Low Voltage High Current Controlled Rectifier with IGBT A.C Controller on Primary Side of the Transformer
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1 AU J.T. 6(4): (Apr. 2003) ow Voltage High Current Controlled Rectifier with IGBT A.C Controller on Primary Side of the Transformer Seshanna Panthala Faculty of Engineering, Assumption University Bangkok, Thailand Abstract This paper deals with the steady state performance of a novel controlled rectifier, using an IGBT A.C controller on the primary side of the input transformer, while a center tapped secondary and normal diodes are used for rectification. Such a rectifier is suitable for low voltage high current applications. The IGBTs are controlled such that this type of controlled rectifier has a better displacement power factor because the line current drawn is symmetrical in relation to the peak of the a.c input voltage. Thus the fundamental component of the line current drawn will be in phase with the line voltage. Theoretically expected and experimentally obtained waveforms of currents and voltages are presented. Keywords: IGBT a.c controller, symmetrical triggering, controlled rectifier displacement power factor, harmonic distortion. Introduction Many industrial applications need lowvoltage, high-current d.c for their operation. Examples of such industrial applications are electroplating, extraction of metals by electrolysis, etc. Most often voltage/current is to be varied and controlled. Since the standard electrical supply available is a.c, controlled rectifiers are used to obtain the variable d.c from an a.c source. ormally a transformer is used to step down the a.c to the required level and also provide isolation. There are two options to obtaining the controlled d.c voltage: R (a) use silicon controlled rectifiers on the secondary side to rectify a.c and produce d.c, or (b) use a.c controller (two back-to-back connected SCRs) on the primary side of the transformer and then rectify the secondary voltage with power diodes. Such schemes are shown in Fig.1 using a single-phase supply. In practice, the scheme shown in Fig.1(b) is used as the current commutation takes place on low current side. The principles of operation of such a scheme are well understood and discussed widely in textbooks in power electronics (Sen 1988).. In this paper, a novel controlled rectifier using Insulated Gate Bipolar Transistor (IGBT) a.c controller (IR 2002) instead of SCR-based a.c controller to achieve R (a) Fig.1. Conventional low-voltage controlled rectification (b) 193
2 In this paper a novel controlled rectifier using insulator gate bipolar transistor (IGBT) a.c controller instead of SCR based a.c controller to achieve the same function is described. The scheme is shown in Fig. 2. The IGBT a.c controller is on the primary side of the step down transformer, while the secondary side is a full wave rectifier with a center tapped secondary. It will be shown that this arrangement will have better performance from a power factor point of view, compared to the scheme in Fig 1(b). during the negative half cycle. The conduction period is made symmetric about the peak of the The signal waveforms at different points in the circuit are shown in Fig. 3 under ideal conditions of operation. In order to maintain high displacement power factor, the gate drive signals have to be displaced by 180 o and symmetric with respect to the peak of a.c wave. Out put current control is obtained by varying the pulse width of the gate drive signal. o special commutation circuits are required even though an R-C snubber is required across the primary winding in practice to absorb the energy in the magnetizing inductance when both IGBTs go into off state. ν S G1 G2 Description of IGBT a.c Controller based Controlled Rectifier Fig.2. Controlled rectification with IGBT a.c controller Working Principles The basic schematic circuit is shown in Fig. 2. Two IGBTs (MOSFETs can also be used) are connected in series opposition and the combination itself is in series with the incoming a.c line. The IGBTs must have in built diodes otherwise external diodes are to be connected across each IGBT. The IGBT1 is switched on and off during the positive half cycle while the IGBT2 is switched on and half R ν g1 ν g2 ν p ν o i i S a.c wave using appropriate gate control strategy. The secondary side consists of an ordinary full wave rectifier with a large smoothing inductor to maintain load current ripple free. Fig. 3. Ideal waveforms of voltages and currents at different points (v s =a.c supply voltage, v p = voltage applied to the primary of the transformer, v g1, vg 2 =gate drive signals, vo = rectified secondary output, I = load current and I s = a.c supply current drawn ) 194
3 From the voltage waveforms, the average output voltage equation is given by: V od.c = 1 p π α α V om sin?d? experimentation. Again when an IGBT is given gate drive, corresponding diode takes over the full current and the other diode commutates off. 2 = Vom cosα p for α varying from 0-90 o i s = 0 i /2 R Assuming a large smoothing inductance in series with the load, the load current can be regarded as constant d.c. In such a case the a.c supply current I S will be square pulses as shown in the Fig. 3. The Fourier series for this type of current is given by: I s 4 4 = Is cosα sin? t - Is cos 3α sin 3? t p 3p 4 + Is cos5a sin5? t p The fundamental component of the supply current drawn from the line is in phase with the supply voltage. Hence, the displacement power factor (also called fundamental power factor) is unity and there is no fundamental reactive power transport to and from the load. This feature is in contrast with the controlled rectifier scheme shown in Fig. 1(b). However, there is some reactive power transport due to harmonic components of current. It is interesting to analyze what happens during the blanking period when both IGBTs are in off condition, thus making primary current zero. This means that the primary can not have equivalent balancing ampere-turns corresponding to secondary ampere-turns. Also the load current on secondary side continues to flow due to the presence of large inductance in series with the load. In order to produce zero secondary ampere-turns and keep the load current constant, the load current splits equally into the two halves of the secondary as shown in Fig. 4 during this period. Both diodes conduct simultaneously and equally. This phenomenon takes places naturally twice in each cycle of the input a.c wave when IGBTs go off. This fact has been verified during Fig. 4. oad current flow path during blanking period i /2 Experimental Results Description of Experimental Set Up In order to verify the working principles and waveforms, the schematic circuit shown in Fig. 5 is constructed and tested. The microcontroller AT 89c51 is programmed to develop the required gate drive signals and two Darlington photo isolators are used to isolate high power circuits from micro-controller and other electronic circuits. Briefly the operation of the circuit is as follows: Sharp pulses from zero crossing detector (not shown) interrupt the microcontroller at 10 millisecond intervals at port pin 3.2 which is the interrupt IT0. Upon receipt of this interrupt, the controller will start Timer0 after loading it with a number derived from the output of the ADC connected to port1. This number can be changed by changing the analog control voltage V C. The run time of timer0 is the initial delay α. When timer0 overflows it generates an interrupt when it will be stopped and timer1 is started after loading it with a number corresponding to (π - 2α) and simultaneously either P2.3 or P2.4 is made high depending on whether the a.c wave is going through the positive or negative half cycle. This positive or negative half cycle information is made available to the controller i 195
4 at port pin P2.1 in the form of a square wave derived from the a.c line using a zero crossing detector (not shown). Corresponding IGBT will be made on by driving its gate high using the transistor and photo Darlington 433. When timer1 overflows, it is stopped and also the IGBT, which was on, is made off by making its gate drive zero. ow, the controller is waiting for the next interruption at IT0 after receipt of which the procedure described above is repeated. The R-C circuit across the primary of the transformer is required in order to provide a path for the magnetizing current of the transformer when IGBT a.c controller goes into off state. The design of these components is difficult as the waveform of the voltage applied to the primary varies depending on the pulse width of the gate drive signals applied to the IGBTs. However, the reactance of the capacitor X C is made equal to the magnetizing reactance Xm of the transformer referred to as primary. This is only a guideline. The series resistance R is there to limit the initial capacitor charging the current at the instant of application of the voltage to the primary by the a.c controller. The initial capacitor current is to be limited to be well within the rating of the IGBT used. 5V 15V 433 P V 15V R G R C R i R G 89C51 P P2.1 P3.2 P1 D0-D7 ADC V C 5V Fig. 5. Circuit diagram of the experimental set up 196
5 Experimental Waveforms The set up is started and load current is adjusted to have a value of about 5 amp. The waveforms of signals at different points in the set up are recorded and shown in Fig. 6. It is interesting to compare these practical waveforms with the expected ideal waveforms shown in Fig. 3. Fig. 6. Experimentally obtained waveforms of currents and voltages 197
6 Conclusions A novel IGBT a.c controller based, controlled rectifier, has been constructed and tested in the laboratory. The experimentally obtained voltage and current waveforms at different points in the circuit agree closely with the theoretically expected waveforms. At medium voltage and power levels this type of controlled rectifier can replace the conventional SCR based controlled rectifier with an added advantage of having unity fundamental power factor. The controlled rectifier has been tested in a steady state and under open loop (manual) control. Control circuits are being developed in the department of electrical engineering to maintain output d.c voltage/current constant under varying load conditions by incorporating closed loop control on the rectifier. These will be reported in a future paper. Acknowledgements The author acknowledges the help rendered by his colleagues, Mr. Wuttikorn Threevithayanon and Mr. Chairat Kumrueng, of the Faculty of Engineering, AU, in recording the test waveforms and in the preparation of this manuscript. References Sen, P.C Power Electronics. Tata McGraw-Hill, ew Delhi, India. IR Application ote A-1017a. International Rectifier, El Segundo, CA, USA. 198
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