Honeywell AC, DC Reference Manual

38-00016-01

AC and DC Chokes

M35201

R

S

T

L

AC

C

DC

U

V

W

R

S

T

C

DC

M35202

U

V

W

L

DC+

L

DC-

in Variable Frequency Drives

TECHNICAL REFERENCE MANUAL

INTRODUCTION

The power structure of a conventional AC drive consists of
three stages. The first stage rectifies the AC supply voltage
into DC voltage. The second stage, the DC link, has a
capacitor in order to filter out voltage ripple and to provide
stable DC voltage for the third stage to operate. The third
stage is the inverter which converts the DC voltage back to AC
voltage using IGBTs (insulated Gate Bipolar Transistors), to
create a pulse width modulated voltage waveform. This
voltage drives a current approximating a sine wave in the
motor.

Additionally, chokes are usually required to be used. They are
needed to shape the input current that is drawn from the
supply and for stability reasons to minimize the influence from
the supply impedance. In shaping the input current, they also
lessen the stresses to the DC-link capacitor, increasing its
lifetime.

In general, the chokes can be placed either on the AC or on
the DC side of the rectifier as presented in Fig. 1 and 2,
respectively.

The AC chokes are placed in each of the three input phases of
the rectifier while the DC chokes are placed in both legs of the
DC link.

The reduction of peak currents does not greatly depend on the
choice between the choke types. The main benefits of using
DC chokes are the somewhat better attenuation of current
harmonics and the smaller voltage drop caused by the
chokes. However, drives using DC chokes need to have
sufficient protection against mains transients.

REDUCTION OF THE HARMONICS

The main reason for using chokes is to add series impedance
to reduce harmonics and stresses on capacitors. This is
achieved with both types of chokes.

The input current waveforms for both choke types are shown
in Fig. 3. The values have been simulated with equal
component values (Ldc/bus = Lac/phase = 400 μH,

C

= 700 μF).

dc

350

PHASE

300

250

200

I (A)

150

VOLTAGE

I_AC
CHOKE

I_DC
CHOKE

Fig. 1. Main circuit topology with AC chokes.

100

50

0

0,001 0,003 0,004 0,005 0,007 0,008 0,009

0,000

t(s)

MCR35203

Fig. 3. Input current waveform comparison between AC

and DC Chokes.

DC chokes produce somewhat better performance in reducing
harmonic currents. With DC chokes, the theoretical level of
current THD that can be reached is 32% while for AC chokes

Fig. 2. Main circuit topology with DC chokes.

the theoretical level is about 37%. (These theoretical levels
are calculated with an infinite inductance.)

AC AND DC CHOKES IN VARIABLE FREQUENCY DRIVES

MCR35204

0

20

40

60

80

100

120

1

5 7 11 13

PERCENT

OF

FUNDAMENTAL

HARMONIC ORDER

IEC61000-3-12

AC CHOKE

DC CHOKE

MCR35205

460

480

500

520

540

560

580

0,58

0,585 0,59 0,595

DC

VOLTAGE

(V)

t(s)

AC
CHOKE

DC
CHOKE

The better harmonic performance of DC chokes is evident in
the lowest harmonic frequency. The DC choke attenuates the
5th harmonic, which is by far the largest contributor to the
overall THD, considerably better than AC chokes. In the case
of the 7th harmonic, the attenuation is also slightly better with
DC chokes.

The AC chokes reduce the higher order harmonic
components better, but these are less significant for the
overall performance than the 5th and 7th harmonic.

While generally the overall harmonic reduction does not differ
greatly between the choke types, a notable disparity is caused
due to requirements placed by the new IEC 61000-3-12
standard (Electromagnetic compatibility: Limits - Limits for
harmonic currents produced by equipment connected to a
public low-voltage systems with input current > 16 A and ≤ 75
A per phase).

The fulfillment of the requirements of the IEC 61000-3-12
standard is achieved more cost effectively with a DC choke
than an AC choke due to the difference in harmonic reduction
capability especially with the fifth harmonic.

Fig. 4 shows harmonic composition of input current
waveforms presented in Fig. 3 and the limit values of IEC
61000-3-12.

Voltage drop across an AC choke reduces the input voltage to
the rectifier and consequently the generated DC voltage and
thus the maximum voltage that can be supplied to the motor.
The voltage drop is usually in the range of 2–3%. This
problem is nonexistent with DC chokes. They do not
significantly reduce the voltage available for the motor as they
have an effect only on the ripple in the voltage and not on the
overall DC-voltage level.

In Fig. 5, the DC-link voltages for the case of Fig. 3 are shown.

Fig. 5. DC-link voltage waveform with AC and DC chokes.

The consequent effect on voltage harmonics is almost similar
with both choke types. The normal voltage harmonic level is
usually 2–3%. The total voltage harmonics level is only about

0.02% higher with AC chokes than with DC chokes in case of
a fairly stiff supply. Considering only voltage harmonics, the
difference between the choke types is practically nonexistent
in normal installations.

Additionally, the displacement power factor DPF is better with
DC chokes (0.99) than AC chokes (0.97).

VOLTAGE DROP AND LOSSES

A notable difference between AC and DC chokes is their
impact on the voltage drop of the drive.

Fig. 4. Input current spectrum and IEC 61000-3-12.

On the other hand, AC chokes can be added to drive systems
later, but the voltage drop and additional losses cannot be
compensated if they are not taken into consideration in the
drive design.

The voltage drop due to AC chokes can be partly
compensated by using larger capacitance in the DC link,
which limits voltage ripple and thus enables higher voltage to
the motor.

THE PROTECTION OF THE RECTIFIER

Other equipment connected to the supply system can cause
transients and spikes to the drive input. The semiconductor
components of the front-end rectifier may thus be subjected to
voltage spikes and current surges.

In this case, the major advantage of AC chokes is the inherent
protection of the rectifier components against the supply
transients. The AC chokes reduce the voltage and current
stresses of the rectifier. However, it must be noted that they do
not offer protection against very fast or high transients.

When DC chokes are used, the protection must be provided
by other means. Fortunately, this can be done by using e.g.
RC snubber and metal oxide varistors (MOVs) that protect the
rectifier components against input transients. In addition,
semiconductors rated for higher voltages need to be used in
the rectifier.

The protection against ground faults can be achieved with
both types of chokes. This requires that DC chokes are
installed in both sides of the DC link.

38-00016—01 2