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Low Voltage Modular Multilevel Converter Submodule For Medium Voltage Applica-Tions
Low Voltage Modular Multilevel Converter Submodule For Medium Voltage Applica-Tions
PCIM Europe 2019; International Exhibition and Conference for Power Electronics, Intelligent Motion, Renewable En-
ergy and Energy Management; Proceedings of
Low Voltage Modular Multilevel Converter Submodule for Medium Voltage Applica-
tions
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Abstract
Modular multilevel converters have been subject to various research topics in the area of medium voltage
conversion. The basic building block of all modular multilevel converters is the submodule, which despite
being simple in terms of its topology, poses significant integration challenges when it comes to practical
implementation. This paper provides an insight into the structure, design considerations and operation of
the modular multilevel converter low voltage submodule for medium voltage applications. Special attention
was paid to the submodule specific power and control parts, which were all experimentally tested, with all
results being presented in the paper.
1 Introduction
IGBT module
HB1 HB2 half-bridge
Hybrid Balancing VSM +15V GD1 +15V
CSM GD3
full-bridge
& Discharge
sw GD1 sw GD3
Flyback fault GD1 GD GD fault GD3
HR
ASPS Hybrid
Balancing GND GD1 GND GD3
THYB RELB OVD
T IGBT v HB1
+
Q1 Discharge v HB2
+15V GD2 +15V
R1 GD4
sw GD2 sw GD4
fault GD2 GD GD fault GD4
Q2 4
PS fail
sw THY
sw REL
OV
R2
+5V
+80V
+15V
i br
GND
+5V +3.3V
GD1..4
sw THY
sw REL
PS fail
T IGBT
V HB1
V HB2
OV
LDO
i br
Fig. 2: MMC Submodule structure. Parts hosted at the Control PCB are labeled yellow.
Fig. 3: Developed MMC Submodule: Power PCB (Top), Control PCB (Bottom)
bank is realized as a parallel connection of three of the SM within the range of ±7 V, three passive
capacitor branches, each one of them consisting of balancing resistors of 62 kΩ are mounted in
a series connection of two 1.5 mF capacitors, giving parallel with each SM capacitor. Experiments (c.f.
the equivalent capacitance of CSM = 2.25 mF. Fig. 4 (top)) have proven that this arrangement of
Employment of series connection of 450 V resistors provides the balancing function, yet with
maximum rated capacitors within the SM, demands the cost of prohibitively high power losses (30 W at
the insulation coordination being conducted for VSM =650 V).
maximum expected SM voltage of VSMmax =900 V. Another approach was to consider hybrid balancing
Furthermore, appropriate control and protective with the aim of reducing power losses, while
measures have to be taken in order to ensure that preserving balancing performance. As shown in
capacitor voltage does not exceed the limits. As Fig. 2, it consists of Active Balancing (AB) circuit
expected, the problem of voltage sharing between introduced in [11], reinforced with the two additional
such two capacitor groups arises, therefore hybrid resistors, R1 and R2, in parallel with the transistors
balancing circuitry is utilized. Q1 and Q2, respectively. Those two resistors aim
to prevent over-voltages across the accompanied
3.3 Hybrid balancing circuit transistors, as well as to serve as a backup solution
in case of fault of any of the transistors within
Initially, simple and well known passive balancing the AB circuit. Under the faulty terms, additional
circuit was considered and implemented in the resistors take over the role of passive balancing
design. In order to maintain the voltage difference circuit.
between the upper and the lower capacitor banks Experiment with hybrid balancing was conducted
4 Control PCB
Control logic of the SM is accommodated at the so-
called Control PCB. Layout of the Control PCB is
presented in Fig. 3, from which several mutually
independent circuits can be identified: Auxiliary
Submodule Power Supply (ASPS),SM’s main
Fig. 4: Thermal images of the passive (top) and hybrid
balancing (bottom)
controller, gate drivers’ circuits, SM’s protection
logic and fiber-optic communication link (FOL). By
(c.f. Fig. 4 (bottom)), and the power consumption means of board-to-board connectors, which provide
was measured to be 4.7 W. Therefore, hybrid both mechanical support and electrical connection,
balancing shows great advantage over the passive Control PCB is mounted on the top of the Power
balancing method in terms of significant power PCB.
consumption reduction for the same balancing
performance, without penalizing the circuit reliability 4.1 Auxiliary Submodule Power Supply
and cost.
In order to simplify insulation requirements in the
surrounding of the SM, as well as due to the
3.4 Voltage and current measurements simplicity of implementation, a Flyback converter
with multiple outputs, supplied from the SM’s
Voltage and current measurements within the SM capacitor, was chosen as a solution for the ASPS.
are hosted at the Power PCB. Current sensing (ibr in Its simplicity lies in the fact that a single switch
Fig. 2) is realized with Allegro ACS759 Hall-effect- controls multiple transformer’s secondary outputs
based linear current sensor with 100 µΩ internal by means of cross-regulation. Flyback transformer
resistance, having the performance optimized at is realized as a planar transformer with PCB
3.3 V. Measured current values are passed on to integrated windings, and hosts seven secondary
the SM’s main controller. windings in total. Feedback voltage used in
Voltage measurements are performed at the three regulation is a +5 V output, which is further on
specific points within the SM: SM capacitor voltage regulated to +3.3 V by means of Linear Dropout
(VSM in Fig. 2), as well as the Half-Bridge (HB) Regulator (LDO), for the purpose of the SM’s
voltages of the IGBT module with respect to SM main controller supply. Another secondary output
ground (VHB1 and VHB2 in Fig. 2). Measurements provides +15 V, used as a self-supply to the
are performed by means of resistive voltage main Flyback PWM controller. Apart from this
dividers, and adjusted to match the 3.3 V range, secondary, four +15 V secondaries with floating
suitable to the SM’s main controller. HB voltage grounds supply the four IGBT gate drivers. Proper
measurements are of particular importance to the insulation coordination between upper and lower
SM’s protection logic, as they provide feedback gate drivers was considered. Protection trigger
4.4 SM Protection
5 Power test
Protection of the SM is realized by means of anti-
parallel thyristors, providing the temporary bypass, Finally, scaled down power test of the SM is
and permanent bypass implemented with bi-stable conducted (limited due to ratings of the used power
relay. Once the faulty condition is detected within supplies). SM capacitor bank was connected to the
the SM, its main controller issues the command constant DC power supply, whereas an inductive
for protection activation. At first, bypass thyristor load was connected to its power terminals. This test
module is activated, and its primary role is to aimed to verify the functionality of the SM’s main
provide temporary path to the branch current controller, gate drivers, and IGBT module. Fig. 7
until the relay closes its contacts, thus providing shows the pulse-width-modulated output voltage as
permanent bypass of the SM. well as the SM output current. Bipolar modulation
SM is also protected against an excessive voltages is implemented, and test is conducted at SM rated
across its power terminals. It is realized utilizing voltage, with the switching frequency of 1 kHz. Even
transil OVDs, which go into the breakdown once though the switching frequency was higher than the
the voltage across the SM’s terminals exceeds one intended for the SM regular operation, it was
VSMmax =900 V. Over-voltage detection results in possible at the cost of reduced output current during
both bypass thyristor and relay activation. the test.
Acknowledgment
[7] D. Weiss, M. Vasiladiotis, C. Banceanu,
This research project is part of the Swiss N. Drack, B. Odegard, and A. Grondona,
Competence Center for Energy Research “IGCT based Modular Multilevel Converter
SCCER FURIES of the Swiss Innovation Agency for an AC-AC Rail Power Supply”, in PCIM
Innosuisse. Europe 2017; International Exhibition and
Conference for Power Electronics, Intelligent
Motion, Renewable Energy and Energy
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