A cascaded multivel converter with a common non-isolated DC link

PEA Ruben

A cascaded multilevel converter with a common non-isolated DC link

D. Soto, R. Pea, M. Vasquez and L. Reyes University of Magallanes P.O. Box 113 D, Punta Arenas, Chile dsoto@ona.fi.umag.cl
Acknowledgement This work has been funded by Fondecyt Chile, contract No. 1010939. Keywords: Multilevel converters, Emerging topologies, FACTS.

Abstract
This paper proposes the use of inductors to implement a single DC link interface in a cascaded multilevel converter. The positive DC rails of consecutive converter are connected via a single inductor. This may eliminate the need for separate DC links normally required in applications demanding the exchange of active power. The operation principle of this novel multilevel converter topology is presented in detail and its performance verified both by simulation and experimental results from a 5-level, low power prototype. The current converter rating, compared with a standard cascaded converter, and the sizing of inductors is also addressed.

Introduction
The cascaded multilevel converter consists of a number of single-phase bridge converters (known as H-bridge) arranged as a series string on their AC sides [1]. Each converter module can produce a three-level voltage waveform and the overall converter voltage can contain up to 2 N + 1 different levels, where N is the number of H-bridge converters in the string. Unlike other multilevel converter topologies, the cascaded requires the least number of components (controlled and passive devices) and can be designed in a modular fashion. These advantages arise as a result of the direct connection of the AC-sides of the H-bridges. However, this also requires the DC-side of each H-bridge to be isolated from the others (i.e. isolated or separate DC links). This makes the provision of active power transfer from/to a single supply/load difficult. Because of this, the cascaded converter is more attractive for applications where separate DC links are already available, such as battery storage energy systems, or where the exchange of active power is not required, such as static VAr compensation systems [2]. A common way of providing separate DC links is to use multiple rectifiers supplied via isolation transformers from the grid [3]. This configuration is been increasingly used in industry. Alternatively, bi-directional DC-DC converters can be used, but this involves a second conversion stage thus increasing the device number and overall converter losses. In this paper the use of interface inductors to directly interconnect the DC links of all the modules of the converter is proposed. Figure 1 shows the proposed cascaded converter with an inductor to interface the DC links of both H-bridge converters in the string. Like the standard cascaded converter, the two modules in Figure 1 implement a 5-level converter. This can be extended to any number of modules by using additional H-bridge converters and inductors. The inductor is placed between the positive rails of two consecutive modules, hence all DC-links become interconnected. This allows the bi-directional flow of energy from the AC-side to DC-side of each converter module, and therefore from the AC-side of the overall converter to a single DC link, thus dispensing with the need of separate DC links and isolation transformers. This may facilitate the implementation of converters that

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ISBN : 90-75815-07-7

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A cascaded multivel converter with a common non-isolated DC link

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H1 swa1 is swb1 vo1 sw'a1 sw'b1

iL2 + vL2 L2 swa2 C1 sw'a2

H2 swb2 vo2 sw'b2 C2

idc

+ vdc -

vo

+ -

Fig. 1 Proposed cascaded multilevel converter with DC link interface reactors (case of a 5-level converter) involves the conversion of active (real) power. Thus, the proposed converter is potential for medium and high power applications using back-to-back configurations such as drives and FACTS controllers that exchange active power with the line. In this paper, the principle of operation of this novel converter topology is explained in detail. A simplified mathematical model of the converter is developed to investigate the underlying commutation process and to derive the basic relationships between converter voltages and currents. The model is based on the switching function that represents the states (on or off) of the converter switches. From this model, the steady state operation of the converter is characterised. Simulation results, from a 7-level PSpice model, and experimental results, from a 5-level prototype, are also presented.

Principle of operation of the proposed converter

Figure 2 shows the definitions of voltages, currents and power flows for the modelling and analysis of the k-th module of an N-module string. The following assumptions and simplifications are made: Capacitor voltages, vCk , are ripple free; Voltages and currents in the converter may contain a DC and an AC component at the fundamental frequency (higher order terms due to switching are neglected); Inductors and converter losses are neglected.
k

H k 1
swak 1 swbk 1

iLk
Lk

Hk
Pk swak swbk ak Ck bk

i Lk +1
Lk +1

H k +1
swbk +1

Ck 1

+ vCk 1
isk is

+ vCk

P( k +1) swak +1

Ck +1

+ vCk + 1

+ vok Pik

isk +1

Fig. 2 A section of the converter showing the k-th H-bridge converter.

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ISBN : 90-75815-07-7

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A cascaded multivel converter with a common non-isolated DC link

PEA Ruben

For simplicity, the converter is controlled using the multi-carrier phase shifted method [4]. Therefore, the switching functions of the switches swak and swbk can be approximated by, neglecting high order harmonics: s ak 1 m + sin wt 2 2 and sbk 1 m sin wt 2 2 (1)

where sbk and sak are the switching function representing the states of the switches swbk and swak , respectively, and m and w are the modulation index and modulation frequency (in rad/s) of the PWM. Considering Fig. 2, the voltage across the (k+1)-th interface inductor, Lk+1, is the voltage difference between the voltages across the upper switches swbk and swak +1 :

vLk +1 = (1 sbk ) vCk (1 sak +1 ) vCk +1

(2)

Because the switches are controlled according to a sinusoidal PWM given by (1), the voltage across each switch has a DC component, equal to half the DC link voltage, and an AC component of fundamental frequency proportional to the DC link voltage and the modulation index. Thus, the DC component of the voltage difference between the DC link of the k-th and (k+1)-th modules (e.g. H1 and H2 in Fig. 1) is zero if capacitor voltages are balanced. Therefore, as far as the DC component is concerned, the DC links are in a parallel-like connection. The inductors provide a virtually zero impedance path for the DC component, thus ensuring a well-balanced DC link. The voltage difference also contains an AC component but the inductor can effectively block this component. The proposed converter preserves most of the characteristics of the standard converter. For example, each converter module contributes a fraction (1/N) to the overall converter voltage and to the net power exchanged by the converter (if the standard converter is equipped with multiple DC-links). However, there are also important differences in terms of the currents and powers that flow through each module. To investigate this, a model of the commutation process of the converter currents is developed in next section. From this, generalised expressions for the current through each inductor and the flow of power through the various ports of the module are derived.

Modelling and steady-state analysis

The use of KLC on the positive rail of each converter module and across dotted line k in Fig. 2 yield the following equations:

Ck

dvCk = sak isk sbk isk +1 + iLk iLk +1 dt dv C N dc = saN isN sbN is + iLN idc dt

k = 1,.., ( N 1) k=N k = 1,.., N

(3) (4) (5)

isk = is iLk

In using (3) to (5), it should be noted that: the first module of the string does not require an inductor. Therefore, iL1 = 0 and is1 = is . Similarly, the negative AC terminal of the last module is the return path for the line current, then isn+1 = is . Using (5) in (4) and (5), it follows that:

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A cascaded multivel converter with a common non-isolated DC link

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Ck CN

dvCk = ( sak sbk ) is + (1 sak ) iLk (1 sbk ) iLk +1 dt dvdc = ( saN sbN ) is + (1 saN ) iLN idc dt

k = 1,.., ( N 1) k=N

(6)

(7)

Replacing (1) in (6) and (7), and then taking the DC components, it can be shown that for steady state operation, (6) and (7) can be written as:

I Lk +1 = I Lk + I L 2 I dc = I Ln + I L cos where I L = m I s

(8) (9)

In (9), I dc is the DC current drawn from/by the single DC supply/load, located at the last module of

is the peak amplitude of the line current (considered to be sinusoidal) the string (e.g. H2 in Fig. 1), I s
and is the angle between the overall output converter voltage, vo , and the line current. Calculating ILN from (8) (considering that IL1 = 0), and then using this result in (9) to express I L in terms of I dc , it is found that each module, with the exception of the last module of the string, contributes 2 I dc / N to the DC current flowing down the string. The mean current through the k-th inductor, Lk, can be expressed as:

I Lk =

2 (k 1) I dc N

k = 1,...., N

(10)

The AC links between converter modules provide the returns paths for the inductor currents. Thus, the input current, isk, hence devices current, increases for converters down the string.. As can be seen from Fig. 2, each module not only exchanges power from/to its AC-side (Pik in Fig. 2), as in the standard converter case, but it also exchanges power with the previous converter module of the string (Pk). It should be noted that in Fig. 2, power flows, Pk, Pk+1 and Pik, are defined with reference to the AC negative terminal of the converter (bk). The active power exchanged by the k-th module through its AC side can be calculated as:

Pik =

1 1 vok isk dt = vok (is iLk ) dt T 0 T 0

(11)

Considering balanced DC link voltages, hence balanced AC-side voltages, the inductor ripple current will be in quadrature with the output voltage of each converter module. Therefore, the active power absorbed/supplied by each module from/to its AC side is 1/N of the power absorbed/supplied by the overall converter. Therefore, the active power exchanged with the previous module is given by:

Pk =

(k 1) Pdc N

k = 1,..,N

(12)

where Pdc is the net power supplied/absorbed by the overall converter.

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ISBN : 90-75815-07-7

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A cascaded multivel converter with a common non-isolated DC link

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Converter rating and sizing of inductors

In examining device ratings and inductor requirements it is useful to express the voltage and current in a per unit form. For easy comparison, the rated voltage and rated current of a standard cascaded converter, of the same effective power rating and number of modules as the proposed converter, are chosen as base values for the per unit system.

Inductors
The required inductance, in per unit value, can be calculated as:

L'k =

1 I
' ripple

k = 1,..,N

(13)

' is the allowable RMS inductor ripple current expressed as a fraction of the base current. where I ripple

In (13), L'k =

Lk Lbase

Lbase = Z base / w

Z base = Vbase / I base

where Vbase and Ibase are the rated converter voltage and current of a standard cascaded converter. Inductors must be rated according to (10). This yields (14) in per unit value.
' I Lk = 2 (k 1)

k = 1,..,N

(14)

The peak energy stored in an inductor is chosen as merit index because it reflects a combined measure of both the inductance and the current rating of the inductor. The total energy stored in the interface 2 ), inductors, as a function of the energy stored in the base inductor at rated current (i.e. Lbase I base shows that the total inductor requirements increases with the square of the number of modules.

Devices
Positive leg devices of the k-th converter module require a current rating of k in per unit. Devices of the corresponding negative leg require a current rating of (k+1) in per unit. Exception must be made in the case of the negative leg of the last module of the string, which is rated at the base current (i.e. 1.0 per unit). In comparing device ratings, the total VA rating required by a converter is useful. As converters have the same ratings and number of modules, the voltage ratings of devices are similar in both converters. Therefore, the total VA rating required by the proposed converter compared to that of a standard cascaded converter, or alternatively to its own nominal VA rating, increases with the number of modules.

Capacitors
In the proposed converter, capacitor ripple voltage is dominated by a component at the fundamental frequency that results from modulating the mean inductor current according to (1). Sizing of capacitors is dictated by this component. Therefore, considering (10), the required capacitance increases as the capacitor locates further down the string.

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A cascaded multivel converter with a common non-isolated DC link

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In a single-phase standard cascaded converter, the size of capacitors is dictated by second harmonic ripple current. For the same ripple current, the smallest capacitance in the DC link of the proposed converter is at least twice as much as that on the DC link of the standard cascaded converter (frequency of the capacitor ripple current reduced by a factor of two). Therefore, the required capacitance on the DC link of the k-th module is:

Ck = 2 C k

k = 1,..,N

(15)

where C is the capacitance of the DC link capacitor of the standard cascaded converter (assumed to be all of the same capacitance). Note that (15) is not in per unit value. Because capacitors have the same voltage as that in the standard cascaded converter, the total stored energy in the DC link capacitors, expressed in terms of the total stored energy in the capacitors of the standard converter, increases with the number of modules.
' is limited to a small In obtaining the previous results it was assumed that ripple current I ripple

fraction (e.g. 1/10) of the rated converter current (base current) and therefore its effects on inductor and device ratings are neglected. Modulation index, m, was set to unity. Therefore, according to (9), the amplitude of I L can be as high as 2 I base . It should also be pointed out that (15) is a rough approximation given only for comparison purposes. The previous results indicate that the proposed converter does not compare favourably to the standard cascaded converter because, in addition to inductors, it requires a significant increase in device rating and in capacitance of the DC link (even if the number of modules if kept low). Therefore, the benefits of having a common DC link must be carefully weighed against the device over-rating and the increase in capacitance of the DC link capacitors.

Simulation results
To validate the previous analysis and verify the operation of the proposed converter extensive simulations were carried out using a PSpice model of a 7-level converter. The converter supplies an R-L load, connected on its AC, side from a battery (i.e. operates as an inverter). Figure 3 shows the overall converter voltage and the load current. As can be seen from this figure, the voltage and current are almost 180 degrees out of phase, with the converter supplying active power to the load. The voltage waveform clearly shows 7-different voltage levels with an equally spaced voltage step, hence well balanced DC link. This is confirmed in figure 4, which shows the DC link voltages for this operation condition. The capacitor voltages have small drift from the battery voltage. This small voltage drop is because of the inductor resistance. The DC component of the battery, capacitor C2 and capacitor C1 voltages are 104.0 V, 100.4 V and 98.3 V, respectively. Figure 5 shows the inductor currents and one of the inductor voltages. The other inductor voltage is similar to that in figure 5 but it is not shown for clarity. For comparison, the DC component of the DC supply current is included in this plot. As seen in Fig. 5, the voltage across the inductor is a 3-level sinusoidal PWM waveform and the inductor currents have a DC and an AC component. The DC values of the inductor currents are -1.50 A and -3.10 A. Considering that Idc = -2.35 A, the DC values of the inductor currents are very close to those predicted by (10) (i.e. 2/3 and 4/3 of Idc). This validates the analysis regarding the inductor currents. For completeness, the voltage across each converter module and the current drawn by its corresponding terminal ak (i.e. isk) are shown in figure 6. As can be seen, converter currents of the second and third modules contain a DC component. This confirms the view that the links between the AC terminals of the modules are also the return path for the inductor currents.

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ISBN : 90-75815-07-7

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A cascaded multivel converter with a common non-isolated DC link

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450V

7.5A

vo is

150V

100V

vdc vC2 vC1

0V

0A 50V

-450V

-7.5A

3.96s

3.97s

3.98s
Time

3.99s

4.00s

0V

3.96s

3.97s

3.98s
Time

3.99s

4.00s

Fig. 3 Overall converter voltage and load current (7-level case)

Fig. 4 DC link voltages

150V

150V

7.5A

vL2
-150V 150V -150V 450V 7.5A -150V

vo1

is

-7.5A 7.5A

vo2 iL2
-7.5A 7.5A

is2

Idc iL3
3.98s
Time

150V

vo3

is3
3.97s 3.98s
Time

-450V

-7.5A

3.96s

3.97s

3.99s

4.00s

-150V

-7.5A

3.96s

3.99s

4.00s

Fig. 5 Inductor voltage, inductor currents and DC supply current.

Fig. 6 Voltage and current at each converter module.

Experimental results
A single-phase 5-level prototype was built to experimentally verify the operation of the proposed converter both in the rectifier and inverter mode. For the inverter mode, the converter supplies an R-L load, connected at the AC-side of the overall converter, from a single DC voltage source. In the rectifier mode, the converter is connected to 70 VAC, 50 Hz grid via an interface inductor of 16 mH. The DC load is a 30 ohms resistance connected at the DC link of the last converter module. The DC link voltage is set, in each case (rectifier and inverter), approximately to 50 V DC. The converter modules use IGBTs as switching devices operating at a switching frequency of 1 kHz. The IGBT PWM gate control signals are generated in an FPGA. The system is controlled from a DSP, which generates the modulation signals (required by the FPGA) synchronous to the grid. A user interface with a PC host allows modulation index changes and/or phase shifting of the modulating signals. The interface inductor and capacitors are of 120 mH and 20.000 uF, respectively. Figures 7 to 9 show the voltages and currents waveforms for inverter operation mode. Figures 10 to 12 show similar waveforms but for the rectifier operation mode.

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A cascaded multivel converter with a common non-isolated DC link

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Scales: 20 V/div, 2 A/div

Scales: 20 V/div, 2 A/div

Fig. 7 Overall converter voltage and load current (inverter mode)

Fig. 10 Overall converter voltage and current (rectifier mode)

Scales: 20 V/div, 2 A/div

Scales: 20 V/div, 2 A/div

Fig. 8 Inductor voltage and current (inverter mode)

Scales: 20 V/div, 2 A/div

Fig. 11 Inductor voltage and current (rectifier mode)

Scales: 20 V/div, 2 A/div

Fig. 9 Voltage and current at converter H1 (top traces) and converter H2 (bottom traces) for the inverter mode.

Fig. 12 Voltage and current at converter H1 (top traces) and converter H2 (bottom traces) for the rectifier mode.

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A cascaded multivel converter with a common non-isolated DC link

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Fig. 7 and 10 show the overall converter voltage and converter current for the inverting and rectification mode, respectively. As can be seen from these figures, in both cases, the converter voltage shows a 5-level voltage waveform with an apparently equal voltage step (50 V approximately). In the case of Fig. 7, the current, like in simulations (Fig. 3), is almost 180 degrees out of phase with respect to the converter voltage (the flow of power is from the DC link to the AC-side of the converter and the power factor is close to unity). The current in rectification mode (Fig. 10), in agreement with power flow from the AC to the DC side of the converter, is almost in the opposite direction with respect to that in Fig. 7. Fig. 8 and 11 show the inductor voltage and current for the same conditions as those in Fig. 7 and 10. As expected, in both cases, the inductor voltage is a 3-level voltage waveform and the inductor current contains a DC component and ripple at the fundamental frequency. As required by a power flow from the DC link to the AC-load, the mean inductor current in Fig. 8 is negative. In contrast, the mean inductor current for the rectifier case is positive (Fig. 11). In general, the results in Fig. 7, 10, 8 and 11 confirm the ability of the proposed converter to operate with a bi-directional flow of power from/to a single DC link and to maintain the balance of the DC link. Fig. 9 and 12 show the voltage and the AC-side input current at each converter module. Converter voltages are, as expected, 3-level PWM voltage waveforms. The input current to the second module contains, in addition to the fundamental current, a DC component. Measurements confirm that mean value of this current is equal in magnitude but opposite in direction to the mean inductor current. As predicted, for the 5-level case, the DC component is equal to the DC current drawn from the DC source. A close examination of the PWM voltage waveforms in Fig. 9 and Fig. 12 reveals that the amplitude of the first converter voltage is slightly different to that of the second converter. This is because of unequal capacitor voltages (unbalance was measured to be approximately 6 V, i.e 12% at 50 VDC). This is due to the low voltage level used in the experimental system. Experimental results, unlike simulation results, were affected by converter losses.

Conclusions
A novel multilevel cascaded converter that eliminates the need for separate DC links of the standard cascaded converter has been proposed. This novel converter topology uses inductors to interconnect the DC links between consecutive modules of the series string. This interconnection enables the bidirectional power flow with a single non-isolated DC link. The feasibility of the proposed converter was verified both by simulation and experimental results. Notwithstanding the low power level involved in the experimental prototype, the results confirms the good performance of the converter in terms of DC link voltage balance and the ability to transfer active power from/to a single DC link. The proposed converter requires, in addition to inductors, an increase in the current rating of switching devices and in the capacitance of the DC link capacitors. However, the use of interface inductor to implement a single DC link should not be ruled out. Preliminary results using inductors both in the positive and negative rails of the DC links indicate that there is not over-rating or capacitor size disadvantage compared to the standard cascaded converter. In addition, the inductor size can be significantly reduced if positive and negative rail inductors are magnetically coupled. This may facilitate the implementation of converters for applications that require the exchange of active power from/to a single AC or DC supply. Thus, the use of inductors in cascade converter to eliminate the need of isolated DC links becomes potential for medium voltage applications, such as adjustable speed drives, and higher power applications, such as FACTSs controllers that requires the exchange of active power with the line.

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A cascaded multivel converter with a common non-isolated DC link

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References
[1] J.-S. Lai, and F.Z. Peng, "Multilevel converters - A new breed of power converters", IEEE Transactions on Industry Applications, Vol. 32, No. 3, May/June 1996, pp 509-517. [2] F.Z. Peng, J.-S. Lai., J. McKeever, and J. VanCoevering, "A multilevel voltage-source inverter with separate DC sources for static VAr generation", IEEE Transactions on Industry Applications, Vol. 32, September/October 1996, pp 1130-1138. [3] P.W. Hammond, "A New Approach to Enhance Power Quality for Medium Voltage AC Drives", IEEE Transactions on Industry Applications, Vol. 33, No 1, January/February 1997, pp 202-208. [4] J. Kuang, B. T. Ooi, "Series connected voltage-source modules for force-commuted SVC and DCtransmission , IEEE Transactions on Power Delivery Vol. 9, N 2, April 1994, pp 977-983.

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