NATIONAL QUALIFICATIONS CURRICULUM SUPPORT Design, Engineering and Technology Electrical Engineering Power Control [HIGHER] Edward Boyle Nacer Tcheir Acknowledgements This document is produced by Learning and Teaching Scotland as part of the National Qualifications support programme for Design, Engineering and Technology. First published 2003 Electronic version 2003 © Learning and Teaching Scotland 2003 This publication may be reproduced in whole or in part for educational purposes by educational establishments in Scotland provided that no profit accrues at any stage. ISBN 1 85955 983 2 TH E TH EO RY O F P E RF EC T CO M PE T I T IO N CONTENTS Staff information and support material Section S1: Outcomes to be covered in this unit 1 Section S2: Teaching and learning advice including how to use the resource material 3 Section S3: Details of starting points 4 Section S4: Assessment procedures showing what is to be assessed, when it is to be assessed and result recording methods 5 Section S5: Resource requirements including course notes, laboratory sheets, book list and audio/visual aids 6 Section S6: Safety 9 Candidate information and support material Section C1: Outcomes to be covered in this unit 11 Section C2: Assessment instruments for the outcomes 13 Section C3: Course notes and tutorials – Switchgear – Power converters – Power control devices – AC to DC conversion – Half-wave uncontrolled rectifiers – Half-wave controlled rectifiers – Full-wave rectifier circuits – DC to AC conversion – AC to AC conversion – DC to DC conversion – Tutorials – Laboratory experiments 14 14 29 33 38 39 45 47 51 52 52 53 55 vi E LE C TR I C A L E N G I N E E R I N G – P O WE R C O N TR O L ( H ) © Le a r n i n g a n d T e a c h i n g S c o t l a n d 2 0 0 3 S TAF F INFO RM AT IO N A N D S UPPO R T M AT ER I A L SECTION S1 Outcomes to be covered in this unit Outcome 1 Describe the construction, function and interruption capabi lity of switchgear. Performance criteria (a) The function and current interruption capability of different types of switchgear are described correctly. (b) With the aid of a diagram the process of a plain air -break circuit breaker opening under fault conditions i s described correctly. (c) The salient constructional features and interruption process of circuit breakers are explained correctly. Note on the range of the outcome switchgear: isolator, isolating switch, circuit breaker and auto -recloser circuit breaker: air break, air blast, vacuum and sulphur hexafluoride constructional features: operating mechanisms, contacts and arc control devices. Evidence requirements Written evidence of the student’s ability to understand the various features of switchgear. Outcome 2 Investigate the operation and performance of a static power converter. Performance criteria (a) The various types of static power converters are listed correctly. (b) The principal features and function of static power converters are described correctly. (c) Diagrammatic representation of a static power converter is accurate. (d) Explanation of the operation of the converter is correct. (e) Evaluation of the key performance characteristics of the converter is correct. Note on the range of the outcome static power converters: AC to DC, AC to AC, DC to AC and DC to DC. converter: phase controlled, cycloconverters, choppers and inverters. E LE C TR I C A L E N G I N E E R I N G – P O WE R C O N TR O L ( H ) 1 © Le a r n i n g a n d T e a c h i n g S c o t l a n d 2 0 0 3 S TAF F INFO RM AT IO N A N D S UPPO R T M AT ER I A L Evidence requirements Written and graphical evidence of the student’s ability to interpret the operation of power converters. 2 E LE C TR I C A L E N G I N E E R I N G – P O WE R C O N TR O L ( H ) © Le a r n i n g a n d T e a c h i n g S c o t l a n d 2 0 0 3 S TAF F INFO RM AT IO N A N D S UPPO R T M AT ER I A L SECTION S2 Teaching and learning advice including how to use the resource material Teaching methods In general the teaching and learning methods used are very dependent on the outcomes of the unit and the facilities and expertise available at the delivering centre. By their very nature, however, the outcomes in the unit lend themselves to the following teaching methods: relate essential theory to practical and industrial requirements laboratory learning activities based on a student -centred circuit testing and analysis approach tutorial exercises computer simulation activities. It is important that all the lecturers/teachers working on this unit use laboratory and computer simulation activities as much as possible. This will reinforce the essential theory and ensure a good understanding of the concepts of power control. Power control unit delivery Main topics Delivery suggested Outcome 1 Construction, function and interruption capability of switchgear Outcome 2 Investigate the operation and performance of a static power converter Explain basic theory, tutorial exercises, laboratory demonstration. Explain theory, tutorial exercises, laboratory exercise, computer simulation. E LE C TR I C A L E N G I N E E R I N G – P O WE R C O N TR O L ( H ) 3 © Le a r n i n g a n d T e a c h i n g S c o t l a n d 2 0 0 3 S TAF F INFO RM AT IO N A N D S UPPO R T M AT ER I A L SECTION S3 Details of starting points Outcome 1 A brief revision of power generation, transmission and distribution highlighting the need for the use of switchgear to ensure safe operation of plant systems. Outcome 2 Prior to describing the principle of operation of various static converters, it will be necessary to explain the power conversion concept and the use of power semiconductor devices for that purpose. 4 E LE C TR I C A L E N G I N E E R I N G – P O WE R C O N TR O L ( H ) © Le a r n i n g a n d T e a c h i n g S c o t l a n d 2 0 0 3 S TAF F INFO RM AT IO N A N D S UPPO R T M AT ER I A L SECTION S4 Assessment procedures showing what is to be assessed, when it is to be assessed and result recording methods The Power Control unit is assessed by two tasks. The majority of the performance criteria are assessed by structured questions. These are used at the end of the topic on completion of the teaching relating to Outcomes 1 and 2. Outcome 2 is assessed by structured questions and a laboratory investigation with a submitted report. The following table shows how the assessment tasks are related to their outcomes and performance criteria. It also lists the evidence to be collected. Outcome PC 1 a Task 1: Structured question Written response b Task 1: Structured question Written/graphical response c Task 1: Structured question Written/graphical response a Task 2: Structured question Written response b Task 2: Structured question Written response c Task 2: Structured question Written/graphical response d Task 2: Structured question Written response e Task 2: Laboratory investigation Written report 2 Assessment task Evidence to be collected The timing and duration of assessment The unit is divided into two separate topics, namely (i ) switchgear, and (ii) static power converters. Candidates should be given a formative assessment prior to the summative assessment at the end of the outcome. This will reinforce the teaching process while preparing the candidates for assessment. The suggested time allocation for tasks 1 and 2 is as follows: Outcome 1: 60 minutes Outcome 2: 60 minutes. E LE C TR I C A L E N G I N E E R I N G – P O WE R C O N TR O L ( H ) 5 © Le a r n i n g a n d T e a c h i n g S c o t l a n d 2 0 0 3 S TAF F INFO RM AT IO N A N D S UPPO R T M AT ER I A L SECTION S5 Resource requirements including course notes, book list and visual aid list Course notes Candidate notes on Power Control are included in the candidates’s Support Material. These should be either adopted by the centre or modified to suit the teaching approach taken and the equipment available. Laboratory sheets Some laboratory experiments are included in this support pack. These shoul d either be adopted by the centre or modified to suit the teaching approach taken and the equipment available. Circuit simulation may also be used to reinforce the practical laboratory work. A suitable product on the market is Electronics Workbench which may be obtained using the details outlined below. Electronics Workbench: Circuit simulation and testing Web address: http://www.adeptscience.co.uk E-mail: info@ adeptscience.co.uk Telephone: 01462 480055, Fax 01462 480213 Address: Adept Science plc 6 Business Centre West Avenue One Letchworth Herts SG6 2HB Electronics and Electrical Principles Web address: http://www.eptsoft.demon.co.uk E-mail: sales@ eptsoft.demon.co.uk Telephone/Fax: 01376 514008 Address: EPT Educational Software Pump House Lockram Lane Witham Essex CM8 2BJ 6 E LE C TR I C A L E N G I N E E R I N G – P O WE R C O N TR O L ( H ) © Le a r n i n g a n d T e a c h i n g S c o t l a n d 2 0 0 3 S TAF F INFO RM AT IO N A N D S UPPO R T M AT ER I A L Crocodile Clips: Simple simulation of science and technology experiments Web address: http://www.crocodile-clips.com/education E-mail: sales@ crocodile-clips.com Telephone: 0131 226 1511, Fax 0131 226 1522 Address: Crocodile Clips 11 Randolph Place Edinburgh EH3 7TA Book list Bradley, D A, Fidler, J K and Dorey, A P, Power Electronics, 1994 Flurscheim, Charles H, Power Circuit Breaker Theory and Design, Peter Peregrinus Ltd on behalf of The Institution of Electrical Engineers (IEE), 1983 Greenwood, Allan, Vacuum Switchgear, 1994 Grigsby, L L, Electrical Power Engineering Handbook, 1999 Lander, Cyril W, Power Electronics, 1993 Lythall, R T, The J. & P. Switchgear Book: Being an Outline of Modern Switchgear Practice for the Non-Specialist User Mazda, F F, Power Electronics Handbook, 1997 Ragaller, Klaus, Current Interruption in High Voltage Networks , 1978 Ramshaw, Raymond S, Power Electronics Semiconductor Switches: Solutions Manual, 1994 Rudman, Jack, Power Electronic Maintainer, 1994 Ryan, H M and Jones, G R, SF6 Switchgear, 1989 Smeaton, Robert W and Ubert, William H, Switchgear and Control Handbook, McGraw-Hill, 1998 Tyler, Electrical Power Technology, 1998 E LE C TR I C A L E N G I N E E R I N G – P O WE R C O N TR O L ( H ) 7 © Le a r n i n g a n d T e a c h i n g S c o t l a n d 2 0 0 3 S TAF F INFO RM AT IO N A N D S UPPO R T M AT ER I A L Visual aids The Electrical Engineering laboratory should have an Electrical Safety notice prominently displayed. These are available from a variety of electrical wholesale outlets and distributors and are relatively inexpensive. Component manufacturers and distributors offer wall charts and posters showing many aspects of Electrical Engineering. They are generally free and available on request. 8 E LE C TR I C A L E N G I N E E R I N G – P O WE R C O N TR O L ( H ) © Le a r n i n g a n d T e a c h i n g S c o t l a n d 2 0 0 3 S TAF F INFO RM AT IO N A N D S UPPO R T M AT ER I A L SECTION S6 Safety The safety of teaching staff and candidates working in the Electrical Engineering laboratory must be the primary concern of everyone involved. This aspect has to take precedence over all other activities and be sustained against all other pressures since electricity can be lethal. There are many aspects to safety, as follows: statutory requirements centre procedures centre structure staff training and behaviour laboratory features candidate training and behaviour. It is beyond the scope of this document to provide details of all of these items, which should be incorporated into a c entre’s safety policy. Lecturers/teachers must however be content that all appropriate safety measures are in place before embarking on work within the electrical engineering laboratory. Candidate training is a recurrent activity that is likely to be the direct responsibilty of the lecturer/teacher. While this has to take place on a continuous basis as work in a laboratory situation proceeds it is helpful to perform specific safety training at the beginning of the course. Such training might form part o f the course induction as its relevance extends to all course units. This is particularly important for electrical engineering candidates as they should be encouraged to develop their own safety culture; this should become a lifelong asset. The lecturer/teacher performing safety training for candidates may find a rich diversity of available material. Of specific relevance is a teaching package prepared by the University of Southampton Department of Electrical Engineering and Technical Support and Media S ervices. The package was prepared in association with and financially supported by the Health and Safety Executive. It consists of : a handbook for undergraduate electrical teaching laboratories a video programme: Not to Lay Blame a booklet: Tutor’s Guide. E LE C TR I C A L E N G I N E E R I N G – P O WE R C O N TR O L ( H ) 9 © Le a r n i n g a n d T e a c h i n g S c o t l a n d 2 0 0 3 10 E LE C TR I C A L E N G I N E E R I N G – P O WE R C O N TR O L ( H ) © Le a r n i n g a n d T e a c h i n g S c o t l a n d 2 0 0 3 CA ND ID A T E INF O RM AT IO N AN D S UPP O R T M A TE R I A L SECTION C1 Outcomes to be covered in this unit Outcome 1 Describe the construction, function and interruption capability of switchgear. Performance criteria (a) The function and current interruption capability of different types of switchgear are described correctly. (b) With the aid of a diagram the process of a plain air break circuit breaker opening under fault conditions is described correctly. (c) The salient constructional features and interruption process of circuit breakers is explained correctly. Note on the range of the outcome switchgear: isolator, isolating switch, circuit breaker and auto -recloser circuit breaker: air break, air blast, vacuum and sulphur hexafluoride constructional features: operating mechanisms, contacts and arc control devices. Evidence requirements Written evidence of the student’s ability to understand the various features of switchgear. Outcome 2 Investigate the operation and performance of a static power converter. Performance criteria (a) The various types of static power converters are listed correctly. (b) The principal features and function of static power converters are described correctly. (c) Diagrammatic representation of a static power converter is accurate. (d) Explanation of the operation of the converter is correct. (e) Evaluation of the key performance characteristics of the converter is correct. Note on the range of the outcome static power converters: AC to DC, AC to AC, DC to AC and DC to DC. converter: phase controlled, cyclo, choppers and inverters. E LE C TR I C A L E N G I N E E R I N G – P O WE R C O N TR O L ( H ) 11 © Le a r n i n g a n d T e a c h i n g S c o t l a n d 2 0 0 3 CA ND ID A T E INF O RM AT IO N AN D S UPP O R T M A TE R IA L Evidence requirements Written and graphical evidence of the student’s ability to interpret the operation of power converters. 12 E LE C TR I C A L E N G I N E E R I N G – P O WE R C O N TR O L ( H ) © Le a r n i n g a n d T e a c h i n g S c o t l a n d 2 0 0 3 CA ND ID A T E INF O RM AT IO N AN D S UPP O R T M A TE R I A L SECTION C2 Assessment instruments for the outcomes The unit can be divided into two sections namely: switchgear static power converters. Switchgear will be assessed by an end-of-topic test in the form of a structured question to determine if you understand the construction, function and interruption capability of switchgear. Assessment time allocation for this first section is 60 minutes. Static power converters will be assessed in the form of a laboratory assignment and a structured question to determine if you understand the operation and performance of static power converters. A written report of the practical investigation has to be submitted, which should include the following: object apparatus circuit diagram description results and conclusions. Assessment time allocation for the second section is 60 minutes. E LE C TR I C A L E N G I N E E R I N G – P O WE R C O N TR O L ( H ) 13 © Le a r n i n g a n d T e a c h i n g S c o t l a n d 2 0 0 3 CA ND ID A T E INF O RM AT IO N AN D S UPP O R T M A TE R IA L SECTION C3 Course notes and tutorials Switchgear Protection of the power system is necessary and without it serious damage coupled with frequent and possibly prolonged shut -downs of services would result. Protection can be achieved by using fuses, which are available up to 11kV but suffer one disadvantage in that when they ha ve cleared a fault they have to be replaced. Especially at the higher voltages this is extremely costly. An alternative to the fuse is the circuit breaker which having operated may be re closed once the reason for its operation has been ascertained. Cir cuit breakers need to have auxiliary devices called relays, which on sensing abnormal conditions, automatically initiate the opening of the circuit breaker, disconnecting the fault from the supply. Auto-recloser This is a circuit breaker that opens on short-circuit current and automatically re-closes after a brief time delay. The open/close sequence may be repeated two or three times. If the short circuit does not clear itself after two or three attempts to reclose the line the recloser opens permanentl y. A repair crew must then locate the fault, remove it and reset the recloser. Isolator An isolator is a mechanical device that is capable of making a circuit under all conditions but only being opened when the circuit is carrying very little or no current. As the name suggests, an isolator is used to isolate a circuit from the supply when essential maintenance work is being carried out. The isolator is usually fitted with an interlocking device to prevent it from being accidentally operated. Isolators on transmission and distribution systems are interlocked with an associated circuit breaker so that they cannot be opened with the circuit breaker in the closed position. The isolator must be able to: carry the full load continuously withstand normal and excess voltages open and close on no-load. 14 E LE C TR I C A L E N G I N E E R I N G – P O WE R C O N TR O L ( H ) © Le a r n i n g a n d T e a c h i n g S c o t l a n d 2 0 0 3 CA ND ID A T E INF O RM AT IO N AN D S UPP O R T M A TE R I A L Circuit breakers A circuit breaker is a mechanical device that is capable of making and breaking an electrical circuit under all conditions. This means that it can be used to energise a circuit with a short-circuit fault on it without causing distress to the device as it opens to interrupt very large current. Circuit breakers are available for circuits with fault levels ranging from a few MVA at 230V when they are known as miniature circuit breakers, up to 3 5000MVA at 400kV three-phase. The fundamental requirements are: faults must be cleared with minimum dislocation of the system faults must be cleared in the shortest possible time. Main faults: failure of insulation to earth or between phases excess or reduction in voltage overloads and short circuits. The circuit breaker must be capable of carrying heavy fault currents until they are cleared. The equipment must do this without serious overheating and be able to withstand the large magnetic forces invo lved. In summary the circuit breaker should: carry full load continuously withstand normal and possible excess voltages make and break the normal rated current make on to a short circuit break on short circuit. Circuit breakers are available for circuits with fault levels ranging from a few MVA at 230V when they are known as miniature circuit breakers, up to thousands of MVA at 400kV three-phase. The main types of circuit breakers used are: oil circuit breaker (beyond the scope of this unit) air-blast circuit breaker air-break circuit breaker (atmospheric pressure) compressed gas (SF 6 ) circuit breaker vacuum circuit breaker. E LE C TR I C A L E N G I N E E R I N G – P O WE R C O N TR O L ( H ) 15 © Le a r n i n g a n d T e a c h i n g S c o t l a n d 2 0 0 3 CA ND ID A T E INF O RM AT IO N AN D S UPP O R T M A TE R IA L All types of circuit breakers consist essentially of pairs of mating contacts, each pair comprising fixed and moving elements. In normal service these elements are in contact to carry the load current, but under fault conditions the two elements will part company to interrupt the circuit. At the instant of separation an arc will be struck between them and will continue until interrupted. Interruption of the arc depends on aid given either by high pressure, forced convection, lengthening of the arc, vacuum or by a combination two or more of these. Air-break circuit breaker Figure 1: Elementary arrangement of air-break circuit breaker This type of circuit breaker employs air as insulant and arc extinguishing medium. It consists essentially of a pair of mating contacts comprising fixed and moving elements. In normal service these elements are in contact to carry the load current, but under fault conditions and on receipt of a tripping signal, which may be initiated by hand or via a protective device, the two elements will part company to interrupt the circuit. At the instant of separation an arc will be struck between them and will continue until interrupted. 16 E LE C TR I C A L E N G I N E E R I N G – P O WE R C O N TR O L ( H ) © Le a r n i n g a n d T e a c h i n g S c o t l a n d 2 0 0 3 CA ND ID A T E INF O RM AT IO N AN D S UPP O R T M A TE R I A L Interruption is largely due to elongation of the arc, which results in cooling and de-ionisation by diffusion. Owing to the high temperature of the arc relative to the surrounding air, the arc is subjected to strong convection currents, which coupled with the electromagnetic effect of the current loop cause the arc to rise vertically. It is therefore drawn into the arc chute where splitter plates assist the cooling and lengthening process so that its length is much greater than the direct distance between the fully open contacts leading to successful interruption. Typical ratings are: 25MVA at 415V; 35MVA at 3.3kV and up to 750MVA at 11kV. Figure 2: Air-break circuit breaker in closed position with one arc chut e removed E LE C TR I C A L E N G I N E E R I N G – P O WE R C O N TR O L ( H ) 17 © Le a r n i n g a n d T e a c h i n g S c o t l a n d 2 0 0 3 CA ND ID A T E INF O RM AT IO N AN D S UPP O R T M A TE R IA L Figure 3: Air-break circuit breaker in open position with one arc chute removed Air-blast circuit breaker The air-blast breaker uses air at a high pressure to rapidly cool and blow out the arc formed as the contacts separate. The basic d ifference in operation between this type and the natural air type is that the moving contact does not remain in the open position. It pulls back drawing the arc, which is blown out and later is forced back into the closed position at high speed. The interrupting process is aided by an axial blast of air at high pressure admitted to the arcing chamber. The cold air rapidly cools and blows out the arc formed. As the air in the blast tube returns to atmospheric pressure after arc extinction, its dielectric strength in the small gap will be insufficient to withstand the normal system voltage, and therefore a separate isolating switch is provided to open automatically after current interruption. When compressed air is released suddenly in the form of high -velocity jets into a relatively still atmosphere, the resulting interaction produces sound which is explosive in nature. When an air-blast circuit breaker opens, such a release 18 E LE C TR I C A L E N G I N E E R I N G – P O WE R C O N TR O L ( H ) © Le a r n i n g a n d T e a c h i n g S c o t l a n d 2 0 0 3 CA ND ID A T E INF O RM AT IO N AN D S UPP O R T M A TE R I A L of air occurs at the exhaust point of each interrupter, and as these multiply with the size of the breaker the emanating noise can be startling at close quarters and very annoying even at some distance. This problem is one of considerable importance if it becomes necessary to locate substations in residential areas, particularly a t the higher voltages and where high air pressures are employed. Noise suppression methods must be used in these areas. Figure 4: Side view of an air-blast circuit breaker fitted with a silencer E LE C TR I C A L E N G I N E E R I N G – P O WE R C O N TR O L ( H ) 19 © Le a r n i n g a n d T e a c h i n g S c o t l a n d 2 0 0 3 CA ND ID A T E INF O RM AT IO N AN D S UPP O R T M A TE R IA L Various stages in the breaking operation of the above a ir-blast circuit breaker are shown in Figure 5: (a) (b) (e) breaker closed main current interrupted in the extinction chamber after the tripping command is given auxiliary spark gap cuts-in low damping resistor when main current has been interrupted auxiliary spark is quenched and high resistance is cut-in to limit overvoltages breaker open; isolator has opened to switch off high resistance. 20 E LE C TR I C A L E N G I N E E R I N G – P O WE R C O N TR O L ( H ) (c) (d) © Le a r n i n g a n d T e a c h i n g S c o t l a n d 2 0 0 3 CA ND ID A T E INF O RM AT IO N AN D S UPP O R T M A TE R I A L Figure 5: Breaking process of an air blast circuit breaker Key: 1. Isolator blades 2. Extinction chamber 3. Auxiliary spark gap 4. Low resistance 5. High resistance 6. Arc E LE C TR I C A L E N G I N E E R I N G – P O WE R C O N TR O L ( H ) 21 © Le a r n i n g a n d T e a c h i n g S c o t l a n d 2 0 0 3 CA ND ID A T E INF O RM AT IO N AN D S UPP O R T M A TE R IA L Figure 6: 400 kV outdoor substation with air-blast circuit breakers (courtesy A. Reyrolle & Co. Ltd.) Sulphur hexafluoride (SF6) circuit breaker This circuit-breaker type uses SF6 sulphur hexafluoride gas, which is a particularly good arc-quenching medium in that it rapidly absorbs free electrons created in an arc. This means that as the current flowing in an arc passes through a zero, electrons which are present and which would allow the arc to restrike as the alternating voltage begins to increase in magnitude once again are absorbed, turning the arc path into an insulating region. The arc duration time is much shorter in sulphur hexafluoride than it would be in air. The construction of the sulphur hexafluoride circuit breaker is very similar to that of the air-blast breaker except that the gas cannot be allowed to escape into the atmosphere. It is therefore held at high pressure and when the breaker operates it expands into a larger, l ow-pressure receiver from which it can be taken and pumped back up to high pressure once more. The following advantages accrue from the use of this gas: a reduced number of series breaks is required for a given voltage and rating. The breaker is much less bulky than its air-blast equivalent 22 E LE C TR I C A L E N G I N E E R I N G – P O WE R C O N TR O L ( H ) © Le a r n i n g a n d T e a c h i n g S c o t l a n d 2 0 0 3 CA ND ID A T E INF O RM AT IO N AN D S UPP O R T M A TE R I A L due to the quicker clearance, burning of contacts is less than in the air break since the gas blast is not released into the atmosphere the operation of the breaker is much quieter than with air blast which can ofte n be heard a very long way away. These breakers are much smaller than other high -voltage breakers and are less noisy than air-blast breakers. They are extensively used on high -voltage transmission networks. Figure 7: Side view of an SF6 circuit breaker E LE C TR I C A L E N G I N E E R I N G – P O WE R C O N TR O L ( H ) 23 © Le a r n i n g a n d T e a c h i n g S c o t l a n d 2 0 0 3 CA ND ID A T E INF O RM AT IO N AN D S UPP O R T M A TE R IA L Figure 8: A cross-sectional view of an SF6 circuit breaker Key: 1. Moving contact actuator 2. Steel connecting pin 3. Guides 4. Gas compression cylinder supports 5. Arcing chamber 6. Gas compression piston 24 7. Gas compression cylinder 8. Moving contact 9. Tungsten-tipped moving contact 10. Moving contact current-collector ring 11. Fixed-contact arcing ring 12. Fixed-contact holder E LE C TR I C A L E N G I N E E R I N G – P O WE R C O N TR O L ( H ) © Le a r n i n g a n d T e a c h i n g S c o t l a n d 2 0 0 3 CA ND ID A T E INF O RM AT IO N AN D S UPP O R T M A TE R I A L Figure 9: 132 kV outdoor substation with GEC SF6 circuit breakers (courtesy GEC Switchgear Ltd.) Figure 10: 275 kV outdoor substation with GEC SF6 circuit breakers (courtesy GEC Switchgear Ltd.) E LE C TR I C A L E N G I N E E R I N G – P O WE R C O N TR O L ( H ) 25 © Le a r n i n g a n d T e a c h i n g S c o t l a n d 2 0 0 3 CA ND ID A T E INF O RM AT IO N AN D S UPP O R T M A TE R IA L Vacuum circuit breaker The ideal situation in which to interrupt a current might seem to be in a perfect vacuum and this possibility was investigate d in the early 1920s. At the time, however, the problems in producing metals that did not contain dissolved gases seemed insurmountable. When contacts made from metals interrupt an arc in vacuum the dissolved gases are liberated, thus contaminating the vacuum. Also without the scouring action of high -velocity air or oil the contact tended to weld together and any liberated metal vapour settled on the insulating surfaces. By careful attention to the geometry of the interior, the problems have been overcome and the vacuum interruption principle has been developed for very high voltages. It may be seen as an ideal process for high -performance circuit breakers. Figure 11: Constructional features of an 11kV vacuum interrupter The vacuum chamber is composed of an insulating envelope fitted with an end plate on each end, maintaining a high degree of vacuum. Inside the vacuum chamber is a pair of contacts – one stationary, one moving – fastened to the end of a fixed stem and a moving stem, respectively. A metallic bellows is provided between the moving rod and its mating end plate, which enables the contacts to open and close, while a high vacuum is 26 E LE C TR I C A L E N G I N E E R I N G – P O WE R C O N TR O L ( H ) © Le a r n i n g a n d T e a c h i n g S c o t l a n d 2 0 0 3 CA ND ID A T E INF O RM AT IO N AN D S UPP O R T M A TE R I A L maintained. An arc shield is installed around the plates so that the vapour produced from the contacts during current switching is prevented from adhering to the inner walls of the insulating envelope. A bellows cover protects the bellows from direct contact with metal vapour. The current interruption process consists of separating a pair of current carrying contacts in a high vacuum environment. The current carriers in the arc are mainly metal ions from the contacts. The arc is shortened by condensation of these metal ions and vapours on to the contacts and shields, and the effectiveness of this determines the efficiency of the interrupting process at the first current zero. These breakers are hermetically sealed hence they are silent and never become polluted. They are used considerably on distribution networks. Another application is for flameproof switchgear for use in situations such as petrochemical plants or wherever inflammable gases may be present. The contacts of the vacuum interrupter, being completely enclosed in the vacuum chamber, are safe in explosive situations. Figure 12: A cross-sectional view of a vacuum interrupter The unique properties of the vacuum interrupter offer many advantages. These include: long life and minimum maintenance completely enclosed and hermetically sealed extremely short and consistent arcing and total brea k times no fire risk no noise and no emission of air or gas during operation E LE C TR I C A L E N G I N E E R I N G – P O WE R C O N TR O L ( H ) 27 © Le a r n i n g a n d T e a c h i n g S c o t l a n d 2 0 0 3 CA ND ID A T E INF O RM AT IO N AN D S UPP O R T M A TE R IA L at the end of its life a unit or ‘bottle’ can be changed quickly, removed and discharged and replaced by a spare. The vacuum interrupter unit has a long shelf -life, but its main disadvantage is its relatively high cost. Figure 13: 132kV outdoor substation with GEC vacuum circuit breakers (courtesy GEC Switchgear Ltd.) 28 E LE C TR I C A L E N G I N E E R I N G – P O WE R C O N TR O L ( H ) © Le a r n i n g a n d T e a c h i n g S c o t l a n d 2 0 0 3 CA ND ID A T E INF O RM AT IO N AN D S UPP O R T M A TE R I A L Power converters In recent years, the power control field has experienced a large growth due to the influence of several factors. There have been revolutionary advances in microelectronics methods, which have led to the development of linear integrated circuits and digital signal processors as controllers in power control systems. Advances in microelectronic fabrication technology have led to the development of computers, communication systems, and consumer electronics, all of which require regulated power supplies and often uninterruptible power supplies. The increasing cost of energy has made it mandatory that the energy in all these systems be utilised efficiently. Power control offers the most cost-effective means of achieving efficient energy utilisation. This increased efficiency is extremely important because of the cost of wasted energy and the difficulty of removing the heat generated by wasted energy. The term power control covers a wide range of electronic circuits in which the objective is to control the transfer of electrical power from a source to a load. This control may take many different forms depending on the type of load. Such control is almost always achieved by using electronic devices operated as a switch in either an open or closed state. The power conversion era marks its beginning from the introduction of the SCR (silicon-controlled rectifier) or thyristor in 1957. Although other controllable devices such as the mercury arc rectifier certainly had been available for many years, such devices were large, often required auxiliary equipment, and were not efficient in low and moderat e voltage circuits. The introduction of the SCR thus marked the beginning of a period in which power control shifted largely from rotating machines and static magnetic amplifiers to electronic devices. During this early period, progress was slowed by reliability problems, but after the early 1960s the SCR began to be used in many more applications. The SCR has limitations in terms of power handling capability and switching speed. To fill some of the shortfalls of SCRs, other semiconductor devices have been developed for use in the power industry. They include the triac, the Gate-Turn-Off thyristor (GTO), the Bipolar Junction Transistor (BJT), the power Metal -Oxide-SemiconductorField-Effect (MOSFET) and the Insulated-Gate Bipolar Transistor (IGBT). Classification of power converters A power converter is an operative unit, consisting of semiconductor devices (electronic valves) and necessary auxiliaries, used for changing one or more of the characteristics of an electric power system. It can thus chan ge voltage and current level, and frequency. E LE C TR I C A L E N G I N E E R I N G – P O WE R C O N TR O L ( H ) 29 © Le a r n i n g a n d T e a c h i n g S c o t l a n d 2 0 0 3 CA ND ID A T E INF O RM AT IO N AN D S UPP O R T M A TE R IA L The term ‘converter’ is also used to designate one member of the converter family, which historically is the most prominent one, namely an apparatus which links a DC network to an AC one. If the flow of powe r is directed from the AC side to the DC side, the converter operates as a rectifier. With the opposite direction of the flow of power, the converter operates as an inverter. Several conversion arrangements are used in the majority of power control applications depending on the types of source and load: AC–DC: In this case, the AC line-voltage is converted by rectification to a unidirectional source, which later may be filtered to approximate a DC source. A controlled rectifier converts the fixed voltag e AC to a variable voltage DC, in which case one application would be as a source to drive a DC motor in a variable-speed mode, such as those used in rolling mills. DC–AC: A DC source is switched to provide an alternating voltage to a load. The inverter converts a fixed voltage DC to a fixed (or variable) voltage AC with variable frequency. The output of such an inverter is not a sinusoid but instead a rectangular or perhaps stepped waveform, which is suitable for driving an AC motor in a variable-speed mode by changing voltage and frequency. AC–AC: In this case, there are two converters: The cycloconverter converts a fixed voltage and fixed frequency AC to a variable voltage and variable (lower) frequency AC. It can be used to control the speed of AC motors. The AC voltage regulator converts a fixed voltage AC to a variable voltage AC (fixed frequency). It can be used to control the speed of an induction motor (voltage control method) and for smooth induction motor starting (soft starter). DC–DC: This type converts DC of one level (constant or variable) to another level (constant or variable). The DC chopper is used to provide a controllable DC output from a DC source by switching the source on to and off the load. This converter is primarily used to control the speed of DC motors. Applications of power converters Power conversion finds application wherever a load needs controlled power modulation. Power semiconductors are used in a wide range of applications. The following gives only a representative sample: 30 E LE C TR I C A L E N G I N E E R I N G – P O WE R C O N TR O L ( H ) © Le a r n i n g a n d T e a c h i n g S c o t l a n d 2 0 0 3 CA ND ID A T E INF O RM AT IO N AN D S UPP O R T M A TE R I A L Industrial applications consist primarily of two areas, motor control and power supplies. The motors that are controlled vary from the very large type as used in steel mills, to the relatively smaller ones, such as in machine tools. Power supplies too come in many shapes and sizes, such as for battery charging, induction heating, electroplating and welding. Consumer applications cover many different areas in the home, such as audio amplifiers, heat controls, light dimmers, ballasts, motor c ontrol for food mixers, washing machines, as well as hand power tools and security systems. Transportation applications include electric vehicles, locomotives, and fork-lift trucks. Equally important are non-motor drive applications, such as DC power transmission, traffic signal control, vehicle electronic ignition and vehicle voltage regulation. Aerospace and defence applications include VLF transmitters, power supplies for space and aircraft; Uninterruptible Power Supplies for vital loads, and switching using solid-state relays and contactors. The control of electric drives may involve the glamour areas of robotics, computer disk drives, space applications or it may be associated with more conventional loads like fans, compressors, pumps and hoists. Wha tever the mechanical load, the power semiconductor converter lends itself to the control of adjustable speed drives, which may be DC or AC drives. DC drives require voltage control. This is provided by controlled rectifiers or by choppers, depending upon what kind of source is available. The DC drive is expensive and the rectifier is inexpensive. AC drives require voltage and frequency control inverters and sometimes cycloconverters accomplish this task. The AC drive is inexpensive and the inverter is expensive. The choice of type of drive depends on cost and versatility. In general, DC drives are found useful in many applications. However, AC drives are becoming prominent as inverter technology continues to improve. Whatever load is to be controlled, there is usually one semiconductor device that is best suited for the application. Power control systems are being installed throughout the world using the previously mentioned devices of ever -increasing ratings. Some examples of large systems in the UK are: The cross-channel link that connects together the AC electricity supply systems of England and France via a high -voltage DC link to enable power to be transferred in either direction. The DC side is at 270kV, 2000MW E LE C TR I C A L E N G I N E E R I N G – P O WE R C O N TR O L ( H ) 31 © Le a r n i n g a n d T e a c h i n g S c o t l a n d 2 0 0 3 CA ND ID A T E INF O RM AT IO N AN D S UPP O R T M A TE R IA L and the AC side is 400kV at 50Hz. The devices in the inverter are thyristors. The Eurostar locomotive, on the Channel Tunnel route, uses induction motors driven by Gate-Turn-Off inverters with more than 1MW of power available for driving the motors. In France and in the tunnel, th e DC link voltage is 1900V. In England the DC link is 750V. The above applications are some examples of spectacular power control developments. Choice of power device The selection of a power device for a particular application depends not only on the required voltage and current levels but also on cost, rating and the ease with which it can be turned ‘on’ and ‘off’. Transistors and GTOs provide control of both turn -on and turn-off, SCRs of turn-on but not turn-off, and diodes of neither. MOSFETs and IGBTs have the simplest driving requirements; they are voltage controlled and the gate current is virtually zero during the ‘on’ period. However, they lack the reverse blocking capability that makes the SCR, Triac and GTO so suitable for AC mains power a pplications. With DC link inverters, the DC side means that turning off thyristors requires a forced commutation circuit, and GTOs are better suited for that. However, if MOSFETs are available with the correct rating then these, with reverse conducting diodes for inductive loads, would be a simpler choice. 32 E LE C TR I C A L E N G I N E E R I N G – P O WE R C O N TR O L ( H ) © Le a r n i n g a n d T e a c h i n g S c o t l a n d 2 0 0 3 CA ND ID A T E INF O RM AT IO N AN D S UPP O R T M A TE R I A L Power control devices Diodes Diodes are mainly used in rectification circuits where fixed voltage DC is required. The diode conducts once the anode polarity is positive with respect to the cathode. When the anode polarity is negative with respect to the cathode, the diode ceases to conduct. The diode has the highest rating of all the semiconductor devices and is the cheapest, but it cannot regulate the magnitude of the rectified voltage. Diodes with out a heat-sink are available up to about 3A. For higher currents the diodes are fitted with heat -sinks or they are of stud-type to be mounted on a heat-sink. Figure 14: Diode package types Figure 15: Diode terminal identification Figure 16: Diode symbol E LE C TR I C A L E N G I N E E R I N G – P O WE R C O N TR O L ( H ) 33 © Le a r n i n g a n d T e a c h i n g S c o t l a n d 2 0 0 3 CA ND ID A T E INF O RM AT IO N AN D S UPP O R T M A TE R IA L Figure 17: Heat sink Thyristors Thyristors are electronic switches used in circuits where control of switch turn-on is required. Thyristors are a family of three -terminal devices, which includes the Silicon-Controlled-Rectifier (SCR), the triac, and the Gate-TurnOff (GTO) thyristor. The three terminals are the anode, cathode, and gate. Thyristor and SCR are terms that are sometimes used synonymously. Thyristors are capable of carrying large currents and large blocking voltages for use in high-power applications, but switching frequencies are limited to about 10 to 20kHz. For the SCR to begin to conduct, it must have a gate current applied while it has a positive anode-to-cathode voltage. After conduction is established, the gate signal is no longer required to maintain anode current. The SCR will continue to conduct as long as the anode current remains positive and above a minimum value called the holding level. The GTO thyristor like the SCR, is turned on by a short -duration gate current if the anode-to-cathode voltage is positive. However, unlike the SCR, the GTO can be turned off with a negative gate current. The GTO is therefore suitable for some applications where control of both turn -on and turn-off of a switch is required. The negative GTO current can be of brief duration (a few microseconds), but its magnitude must be very large compared to the turn -on current. Typically, gate turn-off current is one-third the on-state anode current. 34 E LE C TR I C A L E N G I N E E R I N G – P O WE R C O N TR O L ( H ) © Le a r n i n g a n d T e a c h i n g S c o t l a n d 2 0 0 3 CA ND ID A T E INF O RM AT IO N AN D S UPP O R T M A TE R I A L Figure 18: SCR symbol Figure 19: SCR construction A triac is a bidirectional thyristor, i.e. it has two blocking/forward directions. It is capable of conducting current in either direction. The triac is functionally equivalent to two anti-parallel SCRs (in parallel but in opposite directions) with a common gate. Turn-on can, however, be performed by a positive as well as a negative pulse. The fact that the triac is bi -directional and only needs one heat-sink and one trigger pulse circuit, implies that it is possible to make a simple, cheap electrical and mechanical design especially for low power ratings. Triacs are used in light -dimmer circuits and for controlling the power for heating elements. Figure 20: Triac symbol Figure 21: Triac construction E LE C TR I C A L E N G I N E E R I N G – P O WE R C O N TR O L ( H ) 35 © Le a r n i n g a n d T e a c h i n g S c o t l a n d 2 0 0 3 CA ND ID A T E INF O RM AT IO N AN D S UPP O R T M A TE R IA L Figure 22: SCRs and Triacs – physical appearance Power transistors Transistors operate as switches in power control circuits. Transistor drive circuits are designed to have the transistor either in fully -on or fully-off state. This is unlike other transistor applications, such as an amplifier circuit, where the transistor operates in the active or linear region. Transistors have the advantage of providing control of turn-off as well as turn-on, as opposed to the SCR, which has control of turn-on only. Types of transistors used in power control circuits include BJTs, MOSFETs, and IGBTs. Figures 10 and 11 show the circuit symbols. 36 E LE C TR I C A L E N G I N E E R I N G – P O WE R C O N TR O L ( H ) © Le a r n i n g a n d T e a c h i n g S c o t l a n d 2 0 0 3 CA ND ID A T E INF O RM AT IO N AN D S UPP O R T M A TE R I A L Power BJTs are available in ratings up to 1200V and 400A. They are commonly used in converters operating up to approximately 10kHz. Power BJTs generally are available in higher voltage and current ratings than MOSFETs. The MOSFET is a voltage-controlled device. A sufficiently large gate -tosource voltage will turn the device on, resulting in a small drain -to-source voltage. The drive circuit to turn a MOSFET on and off is usually simpler than that for a BJT. MOSFET ratings are up to 1000V and 50A and as their switching speed is faster than BJTs they are used in converters operating up to and beyond the 100kHz range. The IGBT is an integrated connection of a MOSFET and a BJT. The drive circuit for the IGBT is like that of the MOSFET, while the on -state characteristics are like that of the BJT. IGBTs are suitable for switching speeds up to about 20kHz and have replaced BJTs in many applications. Figure 23: Transistors – physical appearance Figure 24: Transistors – terminal connections E LE C TR I C A L E N G I N E E R I N G – P O WE R C O N TR O L ( H ) 37 © Le a r n i n g a n d T e a c h i n g S c o t l a n d 2 0 0 3 CA ND ID A T E INF O RM AT IO N AN D S UPP O R T M A TE R IA L AC to DC conversion In the UK, generation and transmission of electrical power are by means of alternating current. The power stations use synchronous alternators to generate a voltage at about 11kV, or higher, at a frequency of 50Hz. The voltage is then stepped up using transformers to a value considered economic for transmission; this can be 132kV (the grid), or 275kV and 400kV (the super grid). Grid switching stations are used to interconnect the various voltage levels. Grid supply points have transformers to reduce the voltage to 33kV. Substations reduce the voltage to 415/240V for distribution to homes and factories (there are also other voltage levels). Some electrical equipment can use AC directly, e.g. lamps, space and water heating, cookers, fans, drills, and vacuum cleaners, etc. Other applications require that AC be changed to DC. These include radio and TV sets, computers, battery chargers, TTL and CMOS logic circuits, laboratory power supplies, public transport traction drives, high voltage DC links, etc. The process of changing AC to DC is called rectification. Where the application requires fixed voltage DC, the switching device is a diode. Where the application requires variable voltage DC, controlled rectifiers (SCRs) are used. Rectification is the process of converting a bi -directional (alternating) current or voltage into a unidirectional (direct) current or voltage. This conversion can be achieved by a variety of circuits based on and using any of the switching devices discussed previously, with the use of diodes probably the most common. By using thyristors, power transistors, power MOS, e tc., additional control over the magnitude of the direct voltage can be achieved by varying the point-on-wave at which the device is placed into the conducting state. The operation of rectifiers and converters ranging from a simple half wave rectifier using a single diode to complex full-wave bridge circuits employing several thyristors will be described. The rectifier circuits can be separated broadly into three classes: uncontrolled, fully-controlled and half-controlled. An uncontrolled rectifier uses only diodes and the DC output voltage is fixed in amplitude by the amplitude of the AC supply. The fully-controlled rectifier uses thyristors as the rectifying elements and the DC output voltage is a function of the amplitude of the AC supply voltage and the point-on-wave at which the thyristors are fired. The half-controlled rectifier contains a mixture of diodes and thyristors, allowing a more limited control of the DC output voltage level than the full-wave controlled rectifier. The half-wave controlled rectifier is 38 E LE C TR I C A L E N G I N E E R I N G – P O WE R C O N TR O L ( H ) © Le a r n i n g a n d T e a c h i n g S c o t l a n d 2 0 0 3 CA ND ID A T E INF O RM AT IO N AN D S UPP O R T M A TE R I A L cheaper than a full-wave controlled rectifier of the same rating but has operational limitations. Thyristor converters are used to control the speed and torque of DC motors driven from AC mains. For applications requiring motor ratings of about 10 kW or so, single-phase supplies can be used. For larger power applications, three-phase supplies are used. The separately excited DC motor is used in these drives, allowing separate control of field and armature circuits. The field supply is derived from a diode bridge rectifier and the field current is held constant. The armature is supplied from a thyristor -controlled bridge, which can be half-controlled if only forward control of speed and torque is required. It must be fully controlled if regeneration is required, and there must be two fully controlled full-wave bridges connected in inverse parallel if forward and reverse control of speed and torque are required. Half-wave uncontrolled rectifiers Resistive load When a diode is connected as shown in Figure 25, current flows in the circuit when the anode of the diode is positive with respect to the cathode; that is, current flows in the positive half-cycles of the supply voltage waveforms. In the negative half-cycles the diode blocks the flow of current in the circuit. Since current only flows during positive half -cycles, the circuit is described as a half-wave rectifier circuit. The voltage waveforms across the source, s , load, 0 , and diode, d are shown in Figure 26. When an ideal diode conducts it has no forward resistance, and no voltage is dropped across it. Similarly, when it is in its reverse blocking mode, it has infinite resistance, and no current flows throu gh it. In the latter case, all of the negative half-cycle of the supply appears across the diode, and the reverse blocking voltage rating of the diode must be at least equal to the peak supply voltage. The maximum voltage across the diode when it is block ing is known as the peak inverse voltage. The rectifier circuit therefore converts the alternating supply voltage into a unidirectional DC voltage across the load. In practice the ideal diode does not exist. When conducting, a practical diode has some resistance, and there is small voltage drop across it. When it is in its reverse mode, there is some leakage current, and a small value of negative voltage across the load. E LE C TR I C A L E N G I N E E R I N G – P O WE R C O N TR O L ( H ) 39 © Le a r n i n g a n d T e a c h i n g S c o t l a n d 2 0 0 3 CA ND ID A T E INF O RM AT IO N AN D S UPP O R T M A TE R IA L Figure 25: Half-wave uncontrolled rectifier circuit with resistive load Figure 26: Voltage waveforms for a half-wave uncontrolled rectifier with resistive load Resistive-inductive load Industrial loads typically contain inductance as well as resistance. Current flow will commence directly when the supply voltage goes positive, but the presence of the inductance will delay the current change, the current still flowing at the end of the half-cycle, the diode remains on, and the load sees the negative supply voltage until the current drops to zero. The load current, i 0 , and voltage waveforms across the source, s , load, 0 , resistance, R , inductance, L and diode, d are shown in Figure 34. 40 E LE C TR I C A L E N G I N E E R I N G – P O WE R C O N TR O L ( H ) © Le a r n i n g a n d T e a c h i n g S c o t l a n d 2 0 0 3 CA ND ID A T E INF O RM AT IO N AN D S UPP O R T M A TE R I A L Figure 27: Half-wave uncontrolled rectifier circuit with resistive -inductive load Figure 28: Voltage waveforms for half-wave uncontrolled rectifier with resistive-inductive load E LE C TR I C A L E N G I N E E R I N G – P O WE R C O N TR O L ( H ) 41 © Le a r n i n g a n d T e a c h i n g S c o t l a n d 2 0 0 3 CA ND ID A T E INF O RM AT IO N AN D S UPP O R T M A TE R IA L Fly-wheeling diode Many circuits, particularly those which are half - or uncontrolled, include a diode across the load as shown in Figure 29. This diode is variously described as a free-wheeling, flywheel, or bypass diode, but it is best described as a commutating diode, as its main function is to to commutate or transfer the load current away from the rectifier whenever the load voltage goes into a reverse state. The commutating diode serves one or both of the two functions: one is to prevent reversal of load voltage (except for the small diode voltage -drop) and the other to transfer the load current away from the main rectifer, thereby allowing all of its thyristors to regain their blocking state. When the diode is turned on at t = 0, the load voltage, v 0 , is the same as the supply voltage, v S . The load current, i 0 , builds up. When the diode is turned off, the load current freewheels through diode D2 and v 0 = 0 and when the diode is turned on again, the cycle repeats itself. The correspo nding voltage and current waveforms are shown in Figure 30. Figure 29: Half-wave uncontrolled rectifier circuit with fly-wheeling diode 42 E LE C TR I C A L E N G I N E E R I N G – P O WE R C O N TR O L ( H ) © Le a r n i n g a n d T e a c h i n g S c o t l a n d 2 0 0 3 CA ND ID A T E INF O RM AT IO N AN D S UPP O R T M A TE R I A L Figure 30: Load voltage and current waveforms for half -wave uncontrolled rectifier circuit with fly-wheeling diode Half-wave rectifier with a capacitor filter The half-wave rectifier shown in Figure 31 has a parallel R -C load. The purpose of the capacitor is to reduce the variation in the output voltage, making it more like DC. The resistance may represent an e xternal load, and the capacitor may be a filter, which is part of the rectifier circuit. Assuming the capacitor is initially uncharged and the circuit is energised at t = 0, the diode becomes forward-biased as the source becomes positive. With the diode on, the output voltage is the same as the source voltage, and the capacitor charges. The capacitor is charged to V m when the input voltage reaches its positive peak at t = . As the source decreases after t = , the capacitor 2 2 discharges into the load resistor. At some point, the voltage of the source becomes less than the output voltage, reverse biasing the diode and isolati ng the load from the source. The output voltage is a decaying exponential with time constant = RC while the diode is off. E LE C TR I C A L E N G I N E E R I N G – P O WE R C O N TR O L ( H ) 43 © Le a r n i n g a n d T e a c h i n g S c o t l a n d 2 0 0 3 CA ND ID A T E INF O RM AT IO N AN D S UPP O R T M A TE R IA L The point when the diode turns off is determined by comparing the rates of change of the source and the capacitor voltages. The diode turns off when the downward rate of change of the source exceeds that permitted by the t ime constant of the R-C load. When the voltage comes back up to the value of the output voltage in the next period, the diode becomes forward biased, and the output again is the same as the source voltage. The angle at which the diode turns on in the sec ond period, t = 2 + , is the point where the sinusoidal source reaches the same value as the decaying exponential output. The corresponding voltage waveforms are represented in Figure 32. Figure 31: Half-wave uncontrolled rectifier with R-C load Figure 32: Voltage waveforms for half-wave uncontrolled rectifier R-C load 44 E LE C TR I C A L E N G I N E E R I N G – P O WE R C O N TR O L ( H ) © Le a r n i n g a n d T e a c h i n g S c o t l a n d 2 0 0 3 CA ND ID A T E INF O RM AT IO N AN D S UPP O R T M A TE R I A L Half-wave controlled rectifiers Resistive load The thyristor is a device which blocks the flow of current when the anode is negative with respect to the cathode, and can be triggered int o conduction at any point when the anode is positive (Figure 33). The load is connected in series with the thyristor, which is triggered into conduction by a pulse generator connected between its gate and cathode. The pulse generator produces a short pulse of a few microseconds duration at an angle known as the firing angle, , with respect to the commencement of the supply voltage waveform. The firing angle, , can be changed from zero to , which will change the output voltage. Note that at = 0, the thyristor circuit behaves like a diode circuit and the output voltage will be maximum. However, if the thyristor is fired at = the output voltage will be zero. Since the point in the waveform at which the gate pulse is applied is a function of the phase angle, the circuit is said to be phase controlled. Even if the anode is positive with respect to the cathode, the thyristor does not conduct until the gate pulse is applied. Once it has been applied, the thyristor turns on and conducts; from this p oint onwards in the positive halfcycle, the circuit operates as though it were a half -wave rectifier circuit. If the load is resistive, the current waveform follows the supply waveform. When the anode becomes negative with respect to the cathode, the th yristor enters its reverse blocking mode, and current no longer flows through it. It remains in this state until the next pulse is applied. The voltage waveforms across the source, s , load, 0 , and thyristor, SCR are shown in Figure 34. Figure 33: Half-wave controlled rectifier circuit with resistive load E LE C TR I C A L E N G I N E E R I N G – P O WE R C O N TR O L ( H ) 45 © Le a r n i n g a n d T e a c h i n g S c o t l a n d 2 0 0 3 CA ND ID A T E INF O RM AT IO N AN D S UPP O R T M A TE R IA L Figure 34: Voltage waveforms for half-wave controlled rectifier with resistive load Resistive-inductive load A thyristor rectifier circuit with a load consisting of a resistance and an inductance is shown in Figure 35. The thyristor is fired at an angle, , meaning it starts to conduct at t = . The inductance in the load forces the current to lag the voltage and therefore the current decays to zero at t = instead of t = , which would have been the case if the load was purely resistive. The voltage waveforms across the source, s , resistance, R , load, 0 , and thyristor, SCR , are shown in Figure 35. The current waveform is similar to the voltage waveform across the resistance, R . Figure 35: Half-wave controlled rectifier with resistive-inductive load 46 E LE C TR I C A L E N G I N E E R I N G – P O WE R C O N TR O L ( H ) © Le a r n i n g a n d T e a c h i n g S c o t l a n d 2 0 0 3 CA ND ID A T E INF O RM AT IO N AN D S UPP O R T M A TE R I A L Figure 36: Voltage waveforms for half-wave controlled rectifier with Resistive-inductive load Full-wave rectifier circuits Bi-phase rectifier circuit The bi-phase rectifier circuit is so named because it is energised by a centre tapped secondary winding of a two-winding transformer. The two halves of the secondary winding have emfs induced in them, which act in the same direction. Consequently, during the positive half -cycle of the waveform, diode D1 is forward biased and conducts, while diode D2 is reverse biased and blocks the flow of current. In the negative half -cycle, the polarity of the induced voltage in the secondary winding reverses, so that D1 blocks the flow of the current and D2 conducts. The waveforms in Figure 38 illustrat e the general result. Since the bi-phase circuit needs a transformer, the DC output voltage can be selected by means of the turns ratio of the transformer. Moreover, since the transformer electrically isolates the secondary winding from the primary, the circuit is particularly useful where safety is important. While these features may be advantageous, it has the disadvantage of the cost, size and weight of the transformer. Moreover, the transformer will reduce the electrical efficiency of the circuit. E LE C TR I C A L E N G I N E E R I N G – P O WE R C O N TR O L ( H ) 47 © Le a r n i n g a n d T e a c h i n g S c o t l a n d 2 0 0 3 CA ND ID A T E INF O RM AT IO N AN D S UPP O R T M A TE R IA L Figure 37: Full-wave uncontrolled rectifier circuit with resistive load Figure 38: Waveforms for full-wave uncontrolled rectifier with resistive load 48 E LE C TR I C A L E N G I N E E R I N G – P O WE R C O N TR O L ( H ) © Le a r n i n g a n d T e a c h i n g S c o t l a n d 2 0 0 3 CA ND ID A T E INF O RM AT IO N AN D S UPP O R T M A TE R I A L Bridge rectifier circuit The bridge rectifier does not need a transformer, but one may be necessa ry if both the DC and AC sides of the circuit must be separately earthed. In operation (Figure 39), diagonally opposed pairs of rectifiers conduct. During the positive half-cycles, diodes D1 and D2 conduct while D3 and D4 block the flow of current. In the negative half-cycle, D1 and D2 are reverse biased while D3 and D4 are forward biased. The supply and output waveforms are shown in Figure 40. Figure 39: Full-wave uncontrolled rectifier bridge with resistive load E LE C TR I C A L E N G I N E E R I N G – P O WE R C O N TR O L ( H ) 49 © Le a r n i n g a n d T e a c h i n g S c o t l a n d 2 0 0 3 CA ND ID A T E INF O RM AT IO N AN D S UPP O R T M A TE R IA L Figure 40: Voltage waveforms for uncontrolled rectifier bridge with resistive load 50 E LE C TR I C A L E N G I N E E R I N G – P O WE R C O N TR O L ( H ) © Le a r n i n g a n d T e a c h i n g S c o t l a n d 2 0 0 3 CA ND ID A T E INF O RM AT IO N AN D S UPP O R T M A TE R I A L DC to AC conversion The inverter provides AC load voltage from a DC voltage source. The power devices can be thyristors (SCRs), MOSFETS, IGBTs, etc. The choice of power switch depends on rating requirements and the ease with which the device can be turned on and off. The output frequency of the inverter is controlled by the rate at which the switches are turned on and off, in other words by the pulse repetition frequency of the base, or gate, driver circuit. Thyristors would only be used in very high -power inverters as commutation circuits would be required to turn the thyristors off. Converters that modulate power from a DC source to provide AC power to a load are called inverters. The two parameters of importance in inverters are the output voltage and the output frequency. The switch-mode inverter is the most commonly used. Power semiconductor switches, in different configurations, chop the DC supply waveform so that the load experiences rectangular waves that periodically change polarity to give an alternating voltage. Concern is given to the quality of power absorbed by the load. In most cases a sinewave of a single frequency is desired to minimise losses produced by other harmonics. In s witch-mode inverters there are always some harmonics because the output waveform is synthesised digitally from the rectangular waveforms. Techniques to produce a near-sinewave are called pulse-amplitude modulation (PAM) or pulse-width modulation (PWM) methods. There are two types of switch-mode inverters. They are the voltage -type and the current-type. As its name implies, the voltage -type inverter is fed from a constant voltage source. The voltage chopping to create changing intervals of constant voltage at the load causes the current to change. This type is the one most commonly used. The current-type inverter supplies a constant source current that is not interrupted. The pattern of switching changes the voltage across the load in this case. Current-type inverters are used in some large AC motor drives. If it is important to have an inverter with no harmonics, then, instead of switched-mode inverters, resonant inverters can be used. Resonance of energy between a capacitor and an inductor at the required output frequency will provide a good sinewave output. Current-source inverters are derived by taking the dual of the voltage -source inverters. Current sources replace voltage sources. Current -filter inductors replace voltage-filter capacitors, and series diodes (to block reverse voltages E LE C TR I C A L E N G I N E E R I N G – P O WE R C O N TR O L ( H ) 51 © Le a r n i n g a n d T e a c h i n g S c o t l a n d 2 0 0 3 CA ND ID A T E INF O RM AT IO N AN D S UPP O R T M A TE R IA L at the switches) replace inverse-parallel diodes (to conduct reverse current that a switch would block). AC–AC conversion Cycloconverters The cycloconverter synthesises its output voltage waveform by switc hing between the phases of the AC supply and provides an alternative to the inverter where the output frequencies are restricted to being less than the supply frequency. The simplest form of cycloconverter produces an output in which each half cycle of the output waveform is made up of a whole number of half-cycles of the single-phase supply waveform. By using a multi -phase supply an output waveform can be produced which approximates to a square wave. By altering the point-on-wave at which the individual phases are switched to form the output waveform, an output voltage can be obtained in which the fundamental is emphasised. This approach also means that the output is no longer restricted to frequencies, which can be made up from integer numbers or cycles or parts of cycles of the AC source frequency. Voltage regulators (Phase control) Two antiparallel thyristors connected in series with a load to an AC voltage give a simple example of a direct converter for controlling, for instance, active power. The control can be performed by phase control or by sequence control. The phase control implies a change of the output waveform by letting a thyristor block a smaller or greater part of the half -cycle. With sequence control the ratio between blocked and unblocked half-cycles is varied. DC–DC conversion The power source for the chopper could be a battery or rectified AC. The purpose of the chopper is to provide a variable DC voltage from a fixed voltage DC source. Applications of choppers are in drives f or electric vehicles, in the DC link for variable frequency inverters and in switched mode power supplies. The power switch used can be a power transistor (MOSFET or IGBT). These require base, or gate driver, circuits to turn the switch on, and they turn off when the driver pulse is removed. The power switch could be a thyristor (SCR), but on DC a separate ‘turn-off’ circuit is required and this complication tends to rule out the thyristor for all but very high -power applications. 52 E LE C TR I C A L E N G I N E E R I N G – P O WE R C O N TR O L ( H ) © Le a r n i n g a n d T e a c h i n g S c o t l a n d 2 0 0 3 CA ND ID A T E INF O RM AT IO N AN D S UPP O R T M A TE R I A L Tutorials (Electronics Workbench) Diodes 1. Draw a 12V battery on the left-hand side of the screen, and two 12V bulbs on the right. Label the bulbs R for red and G for green. Add a suitable switch next to the battery to make a ‘signal controller’. The controller must be able to light either the red bulb only, or the green bulb only. This can be achieved with only two wires linking the controller to the bulbs by adding diodes to the circuit. 2. Draw a circuit diagram consisting of 3 bulbs (rated at 12V), 3 switches, a 10V battery and any necessary diodes. Arrange it so that: (a) (b) (c) 3. Switch 1 makes only bulb 1 light up Switch 2 makes only bulbs 1 and 2 light up Switch 3 makes all 3 bulbs light up. Design a power supply that can be plugged into the UK mains supply of 240V, and which produces a smooth DC output of 12V. Take the following steps: (a) (b) (c) (d) Draw the circuit Calculate the AC output voltage required (i.e. the RMS value) from the transformer that causes 12V to develop across the smoothing capacitor Calculate the transformer turns ratio required Check your calculations on Workbench. Note: You should select the POWER IDEAL transformer (by double -clicking on the symbol). Now click on EDIT and change the turns ratio to the value you have calculated. E LE C TR I C A L E N G I N E E R I N G – P O WE R C O N TR O L ( H ) 53 © Le a r n i n g a n d T e a c h i n g S c o t l a n d 2 0 0 3 CA ND ID A T E INF O RM AT IO N AN D S UPP O R T M A TE R IA L Thyristors 4. (a) (b) (c) 5. (a) (b) 54 Design a simple circuit that shows a thyristor employed to switch a lamp on or off. Use a 12V AC supply, and a 20V lamp. Control the thyristor with a switch. When the switch is closed, why does the bulb appear to flash on and off? If the switch is opened just after the bulb has lit, there is a delay before the bulb switches off. What causes the delay? Design a simple circuit that employs a triac to control a lamp. Again, use a 12V voltage source, a 20V lamp and control the triac with a switch. What is the main difference between the action of this circuit and that of the previous one? E LE C TR I C A L E N G I N E E R I N G – P O WE R C O N TR O L ( H ) © Le a r n i n g a n d T e a c h i n g S c o t l a n d 2 0 0 3 CA ND ID A T E INF O RM AT IO N AN D S UPP O R T M A TE R I A L Laboratory experiments Some laboratory experiments (using Electronics Workbench) that could be used to consolidate the theory are given below: 1. 2. 3. E LE C TR I C A L E N G I N E E R I N G – P O WE R C O N TR O L ( H ) 55 © Le a r n i n g a n d T e a c h i n g S c o t l a n d 2 0 0 3 CA ND ID A T E INF O RM AT IO N AN D S UPP O R T M A TE R IA L 4. 5. 6. 56 E LE C TR I C A L E N G I N E E R I N G – P O WE R C O N TR O L ( H ) © Le a r n i n g a n d T e a c h i n g S c o t l a n d 2 0 0 3