Notice # 0001

Version 1.1
April 18, 2005

E LECTRO M AGNETIC I NTERFERENCE SUPPRESSION :

L INE F ILTERS

AND THE

MACH-S YSTEM

Introduction

24VAC
CONTACTOR1

COM

24VAC INPUT POWER LINE FILTER

TRANSIENT SUPPRESSION TEST
APPARATUS
12 14 11 A1
RELAY

XT-1
L
N
24VAC

COM

24VAC:120VAC

A2

COM

12 14 11 A1
RELAY
22 24 21

24VAC
CONTACTOR3

COM

SCOPE
PROBE

12 14 11 A1
RELAY

N1

IN
FILTER
Qualtek
Model 851-02/001
OUT

A2

GND

CONTACTOR2

L1

22 24 21
24VAC

24VAC

Application Notice

Reliable Controls DDC controllers that control package HVAC units are usually exposed to high levels of
electromagnetic noise. The noise source stems from close proximity to high voltage switching devices
such as electronic igniters and contactors. It is quite common for controllers to be powered with the same
24VAC power supplied with the package unit. In most scenarios, it is not an ideal arrangement to use the
same power supply in this manner because of the noise generated by other circuits connected to this same
transformer. It is an established best practice to use a separate power supply for the controller, the
contactors, and other equipment. In some cases, adding separate transformers is not practical or cost
effective, resulting in a shared transformer. When a transformer is shared, such as the unit shown in Figure
1, a line filter should be used to protect the controller from unwanted Electromagnetic noise.

A2

22 24 21
24VAC
CONTACTOR4

COM

12 14 11 A1
RELAY

A2

22 24 21

24VAC
CONTACTOR5

COM

12 14 11 A1
RELAY

A2

22 24 21

Figure 1: Test apparatus for transient analysis with and without a line filter.

2004 Reliable Controls Corporation

120 Hallowell Road . Victoria, BC . V9A 7K2 . 250.475.2036

Page 1 of 4

877.475.9301 . Fax: 250.475.2096

APPLICATION NOTICE: EMI Suppression - Line Filters and MACH-System

EMI

Electro Magnetic Interference (EMI) is generated by the activity of relays, contactors, and
other power switching devices. A contactor switch can produce a large amount of electrical
noise. The noise can be generated by a mechanical switch bounce, or an inductive field
break down of the switching coil in the relay. This noise can be witnessed as a fast transient,
high-frequency, large amplitude burst on the 24VAC power grid. It is not uncommon for
collapsing inductive fields to produce a negative voltage spike twice the amplitude of the
source voltage. Turning off a 24VAC contactor can produce a noise in excess of -90Vpk. In a
situation where the supply transformer is shared, the noise is directly connected (coupled) to
the input power of the controller. This noise can be reduced with the use of Metal Oxide
Varistors (MOVs), transorbs, and other transient suppression devices, connected across the
contacts of the relays and contactors. A large amount of EMI can cause spurious intermittent
problems at the controller logic level at any given time. Due the nature of switching devices
and the order of control sequences, the level of EMI can be considered random. A random
noise problem can eventually produce a random product failure. This random product failure
is usually not permanent; but may cause a lock-up, system crash, or memory loss. While
MOVs separate transformers, and other transient protection devices have proven effective in
suppression, MOVs can fail to catch and suppress all of the noise. Because noise can be
coupled into wires through air or by direct connection, a line filter connected directly to the
input power of the controller is the most effective suppression method.

Line Filters

As it is not practical to put an MOV across all contactors and relays, the line filter is a good 'fix
all' approach to the problem. The line filter acts like a low pass filter by eliminating high
frequency noise, but allowing low frequency power to pass. Figure 1 shows the proper method
for connecting a line filter to a MACH2 controller.
Transient noise reduction is achieved using the Qualtek model 851-02/001 line filter. Figures 2
and 3 show the input power to the MACH2 system with and without the line filter. As shown,
the noise transients are greatly reduced in frequency and amplitude.

2004 Reliable Controls Corporation

120 Hallowell Road . Victoria, BC

Page 2 of 4

V9A 7K2 . 250.475.2036

877.475.9301 . Fax: 250.475.2096

APPLICATION NOTICE: EMI Suppression - Line Filters and MACH-System

Contactor Switch
Noise

24 VAC Input with

Line Filter shifted up
by 20 VDL for clarity

24VAC without
Line Filter

24 VAC Input to a
MACH2 with 5
contactors switching
between mechanical
relays connected to
MACH2 outputs.

The Qualtec Model

851-02/001 is
connected to show the
reduction of transients
to the controller.
Figure 2: 24VAC Input to MACH2 with or without Line Filter.

This data is measured

with a trigger delay of
10mS on Out2 as the
trigger. This is the Input
power to a MACH2
switching 5 contactors
in unison.

24VAC with
Qualtec Filter
24VAC without filter

The scope probe is on

the 24VAC input
terminal block and the
Gnd terminal.
Figure 3: 24VAC input to MACH2 Controller with and without filter (Trigger Delay).

Installation Guidelines

A line filter should be connected to each controller that may encounter noise. Connection lines
from the controller to the line filter should be kept as short as possible.
For installations where one transformer feeds many controllers, a
separate line filter should be used for the input power for each
controller.
A line filter is more effective than providing a separate transformer to power the controller.

2004 Reliable Controls Corporation

120 Hallowell Road . Victoria, BC

Page 3 of 4

V9A 7K2 . 250.475.2036

877.475.9301 . Fax: 250.475.2096

APPLICATION NOTICE: EMI Suppression - Line Filters and MACH-System

L1

GND

N1

OUT

FILTER
24VAC

24VAC
100VA

AC

TO OTHER DEVICES
24VAC
COM

N1

FILTER
24VAC

L1

GND

N1

OUT

L1

GND

OUT

FILTER
24VAC

Figure 4: Line filter installation for multiple controllers on one transformer.

Conclusion

A line filter will not eliminate all noise from a system; but it will attenuate the transients and
noise to a non-harmful level. To ensure that all MACH-System controllers continue to operate
problem free, line filters should be employed when EMI is considered to be a threat to system
integrity.

Obtaining Line Filters

Qualtek Line Filters are available from many sources.

Reliable Controls purchased Qualtek Line Filters through Lectro Components Inc.
(www.lectrocomponents.com)
Reliable Controls resells this product under Part# PLF-2.

2004 Reliable Controls Corporation

120 Hallowell Road . Victoria, BC

Page 4 of 4

V9A 7K2 . 250.475.2036

877.475.9301 . Fax: 250.475.2096