John,

Very interesting. We'll have to keep this in mind.

We do have a dual pole contactor in the furnace circuit but the furnace also 
has a SSR for phase control. The contactor only opens and closes when the SSR 
is open (no current). The harmonic emissions from the phase control is why we 
have the large RF Line Filter.

Thanks for the information.
The Other Brian

-----Original Message-----
From: John Barnes [mailto:[email protected]]
Sent: Tuesday, September 22, 2015 11:53 PM
To: [email protected]
Subject: Re: [PSES] Unexplained High Fallout of Power Supplies

Brian,
How is the furnace shut off?  If you are using a contactor between the main 
line filter and the furnace, a phase line might open when it is carrying high 
current.  The inductance of the line filter will try to keep this current 
flowing, generating a very-high kickback spike at the
*output* of the line filter.

Or, since the contacts in the contactor are unlikely to open/close at exactly 
the same time, a common-mode choke in the line filter can act as a transformer 
putting noise on the open phase(s) if only 1 or 2 phases are connected to the 
load.  Some years ago, Bill Kimmel and Daryl Gerke wrote about a case where a 
3-phase product had a contactor between a line filter and the load, which 
generated horrendous Conducted Emissions noise every time the contactor opened 
or closed, because of this transformer action.  The solution was to replace the 
common-mode choke with 3 separate chokes, one for each phase line.

John Barnes KS4GL, PE, NCE, NCT, ESDC Eng, ESDC Tech, PSE, Master EMC
  Design Eng, SM IEEE (retired)
Lexington, KY
http://www.dbicorporation.com/

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