Development of a Photovoltaic Array Emulator System based on a Full-Bridge Structure

Guillermo Martn-Segura, Joaquim Lpez-Mestre, Miquel Teixid-Casas, Antoni Sudri-Andreu

Centre of Technological Innovation in Static Converters and Drives (CITCEA-UPC) Electrical Engineering Department , Polytechnic University of Catalonia Av. Diagonal, 647 2nd floor 08028 Barcelona, Spain guillermo.martin@citcea.upc.edu Abstract Nowadays solar photovoltaic technology is becoming more and more important every day. Manufacturers and laboratories dedicated to photovoltaic (PV) equipment research and development are arising continuously, and so are their needs of having appropriate test equipments. In this paper, the design and construction of a photovoltaic array emulator (PVAE) is presented. PVAEs are systems able to behave electrically similar to PV arrays but without depending on weather conditions and capable to emulate PV array systems. That makes possible to perform different PV energy production systems tests under many diverse operation conditions and without depending on weather or much more expensive and larger systems. The proposed system consists on a 4.4 kW AC/DC power converter based on a DC/DC full-bridge structure and High Frequency (HF) transformer, that allows testing PV inverters performance up to 4 kW and with a 650 V and 7 A input.
Keywords- photovoltaic; solar array simulator; power electronics; full-bridge

and policy framework against climate change promoting PVs deployment, the importance of PV systems in generation of electricity is actually increasing exponentially, and the tendency proved in this industry during last years [1] shows it is probably to continue increasing the public expenditure on PV R&D and market stimulation. Distributed generation poses new problems to the control of the electric utility, and needs new solutions and technologies to face a massive penetration of PV-generators without renouncing to power quality. Photovoltaic inverters are not an exception, and it is required to know the efficiency of their Maximum Power Point Tracking Systems (MPPTS), the quality of the energy injected in the utility under different situations of irradiation, and specially the performance of the different anti-islanding methods in solar inverters under large penetration of PV. Therefore, becomes vital to have appropriate test equipments for manufacturers and laboratories dedicated to PV inverters R&D. Up to few years ago, inverter manufacturers tested their equipments with real PV-arrays under real irradiance conditions. That was possible because of the small power of those novel systems, but nowadays with hundred kilowatt inverters becomes impossible due to the space and cost as well as for the weather dependency of the test equipments. At first, in order to eliminate atmospheric dependency, some test equipments used lamps to simulate the solar irradiation with its consequent need of huge power for testing equipments having a power bigger than 1 kW [2]. Other ones tried to simulate the Sun by a current source and a diode chain, as it is usually represented a photovoltaic panel by its electrical scheme. However that equipment had thermal stability problems and was limited by its diode chains fill factor. Thus, in order to evaluate the performance of solar inverters from medium to

I.

INTRODUCTION

During past decades, distribution schemes utilized in power grid had been commonly centralized. There were just few high power controlled generators and a demand curve to accomplish by the company in charge of the utility. In the same way, all regulatory specifications, security systems and electrical equipments had been designed for that kind of generation schemes based on few generators and a controlled energy flux. With falling prices of solar cells, rising prices of petrol barrel

high power, power converters capable of reproducing or emulating the electrical behaviour of a PV array were designed. A wide range of array simulators or emulators based in power converters have been proposed and developed during last years. Some of them without galvanic isolation [3], some based on structures with low frequency transformer [2], and some based on HF transformers [4]; some using Pulse Width Modulation (PWM) principle [5], and some using linear converters to avoid EMC-measurements [6]. Trying to emulate the PV current-voltage curve (I-V curve) some converters amplified the curve of a reference solar cell [7], and some obtained the I-V curve from a discrete table stored in a memory and then interpolated the points [3] [4], but most of them used mathematical models of panels I-V curve and calculated it from arrays parameters [2] [5], making possible to modify and simulate the PV curve under different situations easily. In this paper, the development of a PVAE based on a fullbridge structure is presented. First of all, the characteristic I-V curve of a PV module is explained, and the linear model used in this converter introduced. Then, the description of the converter is made and the obtained experimental results of the PVAE presented. Finally the conclusions of this project are exposed. II. CURRENT-VOLTAGE CURVE OF A PV-MODULE

Vmpp: maximum power point voltage Impp: maximum power point current

The I-V curve of different PV-modules connected in series or in parallel, is similar but duplicating the Voc and Vmpp or the Impp and Isc, respectively. The equivalent circuit model of a PV-module is represented by different authors depending on the complexity required on their studies, from the most simple using a current source and a diode, to equivalent circuits with a current source, two diodes and two resistances [8] [9]. Due to its simplicity and flexibility, the mathematical model used in this paper for the I-V curve is a linear model formed by the two lines obtained from joining Voc, Vmpp, Impp and Isc; whose equations are the following:
I = V MPP V OC V + V OC I MPP

(1)

I =

V I SC V MPP V MPP I MPP I SC I MPP I SC

(2)

III.

DESCRIPTION OF THE EMULATOR

The I-V curve of a PV module is depicted in the Fig. 1 and is mainly depending on the temperature, irradiation and the material of the PV cells. Thus, that curve is for a given time instant with a given temperature, solar irradiation and cells material; but it is changing all along the day depending on this parameters. Furthermore the curve in Figure 1 is obtained in ideal conditions with the module surface totally and uniformly illuminated; anyway it is difficult to reach these conditions under real operation: i.e. when having partial shadowing, relative maximum power points arise, fact that confuses MPPTS questioning its good performance.
Isc IM PP p
m ax

A. Description of the converter topology and control scheme More than 50 % of PV-inverters up to 10 kW in the market have an output nominal power below 4 kW and most of them require voltages superior to 450 V [10]. Since the emulator has to test PV-inverters and trying to reach most of markets inverters, this prototypes specifications are: Output voltage: 0-650 V Output current: 0-7 A Nominal Power: 4.4 kW

p
V V v

The electrical scheme of the prototype is given in Figure 2. Attempting to reduce weight and volume and to provide more security by galvanic isolation, the proposed PVAE is formed by a full-bridge structure with HF transformers and PWM principle. The inductances as well as the transformers are of HF too, and calculated to operate in continuous conduction mode.
M P P O C

Figure 1.

Current-Voltage characteristic of a PV-module

As it is seen in Fig. 1, the most important parameters of the I-V curve are: Voc: Open-circuit voltage Isc: Short-circuit current
Figure 2. Electrical scheme of the converter

The converter is fed through three-phase 400V supply and then rectified with a three-phase diode bridge, obtaining a dcwaveform. To reach higher voltages, it has two transformers 1:0.8 with the primary connected in parallel and the output in series. Due to power-losses, the semiconductor devices chosen have been Insulated Gate Bipolar Transistors (IGBT) which will commutate at 18 kHz, and fast recovery diodes in transformers secondary. As it is also seen in Figure 2, there are four sensors to control the converter. Referring to the control, the emulator control scheme proposed is illustrated in Figure 3 and shows how the converter acquires the measurements from voltage and current sensors, how they are treated and a Vload setpoint is calculated from an Iload measured and a defined I-V curve. Then an Ibobin setpoint and a duty-cycle that will lead IGBTs switching are obtained from two programmed Proportional-Integral controllers (PI controllers). It is convenient to notice that, although having the PI-controller Ibobin is not strictly necessary for converters control, it is worth having such a control in order to improve the dynamic response of the converter avoiding possible damages.

controllers using backward approximation and anti-windup correction, as well as over voltage and over current protections. The sensors used to acquire the measurements are two voltage and two current transductors LV25-P and LA55-P respectively, all from the manufacturer LEM. Every PWM cycle (55.5s), the DSP take the data from the transductors, adapt it and follows the process illustrated in Fig.3 as explained previously. Since they accomplish or exceed the specifications needed, two IGBT half-bridge modules KM75GB123D (VCES 1200V, IC 75A) and their corresponding drivers SKHI24 from SEMIKRON have been chosen. The secondary diodes are eight discrete fast recovery diodes DSEI30-12A (VRRM 1200V, ID 26A, trr 40ns) from IXYS, and the rectifier in the primary is a usual three-phase rectifier SKD30/12A (VRRM 1200V, ID 15A, trr 25s) from SEMIKRON. Even though all semiconductors chosen accept at least 1200V in nominal conditions, to avoid over voltages due to parasite inductances in IGBTs and the fast diodes, a DC-link and snubbers have been constructed. Because of the frequency the magnetic cores are going to work and their power losses, Manganese-Zinc Ferrites cores with E shaping have been selected. Two 2.2 kW HFtransformers with three couples of E71 ferrite-cores and 0.8 transformer winding ratio, and two 3.3 mH HF-inductances formed by two couples of E71 ferrite-cores have been used. The capacitors used in this prototype have been two 2200F/450V in parallel for the dc-bus, and two 47 F/400V for the output capacitors, trying to achieve less than 2% of output voltage ripple. The physical implementation of the prototype is shown in Figure 4.

DSP

Capacitors

Inductance

Figure 3. Proposed emulator control method

B. Description of prototypes equipment The microprocessor used to control the converter has been a Digital Signal Processor (DSP) TMS320F2808 from Texas Instruments (TI) because it integrates the peripherals needed, its flexibility in reprogramming, its speed by treating digital signals and its robustness against perturbations. The control board used in this prototype has been developed by CITCEAUPC and includes: four PWM one fault signal coming from drivers in case of short circuit four 12- bit Analog to Digital Converters (ADC) four 12- bit Digital to Analog Converters (DAC)

Fast Diodes IGBTs Transformers RC-snubber

Figure 4. Constructed prototype

IV.

EXPERIMENTAL RESULTS

The emulator control scheme showed in Figure 3 has been implemented with the program Code Composer Studio, supplied by the manufacturer TI. The I-V curve has been programmed following Equations (1) and (2), and the two PI

Once the emulator has been designed and constructed, its experimental performance (steady and dynamic response) has been tested, not before ensuring the correct operation of the PVAE and adjusting the PI-controllers.

A. Initial tests As it has been mentioned, in order to ensure the waveforms obtained were correct and the proper operation of the emulator, some tests with fixed duty-cycle have been done. It can be seen in Figure 5 how the voltage-peaks wont damage the system, and in Figure 6 how even having different current circulating trough the diodes such difference is not remarkable and their addition results in the bobbin current. This tests confirm that the waveforms acquired have been satisfactory.

Voc: 57.6 V Isc: 4.7 A Vmpp: 46.08 V Impp: 4.35 A

During the experimentation, due to lack of a PV inverter, variable resistors have been used as a load, and thirty-five points have been measured. The I-V curve the emulator will reproduce is illustrated in Figure 7, as well as the measured points for different resistances and the real I-V curve of the modules. It is seen how the theoretical values and the experimental measured values are similar. In order to evaluate this accuracy, the deviation has been calculated following the next equation:
(%) =
X theoretica l X measured X theoretica l

(3)

Figure 5. Primary and secondary voltage and current of the upper transformer. (RLOAD =140 and duty-cycle = 0.36)

Figure 7. Real I-V curve of 11 modules IS-200/32 under Standard Conditions, theoretical lines programmed in the emulator and experimental results.

Figure 8 and Figure 9 shows the voltage and current deviations obtained for different resistances.
3,5

Figure 6. Current of the upper diodes in the secondary of the upper transformer and its arithmetic sum (RLOAD =70 and duty-cycle = 0.18)
Deviation (%)

3 2,5 2 1,5 1 0,5 0 0 200 400 600 Theorectical voltage (V)

After these initial tests, and having some values obtained from simulation, the Kp and Ki multipliers of the PI controllers have been completely adjusted. B. Steady state response of the emulator According to the specifications, the converter developed can emulate the behaviour of any PV array up to 4.4 kW with a maximum Voc of 650 V and a maximum Isc of 7A. In this paper eleven series PV-module IS-200/32 have been emulated. These modules come from the manufacturer ISOFOTON and its main characteristics are: Pmax : 200 Wp

Figure 8. Deviation versus experimental theoretical voltage.

3,5 3 2,5 Deviation (%) 2 1,5 1 0,5 0 0 1 2 3 4 5 Theoretical current (A)

Figure 9. Deviation versus experimental theoretical current.

It can be observed that the error between the theoretical and the experimental values is bigger as they are nearer of the short-circuit current. Taking into account the control method described in the previous sections, this is explained because the Vload setpoint obtained under these conditions is much more changeable than in the other conditions, and so more difficult to control. Anyway, the maximum deviation obtained is smaller than 3.5 % and since PV-inverters always start their operation from Voc to reach Vmpp [6], it is not significant for testing inverters. Although this paper only presents an emulation of one single I-V curve, the PVAE has been tested under additional emulating curves, resistances and operating conditions. The average values obtained for the deviation are similar to the ones obtained in this experimentation: less than 1.5% away of Isc; which is a satisfactory result. It has been also observed the output voltage ripple is less than 2%. C. Dynamic response of the emulator In this experimentation has been studied which is the behaviour of the converter when changing the load. As it has been done in the preceding experimentation, the load used has been a variable resistor and the I-V curve has been the one obtained from eleven modules IS-200/32. In this paper the values obtained when the load has changed the point of operation from 435.9 V and 4.3 A to 535.6 V and 3.046 A is presented, Figure 10. And in Figure 11 the behaviour of the emulator in this situation can be observed (the values of the internal variables have been obtained from the DACs). When a sudden change of load happens, the current varies instantaneously. In this case, Vload setpoint becomes zero due to the current increases and the I-V curve programmed. The Ibobin setpoint becomes zero too. The Duty-cycle becomes suddenly smaller and at first increases due mainly to the proportional constant and the difference between the Ibobin setpoint that is zero and the measured Ibobin. The Ibobin setpoint is zero and Ibobin measured diminishes, so the dutycycle lowers too. And it is not until Iload measured becomes lower than 4.7 A (Isc of the modules emulated) that Vload setpoint grows and so do Ibobin setpoint and the Duty-cycle. It can be observed how the converter needs 10 ms to arrive to the desired working point.

Figure 10. Real I-V curve of 11 modules IS-200/32 under Standard Conditions, theoretical lines programmed in the emulator and experimental results.

Figure 11. Load voltage measured, load current measured, Vload setpoint, Ibobin setpoint and Duty-cycle when a sudden change of load.

When having the reverse situation (changing from 535.6 V and 3.046 A to 435.9 V and 4.3 A), the dynamic response is dependant on the load due to the converters structure. It has been tested under many different situations and the response lasts always less than 100 ms. It has to be noticed that, though behave dynamically exactly to a PV-module is impossible because its speed (10-100 s), becomes necessary to emulate PV-modules not to influence on the dynamic of the PVinverters MPPTS. Although some studies talk about 750 ms

MPPTS [11], at the moment it is possible to find some new and latest technology PV-inverters with MPPTS dynamic response of 100 ms, case where the developed PVAE would be adequate. Moreover, it has to be noted that some laboratories specialized in MPPTS test give two or three minutes to PVinverters to find the maximum power point. Therefore, it can be concluded that the dynamic response of the PVAE is satisfactory. V. CONCLUSIONS

REFERENCES
[1] IEA PVPS. Trends in Photovoltaic applications, Survey report of selected IEA countries between 1992 and 2006. IEA PVPS Programme Task 1, 2007, p. 33. [2] OLILLA, J. A medium power PV-array simulator with a robust control strategy. Tampere, Finland: Tampere University of Technology, 1995, IEEE, p. 40. [3] QINGRONG, Z., PINGGANG, S., LIUCHEN,C. A Photovoltaic simulator based on DC Chopper. Brunswick, Canada: University of New Brunswick, 2002 IEEE Canadian Conference on Electrical and Computer Engineering, Winnipeg, Canada, May 2002; 257261. [4] SHANKAR, S., YEW, C., WING, A. A Novel PC Based Solar Electric Panel Simulator. Temasek, Singapore: Temasek Engineering School, 2003, IEEE, p. 848-852. [5] KOUTROULIS, E., KALAITZAKIS, K., TZITZILONIS, V. Development of an FPGA-based system for Real-Teime Simulation of Photovoltaic Modules. Chania, Greece: Department of Electronic and Computer Engineering, Technical University of Crete, 2006, IEEE. [6] HAEBERLIN, H., BORGNA, L. A New Approach for Semi-Automated Measurement of PV Inverters, especially MPP Tracking Efficiency, using a Linear PV Array Simulator with High Stability. Burgdorf, Switzerland: Hochschule fr Technik und Informatik, 2004, 19th European photovoltaic Solar Energy Conference, Paris. [7] ARMSTRONG, S., LEE, C.K., HURLEY, W.G. Investigation of the Harmonic Response of a Photovoltaic System with a Solar Emulator. Galway, Ireland: Power Electronics Research Centre National University of Ireland, 2005, EPE, Dresden, Germany. [8] CASTAER, LL. Modelling Photovoltaic Systems Using Pspice. London, UK: John Wiley & Sons, 2002, p. 41-75. [9] MARKVART, T., CASTAER, L. Practical Handbook of Photovoltaics: Fundamentals and Applications . Oxford, UK: Elsevier Science Ltd, 2003, p.75. [10] SALAS, V. [et. al.] Revisin del estado de la tcnica de lo inversores utilizados en los sistemas fotovoltaicos de conexin red de baja tensin. Madrid, Espanya: Revista Era Solar, edicin 137 marzo-abril 2007 p.48, edicin 138 mayo-junio 2007 p.16. [11] BLANES, J.M., GARRIGS, A., CARRASCO, J. VILA, E. Maximum Power point Estimator For Photovoltaic Solar Arrays. Elche, Spain: Power Electronics Processing Group, University Miguel Hernandez, Electrotechnical Conference: MELECON IEEE Mediterranean, 2006, p.889-892.

Photovoltaic industry is growing exponentially and PVAE is becoming an essential tool for manufacturers and laboratories dedicated to PV inverters R&D. In this paper a PVAE has been presented and its static and dynamic response evaluated. The PVAE is based on 4.4 kW full-bridge structure with two HF transformers with the primary connected in parallel and the output in series to reach higher voltages. The PVAE is controlled by a DSP and uses two PI-controllers and linear model to emulate PV-modules. It allows testing PV-inverters up to 4 kW and with an input of 0-650 V and 0-7 A. The accuracy (less than 1.5% away of Isc ) as well as the dynamic response obtained (less than 100ms) in the experimental results, make us conclude the emulator is suitable for PVinverters testing. ACKNOWLEDGMENTS The authors gratefully acknowledge the valuable advice, support and assistance of all CITCEA-UPC members during the development of this project.