E Motors & Industrial Systems DC POWER CONVERSION APPLICATION CLASS and SYSTEM PROTECTION Application Notes Revision History Revision Description ev. 0 Date ‘Contributors 12676 [ Re Initial —[Tessendort eK DOCUMENT: GEDS\VOL2:\PROJECTS\GENAPPS\STANDARDI\FAULTS.DOC. OWNER: Tessendorf REV: 0 - JAN 28, 1995GE Motors & Industrial Systems TABLE OF CONTENTS ABSTRACT INTRODUCTION. . THYRISTOR AND FUSE FAILURE MODES... DC DRIVE SYSTEM POWER CIRCUIT....... DC CONVERTER FAULTS... APPLICATION CLASS CONSIDERATIONS APPLICATION CLASS IMPLEMENTATION RULES ..... 12-PULSE CONVERTERS FAULT MODES AND CONVERTER CONFIGURATION... FAULT CURRENT IMPACT ON SYSTEM COMPONENTS... CONCLUSION...Motors & industrial Systems ABSTRACT Users of power conversion equipment often refer to IEEE 444-1973 to specify a converter protection class, but may not appreciate that the standard Is subject to Interpretation by the supplier. Details of this interpretation include thyristor failure modes, fuse fallure modes, types of faults considered likely to occur and device utilization, In addition to converter reliability, motor and transformer Integrity are also Impacted by the level and duration of fault currents permitted by the suppliers implementation of the standard. it is not sufficient to specify converter protection without conskieration of system level protective devices and functions. This paper will Identify implementation rules that meet the intent of the IEEE 444-1973 application classes, propose modem alternatives and discuss the level of system protection provided by these approaches, INTRODUCTION Individual interpretation has made the practical implementation of IEEE 444-1973 vary between suppliers, while technological advances have made some of the past practices outmoded. However, the intent of each application is included in the opening sentence describing the class and can still be considered valid: (1) Class | applications require the most relieble converter designs to minimize down time, end normally utitze large high-power converters. (2) Class 1! applications require the most rellable converter design to minimize down time, but ‘generaly utilze smaller converters then class | applications so that the overall economics do ‘not justly all the protective functions. (3) Class i! applications require good continuity of service, but generally in @ less critical ‘service requirement than class 1! epplications, (4) Class IV applications usually involve converters where close coordination between thyristors and fuses cannot be economically achieved. As wittten, the standard only addresses converters for dc motor armature supplies, but the intent can be extended to ac drive systems as well, ‘We will begin by addressing thyristor and fuse failure modes. THYRISTOR AND FUSE FAILURE MODES ‘The reliability of the converter system design is impacted If all of the device failure modes and operational characteristics are not considered. The standard indicates that converter thyristors and fuses must be sasily replaced when they do fail, implying that the failure will not be catastrophic. Table 1 describes some of the possible fuse and thyristor failure modes.Faiture | The device can no longer perform Its normal function. Fatigue _| The device characteristics are altered such that fallure could occur during normal operation. [__Metting _| Normal operation of a fuse when tt clears a faut, [_ Rupture _| ‘The device falls catastrophicall, releasing energy in an uncontrofid and unintended manner Motors & industrial Systems Table 1; Fu ‘Suppliers of power conversion equipment ara chatlenged by the variety of terminology and data provided by fuse and thyristor manufacturers, In some instances, rellable test data is simply not available, The following is a general discussion of the terminology associated with fuses and thyristors. ind Thyristor Fallure Modes Fuse suppliers generally publish metting criteria as a range of time-rms current curves. The fuse may melt at time-current values as low as those shown in the minimum curve, and are assumed to have melted by the higher values of the maximum curve. Evaluation of fuse thyristor protection should be based on the longer interruption time maximum meiting curve to ensure the most reliable converter designs. Some fuses do not have published minimum and maximum melt curves. Ifthe power converter designers choose to apply such fuse, they must decide if a derating factor is required or ifthe single value curve should be used as is. Fuse fatigue is defined by derating the minimum metting curva based on the application. High cyclic current loading generally means a larger derating factor than that used for general industry. Device fatigue is not explicily defined in the standard and may not be considered by all suppliers, Fatigue can be subtle when the effect is to change the characteristics such that the device Itself appears defective, Examples might be a fuse that ruptures during normal operation with no fault present, or a thyristor that ‘suddenly falls to block normal voltage levels. ‘The fuss may rupture rather than mett If certaln limiting fuse design parameters are exceeded. These include ampere-squared-time om maximum melt time, and maximum current level. Thyristor failure is generally defined by an (°T value, absolute temperature level and blocking voltage. Fatigue checks are usually related to a thermal duty cycle with some associated probable failure rate. Fault modes considered to be infrequent can withstand higher currents and temperatures for the same probable failure rate ‘than can more frequently occurring fautts, Thyristor rupture is related to a maximum change in temperature or I°T in some relatively short period of time. Analysis of thyristor characteristics requires an analytical model of thermal losses due to current flow versus ‘time, Including the affect on reducing cell blocking voltage, ‘We will limit our discussion to the bridge type power converter circuit, DC DRIVE SYSTEM POWER CIRCUIT ‘The basic 3-phase, 6-puise, full-wave, fulkreversing bridge power converter circuit is illustrated in Figure 1. In IEEE 444-1973 terminology, this is a Form D Converter in which direct current can flow in elther direction and energy can be inverted from the motor to the ac power system. This converter consists of two anti-parallel Form G Converters which can invert energy, but whose direct current can flow in only one direction.Figure 1; Basic 3-Phase, 6-Pulse Bridge Power Converter Circult ‘The thyristors in Figure 1 are labeled by normal firing sequence in the forward and reverse converter. For example, thytstor 1F is the first thyristor gated In the forward converter and is connected to the P or positive de bus, Gating thyristor 2F, which is connected to the MV or negative de bus, completes the normal de current path. Figure 1 will be used later to illustrate possible fault current paths in the converter drive system. Proper use of the device characteristic data permits implementation rules to be defined for each application class. Continuation of the discussion requires that we now consider the fault modes involved. DC CONVERTER FAULTS AA variety of terminology has been used in reference to converter fault modes. Table 2 summarizes the faults ‘that are normally considered in the design of S-phase power converters. The terminology used in our tables is ‘shown on the left, while other equivalent terminology Is listed in the ight hand colurnn, DC Bus Fault Extemal Overioad Cireutating Current AC Bus Fault Internal Shorted Cell Faiture Thytistor Fallure Diametric Conduction DC inversion DC Shoot-Through ‘Commutation Fallure ‘AG Inversion AC Shoot-Through Conduction-Through Table 2: Converter Fault Terminology Motors & Industrial Systems DCCB@ Motors & Industrial Systems Normal device malfunctions are mentioned in the standard and thyristor failure is included as a fautt mode to bbe considered. Fuse melting is always permitted for isolation of a failed thyristor. The highest reliability (class |) designs would not permit the normal failure of one defective thyristor to fall additional thyristors, The discussion of the implementation rules will address this point and distinguish between single and multi-branch converters. Figures 2 through 5 illustrate fault current conduction paths associated with the listed faults, Note that each highlighted fautt path has altemate conduction paths that could be drawn, At this point we also Introduce the ‘concept of using a reactor, commonly known as a "ripple reactor", to ald in de motor commutation and limit fault current, REACTOR Figure 2: 6-Pulse DC Bus Fault ‘The de bus fault of Figure 2 occurs at the motor terminals. Fault current flows from the power system through ‘an ac fuse, forward bridge thyristor, de circult breaker (OCCB), dc contactor (ARM CONT) and ripple reactor (REACTOR) to tha shorted de bus around the de motor (M). If Included as an alr-core devics, the ripple reactor provides additional current limiting Impedance for this fault. The dc load disconnect ARM CONT could be a breaker or contactor, but is generally assumed to be a slower acting device than the DCCB. In some applications only a high speed ARM CONT Is used. ‘The power system includes the utllity feed and the transformer supplying the converter. The fuse used to protect the thyristor could be in the ac line or, as shown, in the converter leg containing the thyristor. This de motor flashover type of fault oocurs due to an insulation breakdown, improper installation, or a maintenance problem, Itis therefore assumed to ocour Infrequenily. ‘The power system contribution to the dc bus fault current of Figure 2 is Interrupted by elther or both of the ac Jeg fuses melting, DCCB or ARM CONT opening, or elther or both of the thyristors blocking when the ac line voltage reverses. Lack of ac fuses and de disconnect devices would require the thyristors ta biock, or an ac disconnect elsewhere in the system to open. Without device intervention, the motor current would most likely flow until the motor and/or converter is destroyed.GE Motors & Industrial Systems ak ARM CONT REACTOR Figure 3: 6-Pulse Circulating Current Fault The circulating current fault of Figure 3 involves the forward and reverse bridges, in this case a thyristor misgating shorts the bridge intemally and the thyristors must survive the fault current until normal voltage blocking occurs, an ac disconnect operates, or a fuse melts. Inspection of the fault circuit indicates that current is limited only by the ac system impedance. Circulating current fautts are assumed to occur more frequently than de bus faults, In practice, this means that the design criteria for maximum thyristor temperature during this fautt would be lower than the level for less frequent faults, such as the dc bus fault. In the highest reliabilty case, where thyristor protection without melting ‘the fuse is the goal, the circulating current fault usual limits the converter rating. This fauft obviously cannot occur in non-reversing converters since both forward and reverse thyristors are required to form the fault path. A similar circuit can be used to evaluate normal thyristor failure. In this case the designer Is verifying that the fuse will melt and clear the fault current before the surviving thyristor fails. The highest reliability designs may also Include a transformer primary ac disconnect in an attempt to minimize fusa blowing. ‘Shorted cells ara also considered an infrequent occurrence,Motors & Industrial Systems Figure 4: 6-Pulse Diametric Conduction wit ‘The diametric conduction of Figure 4 involves only ac leg fuses, forward bridge thyristors, OCCB and ARM CONT and the de motor. If included as an alr-core device, the ripple reactor provides additional current limiting impedance for this faut. ‘This fault occurs when the motor is inverting power and the bridge fails to commutate property. Without a de device to protect the motor against itself, damaging overourrents will occur. For high rellablity, this faut mode requires the control to open the converter DCCB, motor ARM CONT er a de fuse to melt. The ac leg fuse is riot normally designed to operate properly in a purely dc circuit, but is sometimes the only device supplied for general industry applications. Note that ac line fuses and disconnects provide no protection against diametric conduction faults. In addition, thyristor blocking cannot occur since the de voltage will not change polarity. The diametric conduction fault Fequires some type of de disconnect to protect the thyristors and motor. REACTOR Figure 6: 6-Pulze Commutation Fallure Fautt ‘The commutation fauit of Figure S includes contributions from the power system and the motor, Inclusion of a high-speed DCCB makes this less severe than the circulating current fault, provided DCCB removes the ‘commutation fautt current before it reaches its theoretical peak. If included es an alt-core device, the ripple reactor provides additional current limiting impedance for this fault. The motor fault contribution is sls0 normally much less than that of the power system, This is particulary true in many multh-bridge and common transformer applications. Unlike the circutsting current fault, a transformer primary ac disconnect would not interrupt this fault. Even with tha ac primary circuit opened, the motor wil continue to supply fault current through the transformer secondary windings. To be effective, any ac disconnect must be In the transfarmer secondary. ‘These considerations permit us to define general implementation rutes for the actual power converter design.@ APPLICATION CLASS CONSIDERATIONS Motors & Industrial Systems Implementation of the applications classes requires a definition of the terms most reliable, good and economicaly as referenced in the standard. Supplier A's most rellable class | design probably does not have the same reliability as supplier B's most rellable class | design. Fatigue, for example, has been Introduced as cone factor affecting rellabilty, Atthe time the standard was issued, relatively small thyristor power ratings required most class | applications to have muttiple parallel paths or branches. At the present time, a single branch converter can be rated at several ‘thousand amperes de and implies a different class | design criteria than for a mult-branch converter, DccB L ARM. CONT P a Figure 6: €-Pulse Multi-branch Shorted Cell Fault, Non-reversing Converter REACTOR ‘The standard defines the function of fuses in a class | application as reserved for the isolation of defective or misgated thyristor branches. Multkbranch converters, as shown in Figure 6, hava the added possibility of a fault occurring in only one of the conduction paths, The fault current in that single branch could be three or four times the economical rating of tha thyristor and require the fuse to melt to provide protection, in addition, tt may ‘ot be possible to match the fuse and thyristor characteristics in mutti-branch converters, Multi-branch converters share current between thyristors within each bridge according to the fault balance ratio ‘specified for the converter. Application class 1! distinguishes between faults intemal and extemal to the power converter, Short cirouits on the de bus and ac voltage dips and power loss are considered to be extemal faults, Misgatings that occur in the absence of extemal faults are considered intemal fautts, while the failure of a defective thyristor may also cause an intemal fault. t is very dificult to distinguish between an intemal and external misgating, making Glass II a questionable application. We have seen that bus and motor flashovers are true extemal faults that head to be considered, but are usually not the limiting condition, The inclusion of an absolute current level in the standard makes class Il extremely sensitive to the Individual ‘suppller's interpretation. Standard-speed dc load disconnects have been appiied to clear overload currents below the fuse metting level, which rarely corresponds to the referenced five perunit level. Many present day Power converter designers consider the inclusion of the five perunit current level in class Ill to be an error, It may well have been that the real Intent of including the five perunit current level in the standard was to ensure the use of a de disconnect to minimize fuse blowing. We will now consider the application class implementation rules,APPLICATION CLASS IMPLEMENTATION RULES Motors & Industrial Systems ‘The standard defines certain faut conditions and actions taken for class | in.its Tables 4 and 8. These tables and other comments are consolidated Into the simplified Implementation rules below. In the table a YES Permits, but does not guarantee, that the device will perform In the indicated mode, For example, a fuse may be permitted to melt, but can experience ten or twenty faults without actually melting. ‘The difference Is accounted for by the minimum-maximum range discussed earfler. On the other hand, when a fuse Is subjected to numerous short duration, high current faults, it may melt sooner than expected because of fatigue. The fuse manufacturer says the fuse may mett at the minimum level, will metl at the maximum curve level, and may have a change in characteristics with usage. ‘A.NO means that the device is not expected to operate for the fault modes considered in the system design. Variations In device characteristics may resutt In occasional unexpected failures. Description Circulating |Commutatio | Diametric | DC Bus | Shorted Cell Curent | nFailura_| Conduction | Fault Fallure Fuse MAY fatigue -NOT melt] NO. No No No Yes Fuse MAY melt - NOT No No No NO NO rupture Coll MAY fall - NOT rupture No No No No. No. Deseription Circulating |Commutatio | Diametric | DCBus | Shorted Cell Current | _nFallure | Conduction Fault Fallure Fuse MAY tatigue-NOT melt} NO No No. No DNA Fuse MAY melt - NOT NO No No NO YES fupture Coll MAY fail - NOT rupture No No No No Yes ‘Table 3: IEEE Class | Converter Component implementation Rules. Class | is the most reliable power converter design and was intended for critical and/or large horsepower drives, Except for the shorted cell failure, class | does not even permit fuse fatigue for single branch power converters, in mutti-branch converters, fuse melting in unfailed legs can occur when cells fall. This is an attempt to protect the remaining thyristors, but it may not be successful. When a fuse Is permitted to melt, fuse fatigue does not apply (DNA). Class | requires @ high-speed dc load disconnect device to clear certain faults, The ‘standard references breakers, but suitable contactors are now also available for some converter ratings. Note that under none of the design conditions consklared are fuses or thyristors permitted to rupture. Fallures of this type would be due to highly unusual and unforeseen circumstances, Thyristors, like fuses, can also fatigue if subjected to numerous high current, short duration faults. Fatigue failure is generally considered unacceptable and therefore does not appear in the tables, . ‘The table of implementation rules gives the users of power conversion equipment @ clear expectation of fuse ‘and thyristor fife. On critical drives, high horsepower drives, or when the power system is subject to frequent interuptions that can result fn converter faults, selection of class | equipment should ensure maximum ‘equipment uptime,Motors & Industrial Systems ‘Shorted Cell Fallure Fuse MAY fatigue - NOT melt ONA Fuse MAY melt - NOT YES NO NO NO YES rupture: Cell MAY fall - NOT rupture NO. a Ce No 1 ‘Table 4: IEEE Class Il Converter Component Implementation Rules {mn practice, class | and class I! converters have equal thyristor protection. Class Il and higher were generally considered single branch drives, so separate standards were not developed for single and multkbranch converters. Class Il does distinguish itself from class | by permitting fuse melting for intemal faults. From the tuser’s point of view, the distinction between intemal and extemal fauits is ditficutt to make. Deseription Shorted Cell Fallure Commutatio | Diametrie | DC Bus 4 Falture | Conduction Fault Fuse MAY fatigue - NOT melt DNA ONA. DNA DNA _| Fuse MAY melt - NOT Over 5 times | Over 5 times| Over § times | Over § times | Over 5 times rupture fated current | rated current | rated current | rated current | rated current Cell MAY fall - NOT rupture NO no [ no | no No ‘Table 6: IEEE Class It! Converter Component Implementation Rules ‘The class Il appiication permits fuse metting above five (5) perunit fault current, but is designed to protect against thyristor failure and minimize fuse blowing. it does recognize that to achieve thyristor protection, the fuse may be subject to fatigue and require occasional replacement. {in Table 6, the difference between GEDS and class III is that the five (5) perunit current level is dropped as an impractical consideration. Shorted Cal Failure Fuse MAY fatigue - NOT melt Fuse MAY melt - NOT Yes YES YES YES YES rupture Cell MAY fall- NOT rupture | NO NO no | No NO Table 6; GEDS Converter Component Implementation Rules ‘The best reliability class | application requires ac system Impedance and @ high-speed dc load disconnect to prevent ac fuse blowing. The high rellablity GEDS application may use a standard-speed de load disconnect to Teduce the number of ac fuse metting incidents. In this case, the GEDS application is indistinguishable from lass Ill and functionally equivalent to class iGE Motors & Industrlal Systems Diametric Condi Shorted Cait Failure Fuse MAY fatigue - NOT melt Fuse MAY melt - NOT rupture Cell MAY fail - NOT rupture DNA YES Yes Yes Yes YES YES Yes Table 7; IEEE Class IV Converter Component Implementation Rules In class 1V, thyristors and fuses could be viewed as expendable components that are replaced whenever a fauft occurs, Rupture, however, could never be permitted as a design criteria for any class. In practice, loss of thyristors and fuses for every power system disturbance should not be considered an acceptable implementation of class IV. The relatively high incidence of fuse and thyristor fallure allowed along with the targe number of devices involved, makes class IV generally unacceptable for multi-branch applications, ‘Bridge type power converters are available in several configurations that impact the potential fault modes available, 412-PULSE CONVERTERS ‘The Form CiForm D &-pulse converter of Figure 1 can also be configured in 12-pulse pairs as shown in Figure ‘7 below. The reactor is commonly known #s an “interphase reactor" and is not optional. Each of the converters Is fed from different sources that are phase shifted by 30 electrical degrees. The function of the interphase eactor is to isolate the two phase shifted bridge outputs and at the same time provide the means for harmonic cancellation. This action fiters the rectified de, aids motor commutation and limits fault current.