Photovoltaics is the utility connected distributed energy resource (DER) that is in widespread use today. It has one element, the inverter, which is common with all DER sources except rotating generators. The inverter is required to transfer dc energy to ac energy. With all the DER technologies, (solar, wind, fuel cells, and microturbines) the inverter is still an immature product that will result in reliability problems in fielded systems. Today, the PV inverter is a costly and complex component of PV systems that produce ac power. Inverter MTFF (mean time to first failure) is currently unacceptable. Low inverter reliability contributes to unreliable fielded systems and a loss of confidence in renewable technology. The low volume of PV inverters produced restricts the manufacturing to small suppliers without sophisticated research and reliability programs or manufacturing methods. Thus, the present approach to PV inverter supply has low probability of meeting DOE reliability goals. DOE investments in power electronics are intended to address the reliability and cost of power electronics. This report details the progress of power electronics, identifies technologies that are in current use, and explores new approaches that can provide significant improvements in inverter reliability while leading to lower cost. A key element to improved inverter design is the systems approach to design. This approach includes a list of requirements for the product being designed and a preliminary requirements document is a part of this report. Finally, the design will be for a universal inverter that can be applied to several technologies. The objective of a universal inverter is to increase the quantity being manufactured so that mass-manufacturing techniques can be applied. The report includes the requirements and recommended design approaches for a new inverter with a ten-year mean time to first failure (MTFF) and with lower cost. This development will constitute a ''leap forward'' in capability that leverages emerging technologies and best manufacturing processes to produce a new, high reliability, inverter. The targeted inverter size is from two to ten kilowatts. The report is organized into four sections. A brief introduction by Sandia is followed by Section Two from Millennium Technologies (a company with UPS experience). Section Three is provided by Xantrex (a PV manufacturing company) and the University of Minnesota provided Section Four. This report is very detailed and provides inverter design information that is irrelevant to the layman. It is intended to be a comprehensive documentation of proven technology and the manufacturing skills required to produce a high reliability inverter. An accompanying report will provide a summary of the recommended approach for inverter development.
Islanding, the supply of energy to a disconnected portion of the grid, is a phenomenon that could result in personnel hazard, interfere with reclosure, or damage hardware. Considerable effort has been expended on the development of IEEE 929, a document that defines unacceptable islanding and a method for evaluating energy sources. The worst expected loads for an islanded inverter are defined in IEEE 929 as being composed of passive resistance, inductance, and capacitance. However, a controversy continues concerning the possibility that a capacitively compensated, single-phase induction motor with a very lightly damped mechanical load having a large rotational inertia would be a significantly more difficult load to shed during an island. This report documents the result of a study that shows such a motor is not a more severe case, simply a special case of the RLC network.
Photovoltaic inverters are the most mature of any DER inverter, and their mean time to first failure (MTFF) is about five years. This is an unacceptable MTFF and will inhibit the rapid expansion of PV. With all DER technologies, (solar, wind, fuel cells, and microturbines) the inverter is still an immature product that will result in reliability problems in fielded systems. The increasing need for all of these technologies to have a reliable inverter provides a unique opportunity to address these needs with focused R&D development projects. The requirements for these inverters are so similar that modular designs with universal features are obviously the best solution for a ''next generation'' inverter. A ''next generation'' inverter will have improved performance, higher reliability, and improved profitability. Sandia National Laboratories has estimated that the development of a ''next generation'' inverter could require approximately 20 man-years of work over an 18- to 24-month time frame, and that a government-industry partnership will greatly improve the chances of success.
The Million Solar Roofs Initiative has motivated a renewed interest in the development of utility interconnected photovoltaic (UIPV) inverters. Government-sponsored programs (PVMaT, PVBONUS) and competition among utility interconnected inverter manufacturers have stimulated innovations and improved the performance of existing technologies. With this resurgence, Sandia National Laboratories (SNL) has developed a program to assist industry initiatives to overcome barriers to UIPV inverters. In accordance with newly adopted IEEE 929-2000, the utility interconnected PV inverters are required to cease energizing the utility grid when either a significant disturbance occurs or the utility experiences an interruption in service. Compliance with IEEE 929-2000 is being widely adopted by utilities as a minimum requirement for utility interconnection. This report summarizes work done at the SNL balance-of-systems laboratory to support the development of IEEE 929-2000 and to assist manufacturers in meeting its requirements.
The National Photovoltaic (PV) Program is sponsored by the US Department of Energy and includes a PV Manufacturing Research and Development (R and D) project conducted with industry. This project includes advancements in PV components to improve reliability, reduce costs, and develop integrated PV systems. Participants submit prototypes, pre-production hardware products, and examples of the resulting final products for a range of tests conducted at several national laboratories, independent testing laboratories, and recognized listing agencies. The purpose of this testing is to use the results to assist industry in determining a product's performance and reliability, and to identify areas for potential improvement. This paper briefly describes the PV Manufacturing R and D project, participants in the area of PV systems, balance of systems, and components, and several examples of the different types of product and performance testing used to support and confirm product performance.
Electrical surges on ac and dc inverter power wiring and diagnostic cables have the potential to shorten the lifetime of power electronics. These surges may be caused by either nearby lightning or capacitor switching transients. This paper contains a description of ongoing surge evaluations of PV power electronics and surge mitigation hardware at Sandia.