AU2011203353B2 - Variable frequency drive system apparatus and method for reduced ground leakage current and transistor protection - Google Patents

Abstract

A method of reducing ground leakage current in a VFD system comprising: floating a neutral point on a DC bus of the VFD, and disposing an electrically insulating plate which has high thermal conductivity, a low dielectric constant, and high dielectric strength between a VFD power semiconductor module and a cooling plate. LL-I C)N

Description

AUSTRALIA Patents Act 1990 SMC ELECTRICAL PRODUCTS, INC. COMPLETE SPECIFICATION STANDARD PATENT Invention Title: Variable frequency drive system apparatus and method for reduced ground leakage current and transistor protection The following statement is a full description of this invention including the best method of performing it known to us:- This application is a divisional application of Australian Patent Application No 2005339694, the contents of which are incorporated herein by reference. BACKGROUND OF THE INVENTION 5 [01] Conventional sinusoidal AC voltage supplies provide only fixed motor speed and are unable to respond quickly to changing load conditions. With the advent of variable frequency drives (VFDs), a better performing motor at lower energy costs can be achieved. VFD driven motors rapidly respond to changing load conditions, for 10 example in response to shock loads. VFD driven motors provide precision torque output and continuous speed control, as well. Because of their many advantages, the utilization of VFDs in industrial applications continues to grow. [02] A conventional medium voltage VFD driven motor system is described below 15 with reference to Fig. 1. The neutral point N 26 of the DC bus 20 is grounded to protect the transistor switches from potential voltage spikes that would cause insulation degradation and component failure. The heat sink plate of transistors in the inverter bridge is also grounded, however, the ground connection is not shown in Fig. 1. Fig. 2A illustrates grounding of the inverter bridge transistor module via the heat sink plate 20 126 and is described below in greater detail. Again referencing Fig. 1, three phase cables 30 are connected at one end to the output terminals 52 of the VFD 50. Cables 30 have an inherent capacitance per unit length. The total cable capacitance is shown as Ce 32. These cables feed the motor M 40, which also has capacitance due to windings, shown as CM 42, and motor impedance shown as Zm 44.

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(031 Fig. 3A is a schematic circuit 300 representation of a conventional VFD driven motor system, for example the drive system shown in Fig. 1. Switch S 60 represents the voltage transitions output from the VFD 50. Upon closing of switch S 60, a voltage transition, from grounded neutral to the positive 22 or negative 23 potential on the DC bus 20, output from the VFD 50 is imposed upon the circuit 300. Ground leakage current loNO 200 flows freely in the ground connection with the voltage transitions due to the motor capacitance Cm 42 and the cable capacitance Cc 32. Inverter bridge capacitance, Ct 62, is connected from the neutral point N 26 to equipment ground PE 70 and to true earth ground TE 80 in parallel with the short circuit of the neutral point N 26 connection to true earth ground TE 80. In this conventional configuration because CIB 62 is in parallel with the short circuit connection to ground, CIB 62 contributes negligibly to ground leakage current. [041 Because of their high performance and lower power consumption, VFDs are desirable in a variety of demanding applications, to include fan and pump loads. However, use of VFDs in medium voltage applications can be complicated if low ground leakage current is necessary. Low ground leakage current can bc necessary in potentially explosive environments or in environments requiring reduced electromagnetic interference (EMI). High frequency ground leakage currents, up to the MHz range can lead to EMI, for example in radio receivers, computers, bar code systems, and vision systems. [05] One example of an application requiring low ground leakage current is underground mining; the underground mining environment has unique requirements and safety standards. Underground mining motors are preferably in the medium voltage range (between 690 V and 15 kV) and are typically driven at 4,160 V. A conventional medium voltage VFD providing a 4,160 V output can yield a ground leakage current IGND 200 in excess of ten amps, which flows from the VFD 50 to the motor M 40 in the grounding wire. While using a medium -2voltage motor facilitates the use of smaller cables, the maximum permitted drive to motor ground wire leakage current [oND 200 can be below 1 Amp. [061 Unlike conventional AC sinusoidal motor drives, VFDs output voltage transitions on the time order of microseconds. Consequently, large ground leakage currents are induced due to capacitances CM and Cc, inherent in a VFD driven motor system, even at relatively low voltages, for example 690 volts. Referring to Fig. 3A, disconnecting the neutral point N 26 of the DC bus 20 from TE ground 80 appears to be a viable means of reducing ground leakage current. A schematic representation of disconnecting the neutral point N 26 from ground in a conventional VFD system 302 is shown in Fig. 3B. As shown in Fig. 3B, disconnecting the neutral point N 26 of the DC bus from TE ground 80 changes the circuit model for ground current leakage current, IGND 202. Inverter bridge capacitance, CI 62, is now in series with the parallel combination of cable capacitance Cc 32 and motor capacitance Cm 42. This results in higher impedance for the ground leakage current due to the decrease in total system capacitance. However, disconnection of the neutral point N 26 from TE ground 80 leaves transistors S, -S 12 in the inverter bridge susceptible to voltage spikes. 1071 Disconnecting the neutral point N 26 of the DC bus from TE ground 80, leaves the transistors floating relative to the neutral point N 26 of the DC bus. Voltage spikes at full DC bus potential can be applied across the transistors in the inverter bridge. Referring to Fig. 2A, these voltage spikes are transmitted between the transistors' semiconductor substrate 122 and the transistors' heat sink plate 126 across thin insulator 124. 1081 For lower drive voltages, available transistors rated above the difference between the positive and negative DC bus can be employed in a VFD system having the neutral point of the DC bus disconnected from TE ground and left floating. This configuration is successfully -3employed for example in SMCs Microdrive 2,300 V model'. However, when higher VFD voltage output is needed or desired and when transistors rated at the full DC bus potential are not practical, protecting transistors from full DC bus potential spikes is necessary to prevent reduced component life and component failure. Multiple 5 challenges exist for VFD drive applications. One challenge, for example, is to reduce leakage ground current while protecting the VFD, in particular the inverter bridge. Another challenge is to reduce ground leakage current as much as possible. [09] For other applications, the challenge is to provide a reliable VFD system for motors rated at greater than 4160 V. For, example for a motor rated at greater than 10 4160 V, a VFD providing an output of 6.9 kV output is desirable. However, presently available transistors to build a VFD with a 6.9 kV output are susceptible to compromised transistor insulation and impending component failure. A DC bus rated at 11.5 kV is needed to achieve a VFD output of 6.9 kV. Inverter bridge transistors are available at an insulation rating of 5,100V. Even when the neutral point of the DC bus 15 is grounded, the transistor module insulation 124 (Fig. 2A) breakdown voltage (5,100 V) is less than half the potential on the DC bus (11.5 kV). Yet another challenge in VFD systems is to protect the inverter bridge comprising available transistors connected in series to provide VFD output voltages greater than 4160 V when transistors are rated at less than half of the DC bus voltage. 20 [10] Throughout this specification the word "comprise", or variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps. [11] Any discussion of documents, acts, materials, devices, articles or the like which 25 has been included in the present specification is not to be taken as an admission that any or all of these matters form part of the prior art base or were common general knowledge in the field relevant to the present invention as it existed before the priority date of each claim of this application. 30 4 SUMMARY [12] Described embodiments provide a method of increasing dielectric strength of a power semiconductor in a variable frequency drive (VFD) system comprising: disposing an electrically insulating plate which has high thermal conductivity, a low 5 dielectric constant, and high dielectric strength, an insulator and a heat sink between a VFD power semiconductor module and a cooling plate; wherein an output voltage of said VFD system is greater than or equal to 690 V. [13] Described embodiments provide a variable frequency drive (VFD) system comprising: an inverter bridge, of a VFD power semiconductor module, electrically 10 connected to aDC bus; an electrically insulating plate which has high thermal conductivity, a low dielectric constant, and high dielectric strength; and a cooling plate; wherein the VFD power semiconductor module is mounted on an insulator, a heat sink and on the electrically insulating plate, having high thermal conductivity, a low dielectric constant, and high dielectric strength; wherein the insulating plate is mounted 15 on the cooling plate; wherein the cooling plate is grounded; and wherein an output voltage of said VFD system is greater than or equal to 690 V. [14] For example, the insulating plate may be a ceramic material or may be made of boron nitride. In some embodiments, a capacitance may be formed across the electrically insulating plate between the VFD power semiconductor module and the 20 cooling plate, and said capacitance between the VFD power semiconductor module and the cooling plate may be less than inverter bridge transistor internal capacitance to ground, and a total capacitance to ground of the VFD system may be reduced. [15] In some embodiments, the VFD system may further comprise at least one mounting device which enables electrical insulation and thermal conduction between 25 the VFD power semiconductor module and the grounded cooling plate and secures the VFD power semiconductor module to the insulating plate and secures the insulating plate to the grounded cooling plate. [16] Described embodiments provide a variable frequency drive (VFD) system comprising: a DC bus which has a grounded neutral point; and VFD power 5 semiconductor modules, wherein transistor modules of an inverter bridge are connected in series, the inverter bridge is electrically connected to the DC bus, and an insulation of transistor modules is rated at less than half of a full maximum DC bus voltage rating; an electrically insulating plate which has high thermal conductivity, a low dielectric 5 constant, and high dielectric strength; and a grounded cooling plate, wherein the VFD power semiconductor modules are mounted on an insulator, a heat sink and on the electrically insulating plate, having high thermal conductivity, a low dielectric constant, and high dielectric strength; wherein the insulating plate is mounted on the grounded cooling plate; wherein an effective insulation capability to ground of the VFD system is 10 increased, and wherein an output voltage of said VFD system is greater than or equal to 690 V. For example, said output voltage of said VFD system may be greater than or equal to 4160 V. [17] Some embodiments provide decreased ground leakage current in a VFD driven motor system, while protecting the inverter bridge. 15 [18] One or more of the described embodiments may: reduce ground leakage current in a VFD driven motor system; reduce the ground leakage current by floating the neutral point of the DC bus; float the neutral point of the DC bus while protecting the VFD from component failure due to voltage spikes; 20 increase the impedance for ground leakage currents; further reduce ground leakage current in a medium voltage VFD driven motor system without decreasing system capacitance to ground; decrease the total capacitance to ground of a VFD motor driven system; decrease the total capacitance to ground of a VFD motor driven system by 25 means of a high dielectric strength and low dielectric constant plate disposed between the VFD transistor module heat sink plate and a grounded cooling plate; and 6 improve inverter bridge reliability and component life in a VFD system having transistors rated at less than half of the full DC bus potential by means of additional effective insulation when the neutral point of the DC bus in the VFD is grounded. [19] Exemplary embodiments can be used in low, medium, and high voltage drive 5 applications. [20] In an apparatus according to exemplary embodiments, the neutral point of the DC bus is floating, disconnected from ground. [21] In an apparatus according to further exemplary embodiments, an electrically insulating plate having high thermal conductivity, high dielectric strength, and a low 10 dielectric constant is thermally and electrically connected between the transistor semiconductor substrate and the cooling plate. [22] In an apparatus according to further exemplary embodiments, a common mode filter is installed at the output of the VFD. [23] A method in accordance with some embodiments comprises floating the neutral 15 point of the DC bus and increasing the impedance of the ground leakage path by means of a dielectric substrate. [24] Another method in accordance with some embodiments comprises increasing the impedance of the ground leakage path by means of a dielectric substrate and also increasing the dielectric strength of the transistor module of the VFD to greater than the 20 full DC bus voltage. [25] Another method in accordance with further embodiments comprises floating the neutral point of the DC bus, increasing the impedance of the ground leakage path by means of a dielectric substrate, and installing a common mode filter across the three phase drive cables in a VFD system. 25 [26] Other features and advantages of the embodiments may become apparent to one skilled in the art from the following description in view of the accompanying drawings. 7 BRIEF DESCRIPTION OF THE DRAWINGS [27] Fig. 1 shows a conventional VFD driven motor system. [28] Fig. 2A shows grounding of an inverter bridge across the transistor module's insulating plate and resulting inverter bridge capacitance, according to a conventional 5 VFD system. [29] Fig. 2B shows the series connection of the inverter bridge to ground across the transistor module's insulating plate, the module's heat sink plate, and the electrically insulating, high dielectric strength, low dielectric constant, and high thermal conductivity plate according to some embodiments of the present invention. 10 [30] Fig. 3 A shows a schematic representation of a ground current loop in a conventional VFD system, as shown for example in Fig. I , to include the capacitance of the inverter bridge. [31] Fig. 3B shows a schematic representation of a VFD system having a floating neutral point on the DC bus in the absence of one or more features of described 15 embodiments. [32] Fig. 4 shows a schematic representation of a ground current loop in a VFD system implementing exemplary embodiments, showing the capacitance of the transistor module and the capacitance of the low dielectric constant insulating plate. [33] Fig. 5 shows further exemplary embodiments comprising a common mode filter 20 installed on the three phase drive cables. [34] Fig. 6 shows exemplary embodiments of a mounting means which enables electrical insulation and thermal conduction between the VFD power semiconductor module and the grounded cooling plate and secures the VFD power semiconductor module to the insulating plate and secures the insulating plate to the grounded cooling 25 plate. 8 DETAILED DESCRIPTION [35] Described embodiments reduce ground leakage current by allowing the neutral point N of the DC bus to float without exposing the transistors 5 in the inverter bridge to excessive voltage spikes. [36] Turning first to Fig. 2 A, the conventional grounding of an inverter bridge in a transistor module is shown. Grounding of the inverter bridge is via the transistor module's heat sink plate 126. A capacitance CIB 62 is formed between the semiconductor substrate 122 and the heat sink plate 126 across the thin insulating plate 10 124. The semiconductor substrate 122, the thin insulating plate 124, and the heat sink plate 126 collectively form a conventional VFD power semiconductor module, also commonly referred to as a VFD transistor module. The heat sink plate 126 is then mounted on and electrically connected to the grounded cooling plate 130. [37] Fig. 2B shows grounding of an inverter bridge in accordance with exemplary 15 embodiments. The transistor module's semiconductor substrate 122, insulating plate 124 and heat sink plate 126 are connected together as in the conventional grounding means of Fig. 2A. However, according to an exemplary embodiment, an electrical insulator plate P 175 having high dielectric strength, low dielectric constant, and high thermal conductivity is mounted between the heat sink plate 126 and the grounded 20 cooling plate 130. The heat sink plate is typically made of aluminum silicon carbide. However, the heat sink plate 126 need not be made of aluminum silicon carbide; a material providing good electrical conduction and thermal conduction would be an adequate substitute. [38] The inverter bridge semiconductor substrate 122 is thermally connected to and 25 electrically insulated from the cooling plate 130 via plate P 175. Because the dielectric constant of insulating plate P is low, a small capacitance Cp 176 is formed between the 8a transistor module's heat sink plate 126 -and the cooling plate 130. This capacitance is smaller than and is in series with the transistors internal capacitor Co 62 (Figs. 2A, 2B, and 4). Capacitance CIe 62 is a byproduct of the capacitive coupling between the semiconductor substrate surface 122 and the transistor heat sink plate 126, which are insulated from each other with the thin insulator 124, as shown in Fig. 2A. [391 Referring to Fig. 3A, in the conventional inverter bridge, grounding the neutral point N 26 of the DC bus 20 and grounding one end of C[B 62 to the same TE ground 80 creates a path to the DC Bus for displacement currents generated at every pulse transition. This grounding prevents one transistor from affecting another transistor in the inverter bridge. More particularly, removal of the neutral point N 26 grounding of the DC bus 20 causes one side of CIB 62 to be floating relative to the neutral point N 26 of the DC bus, as shown in Fig. 3B, which allows displacement current crosstalk between transistors in the inverter bridge via respective transistor capacitances, CB 62, which are interconnected via cooling plate 130. This crosstalk can cause excessive voltage spikes between the transistor module's semiconductor substrate 122 and its heat sink plate 126 that can lead to component failure. 1401 It is known by those skilled in the art that modular or isolated base high voltage IGBT transistors require the neutral point of the DC bus to be grounded. Such grounding ensures that the maximum voltage between the transistor terminals and the cooling plate is no more than half of the maximum DC bus voltage. If the neutral point is disconnected from ground, the capacitor, which is formed between the transistor module's semiconductor substrate and its heat sink plate, Cw is still grounded on the cooling plate 130 side. The inverter bridge capacitance is now, floating relative to the DC bus positive and negative voltages 22/23 and is electrically connected to the other transistors' internal capacitances, Cm 62, in the inverter bridge via the grounded cooling plate 130. When the transistors which are attached to the -9positive voltage of the DC bus are turned off, the semiconductor substrate is connected directly to the positive voltage of the DC bus. Then, when the transistors connected to the negative voltage are turned on, this causes internal transistor capacitances, CrB 62, to be charged at the negative voltage potential of the DC bus. Because one side of all of 5 the transistors' respective internal capacitors, QIB 62, are connected together, the semiconductor substrate of the transistors connected to the positive voltage are subjected to the full DC bus voltage. In the typical case, the full DC bus voltage is substantially higher than the transistor's insulation voltage rating and damage to the transistor occurs. 10 [41] Fig. 4 shows a schematic representation 304 of exemplary embodiments of a VFD system incorporating an insulating plate P 175, as shown for example in Fig. 2B. The insulator plate capacitance Cp 176 is now in series with CB 62. The insulator plate capacitance, Cp 176 is connected to the TE grounded cooling plate 130. The series capacitance of CI B and Cp provides higher impedance for the return path to the voltage 15 source V 140, decreasing ground leakage current IGND 204. The insulating plate P 175 (Fig. 2B) also serves to increase the insulation strength between the cooling plate and the power semiconductor. Total system capacitance Csys is decreased as described by equations I and 2 corresponding to the circuit shown in Fig. 4. First, in equation 1, we define the capacitance of the VFD, CvFD. [42] - c)*(C ) * (C ) (C, + Ci) [431 Csys ((c + CM)* CVFD) (2) (CC +CM +CVFD) 20 [44] The decrease in total system capacitance Csys in turn reduces the ground leakage current IGND 204 from the voltage transitions at the output of the VFD according to equation 10 [45] I = Csrs*(dV (3) dt 1461 The following experimental data shown in Tables 1 and 2 was obtained in the presence and absence of an exemplary embodiment of the present invention and confirms the effectiveness thereof. Table 1 summarizes the data obtained under control conditions. The VFD module is a 4160 V output Microdrive (SMC Electrical Products, U.S. Patent No. 6,822,866). The motor is a 500 HP induction motor rated at 4000 V or less. Ground current measurements were made for three phase shielded cable lengths of 30, 250, and 1300 feet. Ground current was continuously measured at the output terminals of the VFD and at the motor. The VFD was switching at I kHz, and the motor speed was maintained at 30 percent. Control measurements could not be made with the neutral point N of the DC bus disconnected from ground and floating in the absence of an insulating plate P 175, as depicted in Fig. 3B. Disconnecting the neutral point N from ground left the transistors of the inverter bridge only protected by thin insulator 124, resulting in component failure due to crosstalk, as expected and as discussed above. A 1.5 pF capacitor was connected in series from the neutral point N to ground and in parallel with Cs, to serve as a very high impedance path, providing more protection than an open circuit. The 1.5 hF capacitor provides a high impedance path for the neutral point to ground without sacrificing the inverter bridge. Table I summarizes the control data obtained without the insulating plate P 175. Current values in Tables 1-3 are RMS. -11- [471 Table (1) GROUND CURRENT MEASUREMENTS FOR 30, 250, and 1300 ft. CABLES (Amps) Without Boron Nitride Plate 30' 250' 1300' @Drive 4.7 18.0 138.3 @Motor 2.3 2.0 3.7 [481 Table 2 summarizes experimental data obtained using an exemplary embodiment of the present invention. The test conditions were the same as those of the control conditions, above, with the following test modifications. An insulating plate P 175 was installed between the heat sink plate 126 and the cooling plate 130 (as shown in Figs 2B and 6). The neutral point N of the DC bus was disconnected from ground and floating. In this exemplary test embodiment, the insulating plate P is ceramic made from boron nitride. Fig. 4 is a schematic representation of the test conditions summarized in Table 2. 1491 Table (2) GROUND CURRENT MEASUREMENTS FOR 30, 250, and 1300 ft. CABLES (Amps) WITH Boron Nitride Plate 30' 250' 1300' @Drive :]0.7 1.1 5.5 @Motor 0.5 0.3 0.4 [501 Additional experimental measurements were made for the system according to another exemplary embodiment, comprising a common-mode filter (CMF 150), shown for example in Fig. 5. The CMF 150, transformer and resistor ballast, is installed across the three phase cables connecting the VFD output to the motor. Acquisition of the data below in Table 3 was made with a 500 HP induction motor running at 50 percent of full speed. All other test conditions were the same as those employed to acquire the test data summarized in -12- Table 2. The VFD was switching at frequency of 1 kHz. Ground current measurements were made at the output terminals of the VFD and at the motor. Current values shown are RMS, as above. [51] Table (3) 5 GROUND CURRENT MEASUREMENTS 250 ft CABLES (Amps) WITH Boron Nitride Plate NoCMF CMF @Drive 5.2 0.05 @Drive 0.8 0.05 [52] As seen from the data in Table 3, above, ground leakage current is reduced to a 10 negligible amount, 50 mA, with installation of the boron nitride ceramic plate and the CMF according to another exemplary embodiment. [53] While boron nitride plates were used in the exemplary embodiments for experimental data acquisition described above, other oxide and nitride materials or other insulating substances that have the desired dielectric and thermal properties 15 described herein can be used. For example, synthetic diamond plates can be used which have the desired dielectric properties and excellent thermal conduction. [54] Installation of the insulation plate 175, as shown in Fig. 2B, enables the use of transistors rated at less than half of the full DC bus potential in building a reliable VFD system with the neutral point of the DC bus grounded. For example, for a motor rated 20 at greater than 4160 V, a VFD providing an output voltage greater than 4160 V, for example 6.9 kV, is desirable. DC buses rated at 11.5 kV are readily available for use in VFDs and are adequate to provide a VFD output of 6.9 kV. Transistors to build the inverter bridge are readily available at a rating of 5,1 OOV. Even when the neutral point is grounded, the transistor insulation (i.e., element 124 in Fig. 13 2A) breakdown voltage (5100 V) is less than half the full potential on the DC bus 11.5 kV. Installation of insulating plate P 175, as shown in Fig. 2B, with sufficient dielectric strength as described above, increases the effective insulation of the inverter bridge transistors analogous to the effect of CP in series with CIB versus Cia alone. The increased insulation improves component life and system reliability. Therefore, installation of the insulation plate P 175 enables multiple transistors to be connected in series (shown for example in Figs. 1 and 5, SI-SI 2) and cooled by a common cooling plate 130 (shown for example in Fig. 2B) to achieve a higher output voltage VFD system at low cost using presently available transistors, rated at below half the full DC bus voltage, while maintaining the benefits of a single grounded cooling plate. 1551 Fig. 6 shows an exemplary embodiment of a mounting means which enables electrical insulation and thermal conduction between the VFD power semiconductor module 50 and the grounded cooling plate 130 and secures the power semiconductor to the insulating plate 175 and secures the insulating plate to the grounded cooling plate 130. The VFD power semiconductor module 50 (also shown in Figs. 2A and 2B) is securely mounted on the insulating plate 175, which is securely mounted on the grounded cooling plate 130 by means of L shaped steel brackets 180. Brackets 180 are fastened directly to the cooling plate 130 on one end and secure the VFD power semiconductor module via set screws 182 and ceramic pellets 184 on the other end. 1561 Fig. 6 shows only one exemplary embodiment of many possible means for securing the VFD power semiconductor module and the insulation plate to the cooling plate. The bracket can be made from any material having sufficient strength to support the clamping forces required by the transistor module specifications. One ordinarily skilled in the art will readily appreciate the various ways of physically securing the VFD power semiconductor -14module to the insulating plate and the insulating plate to the cooling plate while permitting the electrical insulation and thermal conduction capacities of the insulation plate to be realized. 1571 In summary, reduction of ground leakage current in a VFD system is desirable for multiple reasons in numerous application environments. An electrical insulator plate having high dielectric strength, low dielectric constant, and high thermal conductivity mounted between the VFD power semiconductor module and the grounded cooling plate is an effective means of reducing system capacitance thereby reducing ground leakage currents induced with the high frequency voltage shifts of a VFD. Installation of the insulator plate described above protects the transistors in the inverter bridge from insulation breakdown by increasing the insulation between the VFD power semiconductor module and ground. [581 While the present invention has been particularly shown and described according to exemplary embodiments herein, it will be understood by those skilled in the art that various changes can be made in form or detail without departing from the spirit and scope of the invention as defined by the following claims. -15-

Claims (9)

1. A method of increasing dielectric strength of a power semiconductor in a variable frequency drive (VFD) system comprising: 5 disposing an electrically insulating plate which has high thermal conductivity, a low dielectric constant, and high dielectric strength, an insulator and a heat sink between a VFD power semiconductor module and a cooling plate; wherein an output voltage of said VFD system is greater than or equal to 690 V. 10

2. A variable frequency drive (VFD) system comprising: an inverter bridge, of a VFD power semiconductor module, electrically connected to a DC bus; an electrically insulating plate which has high thermal conductivity, a low dielectric constant, and high dielectric strength; and 15 a cooling plate; wherein the VFD power semiconductor module is mounted on an insulator, a heat sink and on the electrically insulating plate, having high thermal conductivity, a low dielectric constant, and high dielectric strength; wherein the insulating plate is mounted on the cooling plate; 20 wherein the cooling plate is grounded; and wherein an output voltage of said VFD system is greater than or equal to 690 V.

3. The VFD system according to claim 2, wherein the insulating plate is a ceramic material.

4. The VFD system according to claim 2 or claim 3, wherein the insulating plate is made of boron nitride.

5. The VFD system according to any one of claims 2 to 4, 5 wherein a capacitance is formed across the electrically insulating plate between the VFD power semiconductor module and the cooling plate, and wherein said capacitance between the VFD power semiconductor module and the cooling plate is less than inverter bridge transistor internal capacitance to ground, and a total capacitance to ground of the VFD system is reduced. 10

6. The VFD system according to any one of claims 2 to 5, further comprising at least one mounting device which enables electrical insulation and thermal conduction between the VFD power semiconductor module and the grounded cooling plate and secures the VFD power semiconductor module to the insulating plate and secures the 15 insulating plate to the grounded cooling plate.

7. A variable frequency drive (VFD) system comprising: a DC bus which has a grounded neutral point; and VFD power semiconductor modules, wherein 20 transistor modules of an inverter bridge are connected in series, the inverter bridge is electrically connected to the DC bus, and an insulation of transistor modules is rated at less than half of a full maximum DC bus voltage rating; an electrically insulating plate which has high thermal conductivity, a low dielectric constant, and high dielectric strength; and a grounded cooling plate, wherein the VFD power semiconductor modules are mounted on an insulator, a heat sink and on the electrically insulating plate, having high thermal conductivity, a low dielectric constant, and high dielectric strength; wherein the insulating plate is mounted on the grounded cooling plate; 5 wherein an effective insulation capability to ground of the VFD system is increased, and wherein an output voltage of said VFD system is greater than or equal to 690 V.

8. The method according to claim 1, wherein said output voltage of said VFD 10 system is greater than or equal to 4160 V.

9. The VFD system according to any one of claims 2 to 7, wherein said output voltage of said VFD system is greater than or equal to 4160V. 15 1In