Welcome to the ACS 2000 Service and Commissioning training, Module 6

5-levels switching topology in ACS 2000.

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In this module we will analyze the configuration and the switching principle of the 5-level
switching topology with High Voltage IGBTs and Phase Capacitor used in ACS 2000.

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One of the most common variable speed drives is the Voltage Source Inverter which
can have the configuration shown in this picture. The front end is a diode rectifier,
transforming the fixed frequency fixed voltage supply into a DC voltage. The DC Link
consists of a capacitor bank in parallel with the DC bus.
The inverter has two IGBTs per phase.
With this configuration, two voltage levels can be applied on each motor phase: either
DC+ or DC-, resulting in a 2-level switching topology.
The output to the motor, the phase to phase voltage, has three levels.
For instance, if IGBTs 1 and 4 are On, the line to line voltage between phases U and V
will be full positive DC bus.
There are redundant combinations when 1 and 2 or 4 and 6 are On: for both of them,
the line voltage UV is 0 volts.
If 6 and 2 are On, the line to line voltage UV will be the full negative DC bus.
Forbidden switching combinations 1 and 6 On or 2 and 4 On would result in a short
circuit of DC+ to DC-.

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In ACS 2000, on each motor phase there are 6 IGBT modules, each module containing
two IGBT s. (Figures A and B)
Four IGBT modules, S1 S2 S3 and S4, are connected to the motor phase; the other two
(Snp1 and Snp2) are connected to the middle of the DC bus, the Neutral Point.
If both IGBTs of each of the 6 modules are turned On simultaneously, as in Figure A, we
will have a three-level switching topology:
S1 and S2 On: + V on the motor phase
S2 and S3 On: 0 (Neutral Point) on the motor phase, via S2 and Snp1 or S3 and
Snp2. So, the configuration is Active Neutral Point Clamped.
S3 and S4 On: minus V on the motor phase.
The topology gives us access to the middle point of the DC bus, the Neutral Point;
consequently, the phase to phase voltage will be modified in steps of half DC bus: + 2 *
V, +V, 0, minus V, and minus 2 * V.
The configuration of ACS 2000 is slightly different: the IGBT s of S1, S4, Snp1 and
Snp2 are still turned On simultaneously, but S2 and S3 are split in S21 S22 and S31
S32. Another detail: a phase capacitor is connected between the IGBTs of S2 and S3,
like in Figure B. S21 and S22 on one side, and S31 and S32 on the other side, are
turned On separately. This detail will transform the 3-level switching topology of Figure
A in a 5 level switching topology, Figure B.

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To emphasize the differences between the 3-level and 5-level topologies, we will modify
the drawing of the inverter diagram for one phase.
In S1, S4, Snp1 and Snp2 both IGBT s are turned On in the same time, like in the
three level topology; we will call this part Cell 3, the three level Active Neutral Point
clamped configuration in p the 5-level topology .
Each of the two IGBT s in S2 and S3 are controlled separately, they are marked S21
and S22, respectively S31 and S32. A phase capacitor Cf is installed between S21 S22
and S31 S32, forming the so called H Bridge. They are grouped in Cell 2, S31 plus S22,
and Cell 1, S21 plus S32.
During the charging sequence of ACS 2000, before closing the Main Circuit Breaker,
the phase capacitor Cf will be pre charged with a quarter of the total DC bus voltage (in
our figure, V / 2)
Cell 3 will adjust the phase voltage in steps of V (half of the total DC bus), while Cell 1
and Cell 2 will adjust the phase voltage in steps of V / 2 (a quarter of the total DC bus).
With this arrangement, a total of 8 switching states are possible, providing 5 different
phase output voltages. The phase voltage can be modified in steps of a quarter of the
total DC bus.

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The 5 voltage levels on the motor phase are:
+V: motor phase connected directly at positive DC bus.
+ V / 2: the motor phase voltage is half of the positive DC bus, a quarter of the total
DC bus voltage.
Zero: motor phase connected to the Neutral Point of the DC bus.
- V / 2, the motor phase voltage is half of the negative DC bus; in absolute value, a
quarter of the total DC bus voltage.
- V: motor phase connected directly to DC bus negative
Our 3 cells configuration provides a total of 8 switching states or vectors, numbered V0 to
V7.
Three of the switching states are redundant: different switching states, but same voltage
on the motor phase. The 8 switching vectors are:
V7; voltage on the motor phase: + V; V7 is unique vector
V5 and V6, redundant vectors: for both, the voltage on the motor phase is + V divided
by 2
V3 and V4, redundant vectors: for both, the voltage on the motor phase is 0 (Neutral
Point).
V1 and V2, redundant vectors: for both, the voltage on the motor phase is - V divided
by 2
V0; voltage on the motor phase: - V; V0 is the other unique vector
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We will analyze in the subsequent slides how the 8 switching states will generate the 5
voltage levels on each motor phase, and also the shape of the resulting phase to phase
voltage at the motor terminals.
We will use the modified inverter phase diagram, marking the IGBT s turned On by a
green circle, and the IGBTs turned Off by a dark blue rectangle.
For Cell 3, both IGBTs of each IGBT Module S1, S4, Snp1, Snp2 are turned On or Off
simultaneously. For cells 1 and 2 the IGBTs in each IGBT Module are turned On and
Off separately; the state On or Off is marked individually for each IGBT S21, S22, S31,
S32.
For each switching state, the current can be either positive or negative.

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Switching state V7: S1, Snp2, S21 and S22 are turned On. The motor phase is
connected directly to DC bus positive, the phase voltage is + V.

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Switching State V6: S1, Snp2, S21 and S31 are turned On. The current path goes from
+ V to motor phase through the phase capacitor Cf, which is charged with V / 2.
The motor phase voltage will be V ( V / 2) = V / 2.

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Switching State V5: S1, Snp2, S22 and S32 are turned On. The current path goes from
Neutral Point (0 volts) to motor phase through the phase capacitor Cf, but with reversed
polarity, - V / 2.
The motor phase voltage will be 0 (- V / 2 =) V / 2, same as state V6.
V5 and V5 apply the same voltage on the motor phase, but:
The current path goes through the phase capacitor Cf
The direction of the current through Phase Capacitor Cf is reversed in V5 by
respect of V6.
Consequently, the redundant vectors V5 and V6 are used to control the voltage of the
phase capacitors: one of them will charge the phase capacitor, while the other will
discharge it.

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Switching State V4: S1, Snp2, S31 and S32 are turned On. The motor phase is
connected directly to the Neutral Point, phase voltage 0.

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Switching State V3: S4, Snp1, S21 and S22 are turned On. The motor phase is
connected also to the Neutral Point, but the current direction is reversed.
Consequently, the redundant vectors V3 and V4 are used to control the Neutral Point
Voltage.

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Switching State V2: S4, Snp1, S21 and S31 are turned On. The current path goes from
Neutral Point, 0 volts, to motor phase through the phase capacitor Cf with direct
polarity, V / 2).
The motor phase voltage will be 0 (V / 2) = -V / 2.

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Switching State V1: S4, Snp1, S22 and S32 are turned On. The current path goes from
DC bus negative, potential V, to motor phase through the phase capacitor Cf, but with
reversed polarity, - V divided by 2.
The motor phase voltage will be - V (- V /2 = - V / 2, same as state V2.
V1 and V2 apply the same voltage on the motor phase, but:
The current path goes through the phase capacitor Cf
The direction of the current through Phase Capacitor CF is reversed in V1 by
respect of V2.
Consequently, the redundant vectors V1 and V2 are used to control the voltage of the
phase capacitors: one of them will charge the phase capacitor, while the other will
discharge it.

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Switching state V0: S4, Snp1, S31 and S32 are turned On. The motor phase is
connected directly to DC bus negative, the phase voltage is - V.

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The combination of the switching states on each motor phase will give the total motor
voltage (phase to phase).
A total of 9 voltage levels will result at the motor terminals.
For instance: if the switching state V7 is applied to phase A, voltage level +V, and V0 on
phase B, voltage level- V, the motor voltage A to B will be: + V (- V) = 2 * V, which
actually the total DC bus .

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Switching vector V7 on A, + V, but V1 on phase B, - V / 2); the motor phase to phase
voltage A to B will be + V (- V / 2 ) = 3 / minus minus V divided by 2 = 3 /2 * V, actually
three quarters of the total DC bus voltage.

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If we keep phase B in switching state V1, - V / 2) but change phase A in switching state
V5, + V divided by 2, the motor voltage A to B will be + V / 2 (- V / 2) = V, which is half
the total DC bus voltage.

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Phase A in Status V5, phase voltage + V / 2
Phase B in status V3, phase voltage = 0
Phase to phase voltage A to B: + V / 2, a quarter of the total DC bus.

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Phase A: vector V4, 0 V
Phase B: Vector V3, 0 V
Voltage A to B: 0 volts.

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The phase to phase voltages can be reproduced symmetrically on the negative side:
- V / 2, - V, - 3 / 2 * V, - 2 * V.

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A total of nine voltage levels can be applied at the motor terminals, phase to phase
voltage.

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A stylized representation of the motor phase to phase voltage

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Motor phase to phase voltage and phase current with the 5-level switching topology.

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Thank you for your attention. You have completed Module 6, 5-level switching topology.
You may now go ahead and move on to the next module.

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