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This article has been accepted for publication in a future issue of this journal, but has not been fully edited. Content may change prior to final publication. Citation information: DOI
10.1109/TIA.2014.2313657, IEEE Transactions on Industry Applications

Development of a 500-kW Modular Multilevel Cascade Convertor for Battery
Energy Storage Systems

Noriko Kawakami
Member, IEEE
Satoru Ota, Hironobu Kon,
Shuji Konno
Toshiba Mitsubishi-Electric Industrial
Systems Corporation (TMEIC)
1 Toshiba-cho Fuchu-shi
Tokyo, 183-8511, Japan
Kawakami.noriko@tmeic.co.jp
Hirofumi Akagi
Fellow, IEEE

Tokyo Institute of Technology
2-12-1, Ookayama, Meguro-ku
Tokyo, 152-8550, Japan
akagi@ee.titech.ac.jp
Hiromu Kobayashi
Member IEEE
Naotaka Okada
Member IEEE
Central Research Institute of Electric
Power Industry (CRIEPI)
2-11-1, Iwado Kita, Komae-shi,
Tokyo 201-8511, Japan
hiromuk@criepi.denken.or.jp

Abstract -- Renewable energy sources such as wind-turbine
and photovoltaic power generators may make the power grid
unstable due to their output fluctuations. Battery energy storage
systems (BESSs) are being considered as a countermeasure for
this issue. A modular multilevel cascade convertor (MMCC) is
expected as a power conversion circuit for BESSs, because each
bridge cell can control the state-of-charge (SOC) of a battery
unit, independent of that of another one, and harmonic current
generated is low enough to eliminate the ac filter, normally
installed on conventional two-level converters, from the MMCC.
This paper describes the development of a real-scale (500 kW)
SSBC (single-star bridge cell) based MMCC for BESSs and
reports successful test results obtained from a downscaled grid
model and a 6.6-kV real-scale distribution line.

Index Terms-- Battery energy storage systems, battery storage
plants, frequency stability, multilevel convertors, power systems,
and pulse-width modulation.
I. INTRODUCTION
In Japan, photovoltaic (PV) power generation systems
have been strongly promoted. By 2012, the accumulated
installations amounted to approximately 6.6 GW, and
national targets for PV installation capacity have been set at
28 GW by 2020 and 53 GW by 2030. However, the output
power of PV systems depends on the weather conditions and
the natural environment, which cause large fluctuations in the
output power, leading to insufficient frequency adjustment
capacity of the power grid. Battery energy storage systems
(BESSs) are being considered as a countermeasure for this
issue, and the installation capacity of BESSs is expected to
increase in the future. "BESSs" require bidirectional ac-to-dc
and dc-to- ac converters. In current actual applications, BESS
converters typically have two-level or three-level topologies
[1] [2]. On the other hand, "a modular multilevel cascade
converter based on single-star bridge cell (MMCC-SSBC)
[3]" has been applied to a 200-V, 10-kW, 3.6-kWh laboratory
prototype BESS, and its control strategy and tactics have
been discussed for the laboratory prototype [4] [5], and a
fault-tolerant control scheme has been proposed and
demonstrated [6]. In reference [7], MMCC and active neutral
point clamped (ANPC) converter topologies were compared
as circuit topologies applicable to BESSs. The authors of [8]
provided an intensive discussion on MMCC topologies that
can be connected directly to ac and dc grids. The authors of
[9]-[13] have presented each bridge cell equipped with a dc-
to-dc converter to mitigate dc voltage variation across each
battery unit and to reduce battery ripple currents.
In the SSBC (single-star bridge cell)-based MMCC
topology, each bridge cell can control the state-of-charge
(SOC) of the battery units independently, and ac filters can
be eliminated from the MMCC because the ac terminal
waveform of the MMCC has very low harmonics. Thus,
MMCC is one suitable topology for BESS converters. The
authors of this paper select an SSBC-based MMCC topology
for a BESS. An optimal design of the number of bridge cells
per phase and the nominal voltage of each battery unit used
bring high efficiency and reasonable cost to the BESS using
the SSBC-based MMCC. This paper develops a 500-kW,
238-kWh BESS employing an SSBC-based MMCC with six
bridge cells per phase as the first step toward actual
applications. It also presents the circuit configuration, control
blocks, and successful test results.
II. SPECIFICATIONS AND CIRCUIT CONFIGURATION
A. Specifications of Battery Energy Storage System
We assumed that the BESSs to be installed in a
distribution line are mainly used for compensating for power
flow fluctuations resulting from output fluctuations of
photovoltaic systems installed in the distribution line, as well
as suppressing any frequency fluctuations in the grid. Table 1
summarizes the main technical specifications of actual
equipment that is expected to be introduced in the secondary
side of distribution substations in the future, as well as
This research has been performed as a part of "Japan Next-generation
Transmission and Distribution Systems Optimal Control Technologies
Demonstration Project", involving 28 entities. This project is partly funded
by the Ministry of Economy, Trade and Industry (METI).
0093-9994 (c) 2013 IEEE. Personal use is permitted, but republication/redistribution requires IEEE permission. See

TABLE I. SPECIFICATIONS OF BATTERY ENERGY STORAGE SYSTEM
Items
Actual
equipment
Verification test
equipment
Power capacity 1000 kW 500 kW
Storage energy capacity 1000 kWh 238kWh
Circuit topology
MMCC-SSBC
Modular Multilevel Cascade Converter
based on Single-Star Bridge Cells
Cascade number 6 6
Capacity of unit cell 56 kVA 28 kVA
DC voltage range 250 V - 380 V
280 V - 380 V
Nominal voltage
331.2V
Output AC voltage of
converter
1500 V 1500 V
Grid side AC voltage 6600 V 6600 V
Power device 600-V, 600-A IGBT
Configuration of each bridge
cell
1-series,
2-parallel, and
4-arm structure
1-series,
1-parallel, and
4-arm structure
verification test equipment. We chose verification test
equipment with sufficient capacity to evaluate technical
issues in actual applications.
B. Main Circuit Configuration
Figure 1 shows the circuit configuration of the verification
test equipment. Six cells, each composed of an H-bridge
IGBT unit and a battery unit, were cascade-connected for
each of the U, V, and W phases to form a single-star bridge
cell (SSBC)-based MMCC. In order to verify cell balancing
control and suppress harmonics, the number of cascades was
chosen to be six. Each cell has a pre-charge circuit consisting
of a switch (SW) and a resistor. The resistor suppresses the
inrush charging current to the dc capacitors of each bridge
cell. After charging dc capacitors from the battery, the main
switch 72P is turned on to connect the battery to the cell. In
this way, it is possible to suppress the peak current which is
caused by the voltage difference between the battery and dc
capacitors even though the battery no-load terminal voltage
varies depending on the SOC of the battery.
The cells are equipped with fuses to limit the short-circuit
current from the battery when a dc short-circuit fault such as
IGBT failure occurs in the bridge cell. To ensure sufficient
fault-ride-through (FRT) capability, the impedance of the
converter transformer was determined to be 8% by numerical
simulations. Considering 10% grid voltage fluctuations and a
5% negative phase sequence voltage, we chose 1500 V as the
secondary side voltage of the transformer so that a rated
power of 500 kW can be output even with the minimum
battery voltage. Figure 2 shows the entire outside view of the
verification converter including converter panels, a
transformer, a circuit breaker for 6600 V side, an auxiliary
power supply, and a control panel. Figure 3 shows the inside
view of converter panels.

Fig. 2. Outside view of the developed equipment

Fig. 1. Main Circuit Configuration
Converter panels
Transformer CB & auxiliary
power supply
Control panel

TABLE II. SPECIFICATIONS OF IGBT UNIT.
Item Specifications
Switching device 600-V, 600-A IGBT two-in-one module
Device topology
1-series, 1-parallel, 4-arm
single-phase bridge
DC voltage
Center voltage 331.2 V
280380 V
(charge/discharge of battery)
Switching frequency 1350 Hz
DC capacitor 30.6 mF
Unit capacitance
constant
60 ms at 331.2 V
TABLE III. SPECIFICATIONS OF LITHIUM ION BATTERY UNIT
Item Specifications
Rated output power 27.8 kW
Rated energy capacity 13.2 kWh
Voltage range
280 V (end of discharge) to 380
V (end of charge)
Nominal battery-unit
capacity
40 Ah
Nominal battery-unit
voltage
331.2 V
C. Specifications of IGBT Unit
Table 2 shows the specifications of the IGBT unit. An
IGBT rated at 600 V was employed as a switching device
because these are widely available on the market.
Considering the turn-off surge voltage, the maximum dc
voltage (battery voltage) of the IGBT unit was set to about
two-thirds of the IGBT rated voltage. Considering the over
current protection design and the cooling design of the IGBT,
600-V, 600-A IGBT two-in-one modules were selected. The
switching frequency was set at 1350 Hz to reduce the
switching loss of the IGBT. The system equivalent switching
frequency for each phase is 1350 Hz 2 legs 6 cells = 16.2
kHz. Through harmonic analysis of the converter output
current, we found that the current harmonics could be
reduced satisfactorily at this switching frequency without ac
output filters.
The IGBTs were mounted on air-cooled heat sinks and
were cooled by fans mounted on the converter panels.
Because IGBT units should be sufficiently insulated from the
ground depending on the voltage resulting from cascade
connection, each unit was fully insulated by insulators.
Dc capacitors are used for suppressing a surge overvoltage
when the IGBTs are switched off and reducing the current
ripple flowing in, or out of, the battery unit.
To suppress the switching surge voltage of the IGBTs, it is
important to reduce the parasitic inductance of the bus bar
between the capacitors and IGBTs. This was realized to
reduce the parasitic inductance by making close contact
between the P-side bus and the N-side bus. The surge voltage
was suppressed below 600 V even when the turn-off current
was 200 % of the rated current.
A current ripple of 1350 Hz flows to the battery and the dc
capacitors according to the ratio determined by the internal
resistance of the battery and the impedance of the dc
capacitors. The capacitance was selected to reduce the 1350
Hz battery current ripple to 5% of the total ripple current. At
the dc side of the H-bridges, a current ripple of 100 Hz, twice
the power grid frequency, is generated. The battery we
selected can tolerate the 100-Hz ripple current. In case of a
battery that cannot tolerate 100-Hz ripple current, a reactor
should be placed between the battery and the GBT unit to
reduce the ripple current.
D. Specifications of Battery
A lithium-ion battery, more specifically, an SCiB
TM

manufactured by Toshiba, was employed as the storage
battery. Each of the battery units is composed of 12 SCiB
TM

modules connected in series. Table 3 shows the specifications
of the battery unit. The 18 battery units as a whole have a
rated output capacity of 500-kW equal to the multilevel
converter, and an energy capacity of about 200 kWh. The
center voltage of the battery is 331.2 V, and the dc voltage
fluctuates from 280 V to 380 V according to the charge-and-
discharge operation and the state of charge (SOC).

Fig. 3. Inside view of the converter panels

Fig. 4. Outside view of the IGBT unit
Insulator

III. CONTROL SYSTEM
This section describes control functions of the developed
MMCC. The control functions are divided into two types of
sub-control. The first one is BESS control that determines the
active power command value of the converter in accordance
with the frequency of the power grid and the SOC of the
battery. The second one is converter current control and SOC
balancing control. Details of each function are described in
the following subsections.
A. Battery Energy Storage System (BESS) Control
Figure 5 shows a control block diagram of the BESS
control. Six major control functions are provided.
1) Central frequency control command value: This
value is transmitted to the BESS from a load dispatch center
of an electric power company.
2) On site frequency control: This block determines
an active power command value according to the frequency
detected by the BESS. If the deviation between a frequency
reference and the detected frequency exceeds a preset dead
band, the controller acts to reduce the frequency deviation.
3) Emergency pre-set power switch control (EPPS):
This control is activated when the detected frequency
exceeds pre-set values and periods. The BESS supplies or
absorbs pre-set power to or from the power grid to decrease
the frequency deviation. This control is expected to act when
the frequency considerably fluctuates as a result of the
demand-supply unbalance over the entire grid due to an
abnormality such as a grid fault.
4) Base power reference: This is a power reference
that is set according to the purpose of basic operation of the
BESS such as load leveling between day and night.
5) Bank power flow compensation control: There is
some concern that the PV systems that are introduced in
residential areas will cause power flow fluctuations in the
distribution network. This control works to reduce such
fluctuations by charging and discharging batteries.
6) SOC control: This system has two SOC control
functions. One is emergency capacity maintaining control,
and the other is SOC reference value management control.
The emergency capacity maintaining control is used to
maintain the battery SOC within a constant range in
preparation for emergency operation, such as EPPS. BESS
stops the operation when the SOC reaches the preset value
while emergency control is not active. The SOC reference
value management control performs charging/discharging
operation to reset the SOC at a preset value when the
command values resulting from other control operations
continue below preset values. The aim of this control is to
secure charge/discharge capacity required for the subsequent
operation of the BESS.
B. Converter Control
Figure 6 shows a block diagram of the converter control,
which is divided into two sub-controls: (1) active power
control, and (2) SOC balancing control.
Active power control controls the output current of the
converter according to the active current command value
from the BESS controller. BESS controls at a power factor of
1.0. The BESS does not have to control the ac voltage using
reactive power because it is installed at a distribution
substation having other voltage control equipment.
The SOC balancing control provides individual SOC
balancing control and phase SOC balancing control. The
individual balancing control aims to balance the SOC of each
battery unit in the same phase. This control corrects the
amplitude of the output voltage command of each bridge cell
to reduce the difference between the average SOC of the
corresponding phase and the SOC of each battery cell. The

Fig. 6. Block diagram of converter control

Fig. 5. Block diagram of BESS control

TABLE . RARINGS OF SCALE DOWN GRID MODEL
Items
Verification
test equipment
Downscaled
grid model
Ratio
Nominal DC voltage 331.2 V 27.6 V 1/12
Converter current 192.5 A 32 A 1/6
Output capacity 500 kVA 6.9 kVA 1/72
Grid side voltage 6600 V 200 V 1/22
Converter side voltage 1500 V 125 V 1/12
Battery energy capcity 238 kWh 19.8 kWh 1/12
phase balancing control aims to balance the average SOC of
each phase. This control adds zero-phase sequence voltage to
the voltage command of each phase to reduce the difference
between the average SOC of all cells and the average SOC of
each phase. This block diagram is based on the same control
theory and method described in reference [5], by extending
the cascade number from three to six.
Both the BESS controller and the converter controller
were arranged in the control panel at ground potential.
The controllers employ DSPs, and PWM (Pulse Width
Modulation) is realized by FPGAs. Gate signals are sent and
insulated by optical fibers to each cell.
IV. VERIFICATION TEST RESULTS
Test results obtained with the developed MMCC will be
described here. Verification was carried out by taking the
following steps.
An H-bridge IGBT unit test: An over-current interrupting
test was conducted using an H-bridge IGBT unit to confirm
that the surge voltage at interrupting over-current does not
exceed the rated voltage of the IGBTs.
Inductor load current test: The 6.6-kV side of the
transformer was short-circuited to cause the rated current to
flow in the converter. Evaluation of the losses of the
converter and the temperature rise were conducted in this test.
STATCOM operation test: With controlling the voltage of
the dc capacitors of the IGBT unit in each bridge cell, the
verification test equipment was connected to the 6.6-kV grid
and operated as a STATCOM. It was confirmed that the
converter can connect to a 6.6-kV real scale grid without
problems.
Downscaled grid model test: To confirm the control
performance such as control during frequency fluctuations
and SOC control, the developed converter was connected to a
downscaled grid model and batteries.
Real-scale distribution line test: The performance such as
the fault-ride-through capability was verified using a 6.6-kV
real-scale distribution line and a 1.6-MVA variable voltage
source at the Akagi testing center of Central Research
Institute of Electric Power Industry (CEPRI).
Representative results of the inductor load current test, the
downscaled grid model test, and the real-scale distribution
line test are described below.
A. Inductor Load Current Test
This test circuit was achieved by connecting an insulated
rectifier to the dc side of each cell, supplying dc power, and
short-circuiting the 6.6-kV side of the transformer. The
converter outputs an ac voltage determined by the output ac
current and the impedance of the transformer. In this test
circuit, a reactive current flows in the converter. To conduct a
temperature rise test and to evaluate losses in the converter,
the reactive current value was corrected to achieve power
losses of IGBT devices equivalent to the losses during
charging/discharging at a power factor of 1.0, which is the
value of actual operation. The conversion efficiency of the
converter at a power factor of 1.0 evaluated and estimated
from the test results (not including the transformer) was
98.2 %. The efficiency at the rated output of the latest three-
level inverter whose dc voltage is in same range is 97 % [14].
The efficiency of the developed converter is about 1 %
higher than the efficiencies of conventional converters under
the same conditions. Employing a modular multilevel
configuration can eliminate ac filters and reduce switching
frequency of each bridge cell. Therefore filter loss and
switching loss of IGBTs can be reduced, the higher converter
efficiency was achieved.
B. Downscaled Grid Model Test
Figure 7 shows the downscaled grid model test circuit.
Table 4 shows ratings of the downscaled grid model test
circuit and the developed verification test equipment.
Although twelve battery units are connected in series for one
cell in the verification test equipment, only one battery unit is
connected in the downscaled grid model test circuit. Thus the
supplied dc voltage was reduced to one-twelfth the voltage of
the verification test equipment. The rated current in the test
circuit was set to one-sixth that of the verification test
equipment.
To evaluate the control capability in the grid disturbances,
three 4-kVA programmable ac power supplies were used to
simulate the power grid. The voltage on the grid side of the

Fig. 7. Downscaled grid model test circuit

transformer was set at 200 V, and the voltage on the
converter side was set at 125 V, one-twelfth of the
verification test equipment, according to battery voltage ratio.
The impedance of the transformer was set at 8 %, equivalent
to that of the verification test equipment. The full scale
developed converter and a control panel, whose feedback
gains were adjusted, were used in the test.
For representative test waveforms, Figure 8 shows
waveforms of the start-up test, Figure 9 shows waveforms of
the EPPS function test, and Figure 10 shows waveforms of
the phase SOC balancing control function test. In Figure 8 (a),
the switches (SW) of the pre-charge circuits were turned on
in response to the start up command, and the dc capacitors in
each bridge ell were charged via pre-charge resistors. After
the charging completed, the main switch 72P, which was
connected in parallel with the pre-charge circuit, was turned
on to connect the battery and the IGBT unit. After that, the
converter synchronized with the system voltage and excited
the transformer with soft-start for preventing an inrush
current which causes disturbances in the system. Then, the
main switch of the ac side 52PR was turned on, and the
converter started the charging and discharging operation in
accordance with the power command. Figure 8 (b) shows
magnified waveforms of the synchronization and turning-on
of the 52PR.
In Figure 9, the frequency of the grid simulator power
supply was increased from 50 Hz to 51 Hz. The detected
frequency exceeds 50.5 Hz, which is the level for activating
EPPS control operation, and after an operation delay time of
1.1 seconds elapses, the converter absorbed 500 kW as the
EPPS preset charge power from the standby mode.
When the frequency recovered to 50 Hz from 51 Hz, the
frequency falls below 50.5 Hz, which is the EPPS control
release level, and after the release delay time of 1.1 seconds
elapses, a charge power of 500 kW is reduced to zero with a
soft stop time of one second.
The operating level, the release level, delay time, and soft
stop time are parameters that can be changed.
Figure 10 shows the phase SOC balancing function test.
The SOC of phase U was pre-shifted up by 10% to check the
SOC balancing control function. The SOC of each phase is
the average SOC of the six cells in that phase. With this

Fig. 9. EPPS function test

Fig. 10. Phase SOC balancing control test

(a) Entire sequence
Fig. 8. Start-up test

(b) Magnified of synchronization

phase SOC balancing control, the differences in SOC among
the phases was gradually decreased, and eventually the
variance in SOC was suppressed to below 0.5%. With this
function, for example, in a situation where one battery unit is
replaced, the SOC can be balanced across the batteries during
operation without having to adjust the SOC of the
replacement battery to the SOC of the other batteries.
In addition to the tests described above, an emergency
capacity-maintaining function test, an SOC reference
management function test, a bank power-flow control
function test and a test including total 19 test items were
conducted, and the results were satisfactory.
C. Real-scale Distribution Line Test
This verification test equipment was installed at the Akagi
testing center of the Central Research Institute of the Electric
Power Industry (CEPRI). The performance test of the entire
BESS including full scale battery units was conducted using
the 6.6-kV real-scale distribution line. Figure 11 shows an
overall external view of the equipment installed at the Akagi
testing center. The batteries were housed in an outdoor
enclosure provided individually for each phase. A total of
three outdoor enclosures were used for batteries. The
converter was housed in one other enclosure.
At the Akagi testing center, tests were conducted with two
test circuit configurations. In test system 1, the distribution
line of the Akagi testing center was connected to the 66-kV
power grid of Tokyo Electric Power Company. With this test
circuit configuration, basic performance tests, such as a
continuous charge/discharge test and harmonic measurement,
were confirmed. In test system 2, a 6.6-kV 1.6-MVA
programmable ac voltage source that can vary the phase and
voltage was used. With this test circuit configuration,
continuous operation performance is confirmed in the
presence of disturbances on the grid side; the items that were
confirmed included the fault-ride-through capability, phase
and frequency jump and distorted voltage.
For representative waveforms, Figure 12 shows a
reference step response test, and Figure 13 shows a fault ride-
through capability test. Both tests were conducted in test
system 2. Figure 12 shows step response waveforms when
the power reference of the BESS is changed from charge at
500 kW to discharge at 500 kW. The response time was
within 20 ms, a sufficiently quick response for a BESS.
Figure 13 shows waveforms of a fault ride-through
capability test (three-phase ground fault with 20% of
remaining voltage and one second duration). The operating
condition was discharge at 500 kW. The developed MMCC
continued its operation. Under this fault condition, power
conditioning systems (PCSs) for photovoltaic power
generation systems that will be connected to the power grid
after March 2017 are required to continue operation under
Japan's Grid Connection Code. At the time the grid fault
occurred, the over-current was about 155%, below over
current protection level of 200%, and BESS continued to
operate.
Fig. 11. Overall external view of the BESS at Aakagi testing center

Fig. 12. Power reference step response test
(charge 500 kW to discharge 500 kW)
Battery U
Battery V
Battery W
Converter

Figure 14 shows a current waveform of the 500 kW
charging operation and its harmonic analysis. The total
harmonic distortion below 20 kHz was 1.37% without ac
filters. This test was performed with test circuit 1.
V. CONCLUSIONS
A 500-kW BESS converter employing a SSBC-based
MMCC with a novel circuit configuration has been
developed. Successful control function test results were
obtained using a downscaled grid model and a 6.6-kV real-
scale distribution line.
Because harmonic specifications can be satisfied by
employing the MMCC circuit configuration without an ac
filter and without having to increase the switching frequency
of the devices, it was possible to reduce device losses and ac
filter losses, achieving a 98.2 % in converter efficiency. The
step response time to the active power reference was
satisfactory at below 20 ms. It was found that operation
continued under various grid disturbance conditions, such as
grid fault conditions with a three-phase ground fault of 20%
and one second duration, ensuring a satisfactory fault ride-
through capability. Thus, we successfully verified that our
BESS converter has satisfactory performance that will be
required for stable operation of a distribution line when a
large number of photovoltaic power generation systems are
connected to the distribution line in future.
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Fig. 13. Fault ride- through capability test
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-80
-60
-40
-20
0
20
40
60
80
0.00 0.02 0.04 0.06 0.08 0.10
C
u
r
r
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[
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[14] The brochure of SOLAR WARE 500U of TMEIC
http://www.tmeic.co.jp/catalog/download.php?id=35

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