PRACTICAL PROBLEMS ASSOCIATED WITH THE OPERATION OF ASDS BASED ON ACTIVE

FRONT END CONVERTERS IN POWER DISTRIBUTION SYSTEMS

Luis Morn
(1)
Jos Espinoza
(1)
Mauricio Ortz
(1)
Jos Rodrguez
(2)
Juan Dixon
(3)



(1)
Dept. of Electrical Engineering
(2)
Dept. of Electronic Engineering
(3)
Dept. of Electrical Engineering

Universidad de Concepcin

Universidad Tcnica Fed. Sta. Mara

Universidad Catlica de Chile

Casilla 160 C, Concepcin

Casilla 110-V, Valparaso

Casilla 306-Correo 2, Santiago

CHILE

CHILE

CHILE

lmoran@die.udec.cl

jrp@elo.utfsm.sl

jdixon@ing.puc.cl


Abstract.- This paper presents and discusses different
problems associated with the operation of ASDs based on
active front end PWM rectifiers in power distribution
systems. Problems generated with high frequency current
harmonics, interaction with sensitive digital protection
schemes, and the circulation of leakage grounding
currents, are described. Practical problems generated by
the interaction with existing ASDs based on diode
rectifiers are also analyzed. Actual current and voltage
waveforms associated with the operation of active front
end based frequency changers in industrial power
distribution systems illustrate the practical problems
discussed in this paper.

I.- INTRODUCTION
Active front end converters are becoming and
interesting solution for power factor correction and low
frequency current harmonic elimination in static power
conversion systems. Due to current harmonic restrictions
in power distribution systems, active front end rectifiers
offer a viable alternative to replace traditional six pulse
diode rectifiers in frequency changers. Active front end
(AFE) rectifiers have been investigated for the last decade
and provide a good solution for the rectifying stage in
frequency changers. The main characteristics of AFE
rectifiers are the generation of reduced low frequency line
current harmonics, due to the use of pulse-width
modulation (PWM), a better overall power factor,
substantially smaller filter requirements, and inherent
regeneration capabilities [1]. Moreover, with the
development of new high voltage and current gate
controlled semiconductors, such as Insulated Gate Bipolar
Transistors (IGBTs) and Integrated Gate Controlled
Thyristors (IGCTs), and with the implementation of
multilevel structures, PWM-AFEs rectifiers are becoming
the standard solution for large-power medium-voltage
ASDs, and are responsible of the drastic increment in the
market share of PWM voltage-source controlled
converters [2]. It can be easily predicted that phase-
controlled and diode based rectifiers - which are currently
used in frequency changers - will eventually be replaced
by PWM-AFEs, thus improving power quality and power
factor at industrial facilities [1].
So far, several technical papers have been published
describing the principles of operations, design
considerations, control strategies, and PWM techniques
that optimize the performance of AFE rectifiers in
frequency changers [3]. Typical power circuit
configuration of this type of static converter is shown in
Fig. 1. Basically, these converters do not feature low
frequency harmonic generation as introduced by diode
and phase-controlled rectifiers, and can operate at leading
or unity displacement power factor. This is achieved by
the high switching frequency used to generate the required
PWM pattern that creates high frequency harmonic
components. However, technical information regarding
practical problems associated with high frequency current
harmonics in power distribution systems has been seldom
presented and discussed.


[ ]
ac
mains
dc
filter
i
dc
i
s
[ ] v
s
L r
input
filter
AFE
rectifier
[ ] v
r
C
d c
1 3 5
4 6 2
voltage source
inverter
motor
+
-
v
i
[ ] i
l
i
i
1 3 5
4 6 2
IM

Fig. 1.- Power circuit topology of a frequency changer implemented with
a PWM Active Front End Rectifier.

This paper presents and analyzes practical problems
created by the operation of AFE based frequency changers
in industrial power distribution systems. Problems facing
the inverter side have been analyzed, especially regarding
the overvoltages and leakage currents induced at the
motor terminals [4], [5]. In general, the analysis has been
focused in the leakage currents generated by common
mode voltages due to the inverter high frequency
operation. However, problems created at the rectifier
terminals due to high frequency currents and voltages
have not been reported in the technical literature. This
paper addresses these issues explaining their origins,
technical implications and possible solutions.


II.- PRINCIPLES OF OPERATION
Basically, active front end rectifiers can be represented
by a controlled voltage source, since the dc voltage
imposed across the electrolytic capacitor is reflected at the
rectifier input terminals, modulated by the switching
function as shown in Fig. 2.

L
r
R
i
sa

+
-
v
sa
v
ra

V


Fig. 2.- Single-phase active front end rectifier equivalent circuit.

If the rectifier uses pulse-width modulation, the input
voltage dominant harmonics are pushed to higher
frequencies, improving the input current waveform, as
shown in Fig.3. A higher switching frequency generates a
more sinusoidal input current.


(a) (b)
Fig. 3.- Simulated AFE input current and voltage waveforms (rectifier
switching frequency is 1.5 kHz). (a) AFE rectifier input voltage. (b) Ac
mains phase to neutral voltage and rectifier ac input current.

Another characteristic of active front-end rectifiers is
the ability to control the input power factor. Leading,
unity, or lagging power factor can be achieved by
adjusting the amplitude of the converter dc voltage. In
order to operate with leading power factor, the
fundamental component of the rectifier input voltage must
be larger than the source voltage, as illustrated in the
phasor diagram shown in Fig. 4.



Ri
sa

jX
r
i
sa
v
sa

i
sa

v
ra



Fig. 4.- Phasor diagram of the AFE rectifier.

The active power absorbed by the converter is
controlled by adjusting the amplitude of the rectifier input
voltage V
ra
and the associated phase shift angle . The
equation that defines the active power absorbed by the
converter is (1).
P = ) sin(
r
ra sa
X
V V
(1)
Actual current and voltage waveforms obtained in a
690 V pulp mill plant power distribution system show the
difficulties created by the operation of a high power AFE-
based frequency changer. In particular Fig. 5 and 6 show
the different waveforms associated with the operation of
the rectifier in the passive (diode-based rectifier) and the
active mode (AFE) modes. The passive (diode-based)
mode is achieved by the frequency changer by shorting
the gating signals of the power semiconductors of the
rectifier stage. While operating in the passive mode, the
input current and respective frequency spectra are well
known, (Fig. 5-c, d). It is important to note the presence of
the inverters switching frequency in the phase-to-ground
voltage, Fig. 5-a, b (25 50 = 1.25 kHz).

(a)
-1000
-800
-600
-400
-200
0
200
400
600
800
1000
-0,025 -0,02 -0,015 -0,01 -0,005 0 0,005 0,01 0,015 0,02 0,025

(b)
0
50
100
150
200
250
300
350
400
450
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51 53 55 57 59 61 63 65

(c)
-800
-600
-400
-200
0
200
400
600
800
-0,025 -0,02 -0,015 -0,01 -0,005 0 0,005 0,01 0,015 0,02 0,025

(d)
0
50
100
150
200
250
300
350
400
450
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51 53 55 57 59 61 63 65

Fig. 5.- Voltage and current waveforms for the operation as a 6 pulse
rectifier. (a) Phase to ground voltage, (b) Phase to ground voltage
frequency spectrum (50 V/div). (c) Rectifier input current waveform
(200 A/div), (d) Rectifier input current frequency spectrum (50 A/div).

However, during the operation in the active mode the
phase to ground voltage distortion increases dramatically,
as shown in Fig. 6-a, b, but the input current is almost
sinusoidal (Fig. 6-c, d). It is important to note the presence
of both inverters and rectifiers switching frequencies in
the phase-to-ground voltage, Fig. 6-a, b (25 50 = 1.25 kHz
and 50 50 = 2.5 kHz).
The problems associated with the operation of diode-
based rectifiers have been well documented in the
technical literature. They are basically related with the
generation of low frequency current harmonics (5
th
, 7
th
,,
6q 1, q = 1, 2, ). These harmonics increase the power
distribution losses and reduce the power quality, but they

can be attenuated with the use of passive filters. On the
other hand, the problems associated with the operation of
AFE rectifiers are associated with the converter design
characteristics, switching frequency, and power
distribution topology, as it will be shown in the next
sections.

(a)
-1500
-1000
-500
0
500
1000
1500
-0,025 -0,02 -0,015 -0,01 -0,005 0 0,005 0,01 0,015 0,02 0,025

(b)
0
50
100
150
200
250
300
350
400
450
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51 53 55 57 59 61 63 65

(c)
-800
-600
-400
-200
0
200
400
600
800
-0,025 -0,02 -0,015 -0,01 -0,005 0 0,005 0,01 0,015 0,02 0,025

(d)
0
50
100
150
200
250
300
350
400
450
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51 53 55 57 59 61 63 65

Fig. 6.- Voltage and current waveforms for the operation as active front-
end rectifier. (a) Phase to ground voltage, (b) Phase to ground voltage
frequency spectrum (50 V/div). (c) Rectifier input current waveform
(200 A/div), (d) Rectifier input current frequency spectrum (50 A/div).

III.- DESIGN CONSIDERATIONS
The design of the input reactor and the selection of
the switching frequency play an important role in the
interaction between the AFE rectifier and the power
distribution system. In fact, the size of the input reactor
defines the magnitude of the converter dc voltage and
must be related with the switching frequency in order to
achieve a required harmonic distortion at the input
current.

3.1.- Input reactor connected between the rectifier and the
ac main

This reactor is required to shape sinusoidal current
waveforms, to provide the rectifier operation as a boost
converter, and to absorb the instantaneous voltage
differences between the distribution system and converter
terminals. Normally, the required inductance is quite
large, and depends on the rectifier switching frequency,
which is usually in the audible range creating an annoying
audio noise (larger than the 80 dB allowed by
international standards), and a large dv/dt in case of power
outages. Also, the circulation of the line current through
the input reactor generates a phase to ground voltage with
large harmonic distortion, creating serious EMI problems
(Fig. 6-a), and a large current through the neutral to
ground. The operation in the active mode increases the
circulation of high frequency ground currents due to
leakage capacitance of cables, motors and transformers, as
shown in Fig. 7.

-4
-3
-2
-1
0
1
2
3
4
5
-0,025 -0,02 -0,015 -0,01 -0,005 0 0,005 0,01 0,015 0,02 0,025

Fig. 7.- Circulating current across the neutral to ground distribution
transformer during the operation as AFE (1 A/div)

Amplification in the oscilloscope time scale allows a
more detailed analysis of the current waveforms, showing
the presence of current harmonics associated to the
rectifier and inverter switching frequencies, as shown in
Fig. 8.

(a)
-4
-3
-2
-1
0
1
2
3
4
5
-0,001 -0,0008 -0,0006 -0,0004 -0,0002 0 0,0002 0,0004 0,0006 0,0008 0,001

(b)
0
0,1
0,2
0,3
0,4
0,5
0,6
0,7
0,8
0,9
1
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51 53 55 57 59 61 63 65

Fig. 8.- Amplification of the circulating current across the neutral to
ground distribution transformer during the operation as AFE. (a) Ground
to neutral current (1 A/div). (b) Associated frequency spectrum (the
rectifier switching frequency is 1.25 kHz and the inverter switching
frequency is 2.5 kHz.).

-2
-1,5
-1
-0,5
0
0,5
1
1,5
2
-0,025 -0,02 -0,015 -0,01 -0,005 0 0,005 0,01 0,015 0,02 0,025

Fig. 9.- Circulating current across the neutral to ground distribution
transformer during the operation as a 6 pulse rectifier (0.5 A/div).

During the operation as a passive converter (diode
rectifier) the circulation of the neutral to ground current is
reduced from 1.5 A (rms) to 0.3 A (rms) and the
associated frequency spectrum is completely different,
since the high frequency components are generated by the
inverter switching frequency, as shown in Fig. 9 and 10. It
is important to note that the amplitude of the high
frequency ground current generated by the operation of
the PWM-AFE rectifier can not be reduced by increasing
the ground resistance, since it circulates mainly through
leakage capacitance, and contributes to increase the high
0.57 A @
25*50 Hz = 1.25 kHz
0.67 A @
50*50 Hz = 2.5 kHz

frequency distortion in the neutral to ground voltage. The
most effective way to mitigate this effect is with passive
filters.

(a)
-2
-1,5
-1
-0,5
0
0,5
1
1,5
2
-0,001 -0,0008 -0,0006 -0,0004 -0,0002 0 0,0002 0,0004 0,0006 0,0008 0,001

(b)
0,00
0,05
0,10
0,15
0,20
0,25
0,30
0,35
0,40
0,45
0,50
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51 53 55 57 59 61 63 65

Fig. 10.- Amplification of the circulating current across the neutral to
ground distribution transformer during the operation as a 6 pulse
rectifier. (a) Ground to neutral current (0.5 A/div). (b) Associated
frequency spectrum.

3.2.- Dc link voltage

Most of commercially available AFE based frequency
changers can operate their rectifier stage as a diode
rectifier (passive mode) or as an AFE rectifier (active
mode). For operation in the passive mode, the dc voltage
of the frequency changer is 6 times the phase to neutral
source voltage, while in the active mode the dc voltage is
increased, at least 20 %, due to the boost characteristics
imposed by the AFE. The actual value depends on the
input reactance and switching frequency as shown in Fig.
11. A larger value in the dc link voltage, increases the
voltage stress at the ac side of the AFE, and contributes to
increase the rms value of the leakage currents flowing to
ground. Moreover, a large value in the dc voltage forces
the AFE to operate with a lower modulation index (in
order to generate the required ac rms voltage) which
increases the number of over-voltages per cycle affecting
the load insulation.


Fig. 11.- Amplitude of the dc voltage as a function of the input reactor
value.

IV.- INTERACTION WITH THE POWER DISTRIBUTION
SYSTEM
As it was mentioned in the previous sections, the high
switching frequency used in the PWM AFE rectifiers
creates a new frequency spectrum in the input current,
generating different side effects in the operation of the
power distribution system. Some of these new problems
are discussed below.

4.1.- Switching frequency interaction

The operation of the rectifier and the inverter at
different switching frequencies, in the frequency changer,
creates an input current with a frequency spectrum that
presents both dominant harmonics synchronized at each
switching frequency (Fig. 6). These high frequency
current harmonics increase the losses and stresses in the
input reactor.

4.2.- Interaction with other converters connected at the
same bus

From the power distribution point of view, the AFE
rectifier operates as a current source (voltage source in
series with the link reactor), and as such injects high
frequency current harmonics into the grid. If ASDs that
use diode-based rectifiers (standard ASD) are connected
to the same ac grid, the high frequency current
components are pushed into their dc bus. This is due to the
fact that they offer a low impedance path to these high
frequency current components (due to the dc link
capacitor presence), overloading the respective converter.
Moreover, if the standard ASD is operating at light load,
its dc bus voltage will tend to increase until the converter
shuts down, hopefully by means of the dc link over
voltage protection. This phenomenon is not usual, but may
happen with serious consequences, as shown in Figs. 12
and 13. In particular, Fig. 13 shows that the diode rectifier
is absorbing high frequency current harmonics generated
by the AFE rectifier (23
th
and 25
th
). These harmonics
contributes with active power to the dc capacitor
increasing the dc voltage by 15 % in this case.

13.2/0.38 kV
1000 kVA
5.5%
DIODES AFE
4 mH 0.5 mH
250 kW 100 kW
I
AFE
I
DIODES

Fig. 12.- Power system topology of an AFE rectifier connected to the
same bus of a conventional frequency changer.

There are two ways to avoid this problem, the first is
to connect a high pass filter to the same power distribution
bus, tuned at the lowest switching frequency of the
frequency changer (normally the inverter switching
frequency), and the second is to connect a reactor in series
to each diode-based rectifier (as in standard ASDs). The
first solution normally is not considered, since the THD of
192 mA @
25*50 Hz = 1.25 kHz
44 mA @
3*50 Hz = 150 Hz
90 mA @
47(53)*50 Hz = 2.35(2.65) kHz

the AFE input current is quite low (normally below 5 %);
however, it eliminates the circulation of high frequency
current components through the power distribution
system.

(a)
(b)
(c)

(d)


Fig. 13.- Current and voltage waveform measured in a power distribution
system. (a) Phase to neutral bus voltage (500 V/div). (b) Input current of
the AFE rectifier (100 A/div). (c) Input current of the diode rectifier (100
A/div).

4.3.- Problems associated with ground protections

Normally ground fault are eliminated with zero
sequence relays connected through ring transformers or to
the neutral to ground connection. In case no ground fault
is present in the system, zero sequence currents do not
exist. However, if an active front end converter is
connected to the power distribution system, high
frequency current harmonics get sink into the ground
across parasitic capacitances, which are reflected to the
secondary of the ring current transformer forcing the
operation of ground fault relays (Fig. 14).

(a)
-40
-30
-20
-10
0
10
20
30
40
-0,05 -0,04 -0,03 -0,02 -0,01 0 0,01 0,02 0,03 0,04 0,05

(b)
-2,5
-2
-1,5
-1
-0,5
0
0,5
1
1,5
2
2,5
-0,05 -0,04 -0,03 -0,02 -0,01 0 0,01 0,02 0,03 0,04 0,05

Fig. 14.- Voltage and current neutral to ground waveforms during the
operation of an AFE rectifier. (a) Neutral to ground voltage. (b) Neutral
to ground current.
If the ASD operates the rectifier stage as a diode-
based one, the neutral to ground current and voltage
waveforms are nearly zero, as shown in Fig. 15.

(a)
-40
-30
-20
-10
0
10
20
30
40
-0,05 -0,04 -0,03 -0,02 -0,01 0 0,01 0,02 0,03 0,04 0,05

(b)
-2,5
-2
-1,5
-1
-0,5
0
0,5
1
1,5
2
2,5
-0,05 -0,04 -0,03 -0,02 -0,01 0 0,01 0,02 0,03 0,04 0,05

Fig. 15.- Voltage and current neutral to ground waveforms in an ASD
operating the rectifier in the diode-based mode. (a) Neutral to ground
voltage. (b) Neutral to ground current.

One possibility to avoid this type of problem is to
connect a passive filter tuned at 50 or 60 Hz, at the
terminals of the secondary winding of the current
transformer. In this way the ripple current generated by
the PWM-AFE rectifier circulates through the filter and
does not propagate to the protection relay.

V.- CONCLUSIONS
Practical problems associated with the operation of
active front end rectifiers have been presented and
analyzed in this paper. Most of the problems are
associated with the circulation of high frequency current
harmonics through leakage capacitance of power
distribution systems. The circulation of high frequency
current harmonics produces interaction with other static
converters connected to the same bus, increases the
amplitude of neutral current, and activating the operation
of zero sequence relays. Each of the aforementioned
problems has been demonstrated with actual waveforms
obtained in a pulp and paper mill plant. Solutions for each
of the presented cases have been proposed.

ACKNOWLEDGMENT
The authors would like to thanks Fondecyt (the
Chilean Research Council) for the financial support given
through the project # 1020460.

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[2] S. Bernet, Recent Developments of High Power Converters for
Industry and Traction Applications, in IEEE Trans. on Power
Electronics, vol. 15, n 6, November 2000, pp. 1102-1117.
[3] D. Zhou, D. Rouand, Regulation and Design Issues of a Pulse-
Width Modulation Three-Phase Rectifier, in Industrial Electronic
Conference, San Jos, California, 1999.
[4] M. Melfi, J. Sung, S. Bell, G. Skibinski, Effect of Surge Voltage
Rise-time on the Insulation of Low-Voltage Machines Fed by PWM
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[5] A. von Jouanne, H. Zhang, A. Wallace, An Evaluation of
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