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Zigzag Connected Autotransformer-Based 24-pulse AC-DC Converter

Article  in  International Journal of Emerging Electric Power Systems · February 2015

DOI: 10.1515/ijeeps-2014-0102

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Chen Xiao-qiang and Qiu Hao*
Zigzag Connected Autotransformer-Based
24-pulse AC-DC Converter
Abstract: In this paper, a zigzag connected autotransfor-
mer-based 24-pulse AC-DC converter is designed, modeled
and simulated to feed direct torque controlled induction
motor drives. Winding arrangements and parameters of
the autotransformer and interphase reactor are given.
Moreover, the design procedure of the autotransformer is
modified to make it suitable for retrofit applications.
Simulation results indicate that the system is capable of
eliminating up to 21st harmonics in the ac mains current.
The effect of load variation and load character is also
studied to demonstrate the performance and effectiveness
of the proposed 24-pulse converters. A set of power quality
indices at ac mains and dc side are presented to compare
the performance of 6-, 12- and 24-pulse converters.
Keywords: multi-pulse rectifier, autotransformer, harmo-
nic suppression, power quality improvement
DOI 10.1515/ijeeps-2014-0102
1 Introduction
Nowadays, variable frequency induction motor drives
(VFIMDs) are widely used in many applications such as
transportation systems, ship propulsion and air condi-
tioning. These VFIMDs are usually employing the techni-
que of direct torque control [1] owing to its easy
arrangement and low cost. Supplying power of these
induction motor drives is normally a 6-pulse diode bridge
rectifier and a three-phase voltage source inverter. The 6-
pulse diode rectifier injects harmonic currents into the ac
mains, thereby leading to poor power factor and low
rectifier efficiency. In order to prevent the detrimental
effects of the harmonics, many stringent power quality
standards have been issued. IEEE 519–1992 [2] and
International Electrotechnical Commission (IEC) 61000-
3-2 [3] are the most prominent ones in this field.
*Corresponding author: Qiu Hao, School of Automation and
Electrical Engineering, Lanzhou Jiaotong University, Lanzhou
730070, China, E-mail: qiuhao.zju@gmail.com
Chen Xiao-qiang, School of Automation and Electrical Engineering,
Lanzhou Jiaotong University, Lanzhou 730070, China,
E-mail: 13919289637@139.com
Int. J. Emerg. Electr. Power Syst. 2015; 16(1): 23–32
Multipulse ac-dc converters are found to be robust,
efficient, cost-effective and easy in control over its coun-
terparts. The conventional 12-pulse rectifier based on
delta-wye isolated transformer is an obvious example.
However, the kilo-volt-ampere (kVA) rating of the trans-
former is 1.03 Po, where Po is the output power of the load
[4]. When line voltage isolation is not required, multi-
pulse ac-dc converters based on autotransformer bring
about lower volume, ratings of magnetics, cost and
losses, as only a small portion of the total power of the
load is processed in the transformer.
Different configurations of 12- and 18-pulse ac-dc con-
verter systems have been reported in references [4–8]. Choi
et al. [4] presented a delta-connected autotransformer with
reduced kVA ratings. On the basis of the proposed trans-
former connection, a 12-pulse rectifier system with auto-
transformer kVA rating of 0.18 Po and an 18-pulse scheme
with autotransformer kVA rating of 0.l6 Po was proposed,
respectively. De Seixas and Barbi [5] put forward an 18-
pulse fork-connected autotransformer-based rectifier sys-
tem followed by switched mode power supplies (SMPS)
and the measured total harmonic distortion (THD) of line
current and input power factor (PF) was 8.6% and 0.99,
respectively. Fernandes et al. [6] described a single and
general mathematical expression which unified all delta
and wye auto-connected transformer arrangements for 12-
and 18-pulse ac-dc converters. The obtained expression
simplified the process to determine turn ratios and pola-
rities for all windings of the autotransformer. Kamath et al.
[7, 1122–1127] analyzed an asymmetrical autotransformer
topology suitable for 18-pulse rectification, which didn’t
need interphase reactor (IPR) and zero sequence current
blocking transformer (ZSBT) for equal current sharing
between the diode bridges. Meng et al. [8] put forward
the effect of voltage transformation ratio on the kVA rat-
ings of delta auto-connected transformer for 12-pulse ac-dc
converter and gave an optimal configuration of the auto-
transformer with minimal kVA ratings and the least wind-
ings. However, these 12- and 18-pulse converters may not
qualify as clean power at high loads as the THD of supply
current cannot meet IEEE 519–1992 standard requirements.
Increasing the number of pulses leads to further
reduction in input current harmonics, but it also results
in an increase in cost and sophistication. Kalpana et al. [9]
24 C. Xiao-qiang and Q. Hao: Zigzag Connected Autotransformer
designed a polygon connected autotransformer-based
20-pulse ac-dc converter to feed SMPS of moderate rating.
The ac mains current was nearly sinusoidal with low
THD, and the power factor was close to unity. Chen and
Horng [10] presented a passive 28-step current shaper
for three-phase rectifier system, with a phase staggered
transformer on the ac side and six IPRs on the dc side.
However, the THD of ac mains current obtained was 6.54%
high even at full load and might deteriorate further as load
decreased. Nakhaee and Jalilian [11, 1–6] used a star con-
nected autotransformer-based 12-pulse ac-dc converter
and incorporated dc ripple reinjection technique to double
the converter’s pulse numbers. The autotransformer was
also modified to make its dc link voltage very close to that
of a 6-pulse rectifier. At full load, the THD of ac mains
current was 4.83%, while under light load, the THD of
ac mains current was 12.71%, which didn’t adhere to
IEEE standard 519–1992 limits. Singh and Gairola [12] pro-
posed 12- and 24-pulse rectifiers using zigzag connected
autotransformer to feed vector-controlled induction motor
drives. The proposed autotransformer didn’t need a ZSBT.
However, the dc link voltage was much higher compared
with that of a 6-pulse rectifier.
This paper analyzes a zigzag connected autotransfor-
mer-based 24-pulse rectifier feeding a direct torque con-
trolled induction motor drive (DTCIMD) load at full
length. Moreover, the design of the proposed autotrans-
former is modified to make it suitable for applications
where a 6-pulse rectifier is being used. The MATLAB
model of 24-pulse ac-dc converter is presented. Through
simulation results, it can be observed that the proposed
24-pulse AC-DC converter has a significant improvement
in power quality parameters. To compare different
power quality indices such as THD of supply current
and voltage, distortion factor (DF), displacement factor
Figure 1 24-pulse ac-dc converter based on zigzag auto-connected transformer
(DPF), ripple factor (RF), we present detailed simulations
for 6-, 12- and 24-pulse rectifiers.
The rest of the paper can be divided into four parts.
In part 2, a zigzag connected autotransformer-based 24-
pulse converter is studied and designed in detail. The
simulation models are shown in part 3. In part 4, simula-
tion results are given and discussion is carried out. The
conclusion is made in part 5.
2 Analysis and design of the
proposed rectifier
The basic concept of harmonic mitigation through multi-
pulse rectifier makes use of two or more converters,
where the harmonics generated by one converter are
cancelled by other converters through proper phase
shift given by Paice [13, 31].
Phase shift ¼ 60=Number of 6-pulse converters
To achieve the 24-pulse rectification, the phase shift
required among different sets of phase voltages is 15°.
Figure 1 shows the circuit diagram of the proposed zigzag
connected autotransformer-based 24-pulse ac-dc converter.
2.1 Zigzag connected autotransformer
The proposed topology employs a zigzag connected auto-
transformer which is fed from three-phase ac input vol-
tages (Va, Vb, Vc), then it generates four sets of balanced
three-phase voltages, i.e. (Va1, Vb1, Vc1), (Va2, Vb2, Vc2),
(Va3, Vb3, Vc3), and (Va4, Vb4, Vc4) all displaced at an
angle of 15° desired for the 24-pulse ac-dc conversion.
 C. Xiao-qiang and Q. Hao: Zigzag Connected Autotransformer 25

(b)

(a)

Figure 2 (a) Winding arrangement of 24-pulse zigzag connected autotransformer. (b) Phasor diagram of 24-pulse zigzag connected
autotransformer

To achieve the required 15° phase shift, voltages (Va1, Vb1, Va1 ¼ Vff7:5 ; Vb1 ¼ Vff  112:5 ; Vc1 ¼ Vff127:5 ð3Þ
Vc1) and (Va2, Vb2, Vc2) are at an angle of þ 7.5° and –7.5°,
respectively, with respect to ac mains voltages. Similarly, Va2 ¼ Vff  7:5 ; Vb2 ¼ Vff  127:5 ; Vc2 ¼ Vff112:5 ð4Þ
voltages (Va3, Vb3, Vc3) and voltages (Va4, Vb4, Vc4) are at
an angle of þ 22.5° and –22.5°, respectively, with respect
Va3 ¼ Vff22:5 ; Vb3 ¼ Vff  97:5 ; Vc3 ¼ Vff142:5 ð5Þ
to supply voltage. The zigzag connected autotransformer
winding arrangement for 24-pulse rectifier system is
shown in Figure 2(a) and its phasor diagram is shown Va4 ¼ Vff  22:5 ; Vb4 ¼ Vff  142:5 ; Vc4 ¼ Vff97:5 ð6Þ
in Figure 2(b). The zigzag connection is also known for its
inherent zero sequence current blocking ability. Thus, From Figure 2(b), the output voltages of phase “a” of
ZSBT is not required in the proposed topology. zigzag autotransformer can be expressed as:

Va1 ¼ K1 ðVab  Vca Þ  K2 Vbc ð7Þ

2.2 Design of autotransformers for 24-pulse
conversion Va2 ¼ K1 ðVab  Vca Þ þ K2 Vbc ð8Þ

The number of turns for every winding is determined as a
function of the input phase voltage, Va. These winding
voltages, as marked in Figure 2(b), are expressed by the
following relationships.
Supposing that the three-phase supply voltage
applied to the input of autotransformer is:
Va ¼ Vff 0 ; Vb ¼ Vff  120 ; Vc ¼ V ff 120 : ð1Þ
pffiffiffi pffiffiffi pffiffiffi
Vab  
¼ 3Vff30 ; Vbc ¼ 3Vff  90 ; Vca ¼ 3Vff150 :  K1 ¼ 0:57735; K2 ¼ 0:13165; K3 ¼ 0:21498; K4 ¼ 0:07869
ð2Þ
where, V is the rms value of phase voltage.
The four sets of required voltages for the diode
bridges DB1 to DB4 are:
Va3 ¼ K1 ðVab  Vca Þ  ðK2 þ K3 ÞVbc þ K4 Vca ð9Þ
Va4 ¼ K1 ðVab  Vca Þ þ ðK2 þ K3 ÞVbc  K4 Vab ð10Þ
The values of these constants K1 to K4 determine the
winding turns as a fraction of input phase voltage for
the 24-pulse rectifier. Using eqs (7)–(10), the values can
be calculated as:
In order to make the proposed 24-pulse rectifier suitable
for retrofit applications, the design procedure of the zig-
zag autotransformer is modified with flexibility to adjust
its output voltage the same as that of a 6-pulse rectifier.
26 C. Xiao-qiang and Q. Hao: Zigzag Connected Autotransformer

(b)

(a)

Figure 3 (a) Winding arrangement of 24-pulse zigzag connected autotransformer for retrofit applications. (b) Phasor diagram of voltages of
24-pulse zigzag connected autotransformer for retrofit applications

Due to the 24-pulse operation, the average voltage at dc Therefore, the same dc link voltage as that of a 6-pulse
link is higher than that of a 6-pulse rectifier by about diode bridge rectifier is achieved merely by changing the
1.4%. Figure 3(a) shows the winding arrangement of transformer winding tapings.
zigzag auto-connected transformer for retrofit applica- The kilo-volt-ampere (kVA) rating of the transformer
tions. Figure 3(b) shows the generalized phasor diagram is calculated as [13, 36]:
of phase voltages to produce different voltage ratios from P
Vrms  I rms
the proposed autotransformer while still maintaining the kVA ¼ 0:5  ð16Þ
1000
required 24-pulsed operation. This can be achieved by
varying the tap position in the autotransformer. where Vrms is the voltage across each winding and Irms is
From Figure 3(b), the output voltages of phase “a” in the current through each winding. The kVA rating of the
zigzag transformer configuration for retrofit applications IPR can also be calculated using eq. (16).
can be calculated by:

Va1 ¼ K1 Vab  K5 Vca  K7 Vbc ð11Þ 2.3 Interphase reactor

Va2 ¼ K1 Vab  K5 Vca þ K8 Vbc ð12Þ
A small rating interphase reactor (IPR) is needed to absorb
the difference in dc output instantaneous voltages of four
Va3 ¼ K1 Vab  K5 Vca  ðK7 þ K9 ÞVbc þ K10 Vca ð13Þ diode rectifier bridges. IPR can ensure the independent
operation of the rectifier bridges and symmetrical conduc-
Va4 ¼ K1 Vab  K5 Vca þ ðK8 þ K9 ÞVbc  K10 Vab ð14Þ
tion of each diode, resulting in 120° conduction of each
diode per cycle and proper harmonic mitigation. The dc
K5 þ K6 ¼ K1 ð15Þ
link voltage at any instant is the mean value of all four
These retrofit design equations result in the winding output voltages of diode bridge rectifiers and it fluctuates
constants K5 to K10 are as follows: with 24-pulse ripple. Figure 4 shows the winding config-
uration of the IPR. The IPR comprises a central core with
K5 ¼ 0:56747; K6 ¼ 0:00988; K7 ¼ 0:12559; K8 ¼ 0:13547; four legs and all of them are excited in the same direction,
K9 ¼ 0:21315; K10 ¼ 0:07801 which prevents IPR from entering saturation.
 C. Xiao-qiang and Q. Hao: Zigzag Connected Autotransformer 27

3 MATLAB-based simulation
To compare their performance, 6-pulse, 12-pulse and 24-
pulse rectifiers are modeled and simulated in MATLAB
along with Simulink and SimPowerSystems toolboxes.
The ac-dc converter feeds a 20 hp (15 kW) DTCIMD load
with a three-phase input of 380 V, 50 Hz AC supply. The
MATLAB model of the proposed 24-pulse ac-dc converter is
shown in Figure 5. Figure 6 shows simulation model of the
24-pulse autotransformer for retrofit applications, which
consists of three single-phase multi-winding transformers.

4 Results and discussion

To illustrate the improvement in performance of the pro-
posed 24-pulse rectifiers based on zigzag connected auto-
transformer, a conventional 6-pulse diode bridge rectifier
and a zigzag autotransformer-based 12-pulse rectifier [12]
have also been modeled and simulated. Simulation
results of 6-, 12- and 24-pulse rectifiers are given in
Figure 4 Winding configuration of IPR
Tables 1–2 and waveforms are presented in Figures 7–10.

Figure 5 MATLAB model of the proposed 24-pulse ac-dc converter

Figure 6 MATLAB model of 24-pulse zigzag auto-connected transformer for retrofit applications
28 C. Xiao-qiang and Q. Hao: Zigzag Connected Autotransformer

Table 1 Comparison of power quality parameters of 6-, 12- and 24-pulse rectifiers

Topology THDv (%) THDi (%) Is (A) DF DPF PF Vdc (V)

FL FL LL FL LL FL LL FL LL FL LL FL LL

6-pulse 4.70 26.8 49.0 24.0 4.96 0.966 0.961 0.960 0.929 0.928 0.895 505 511
12-pulse 3.98 11.6 12.8 23.8 4.80 0.993 0.992 0.999 0.998 0.996 0.992 523 528
24-pulse 3.17 5.05 5.84 23.7 4.78 0.999 0.998 0.999 0.997 0.998 0.995 511 516
24-pulse retrofit 3.12 5.07 5.86 23.7 4.77 0.999 0.998 0.999 0.997 0.998 0.995 506 512

Notes: THDv: THD of supply voltage; THDi: THD of supply current; Is: rms value of phase a input supply current; Vdc: average dc side output voltage; FL:
full load; LL: light load.

Table 2 Power quality indices of proposed 24-pulse rectifier for retrofit applications under varying loads

Load (%) THDv (%) THDi (%) Is (A) DF DPF PF Vdc (V) RF (%)

20 1.08 5.86 4.77 0.998 0.997 0.995 512 0.44

40 1.70 5.66 9.34 0.998 0.998 0.996 511 0.48
60 2.23 5.46 13.8 0.998 0.998 0.997 509 0.51
80 2.66 5.28 18.1 0.999 0.999 0.998 508 0.56
100 3.12 5.07 23.7 0.999 0.999 0.998 506 0.59

Figure 7 Supply current and its spectrum at light load (20%) for 12-pulse converter
 C. Xiao-qiang and Q. Hao: Zigzag Connected Autotransformer 29

Figure 8 Supply current waveforms and its spectrum at full load for 12-pulse converter

Figure 9 AC mains current and its spectrum of 24-pulse converter for retrofit applications at light load (20%)
30 C. Xiao-qiang and Q. Hao: Zigzag Connected Autotransformer
Figure 10 AC mains current and its spectrum of 24-pulse converter for retrofit applications at full load
4.1 Performance of 6-pulse rectifier
The 6-pulse converter’s THD of ac mains current at full
load is 26.8% and at light load which is 49.0%. The PF is
0.928 under full load and 0.895 under light load. The
results are given in Table 1, which indicates that the
power quality parameters don’t comply with IEEE stan-
dard 519–1992 requirements [2].
4.2 Performance of 12-pulse rectifier
To improve the power quality indices, a 12-pulse rectifier
based on zigzag auto-connected transformer for DTCIMD
has been modeled and simulated. It can be obtained from
Table 1 and Figures 7 and 8 that the THD of supply
current at full load is 11.6% and at light load it is
12.8%, while the PF is 0.996 and 0.992 under these con-
ditions. However, the dc side voltage is much higher than
that of a 6-pulse rectifier, thus limiting its applications. It
is clear that the 12-pulse rectifier cannot adhere to IEEE
Standard 519–1992 limits [2]. Moreover, the existence of
low order harmonics (5th, 7th, 11th, and 13th) is also one
of the drawbacks of 6- and 12-pulse ac-dc converters.
4.3 Performance of 24-pulse rectifier
In the proposed 24-pulse rectifier, the THD of ac mains
current under full load and light load as given in Table 1
is 5.05% and 5.84%, and the PF under these conditions is
0.998 and 0.995, respectively. But the dc link voltage Vdc
is higher compared with that of a 6-pulse rectifier. The
results are shown in Table 1.
The design of the proposed autotransformer is mod-
ified for applications where a 6-pulse diode rectifier
bridge is being used. The arrangement of the modified
transformer is very similar to the proposed 24-pulse zig-
zag autotransformer except the difference in number of
turns in the winding tapings.
The proposed 24-pulse rectifier for retrofit applications
is also modeled and simulated. It can be observed from
Table 1 and Figures 9 and 10 that, at full load, the THD of
supply current obtained is 5.07% and the PF is 0.998. At
light load condition, the THD of ac mains current is 5.86%
and the PF is observed as 0.995. The dc side output voltage
is almost the same as that of a 6-pulse rectifier.
To study the effect of load variation on different power
quality parameters, the load is varied on the DTCIMD. It
can be observed from Table 2 that the THD of ac mains
 C. Xiao-qiang and Q. Hao: Zigzag Connected Autotransformer
Table 3 Comparison of power quality indices under capacitive, inductive and resistive load
Load type THDv (%) THDi (%) Is (A)
Capacitive 0.47 69.9 1.20
Inductive 3.36 4.95 26.4
Resistive 3.37 4.96 26.4
current is always below 6%, thus meeting IEEE Standard
519–1992 limits for systems with short circuit ratio (SCR)
greater than twenty [2]. The PF is also improved to near
unity under varying loads. In short, the greatly improved
performance of the proposed 24-pulse rectifiers makes
power quality indices such as THDi, THDv, DF, DPF, and
PF satisfactory for various load conditions.
Simulations on a capacitive load (C ¼ 4700 μF, R ¼
15 Ω), an inductive load (L ¼ 40 mH, R ¼ 15 Ω) and a
resistive load (R ¼ 15 Ω) are discussed here to study the
effect of load character on various power quality para-
meters, which is tabulated in Table 3. It can be obtained
from Table 3 that when output load is capacitive, THDv is
only 0.47% while THDi is 69.91%, meaning that input line
voltage is almost sinusoidal but input line current is
distorted seriously. Moreover, Vdc and PF are deteriorated
while RF is improved compared with inductive and resis-
tive load. Supply current decreases gradually to only 1.20
A rms, indicating that power backflow will happen if load
is capacitive. When load is resistive, the ac-dc converter’s
performance is almost the same compared with inductive
load, except for tiny difference in THDv, THDi and RF.
The 24-pulse harmonic mitigator proposed here needs
a zigzag auto-connected transformer of 3.01 kVA, two inter-
phase reactors of 0.258 kVA, totaling all the required mag-
netics of 3.268 kVA, that is to say, only 21.8% of the load
power rating. In comparison with the total magnetics rat-
ings of delta (31.55%) [4], asymmetrical polygon (45.47%)
[9] and tapped-delta (32.0%) [7] configuration-based ac-dc
converters, the total ratings of magnetics of the proposed
24-pulse ac-dc converter are much less.
Although increasing the pulse number can bring dra-
matic improvement in different power quality indices, it
will also make the transformer configuration become
cumbersome and more the number of diode bridges rec-
tifiers will be required, leading to increased cost and
components in the overall ac-dc converter system.
5 Conclusions
A zigzag connected autotransformer-based 24-pulse rec-
tifier has been designed, modeled and simulated for a
31
DF DPF PF Vdc (V) RF (%)
0.992 0.999 0.996 532 0.09
0.999 0.999 0.998 506 0.53
0.999 0.999 0.998 506 0.19
DTCIMD load. The proposed ac-dc converter can sup-
press less than 23rd harmonics in the supply current.
The proposed rectifier has the flexibility to vary the dc
link voltage, simply by changing the autotransformer’s
winding turns ratio, which makes it suitable for retrofit
applications. The low equivalent kVA rating of the pro-
posed zigzag auto-connected transformer has resulted
in a system of lower volume, weight, losses and cost
compared with conventional isolated transformer-based
ac-dc converter. The simulation results have shown that
the THD of input current remains below 6.0% and the
PF with almost close to unity in the wide operating
range of the loads. The improvement in power quality
parameters is considerable in the proposed 24-pulse
rectifier.
Funding: This paper is funded by the Science and
Technology Plan Project of Gansu Province (145RJZA098).
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