Reactors & Filters
Motor Guarding Transient Filters
The steep voltage wave fronts of the Pulse Width Modulated (PWM) output of Adjustable Frequency Drives (AFD’s) produce high frequency effects which may damage the insulation of motors operated by the equipment. The problems result from two distinct effects.
High DV/DT Effects
The rapid rate of voltage rise (dv/dt) at the leading edges of each output pulse of the PWM inverter, produces an uneven distribution of voltage within the motor windings. The result is a concentration of the voltage at particular points of the winding causing abnormal stress leading to breakdown of the insulation. This phenomenon has been described as “first coil breakdown” and is well documented.
Reflections in Long Lines and Cables
A long cable, in addition to resistance, has distributed inductance and capacitance, producing effects similar to a transmission line as shown below.
Figure 1: Electrical representation of a long transmission line
The high frequencies present in the output of PWM waveforms cause reflections in long conductors connecting the motors to the drives (see Fig. 2). Harmful effects with conductors as short as 10 meters have been observed. However, the effects are most severe with cables of lengths greater than 50 meters leading to the doubling of the applied voltage. This translates to voltage peaks approaching 1600 Volts in 575 Volt systems
Figure 2: Output of a PWM inverter reaching 200% due to reflections in long cables
The combination of these two effects stresses the winding insulation considerably beyond design limits and has been known to shorten the insulation life and in some instances leads to early catastrophic failure of motors.
It has been demonstrated that these transient effects can be reduced by using filters placed at the output of the AFD’s thereby allowing safe operation of the motors and an expectation of full insulation life (see fig. 3). After years of experience and research, Rex Power Magnetics has developed a comprehensive line of state of the art output filters suitable for a wide range of prospective applications. The filters are constructed using optimized combinations of inductors and resistors.
Figure 3: Voltage peak reduced to less than 125% appearing at the motor, due to the addition of a Rex Motor Guarding Filter.
- The prospective voltage spike of 200% at the motor due to reflections in the cable is typically reduced to less than 125% as shown in Figure 6b. This is a significant improvement over using Line Reactors alone.
- The dv/dt is reduced promoting more uniform voltage distribution among the motor windings.
- Standard filter designs are suitable for a wide range of applications including line lengths of 100 meters and switching frequencies up to 5 kHz. A wider range and mix of applications and conditions are possible by consulting the office.
- Filter designs are capable of reducing reflection transients even in the most severe cases involving cables with grounded metal casings.
- The losses introduced with the use of these filters are small, approaching the losses experienced in using cables without filters. The use of Rex output filters generally introduces no additional losses but merely transfers the losses associated with charging and discharging the line capacitance from the cable to the filter. Thus the use of Rex filters has little effect on the efficiency of the system.
- Components used in the filters are specified for specialized qualities and are operated at a fraction of their design limitations to reduce stress and provide reliability. These steps ensure that the filters will operate without overheating even at the limits of their specifications at the extremes of the longest metal-sheathed cables.
| Capacity | 2A to 320 A Three Phase |
| Voltage Class | 600V Max |
| Cooling | Air Cooled (ANN / AN) |
| Frequency | 60Hz (50/60Hz Optional) |
| Conductors | Copper (Cu) Windings |
| Insulation System | 180°C Insulation System (2 – 11A) (115 °C Temp Rise Max) 220°C Insulation System (17 – 320A) (150 °C Temp Rise Max) |
| Sound Level | Below 40dBA |
| Overload Capability | 150% of rated current for 1 min. |
| Saturation Level | Not less than 250% of rated current (min 50% of rated inductance at 350% rated current) |
| Enclosure Type | Type 1 Indoor |
| Warranty | 12 Months (See Warranty and Limitations) |
| Quality System | ISO 9001:2015 Quality Management System |
| Certifications | CSA Certified UL Listed |
| Reference Standards | IEEE C57.110 NEMA ST-20 |
| Open Motor Guarding Filter Reactors | |||
| Current Rating [A] |
Part No. | Dimensions Open Core & Coil A/B/C/D/E |
Weight (Lbs) |
| Open | |||
| 2 | 2C5LF | 8.25/6.50/7.00/7.25/2.00 | 5 |
| 4 | 4C5LF | 8.25/6.50/7.00/7.25/2.00 | 6 |
| 8 | 8C5LF | 8.25/6.50/7.00/7.25/2.00 | 9 |
| 11 | 11C5LF | 8.25/6.50/7.00/7.25/2.00 | 10 |
| 17 | 17C5LF | 8.25/6.50/7.00/7.25/2.00 | 11 |
| 27 | 27C5LF | 8.25/7.20/7.00/7.25/2.00 | 19 |
| 34 | 34C5LF | 8.25/7.20/7.00/7.25/2.00 | 25 |
| 45 | 45C5LF | 11.00/9.00/8.10/10.00/4.00 | 29 |
| 60 | 60C5LF | 11.00/9.00/8.10/10.00/4.00 | 30 |
| 80 | 80C5LF | 11.00/12.00/6.80/10.00/4.00 | 42 |
| 100 | 100C5LF | 11.00/12.00/6.80/10.00/4.00 | 47 |
| 130 | 130C5LF | 11.00/12.00/6.80/10.00/4.00 | 48 |
| 160 | 160C5LF | 11.00/13.00/8.20/10.00/4.00 | 49 |
| 200 | 200C5LF | 11.00/13.00/8.20/10.00/4.00 | 68 |
| 255 | 255C5LF | 11.00/13.00/8.20/10.00/4.00 | 84 |
| 320 | 320C5LF | 11.00/13.00/8.20/10.00/4.00 | 90 |
| 410 | 410C5LF | 14.00/14.50/14.00/13.00/6.00 | 95 |
| 500 | 500C5LF | 20.00/16.00/18.00/19.00/8.00 | 140 |
| 600 | 600C5LF | 20.00/17.50/18.00/19.00/8.00 | 148 |
Rex filters are current rated, therefore easy to specify. Simply use the total motor load current to select the appropriate filter rating. Filters are available enclosed or open style. Add the suffix /E at the end of the part number to denote enclosed style.
| Enclosed Motor Guarding Filter Reactors | ||||||
| Current Rating [A] |
Part No. | Enclosure Size | Enclosure Dimensions | Weight (Lbs) | ||
| length | Depth | Height | Enclosed | |||
| 2 | 2C5LF/E | E1-0 | 9.50 | 7.00 | 8.00 | 14 |
| 4 | 4C5LF/E | E1-0 | 9.50 | 7.00 | 8.00 | 15 |
| 8 | 8C5LF/E | E1-0 | 9.50 | 7.00 | 8.00 | 19 |
| 11 | 11C5LF/E | E1-0 | 9.50 | 7.00 | 8.00 | 20 |
| 17 | 17C5LF/E | E1-1 | 12.00 | 9.00 | 9.50 | 23 |
| 27 | 27C5LFE | E1-1 | 12.00 | 9.00 | 9.50 | 32 |
| 34 | 34C5LF/E | E1-1 | 12.00 | 9.00 | 9.50 | 37 |
| 45 | 45C5LF/E | E1-3 | 15.10 | 11.00 | 14.00 | 48 |
| 60 | 60C5LF/E | E1-3 | 15.10 | 11.00 | 14.00 | 50 |
| 80 | 80C5LF/E | E3R-4 | 15.75 | 16.00 | 21.00 | 68 |
| 100 | 100C5LF/E | E3R-4 | 15.75 | 16.00 | 21.00 | 78 |
| 130 | 130C5LF/E | E3R-4 | 15.75 | 16.00 | 21.00 | 79 |
| 160 | 160C5LF/E | E3R-4 | 15.75 | 16.00 | 21.00 | 88 |
| 200 | 200C5LF/E | E3R-4 | 15.75 | 16.00 | 21.00 | 99 |
| 255 | 255C5LF/E | E3R-4 | 15.75 | 16.00 | 21.00 | 115 |
| 320 | 320C5LF/E | E3R-6 | 20.50 | 20.75 | 26.50 | 150 |
| 410 | 410C5LF/E | E3R-6 | 20.50 | 20.75 | 26.50 | 158 |
| 500 | 500C5LF/E | E3R-6 | 20.50 | 20.75 | 26.50 | 200 |
| 600 | 600C5LF/E | E3R-6 | 20.50 | 20.75 | 26.50 | 210 |
Note: All Rex enclosures larger than #3 are standard NEMA 3R sprinkler proof. Boxes #7 and smaller can be floor or wall mounted. Consult our engineering department for the most up-to-date information on enclosures. See standard enclosures page for detailed drawings.
Product Catalogs
Line Reactor Catalog (English)
Instruction Sheets & Manuals
- The prospective voltage spike of 200% at the motor due to reflections in the cable is typically reduced to less than 125% as shown in Figure 6b. This is a significant improvement over using Line Reactors alone.
- The dv/dt is reduced promoting more uniform voltage distribution among the motor windings.
- Standard filter designs are suitable for a wide range of applications including line lengths of 100 meters and switching frequencies up to 5 kHz. A wider range and mix of applications and conditions are possible by consulting the office.
- Filter designs are capable of reducing reflection transients even in the most severe cases involving cables with grounded metal casings.
- The losses introduced with the use of these filters are small, approaching the losses experienced in using cables without filters. The use of Rex output filters generally introduces no additional losses but merely transfers the losses associated with charging and discharging the line capacitance from the cable to the filter. Thus the use of Rex filters has little effect on the efficiency of the system.
- Components used in the filters are specified for specialized qualities and are operated at a fraction of their design limitations to reduce stress and provide reliability. These steps ensure that the filters will operate without overheating even at the limits of their specifications at the extremes of the longest metal-sheathed cables.
The steep voltage wave fronts of the Pulse Width Modulated (PWM) output of Adjustable Frequency Drives (AFD’s) produce high frequency effects which may damage the insulation of motors operated by the equipment. The problems result from two distinct effects.
High DV/DT Effects
The rapid rate of voltage rise (dv/dt) at the leading edges of each output pulse of the PWM inverter, produces an uneven distribution of voltage within the motor windings. The result is a concentration of the voltage at particular points of the winding causing abnormal stress leading to breakdown of the insulation. This phenomenon has been described as “first coil breakdown” and is well documented.
Reflections in Long Lines and Cables
A long cable, in addition to resistance, has distributed inductance and capacitance, producing effects similar to a transmission line as shown below.
Figure 1: Electrical representation of a long transmission line
The high frequencies present in the output of PWM waveforms cause reflections in long conductors connecting the motors to the drives (see Fig. 2). Harmful effects with conductors as short as 10 meters have been observed. However, the effects are most severe with cables of lengths greater than 50 meters leading to the doubling of the applied voltage. This translates to voltage peaks approaching 1600 Volts in 575 Volt systems
Figure 2: Output of a PWM inverter reaching 200% due to reflections in long cables
The combination of these two effects stresses the winding insulation considerably beyond design limits and has been known to shorten the insulation life and in some instances leads to early catastrophic failure of motors.
It has been demonstrated that these transient effects can be reduced by using filters placed at the output of the AFD’s thereby allowing safe operation of the motors and an expectation of full insulation life (see fig. 3). After years of experience and research, Rex Power Magnetics has developed a comprehensive line of state of the art output filters suitable for a wide range of prospective applications. The filters are constructed using optimized combinations of inductors and resistors.
Figure 3: Voltage peak reduced to less than 125% appearing at the motor, due to the addition of a Rex Motor Guarding Filter.
| Capacity | 2A to 320 A Three Phase |
| Voltage Class | 600V Max |
| Cooling | Air Cooled (ANN / AN) |
| Frequency | 60Hz (50/60Hz Optional) |
| Conductors | Copper (Cu) Windings |
| Insulation System | 180°C Insulation System (2 – 11A) (115 °C Temp Rise Max) 220°C Insulation System (17 – 320A) (150 °C Temp Rise Max) |
| Sound Level | Below 40dBA |
| Overload Capability | 150% of rated current for 1 min. |
| Saturation Level | Not less than 250% of rated current (min 50% of rated inductance at 350% rated current) |
| Enclosure Type | Type 1 Indoor |
| Warranty | 12 Months (See Warranty and Limitations) |
| Quality System | ISO 9001:2015 Quality Management System |
| Certifications | CSA Certified UL Listed |
| Reference Standards | IEEE C57.110 NEMA ST-20 |
| Open Motor Guarding Filter Reactors | |||
| Current Rating [A] |
Part No. | Dimensions Open Core & Coil A/B/C/D/E |
Weight (Lbs) |
| Open | |||
| 2 | 2C5LF | 8.25/6.50/7.00/7.25/2.00 | 5 |
| 4 | 4C5LF | 8.25/6.50/7.00/7.25/2.00 | 6 |
| 8 | 8C5LF | 8.25/6.50/7.00/7.25/2.00 | 9 |
| 11 | 11C5LF | 8.25/6.50/7.00/7.25/2.00 | 10 |
| 17 | 17C5LF | 8.25/6.50/7.00/7.25/2.00 | 11 |
| 27 | 27C5LF | 8.25/7.20/7.00/7.25/2.00 | 19 |
| 34 | 34C5LF | 8.25/7.20/7.00/7.25/2.00 | 25 |
| 45 | 45C5LF | 11.00/9.00/8.10/10.00/4.00 | 29 |
| 60 | 60C5LF | 11.00/9.00/8.10/10.00/4.00 | 30 |
| 80 | 80C5LF | 11.00/12.00/6.80/10.00/4.00 | 42 |
| 100 | 100C5LF | 11.00/12.00/6.80/10.00/4.00 | 47 |
| 130 | 130C5LF | 11.00/12.00/6.80/10.00/4.00 | 48 |
| 160 | 160C5LF | 11.00/13.00/8.20/10.00/4.00 | 49 |
| 200 | 200C5LF | 11.00/13.00/8.20/10.00/4.00 | 68 |
| 255 | 255C5LF | 11.00/13.00/8.20/10.00/4.00 | 84 |
| 320 | 320C5LF | 11.00/13.00/8.20/10.00/4.00 | 90 |
| 410 | 410C5LF | 14.00/14.50/14.00/13.00/6.00 | 95 |
| 500 | 500C5LF | 20.00/16.00/18.00/19.00/8.00 | 140 |
| 600 | 600C5LF | 20.00/17.50/18.00/19.00/8.00 | 148 |
Rex filters are current rated, therefore easy to specify. Simply use the total motor load current to select the appropriate filter rating. Filters are available enclosed or open style. Add the suffix /E at the end of the part number to denote enclosed style.
| Enclosed Motor Guarding Filter Reactors | ||||||
| Current Rating [A] |
Part No. | Enclosure Size | Enclosure Dimensions | Weight (Lbs) | ||
| length | Depth | Height | Enclosed | |||
| 2 | 2C5LF/E | E1-0 | 9.50 | 7.00 | 8.00 | 14 |
| 4 | 4C5LF/E | E1-0 | 9.50 | 7.00 | 8.00 | 15 |
| 8 | 8C5LF/E | E1-0 | 9.50 | 7.00 | 8.00 | 19 |
| 11 | 11C5LF/E | E1-0 | 9.50 | 7.00 | 8.00 | 20 |
| 17 | 17C5LF/E | E1-1 | 12.00 | 9.00 | 9.50 | 23 |
| 27 | 27C5LFE | E1-1 | 12.00 | 9.00 | 9.50 | 32 |
| 34 | 34C5LF/E | E1-1 | 12.00 | 9.00 | 9.50 | 37 |
| 45 | 45C5LF/E | E1-3 | 15.10 | 11.00 | 14.00 | 48 |
| 60 | 60C5LF/E | E1-3 | 15.10 | 11.00 | 14.00 | 50 |
| 80 | 80C5LF/E | E3R-4 | 15.75 | 16.00 | 21.00 | 68 |
| 100 | 100C5LF/E | E3R-4 | 15.75 | 16.00 | 21.00 | 78 |
| 130 | 130C5LF/E | E3R-4 | 15.75 | 16.00 | 21.00 | 79 |
| 160 | 160C5LF/E | E3R-4 | 15.75 | 16.00 | 21.00 | 88 |
| 200 | 200C5LF/E | E3R-4 | 15.75 | 16.00 | 21.00 | 99 |
| 255 | 255C5LF/E | E3R-4 | 15.75 | 16.00 | 21.00 | 115 |
| 320 | 320C5LF/E | E3R-6 | 20.50 | 20.75 | 26.50 | 150 |
| 410 | 410C5LF/E | E3R-6 | 20.50 | 20.75 | 26.50 | 158 |
| 500 | 500C5LF/E | E3R-6 | 20.50 | 20.75 | 26.50 | 200 |
| 600 | 600C5LF/E | E3R-6 | 20.50 | 20.75 | 26.50 | 210 |
Note: All Rex enclosures larger than #3 are standard NEMA 3R sprinkler proof. Boxes #7 and smaller can be floor or wall mounted. Consult our engineering department for the most up-to-date information on enclosures. See standard enclosures page for detailed drawings.
Product Catalogs
Line Reactor Catalog (English)
