded limits by 12dB.

• Radiated Immunity (IEC 61000-4-3) – The filter’s own shielding was resonating at 50MHz, worsening interference.

Their engineering team had tried everything: extra capacitors, toroidal chokes, even a full PCB redesign. Nothing worked.

Our Breakthrough

We took possession of the filter and assembled a SWAT team of EMC specialists. Here’s how we turned it around in 7 intense days:

Day 1–2: Forensic Analysis

• Discovered the Y-capacitors were creating a ground loop via the chassis.

• Oscilloscope traces revealed ringing at 2MHz from poor damping in the LC stages.

Day 3–4: Surgical Modifications

• Replaced generic X2 capacitors with low-ESR film types (reduced HF losses by 40%).

• Added a common-mode choke with nanocrystalline core (suppressed 30MHz+ noise).

• Redesigned the PCB layout to minimize parasitic coupling.

Day 5–7: Validation & Victory

• Pre-tests showed a 15dB improvement at worst-case frequencies.

• Final lab test: Passed EN 55011 Class B with 6dB margin!

Why This Matters for You

Many filters fail not because of poor design, but due to hidden interactions between components. Our approach combines:

1. Deep EMC expertise (we’ve fixed 200+ filter designs).

2. Advanced tools like near-field probes and 3D EM simulation.

3. Real-world solutions – no theoretical "textbook fixes."

Need Your Filter to Pass EMC?
Just provide:
✅ Target standards (e.g., MIL-STD-461, CISPR 32).
✅ One sample unit (or even just schematics).

We’ll deliver:
✔ Diagnostic report within 48 hours.
✔ Modified design that actually passes.
✔ Test-ready unit – no guesswork.

Contact us today. Let’s turn your EMC nightmare into a compliance success story.