EMI/RFI Filters for Fast DC EV Charging Stations

Introduction

The surge in demand for electric vehicles (EVs) is a significant part of global efforts to reduce pollution and reliance on fossil fuels. As more people adopt EVs, the need for efficient and accessible charging infrastructure has grown. Early slow chargers, which required long wait times, are being replaced by fast charging stations that offer quicker charging times and enhanced efficiency, contributing to greater EV adoption.

Smart DC fast charging stations are crucial to facilitating this transition, especially for long-distance EV travel. However, their increased power demands, high switching frequencies, and sophisticated electronics create significant challenges—one of the most pressing being electromagnetic interference (EMI).

EMI Effects in Smart Fast Chargers

EMI presents serious challenges in the design and operation of electric vehicle (EV) fast chargers, particularly due to high power levels, fast switching frequencies, and the presence of sensitive electrical and electronic systems within the charging units.

One key source of EMI in smart fast chargers is the power converters used, such as DC-DC converters. These converters often employ high-speed switching components like Insulated-Gate Bipolar Transistors (IGBTs), operating at frequencies between 20 kHz and 200 kHz. Advanced semiconductor materials such as silicon carbide (SiC) and gallium nitride (GaN) push these switching frequencies even higher, into the MHz range, leading to even greater EMI.

EMI can affect both the charger itself and its surrounding environment:

• Internal Disruptions: These may include signal interference, power supply disturbances, and component stress within the charger.
• External Disruptions: Nearby devices may experience crosstalk, wireless communication interference, or malfunction due to radiated EMI.
• Conduction and Radiation: EMI can manifest through both conducted (via power lines) and radiated (through electromagnetic waves) interference, impacting the charger’s electromagnetic compatibility (EMC), the performance of the vehicle being charged, and the functionality of other sensitive equipment in the area.

Standards and Regulations for EV Chargers

To address these challenges, various international standards and regulations have been set for both EMI mitigation and the overall safety of EV chargers. These standards ensure chargers meet electromagnetic emission limits and other safety requirements, protecting users and the environment.

Key standards include:

• IEC 61851 Series (IEC 61851-1, IEC 61851-23, IEC 61851-21-2) for the EMC and operational safety of EV chargers.
• UL 2202 and UL 2251 for safety requirements concerning EV chargers and related connection components.

These standards are vital for ensuring that charging stations do not generate excessive EMI, thus safeguarding nearby electronic devices and ensuring the safe operation of EV charging infrastructure.

Mitigation Techniques for EMI in Chargers

Effective EMI control is crucial from the initial design phase. Below are several key design strategies to minimize EMI in smart fast chargers:

1. Choosing Low EMI Components
   • Component Selection: Components with low EMI emissions or enhanced noise immunity—such as low-noise op-amps, shielded inductors, or specially designed low-EMI integrated circuits (ICs)—can significantly reduce EMI.
   • Frequency Range Considerations: Select components that handle high-frequency transients effectively, particularly when high-speed switches are in use.
2. Good PCB Layout
   • Minimize Loop Areas: Large loops in the PCB’s power and signal paths can act as antennas and radiate EMI. Reducing loop sizes and ensuring a continuous ground plane helps reduce EMI.
   • Use of Ground and Power Planes: A solid ground and power plane structure improves signal integrity by providing low-resistance and low-inductance paths.
   • Trace Design: Short, wide traces reduce resistance and inductance, lowering EMI. Additionally, reducing the number of vias helps minimize EMI.
3. Proper Routing and Laying of Cables
   • Twisted-Pair Cables: Effective for cancelling out EMI in differential signal pairs.
   • Shielded Cables: Crucial for protecting sensitive signals, particularly in analogue or high-speed digital circuits.
   • Separation of Power and Signal Cables: Keeping power and signal lines apart minimizes the coupling of noise into sensitive signals.
4. Minimizing Ground Loops
   • Single-Point Grounding: A single-point grounding strategy avoids ground loops by ensuring that all grounds converge at one central location.
   • Star Grounding Scheme: This layout helps further minimize interference from currents flowing in ground paths.
   • Ground Isolation: Isolation techniques like isolating transformers or optocouplers help prevent interference caused by ground loops.
5. Effective Grounding
   • Low Impedance Ground Paths: Wide traces or dedicated ground planes ensure low-impedance paths that prevent radiation of unwanted noise.
   • Shielding Enclosures: Using metallic enclosures or Faraday cages for external shielding can block EMI from external sources and contain emissions from the charger itself.
6. Decoupling and Filtering
   • Decoupling Capacitors: These are critical for suppressing high-frequency noise at power supply lines and on the power pins of components.
   • Power Supply Filters: Use of inductors and capacitors can filter out noise from power supplies before it propagates through the system.
7. Physical Placement of Components
   • Shielding Sensitive Circuits: Position analogue and high-speed digital components as far apart as possible to prevent interference from noisy switching components.
   • Distance from External EMI Sources: Ensure sensitive signal paths are kept away from potential sources of interference like power supplies, motors, or high-frequency components.

EMI/RFI Filters for EV Chargers

To address EMI in smart fast chargers, EMI/RFI filters are essential tools. These filters are designed to reduce or eliminate high-frequency noise that could interfere with both the charger and its surrounding environment.

The MF 620 series EMI/RFI filters, developed by EMIS, are designed specifically for DC fast charging stations. These filters comply with international standards such as UL 2202 and IEC 61851-23, making them a reliable solution for mitigating EMI in EV chargers.

Key features of the MF 620 series include:

• Multistage DC EMI Filters designed for a variety of voltage and current levels:
  • DC Voltages: 500V, 1000V, 1500V.
  • Current Ratings: 150A, 300A, 450A, 600A, 1000A, 1600A.
• Y Capacitor Options: Selectable between 0nF, 100nF, 200nF, and 2000nF.
• Available in different mounting configurations and termination types to accommodate a wide range of installation environments.
• UL Certification: Compliant with UL60939-3, ensuring adherence to safety standards.
• Compact Design: Smaller footprint and lighter weight offer flexible installation options.
• Protective Covers and Accessories: Included for enhanced safety and installation convenience.

By integrating these advanced EMI filters, fast charging stations can significantly reduce EMI emissions, protecting sensitive equipment and ensuring compliance with EMC and safety regulations.

Conclusion

The rapid growth of electric vehicle adoption is driving the demand for fast, efficient charging stations. However, the increased power levels and high-frequency switching involved in DC fast chargers bring the challenge of EMI. Careful EMI management is crucial to avoid disruptions in both the charger’s operation and surrounding electronics. Mitigation techniques such as careful component selection, optimized PCB layout, and the use of EMI filters like the EMIS MF 620 series play a vital role in addressing these challenges. By adopting these solutions, EV fast charging stations can reduce EMI, enhance performance, and comply with both safety and EMC standards, ensuring a safe, efficient, and reliable charging experience for all users