Cost Effective Multi - Pulse Transformer Solutions

For Harmonic Mitigation in AC Drives

Gary L. Skibinski Nick Guskov Dong Zhou
Rockwell Automation Drives Division
6400 W. Enterprise Drive Mequon, WI 53092
Tel: 262-512-7151 Fax: 262-512-8300 Email: glskibinski@ra.rockwell.com

Abstract – More and more ac drive installations are requiring utility distribution
transformer transformer Drive
manufacturer’s to improve line side harmonics to ultimately meet 600m of
IEEE Harmonic Std 519-1992 on site [1]. This paper reveals several PCC1 PCC2 cable PCC3 AC

patented transformer topologies for such an effort. Compared with
other harmonic solutions, auto and isolated transformers possess
advantages as being simple, reliable, minimal line resonance
problems and relatively cost effective. The proposed nine and
twelve-phase auto-transformers can be viewed as a polygon winding
type, where besides achieving an improved input current
harmonics, junction points among various windings along the
polygon can be wired out for step- down, unity and step-up voltage
transfers. When electrically isolated primary windings are added,
unlimited transfer ratio is available for every application.
Application of these new industrial transformer devices, along with
simple power diode energy conversion methods, result in a robust
and reliable system that provides good DC bus regulation for AC
drives utilizing a common DC bus configuration. The proposed
topologies also provide a high AC input power factor and minimize
harmonic currents to the Utility Interface. The paper provides
technical analysis and field site data on the new topologies, as well
as per unit metric comparison to other harmonic mitigation
techniques versus horsepower size.
I. INTRODUCTION
Standard AC drive topologies utilize AC-DC-AC power
conversion with a three phase rectifying bridge for the AC-DC
function. A three-phase diode or SCR bridge generates 6 pulse
type current that is ~ 32% rich in total harmonic current
distortion [2]. As ac drives proliferate, equipment system
specifications limiting the amount of harmonic current injected
into the grid are becoming more common and thus solicit cost
effective harmonic mitigation solutions.
System specifications are often written so measured total
harmonic distortion at the Point of Common Coupling (PCC) in
Fig. 1 complies with the maximum low voltage total harmonic
distortion levels (THDV) and system classification of IEEE 519
Table 10.2 and current distortion limits of Table 10.3. The PCC
is usually at the power metering point (PCC1) where other
customers connect to the common line voltage but may also be
at (PCC2) or (PCC3) within a plant where linear and non-linear
loads are connected. System classification and (THDV) options
are Special Application @ 3%, Dedicated System @ 10 % and
most specified option of General System @ 5%. Current
harmonic distortion (THDI) of a single non-linear load is defined
as the square root of the sum of the squares of all harmonic
currents divided by the fundamental component of the non-linear
load. However, Table 10.3 defines total harmonic current
AC
2500kVA 250kVA
5.75%Z 5.75%Z Linear Linear
480Vsec 480Vsec
Load A Load B
Other
Customer
Fig. 1 One line showing various harmonic distortion measurement points
h=n 2
∑ Ih
h=2
TDD = Eq. (1)
IL
Fig. 2 shows THDI of available solutions applied at PCC3.
Only the 18 pulse, active filter and synchronous converter front
end solutions are able to meet IEEE TDD limit of 5% at PCC3
and PCC1. The passive LC type has a typical THDI ~9% and is
regarded as cost effective [3]. However, it is well known to
have problems of resonance and leading power factor at no-
load condition [4]. The LC filter requires a detailed harmonic
analysis to determine if a TDD limit of 5% is possible at PCC3
in the installation. Active shunt, series and even hybrid filters
are promising but remain expensive and questionable in
reliability [5]. Analysis of Harmonic Canceling Reactors [6] or
Line-side Inter-phase Transformer (LIT) [7] shows their
effectiveness but does not prove their cost competitiveness.
An Auto-transformer solution is investigated in this paper as
a preferred embodiment because it does not introduce
resonance in power system, is reliable and relatively cost
effective. Integrating power switching devices with an auto-
transformer may reduce size, but sacrifices the optimum cost
target [8]. Traditional pure-passive auto-transformers may be
potentially more cost effective, but they also pose a problem in
sharing bridge currents in such multi-pulse application.[9]
In this paper, various patented topologies [10-12] of new
auto and isolation transformers are proposed for harmonic
mitigation, that inherently solve the diode current balancing,
and are proven with test results and product in the field.
Typical (THD_I), %
1 10 100 1000
Basic Drive without dc link choke
Addition of dc link choke
Addition of 3% line reactor

distortion limits in a system as Total Demand Distortion (TDD). Addition of passive filter

TDD limiting values are dependent on the ratio of short circuit 12 pulse auto transformer
current (ISC) at the PCC to the maximum demand load current 18 pulse auto transformer IEEE 519
(IL) supplied by the user. There are five classifications of (ISC/IL), Active filter IEEE 519
but worst case TDD limit of 5% for an (ISC/IL)< 20 is often used. Synchronous converter IEEE 519

IEEE 2003 Industry Application Society (IAS) conference Fig. 2. Summary of harmonic mitigation solutions
 11
II. PRIOR ART OF MULTI-PULSE TRANSFORMER CIRCUITS
14
22
18-pulse isolation transformers that convert three-phase to 15

nine-phase AC power are well known but have several 24 25

shortcomings. First, isolation transformers must be rated for the 21
40° 40°
full power required on both primary and secondary windings. 16

Second, as a result of separate primary and secondary windings, 23

isolation transformers are relatively large. When isolation

20
between a utility supply and a rectifier is not required,
13
employing an auto-transformer, consisting of a plurality of series 12
17
and common windings, may advantageously reduce the size,
19
weight and cost of the 3-phase to 9-phase converter. 18
(a) Reference [14]
200
Fig. 3 shows an exemplary 3-phase to 9-phase auto-
210
transformer topology [13]. Three phase AC input lines are linked
to three input nodes (1,2,3) and nine output nodes (1-3, A-F) 211 218

provide voltage to three separate six pulse bridges. 18-pulse

operation is obtained with +/- 20 degree phase shift around 221
220

nodes 1,2 and 3. One problem is an inherent impedance 212 40° 40° 218

mismatch in the topology since one bridge is fed directly form 219

the line and the other two bridges are fed through the short
transformer windings which are characterized by a certain
213 202
amount of leakage reactance. This results in looping currents 217

among the 3 bridges, which further requires relatively bulky and 201

expensive inter-phase transformer hardware to correct. 214 215

(b) Reference [14]
Secondly, current-sharing problems among the three bridges is 300

exacerbated when irregular and unpredictable pre-existing AC 310

line harmonics occur as different source harmonics that 311 318

substantially change bridge current sharing.

One solution to the looping and sharing current problems is 320 321

to provide an autotransformer that equally spaces output 312

40° 40° 317

voltages in phase. Thus, where nine outputs are required, the 319

outputs can be phase shifted from each other by 40 degrees each.

In Fig. 4a this is accomplished in a step-down autotransformer
with three coils, having serial windings that form a delta and 313
302

316
stub windings magnetically coupled with the serial winding from 301

the same coil [14]. Three phase AC inputs are linked to the apex
315
nodes (11,12,13). Direct output nodes (14,17,19) and indirect
314
(c) Reference [15]
500
output nodes (15,16,18,19,21,22) all have identical voltage
magnitude vectors with the required 40-degree phase shift. The 6
leaf secondary windings solely process secondary power. 510 518
Fig. 4 shows other nine-phase step-down autotransformer 520
configurations investigated. A step-down version is needed to 511 521 20° 20° 517

compensate for a 14% increase in dc bus voltage that occurs

from 3-phase to 9-phase conversion. Fig. 4b and Fig. 4c contain
519
even more secondary leaf windings. Fig. 4d uses only 3 512 516

secondary leaf windings resulting in more efficient usage of

502
501
513 515

514
(d) Reference [16]
600

610
611 618

620

630
602
40° 40° 617 631 622

619

632
621

601 613 616 603

614

Fig. 3 Prior art 9-phase unity-gain autotransformer topology with +/-

615
(e) Reference [17]
20 degree phase shift between output voltages [13] Fig. 4 Prior art 9-phase step-down autotransformer topology with 40
degree phase shift between output voltages
 IR
H1 X1
H6

R1 R2
X2 X9

h6
θ
x1
R
3 Phase S 40° 40°
AC X3 X8
Source T

O
H4 H3

X4
X7 +
DC

R3 R5 Output
X5 R4 -
H5
H2 X6

Fig. 6 Proposed nine-phase 18 pulse autotransformer in a step-down ac-dc system topology

material. However, the calculated step-down ratio may be eliminates the looping and sharing current problems, the stub
difficult to achieve. Fig. 4e has main windings in Y connection, winding requirement in each of the prior art renditions results
Y connected leaf windings and a separate non-power isolated in increased kVA requirements, increased winding and core
delta winding loop needed for circulating non sinusoidal material and increased physical size.
currents. Thus, the next section proposes 3-phase to 9-phase
Fig. 5 shows other nine-phase unity-gain autotransformer autotransformer solutions that do not have looping and sharing
configurations. A 6-pulse drive guarantees 460V Output with current problems, are relatively inexpensive to construct, that
480V AC input. A unity-gain autotransformer version, with an can be utilized as step-down or unity gain and that can have an
inherent 18-pulse higher DC bus voltage value, is sometimes optional primary winding to accommodate any voltage transfer
desirable for applications requiring 460V Output under low line ratio desired.
conditions of the 480V AC input.
While staggering the transformer outputs by 40o essentially III. PROPOSED MULTI-PULSE TRANSFORMER CIRCUITS
100
A. 9-Phase Step-down & Unity Phase Shifting Autotransformer
101
108
One design objective is to develop a single auto transformer
topology that can be utilized as a step-down or unity-gain
transformer. This feature enables a manufacturer to reduce
102 40° 40°
107 design and manufacturing cost as one transformer is used for
109 two different applications. Fig. 6 shows a nine-phase auto-
transformer topology incorporated in a step down ac-dc power
conversion system [10]. The transformer is wound on a regular
103
106 three-pole core with 15 windings, where each phase has five
windings. For example phase R consists of windings R1-R5. On
each pole all windings are wound such that their polarities are in
104 105
(a) Reference [14] the same direction. This polarity alignment assures inductance in
400

each winding is added up along the magnetic path length.

401 408
A second design objective is to provide 18-pulse
performance at lowest cost. To this end, the proposed
410
autotransformer only includes serial windings and does not
402
40° 40° 407
require leaf windings, which solely process one side power.
409 These results in better material utilization than prior art designs
for the same transformation results. The plurality of the series
406
windings is arranged to form a polygon.
403
The step-down transformation objective of Fig. 6 has
404
winding junction points H1-H6 and X1-X9 wired for
405
(b)Reference [15] input/output, respectively. Since X1-X9 has equal magnitude
Fig. 5 Prior art 9-phase unity-gain autotransformer topology with 40 and equal 40ophase shift, they serve as a nine-phase voltage
degree phase shift between output voltages output for rectification and DC output. Such DC output has 18-
 X1
pulse low ripple performance. Utility line RST input power
connections, with their 120o phase shift set, can be connected to X2
R1 R2 X9
two sets of nodes; either [H1_H2_H3] or [H4_H5_H6] for a H1 H6

same step-down ratio.

x1 H1
A third design objective is to eliminate the looping and h6
sharing current problems. This is accomplished by the equal X3
40° X8 R1
40°
X1-X9 secondary voltage magnitudes which are separated by T1
O
equal 40o phase shift angles. 40°
H2
H3
The step-down magnitude between primary and secondary H4
H3
voltages can be analyzed by viewing Fig. 6 as a voltage plane H2 H5 S1
X7
where distance between nodes represents voltage magnitude X4
R5
R3
(b)
Lines can be drawn between nodes and the Origin (O). The
angle between two lines represents a phase shift angle of two R4
node voltages. For example, the phase angle between nodes X1 X5 X6

and X2 is 400. A nine-phase autotransformer requires nine (a)

output nodes X1-X9 whose voltages are identical and spaced Fig. 7 Proposed nine-phase autotransformer in a step-up ac-dc system
apart 400 on the dotted unit line circle of Fig.6. Nodes X1-X9
serve as output secondary voltages. It is seen that the voltage seen the output voltage vector lengths and magnitudes are
magnitudes at the step-down input set (H1_H2_H3) of Fig. 6 identical on the unit circle with the required 400 phase shift
are greater than the voltage magnitudes at the output set (X1- angle, while the input voltage vector magnitudes are identical
X9). Step-down voltage magnitude will be proportional to the in length to the output voltage vectors.
length of vector X1 (i.e. output vector length) to the length of
B. 9-Phase Step-up & Unity Phase Shifting Autotransformer
vector H6 (i.e. supply vector length). The following equations
are formulated from the trigonometric relationship in Fig.6. Winding re-arrangement of the 15 nine-phase auto-transformer
 cos 20o (1 − cos 40o )  windings in Fig. 6 gives an alternate in Fig. 7a, capable of
θ = tan −1 
 sin o + cos o sin o  ≈ 13.08
o
Eq.2
 20 40  x1
20 unity and step up with a ratio of = 1.28 [11]. Unity three
h6
V sec X1
= = cos ( 40o − θ ) ~ 0 .8916 Eq.3 phase to nine phase voltage transformation is realized by
V pri H6 connecting the primary three phase source to either node sets
Thus, the step-down magnitude is 10.84 %. Fig. 6 can also be of [X1_X4_X7], [X2_X5_X8] or [X3_X6_X9] while the
used to identify the lengths of windings R1 through R5 with secondary output nine phases are taken from X1 to X9. There
respect to the supply voltage magnitude vector H6. From Fig. 6 are three sets of parallel windings. One phase set in Fig. 7a
the following relationships can be developed: consists of R1 through R5. Thus, each phase set has five
R1= R 2 = sin ( 40o − θ ) H 6 ≈ 0 .4527 * H 6 Eq.4 windings wound on one pole of a conventional three-pole
magnetic core.
R 4 = 2 sin ( 20o ) cos ( 40o − θ ) H 6 ≈ 0 .6099 * H 6 Eq.5 When either set of [H1_H2_H3] or [H4_H5_H6] nodes are
R 5 = R3 = sin ( 20o + θ ) H 6 − 0.5 * R 4 ≈ 0 .2409 * H 6 Eq.6 used to connect to the primary power source, this topology is
The lengths expressed in Eq.4 – Eq.6 are proportional to the capable of step-up voltage transformation. The ratio is defined
turns ratios of windings R1 through R5. Thus, for windings R1 by the trigonometric relationship as:
through R5 the turns ratios are: V sec X1 1
= = ~1.28 Eq.8
R1 : R 2 : R3 : R 4 : R5 = 1: 1 : 0.5321:1.3472 : 0.5321 Eq.7 V pri H6 2
[
(sin 50o ) + tan (30o ) (1 − sin 50o)
2
]
Although non-integer numbers of winding turns can be Again, each winding turns can be calculated in lengths:
achieved, integer number of turns is preferred for ease of
manufacturing. Table 1 lists possible winding turn

[ 
R1 = R 2 =  (cos 50o ) − tan (30o ) (1 − sin 50o)  * X 1 ≈ 0.5077 * X 1
 
] Eq.9
combinations to achieve the turns ratios of Eq. 7. A maximum  1 − sin 50o 
error introduced because of integral winding turn numbers is R3 = R5 =   * X 1 ≈ 0.2701* X 1 Eq.10
 cos 30o 
shown. Combination 3 has the lowest maximum error and is  
preferred. ( o )
R 4 = 2 * sin 20 * X 1 ≈ 0.6840 * X 1 Eq.11
Table 1 Consequently,
_______________________________________________________________
Combination # R1 R2 R3 R4 R5 Max Error R1 : R 2 : R3 : R 4 : R5 = 1: 1 : 0.5321:1.3472 : 0.5321 Eq. 12

1 15 15 8 20 8 0.77 % Possible turns for each winding are summarized in Table 2

2 28 28 15 38 15 0.31 % Table 2
3 32 32 17 43 17 0.07 % _______________________________________________________________
4 43 43 23 58 23 0.25 % Combination # R1 R2 R3 R4 R5 Max Error
1 15 15 8 20 8 0.77 %
Fig. 6 topology also meets the unity voltage transfer design 2 17 17 9 23 9 0.29 %
objective when RST are connected to either one of 3 21 21 11 28 11 0.71 %
[X1_X4_X7], [X2_X5_X8] or [X3_X6_X9] sets of nodes. It is 4 23 23 12 31 12 0.52%
 R1 X1 R2 X12 R3
H1 H6
Y1

X11
X2
x1
x12 h6
6 Phase
Y4 Y6 Rectifier
o DC
30 X10 Module Out
X3
#1

H3
H4

6 Phase

o X9 Rectifier
X4
30 o
15 Module
Y2 Y3
#2

R X5 X8

Y5
S
Three
H5
Phase T H2 R4 X6 R5 X7 R6
AC
Power
Source
Fig. 8 Proposed twelve-phase 24 pulse autotransformer in a step-down ac-dc system topology

C. 9-PhasePolygon Secondary for Isolation Transformer
The autotransformer topology of Fig. 6 or Fig. 7a can be
utilized as a secondary of an isolation transformer. Addition of
three more windings electrically isolated from the fifteen
polygon windings, shown delta connected in Fig. 7b, converts
the entire topology into an isolation transformer with arbitrary
voltage transfer ratio. The delta primary winding can be added
to Fig. 6 in a similar manner.
With electrically isolated primary windings, unlimited
voltage transfer ratio is available for every application, such as
medium/low voltage transformation with medium voltage
feeders to eliminate the need for an interface step-down utility
transformer. For example, an 800 HP isolation transformer
with 4.2 kV primary / 600 V step-down polygon secondary was
manufactured and installed. This eliminated the need for a 1.5
MVA 4.2 kV primary / 600 V step-down utility transformer
that would normally have fed a 600V/600V polygon
autotransformer design.
D. 12-Phase Step-down/up & Unity Phase Shifting Autotransformer
Fig. 8 shows a twelve-phase auto-transformer configured as
step-down in a 24-pulse ac-dc conversion system [12]. A
twelve-phase 24-pulse rectifier system requires 30 degree
phase shift between the 12 output voltage nodes to eliminate
circulating and sharing current problems.
There are eighteen windings are arranged into a hexagon
where all winding junctions can be utilized for various voltage
transfer functions. These 18 windings are divided into three
groups wound on three magnetic poles of a transformer core.
Each pole phase has six windings that are interconnected with
the same polarity. The polarity alignment assures inductance in
each winding is added up along the magnetic path. Each phase
consists of six windings (R1-R6 for phase R). Secondary
voltages are supplied from equal magnitude points X1 to X12.
Voltage transformation is determined by the trigonometry
illustrated in Fig. 8. Figure 8 can be viewed as a voltage plane
where distance between nodes represents voltage magnitude.
The voltage vector of each output phase is represented by a line
from the origin node to its output node, such as X1. This line
length represents voltage magnitude of the output phase. It is
desirable for all output phases to have equal voltage
magnitudes, so all output nodes X1 to X12 are on a circle with
phase difference between phases of 30o. The twelve secondary
outputs are connected to two six-phase rectifiers and their
results are summed for a much lower ripple DC output.
Step-down autotransformer operation occurs when primary
voltages RST are connected to a set of [H1_H2_H3] or
[H4_H5_H6]. The step-down ratio is thus 0.8966.
V sec X7 cos (30 o)
= = ~ 0 .8966 Eq. 13
V pri H2 cos (15 o)
Unity-gain autotransformer operation occurs when primary
voltages RST are connected to a set of [X1_X5_X9],
[X2_X6_X10], [X3_X7_X11] or [X4_X8_X12].
Step-up autotransformer operation occurs when primary
voltages RST are connected to a set of [Y1_Y2_Y3] or
[Y4_Y5_Y6]. The step-up ratio is thus 1.035.
V sec X7 1
= = ~ 1.035 Eq.14
V pri Y5 cos (15o)
The turns ratio among set R1 – R6 is thus:
R1: R 2 : R3 : R 4 : R5 : R6 = 1: 1.733 :1 :1: 1.733 :1 Eq.15
E. 9-Phase / 12 phase Autotransformer kVA Rating, Size & Cost
An equivalent autotransformer VA rating assists in
comparing cost and size of the autotransformer topologies to
that of a conventional isolated transformer. Equivalent rating is
based upon the sum of all products of the sinusoidal equivalent
voltage across the windings and relevant rms current through
the windings [18]. Winding voltage is near sinusoidal but
current waveforms are not. The VA rating was computed with
simulation waveforms. Subsequent kVA rating calculation with
respect to the DC output is 2.3 for a conventional isolated 18
pulse transformer, 0.84 for the 18-pulse nine-phase auto-xfmr
 Utility
90 Iload Tr ansfo rmer
80

70
Volume,
Cub. Ft 60

50 T1 T2
40
300 300
KVA KVA
30 Iharm Iharm
VFD Harmonic DC Drive
20
Analyzer
10 18 pulse
6 pulse
0 ~ AC Drive
100 HP
DC D rive ~
50
18p Isolation XFMR ~ 149 Amps
180 Amps
500 Vdc
=
100 480 Vac
200 18p AutoXFMR
400
600
Ratings, HP 800

Fig. 9 Cubic volume of 18-pulse auto-xfmr vs. conventional 18-pulse

isolated transformer vs. HP rating
Load:100%
8
Fig. 12 Test setup used to test a 100 hp 18-pulse phase shifting step down
7
autotransformer.
t
6

18 pulse Isolation XFMR 200

5

150
4
18 pulse Auto XFMR 100
3
50
Amps
2 0.00 12.11 24.22 36.32 48.43
0
1
-50

0
0 100 200 300 400 500 600 700 800 -100

Transformer Rating [hp]

-150
Fig. 10 Relative cost of 18-pulse auto-xfmr vs. conventional 18-pulse mSec
isolated transformer vs HP rating -200

500 hp DC bus Inverter Input Bay (a) RST Input current waveform of 100 hp 18-pulse phase shifting step
down auto-xfmr @THDI =4.8% measured with Fluke 41 Power Analyzer
200

VFD
DC Bus
choke 100

18 pulse
rectifier
0A

Input LR
5% Z
-100A

18 pulse -200A
100m 105m 110m 115m 120m 125m 130m 135m 140m 145m 150m
auto I(Rr)
Time
Xfmr.
(b) RST Input current waveform of 100 hp 18-pulse phase shifting step
down auto-xfmr @THDI =3.5% using P Spice circuit simulation
Fig. 11 Proposed 9-phase 18-pulse step-down autotransformer @ 500 hp

and 0.74 for the 24-pulse twelve-phase auto-xfmr. These 20

calculations verify the cost and size advantages of the new 18
Input
auto-xfmr topologies in Fig.9 and Fig.10 over existing isolation Current 16
THD, %
transformer methods. Fig.11 shows an 18-pulse auto-xfmr and 14 Tested Total THD = 4.6%
Simulated Total THD = 3.5%
Rectifier Bridge is about ½ the cubic volume of the 500 HP 12
10
inverter. 8
6
IV. HARMONIC PERFORMANCE OF MULTI-PULSE CIRCUITS 4
2
A. 9-Phase 18-pulse Autotransformer Simulation & Test Results 0
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31
Harmonic number
Fig. 12 shows a test setup used to test a 100 hp 18-pulse phase Simulation Test
shifting step-down autotransformer. Load to the AC drive (c) RST Input current harmonic spectrum of 100 hp 18-pulse phase
motor was a dc motor connected to the shaft. shifting step down auto-xfmr from simulation & test
Fig. 13 shows harmonic mitigation performance of 18-pulse Fig. 13 Harmonic mitigation performance of 18-pulse autotransformer –
autotransformer with test and simulation results. The RST input Test and simulation
 100

6-pulse _ 75 hp

6-pulse _ 75 hp + Harmonic Filter

10

12-pulse _ 650 hp
autotransformer

18-pulse _ 250 hp
autotransformer

Fig. 14 Simulated Phase R input Current and X1-X9 Output current 1

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
Load, %
current waveform of Fig. 13(a) is nearly sinusoidal with a
measured THDI =4.8 %. The simulated RST current waveform Fig. 16 Current THD at input terminals for various front end topologies
of Fig. 13(b) has a calculated THDI =3.5%. Simulated under varying load
harmonic current spectrum results in Fig. 13(c) show the 6

classic dominant 18 +/- 1 (17th & 19th) harmonics at ~ 2% of 12-pulse _ 650 hp

autotransformer
fundamental, with the 5th, 7th 11th and 13th virtually eliminated. 5
6-pulse _ 75 hp + Harmonic Filter

Tested harmonic current spectrum results in Fig. 13(c) show

agreement with the (17th & 19th) harmonics, but contain a 3rd, 4 6-pulse _ 75 hp

5th, 7th 11th and 13th components. The reason is attributed to

unbalanced input line voltages. Presence of unbalanced 3

negative sequence voltage in the power source does not effect 18-pulse _ 250 hp
autotransformer
multi-pulse dc output but causes a third harmonic in the 2

converter line current [18]. A similar reason is attributed to the

5th and 7th components that appear only in measurement. 1

Fig. 14 shows simulated Phase R input line current along

with secondary X1- X9 line currents. Discrete positive and 0

negative rectifier conduction pulses of current in each line is 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

seen line with current magnitudes that are perfectly balanced.
The discrete line pulse magnitudes indicate there is no current
sharing problem and also no circulating current problem.
B. 12-Phase 24-pulse Autotransformer Simulation & Test Results
Fig. 15 shows harmonic mitigation performance of Fig.8 24-
pulse autotransformer with test and simulation results. The
Phase R input current waveform of Fig.15(a) is also nearly
sinusoidal with a measured THDI =4.1 %. The simulated RST
current waveform of Fig.15(b) has a calculated THDI =2.4 %.
Load, %
Fig. 17 Voltage THD at input terminals for various front-end topologies
under varying load
C. 18-pulse AutoXFMR Comparison to Other Mitigation Techniques
Input current and voltage THD of 75 hp, 250 hp and 650 hp
drives is compared for various front-end topologies:
• 6-pulse drive with 6 SCR Bridge converter attached to PWM inverter
• 12-pulse phase shift autotransformer with diode bridge & PWM inverter
• 18-pulse phase shift autotransformer with diode bridge & PWM inverter
• 6-pulse drive with hybrid harmonic tuned filter [3]

Fig.15a Input current of 24 pulse AC Drive with input voltage THD =
0.9% (on test floor) and Current THD = 4.1%
The drives utilize the same inverter and control board. Loading
was similar to the test dyne setup of Fig.12. Tests were
performed at different hp test cells on the manufacturing floor
depending on drive size tested. Fig. 16 & Fig. 17 data is
presented as providing insight on different harmonic mitigation
techniques and not absolute since harmonic currents and
voltages are largely dependent on system impedance’s within
the power distribution system.

V. METRICS OF NEW MULTI-PULSE AUTOTRANSFORMERS

In a similar fashion other metrics are investigated in Table 3

with the various front-end topologies of Section IV.C. These
include power factor, displacement factor, K-factor and
efficiency.

Fig. 15b Input current of 24 pulse AC Drive with balanced input voltage
(simulation) and Current THD =2.4%.
 Table 3
_______________________________________________________________ 1.000
Category 6-Pulse 12-Pulse 18-Pulse Distortion PF 0.990

Current THD 30 – 35 % 6.5– 9.5 % 4.5– 5 % =sqrt(1/(1+THD2)) 0.980

Power factor 0.92 – 0.95 0.97 – 0.98 0.98 – 0.99 0.970

Displacement Factor 0.95 – 0.97 0.96 – 0.98 0.98 – 0.99 0.960

K – factor 3.0 – 5.0 2.0 – 3.0 1.0 – 2.0 0.950

Efficiency 96.5 – 97.5 % 97.0 – 98.0 % 97.5 – 98.0 % 0.940

______________________________________________________________ 0.930

0.920

A. Power Factor 0.910

0.900

0.890
Definitions are in order when discussing power factor of non- 0.880
linear converters. 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50

% I(THD)
Total Power Factor (pf total): the ratio for the total power input, Fig. 19 Distortion power factor vs. THDI
in watts to the total volt-ampere input to the converter.
Displacement Power Factor (pf disp): the displacement
component of power factor. The ratio of the active power of
the fundamental wave, in watts, to the apparent power of
the fundamental wave, in volt-amperes.
Distortion Power Factor (pf dist): the ratio of the root-mean-
square of the harmonic content to the root-mean-square of
the fundamental component, expressed as a percent of
fundamental.
Equation 16 (set of equations) Fig. 20 Simulation of 480V 18-pulse nine -phase step-down
autotransformer line-neutral 400 Vpk voltage and phase R line
For Three-Phase, Non-Sinusoidal, Balanced Systems current of 400 Apk. Total power factor approaches unity.
(the following approximations apply when V(THD) < 5%)
Fig. 20 shows the proposed 18-pulse autotransformer topology
True Apparent Power = S = V*Itotal (kVA) has a near unity total power factor from simulation, as also
Apparent Power = S1 = V*Ifund (kVA)
Real Power = P = V*Ireal (kW) shown Table 3. Fig. 21 shows measured total power factor of
True Reactive Power = Qt = V*sqrt(Ireact2 + Iharm2) the proposed 18-pulse autotransformer compared with the other
Reactive Power = Q = V*Ireact (kVAR) various front-end topologies. Fig. 22 shows measured
Harmonic Power = D = V*Iharm (kVAR) displacement power factor of proposed 18-pulse auto-xfmr
S = sqrt(P2 + Q2 + D2) = sqrt(P2 + Qt2)
compared with the other various front-end topologies.
1
pf total = true pf = pf disp * pf dist = Ireal / Itotal = P/S 18-pulse _ 250 hp
autotransformer
pf disp = cos (angle between Ireal and Ifund) = Ireal / Ifund = P/S1
0.9
pf dist = cos (angle between Ifund and Itotal) = Ifund / Itotal = S1/S 12-pulse _ 650 hp
THID = Iharm / Ifund autotransformer
0.8
pf dist = sqrt(1/(1+THD_I2 )) 6-pulse _ 75 hp

2 2 2 0.7
Itotal = sqrt(Ireal + Ireact + Iharm )
Itrue react = sqrt(Ireact 2 + Iharm2)
0.6

6-pulse _ 75 hp + Harmonic Filter

These relationships are best visualized by the power cube 0.5
representation in Fig. 18 [19]. Fig. 19 plots the pf dist equation.
This plot can be used with the THDI values in Table 3 to 0.4
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
generate Table 3 displacement factor for various multi-pulse Load, %

topologies or filter with known THDI values. Fig. 21 Total power factor at input terminals for various front end
REACTIVE topologies under varying load
Current
1 18-pulse _ 250 hp
autotransformer
0.98 6-pulse _ 75 hp
12-pulse _ 650 hp
Iharm autotransformer
0.96
D 0.94

Ireact 0.92

Itotal
Q 0.9
Itrue react
S Qt 0.88

Ifund 0.86
6-pulse _ 75 hp + Harmonic Filter
S1 0.84 (0.34 @ 25% load)
Ireal
P REAL
0.82

Current 0.8
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
(in phase with line voltage, V) Load, %

HARMONIC Fig. 22 Displacement factor at input terminals for various front end
Current
topologies under varying load
Fig. 18 Power Cube relationship of power factor definitions
B. K- Factor VI. MULTI-PULSE OPERATION WITH NON-IDEAL INPUT POWER

K – Factor is a calculation used to determine transformer de-
rating in the presence of excessive current harmonic heating in
the primary/secondary coils [20-22]. K – Factor is defined as:
h = h max
k= ∑ 2 h
Ih
h =1
where Ih = rms current at harmonic h , in per unit of rated rms load current
Table 3 shows the 18-pulse and 24 pulse autotransformer
topologies have the lowest value. Larger K-factor means larger
size and cost.
Thus, due to the lower fundamental input current with total
pf ~1 and lower harmonic currents, there is capital equipment
savings in the feed transformer cost with 18-p and 24-p systems
that offset original purchase cost. Also, $ cost savings is similar
for cables, fuses and breakers. These is also an operating $
savings in power factor penalty cost for very large kVA
systems with dedicated 18 pulse inputs with pf ~1.
C. Efficiency
This section calculates the input-output efficiency of a nine-
phase autoxfmr, 18 diode rectifier, pwm inverter and ac motor
compared to a 6 SCR rectifier, DC link choke, pwm inverter
and ac motor. Fig. 24 shows that 18-pulse system efficiency
may be equal or better than for a 6-pulse system. Some
differences may be the SCR forward voltage drop at higher
input current vs. a diode drop at lower input current in the 18-
pulse system. DC link power and output kVA to the motor
were made equal in Fig. 23 in both cases. Table 4 data for rated
100 hp load shows measured results with a FLUKE 41 Power
Analyzer that measured VLL and Iline .
Table 4
_______________________________________________________________
Drive Vin Iin kVA in kWin PF THDv THD I Vdc Idc kWdc
6 pulse 480 129.6 107.6 101.1 0.94 1.5 32.6 648 151.4 98.11
18 pulse 480 121.6 100.98 99.9 0.99 1.2 4.5 670 146.4 98.09
______________________________________________________________
_______________________________________________________________
Drive Eff Conv Vout Iout kVAout kWout Eff. inv Eff drive system
6 pulse 97.0% 460 138 109.8 97.74
18 pulse 98.1% 460 138 109.8 97.74
AC/DC
Pin Pdc
DC Link
Converter
Fig. 23 Loss model of AC Drive system to calculate input-output efficiency
Efficiency, %
100.00
95.00
18 pulse System Efficiency,
90.00
Non-ideal power source characteristics may cause current
unbalance (up to 80% seen) and increased THDI in prior art
Auto-XFMR circuits with parallel bridge converters.
2 Pre-existing voltage harmonics is one contributor to current
Eq.17 unbalance. Pre-existing 5th harmonic voltage induced on the
desired PCC connection may be due to 6-pulse VFD (5th, 7th
dominate) operation at a distant location in Fig.1 plant one-line
diagram. A pre-existing 5th harmonic voltage of 2.5% is used for
analysis based on best field data to date.
Utility source voltage unbalance is another contributor to
current unbalance. ANSI C84.1-1982 [23] defines 3-phase %
voltage unbalance in Eq. 18. A value of 1% covers ~ 70% of all
field sites according to [23] and is thus a worst case design
criteria.
(
3 V max − V min ) *100
% V unbalance = Eq.18
V a +V b + V c
THDI comparison at the input terminals to a drive with an 18-
pulse phase-shifting Autotransformer was simulated with a 300
kVA 480V line under the following Type I – Type III
combinations of utility Power Source input conditions.
Type I - Balanced Input Line Voltage & No pre-existing Harmonics
Type II - Imbalance (1%) Input Line Voltage & No pre-existing Harmonics
Type III - Imbalance (1%) Input Line Voltage & 2.5 % 5th Harmonic Voltage
Test - Obtained on test Floor
Fig.25 shows a Type I power source results in a THDI = 3.25%
at full load and just over 5% at ¼ load. Type II power, with 1%
line unbalance, raises THDI to 4.8% at full load and 9% at ¼
load. However, IEEE-519 TDD limit of 5% at full load is still
met at drive input terminals. Test floor 1% unbalance
conditions match Type II simulation results very well with load.
Type III power with 1% unbalance lines and 2.5 % pre-existing
5th harmonic voltage causes the highest THDI at 7% for full
load. Higher THD is a result of the 5th harmonic voltage phase
angle causing a slight dc voltage unbalance in the rectifier
output and thus some current unbalance, as explained in [18].
However, converter bridge and autotransformer can still
operate continuously under this condition. Also, if the 18-pulse
THDI of 7% is combined with even a small linear load at the
99.6% 96.8% PCC, then IEEE-519 TDD limit of 5% may still be met.
99.6% 97.8%
Pre-existing 5th harmonic condition was tested by removing
DC/AC
the dc drive isolation transformer in Fig.12, so that the dc drive
Pout 6-pulse current harmonics presented a THDV of 7.4% at the 18-
pulse autotransformer line inputs as shown in Fig.26. The
resulting current waveform simulation and test results of Fig.26
Inverter also show general agreement.
THD_I
%
15.0
18p VFD THD (PS I), %
12.5 18p VFD THD (PS II), %
18p VFD THD (PS III), %
18p VFD THD (Test), %
10.0
7.5

85.00 5.0
6 pulse system Efficiency, %
80.00
2.5
75.00
0.0
70.00 25 50 75 100
0 20 40 60 80 100 Load, %
VFD Load, %
Fig. 25 Harmonic mitigation performance of 18-pulse VFD with phase
Fig. 24 Efficiency comparison of nine-phase auto-xfmr with 6-pulse system shifting Auto-xfmr under different input line conditions

(a) test input voltage THD=7.3% at input terminals to 18-pulse autoXFMR
(b) Test floor input current THD=8.7% at input of 18-pulse autoXFMR
(c) Simulated input current THD=6.4% at input of 18-pulse autoXFMR
Fig. 26 Test results and simulation of new 18-pulse VFD / AutoXFMR at
full load but under adverse line voltage THD of 7.3% that exceeds
IEEE 519 General System voltage limit of 5%
Fig.27 shows a test harmonic mitigation comparison between
the new 18-pulse VFD / AutoXFMR vs. 6-pulse VFD with a
Hybrid Tuned Harmonic Filter [3] operated at different loads.
Type II 18-pulse curve is re-plotted from Fig.25. The THDI 6-
pulse with filter curve exceeds the 18-pulse curve at most loads
but is 7% at full load. However, at full load dc bus voltage is
well below rated, so that rated inverter output voltage cannot be
obtained. This is due to the large %Z input reactors of the tuned
filter acting as commutating reactor voltage drops. Thus, while
input harmonic current is reduced with hybrid tuned filters,
output rated voltage and output torque is likewise reduced.
THD_1
[%]
15 0
12.5
6p + Harmonic Filter,
10.0
7.5
5.0
18p VFD THD,
2.5
0 [16] J. Traver et al, “Multiphase low harmonic distortion transformer”, U.S
0 20 40 60 80 100
Load, %
Fig. 27 Tested harmonic mitigation performance of 18-pulse VFD /
AutoXFMR vs. 6-pulse VFD + Harmonic filter @ different loads
VII. CONCLUSION
This paper proposed several nine and twelve-phase auto-
transformers topologies to meet standard IEEE 519. Compared with
other solutions, autotransformers possess such advantages as being
simple, reliable, no resonance problem and relatively cost effective, as
well as small physical size. The proposed AC/DC converter
topologies utilizing these transformers were shown to not have current
sharing problems.
The proposed nine- and twelve-phase auto-transformers can be
viewed as polygon type, where besides achieving much improved
input current harmonics, various winding junction points along the
polygon can be wired out for various step down, unity and step up
voltage transfer ratios. With electrically isolated primary windings,
unlimited ratio is available for every application, such as medium/low
voltage transformation with medium voltage feeders to eliminate
needs for step-down utility transformer.
Working units at industrial field sites, ranging in hp sizes from 50
hp to 800 hp, are based on these topology patents [8-11]. The paper
provided technical analysis and field site data on the new topologies,
as well as comparison to other harmonic mitigation techniques versus
horsepower size.
Acknowledgement: Authors wish to thank B. Eisenbrown, J. Simons, K.
Phillips of RA for support, R. Hoadley for engineering assistance, and K.
Jurkowski, G. Zenke and B. Hachey for producing the multi-pulse product line.
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