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THREE PHASE FULL/HALF CONTROLLED BRIDGE

CONVERTER [FOR 1 HP DC MOTOR]

AIM: To study control and power circuit of three phase full/half controlled SCR BRIDGE
Converter.

APPARATUS:

1. 3-phase full/half controlled converter kit (POWERCON Make).

2. CRO (440 V PP) Dual Trace.
3. Attenuator CRO Probe.

SPECIFICATIONS:

INPUT: 440V, 3Phase, 50Hz, R, Y, B, N, 4-wire in lagging sequence.

[Neutral is must for control circuit power supply].

OUTPUT: 0 500V, 3Amp

LOAD: R Load -40W TO 100W LAMPS

INDICATIONS AND CONTROLS:

1) Power on for control circuit [ LED indication ]
2) Power on for power circuit [ NEON indication ]
3) Start-stop push buttons.
4) Soft-start [ACCELERATION] control on panel.

NOTE:
DO NOT INSERT ANY OBJECT INTO THE OUTPUT CONNECTOR OR ANY TEST POINT. IT
MAY DAMAGE THE UNIT PERMANENTLY.
USE UNEARTHED CRO OR POWERSCOPE ONLY.
TAKE CARE OF YOURSELF WHILE HANDLING 3PHASE SUPPLY.

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THEORY:
The operation of a 3-phase fully-controlled bridge rectifier circuit is described here. A three-
phase fully-controlled bridge rectifier can be constructed using six SCRs as shown below.

The three-phase bridge rectifier circuit has three-legs, each phase connected to one of the
three phase voltages. Alternatively, it can be seen that the bridge circuit has two halves, the
positive half consisting of the SCRs S1, S3 and S5 and the negative half consisting of the
SCRs S2, S4 and S6. At any time when there is current flow, one SCR from each half
conducts. If the phase sequence of the source be RYB, the SCRs are triggered in the
sequence S1, S2, S3, S4, S5, S6 and S1 and so on.
The operation of the circuit is first explained with the assumption that diodes are used in
place of the SCRs.
The three-phase voltages vary as shown below.

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Let the three-phase voltages be defined as shown below.

It can be seen that the R-phase voltage is the highest of the three-phase voltages when is
in the range from 30o to 150 o .It can also be seen that Y-phase voltage is the highest of the
three-phase voltages when is in the range from 150 o to 270o and that B-phase voltage is
the highest of the three-phase voltages when is in the range from 270 o to 390 o or 30 o in the
next cycle. We also find that R-phase voltage is the lowest of the three-phase voltages when
is in the range from 210 o to 330 o. It can also be seen that Y-phase voltage is the lowest of
the three-phase voltages when is in the range from 330 o to 450 o or 90 o in the next cycle,
and that B-phase voltage is the lowest when is in the range from 90 o to 210 o. If diodes are
used, diode D1 in place of S1 would conduct from 30 o to 150 o, diode D3 would conduct from
150 o to 270 o and diode D5 from 270 o to 390 o or 30 o in the next cycle. In the same way,
diode D4 would conduct from 210 o to 330 o, diode D6 from 330 o to 450 o or 90 o in the next
cycle, and diode D2 would conduct from 90 o to 210 o. The positive rail of output voltage of the
bridge is connected to the topmost segments of the envelope of three-phase voltages and
the negative rail of the output voltage to the lowest segments of the envelope.
At any instant barring the change-over periods when current flow gets transferred from diode
to another, only one of the following pairs conducts at any time .
Period, range of Diode Pair in conduction
o o
30 to 90 D1 and D6
90o to 150o D1 and D2
o o
150 to 210 D2 and D3
o o
210 to 270 D3 and D4
270o to 330o D4 and D5
o o o o
330 to 360 and 0 to 30 D5 and D6
If SCRs are used, their conduction can be delayed by choosing the desired firing angle.
When the SCRs are fired at 0 o firing angle, the output of the bridge rectifier would be the
same as that of the circuit with diodes. For instance, it is seen that D1 starts conducting only
after = 30 o. In fact, it can start conducting only after = 30 o , since it is reverse-biased
before = 30 o. The bias across D1 becomes zero when = 30 o and diode D1 starts getting
forward-biased only after =30 o. When VR() = E*Sin (), diode D1 is reverse-biased
before = 30 o and it is forward-biased when > 30 o. When firing angle to SCRs is zero
degree, S1 is triggered when = 30 o. This means that if a synchronizing signal is needed for
triggering S1, that signal voltage would lag V R () by 30 o and if the firing angle is a, SCR S1
is triggered when = + 30 o. Given that the conduction is continuous, the following table presents the SCR pair
in conduction at any instant.

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Period, range of SCR Pair in conduction

+ 30o to + 90o S1 and S6
+ 90o to + 150o S1 and S2
+ 150o to + 210o S2 and S3
+ 210o to + 270o S3 and S4
+ 270o to + 330o S4 and S5
+ 330o to + 360o and + 0o to + 30o S5 and S6

The operation of the bridge-rectifier is illustrated with the help of an applet that follows this
line. You can set the firing angle in the range 0 o < firing angle < 180 o and the instantaneous
angle. The applet displays the SCR pair in conduction at the chosen instant. The current flow
path is shown in red color in the circuit diagram. The instantaneous angle can be either set in
its text-field or varied by dragging the scroll-bar button. The rotating phasor diagram is quite
useful to illustrate how the circuit operates. Once the firing angle is set, the phasor position
for firing angle is fixed. Then as the instantaneous angle changes, the pair that conducts is
connected to the thick orange arcs. One way to visualize is to imagine two brushes which are
120 o wide and the device in the phase connected to the brush conducts. The brush that has
"Firing angle " written beside it acts as the brush connected to the positive rail and the other
acts as if it is connected to the negative rail. This diagram illustrates how the rectifier circuit
acts as a commutator and converts ac to dc. The output voltage is specified with the
amplitude of phase voltage being assigned unity value .

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ABOUT THE UNIT:

The unit consists of following blocks:
1) 3N1 PCB: starter, P.S.12V.
2) Power supply, Ramp & chopper card.
3) Control card.
4) Synchronizing transformers.
5) Converter card

The 3 phase input goes to synch transformers directly. The 3N1 card generates the
control supply 12V after mains on. In the stop state G. K. pulses are not generated using
inhibits contact which disables the chopper circuits & pulls it to a high level. One of the RL1
contacts is used to keep reference voltage at zero in stop state.

The control card circuit consists of the total control circuitry required for firing the thyristor.
It has following major blocks.
1. Pulse generating circuit
2. Pulse gating circuit.
3. Pulse amplifying & isolation pulse transformers.

1. POWER SUPPLY, SOFT STARTER AND CHOPPER CIRCUIT CARD:

The power supply circuit provides the regulated dc power [+/- 12 V] using IC 7812 & 7912 to
the control circuit & +18 V dc unregulated for the pulse amplifier circuit.
The soft starter circuit consists of an integrating amplifier [IC 358]. The dc voltage from
ALPHA POT is applied to this circuit which slowly charges & discharges the capacitor with a
predetermined rate set by the presets P1 & P2 (ACCELERATION & DECELERATION).The
slowly changing voltage is applied to the comparators on the control card for generating the
firing angel. The chopper circuit [IC 555] gives a continuous pulse train of 5 kHz (approx.) to
the firing circuitry.

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2. SYNCHRONIZING TRANSFORMERS:
There are three transformers of center-tapped secondary [15 - 0 - 15]. The primaries are
connected to the three phase supply 440V [WITH] or directly through a relay which energizes
with `power on'. Transformer secondary output voltages are available in phase[R+Y+B+] and
180 degree out of phase [R-Y-B-] for all the three phases [R+R-Y+Y-B+B-] these secondary
outputs are the SYNCHRONIZING signals because they synchronize the SCR GATE
PULSES with mains supply.

3. PULSE GENERATING CIRCUIT:

In this circuit secondary voltages are compared with DC voltage (varied by pot.) which gives
a square wave output as a gate pulse. The secondary voltages are applied in a sequence
R+B- Y+R- B+Y- in which the SCRs come into action one after another [1 6 2 4 3 5 for
LAGGING &1 5 3 4 2 6 for LEADING sequence].
The square wave pulses are differentiated, rectified and applied to the Monoshots for
generation of fixed duration pulses for all firing angel positions. They are then chopped by the
continuous pulse train so as to make a bunch of pulses for triggering instead of a single wind
pulse. This reduces the gate dissipation & re-triggers the SCRs which are necessary for
highly inductive loads. Thus we are ready with a bunch of pulse for each half cycle of the 3
phase supply [R+B- etc].

4. PULSE GATING CIRCUIT:

Using diode OR Gates the bunch of each half is coupled to the next half to form a pair of two
bunches. This pair makes SCRs conduct at a time because first bunch is conducting SCR &
is for outgoing SCR & conducting SCR the second is common for incoming SCR. The
sequence of SCRs for incoming & outgoing groups are exactly opposite for positive [lagging]
& negative [leading] sequence of the 3 phase supply.

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5. PULSE AMPLIFYING CIRCUIT:

Pulse available from gating circuit, are at low voltage level. To trigger the thyristor, gate signal
must have sufficient amplitude [2 to 12 volts for different types of SCRs]. So these pulses are
amplified and applied to the thyristors through pulse transformers. Pulse transformers are
also used to isolate control circuit from power circuit

CONVERTER CARD: This card consists of 6 SCRs connected in a fully controlled bridge
circuit configuration. The firing pulses are taken from pulse amplifier.

POWER CARD:-
It consists of Three SCRs & three diodes in half controlled bridge circuit configuration.
as shown in the figure. The GK pulses are internally connected to SCRs with proper
sequence.
3 PHASE THYRISTOR CONVERTER

DC O/P

HALF CONTROLLED BRIDGE CIRCUIT

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TEST POINTS

TP wrt XXX CONNECTION DESCRIPTION WAVEFORM AMPL.

R+ input Sine 15V
TP1 wrt GND INBUILT
Y+ input Sine 15V
TP2 wrt GND INBUILT
B+ input Sine 15V
TP 3 wrt GND INBUILT
R- input Sine 15V
TP4 wrt GND INBUILT
Y- input Sine 15V
TP5 wrt GND INBUILT
B- input Sine 15V
TP6 wrt GND INBUILT
DUTY CYCLE Square wave +12V to -12V
TP 7 wrt GND INBUILT
Collector of Q1 Chopped square wave +12V
TP 8 wrt GND INBUILT
Collector of Q2 Chopped square wave +12V
TP 9 wrt GND INBUILT
Collector of Q3 Chopped square wave +12V
TP 10 wrt GND INBUILT
Collector of Q4 Chopped square wave +12V
TP 11 wrt GND INBUILT
Collector of Q5 Chopped square wave +12V
TP 12 wrt GND INBUILT
Collector of Q6 Chopped square wave +12V
TP 13 wrt GND INBUILT
DC 0
GND INBUILT CONTROL CARD GND

Sine 230V AC
TP 14 wrt GND INBUILT R
Sine 230V AC
TP 15 wrt GND INBUILT Y
Sine 230V AC
TP 16 wrt GND INBUILT B
--- -----
TP 17 wrt GND INBUILT Neutral
Armature Output 500V DC - R LOAD
TP 18 wrt TP19 INBUILT
Voltage 200V DC - MOTOR LOAD
200V DC
TP 20 wrt TP21 INBUILT Field

CAUTION:

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1. Connect proper sequence of 3 phase supply to the converter unit.

2. Use unearthed CRO or power scope white observing waveforms.
3. Do not observe control and power test points waveform simultaneously on CRO.
4. Do not touch the supply pins or output connections when the 3-phase supply is ON.

STEPS:
1) Check all the 3 phase voltages wrt neutral using DMM. [Do not switch on the unit for this
measurement.]
2) Connect 3Phase input supply with 4 wires to the unit at R, Y, B, & N terminals (CHECK
THE COLORS).
3) Switch ON the 3 ph supply. Neon indicators will glow. Any neon not glowing indicates
absence of the phase or fuse blown.
4) Check the phase sequence of R, Y, B using power-scope or unearthed CRO. [Use 10
probes & put CRO on-line trigger mode. Observe two channels at a time & note the
phase difference of 120 degree between them.]
The unit needs the inputs in lagging sequence only -i.e. in R-Y-B, Y lags R by 120 & B
lags Y by 120 This is required for correct synchronization of generated pulses.
5) After correctly connecting the inputs. Switch on the mains.[NEON glows]
6) Keep `ALPHA' POT anticlockwise.
7) Press START button. Red LED ON will glow.
8) Observe TP1, TP2, and TP3 wrt GND and verify their phase difference by using dual
trace CRO. Observe two phases at a time. Keep the CRO in line trigger mode only.
Otherwise you can not see the phase difference.
9) Observe the control outputs TP8 to TP13 wrt GND.
10) Turn the ALPHA pot clockwise & observe the effect of ALPHA pot on each test point.
11) Press STOP button.

PROCEDURE: - (R LOAD)

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1) Connect 3 phase input supply to the unit in proper R-Y-B-N sequence.

2) Connect two 40 W lamps in lamp holders.
3) Keep the ALPHA / SPEED pot at minimum position.
4) Switch on the mains by rocker switch.
5) Press start button, output LED glows.
6) increase the ALPHA / SPEED pot clockwise and observe the output
7) Observe all control test points on CRO as per chart given.
8) Observe output voltage waveform at TP18 wrt TP19 & TP20 wrt TP21.

OBSERVATION TABLE:-
R LOAD.

Pot position Output voltage (V dc)

1
2
3
4
5
6
7
8
9
10

CALCULATION:-
For 3 phase half controlled converter output voltage is given by

3 3

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V dc = Vm (1+Cos)
2
Where Vm = Peak value of phase voltage

= Firing angle.
Calculate output voltage for various values of ALPHA.

OBSERVATION TABLE:-

Firing angle/ ALPHA OUTPUT VOLTAGE Observed Voltage

(degree) CALCULATED

Calculated observed values of output DC voltage are almost same. The minute different may

Be due to variation on supply voltage & errors in taking observation

PROCEDURE: - (MOTOR LOAD)

1) Connect 3 phase input supply to the unit in proper R-Y-B-N sequence.

2) Connect two 40 W lamps in lamp holders.

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3) Keep the ALPHA / SPEED pot at minimum position.

4) Connect 6-pin Jones plug of DC motor to the unit tightly.

5) Switch on the mains by rocker switch.

6) Keep direction switch at FWD position.

7) Rocker switch glows, field on LED glows.

8) Press start button, output LED glows.

9) Wait for motor response increase the ALPHA / SPEED pot clockwise and

observe the motor speed.

10) Fill corresponding readings in observation table.

11) Observe output voltage waveform.

12) Plot graph of speed vs. armature voltage.

13) Now increase the load by using wing nut, Keep o/p voltage constant to 80%

of maximum value & again take the reading as per observation table.

14) Repeat above procedure by keeping direction switch at REV position.

OBSERVATION TABLE:-
MOTOR Load.

Output voltage Speed (rpm)

(V dc) Load (kg)

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OBSERVATION TABLE:-
MOTOR Load.
SAMPLE READING ONLY

Output voltage
Load (kg) Speed (rpm)
(V dc)

1 190 0 1490
2 188 .500 1475
3 186 1000 1450
4 184 1500 1437
5 182 2000 1392

WAVEFORMS:

SYNC.
X MER
OUTPUTS TP1 TO TP3
WRT GND

2 3

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TP4 WRT
CLK
IG3
IG4
IG2
IG6
IG1
IG5 TP6
TP7
TP5
TP8
GND
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-B -R -Y

TP9

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2A
Rectifier
R 120IRN25 X 6 5A
N R Y B To field
N
200 V DC

100 W x 2
C.T.card S1 S2 S3 LAMP

1
1
R 2 5
5A
FIELD
5A Y
1 8
5A B 2
D1 D2 D3
LAMP

2
CONVERTER CIRCUIT

Diode
bridge SYNCHRONISING TRANSFORMER
S C card
rectifier
START

card

4
3 N 1 card
R
0 -13V

STOP

1 5 15V 15V 15V 15V 15V 15V

5

8
8

5
RL1 POWER R+
R-
4 8 SUPPLY Y+
Y_
+ /- B+
N
12 V B-
RECTIFIER
R+ R- Y+ -Y B+ B-

Cosine
+12V GND -12V comparator Diff G2 K2
F/B
VTG I/P R+ MONOSHOT CHOPPER diode OR
SET REF VTG
REF VTG PULSE
-5 TO +5
GENERATOR
REF VTG

VTG SWING
CARD WITH AMPLIFIER G4 K4
F/B CONTROL 3 NOS
POT

CKT

6 NO. OF ABOVE BlOCKES ARE USED

[ R+, R- ,Y+, Y-, B+, B-] G6 K6
-12

CHOPPER O/P

3 PHASE CONVERTER DC DRIVE (1HP)

Half-controlled bridge converter with R load

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B SCR1
D1 SCR2
D2 SCR3
D3 RL