Total Harmonic Distortion (THD) Solutions – Clean Power for Reliable Operations

Modern industry runs on variable frequency drives (VFDs). They control the speed of pumps, fans, compressors, and conveyors with precision, saving enormous amounts of energy and improving process flexibility. But VFDs also create a hidden problem: harmonic distortion.

Every time a drive converts AC to DC and back, it draws current in short pulses instead of smooth waves. Those pulses introduce unwanted frequencies into the electrical system—what engineers call total harmonic distortion (THD). Left unmanaged, THD causes overheating, nuisance trips, voltage distortion, wasted energy, and compliance issues with IEEE-519 or utility standards.

That’s where Crossman Automation comes in. As Western Canada’s trusted partner for motors and drives, we supply and integrate harmonic mitigation solutions—from compact filters to fully engineered low-harmonic drives—that eliminate distortion at the source, protect equipment, and ensure your facility delivers clean, reliable power.

Why Harmonic Distortion Matters

Unchecked harmonics have both technical and financial consequences:

  • Overheating: Transformers, cables, and motors run hotter, reducing lifespan.

  • Voltage distortion: Sensitive control systems, PLCs, and instrumentation may malfunction.

  • Increased losses: Harmonics waste energy, leading to higher operating costs.

  • Grid penalties: Utilities impose fines or restrictions when THD exceeds limits.

  • Reduced reliability: Nuisance trips and premature equipment failures raise maintenance costs.

Whether you operate a water treatment plant, a mine, an oil facility, or a commercial building, keeping THD under control is essential for safety, efficiency, and compliance

Crossman’s THD Mitigation Solutions

Crossman Automation offers a complete portfolio of harmonic mitigation products. By evaluating your system load, supply conditions, and compliance requirements, we design the right combination of technologies:

1. Harmonic Filters

  • Passive Harmonic Filters: Tuned RLC filters that reduce specific harmonics created by VFDs. Simple, reliable, and cost-effective for stable loads.

  • Active Harmonic Filters: Dynamic, electronic systems that measure harmonics in real time and inject corrective current. Ideal for facilities with variable loads or multiple drives.

  • Example: Danfoss VLT® Advanced Harmonic Filter (AHF 005/010) – reduces THDi to 5–10%, compact and efficient for retrofit or new installations.

2. Low-Harmonic Drives / AFE VFDs

  • Low-Harmonic Drives: VFDs with built-in rectifier technology to keep THDi < 5–10% without external filters. Compact, efficient, and compliant.

  • Active Front End (AFE) VFDs: Premium drive topology using IGBTs on the input side. Achieves ultra-low harmonics, near-unity power factor, and regenerative capability for returning energy to the grid.

  • Examples:

    • Danfoss VLT® AQUA Drive LH – low-harmonic performance for water and wastewater pumps.

    • Danfoss VACON® NXP AFE Drive – regenerative, clean-input solution for mining, oil & gas, and heavy industry.

 

With these categories, Crossman covers both retrofit filter solutions and integrated low-harmonic drives—giving you flexibility to match performance, budget, and application.

How We Help Clients Choose

Every facility is different. Crossman’s engineers review:

  • Load profile: Are your drives running constant or variable loads?

  • Compliance requirements: Do you need to meet IEEE-519, utility standards, or internal specifications?

  • System conditions: Weak grid? Generator-based power? Remote site?

  • Budget and footprint: Is the lowest installed cost or the smallest footprint the priority?

From there, we recommend the optimal path—whether that’s a passive filter for a pump room, an active filter for a multi-drive plant, or an AFE drive for a mining conveyor powered by a generator.

Danfoss Harmonic Mitigation – Proven Technology

Crossman partners with Danfoss, a global leader in drives and power quality solutions. Their harmonic portfolio includes:

  • VLT® Advanced Harmonic Filters (AHF 005/010) – compact passive filters delivering 5–10% THDi.

  • Low-Harmonic VLT® AQUA and HVAC Drives – all-in-one solutions for clean power in pumping and building systems.

  • VACON® NXP AFE Drive – regenerative drive platform for the toughest industrial environments.

  • MyDrive Harmonics Software – simulation tools that allow accurate prediction and compliance verification before equipment is installed.

By leveraging Danfoss technology with Crossman’s integration expertise, clients achieve reliable, compliant, and cost-effective solutions.

Industries That Benefit from THD Mitigation

Harmonic mitigation is critical across many industries:

  • Water & Wastewater Treatment: Stable pump operation, reduced water hammer, improved process control.

  • Mining & Aggregates: Reliable conveyor and crusher performance, compliance with weak grids or generators.

  • Oil & Gas: Stable power systems for drilling, artificial lift, and offshore platforms.

  • Commercial Buildings: Clean HVAC power for hospitals, data centers, and high-rise complexes.

  • Manufacturing: Protecting sensitive equipment and ensuring consistent product quality.

Wherever VFDs are deployed, harmonic distortion is an issue—and Crossman has the tools to solve it.

Why Choose Crossman Automation?

  • Comprehensive Portfolio: Passive filters, active filters, and low-harmonic/AFE drives.

  • Expertise: Decades of experience in power quality, automation, and industrial integration.

  • Local Presence: Edmonton-based inventory and service for fast delivery across Western Canada.

  • Compliance Assurance: Solutions engineered to meet IEEE-519 and utility requirements.

  • Single-Source Responsibility: From harmonic studies and product supply to panels, commissioning, and after-sales service. 

Let’s Clean Up Your Power

Harmonic distortion doesn’t have to cost you downtime, energy, or compliance headaches. With Crossman Automation and Danfoss harmonic solutions, you can run your VFDs with confidence, knowing your power is clean, reliable, and future-proof.

Contact Crossman today to request a harmonic study or quote on THD mitigation solutions—and discover how we can help your facility achieve clean power and long-term savings.