DESIGN AND CONTROL OF A CASCADED INVERTER BASED TRANSFORMERLESS SINGLE PHASE PHOTOVOLTAIC SYSTEM

Martina Calais1, Vassilios G. Agelidis2, and Michael S. Dymond3 Australian Cooperative Research Centre for Renewable Energy (ACRE) Centre for Renewable Energy and Sustainable Technologies Australia (CRESTA) 2 School of Electrical and Computer Engineering Curtin University of Technology, PO Box U 1987, Perth, AUSTRALIA 6845
3 1

PowerSearch LTD, Bentley, AUSTRALIA 6102

ABSTRACT Different design and control aspects of a cascaded inverter based transformerless single phase grid connected photovoltaic system are discussed in this paper. An analysis of Perth weather data shows that high efficiencies of the system are desirable particularly at operating points of the system near the rated power of the array. For the maximum power point tracking an algorithm is proposed, which is based on the naturally occurring perturbations in a single phase system. The described system control minimises mismatch losses and simulation results show, that despite different photovoltaic sub array voltages, controllability of the grid current can be achieved. Keywords: Grid connected Photovoltaics; Inverters; Maximum Power Point Tracking; Control. NOMENCLATURE a1 Upper switch in leg a of full bridge 1 A Unstable operating area b2 Lower switch in leg b of full bridge 1 B Operating area near the Maximum Power Point c1 Upper switch in leg c of full bridge 2 C Stable operating area C1 Buffer capacitor 1 (F) C2 Buffer capacitor 2 (F) d2 Lower switch in leg d of full bridge 2 E1 Voltage across PV sub array 1 (V) E1ref Reference voltage for PV sub array 1 (V) E2 Voltage across PV sub array 2 (V) Eb Voltage extremum in second measurement interval (current measurement) Eb Voltage extremum in second measurement interval (previous measurement) fcs Control signal frequency (Hz) fs Switching frequency (Hz) G Irradiance (W/m2 ) iinv Inverter output current (A) Linv Filter inductance (H) P1 Output power of PV sub array 1 (W) P1av Average output power of PV array 1 (W) Pa Power extremum in first measurement interval Pb Power extremum in second measurement interval PSTC Rated photovoltaic module power under Standard Test Conditions (W) t Time (s)

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Cell temperature (C) Cell temperature before a temperature jump (C) Cell temperature after a temperature jump (C) Inverter output voltage (V) Power de-rating due to temperature (%/C) Voltage increment in MPPT algorithm Module efficiency under Standard Test Conditions (%)

INTRODUCTION A recent European market survey on single-phase inverters for grid-connected photovoltaic systems (Welter, 1999) reveals the benefits of transformerless topologies: they are more efficient, less expensive, lighter and smaller compared to inverters which include a transformer. When combining a transformerless topology with a multilevel concept further improvements can be achieved since less AC filter effort is required. As part of a joint research project between CRESTA and PowerSearch Ltd, a 1.9 kW prototype single-phase grid-connected photovoltaic (PV) system incorporating a multilevel cascaded inverter is currently under development (Calais, Agelidis, & Dymond, 1999a; Calais, Agelidis, & Dymond, 1999; Calais, Agelidis, & Meinhardt, 1999b). In this paper different design and control issues of the system are described and discussed. The paper is organised as follows: The first section gives a brief overview of the system and its control. Then design issues relating to the PV array of the grid connected system are discussed in the second section. The third and fourth section describe the Maximum Power Point Tracking (MPPT) algorithm and the grid current control method. The last section summarises the main findings. SYSTEM DESCRIPTION The investigated system (as shown in Fig. 1 for the grid connected application) consists of two PV arrays (1 and 2, each having a power output of 960 Wp at G=1000 W/m2 and T=25 C), two buffer capacitors (C1 =C2 = 680 F), a cascaded inverter, an AC filter simplified in Fig. 1 with a filter inductance, and the grid, represented by a single phase voltage source with an RMS value of 240 V and a frequency of 50 Hz.

Figure 1: Simplified diagram of the grid connected PV system. The cascaded inverter consists of two full bridges which are connected in series on their AC side. Since each full bridge can generate a three level AC output voltage, the given cascaded topology can generate an AC output with five levels as shown in Fig. 2. In the example inverter output voltage in Fig. 2 it is assumed that the DC input voltages E1 and E2 are equal ( E1 = E2 =E).

The system control shown in Fig. 1 includes the MPPT, a secondary DC voltage controller and the current control of the current iinv fed into the grid. The MPPT determines the operating point of the PV arrays by finding the voltage corresponding to the MPPs of the two PV sub arrays. The secondary voltage control ensures that the buffer capacitor voltages are kept at the MPP voltages and calculates the amplitude of the reference current for iinv. Assuming a constant grid voltage, the amplitude of the iinv determines the real power transferred from the PV array into the grid.

Figure 2: Example of the cascaded inverter output voltage. The intervals I to VI indicate the different modes the inverter operates in. DESIGN ISSUES When avoiding the transformer in the given topology there is no means of stepping up the inverter output voltage vinv to the required rms value of 240 V. Therefore, high DC bus voltages are necessary to ensure the power flow from the two PV sub-arrays to the grid. The system can only operate when the sum of the DC bus voltages E1 +E2 is greater than the amplitude of the grid voltage at all times. This constraint determines the minimum power rating of the system. Most crystalline PV modules available on the market today have 36 cells in series and operating voltages of approximately 17 V at 25C and 1000 W/m2 (Kreutzmann, 1999). However, when the temperature increases, the operating voltage can drop to as low as 12 V per module. Due to this behaviour, at least 14 crystalline 36-cell-PV modules in series are required for each of the two subarrays allowing for system power ratings of 1.3 kW and above. With amorphous silicon PV modules, the operating voltage does not drop as significantly with increasing temperature as it does with crystalline modules, thus reducing the number of modules required and allowing for smaller system power ratings. However, the drawback with amorphous modules is the generally by factor 2 lower efficiency compared to crystalline modules. The energy generated by a PV system depends on the type of PV modules used and its location. In order to determine for Perth, at what power level the efficiency of a PV inverter has to be highest, a case study based on 5 minute daily weather data collected at CRESTA (ambient temperature measurement, insolation measurement on a plane tilted at 30 facing north, recording period: April 98 March 99) has been undertaken. Two types of modules with specifications as listed in Table 1 have been considered. Type PSTC (W) P (%/C) STC (%) Mono55 12.2 -0.44 crystalline Poly-crystalline 60 10.9 -0.34 Table 1: PV Module Specifications (Standard Test Conditions (STC): Tc=25 C, G=1000 W/m2 , 1.5 AM.) Fig. 3 shows the energy generated by the PV modules at certain power levels divided by the total energy generated over the time April 98 March 99. Neglecting wiring losses the graph represents the input energy of the PV inverter at different power levels, normalised to the peak power rating of the PV array of the system. The higher the bar at a certain power level, the higher should be the efficiency of the inverter to allow for low-loss conversion. It is also interesting to see, that a system with poly-crystalline modules shifts the operation closer to the rated power. An overall comparison shows, that the polycrystalline modules perform better in

Perth, although their efficiency at Standard Test Conditions (STC) is lower than that of the mono-crystalline modules. (Comparing two PV arrays of the same power rating over the investigated period in Perth, approximately 3.7 % more energy would be generated by the polycrystalline array).
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Figure 3: Energy converted by a PV inverter at different power levels and for different module types in Perth. (The rated power of the inverter is equivalent to the peak power of the PV arrays). According to Fig. 3, high efficiency of a PV inverter operated in Perth is particularly important at the high power levels. To achieve this, it is important to choose filter elements and semiconductor devices with low conduction losses since these losses increase with the square of the current decreasing the efficiency of the inverter especially at high power levels. For the prototype system MOSFETs (Drain-Source Voltage rating: 400 V) with low RSDon values (120 m) have been selected in order to keep conduction losses low in the semiconductor devices. Care has to be taken when modules with low power de-rating factor are used and the rated power of the inverter is identical to that of the PV array. Then overloading of the inverter above the rated power has to be possible for short periods. MAXIMUM POWER POINT TRACKING An important consideration in the operation of a photovoltaic (PV) system is the means of continuously adjusting the PV array operating point so that maximum output power is achieved for the given conditions. Various maximum power point tracking (MPPT) algorithms to fulfill this task are being considered or are currently used in PV applications (Atlas & Sharaf, 1992; Atlas & Sharaf, 1996; Duschl, 1993; Keller, 1995; Wasynczuk, 1983). One common method is the perturb and observe method, where the array voltage is periodically incremented or decremented. If a perturbation leads to an increase (decrease) in power, the subsequent perturbation is made in the same (opposite) direction. In (Avril, 1994) an MPPT algorithm for single phase PV systems is described, which uses the naturally occurring perturbations in a single phase system. There, the oscillation of the instantaneous AC power at twice the line frequency causes an oscillation (perturbations) of the DC voltage and DC power. The method proposed in (Avril, 1994) uses the results of the analysis of the phase relationship between the oscillations in the DC voltage and DC power to track the MPP. To understand the tracking method of this MPPT algorithm an analysis of the PV array output parameters (current, voltage and power) is necessary. These change according to the operating point as shown in a simulation (Fig. 4b) where the power fed into the grid is higher than what is

available from the PV arrays causing the buffer capacitors to slowly discharge. Only one half of the system (PV sub array 1) is analysed. The analysis of the AC waveforms of E1 and P1 shows that the extrema can be used to determine which part of the P-V curve the system operates in. The Power-Voltage characteristic of the PV sub array 1 can be divided into three operating areas: A, B and C as shown in Fig. 4a. In operating area A, E1 is always lower than the voltage at the MPP, in operating area B, E1 is close to the voltage at the MPP, and in operating area C, E1 is always greater than the voltage at the MPP. Fig. 4b shows that e.g. a small ripple in the PV array output power, P1 , occurs, when the system operates in B. Higher ripple can be detected when operating in A or C. The results of the analysis of Fig. 4b can be summarised as follows: The operating area determines which extrema of E1 and P1 occur at the same time: For operating area A the maxima of E1 and P1 occur at the same time For operating area B the frequency of P1 increases. For operating area C the maximum of E1 and the minimum of P1 occur at the same time. The ripple of P1 increases when the operating point is moving away from the MPP.

To give an example, the case that the system operates in the area C is assumed, so that a shift of the operating point towards the MPP is desired. The operation in area C can be detected by measuring two consecutive extrema of both voltage and current, calculating the corresponding power extrema (Pa and Pb , see Fig. 4c) and comparing those. Pa is only greater than Pb in operating area C, so this comparison leads to the information which area the system operates in. In case the operating point of the system is changing, the direction of change can be detected by comparing measurements of two consecutive voltage maxima (Eb and Eb , see Fig. 4c) (or two consecutive voltage minima). If an increase (decrease) in the voltage E1 is required, the MPPT increases (decreases) the reference voltage E1ref by V. However, when the system operates in area B (near the MPP) the reference voltage can be replaced by the average value of the current voltage E1 . The secondary DC voltage control enhances the stability of the system. When operating at the MPP, the voltage changes only slightly with varying irradiance but considerably with changing temperature. Since temperature changes occur continuously but slowly the MPPT algorithm is capable of accurately tracking the MPP during temperature changes. Irradiance changes, however, occur suddenly e.g. caused by passing clouds. A secondary DC voltage control then ensures a stable operating point. Immediately after a change in irradiance level, E1ref does not match the MPP voltage any more but is within a narrow range near the new MPP voltage. Hence the MPPT starts its search very close to the new MPP. For the DC voltage control a P-controller is sufficient. A PI-controller is not suitable since this would add a second integrating part to the control loop which already has integrating behaviour due to the buffer capacitor. To show the influence of the ripple based algorithm implemented in the system control the unrealistic but worst case of a temperature change (the MPP voltage is changed considerably) is simulated since the actual tracking process can be studied well.

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Figure 4: (a) Power-Voltage characteristic of PV sub array 1 (G=800 W/m2 , Tc=25 C). (b) Slow discharge of the DC buffer capacitor C1 to show the relationship of power and voltage extrema in the different operating areas A, B and C. (c) Detail of Fig. 3b to show the necessary measurements to detect operating area and direction of change.

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Figure 5: Simulation results for the MPPT algorithm: G=1000 W/m2 for a cell temperature jump from Tc_before=25 C to Tc_after= 45C. (a) PV array 1 output power, P1 , P1av . (b) PV array output power, P1 . (c) amplitude of reference current ref. Chosen is an irradiance level of G=1000 W/m2 , and a cell temperature jump from Tc_before=25 C to Tc_after= 45C occurs. The simulation starts in the operating area C on the P-V curve for PV array 1 for Tc_before=25 C as shown in Fig. 5 a. The MPPT algorithm constantly decreases the value of E1ref until the first MPP is found. After the temperature jump the operating point moves to the operating area C of the P-V curve for Tc_after= 45C. The tracking starts again until the new MPP is detected. Fig. 5b shows the ripple of P1 . The MPP is detected when the ripple of P1 increases in

frequency and decreases in amplitude. Once the MPP is found, no variation of the reference current amplitude ref is required (see Fig. 5c). In Fig. 5a the diamonds display the mean power delivered by the PV sub array 1. Due to the power ripple the mean power is always smaller than the maximum power. The diamonds also indicate the tracking process of the algorithm. CURRENT CONTROL In order to minimise mismatch losses it is desirable to track the two PV sub arrays individually. However, operating the two PV sub arrays at different voltage levels complicates the control. To be able to control the current iinv , enough voltage reserve to decrease and increase the current in the inductor Linv has to be available at all times. When considering different PV sub array operating voltages, this can become difficult at the mode changes of the inverter (see Fig. 2), and between modes I and II, I and III, IV and V, and V and VI control can be lost if one of the PV sub array voltages is used to determine the mode change. One solution to this control problem is to operate the inverter during the transitions from mode I to mode II, mode II to III, mode IV to V, and mode V to VI as a normal full bridge in a ``bipolar'' way, switching between zero states and E1 +E2 in the positive half wave (as shown in Fig. 7g) or between zero states and -E1 -E 2 for the negative half wave respectively. The transition periods where this bipolar operation is necessary are indicated in Fig. 6 for two different PV sub array voltages (Emax and E min ).

Figure 6: Intermediate modes location and length under average grid voltage amplitudes. Fig. 7 shows simulation results for one positive halfwave. The current control method used is a Zero Average Current Error control method (Polarised Ramptime ZACE) (Borle, 1998). Despite different PV sub array voltages (E1 and E 2 , see Fig. 7h), the current iinv follows its sinusoidal reference. The quality of the current injected into the grid can be further improved through additional filters. Fig. 7 also shows the ability of the cascaded inverter to distribute the required switching actions equally on the 8 available switches. Figs. 7b-e show gate signals of the switches a1, b2, c1, and d2 . The switching frequency of all switches is _ of the frequency of the control signal which is the relevant frequency for the filter design. CONCLUSION Different design and control aspects of a cascaded inverter based transformerless single phase grid connected PV system have been discussed in this paper. For the application of the system in Perth an analysis of one year 5 minute weather data shows, that high efficiencies of the system are desirable particularly at operating points near the rated power. The analysis also shows different performance results for specific poly- and mono-crystalline modules, with the poly-crystalline module performing better despite lower efficiency at Standard Test Conditions but better temperature behaviour.

Figure 7: Simulation results: Polarised Ramptime ZACE current control method and cyclic switching sequence considering different PV sub array voltages, Linv =4mH, C1 =C2 =600 F, inv =5 A, (a) control signal (fcs10 kHz), (b)-(e) gate signals for switches a1 , b2 , c1 and d2 (see Fig.1) ( fs2.5 kHz), (f) unfiltered inverter output current iinv , (g) inverter output voltage vinv , (h) PV sub array voltages E1 and E2 .

For the control of the system an MPPT algorithm is applied, which is based on the naturally occurring perturbations in a single phase system. Simulation results show the capability of the algorithm of accurately tracking the MPP. The described system control allows for individual tracking of both PV sub arrays and simulation results show, that despite different PV sub array voltages, controllability of the grid current can be achieved. The prototype system is currently being built and experimental results to verify the simulations results presented in this paper will be available in the near future. ACKNOWLEDGEMENTS Thomas Friese, Fachhochschule Karlsruhe, Germany, and Lawrence Borle, PowerSearch, Australia, have contributed to this paper through valuable discussions and help with generating the simulation results. The work described in this paper has been supported by the Australian Cooperative Research Centre for Renewable Energy (ACRE) and the Alternative Energy Development Board (AEDB). Martina Calais currently receives an ACRE Postgraduate Research Scholarship. ACREs activities are funded by the Commonwealths Cooperative Research Centres Program. Thanks also go to CRESTA and PowerSearch LTD for providing the research facilities. REFERENCES ATLAS, I., & SHARAF, A. (1996). A novel on-line MPP search algorithm for PV arrays. IEEE Transactions on Power Conversion, 11(4), 748-754. ATLAS, I., & SHARAF, A. (1992). A fuzzy logic power tracking controller for a photovoltaic energy conversion scheme. Electric Power Systems Research, 25, 227-238. AVRIL, J. (1994). Optimisation of a single phase grid connected pulse-inverter for PV systems (Untersuchungen zur Betriebsoptimierung eines einphasigen Pulswechselrichters fr Photovoltaikanlagen im Netzparallelbetrieb, in German).PhD Thesis, Fern-Universitaet Hagen, Germany. BORLE, L. J. (1998). A Three-Phase Grid-Connected Inverter with Improved Ramptime Current Control in Programmable Logic. Paper presented at the IEEE Conference Power Electronics Drives and Energy Systems for Industiral Growth (IEEE PEDES'98), Perth, Western Australia. CALAIS, M., AGELIDIS, V. G., & DYMOND, M. S. (1999). When to Switch Which Switch in a Five Level Single Phase Cascaded Inverter. Paper presented at the Australasian Universities Power Engineering Conference 1999 (AUPEC'99), Darwin, Australia. CALAIS, M., AGELIDIS, V. G., & MEINHARDT, M. (1999b). Multilevel Converters for SinglePhase Grid Connected Photovoltaic Systems: An Overview. Solar Energy, 66(5), 325335. CALAIS, M., AGELIDIS, V. G., & DYMOND, M. S. (1999a). A Cascaded Inverter for Transformerless Single-Phase Grid-Connected Photovoltaic Systems. Paper presented at the World Renewable Energy Congress, Perth, Western Australia. DUSCHL, G. (1993). Experimental and theoretical examination of solar-electric systems with MPP controllers (Experimentelle und theoretische Untersuchungen an Solar-elektrischen Systemen mit MPP-Reglern, in German). PhD Thesis, Technical University Berlin, Berlin, Germany. KELLER, G. (1995). Presentation of different MPP control methods (Darstellung unterschiedlicher MPP-Regelverfahren, in German). Paper presented at the Zehntes Symposium Photovoltaische Solarenergie, Kloster Banz, Germany. KREUTZMANN, A. (1999). From 0.075 to 315 Watt, Market Survey Photovoltaic Modules 1999 (Von 0,075 bis 315 Watt, Marktbersicht Solarmodule 1999, in German). PHOTON das Solarstrom Magazin (German Solar Electricity Magazine)(2-99), 52-59. WASYNCZUK, O. (1983). Dynamic behaviour of a class of photovoltaic power systems. IEEE Transactions on Power Apparatus and Systems, 102(9), 3031-3037. WELTER, P. (1999). Power up, Prices down, Grid Connected Inverter Market Survey (Leistung rauf, Preise runter, Martbersicht netzgekoppelter Wechselrichter, in German). PHOTON das Solarstrom Magazin (German Solar Electricity Magazine)(3-99), 48-57.