Few Words About Frequency Converters

Few Words About Frequency Converters (on photo cabinet with Danfoss FC302 frequency converters)

Introduction
Since the late 1960s, frequency converters have undergone extremely rapid changes, largely as a result of the
development of microprocessor and semi-conductor technologies and their reduction in prices. However, the
basic principles of frequency converters remains the same.
Frequency converters can be divided into four main components:

Figure 1 - Simplified frequency converter

1. Rectifier
The rectifier, which is connected to a single/three-phase AC mains supply and generates a pulsating DC
voltage. There are two basic types of rectifiers controlled and uncontrolled.

2. Intermediate circuit
The intermediate circuit. There are three types:
1. One, which converts the rectifier voltage into a direct current.
2. One, which stabilises or smoothes the pulsating DC voltage and places it at the disposal of the inverter.
3. One, which converts the constant DC voltage of the rectifier to a variable AC voltage.

3. Inverter
The inverter which generates the frequency of the motor voltage. Alternatively, some inverters may also
convert the constant DC voltage into a variable AC voltage.

Control circuit
The control circuit electronics, which transmit signals to- and receive signals from the rectifier, the
intermediate circuit and the inverter. The parts that are controlled in detail depends on the design of the
individual frequency converter (see Figure 2).
What all frequency converters have in common is that the control circuit uses signals to switch the inverter
semi-conductors on or off. Frequency converters are divided according to the switching pattern that controls the
supply voltage to the motor.
In figure 2, which shows the different design /control principles:
1. Is a controlled rectifier,
2. Is an uncontrolled rectifier,
3. Is a variable DC intermediate circuit,
4. Is a constant DC voltage intermediate circuit,
5. Is a variable DC intermediate circuit,
6. Is a PAM inverter and
7. PWM inverter.

Figure 2 - Different design / control principles of frequency converter

Current Source Inverter: CSI

(1 + 3 + 6)
Pulse-amplitude-modulated converter: PAM
(1 + 4 + 7) (2 + 5 + 7)
Pulse-width-modulated converter: PWM/VVCplus
(2 + 4 + 7)
Direct converters, which do not have an intermediate circuit should also be briefly mentioned for completeness.
These converters are used in the Mega-watt power range to generate alow-frequency supply directly from the
50 Hz mains and their maximum output frequency is about 30 Hz.

Home / Technical Articles / Surge Protection for Frequency Converters

Surge Protection for Frequency Converters

Posted Nov 26 2012 by Edvard in Protection with 4 Comments

Figure 1 - Schematic diagram of a frequency converter

In principle a frequency converter consists of a rectifier, a d.c. link converter, an inverter and of the control
electronics (Figure 1 above).
At the input of the inverter the single phase or interlinked, three-phase a.c. voltage is changed into a pulsating
d.c. voltage and is pushed into the d.c. link converter that also serves as energy store (buffer). Capacitors in the
d.c. link converter and the LC networks connected to earth in the a.c. line filter, can cause problems with the
residual current devices (RCD) connected in series.
The reason for this is often wrongly seen in the application of surge arresters.
The problems, however, result from the short-term induction of fault currents by the frequency converter. These
are sufficient to activate sensitive earth leakage circuit breakers (RCDs).
A surge-proof RCD circuit breaker available for a tripping current In = 30 mA and a min. discharge
capability of 3 kA (8/20 s) provides a remedy.

Figure 2 - EMC conforming shield connection of the motor supply line

By the control electronics, the inverter delivers a clocked output voltage. The higher the clock frequency of the
control electronics for the pulse-width-modulation, the more sinusoidal is the output voltage. With each cycle, a
peak voltage is created that is superimposed on the curve of the fundamental frequency. This peak voltage
reaches values of 1200 V and higher (according to the frequency converter).
The better the simulation of the sine curve at the output, the better is the performance and control response of
the motor. This means, however, that the voltage peaks appear at the output of the frequency converter more
frequently.
For choosing of surge arresters, the maximum continuous operating voltage Uc has to be taken into account.
It specifies the maximum permissible operating voltage a surge protective device may be connected to. This
means that surge protective devices with a correspondingly higher Uc are used at the output side of the
frequency converter.

This avoids faster ageing due to gradually heating of the surge protective device under normal operating
conditions and the consequential voltage peaks. This heating of the arrester leads to a shorter service life and
consequently to a disconnection of the surge protective device from the system to be protected.
The voltage at the output of the frequency converter is variable and adjusted a little bit higher than the nominal
voltage at the input. Often it is approx. + 5 % during continuous operation, in order to compensate the voltage
drop at the connected line, for example.

Figure 3 - Structure of a frequency converter with SPD

Example with Dehn devices

1 - DEHNguard S DG S 275
2 DEHNguard S DG S 600
3 BLITZDUCTOR XT
Otherwise, one can simply say that the maximum voltage at the input of the frequency converter is equal to the
maximum voltage at the output of the frequency converter.

The high clock frequency at the output of the frequency converter generates fieldborne interferences and
therefore, requires necessarily a shielded cabling so that adjacent systems are not disturbed.
For shielding the motor power supply line, a bilateral shield earthing at the frequency converter and the drive
motor has to be ensured. The large-surface contacting of the shield results from the EMC requirements.
Advantageous is here the use of constant force springs (Figure 2).
By means of intermeshed earth-termination systems, i.e. the earth-termination system the frequency
converters and the drive motor are connected to, potential differences are reduced between the parts of
the installation and thus equalising currents via the shield are avoided.
Figure 3 shows the example of use of surge protective devices Type DEHNguard on the power supply side and
type BLITZDUCTOR for 0 20 mA signals. The protective devices have to be individually adapted according
to the interface.
For the integration of the frequency converter into the building automation it is absolutely essential that all
evaluation and communication interfaces are connected with surge protective devices in order to avoid system
failures.