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State of the Art and Recent<br />
Developments of Medium Voltage<br />
Converters<br />
Steffen Bernet<br />
Berl<strong>in</strong> University of Technology<br />
Power Electronics Lab<br />
Berl<strong>in</strong>, Germany<br />
Power Electronics Lab<br />
All rights reserved.Prof. Bernet 9/2003-1
Outl<strong>in</strong>e<br />
1. Market Overview of Industrial Medium Voltage Drives (MVD)<br />
2. Basic Function and Characteristics of 2L-VSC, 3L-NPC VSC,<br />
3L-FC VSC and 4L-FC VSC<br />
3. Comparison of IGBTs and IGCTs <strong>in</strong> a 3L-NPC VSC<br />
4. Application Example<br />
• Medium Voltage Drive ACS 6000<br />
5. Conclusions<br />
Power Electronics Lab<br />
All rights reserved.Prof. Bernet 9/2003-2
Two Level – Voltage Source Converter (2L-VSC)<br />
V dc<br />
S 1a S 1b S 1c<br />
a b<br />
M<br />
S 2a<br />
S 2b S 2c<br />
c<br />
reference-, carrier signal<br />
1<br />
0.5<br />
0<br />
-0.5<br />
-1<br />
0 0.005 0.01 0.015 0.02<br />
t [s]<br />
IGBTs / Diodes : 6 / 6<br />
Commutation cells per phase leg : 1<br />
Modulation scheme of 2L-VSC<br />
(f c = 875 Hz, f o = 50 Hz, m = 1.114)<br />
Rated commutation voltage: V dc<br />
(e.g. V ll =2.3kV, V com = V dc,n =3400V → 6500V IGBTs / IGCTs)<br />
Power Electronics Lab<br />
All rights reserved.Prof. Bernet 9/2003-3
Two Level – Voltage Source Converter (2L-VSC)<br />
V aM =V dc /2<br />
S 1a<br />
v aM<br />
V dc<br />
M<br />
a<br />
V dc /2<br />
S 2a<br />
-V dc /2<br />
Power Electronics Lab<br />
All rights reserved.Prof. Bernet 9/2003-4
Two Level – Voltage Source Converter (2L-VSC)<br />
V aM =-V dc /2<br />
S 1a<br />
v aM<br />
V dc<br />
M<br />
a<br />
V dc /2<br />
S 2a<br />
-V dc /2<br />
Power Electronics Lab<br />
All rights reserved.Prof. Bernet 9/2003-5
Converter Voltages and Spectrum of 2L-VSC<br />
(V ll = 4,16 kV, V dc = 6,1 kV, f c = 875 Hz; m = 1,114; f a = 50 Hz; q = f c /f a = 17,5)<br />
output volatge u aM [V]<br />
4000<br />
2000<br />
0<br />
-2000<br />
-4000<br />
0 0.01 0.02 0.03 0.04<br />
u ll /u ll,1<br />
1<br />
0.5<br />
output volatge u ll [V]<br />
5000<br />
0<br />
-5000<br />
0 0.01 0.02 0.03 0.04<br />
Power Electronics Lab<br />
All rights reserved.Prof. Bernet 9/2003-6<br />
t [s]<br />
0<br />
0 1000 2000 3000<br />
f [Hz]<br />
L ll<br />
= 3 = (2L-1)<br />
f 1cb =f c =875 Hz
Three Level NPC Voltage Source Converter (3L-NPC VSC)<br />
V dc<br />
S 1a<br />
S 1b<br />
S 1c<br />
D 1a D 1b<br />
D 1c<br />
S 2a<br />
a<br />
S 2b<br />
b<br />
S 2c<br />
c<br />
reference-, carrier signal<br />
1<br />
0.5<br />
0<br />
D 2a<br />
S 3a D 2b S 3b D 2c<br />
S 3c<br />
-0.5<br />
S 4a<br />
S 4b<br />
S 4c<br />
-1<br />
0 0.005 0.01 0.015 0.02<br />
IGBTs / Diodes : 12 / 12 + 6<br />
Commutation cells per phase leg : 2<br />
Rated commutation voltage: V com =V dc / 2<br />
(e.g. V ll =2.3kV, V dc,n =3400V, V com = V dc,n / 2<br />
= 1700V → 3300V IGBTs / IGCTs)<br />
t [s]<br />
Modulation scheme of 3L-NPC VSC<br />
(f c = 875 Hz, f o = 50 Hz, m = 1.114)<br />
Power Electronics Lab<br />
All rights reserved.Prof. Bernet 9/2003-7
Output Voltage of 3L-NPC VSC<br />
V aM =V dc /2<br />
v aM<br />
V dc<br />
V dc /2<br />
M<br />
D 1<br />
S 1<br />
S 2<br />
a<br />
V dc /2<br />
-V dc /2<br />
V dc /2<br />
D 2<br />
S 3<br />
V aM<br />
V dc<br />
/2<br />
S 1<br />
on<br />
S 2<br />
on<br />
S 3<br />
off<br />
S 4<br />
off<br />
S 4<br />
0<br />
-V dc<br />
/2<br />
off<br />
off<br />
on<br />
off<br />
on<br />
on<br />
off<br />
on<br />
Power Electronics Lab<br />
All rights reserved.Prof. Bernet 9/2003-8
Output Voltage of 3L-NPC VSC<br />
V aM =0<br />
v aM<br />
V dc<br />
V dc /2<br />
M<br />
D 1<br />
S 1<br />
S 2<br />
a<br />
V dc /2<br />
-V dc /2<br />
V dc /2<br />
D 2<br />
S 3<br />
V DC<br />
/2<br />
S 1<br />
on<br />
S 2<br />
on<br />
S 3<br />
off<br />
S 4<br />
off<br />
S 4<br />
0<br />
-V DC<br />
/2<br />
off<br />
off<br />
on<br />
off<br />
on<br />
on<br />
off<br />
on<br />
Power Electronics Lab<br />
All rights reserved.Prof. Bernet 9/2003-9
Output Voltage of 3L-NPC VSC<br />
V aM =-V dc /2<br />
v aM<br />
V dc<br />
V dc /2<br />
M<br />
D 1<br />
S 1<br />
S 2<br />
a<br />
V dc /2<br />
-V dc /2<br />
V dc /2<br />
D 2<br />
S 3<br />
S 1<br />
S 2<br />
S 3<br />
S 4<br />
V DC<br />
/2<br />
on<br />
on<br />
off<br />
off<br />
S 4<br />
0<br />
off<br />
on<br />
on<br />
off<br />
-V DC<br />
/2<br />
off<br />
off<br />
on<br />
on<br />
Power Electronics Lab<br />
All rights reserved.Prof. Bernet 9/2003-10
Converter Voltages and Spectrum of 3L-NPC VSC<br />
(V ll = 4,16 kV, V dc = 6,1 kV, V com = 3,05 kV f c = 875 Hz; m = 1,114; f a = 50 Hz)<br />
output volatge u aM [V]<br />
4000<br />
2000<br />
0<br />
-2000<br />
-4000<br />
0 0.01 0.02 0.03 0.04<br />
u ll /u ll,1<br />
1<br />
0.5<br />
output volatge u ll [V]<br />
5000<br />
0<br />
-5000<br />
0 0.01 0.02 0.03 0.04<br />
t [s]<br />
Power Electronics Lab<br />
All rights reserved.Prof. Bernet 9/2003-11<br />
0<br />
0 1000 2000 3000<br />
f [Hz]<br />
L ll = 5 = (2L-1)<br />
f 1cb =f c =875 Hz
Multi-Level VSC (e.g. 3L-FC VSC)<br />
S 1<br />
C 1<br />
S<br />
1 2<br />
V dc<br />
M<br />
V<br />
2 dc<br />
S 4<br />
IGBTs / Diodes : 12 / 12<br />
Fly<strong>in</strong>g Caps: 3<br />
S 3<br />
Commutation cells per phase leg : 2<br />
Rated commutation voltage: V com =V dc / 2<br />
(e.g. V ll =2.3kV, V dc,n =3400V, V com = V dc,n / 2<br />
= 1700V → 3300V IGBTs )<br />
a<br />
reference-, carrier signal<br />
1<br />
0.5<br />
0<br />
-0.5<br />
-1<br />
0 0.005 0.01 0.015 0.02<br />
t [s]<br />
Modulation scheme of 3L-FLC VSC<br />
(f c = 875 Hz, f o = 50 Hz, m = 1.114)<br />
Power Electronics Lab<br />
All rights reserved.Prof. Bernet 9/2003-12
Multi-Level VSC (e.g. 3L-FC VSC)<br />
v aM<br />
V dc /2<br />
V<br />
aM<br />
=<br />
1<br />
V<br />
2<br />
dc<br />
S 1<br />
C 1<br />
S<br />
1 2<br />
V dc<br />
M V<br />
2 dc<br />
S 4<br />
S 3<br />
a<br />
-V dc /2<br />
V aM<br />
S 1<br />
S 2<br />
S 3<br />
S 4<br />
V dc<br />
/2<br />
on<br />
on<br />
off<br />
off<br />
0<br />
on<br />
off<br />
on<br />
off<br />
-V dc<br />
/2<br />
off<br />
off<br />
on<br />
on<br />
Power Electronics Lab<br />
All rights reserved.Prof. Bernet 9/2003-13
Multi-Level VSC (e.g. 3L-FC VSC)<br />
v aM<br />
1 1 1<br />
V = V − V = V − V =<br />
aM dc C1<br />
dc dc<br />
2 2 2<br />
0<br />
V dc /2<br />
S 1<br />
C 1<br />
S<br />
1 2<br />
V dc<br />
M<br />
V<br />
2 dc<br />
S 4<br />
S 3<br />
a<br />
-V dc /2<br />
V aM<br />
S 1<br />
S 2<br />
S 3<br />
S 4<br />
V dc<br />
/2<br />
on<br />
on<br />
off<br />
off<br />
0<br />
on<br />
off<br />
on<br />
off<br />
-V dc<br />
/2<br />
off<br />
off<br />
on<br />
on<br />
Power Electronics Lab<br />
All rights reserved.Prof. Bernet 9/2003-14
Multi-Level VSC (e.g. 3L-FC VSC)<br />
v aM<br />
V<br />
aM<br />
=−<br />
1<br />
V<br />
2<br />
dc<br />
V dc /2<br />
S 1<br />
C 1<br />
S<br />
1 2<br />
V dc<br />
M<br />
V<br />
2 dc<br />
S 4<br />
S 3<br />
a<br />
-V dc /2<br />
V aM<br />
S 1<br />
S 2<br />
S 3<br />
S 4<br />
V dc<br />
/2<br />
on<br />
on<br />
off<br />
off<br />
0<br />
on<br />
off<br />
on<br />
off<br />
-V dc<br />
/2<br />
off<br />
off<br />
on<br />
on<br />
Power Electronics Lab<br />
All rights reserved.Prof. Bernet 9/2003-15
output volatge u aM [V]<br />
output volatge u ll [V]<br />
Output Voltage of 3L-FLC VSC<br />
4000<br />
2000<br />
0<br />
-2000<br />
(V ll = 4,16 kV, V dc = 6,1 kV, V com = 3,05 kV f c = 875 Hz; m = 1,114; f a = 50 Hz)<br />
-4000<br />
0 0.01 0.02 0.03 0.04<br />
5000<br />
0<br />
-5000<br />
0 0.01 0.02 0.03 0.04<br />
t [s]<br />
Power Electronics Lab<br />
All rights reserved.Prof. Bernet 9/2003-16<br />
u ll /u ll,1<br />
1<br />
0.5<br />
0<br />
0 1000 2000 3000<br />
f [Hz]<br />
L ll = 5 = (2L-1)<br />
f 1cb =2·f c =1750 Hz
Multi-Level VSC (e.g. 4L-FC VSC)<br />
S 1<br />
S 2 S 3<br />
1<br />
V<br />
V<br />
3 dc<br />
3 dc<br />
S 6<br />
2<br />
a<br />
V dc<br />
M C 1 C 2<br />
IGBTs / Diodes : 18 / 18<br />
Fly<strong>in</strong>g Caps: 6<br />
S 5<br />
S 4<br />
Commutation cells per phase leg : 3<br />
Rated commutation voltage: V com =V dc / 3<br />
(e.g. V ll =2300 V, V dc,n =3400V, V com = V dc,n /<br />
3 = 1133V → 2500V IGBTs )<br />
reference-, carrier signal<br />
1<br />
0.5<br />
0<br />
-0.5<br />
-1<br />
0 0.005 0.01 0.015 0.02<br />
t [s]<br />
Modulation scheme of 4L-FLC VSC<br />
(f c = 875 Hz, f o = 50 Hz, m = 1.114)<br />
FC VSC<br />
• V C =V DC / (L-1)<br />
• f 1cb =(L-1)f c<br />
Power Electronics Lab<br />
All rights reserved.Prof. Bernet 9/2003-17
Multi-Level VSC (e.g. 4L-FC VSC)<br />
4-Level-FLC Converter<br />
v aM<br />
V<br />
aM<br />
=<br />
1<br />
V<br />
2<br />
dc<br />
V dc /2<br />
V dc /6<br />
S 1<br />
S 2 S<br />
2<br />
3<br />
1<br />
V dc<br />
M C 1 V C 2<br />
3 dc<br />
V<br />
3 dc<br />
S 6 S 5<br />
S 4<br />
a<br />
-V dc /6<br />
-V dc /2<br />
S 1<br />
S 2<br />
S 3<br />
S 4<br />
S 5<br />
S 6<br />
V dc<br />
/2<br />
on<br />
on<br />
on<br />
off<br />
off<br />
off<br />
V dc<br />
/6<br />
on<br />
on<br />
off<br />
off<br />
off<br />
on<br />
-V dc<br />
/6<br />
on<br />
off<br />
off<br />
on<br />
on<br />
off<br />
-V dc<br />
/2<br />
off<br />
off<br />
off<br />
on<br />
on<br />
on<br />
Power Electronics Lab<br />
All rights reserved.Prof. Bernet 9/2003-18
Multi-Level VSC (e.g. 4L-FC VSC)<br />
4-Level-FLC Converter<br />
v aM<br />
1 1 1 1<br />
V = V − V = V − V = V<br />
aM dc C 2 dc dc dc<br />
2 2 3 6<br />
V dc /2<br />
V dc /6<br />
S 1<br />
S 2 S<br />
2<br />
3<br />
1<br />
V dc<br />
M C 1 V C 2<br />
3 dc<br />
V<br />
3 dc<br />
S 6 S 5<br />
S 4<br />
a<br />
-V dc /6<br />
-V dc /2<br />
S 1<br />
S 2<br />
S 3<br />
S 4<br />
S 5<br />
S 6<br />
V dc<br />
/2<br />
on<br />
on<br />
on<br />
off<br />
off<br />
off<br />
V dc<br />
/6<br />
on<br />
on<br />
off<br />
off<br />
off<br />
on<br />
-V dc<br />
/6<br />
on<br />
off<br />
off<br />
on<br />
on<br />
off<br />
-V dc<br />
/2<br />
off<br />
off<br />
off<br />
on<br />
on<br />
on<br />
Power Electronics Lab<br />
All rights reserved.Prof. Bernet 9/2003-19
Multi-Level VSC (e.g. 4L-FC VSC)<br />
4-Level-FLC Converter<br />
1 1 2 1<br />
V = V − V = V − V = − V<br />
aM dc C1<br />
dc dc dc<br />
2 2 3 6<br />
v aM<br />
V dc /2<br />
V dc /6<br />
S 1<br />
S 2 S<br />
2<br />
3<br />
1<br />
V dc<br />
M C 1 V C 2<br />
3 dc<br />
V<br />
3 dc<br />
S 6 S 5<br />
S 4<br />
a<br />
-V dc /6<br />
-V dc /2<br />
S 1<br />
S 2<br />
S 3<br />
S 4<br />
S 5<br />
S 6<br />
V dc<br />
/2<br />
on<br />
on<br />
on<br />
off<br />
off<br />
off<br />
V dc<br />
/6<br />
on<br />
on<br />
off<br />
off<br />
off<br />
on<br />
-V dc<br />
/6<br />
on<br />
off<br />
off<br />
on<br />
on<br />
off<br />
-V dc<br />
/2<br />
off<br />
off<br />
off<br />
on<br />
on<br />
on<br />
Power Electronics Lab<br />
All rights reserved.Prof. Bernet 9/2003-20
Multi-Level VSC (e.g. 4L-FC VSC)<br />
4-Level-FLC Converter<br />
V aM<br />
V<br />
aM<br />
=−<br />
1<br />
V<br />
2<br />
dc<br />
V dc /2<br />
V dc /6<br />
S 1<br />
S 2 S<br />
2<br />
3<br />
1<br />
a<br />
V dc<br />
M C 1 V C 2<br />
3 dc<br />
V<br />
3 dc<br />
S 6 S 5<br />
S 4<br />
-V dc /6<br />
-V dc /2<br />
S 1<br />
S 2<br />
S 3<br />
S 4<br />
S 5<br />
S 6<br />
V dc<br />
/2<br />
on<br />
on<br />
on<br />
off<br />
off<br />
off<br />
V dc<br />
/6<br />
on<br />
on<br />
off<br />
off<br />
off<br />
on<br />
-V dc<br />
/6<br />
on<br />
off<br />
off<br />
on<br />
on<br />
off<br />
-V dc<br />
/2<br />
off<br />
off<br />
off<br />
on<br />
on<br />
on<br />
Power Electronics Lab<br />
All rights reserved.Prof. Bernet 9/2003-21
output volatge u ll [V]<br />
Converter Voltages and Spectrum of 4L-FLC VSC<br />
4000<br />
2000<br />
(V ll = 4,16 kV, V dc = 6,1 kV, V com = 2,03 kV f c = 875 Hz; m = 1,114; f a = 50 Hz)<br />
0<br />
-2000<br />
-4000<br />
0 0.01 0.02 0.03 0.04<br />
5000<br />
0<br />
-5000<br />
0 0.01 0.02 0.03 0.04<br />
Power Electronics Lab<br />
All rights reserved.Prof. Bernet 9/2003-22<br />
t [s]<br />
1<br />
0.5<br />
u ll /u ll,1<br />
output volatge u aM [V]<br />
0<br />
0 1000 2000 3000<br />
f [Hz]<br />
L ll = 7 = (2L-1)<br />
f 1cb =3·f c =2625 Hz
Converter Comparison - f c = 750 Hz<br />
(V ll,ν=1 = 2,3 kV, V dc =3400V, f c =750Hz, 2L-VSI: 6.5kV IGBTs, 3L-NPC / FC VSI:<br />
3.3kV IGBTs, 4L-FC VSC: 2.5kV IGBTs, S S = 38,61 MVA = const.)<br />
2L-VSC<br />
3L-NPC VSC<br />
3L-FLC VSC<br />
4L-FLC VSC<br />
Rated IGBT current I C,n<br />
990 A<br />
975 A<br />
975 A<br />
858 A<br />
Max. phase current I ph,max<br />
@ T j,max<br />
= 125° C, f c<br />
= 750 Hz<br />
600 A<br />
897 A<br />
871 A<br />
726 A<br />
Maximum apparent converter<br />
output power S C,max<br />
2.390 MVA<br />
3.573 MVA<br />
3.47 MVA<br />
2.892 MVA<br />
4<br />
output power [MVA]<br />
3<br />
2<br />
1<br />
0<br />
149,5% 145%<br />
121%<br />
100%<br />
2L-VSI 3L-NPC 3L-FLC 4L-FLC<br />
⇒ 3L–NPC VSC enables the<br />
highest converter output<br />
power<br />
Power Electronics Lab<br />
All rights reserved.Prof. Bernet 9/2003-23
Converter Comparison - f c = 750 Hz<br />
(V ll,ν=1 = 2,3 kV, V dc =3400V, f c =750Hz, 2L-VSI: 6.5kV IGBTs, 3L-NPC / FC VSI:<br />
3.3kV IGBTs, 4L-FC VSC: 2.5kV IGBTs, S S = 38,61 MVA = const.)<br />
40<br />
30<br />
total losses Ploss Vll = 2.3 kV<br />
2L-VSI f c=750Hz<br />
3L-NPC f c=750Hz<br />
3L-FLC f c=750Hz<br />
4L-FLC f c=750Hz<br />
40<br />
30<br />
loss distribution Vll=2.3kV, fc=750Hz<br />
PconT<br />
PconD<br />
PonT<br />
PoffT<br />
PoffD<br />
Ploss [kW]<br />
20<br />
Pv [kW]<br />
20<br />
10<br />
10<br />
0<br />
0 200 400 600 800 1000<br />
I ph h [A] [A]<br />
0<br />
2L-VSI 3L-NPC 3L-FLC 4L-FLC<br />
Total converter losses as a<br />
function of phase current<br />
( f c = 750 Hz, f o = 50 Hz, m = 1.11,<br />
cos (ϕ) = 0.9)<br />
Loss distribution<br />
(I ph = 600A, f c = 750 Hz, f o = 50 Hz,<br />
m = 1.11, cos (ϕ) = 0.9)<br />
Power Electronics Lab<br />
All rights reserved.Prof. Bernet 9/2003-24
Converter Comparison - f c = 750 Hz<br />
harmonic content of l<strong>in</strong>e-to-l<strong>in</strong>e voltage<br />
(V ll,ν=1 = 2,3 kV; S S = 38,61 MVA; m = 1.11)<br />
2L-VSC, f C = 750 Hz, f 1cb = 750 Hz<br />
10 0 harmonic content of l<strong>in</strong>e-to-l<strong>in</strong>e voltage 2L VSC,fc=750Hz<br />
3L-NPC, f C = 750 Hz, f 1cb = 750 Hz<br />
10 0 harmonic content of l<strong>in</strong>e-to-l<strong>in</strong>e voltage 3L-NPC VSC,fc=750Hz<br />
Vll,n/Vll,1<br />
10 -1<br />
Vll,n/Vll,1<br />
10 -1<br />
10 -2<br />
0 500 1000 1500 2000 2500<br />
f [Hz]<br />
10 0 harmonic content of l<strong>in</strong>e-to-l<strong>in</strong>e voltage 3L-FLC VSC,fc=750Hz<br />
10 -2<br />
0 500 1000 1500 2000 2500<br />
f [Hz]<br />
3L-FLC, f C = 750 Hz, f 1cb = 1500 Hz harmonic 4L-FLC, content fof C l<strong>in</strong>e-to-l<strong>in</strong>e = 750 voltage Hz, 4L-FLC f 1cb VSC,fc=750Hz = 2250<br />
10 0 Hz<br />
Vll,n/Vll,1<br />
10 -1<br />
Vll,n/Vll,1<br />
10 -1<br />
10 -2<br />
0 500 1000 1500 2000 2500<br />
f [Hz]<br />
10 -2<br />
0 500 1000 1500 2000 2500<br />
f [Hz]<br />
Power Electronics Lab<br />
All rights reserved.Prof. Bernet 9/2003-25
Converter Comparison - f c = 750 Hz<br />
THD and WTHD of l<strong>in</strong>e-to-l<strong>in</strong>e voltage<br />
(V ll,ν=1 = 2,3 kV; S S = 38,61 MVA; m = 1.11)<br />
60<br />
50<br />
∞<br />
∞ ⎛V<br />
⎞<br />
2<br />
ll,n<br />
∑V<br />
∑<br />
⎜<br />
ll,n<br />
⎟<br />
=<br />
n=<br />
2⎝<br />
n<br />
n 2<br />
⎠<br />
THD = WTHD =<br />
n :<br />
V<br />
V<br />
ll,1<br />
ll,1<br />
2<br />
order of harmonics<br />
THD<br />
WTHD<br />
3<br />
57%<br />
2.5 2,8%<br />
THD [%]<br />
40<br />
30<br />
20<br />
10<br />
29%<br />
36%<br />
21%<br />
WTHD [%]<br />
2<br />
1.5<br />
1<br />
0.5<br />
1,5%<br />
0,8%<br />
0<br />
2L-VSI 3L-NPC 3L-FLC 4L-FLC<br />
0<br />
0,3%<br />
2L-VSI 3L-NPC 3L-FLC 4L-FLC<br />
Power Electronics Lab<br />
All rights reserved.Prof. Bernet 9/2003-26
Converter Comparison – f 1cb = 750 Hz<br />
(V ll,ν=1 = 2,3 kV, V dc =3400V, f c =750Hz, 2L-VSI: 6.5kV IGBTs, 3L-NPC / FC VSI:<br />
3.3kV IGBTs, 4L-FC VSC: 2.5kV IGBTs, S S = 38,61 MVA = const.)<br />
2L-VSC<br />
3L-NPC VSC<br />
3L-FLC VSC<br />
4L-FLC VSC<br />
Rated IGBT current I C,n<br />
990 A<br />
975 A<br />
975 A<br />
858 A<br />
Carrier frequency f c<br />
750 Hz<br />
750 Hz<br />
375 Hz<br />
250 Hz<br />
Max. phase current<br />
I ph,max<br />
@ T j,max<br />
= 125° C<br />
600 A<br />
897 A<br />
1009 A<br />
840 A<br />
Maximum apparent converter<br />
output power S C,max<br />
2.390 MVA<br />
3.573 MVA<br />
4.02 MVA<br />
3.346 MVA<br />
5<br />
output power [MVA]<br />
4<br />
3<br />
2<br />
1<br />
100%<br />
149,5% 168% 140%<br />
⇒ 3L – FLC VSC enables the highest<br />
converter output power S C,max<br />
0<br />
2L-VSI 3L-NPC 3L-FLC 4L-FLC<br />
Power Electronics Lab<br />
All rights reserved.Prof. Bernet 9/2003-27<br />
(V ll,ν=1 = 2,3 kV; S S = 38,61 MVA)
Converter Comparison – f 1cb = 750 Hz<br />
(V ll,ν=1 = 2,3 kV, V dc =3400V, f c =750Hz, 2L-VSI: 6.5kV IGBTs, 3L-NPC / FC VSI:<br />
3.3kV IGBTs, 4L-FC VSC: 2.5kV IGBTs, S S = 38,61 MVA = const.)<br />
Ploss [kW]<br />
40<br />
30<br />
20<br />
10<br />
total losses Ploss Vll = 2.3 kV<br />
2L-VSI f c=750Hz<br />
3L-NPC f c=750Hz<br />
3L-FLC f c=375Hz<br />
4L-FLC f c=250Hz<br />
Pv [kW]<br />
30<br />
25<br />
20<br />
15<br />
10<br />
loss distribution Vll=2.3kV<br />
PconT<br />
PconD<br />
PonT<br />
PoffT<br />
PoffD<br />
5<br />
0<br />
0 200 400 600 800 1000<br />
II ph h [A]<br />
Total converter losses as a<br />
function of phase current<br />
(f o<br />
= 50 Hz, m = 1.11, cos (ϕ) = 0.9)<br />
0<br />
2L-VSI 3L-NPC 3L-FLC 4L-FLC<br />
Loss distribution (I ph<br />
= 600A,<br />
f c,2L-VSC<br />
= 750 Hz, f c,3L-NPC VSC<br />
= 750 Hz,<br />
f c,3L-FLC VSC<br />
= 375 Hz, f c,4L-FLC VSC<br />
= 250 Hz<br />
f o<br />
= 50 Hz, m = 1.11, cos (ϕ) = 0.9)<br />
Power Electronics Lab<br />
All rights reserved.Prof. Bernet 9/2003-28
Converter Comparison – f 1cb = 750 Hz<br />
10 0 harmonic content of l<strong>in</strong>e-to-l<strong>in</strong>e voltage 2L VSC,fc=750Hz<br />
Harmonic Content of l<strong>in</strong>e-to-l<strong>in</strong>e Voltage<br />
(V ll,ν=1 = 2,3 kV; S S = 38,61 MVA; m = 1.11)<br />
2L-VSC, f C = 750 Hz, f 1cb = 750<br />
Hz<br />
3L-NPC, f C = 750 Hz, f 1cb = 750<br />
Hz<br />
harmonic content l<strong>in</strong>e-to-l<strong>in</strong>e voltage voltage 3L-NPC VSC,fc=750Hz<br />
0<br />
10<br />
Vll,n/Vll,1<br />
10 -1<br />
Vll,n/Vll,1<br />
10 -1<br />
10 -2<br />
0 500 1000 1500 2000 2500<br />
f [Hz]<br />
3L-FLC, f C = 375 Hz, f 1cb = 750 Hz<br />
10 0 harmonic content of l<strong>in</strong>e-to-l<strong>in</strong>e voltage 3L-FLC VSC,fc=375Hz<br />
10 -2<br />
0 500 1000 1500 2000 2500<br />
f [Hz]<br />
4L-FLC, f C = 250 Hz, f 1cb = 750 Hz<br />
10 0 harmonic content of l<strong>in</strong>e-to-l<strong>in</strong>e voltage 4L-FLC VSC,fc=250Hz<br />
Vll,n/Vll,1<br />
10 -1<br />
Vll,n/Vll,1<br />
10 -1<br />
10 -2<br />
0 500 1000 1500 2000 2500<br />
f [Hz]<br />
10 -2<br />
0 500 1000 1500 2000 2500<br />
f [Hz]<br />
Power Electronics Lab<br />
All rights reserved.Prof. Bernet 9/2003-29
! 3L-NPC VSC:<br />
Summary - Topologies<br />
! M<strong>in</strong>imum losses for a given expense of semiconductors<br />
! Maximum S C for f c =const<br />
! 3L-FLC VSC<br />
! Maximum converter output power for a constant frequency of the first<br />
carrier band<br />
! Identical losses like 3L-NPC VSC for identical spectrum<br />
Power Electronics Lab<br />
All rights reserved.Prof. Bernet 9/2003-30
Summary - Topologies<br />
! 4L-FLC VSC<br />
! attractive if very high switch<strong>in</strong>g frequency, low harmonic distortion, a small<br />
output filter or a high output voltage (V ll >= 4.16 kV) is required<br />
! 2L-VSC<br />
! poorest utilisation of semiconductors, lowest maximum carrier frequency<br />
and worst harmonic distortion<br />
! attractive for fs
PWM 3L-NPC VSC with Active Front-End<br />
Medium Voltage<br />
Ma<strong>in</strong>s (e.g. 20kV)<br />
Ma<strong>in</strong>s<br />
Transformer<br />
3.3kV<br />
Ma<strong>in</strong>s<br />
Rectifier<br />
(Active Front End)<br />
3L-NPC-VSR<br />
DC Voltage L<strong>in</strong>k<br />
Inverter<br />
3L-NPC-VSI<br />
3.3kV<br />
Synchronous<br />
Mach<strong>in</strong>e<br />
SM<br />
Power Electronics Lab<br />
All rights reserved.Prof. Bernet 9/2003-32
Data of 3L-NPC-VSI<br />
•V ll =3300V, I o =1050A, S=6MVA<br />
•V dc =4840V, f c =840Hz<br />
• S<strong>in</strong>usoidal PWM with added third Harmonics<br />
•IGBT:<br />
Eupec (Series connection, V CES =3300V, I C =1200A,<br />
A Si =100%, R G+ =1.8Ω / R G- =3.3Ω)<br />
• 91mm RCIGCT:<br />
ABB (V DRM =4500V, I tgqm =2190A, A Si =69% / 34.5%)<br />
Power Electronics Lab<br />
All rights reserved.Prof. Bernet 9/2003-33
3.3kV 3L-NPC-VSI with IGCTs<br />
L R1i T 11i<br />
T 21i T 31i<br />
D C1i<br />
V dc<br />
/2<br />
V dc<br />
/2<br />
R S1i<br />
T<br />
C 12i<br />
T 22i<br />
T 32i<br />
i o1<br />
... i o3<br />
V l1 .. l 3<br />
C1i<br />
T<br />
C 13i T 23i<br />
T 33i<br />
C2i<br />
R S2i<br />
L R2i<br />
D C2i<br />
T 14i<br />
T 24i<br />
T 34i<br />
(91mm, 4.5kV IGCT (2700V; 2190A), A Si =34.5%, V dc =4840V, I o =1050A, S=6MVA)<br />
Power Electronics Lab<br />
All rights reserved.Prof. Bernet 9/2003-34
3.3kV 3L-NPC VSI with 3.3kV IGBTs<br />
V dc<br />
/2<br />
T 11i<br />
T 21i<br />
T 31i<br />
(3300V, 1200A) IGBTs,<br />
(A Si<br />
=100%), V dc<br />
=4840V,<br />
I o<br />
=1050A, S=6MVA<br />
T 12i<br />
T 22i<br />
T 32i<br />
V l1 .. l3<br />
i o1<br />
... i o3<br />
V dc<br />
/2<br />
T 13i<br />
T 23i<br />
T 33i<br />
T 14i<br />
T 24i<br />
T 34i<br />
Power Electronics Lab<br />
All rights reserved.Prof. Bernet 9/2003-35
VSC Losses versus Output Current<br />
140000<br />
P LOSS<br />
120000<br />
[W]<br />
100000<br />
80000<br />
60000<br />
40000<br />
20000<br />
0<br />
Psw_IGCT+Pclamp<br />
Psw_IGBT<br />
Pcon_IGBT<br />
Ptotal_IGCT<br />
Ptotal_IGBT<br />
Pcon_IGCT<br />
0 200 400 600 800 I1000 o [A] 1200<br />
((3300V, 1200A)-IGBT module (A Si =100%), (4500V, 2190A)-IGCT(A Si =34.5%),<br />
V ll =3008V, V dc =4840V, cosφ o =1, cosφ i =-1, f s =840Hz, T j =125°C)<br />
Power Electronics Lab<br />
All rights reserved.Prof. Bernet 9/2003-36
Circuit Configuration of ACS 6000<br />
RECTIFIER<br />
DC VOLTAGE LINK<br />
INVERTER<br />
T 11r<br />
T 21r T 31r<br />
D C1r<br />
L R1r<br />
L R1i T 11i<br />
T 21i T 31i<br />
D C1i<br />
R S1r<br />
R S1i<br />
V m1 .. m3<br />
T 12r<br />
T 22r<br />
T 32r<br />
C C1r<br />
V dc<br />
/2<br />
C C1i<br />
T 12i<br />
T 22i<br />
T 32i<br />
i o1<br />
... i o3<br />
V l1 .. l 3<br />
T 13r T 23r<br />
T 33r<br />
C C2r<br />
V dc<br />
/2<br />
C C2i<br />
T 13i T 23i<br />
T 33i<br />
R S2r<br />
R S2i<br />
T 14r<br />
T 24r<br />
T 34r<br />
D C2r<br />
L R2r<br />
L R2i<br />
D C2i<br />
T 14i<br />
T 24i<br />
T 34i<br />
(3.3kV PWM Drive for SM and IM)<br />
Power Electronics Lab<br />
All rights reserved.Prof. Bernet 9/2003-37
Characteristics of MV Drive ACS 6000<br />
• Power range: 3 MVA-27 MVA<br />
• Base Units: 5MVA / 7 MVA / 9 MVA<br />
• Voltage: V ll =3.3 kV (4.5kV IGCTs)<br />
• Rectifier:<br />
• Active front end (3L-NPC-VSI)<br />
• Diode front end (6p, 12p, 24p)<br />
• Common DC Voltage Bus<br />
• Inverter: 3L-NPC-VSI<br />
• Protection: Internal shoot through<br />
• Output filter: RLC-filter limits dv/dt ≤ 3kV/µs<br />
• Control / Modulation:<br />
• Inverter: Direct Torque Control<br />
• Rectifier: Vector Control + Optimized Pulse Patterns<br />
• In<strong>format</strong>ion: http://www.abb.com/drives / http://www.abb.com/powerelectronics<br />
Power Electronics Lab<br />
All rights reserved.Prof. Bernet 9/2003-38
ACS 6000 - the compact high power drive<br />
4.9 m<br />
LSU<br />
TEU&COU<br />
INU<br />
CBU<br />
WCU<br />
L<strong>in</strong>e Supply<br />
Unit (6p- or<br />
12p-diode<br />
supply)<br />
Power Electronics Lab<br />
All rights reserved.Prof. Bernet 9/2003-39<br />
-Term<strong>in</strong>als<br />
beh<strong>in</strong>d the<br />
control<br />
sw<strong>in</strong>g frame<br />
Inverter Unit<br />
- 3 phase modules<br />
S = 9 MVA<br />
DC-L<strong>in</strong>k<br />
Capacitor<br />
Bank Unit<br />
Water<br />
Cool<strong>in</strong>g<br />
Unit
Conclusions<br />
State of the Art<br />
- Increas<strong>in</strong>g importance of PWM-VSIs<br />
- Industry: Replacement of Cycloconverter and LCI<br />
- Energy Systems: W<strong>in</strong>dparks, HVDC, STATCOMs,<br />
Active Filters, High Power UPS<br />
- Traction: L<strong>in</strong>e Side Converter, Mach<strong>in</strong>e Side Converter<br />
- PWM -Converter Topologies / Semiconductors<br />
- Industry: 3L-NPC VSC, CSI, Multi-Level Converter<br />
(e.g. 4L-FC VSC, Isolated Cell VSC) – IGCT, IGBT<br />
- Energy Systems: 2L VSC, 3L -NPC VSC<br />
(e.g. HVDC, High Power UPS) – IGCT, IGBT<br />
- Traction: 2L VSC, (3L-NPC / FC VSC) – IGBT, GTO<br />
Power Electronics Lab<br />
All rights reserved.Prof. Bernet 9/2003-40
Conclusions<br />
! Characteristics of future AC Drives:<br />
! L<strong>in</strong>e friendly<br />
! Wide range of converter voltage (2.3kV....13.8kV) and power<br />
(500kW....>27 MW)<br />
! Motor friendly<br />
! Retrofit applications<br />
! High reliability<br />
! High efficiency<br />
! High power density<br />
! Low costs<br />
Power Electronics Lab<br />
All rights reserved.Prof. Bernet 9/2003-41