7 AD-A0O 877 DELTA ELECTRONIC CONTROL CORP IRVINE CALIF

F/B 10/1DESIGN, CONSTRUCTION AND TESTING OF A 60 KW SOLAR ARRAY AND POW- ETCU)AUG 79 J S SUELZLE DAAK7O-78-C-GOIB

UNCLASSIFIED DECC-61211-003 NL

2flfllfllfllfllfllflEEE-EEEEEI-EOEhhEE~hEEghEEEmullllllullulIIE*E1111111II-EhlgllEEgllEE

Report DECC-61211-003

DESIGN, CONSTRUCTION AND TESTING OF' A 6o Kcw

SOLAR ARRAY AND POWlER CONVERSION SYSTEM

L~.Final Report L EVEI~o0 J.S. ule

Delta Electronic Control Corporation2801 S.E. Main Street0 Irvine, California 92714

August 1979 V

Prepared for

co Department of the Army*L1 Mobility Equipment Research and Development Command

I . IFort Belvoir, Virginia 22060

Approved for Public Release;CU Distribution Unlimited

80 2 15 ()

DISCLAIMER NOTICE

THIS DOCUMENT IS BEST QUALITYPRACTICABLE. THE COPY FURNISHEDTO DDC CONTAINED A SIGNIFICANTNUMBER OF PAGES WHICH DO NOT

REPRODUCE LEGIBLY.

Report DECC-61211-003

DESIGN, CONSTRUCTION AND TESTING OF A 60 KW

SOLAR ARRAY AND POWER CONVERSION SYSTEM

Final Report

J.S. SuelzleDelta Electronic Control Corporation

2801 S.E. Main StreetIrvine, California 92714

August 1979

Prepared for

Department of the ArmyMobility Equipment Research and Development Command

Fort Belvoir, Virginia 22060

Approved for Public Release;Distribution Unlimited

/.N

S&CURIY CLASSIFICATION Of TIlS PACE (When Does EtetE)

REPOT DCUMNTATON AGEREAD INWTRUCTIONSREPOT DCUMNTATON AGEBEFORE COMPLETING~ FORM4

1. REPORT Mummail 2. GOVT ACCESSION NO. V ClIVENwVs CAT &LOGi LiMse"

DECC-6Finl 3 ___________

De9sign, Construction and Testing of a 6' Fnl~'t T1 i-kW Solar Array and Power Conversion*PEOMIG0GR0T LS"

7. Au~sOR~s)* CONTRACTOR GRANT NuMALA.,

)J .S.S Suel z le D-K 78C 8

9. PERFORMING ORGANIZATION NAME AND ADDRESS 10 PROGRAM ELEMENT. PROircY.T~-

Delta Electronic Control Corporation AREA 6 WORK UNIT NOMflERS

2801 S.E. Main StreetfIrvine, CA 92714 1 /

IL CONTROLLING OFFICE NAME AND ADDRESSTE

U.S. Army Mobility Equipment Research and _'~jAuE9~"WDevelopment Command, Fort Belvoir, VA. ITNUM" E IF

14 MONITORING AGENCY NAME A AESSIf difi.,e. I'Mm Cnnt11-Iting 0III, eI S SF.CjflII CLASS (-f IN , *1510tI

Unclassifiedi%a nELAS ICATIjON 6_ON(.ACI

SCHNEfULE

16. DISTRIBUTION STATEMENT (of tis ftepofl)

Approved for public release; distribution unlimited

17 DISTRIBUTION STATEMENT (of the obstract *rIe,.d I, Black 20. it diII-.n fr-n RopoI)

III SUPPLEMENT ARY NOTES

to XEV WORDS fCn",.',*,,..d. It or.lf - .', ,, I,~ ho 1... . .

Photovoltaic, power conversion, peak power tracking, automaticreactive power control, efficient, utility augmentation

ABSTRACT (Contin, an rovems. side of oa.., ., I,It .M ho,, m.

A 60 kW photovoltaic array and power conversion

system wasdesigned, constructed, tested and installed by Delta ElectronicControl Corporation. The system is currently operative, augment-ing a remote diesel power generating station at Mt. Laguna AirForce Station. The system, which operates without on-site energystorage, operates unattended, extracting the maximum availablepower from the solar array. 4

D *j,7 1471 EDITIONOF I'NOVAIS IS O6OLZTIE

J~~c~j~7 () SECURITY CLASSIFICATION OF THIS PAGE (When Dots.I.I.*

PREFACE

The work reported herein was performed by DECC (Delta

Electronic Control Corporation) under contract to the

United States Army Mobility Equipment Research and

Development Command (contract DAAK7Q-78-C-0018). The

Contracting Officer's Representative is Donal Faehn

at Fort Belvoir, Virginia. The work was sponsored by

the U.S. Department of Energy and the U.S. Air Force.

The entire project was under the direction of the

Defense Photovoltaic Program Office, U.S. Army MERADCOM.

Appreciation is expressed to Dietrich J. Roesler, pre-

sently of the Department of Energy, for his efforts as

Contracting Officer's Representative during the early

stages of the contract.

I)JRt / 1 Rld/or

i a

.... . .. ... . . . .. . . . . .. . .. ... . l ,

SUMMARY

The objective of the effort described in this reportwas to demonstrate that a dc-ac photovol.taic energyconversion system without on-site energy storage couldeffectively augment a utility, e.g. a remote militarygrid. Delta Electronic Control Corporation (DECO)designed, constructed and installed such a system usingphotovoltaic modules provided by Jet Propulsion Lab-oratories under the Low-Cost Solar Array Project. The60 kW photovoltaic system is installed at Mt. LagunaAir F'orce Station where it augments a remote dieselpower plant. The system is entirely automatic, comingon-line when there is sufficient solar power availablein the morning, and returning to a stand-by state whenthe solar power is irsufficient to operate the system.The system is designed to extract the maximum poweravailable from the photovoltaic modules and operatesunmanned for extended periods of time. All observationsto date support the conclusion that such a system caneffectively augment a utility.

TABLE OF CONTENTS

PARAGRAPH TITLE PAGE

Preface 1.

Summary ii

1.0 Introduction 1

2,0 Design and Construction

2.1 The System2

2.2 The Array 2

2.2.1 The Modules 52.2.2 Module Frames 5

2.2.3 Supports 12

2.2.4 Pertmuient Site Preparationand Footings 12

2.2.5 Flectrical Unterconnectionof Panels 12

*. .6 Grounding 17

2.3 Paralleling and Monitoring Panel 17

2.4 Power Conversion Unit 20

2.4.1 Input niid Output Contactors 23

2.4:2 Voltage Limiter 23

2.4.3 D-AC Inverter 21

2.4.4 System Control Circuitry 26

2.4.4.1 Peak Power Tracking and Power

Flow Control 26

2.4.4.2 Automatic Start-Up

2.4.4. . S1ut-Down 30

2.4.5 Monitors 33

2.5 Data Acquisition System 34

3.0 Results 42

3.1 Operation of the Power ConversionUnit From an Array Simulator 42

3.2 Field Tests With PV Array at tleDECC Facility 42

3.3 Operation at the Permanent Site 44

3.4 System Performance 44

3.4,1 Modes of Operation 45

3.4.2 The Power Conversion System 45-

i-A

3.4.2:1 Input Power 463.4.2. InputVoltage 4

3.4.2.3 Output Power 46

3.4.2.4 Output Voltage 46

3.4.2.5 Efficiency 47

3.4.2.6 Harmonic Distortion and Waveform 47

3.4.2.7 System-Grid Interaction 47

3.4.2.8 Protective System 52

3.4.2.9 Expansion Capability 533.4.2.10 Electromagnetic Interference 53

3.4.2.11 Audible Noise 54

394*4.1 Output Power 5

3.4.4.2 The PV Modules 5

4oConclusions and Recommendations 62

41The Array Structure 62

4.2 ~ Array Wiring 6

4.3 Row Terminal Boxes 65

4.4 Solar Power Modules 654.5 Array Shorting 664.6 The PMP 68

4.7 Power Conversion Unit 68

4.8 Ground-Fault Protection 68

4.9 Operation 694.10 Conclusion 70

Appendix A Acceptance Test Al

Appendix B EMI Tests on Comparable Power

Conversion Equipment B1

iv

LIST OF FIGURES

FIGURE TITLE PAGE

2-1 Block Diagram of the PhotovoltaicPower Generation System 3

2-2 Solar Power Module 6

2-3 Solarex Module 7

2-4 Solar Power Module: I-V Curves 9

2-5 Solarex Module: I-V Curves 10

2-6 Welding of a Solar Power Frame 11

2-7 Solar Power and Solarex FrameAssemblies 13

2-8 Frames Mounted on Shear Panels 14

2-9 Permanent Site After Grading andTrenching 15

2-10 Photovoltaic Array Installed atMt. Laguna 16

2-11 Array Interconnections 18

2-12 Schematic Diagram of the Parallelingand Monitoring Panel 19

2-13 Paralleling and Monitoring PanelFront View 21

2-14 Paralleling and Monitoring PanelInterior View 22

2-15 Power Conversion Equipment 24

2-16 Block Diagram of the Power ConversionUnit 25

2-17 Four-Quadrant Power Control 28

2-18 Start-Up Sequencing 29

2-19 Output from Demonstration Program onData Acquisition System 38

2-20 Data Acquisition System Output 39

2-21 Data Acquisition System Output 40

2-22 Typical Data Acquisition System Output--I-V Curve for a Solarex String 41

V

3-1 Power Conversion System Efficiency 48

3-2 Output Current Waveform 49

3-3 Grid Voltage Waveform at System Output 50

3-4 Rate of Rise of Output Current atTurn-On 51

3-5 Test Set-Up for Cell Breakdown Tests 58

3-6 Comparison of Current-Normalized I-VCurves for Solar Power and SolarexPhotovoltaic Cells 60

LIST OF TABLES

TABLE TITLE PAGE

2-1 Solar Power System Characteristics 42-2 Photovoltaic Module Characteristics 8

2-3 Monitors 35

2-4 Outputs to the Data Acquisition System 37

vi.

1.0 INTRODUCTION

This report discusses the design, fabrication and testing

of a photovoltaic power generation system. The system

consists of a 60 kW photovoltaic (PV) array, a 75 kVA

solid-state power inverter, and interconnecting, control

and monitoring equipment. The output of the inverter

drives the local utility grid in parallel with existing

diesel generators, providing up to 10% of the grid power.

The effort is part of the Military Applications of Photo-

voltaic Systems project, a joint effort of the Department

of Energy and the Department of Defense.

The objective of the effort has been to demonstrate that

a dc-ac photovoltaic energy conversion system without

on-site storage can effectively augment a remote military

power grid.

The system was originally assembled and tested at the

Delta Electronic Control Corporation (DECC) facility.

Because of time considerations and the delivery schedule

for PV modules, the tests at DECC were performed with

a half-power (30 kW) array. At DEOC the power conversion

equipment operated into the local utility grid.

2.0 DESIGN AND CONSTRUCTION

2.1 THE SYSTEM. Figure 2-1 is a simplified block diagram

of the photovoltaic power system. Power from the PV

array is fed to the dc-ac power conversion unit through

a paralleling and monitoring panel (PMP). The power

conversion unit operates from the dc array voltage and

provides ac power suitable for transmission to the util-

ity grid (main diesel generator bus). The power conver-

sion unit has the following features:

(1) Dynamic peak power tracking (PPT) to extract

the maximum available power from the array

at any time and feed all available power to

the grid;

(2) Output power control circuitry to synchronize

the output to the grid and to control the

real and reactive components of the output

power;

(3) Automatic start-up and shut-down controls

for unmanned operation;

(4) Automatic protection circuitry.

The major parameters of the system are listed in Table 2-1.

2.2 THE ARRAY. The photovoltaic array is rated at 60 kW

at 50 C ambient and 1000 W/W 2 insolation. It is composed

of 169 strings of PV modules, each string consisting of

14 seriesed modules. A reverse diode installed across

each module bypasses and protects the module during

occlusion or malfunction.

2A

0 0

~ 4 4J

0

00

.B C)

0 40

miiC

4)0 Cl).rii >

0U+

T&BLE 2-I. SOLAR POWER SYSTEM CHARACTERISTICS

ARRAY

COMPOSITION

Vendor Code Z modules 756 (13 kWp)

Vendor Code Ymodules 1610 (117 kWp)

Number of modules perseries string 14

Number of series strings 169

ELECTRICAL

Output power (a) 500c, 1kW/r 2 60 kW

Normal operatint- outputvoltage 180?(-2() Vdc

Estimated annuial energyoutpit 120,OO kWhi

POWER CONVERSION SYSTEM

MFC IIAN LCAL

PMi, 76"i x 361"w x "2"d

Power conversion untit 79"Ii x 86"w x 1:"k

Coolitng I1lowtrs iitegral topower convoersLoii itnit

ELECTRICAL

I tput voltag;e 180-29() Vdc Ol)V'ritio1 ,100 Vdc maxitml

Output power 77, kW

On t)pLt frequenc) hatched to rrid (6O i1z)

O1utput voltage Matchod to Igrid(277/18() Vac, "-pli-s4-e)

lE'fficiency 92% a 60 kW91% 0 30 kW

Output current distortion(TI|D) 2.0% " 60 kW

4

2o2o1 The Modules. The modules are of two typess the vendor

Code ZI modules shown in Figure 2-2 comprise 115 of the

strings (78% of the rated power); and the vendor Code Y

modules shown in Figure 2-3 comprise 54 strings (22% of

the rated power). These two types of Block 11 2 modules

differ in almost all parameters including electrical out-

put and physical dimensions. Table 2-2 lists the major

characteristics of the two types of modules and Figures

2-4 and 2-5 show typical I-V curves for the two types of

modules.

The modules of each series string were matched for output

current characteristics so that the higher-current modules

would not be limited by low-current modules in series.

The short-circuit current data provided by the manufactur-

ers were used for current matching.

2.2.2 Module Frames. Support frames were designed for the two

types PV modules. The frames for both were constructed

from rectugular steel tubing with T-section or rilht

angle cross braces. Figure 2-6 shows one of the Code Z

module frames being welded on a jig developed at DPCQ for

that purpose. After construction, the frames were hot-dip

galvanized for protection against the environment, rthe

Code Z support frames hold 7 modules (half of a string)

and the Code Y support frames hold 14 modules

I Refer to Report Number DOE/JPL-1012-W0, "1, viroumentalTesting of Block ITI Solar Cell Modules September 1, 1'7Q,prepared by Jet Propulsion 1,aboratory [,Pl )

2 .1P, designation.

5

TOP V,:1A 1

Photos courtesy of JPL

FIGURE CODF Z MODILE

'I6

TOP

BOTTOM

1 IAI I~ - I CODE, ' MOIl1I,

TAiBLl 2-2". PHOTOVOLTAIC MODULF C HARA'CTIlISTICS

CODE Y CODE Z

PHYSICAL

Dimensions

Length 22. to 0 to

Widtl 22. o" 1. "

Ile igl t I . 8" I ."

Weirht q Ibs. I.7 Ibs

Ntmel)er o1 el c s vI; IsO

Cel t I li mtete 1"1

Cell type N-P 11-N

F1, 'T"R TICA IL

Rated voltage I).8 V I.8 V

Rnted cilrreiit I.1$ A 1.81 A

Rated power l8s. w 2.0 W

!$

2.8[

MODULE SERIAL NQ: 780102405

2.4 -MODULE IRRADIATION; 100mW/cm2, AM1.S

MAXIMUM POWER

1.6- AT NOCT*

1.0 -CELLTEMP (*C)

*NCT=N ivn I'emenxuriix

VOLTAGE (VOLTS)

FIGURE 2-4.. CODE Z MOTAIL~s I-V CIURVFS

2.0

MODULE SERIAL NO: 032537921.6- MODULE IRRADIATION. l00niW/cm2 AMI.5

1.4

'Ur.

z

.6-

CELL0TEMP Q C

NOCT* +20 -20

*NOCT=Norma. OperatingCell Ternperiiture=147. 10C

0

VOLTAGE (VOLTS)

FIGURE 2-5- CODE Y MODULES I-V CURVES

10

ALA

(one string). See Figure 2-7.

2.2.3 Supports. The module frames are supported by wooden

shear panels as shown in Figure 2-8. At the DECC tempo-

rary installation these shear panels were placed directly

on the ground. At the permanent site they are mounted

to concrete footings to withstand 120 knot winds.

The 250 tilt angle of the panels was selected to provide

the maximum integrated annual output power at the 32. 0

latitude of the permanent site.

2.2.4 Permanent Site Preparation and Footings. Figure 2-9

shows the permunent site for the solar installation

after grading and trenching. Concrete footings, 12" x 12"

in cross section and 191 to 28' in length, were cast at

a remote location, transported to the array site and set

into the soil. Splices between footings were poured in

place. The wooden shear panels are bolted and braced to

the concrete footings, and the frames are bolted to the

shear panels.

Figure 2-10 is a photograph of the installed array.

2.2.5 Electrical Interconnection of Panels. Each row of PV

modules consists of several strings (typically 12 for

Code Y and 9 for Code Z). The outputs of the

series connected strings are wired to a row terminal

-B j.12

3"x11x'1 6"

RECTANGULARTUBING

FIGURE~~~~ 2-7. COEZ6N"CD

1683

flwr

4e,

a '.-*-.L4

H

-, <

H

1<I.

I h-I

-, V

- .-

-I

I;

> I

16

box. In addition to providing a termination point for

array wiring, the row terminal box contains surge sup-

pressors for lightning protection and test plugs for

monitoring individual string voltages. The array inter-

connections are depicted in Figure 2-11.

Underground multiconductor cables from the row terminal

boxes connect the series-string outputs to the parallel-

ing and monitoring panel. The paralleling and monitor-

ing panel is located in a building with the power conver-

sion unit. The power conversion building- is visible at

the left side of Fitulre 2-10.

2.2.6 Groundint. The PV module frames of each row are connect-

ed together and to a buried Cround bits which runs along

the west end of the array. The ground bus also circles

the power conversion building to provide a Tround for the

power conversion equipment. It is connected to the diesel

power plant ground.

2.3 PARALLELING AND MONITORING PANEL. Figure 2-12 is a sim-

plified sclematic diagram of the paralleling and monitor-

it r panel. The output of each string of PV modules is

normally connected to the common bus through a fise re-

presented by Fl, a blocking diode CR1 and a switch S1.

Meters MI, M2, M3, and M6 monitor the operation of-the

entire array: output voltage, current power and accumu-

lated kilowatt-hours. The 169 switches represented by

17

Module Module' [ l.e Mdule [Modul e Module

1 2 7 8 1") 14

+ + + + -, +

At gntra-tring Wiring

Stringi IStrifid [" trill

S 2 -L 11

L Row Terminal Box

41 Undercround Multiconductor Cable to PMP

B. Inter-String Wiring, On1e of Eighteen Rowe

FIGURE 2-II. ARRAY INTERCONNECTIONS

18

0. 0ar

00

H go4 0

0 0

CA 0 0

~0 En

_____ _____F-4

10 r14UOUl

.00

> HZ

HO

0

0Z

0~ H4FO~ 0 P-

44)

19

Si are three-position switches. In the normal "line"

position each switch connects the corresponding string

to the common bus. In the "off" position, the switch

disconnects the string from the remainder of the system.

In the "test" position the switch connects the string

to a test bus for evaluation. M4 and M5 provide measure-

ment of the test-string voltage and current into a load

selected by S2t open, shorted, load A or load B. Loads

A and B are the average peak-power loads for the Code Z

and Code Y strings respectively.

A shunt resistor represented by RI is incorporated in

each string to provide individual string-current informa-

tion to a data acquisition system provided under separate

contract. (For more details see paragraph 2.5)

Fiutires 2-13 and 2-14 show the front panel und interior

construction of the paralleling and monitoring ptunel.

The wheel-like construction at the back of the cabinet

is the "- array bus" shown in Figire 2-12. The resistors

Ri can he seen radiating outward from it.

A ground fault detector is included in the paralleling

and monitoring panel. The detector transmits a fault

,ignal to the power conversion module to operate a warn-

ing lamp.

2.14 POWER CONVERSION UNIT. The power conversion unit, shown

20

I t,

i 4$t v it i, i

7 At,

I"I I%( AN h) MO I IO IN( ___F

:?O I' V

-i 43

in Figure 2-15, includes input and output contactors,

an input voltage limiter, a dc-ac inverter, and system

control circuitry. Figtre 2-16 is a simplified block

diagram of the power conversion unit.

2.4.1 Input and Output Contactors. Input contactor KI is

operated to short the PV array and disconnect the array

from the pre-regulator when the inverter is off for any

reason. Output contactor K2 is operated to isolate the

inverter front the grid when the inverter is off. K1 and

K2 are used in the automatic start-up and shut-down

sequences.

2.4.2 Voltage Limiter. The preregulator limits the maxinuxin

inverter input voltage to 290 Vdc. During nornal opora-

tion this thyristor buck-type regulator is in the "ftill

on" condition and dissipates very little power (less

than 16). The limiter protects the inverter dutiiing the

start-up sequence between the time Kl is activated and

the time K2 is activated. During this period the iput

voltage front the unloaded array can be ats high ats 400 Vdc.

2.4.4 DC-AC Inverter. The dc-ac inverter is the same inverter

used by DECC in its Uninterruptible Power Supplies. This

self-commutated power inverter uses pulse-width modula-

tion techniques to generate a 3-phase, 12-step sine-wave

synthesis. The pulse-width modulation provides control

of the dc/ac voltage ratio. The lowest order harmonic

23

I A

*640*0

A4

- - -- Cl

-- - a - - a a-

- -- -- - - - a a a

- - - - - - -a - a a a

24

.0

0- V

C'd E 0.

4J~

L- F

N N CUU 0

4+) 4D

k 04HH

25)

produced by the synthesis is the eleventh. Only ininimal

filtering is required to ensure a total harmonic distor-

tion of less than~ 3%. The series inductive component of

the output filter is also used in power flow control.

2. '.~s System Control Circuitry. The system control includes

array peak power trackine anid output power control, auto-

mat ic start-uip and shut-down controls, automatic safety

and protection c ircuiitry, remote sinit-down control, and

status moni tors.

2.4'. 1 Peak Powet, Tracking and Power Flow Control. Peak power

trackinug anid power I'1ow conitrolIs ext rac t the maximlum

aval latle power From the array, provide stability in the

face o t chaninitg a rray1 c ondi t ions, and minimiz~e the re-

act ive' outpuit power.

Th~e priI aryV -on t rol loo gneats phja e i t'1erenc e

9,ac ross the, serie s inductive c omponrent of the output

t'il.ter, resuilt lug in the flow of power to the grid and

load lug or the array.

A secondary control loop provides the peak power tracking.

Control c irculitry applies a half-Mortz modulation to the

phase diftference, .p and the pulse-width modulation index

of' he ilvrte, an moitos te drivaivedP/V a th

the peak power point.

A tertiary control ioop adjusts the output ac voltage

from the inverter for zero reactive power as depicted

in Figure 2-17.

2.4.4.2 Automatic Start-Up. The solar power conversion system

was designed to allow unattended operation over long

periods of time; operation is entirely automatic from

start-up to shut-down. The operation sequencing is de-

picted in Figure 2-18. When there is insufficient solar

power available to support the system losses, (e~g. at

night) the power conversion unit turns off automatically.

When the power conversion unit is off, the input con-

tactor Kl is deactivated, shorting the array. A small

amount of power (65 watts) is drawn from the utility

grid to power stand-by circuitry. In the course of a

normal day, as the insolation increases, the array out-

put current through Kl increases. When this current

reaches 10% of the peak current, the start-up sequence

is initiated. If the grid voltage is not within 10% Of

the nominal value, start-up is delayed until the grid

returns to that range.

When the start-up conditions are met, the start-up se-

quence is initiated (TO). At To, bias power supplies

are energized. Five seconds later (T 0+5)o the input con-

tactor is energized, unshorting the array. The input

27

L

V. V

V. = Inverter output voltage1

V = Grid voltagegVL = Voltage across L

L = Effective series inductance ofoutput filter

a. Single-Phase Equivalent Circuit

J

v L

Vg

power flow control

: power factor angle

V V: adjusted to set G =0

b. Vector Diagram

FIGURE 2-17. FOUR-QUADRANT POWER CONTROL

28

LI

zd -) A- -- 4-

HH

P 0~ 0

UUr 0- 0 C

0 0. .U

0~ tu)0f

4.))

I'd-4 000 -

C:

CHr

b.) 0

00 -v. +4UU)

00 0 00 ) 0

0 1)4. 0 0 L taI0 (z 0 &0

44 i >U C4d U)U)4, U)

.0 4U) 0 U) Tq 1 0L c

k 0 4 *v4, 0) 0U) 0~ kU 0 CU -C0i C);I4L>~ .. -P v4

4J CUF.la 0 )), 2 0

'0 L~ 3) 0 4-29.

voltage to thle power conversion unit rises and the pre-

regulator anid inverter comimence operation. Control

circuitry synichronizes the inverter output to the grid

and controls the inverter ouitput voltage. The preregu-

lator limits the input voltage to 290 Vdc.

Teti seconds latex, (T 0 +15), frequency error and lilie match

error detectors are activated. If the output frequency

deviates front the range of 00+2 Hz at any time after

T 0+1'), thle power conversion unit is g-ated off and "'error

recyc le" sequeticke is initiated ( see paragraph 2. 4.4.*3)

At T 0 +20, the three-phiase output contac tor K2 closes.

Closure is prevented, however, if the voltage across K:?

(any phalse) is gr eater thai: 7 of tile nominal linie-to-

neutral voltage. This assures that thle inverter output

is inatchedi to the g-rid inl voltage and phase.

After T ()+20, thle Power Conversion unit is ill thle opera-

t ion~al miode; all power flow. control and fault detection

circulittry is activated.

.4 ~. 3 Shut-Dow-ni. There are six basic types of shut-dow-n for

the power conversion unit:

(1) Manuacl Shut-down in Response to the On-Off Control

Switch. When the Inverter Power System on-off switch

on the front panel of the power conversion unit is turned

30

wmmU

to the "Orr'" posiitoni, itor'ini 81u1 i-dowii 01'etIil's 'phi

POw('r couive r-41 oil ilt t ri'tfl i is 0 F' jiant-I I the' ow I tela Ls

tlrfliod to tilt,'toil,, p081. ti. Ol * 'Phi' powe r coiaveisiol 01 illit

thIeni starts lip i.f' the tiornui stioTt,-ap eoaid Iti ouas 11', ie

(2) M11.11111i Shilt-dowai Ii Re poaa so to the~ Einlrgvsliy 011'

Switch el 11111,111c the, wlomen it iy FVme' rgean'y 0r1' sitch'

iii1t Iiate 8 l ordeorlIy i t t;-dowii its tilt oti-oI swi 8tc'h does,

anld id-s0 oj)olls lilt ox terui . I tl.cii It 1wi';%kori, lreIIov i-i ii ii

ac0 powo'r t'vom tilt, titilt Thai' c I rot I Ie''kei 1.8 muomitod'

Ott tht' ivol. ofthi W'1' C rvolive ai4 I i )lidi ii. ,lldt mulst

Ill voe'i' 108e'I t1zl1al Iy to t-o iHiuIt' oivn'1liti 011

thte power' oIviab nI.I roil tile PV ara'l£V isI i-ltl' ii

Itth Is lOVQI'8e po ilo'2 low i'vos il-el it'v callt's lhitill%0

4b111111 ofa ph-o r ''l to C 'lw n 111- rih ti.' t * e 'I I' t oa ll- Cht I' i

rfv ~ ys ' tilt' I-VV S4 I)1.8 dl prevol 41111 8! I'o 1111l t- 10a

01- lil ' t te , t lt, ihtit' lug l-s~ri i l 1111 1 shitt o wi otII

(I, itt;-iowii wi th Aittonuioth l i' t. iirt whientheli F'.11t t;IsM

Cie~ia'ei Aui illtei'lovc C Ii'dI.t till'lm tilt powor 1'CoiivOX'M i

tiltilt ofT' It' all tinto riock loop 1 s opened. Tlhie titerloc k

loop itic hides4 alxi 1. ary l~ciltat .s Oil tilt, 11141 jort 14s~'t-4,1ii

siw t tes , i.tieI tilt t lt- theit emt tt c iv t' I t twnaki'' o lit

tmI L t vo -Atavt -% ait tmit i t. I aI v wimi thev lk-op i . v I oftit

1 ) rovidedl till 1101i11111 s 1 a11 tt;-11 0p kitl( i. t.f l I I lle tilt

I) ) Slitit-dowit witth Anttoia tic Hlecyc 1 lug. tysv ys 1 ('11

'lil t's, s4ttch .. lit li Itv ltit. di st~it'it's , I t'ttd t o Io

t rat Ie to I It i na1 tnx r'e . PTe powt' 1, c oi%-(,s 1 on11 m% it pr1,o 1 4, s

it sc1. t, i l 1. I t t IIt, -4t' V IIn11. t s 11.% slt I t.II I I ( I kloI ttI*I Io I1vo i di

1111ttt0t' 4' S sit 11% i t't I 4 t III nh t 4, 'venl i oil t til 10,: CO~tt 0%vr I ti

111111. 1 a i t -1t' d t t-o 'st k t - il ;I t; it ;%%It -opw t .n t a N. S

vt't ko t s I tt't I stil' tt -down I C ut lit .t4' t itt I % II %-id a t i i o

i I'll f i tt' M tiltatI, v s t ' 1n .4 t't ' - tll t'It si htV Mlp ;I V

w fi I I I1 80 s trottis 0o I lit, o1. t, i ma I oan I I , t lit, ow I~~' % tOtt-

v&e 1-M 1 oil t uIIn A I sIt I I -; lohOito t I 1 ', t,' t u I I I y Ill I vt Vali I I is

(a) IcII.;it -&illtv gduil u i'it'civ h ~ t I f :'tg'(o0: i

v) v i k i i 'vo t age ull t N. t'gt it I I + I 1014)0

v) rics i dt vol I t lw t'i'ttt t'VcItt I I lii' loit't 111.1 vt't+

Vu c su st I vI , oil 't'l I t' ita 100ol ampsil I' 1 04 )ow ,I 0 n1 Vi V-

..;till till i . (t",ta I t 4 ' I . it 1 7' o iiils poea k Itt, anI a-II

staot -11p1.

(i) Sil t -ulowii H4,4t''i rt I 1tg Manna 1 11 o -t ( t So Sven ltVim I t t'ti-

11 e 1115 t'fht4' thei potWtt' V t'1 OIt' lou I uti tI %11hut tiowit

until reset maiuily. These tire f'aults which require

attention by service persornirel. They includes

(a) Overvoltage at the dc bus-- input voltage

regulator not operating properly,

(b) Output undervoltage during start-up sequence-

inverter has not produced full output voltagee

by the expected point ini tihe setilencef

(c ) Openi fuse-at output or tit inverter power

stageo,

(d) Excessive reverse power into the inverter

from the grid--power flow control c ircuit ry

tIot opei'atitig Ipoerly,

(e) overtemp r'atrv w Ithi in the p)ow'er c otiverstIoni

unlit, anld

(f') Incorj'ect bias voltageos-bias suipplies iot

opei'ati It uI popt'] .

All six typos of' shut-dowii diet i viit KI , shorti tig the

array , .1nd( openl the Output con tac tor K2. * ilA supplie s

rematn atitvated f'or it shiort t int to as sure' orderlN

shut-dowit.

2.4 r Moitors * The solar power couwers toil system inc ludes

r meters 1(i stiltus lamtps For mo1u1to ring of uormal itid

abnormal operiit ion. 1iThe PMI' hits .qix mevtot's; the power

couvei'sion uiI.t hias elevenl meteprs tud twenty-six .4titus

lamps. Gonornrlly, fault condition iudiciitor lamps ro-

maxin it after shut dowit to assist iii fault diagnosis.

The monitors and their functions are listed in Table 2-3.

No audible alarm is included in this system which is in-

stalled in an unmanned building.

2.5 DATA ACQUISITION SYSTEM. A data acquisition system, pro-

vided under separate contract, processes digital and

analog outputs from the power conversion system for local

monitoring or for recording on magnetic tape. The outputs

provided by the power conversion system are listed in

Table 2-4. The data acquisition system will also monitor

a weather station to be installed at a lateor data; al

insolometer has beei installed already. Tho data acqui-

sition system inc ludes data scatnuers, a pro(grammttable

computer, input keyboard, CRT display, printer, anid a

dynamic load. Fitres 2-19 throtih 2-22 are typical of

the types of output available at the CRT and p-riiter.

Figure 2-22 is an I-V curve for a s i.iglv ('ode Z

string. The curve is geterated itsing the dynamic load.

The data acquisition system was provided by Santdia

Laboratories.

34

0

44-2

0'

02 d ) j)C

4) -10$4 D f

(d) 4U) U 1

o PU 4) CZ -fI4) 1 dcd

4) P m0 >> 4 'r - P , 0 :3 4 )

UUU-- 9 0- c0 P0C P uz )4 d kC--P 4 0 Cd4) 0 ) 4) $ CUC' -1 0U 4- Q - 0

> 0. o Y4-) P 14 4) ~-4 C.) -PHD 4 )k$o$0> )4)4 -)riPQ , , P4)C - V)+ QUU~ p) HOO +d 4) O0

M 4 -P- C 4)4D 4-)4DZ UZ 0 Z 4) + ) P4) 4' 0$ r r. 4-) 4)W. o 40 :3 ou 4 d4) 00 4)-P 0v 0 i CU 4) $.i( )-l ) 0 - Q 4 4 00 40 .- H -PP$ $4 4 Q) r 4) 4 >-~ 0 0 + -4 D

0 -0 - -H $4l -r4-) - PJj 4 CU P 4) 0 CU $4 u Z 9 0 0 0 0 0 (:0 .) d d41 F 9 F~ > 0 0 .,j> 00 kk 4 O- H Z 4 0

z ~ ~ ~~. +)P4-H$4 or o~ 0 P- - 0-PC4 >. H ,u :$4 k CI4) $4o0U) 4) UP-P-P b~~4J + -P-J P-4 P4- d$4k4-'4 4) 4) o co.)4k

>1> % > - - - 4): 30 : r 0 z 4) U 4)() .,1 ; 1- 1 > ) U~0- W 40- d~4 00 3." S 04 4-4 C-P44-) 04 u Cd 4 4) 1 1 1 -P

H C 1 4) Q.+ 4UU-1 4- .q+) + 41 04) +*r4 -, (4 H4-P$4)O> H -r

o d k$ 4a 4) k~U z 00 00 0-P_ Cd 4 4P+) 0 44 4-4-P4

n 14 -4 4 H H F-P- 0P- 0 00 00 I4)40 w D0

4) 4)4(D4)Q) 4) (1

CU 0CdC CCd mmCUmP914 44 P4 04 04 13

u () u u() u u CW 4 4 4Db. b r4-r -HE H-HEEEEr -

0 00 0 00 1 1 111 11 1-P- --- P- P-P P- P 4-)-P -P -P -P4 P- 3+ )4 J 3+ )- P- P-

.Hr jr r 4Hr r r H-H- H-f H-l *l r r H r r r r r r r 4 H 4

;Ik 4 $4 $ 4 k 4;;4 & $4k$k4 k &I 4 k $4 k $4$4 4 $4k

0O4) 4) 4) 4) 4))oococQ 0OC)O.OOOC).O4 -4 i - r-- -P - -HH H4 $4-14$4 $- 44 ;q4$44$ kf,

0

.ri 0 -NCli1 -t O L

35

0 j b.

V. 0 00 0 0t 4 ~ 4

0 0 0 4) 04 . 44cU L

> >

0) +1 4)PrE4

4) 0 o4

0 Q4 CHWW4)uMOH

La.I

4, -

-H -

) k k $4 $4 14$4 . 14

0 0000 00 oo00

0

or 00 0000000-0 mmmmmmom

36

TABLE 2-4. OUTPUTS TO THE

DATA ACQUISITION SYSTEM

Output Type Voltage

Series string current(169 outputs) Analog 1OOmV/A

Array current Conditionedanalog 5V/300A

Array voltage Conditionedanalog 5V/500V

Array power Conditionedanalog 5V/1OOkW

Array kWhr BCD 0/14 V

Output power Conditionedanalog 5V/1OOkW

Output kWhr BCD 0/14 V

On/Off Binary 0/14 V

Off-minsufficientsolar power Binary o/14 V

Off--error shutdown Binary o/14 V

Off--error recycle Binary 0/14 V

37

tlT t Hu(iTfal Sol~.' T 1wfI

~~4Jrt~fl il& [I I I- 111 1! uEYr

CLL _20TOM WL

&W1511toN .1 r

FIGURE 2-19. OUTPUT FROM DEMONSTRATION PROGRAM OND)ATA ACQUISITION SYSTEM

738

. - ' . .- ' ' ' -

.. . . . , .. . . . . .. .. . . . . .. . .. . . . . , , - r . , . . . .. . ..L- .. . . . - . . . . ' ' . .

rt,.I 14, 1 ;'9 1 "1-8 ,8 23

SYSTEI $TATLI$

S',STEM C OhlI 11 IOtNS

:.,:LFr 114i.,LAFI ION IS ' 1000.8 WATTS PER SCURRE IETEP

114 .ItIENT AIR TEIlP'EPTLIPE IS 68.0 DEGREES F

iF'PH', iIL11UT CUkRPEtT IS 250.9 RMPS

APPH- li' ll F' V i' Tl-,i IS 22. .4 VOLTS

mF'A.' 0I1PUI POWER 1. 57.6 KILOWATTS

(ONVEPTEF UL'TPUT F'IWER IS 52.0 KILOWATT':

i*RA, MET'R FFHDI, IS I1'F. KWH

',tjVF"P'k IETEF PEHEIING IS 899I WH

iwBt fiih t4 F ': INC C.FtElU . FF1I1I THE ARRAY

I,,l L.$ 1".7" - I 3 2" I IME AT STIPT OF SC Ai

i. 1.u 17. ;4 1.O 1.'98 1.98 1.". 1.67 1 .75' 1. - I 80 1.72 1.2 ) 2.0 2.00 2.01 2. O1 .0,

• .' 2. 1: 1 94 1.7. 1.99: 1.62 1.. 1 2-.00 1.81 I "

I.67 1 1 17 2.03 1.59 1.94 1.64 1.90 1.744 1.64 1 .8 1. 72 1.88 1.96 1.84 1.86 1.94

1.'4 101 1 h7 1.' 1.6 1.85 1.60 1.64 1.93 1.9'

1. 1.45 1 133 1. 31 1.89 1.65 I T2 1.94 1 .60 1.91.77 1 5' 1.90 1.4 1.52 1.91 1.71 1.88 1.91 1.81

, . I, 15:; 1. 89

6' 1 . 4 .' 1l ,45

1.0 1 : 1.85 1.-: 1 64 1.37 1.86 1.82 1.' 1.sl. , 1 1.5 1 1 1. 38 1.94 1.94 2.06 1I... ,.0 '

1: 2.20 1.66 1. I172 2.08 1 63 1.60 1.13 1.8

1 i'l 1.14 1.01 1 L 3 1.16 1 .15 1.23 1.21 1. :1.11 I.2"J .14 1.11 1.13 1. 10 1 .0 1.05 .91 1011.)1 1.11 .0. 1 0': 1.04 1.05 1 .0: 1.13 1.04 .

1, 1.12 1 .L I .0 .89 1.09 .92 1 .09 1.03 1 '1 I 1 0 1. 11 1.11 1.15 1.12 1.08R 1.19 1.13

14, 1","9 at 1"' 8:45 TIME RT END OF SCAN

FIGURE 2-20. DATA ACQUISITION SYSTEM OUTPUT

39

. 14

"1... , , '"-a # ' , ,

I T LIi ' THRI I T -L% I-'I (J'.):. 1 1 h 7 I U.'l!1 '. I i.9 F' I-_

. \. Iii 'I i",II

Li "4 I

W~~~ ~ ~ I\1 111R

f I tl LILM04 i t1T 1.1, i I r. tol

q.1

FIGUR 2-1 AAACUSTO YSE U1U

- l ' "4o

hl,9 13,19?9 1 '3I:54

Opl,) c rcult ,o t i , i ' 7'06. 92 Vo: I"Sksort c i rc iI C .dr r ', I1 . " Aimp,

max I filuM powtr of I' r Ing ls 176. Z . | 1 7 t i

u,,I.|, 2%0. 87b Vo I . "04 . IIpi

. 800

LA)EL

U

_-1CL

I..)

.10 0

clCLi-i

.200

FIF~tY C..T HGE: T '

Run on C1ug 1 3,1973 i 17: 1~E:kj

FIGURE*2-22. TYPICAL DATA ACQUISITION SYSTEM OUTPUT-

I-V CURVE FOR A CODE Y STRING

41

II

3.0 RESULTS

Since the first testing of the power conversion unit in

September of 1978, the results have been extremely gratify-

ing.

3.1 OPERATION OF THE POWER CONVERSION UNIT FROM AN ARRAY

SIMULATOR. In early September, 1978, construction of

the power circuitry and basic control circuitry of the

power conversion unit were completed. Normal operation

of the power circuitry was verified in September. In

early October, the power conversion unit, operating from

a current-source array simulator, delivered power into

the Snuthern California Edison Company utility grid.

The tests demonstrated the stability of the power control

circuitry and the operation of the peak power tracking

circuitry. The tests performed were primarily qualita-

tive and the tinit met design goals, operating stably and

tracking peak power to within l9.

3.2 FIELD TESTS WITH PV ARRAY AT THE DECC FACILITY. During

the autumn of 1978, a partial array was installed at DECC

to allow system testing. The array consisted of some

Code Z and some Code Y PV modules mounted to their

frames and interconnected as they would be at the per-

manent site at Mt. Laguna. Some of the module frames

were mounted to shear panels while the remainder of the

shear panels were being installed at the permanent site.

42

By January 10, 1979, enough strings of PV modules were

installed to begin system testing. There wer'e no sur-

prises when the system was operated in its normal mode,

extracting power from the array mid providing power to

the local utility grid. By March, 1Q79, the system had

operated successfully at array power levels up to 27 kW

(the maximum available from the partial array). The

system operated normally, without unnecessary operator

intervention for 43 days ( 414 operating hours) at the

DECC facility, extracting a total of 6218 kWhr from|| the

array and providing a total of 4861 kWhr to the utility

grid. Because the testing was performed during a southe'n-

California winter, the array was exposed to a variety of

environmental conditions: temperatures from 3t4-OOF,

bright sun, dark clouds, thick fog, heavy rain, and hail

with stones up to 3/8 inch iin diameter driven by strong

winds. The only environmental damage observed was the

flooding of some temporary underground cables from the

array to the power conversion system. Because of the

temporary nature of the installation, a-nd the expectation

that the underground conduit would remain dry, the tempo-

rary cables had not been designed for submerged operation.

Thoughout the testing at DECC the power conversion system

operated without failure. The entire system operated

through an hour-long series of intermittent brown-outs

and black-outs of the local utility grid, shutting

down for self-protection when necessary and restarting

automatioally when appropriate.

43

3.3 OPERATION AT THE PERMANENT SITE. On May 29, 1979, the

power conversion unit, PMP and a few remaining array

elements were shipped to the permanent site at Mt. Laguna

Air Force Station. Most of the PV array and system inter-

connect wiring had already been installed at that time.

The power conversion equipment was installed and opera-

tional within a week. Since completion of the installa-

tion in July, the system has been tested and operated

under the local conditions. A formal acceptance test was

performed to verify conformance of' tile system to the

primary requirements of the purchase description. A copy

of the procedure and results of tile system tests at Mt.

Laguna and at DFCC are discussed below.

3.'I SYSTEM PERFORMANCE. Tests performed at DFCC and at the

permanent site verified that the photovoltaic power con-

version system met all of tile primary requirements of

the purchase description. Although tile formal acceptance

test (Appendix A) was performed during a brief two day

period and under tile prevailing environmental conditions,

additional data were taken during later operation and are

reported here. The data acquisition system was particu-

larly helpful in taking approximately concurrent readings

of the monitored parameters. At the time of the observa-

tions, the data acquisition system was programmed to

44

provide "1hard copy" daIt" 1)titltolits onl request.

34. 1 Modes of Operation. Tho purchase description for the(

PV system called for a power convermion unit ciilpabl('

of operating in two distinctly di fferent modes with

only minor modi fications of the circuitry: (1) tile

atigmentat ion mode, wi th the system operating ini parallelI

with a uitility Irid and no hte s toratge , and (2?) tule

s tuid-alone mode, ilidepetldenit. of ' u 1. 1 1t poweri', wi th

battery storaev andi opel'mti on 1 mto a1 dodi-catod loau.

Thto powert cmOive PstIoi sy st em i Wl t i'st ei i-ii mode(1 1 , tho

.lgle t11-1ia t I on mode o, only.* The' Pc sumi t of 1. hosv5 tests

a .1ro ) tidh Io The poworu c ircu it ry of' the sy stvcii,

Ic ilig the' dc-dc( conveter ( Inplt regu a toIr/Vo It age

1 jmi tler) anid (ic-ac iiiverter are thoso tsed liv IWF' lit

its 02.1) liicmtoerrmpti.ble PloWor Smiplies (I'Ss ). Time

UPIS opera ito. 5 1Lkt' a :110(1 ? PV powr colive rsioti sys tenm,

e xc opt tha t the( Iiinpu t dc -c -oniverter operates f'romi

rce'ti fied tti-I-Ity power ra ther thii solaim powe.' 0111ny

the conitrol c ircititry wouild lim-vv to be modif1icvd to ccii-

ye rt the PV system from mode t toi mod.' 2 ope rait ion TI 'i v

02.1) kW UiPS charactertstics an,(' described below as 41n

Imdi at ion of' the performa-mce which can be expected in

a stand-a lotte op('ra ttont of' the( TPV juower c oliver1s iou1 sy'stem.

1.14.2 The Power Coniversion Systemi.

1. & .2 *I. input Power. The owr~ emi xverxs toii sys$tem opt' iatotd prio-

perl'1y thrlough-Oout thlt ranlge t'xoml no0 i uxput Powe'r upl to

thle max twuni obst'i impt poweri, (P)kW * Thlt power Coll-

V0ex's ton sys temt tracked tile array penk power to wi thit

1% ( typically 0.1'4) ovoX' tile Input poweir ranige of 10-00 kw.

~* * * 2 llpt. Volt age * Thlt power conlve'i onl systeml operiatetd

pi'ope 'l y over thle rangeI~ ort peiak piwer1 p0oint s eltv oilit ered

and pr1ottttt ttsel t' aga Lust unloadted arrayv voltage.* The q

sy stemtt wasM totodtel t Litlput VoltagoM 2'01A allove mid lie low

thle twill power poijut 11% ope'at tlg tilt,' nutiltx 1 ovori'ite

akitlitstiiit . phe systeii opt't'ttetl stalIy bot'h ab~o and

bet'low tile' pe'ak powerI po i it

Ol.: * til Oupt Powt'u'. Opteralt out Io(t' t lit, powe r k colive 'SLou sy steml

fta s hoot' dt ttimoti s t 1'.t t td ,akt oil t, litt powe, I, I o'v t, I s up1 t o 60 k W

I 4 . .~i Olt t put vol tiage * As t estetd Lit mtott I opj'rat Ion, tilt powerF

ciy't ott Systemlt olitilput voltait Is ekilal. to thle liti-itv

gid t vot tlt' 11%. tI altitty. * PTe 4vs8tt out opt' vat ed pro pt' x.1

overt ii I i t%-va.ttgt gid t cotdi t tons e'it' olilttrt'a dur'Lig

te's t ittig.

ie'tu t ilt, 5itim.tt'tvt' Fr tot' hs liteen1 It sod I tII UPS appl lIt'l at I OtIM

i t iias ditttotts t at a'd t'xt'a 1 it olitplt eftaalett'ivst ics.

T'lt,' va I t 'tt't t'lu I it ti ott i s t yp Iti1 ly + 1%6 wi tit a Itamea

itilta 1attta'a tfit' les tittit 0, '1q0 titt) 1.1 o- to-titrt.l 1Volt afgt

PTe phxaist' t aiat''t'Imti 120+1'I0 for Ionta tutilbatii't till

to 30%.

3.4.2.5 Efficiency. The measured efficiency of the system is

plotted as a function of output power in Figure 3-1.

The overall power conversion efficiency is 92% at 60 kW

and 91% at 30 kW. The no-load losses (input power from

array with zero output power) are less than 2.6 kW at

all normal array input voltages. The stand-by losses

are approximately 65 kW.

3.4.2.6 Harmonic Distortion and Waveform. The measured total

harmonic distortion of the output current in mode 1

operation is 2.696 over the output power range of 30-60 kW.

Below 30 kW the distortion amplitude remains relatively

constant (approximately 1.3* of the full power output).

The output current waveforms at 14 kW and 45 kW are shown

in Figure 3-2. There is no observable disturbance to the

utility grid voltage. Figure 3-3 shows the grid voltage

(a) with the power conversion system off, and (b) with

the power conversion system on and delivering 40 kW to

the grid.

The output voltage of the same inverter operating as an

UPS has a total harmonic distortion of less than 3% with

a maximum single harmonic distortion of less than 2%.

t.14.2.7 System-Grid Interaction. The power conversion system

incorporates soft-start characteristics to avoid

47

80

~60-

50.

10 20 30 40 50 60POWER NkW)

FIGURE ')-I1. POWER CONVERSION SYSTEM EFFICIENCY

AS A FUNCTION OF OUJTPUT POWER

48

Ii

I S

I,. I. I

~ \ S.

i~t~ i

I. -.

LI

I * I

\ .\ "1

Ii

spoon

FIGURE ~I 1 RATE~ OF WISP' OF' O UT'PUT ('1 IH1R IKN ATl ltI'PN- oN,

lIOIUIONTAi ,I,[ LE -4coN1)SIDLVIS ION

VERTI1CAL. SCALF :152 ANIS/I)JV-1.SIN

disturbance of the grid at turn-on. Figure 3-4 shows

the typical rate of rise of the output current at turn-

on. The small mismatch in voltage and phase across the

output contactor is responsible for the discontinuity

seen at the point of turn-on. There is no observable

disturbance to the grid at turn-on.

There was some initial concern that the abrupt current

change at turn-off would affect the Mt. Laguna grid.

Fault shut-down during high-power operation was of partic-

ular concern. DECC planned to perform a set of tests,

shutting the system off, first at very low power, and

then at higher power levels to determine the affect on

the grid. During the first day of testing, however, the

system was accidently shut down with 65 kW output to the

grid. Since no significant disturbance was observed at

the main power station, no further tests were deemed

necessary.

3.4.2.8 Protective System. The protective circuitry of the PV

system includes, but is not limited to, that required by

the purchase description for the system. (See paragraph

2.4.4.) All protection circuitry operated properly and

workable fault thresholds were established for all pro-

tective circuits.

52

During the design phase it was hioped that the ground fault

detector couild be oper;ated to provide anI additional mea-

sure of' personnel protection by iniiat ing the shut-down

and array- short ing -iequenc e wl en potentiallyv dangterouls

ground fault currents (more thani 50~ mA) Were dletected.

During tests at DFCC , however, i t was found thant whereas

the normal ground current on ;I d ry dat was approximate ly

2 mA, the total array g-roxnd ctinrreu t on Wet days frequently

reached 50 mA * Thu s the grotiid Cturn1t de tector-, as deliver-

ed, operates to provide an i hid ieat Lont of excessive ground

current otIl,, .

3. . 9 Expansion Capabil1i ty . The powert c onive si on svstem meets

the purchalse de se 1.1pt ion requiro'ment s fo r ex pandahi iit\'

in eithaer ope ratinug mode.* III mode, , add in ug mo ther inde-

pendent power c onvers iont -N-st em is e omplIe t clN stra~iighut-

forward.* Fac ii sv stemt is i deedntteon t ro Iled t~o oper-

ate into thme utilIitvl griti.

In mode 2, C ombila t ionl oft two on it s maly he acieved by

operatingl iin a master-si ave mode. flte inuverter has beeni

operated in thi s matnuel in manyi UPS itistallilt tolls.

3.4.*2.*10 Electromagnietic Interferenice. As unttioned a1bove, the

power conversion circuitry and cabinet designi of the PV

system tire identical to those of DFCC's 6:1.5 kVA I'PSs.

aThe resuilts of EMI tests performed on one Suchl UTPS unit

are given in Appendix 11 of this report. The PV power

conversion unit includes additional input and output

filtering which should result in even lower conducted

emissions, and the removal of input rectifiers should

result in a slightly lower radiated emission in the PV

unit. Because of the low EMI levels, the low frequency

of the emissions, and the 200 yard distance between the

power conversion building and the nearest sensitive equip-

ment (with its 100 Mhz to several G~lz operating range),

there should be no significant interference with that

equipment. None has been reported.

3.4.2.11 Audible Noise. No lactual acotistic noise measurements

were made on the power conversion system. An uninter-

ruptible power supply using the same inverter, converter,

cabinet and blowers has a maximum acoustic noise of 85dB

measured at 6 feet from the cabinet. Two cooling fans

mounted in the ceiling of the power conversion building

produce a net ligible increase in the sound level.

3.4.3 The Array. Although the emphasis of this contract is

on the development and operation of the power conversion

system, some significant observations have been made about

the PV array itself.

'.4.4.1 IOtput Power. The measured array output power reached

a peak value of 69 kW. This higher-than-rated array

power was observed at a time when the insolation was

enhanced by reflection from nearby clouds. On a clear

54

August day with 1016 WIM 2insolation and 71OF ambient

temperature, the array output power was 58 kW. WIhen

the data from the data acquisition system is reduced,

extensive detailed information on output power as a func-

tion of insolation and temperature will be available from

Sandia Laboratories.

3.4.4.2 The PV Modules. The only major problem which has arisen

in the system is with the Code Z PV modules. During

the system tests at the DECC facility, it was observed

that some of the Code Z PV cells operated at a con-

siderably higher temperature than others. The heating

effect was observed both with the array shorted and with

the array providing power to the power conversion system.

When the PV modules were shipped to Mt. Laguna, the tech-

nicians installing them began to notice bulges, or

"bursts" in some of the cells. New bursts are still

appearing at the time of this report. Although there has

been no appreciable reduction in the output power of the

array, it is clear that the continued development of

bursts will eventually cause deterioration of module per-

formance and failure of some modules to produce power.

The tendency of cells to develop bursts appears to be

correlated to the presence of high temperatures. The

bursts may be caused by even or uneven expansion of the

cells or of gasses trapped under the cells during

55

encapsulation.

Jet Propulsion Laboratory (JPL), who provided the PV

modules under contract with the Department of Energy,

iz studying the temperature and burst problems and will

be publishing a full report of their findings. They

have found that the temperature of some cells exceeds

the temperature of others by as much as 800C. Two

heating mechanisms are responsible for the high tempera-

turest heating due to photocurrents in reverse biased

cells, and heating due to leakage or breakdown in re-

verse biased cells. A cell of a loaded module becomes

reverse biased when its current production capability

is significantly less than that of the cells connected

in series with it. The first heating mechanism occurs

in any reverse biased cell: the power dissipated by

this mechanism is equal to the photocurrent generated

in the cell times the bias voltage and may be as much

as the peak available power of the rest of the cells

of the module. The power, however, is distributed over

the entire photocurrent-generating area of the cell

for maximum power densities of approximately three

watts per square inch.

The second heating mechanism does not occur in all cells,

but does result in much higher power densities. Uneven

heating in some cells led DECC to investigate the reverse

56I. ih.

breakdown characteristics of the PV cells. Tests were

performed on eight Code Z modules (320 cells). The test

set-up is shown in Figure 3-5. With a module shorted, its

cells were occluded one at a time by an opaque disc.

Ideally, covering one cell in the series set should result

in an open circuit and zero current through an external

short. In actuality, electrical leakage and leakage of

light around and under the covering disc result ini some

output current. For most cells, the "dark" current was

between 10 and 100 milliamps. Sixteen percent of the

cells, however, had "dark" currents in excess of 200

milliamps, 7.80 had "dark" currents in excess of 500

milliamps, and 2.2% had "dark" currents in excess of one

amp. The cells exhibiting "dark" currents of more than

500 milliamps became discernably hotter than the other

cells. In general the heating occurred in a very small

area of the cell, causing an extremely rapid rise in tem-

perature. In one case, when the opaque disc was inadver-

tently left in place too long, the surface of the module

reached a temperature of the order of 80-1000C. The result

was visible melting of the solder and of either the plastic

or the adhesive material under the cell. The cell became

physically distorted at the hot spot. These tests, per-

formed with totally occluded cells, resulted in greater

localization of the dissipation than would normally occur.

Under normal partial occlusion, the power dissipated in a

cell would be shared by the distributed photocurrent dis-

sipation and the localized breakdown dissipation.

57

K> Ixj~4)

4-)8 /H

0 I

Tite Code Z modules .4rev particularly prone to reverse bills-

tug. The I-V characteristics t'or the two ty-pes of' cells-

Lire different as soonttit Figuire 13-0. Vendor Z has attatined

a very sharp I-V curve with at consequent htigh coil eC~i-

ciency. Thto penalty paid for, tit- charc torts tic is the

str'ong dependence of' thet voltage on the current ait high

currents * IV onle cell can' t pr'oduc e as 111icit cuirrenit ats

the other cell s of' the module, the revinailitdei' of' thet modleb

maliy apply a1 sign I t1iclant reverse, voltalge to the liti tiig

Cell ( throuigh the, load).

Tests at IWCC von it'd what thlt en rvt' prod xIct with tilt

1110(1111 oper:a th- I tttito a niormal I oJd , at 20' dit' i ci one In

thlt cliveont c apal.)L I tv of' oile cel c.1ust s at sigiiIc att

(1.0-20? Vdc ) t'eve rst, Voltage across the c oll %Ixk sltn1' 1-

cant power d Iss ipat: bit in tito veil. Opt'atitg into at

short ciL en .1t , htoweve r, 41 vti't'vilt dot ic ietlt oil(lonly 10(%

wi 11 have the saint'e I' t'vet.

Un'o ttunAte ly , seoe t i real iit co"1d nd ition 5c anl re0sul t

ItI L0-20% itso latitl var tatt.i ots he twt'ot c-ells of' a m10(11it'o.

Singlev cci s mlIv hoe('l 01WS1itadowt'tItilt(t, to weed gr'owtht, auld

dirt i st ribu11tion is lit noet'ssai -ly even * Condenised or

proc ip i.ta ttd watter onl the mo(,dules somet timtos causes dirt

to collect on the lower cells. 11ind droplpings tire not

evenly istributed.

'iALI

Code Z

Code Y

L~

H

0.25 0.5

VOLTAGE

FIGURE 3-6. COMPARISON OF CURRENT-NORMALIZED

I-V CURVES FOR SOLAR POWER AND

SOLAREX PHOTOVOLTAIC CELLS

60

.'ONCI 'SIONS AND RECOMMENDATIONS

With the exception of the problems with the Code Z

photovoltaic modules, the operation of the 60 kW Solar

Array avid Power Conversion System has been more than satis-

factory in every way. The array has produced power in

excess of its rated ouitpuat, and the power conversion sys-

tem hits operated within its design goals and withotit fail-

tire during months of testing at DECC and at Mt. Lagna.

Much more information concerning long torm system opera-

tion will become available as the system continuies to

operate at Mt. Lagina and data become, ava ilahie frolm thle

data acquisition system.

Even a system as totally successfutl as this one imust be

evaluated carefuilly at completion with an eye to possible

improvements in future systems. Some of DFCCs observa-

tions and conclusions onl the Mt. Latna system are, di s-

cussed below along with some recommendations for ftuire

systems.

24.1THE ARRAY STRUCTURE. The mountintg frames for thle PV

modules were designed to support and protect thle modulezs

during winds of up to 120 knots. The fram~es were sized

on the basis of series stringr size, tile Code y frames

holding a complete string and the Code Z frames hold-

ing half a string. Thle PV modules couild theni be installed

onl tae frames and the intra-string wiring performed indoors

61

with the panels not exposed to sunlight. Although the

assembled frames proved rather too large and heavy to be

carried by two men, this sizing of frames proved especially

convenient in this application where part of the array was

installed at DECC, disassembled, and moved to Mt. Laguna.

For systems to be installed in a more benign environment,

some savings in weight and cost might be achieved by re-

designing the frames. The frames were easy to construct

using welding jigs developed for that purpose, and a com-

plete Code Y frame could be assembled in approximately one

hour by an experienced welder.

In future systems, the use of wood for the shear panels

should be evaluated in terms of ease of installation and

site environment. Mechanical alignment of the long rows

of modules was difficult, and many mounting holes had to

be redrilled. The use of adjustable U-channel mountings

would ease the installation of large arrays. The ability

of' thv wood panels to withstand the harsh Mt. Laguna

environment should be evaluated after a few years of

exposure.

4.2 ARRAY WIRING. In this system, approximately 1000 cable-

mounted disconnect plugs were installed within the series

strings to allow isolation of pairs of modules and redue-

tion of the maximum daytime service-point voltage to

50 Vdc. The protection provided by these plugs is

62

- . .'j

redundant. Servicing can be performed safely during

periods of low insolation or with the panels covered by

opaque covers supplied for that purpose. In future sys-

tems, the impact of these plugs on construction time,

cost and reliability should be weighed carefully against

the questionable contribution to safety.

Ideally, future PV modules should be fabricated with the

reverse diode installed internally and all connections

made through a connector molded into the unit. This

would drastically reduce the time required to install

large arrays and eliminate the need for additional dis-

connect plugs by eliminating any exposed terminals. At

the very least, the Junction box covers should snap into

place, rather than be held in place by four screws. Using

time estimates from MIL-HDIIK-472, more than 169 man-hours

were required Just to remove and replace the covers of

the junction boxes during wiring of this array. Location

of a faulty reverse diode within a strig could take as

long as an hour because of the time required to gain access

to the diodes in the junetion boxes.

In the Mt. 1a-na installation, the intra-string connect-

ing wires were mounted to the module support frames with

metal I-clip, to reduce wind damage to the wires. In the

design of future installations, some thouight might be

given to the provision of mounting holes or anchors for

tie wraps or other cable mounts.

61

4.3 ROW TERMINAL BOXES. The row terminal boxes on the array

provide a termination point for series string outputs

and underground cables, and include surge suppressors for

lightning protection. They also include test Jacks for

measuring the outputs of all strings in that row. Since

the same information is available at the PMP, or at the

string output connector mounted to the PV module frame,

these terminals appear to be superfluous. Throughout

installation, checkout and testing of the system no

engineer or technician used these test jacks.

4.4 SOLAR POWER MODULES. There are two distinct problems to

be addressed concerning the Solar Power modules: (I)

how future module design might overcome the problems ob-

served with these modules, and (2) what might be done to

improve the operation and lifetime of existing modules.

The solution of the first problem is generally understood.

Both dissipation mechanisms described above can be mini-

mized by the addition of reverse diodes across subsets

of cells of a module. The number of cells in a subset,

"n", must be chosen such that (1) the peak power of n-1

cells can be dissipated by the nth cell without damage

to the cell, and (2) the maximum voltage of n-1 series

cells does not cause reverse breakdown in the nth cell.

From the construction of the Solar Power modules, it

appears to be relatively easy to install two reverse

64t a

diodes in the module, each diode across 20 of the cells.

Installation of these diodes would reduce the maximum

photocurrent dissipation in a cell by a factor of two,

and eliminate breakdown in all but a small fraction of

the cells. DECC estimates that the cost of installing

these diodes would be approximately $30 per module.

Some consideration might be given to installing four

diodes, each across 10 cells. This modification would

be more difficult and the cost would be more than twice

the cost of installing 2 diodes. Further studies by JPL

should determine whether it is necessary to reduce the

maximum power by more than a factor of two, and whether

installation of the diodes could be performed without

adversely affecting the reliability of the module.

4.5 ARRAY SHORTING. The input contactor KI of the power

conversion system shorts the array whenever the power

conversion unit is off. The purpose of this is twofold.

Firstly, with the power conversion system off and the

array unshorted, the voltage at the unloaded array can

be as high as 400 Vdc. Shorting the array removes the

high voltage for the connected strings providing added

protection for service personnel. Shorting could be

particularly useful in the case of a ground fault due

to personnel contact between high voltage and ground.

Secondly, the current through the shorting circuit

65

breaker is monitored to detect the presence of sufficient

solar power for start-up.

In view of the problems with the Solar Power modules, the

wisdom of shorting PV arrays has been questioned. Al-

though it would alleviate the problem somewhat, eliminat-

ing the shorting of the array will not solve the problem

of the Solar Power modules. Occluded cells are being

reverse biased whether the array is operating into a

short or into the power conversion system. There are,

however, other arguments for leaving the array open. The

high current contactor required for shorting the array

is generally quite expensive. It must be rated for inter-

ruption of the entire short circuit current. An insolo-

meter or two redundant insolometers could be used to sense

the presence of sufficient power for turn on. A shorting

switch or connector could be provided to allow shorting

of individual series strings or subarrays during servic-

ing.

DECC does not recommend that the present Mt. LaCuna system

be modified to operate with an open array. In normal

operation, the array will be shorted only when there is

insufficient solar power available, and the stress on the

PV cells is minimal. If the system is to remain off for

extended periods of high insolation, the individual strings

can be unshorted manually at the string select switches

in the PMP. In the design of future systems, the trade-

66

off between cost and safety will have to be evaluated.

Some of the factors affecting the decision will be the

array voltage, array current, and PV cell characteristics.

4.6 THE PMP. Prior to the installation of the data acquisi-

tion system, the PMP was invaluable in identifying faulty

or inoperative strings of PV modules. One improvement

which might be made in future systems would be to replace

the fixed loads with a variable load (static or dynamic)

to allow plotting of the I-V curves of individual strings.

4.7 POWER CONVERSION UNIT. To allow mode 2 stand-alone opera-

tion as required by the purchase description, the power

conversion unit had to include an input dc-dc power con-

version stage to supply a regulated charge voltagre to the

battery. In the augmentation mode, thourh, the dc-dc con-

verter is operated only to protect the power inverter from

the high array voltages present at start-up. For fuiture

systems operating in the augmentation mode only, considera-

tion should be given to redesigning the inverter using

components capable of operating at the maximum array volt-

age. Improvements in cost, efficiency and simplicity

would result from elimination of the dc-dc conversion

stage.

4.8 GROUND-FAULT PROTECTION. Because of the ground current

measurements made during tests at the temporary site at

DECC (paragraph 3.4.2.8), the ground-fault detector does

67

... . . . - " ... . . . .' . .. .. ... .I'£III I II III l rol i.. .

not initiate a shut-down and array-shorting sequence.

Although the 50 mA protection threshold was frequently

exceeded at the temporary installation, it will not

necessarily be exceeded with the system properly install-

ed at the permanent site, even during wet weather. DECC

recommends that operating personnel at Mt. Laguna monitor

the "ground fault" status lamp periodically during the

coming wet season, when the soil around the underground

cables is saturated with water. If the ground current

does not exceed 50 mA during these operating conditions,

the ground fault circuit should be modified. Addition of

a single wire will change the control circuitry so that a

ground fault indication initiates a shut-down, shorting the

array and removing high voltage from the array.

4.9 OPERATION. To date the system has operated reliably with-

out fault shutdowns. The power conversion system, however,

is located in an unmanned building and service personnel

must be dispatched periodically to verify that the system

is operating. It is therefore possible that the system

may remain off, with the array shorted, for some period

of time.

When the system wiring was done, extra wires were strung

through the conduit from the power conversion building

to the manned, diesel power generating station. It is

recommended that these wires be connected such that

on/off status contacts in the power conversion unit are

68

operative to drive a lamp or other indicator in the manned

diesel power station. In this way, system shutdowns can

be attended to promptly without unnecessary stress on the

array or loss of solar power.

4.10 CONCLUSION. The 60 kW solar power array and power conver-

sion system is the first of its type: designed to be a

working component of a power generating station and to

provide a significant portion of the station power. The

primary design emphases were making the system stable,

efficient, self-protected, self-sufficient, and automatic.

Unlike previous research and development systems, the

Mt. Laguna solar power plant was designed to operate com-

pletely unmanlned over extended periods of time.

No major technical difficulties were encountered in the

development of the system. The design of the control

circuitry avoided the instabilities which have plagued

so many photovoltaic systems. All observations to date

support the belief that a dc-ac photovoltaic energy con-

version system without on-site energy storage can effec-

tively augment a utility grid, even in a remote location.

Continuing long-term operation and observation of the sys-

tem in the future will determine the system lifetime,

maintenance requirements and the actual fuel savings re-

sulting from system operation.

69

APPENDIX A

ACCEPTANCE TEST

Al

I-

AL' 1' II'ANt'' 1'vs iuot I'i' I) l N I

Fl 111

'4~o1. \ POWL'A1. t2QNVI R S LON SFl'

CON IRAC IDELTA ELECTRONIC CONTROL CORPt I V LWZ V IRVINE, CALIFORNIA, US A

CMI ('K

MIG DIECAP%'ROVL1'

APPRnVI D SIZE CODE IDENT NO IORAWING NO lviR

APV,'0VED 33434 7-10SCALE JWT SHEET

,HOP GRAPHICS/ACCUP11SS11

-,Ro" NOA-064 A

1.0 SCOPE

The purpose of this test proc edure is to y ify li-oper

operation of the Photovoltaic Power ('nolver .ion Sys.tem,

DECC Model 61211, provided under I .,*. A 'iu\' I:IAD(PC

Conitrict DAAK7O-78-C-O018. Ti tests to bo perfornmed

fall into three main categories: (I) tests of tlh,

invorter anld PMP operatioi, (2) system tosts at

the D"CC facility (with a pa'tial a Ir';i ), ,i1d (3)

field tests of the final in-;tallatioll.

2.0 APPLCABLF DOCUIFNTS

MER.ADCOM Contract I)AAK70-78-C-OO18, Purch.ipsDescription

DFCC Workmanship .'tandards Mamual

3.0 TFST REQXIIREMENTS

3.1 GENERAL. Unless otherwise noted, all test- are to ,e

performed at ambient couditions. 'he te'st equipenIet

in Tall, 1 shall be used. Slihst i t, ioll of k'qttuivalv'lt

e(Iuipment shall be allowed only wlu'ii anproved by the

DECC QA manager, and all equipment substitutimn sliall

be noted on the data sheets. All test eqiilmezlt shall

have a sticker or tag showing the calibration date

A3

-A

and tiit tliate tile ne'xt ciltllati oil Ii dum.. No ot'qu i p-

,Int'l Is shal II ybe Ii'ic be te It 0 Iv (A te ' c. i I rtiIoil I

due' * 1w sourW(' midt 0 13( loads I not '101 IWL'ca1..bat t

if .id('(llltatly moitorod by calii ta ted vqu i p100

s'uitiiits arel to be pe rlorod -(1 i(I 11114e la t .i rl'i'Ol'ile

inldeat 1 'd ill Sec tion It

1.2 INSP'L'l'I ON * All ot~titpilent shoi h e i spweteod Cr (-meti-

fot'iu11nce to draiwil ig anId to tho ~ Dl( \orl'lii~iill i p st .1ii(l-

'rds anId slhi 1 t1it- itimpected I'tti'l e' t' i 1 l jH l.tI

I 10V N' tr F STl an F Ii I P O t I Nti Vi. Fii N'F \ ~ 1) 11N 1

Ii t- t. 11 ,ii ~ i I i .I r h 't. I ' I ti I \. 4 t Ii I , I I

1.i~ o I c o I .Oi VI I ihi it I e I, I ,'ih . , I t I I

to Ilol~ls IS k I ?0 %*dc''l~l AN) ~l. Us (lilti. I 11)t' Iitttl'

%t. Io I1w c x sJ . S t

i A , C o, tl 11

verter and PMP meters (Table 2). Calculate the per-

centage deviation of each panel meter reading, f'rom

the calibration source and record as indicated in

Table 2. Meter locations are shown in Filure 1.

3.5 TESTS WITH PARTIAL ARRAY. These tests are to be per-

formed at the DECC facility using a partial ai ray

(consisting of both types of PV panels) akiid the

Southern California Edison Company utility g,,rid.

See Figure 2. The purpose of these tests is to

verify proper and stable operation with a l)ioto-

voltaic soairce and utility interf'ace. J,,rform the

measurements and record the data is indicated .

Section I4 (Tables 3 and 4).

3.6 EXTENDED 01IERATION. Pollowing- tle 'ormall te-st. I i

the D'CC facility, operate the sys(-emi 1'om hit' &rr;tv

and into the utility until the peim;,,iit site is

ready. Keep an operation log to tiote ;my unsual

operating, conditions or system mnouil'mictiois. |Apjwnd

the log to the test data as Table 5. Note prill-iry

array parameters under various weaither cotiditious.

3.7 TESTS AT Till.' PERMANENT SITE. 'I'uest t('t.- veril'y

proper installation and operation ai the pel'. iiiit

site. The tests include verification Of proper

A5

intercounnection of the arraiy an I'M11, vor'if ic;Itioii ot'

stabi I! ty with full power array mut~i lokc:ii m, ild

check of protection circuitry. Peru rm the iguwasmre-

merits and record the data as indiciitedl in Soc tioi 11,

Tables 6, 7, aid 8.

A6

SN 101

i)at,, 4/27/784.0 TEST PROCEDURES

4.1 INSPECTION. Inspect all equipment for coill'ormanc,.

to drawing and DECC workmanship standard.-. Inspect

for general appearance. Attach to this procedure

a list of all non-conformances. If there are

none, indicate so below.

No non-conformance_ _ _ _

4.2 ISOLATION TEST OF Tl': INVI.IIT, ANI) I'MPi. PIrforli

the procedure described in' paralrralh 3. 3. Record

the measurod lenkaj:o currents helow.

Lakag-e from inptit leads to chisisis-osL,,,\

[,eakagle from output leads to cl,,t sisO I I 1\

4.3 M F'"I' ACURACY, INVI'TIE ANi) PMIP. Verify tiln,'-

ctivacy of the iiiverter and 'I'1 panel mete i's .i s do-

scribed in parallraph 3.4. lH,,erd dlati, im Table .

4.4 rv.STS WITH A PARTIAL ARRAY.

Note: Except where noted, mea sliroentll at ;i' e to be'made with the iierter in the AITI') mode.

4.4.1 Standby Power and Current. Coinect the system it,

the normal fashion with the pirtinl array ,miid the

local grid. Place all string swit,'h,,s on the PMI'

in the enter (off) position. With t ;tnra al. met-,',

neasur the input ctlrrent tiii the Ilnp it poucr I'l o

A7

tl" it ili ty g:rid with the sy.st.o.,i oftT. IHvCo rd tlhe

mlll ilt lltlc ut s in Ta)1le I".

4.4.2 Start-V p. On a sunny day, switch tho stril switch..

to the LINE position one at a tim. Each -vwitch

iieton should result in an incret ,, in the, 11)t

cutrrent (M2). The inverter will ovettually starl up.

Record the input current (W?) ,jll.-t p'ior tt, start-u).

After start-up, record the inputt 1 ,. vt r (W) :111d til

outptt power (M117). Calciulat" t t, p owr'P to.,-, in

the system (M3-M17).

4.4.3 Operation. Perform the motsuiivetm.t, indicatol iLi

Table 3 and record the result- ill ';011% '.

I.4.4 Fault Protection and Automatitc Shut-l)owi. Test til,,

fault protection and shtit-dowt 'eatLtros mnd vriL'y

operation as indicated in Table 14. List any fail-

tires or unusual operations or conditotts it the

c olllnell t s C0 ll1un

1e.5 TESTS AFTrER FINAL INSTALLATION.

Note: Except where noted, measimreiietts ;o'e

to he mt'tlde with the inverter in the AUTO imode.

4.5.1 Strt-Up. On a sunny day, switch the stritt,

switches to the LINE position one at it time.

Verify that each switch action results in ui

increase in the input current (M2). Verify that

A8

the inverter starts up at approximately 35 amps in-

put cti'rent.

4.5.2 Operation. Perform the measurements ijndicated in

Table 6 and record the data in Table 0.

4.5.3 Fault Protection and Automatic Siit-)own. Tst

fault protection and shut-down fatuires ;and verify

operation as indicated ini Table 7. Perform ititer-

lock test by opening and closiniig the remote circuit

breaker. List any failures or tlunu1.Suail cotiditions

in the comments column.

4.5.4 Comparison of Solar Cell Strini- Oiitltits. This test

is to be performed under conditions of stable iiol-

ation. If possible it should be porformed under

conditions of maximum insolation (between 1 I A.M. arnd

1 P.M. Pacific Standard Time on a clear sun,,y day.)

Select one Solar Power string and one Solare.x string

to serve as a reference. Operate the system in the

normal manner from the full array and into the utility

aet. Using the outputs to the data acquisition sys-

tem, measure the output current from each string com-

pared to the reference string. Record thre current of'

both and the ratio of the measured string, cutrrent to

the refrence string current.

A9

4.5.5 Outputs to Data Acquisition System. The presen,:e of

string current outputs has been verified. Check cal-

ibration of analog outputs and presence of proper dit-

ital outputs as indicated in Table 8.

AIO

09

* All

LiL0J N

i

0 NIIgo-

4UI Lii

-.j

z40 L -dr

A12

a.

LAJ

LL.

A1'

Table 1. Test Equipment

DC Insulation Tester DECC Model b1107

Digital multimeter Danai 4200 or equivalent

Distortion analyzer 11P 13,1A or equivalent

Oscilloscope Tektronix 54311 orequivalent

Oscilloscope camera Tektronix C-12

Power meter Scientific Col'mbu.iDL-A2-609( oreqtiivalent

Stopwatch Accurate to 0.54

A 114

c *d

In. *l

-c 0 0 C

$f4

+N N' z

4-) 4- M 0 o o ON 41o0 0 4) 0 '0" 0' v) 0

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DESIGN, CONSTRUCTION AND TESTING OF A 60 KW SOLAR ARRAY AND PON--ETC(U)AUG 79 J S SUELZLE DAAK70-T -C-O018

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INSERT

Data for Model 61211 Solar

Power Conversion System

SN 001

The data log for system operation at the DECC facility was

lost during the move of the system from DECC to Mt. Lagtua.

The following summary data are available:

Total input kWH at DECC 6218

Total output kW1l at DECC 4861

Total running time at DFCC 413.6 II

The system was operated for 43 days, not including down-time

due to flooding of the temporary wiring from the array

to the PMP.

More extensive data will be available from Sandia when

Data Acquisition System output data are reduced.

A21

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ATP 61211 g4 001

Data taken using Data AcquisitionSystem __ _ _

'T'ah, t&e, Comparvisoi- of ,' Sir1." O pitIt

Sol;r 'owor hoferenve String, Nmier 40

Strin, Stping efer. Ratio Sf ri n, Strig lh, ', ,No. * oil tpln t Striing N* OIt I puit Stri tIll

Output ,n? it -t

1.9? 1.82 1.05 4, 1.5, 1.2 '. 7

2 1.90 1.04 1. 82 1.00

3 I1.62 .89 .,( I1. 57 .*(,

1 . 90.... ....... .. 4.8

.1 81

5 1.8,j 1 .00 . 1.8( 1.02

6 1.8' 1.01 ? (.)8 2

7 1.61 .8 ~1.14".7

9 .7 " 1.52 .87

0O 10 I 10 8 . ,1 T

ooI . 8 '1 1 . 00 8

8 1 ''_3 1. Or .91 16

1 14 1.(15 . 1 VT 1 , 62 0.8

4)15 .6 .91 18

1.I 92 -1.05 ,'I1 82 It .Oi'

T4 188 6 921.0 1 1 .2

19 1.91 1.05 14;. .I'.. ___ 1 * 0 •1

117

21 1.89 1 .04 424 t .()I ,

22 1.9 t014 1.8 O

ATI' 1112 1 1N 001

8 8. Conparison lla' Si it ,' 011' 11i,'' (,'mll I %)

o1 rPowo'r lie f'vretw e Stritig N~timi' '4

Stritifr str1li He fein , Un t to St 1Ili- : >t 1" Iil l llev','1' 1 1 ,No. O11t|+tlt Stt'i11e No. O t ll l i ,A ri,1 "1,

Ott) 1.8 .9tI ti .1.2 10

7.7' .8 71 1.27 1 8.

4 9, I . 8 i . 0 1 7 '' •1 . 7 • 8 6(I I'1.I . .. 8

0.2 1.00 0" . 9- .8

9o.. 1 .0 9

3,1 .53 .8 , .79.... I i i i

' 0 1 . 9 , 1, .0 0

1".1'' oI ! v'i • I 1. 0 . s8

',7 'N2 i0 9 6 j.1

4

8 o.24 .90 8 1 1 .1 .88

1 ."0

059 .8 I .9' I I .76 ,

j iW, I . 1802 1.7 I .. 65

61H I .61 I.0 ,1 1 1.79 .98'

.;,1.0 .(10 Si' 1.00 .88

oi "Al S. 4

611 1., .8 ,, 1,,01 h .720

r 1II 1 8 .l. .. "88 .6 iL

(10 Ib .61 1 9 1.71 94

.8.1.8~

A 12

ATP 61211 SN 001

Dyte____2_7_dy

QA

Table 8. Comparison of String Outputs (cont'd)

Solar Power Reference String Number 4o

String String Refer. j RatioNo. Output StringII Output

93 1.76 1.82 .97

94 1.82 1.00

95 1.78 I .98

96 1.79 .98

97 1.78 .98

98 1.93 1.o6

99 1.87 1.03

100 1.91 1.05

101 2.03 1.12

102 2.07 1.14

103 3 1.00

104 1.87 1.03

105 1.69 .93

106 1.90 1.04

107 1.52 .84

10 1.- - .80

109 .62

110 1.39 1 .76

111 1.20 .66

112 1.73 .95

113 1.43 .79

11 1.65 .91

115 .64 90.. 4A33

ATP 61211 SN 001

1).,t,' 8/2/79

Table 8. Comparison of Strini(: Otpit. (colit 'd)

Solarox Ileforence Stritij Ntmbler 136

String String Refer. Ratio Stri It'I Styr tIfer. i., i,,

No. 011tplit Stri itr {No. (h| lti I: , t H atl t p13 t pIt

116 I 1.09 1.00 1.09 I'T) .76 1.0 .76

117 .91 .91 111) .97 .97

118 1 09 1.09 11 I. 0 1 . I0+

119 .83, 8 i 1.52 1.05 1.05

120 1.06 I 1.06 I1'1 1.02 1.02

121 .97 1-. oIe 1.04 1.04

12 10 1.06 Ills I 98 .98122 I .06 I o6 14•89

__-_..._ .....

123 .(6 I .9( I!'(, 1 1.02 1 .02

1211 .85 .85 1117 1.01 1.01

12r .95 .95 048 1.06 .1.06

126 1.06 1.06 1 ',) .95 ,95

127 1 .03 1 .0 .96 .96

128 I* I 1 I1 1 1 1.04 1.04

12 ) 1. 10 1. 10 1 1.01 1.01

130 1.0') 1.09 b .96 .96

131 1.01 1.01 lIt .99 .99

132 .09 1.09 55.81 81

113 1.06 6 156 1.02 1.02

134 1.01 io0 1r,7 .86 .8b

135 1.0.) 1.03 158 1.03 1 I.0-

136 1.00 1.00 .96 .96

1 1.01 1.01 1,w 1.06 ,.06

38 .98 -. 98 161 1.02 J o2__ jIO2 -A

ATP 61211 -O II..,_812179 . .

'ble( 8. Comparison olf Stvit I' (hitImt-, ('olt 'Ii

S i lrvx Reference String Nimli, 136

String String Refer. Ratio

No. Otitput StringOutput

162 1.01 1.00 1.01

163 1.05 1.05

164 1.01 1.01

165 1.05 1.05

166 1.01 1.01

167 .99 .99

168 1.10 1.10

169 .-4 ... 4

A35

- ________

"'N 001-.§Z,,-82/72

Bly

Table 8. Outputs to Data Acquisitiol, yste,

Analog

Meas'd Input to % Calib.Value I).A.S.

Input voltage

Input current Meters compared toactual Data Acquisi- < I%

Input power tion System printout C

Output power <1%

BCD

Veri fe(

Input -WlI itoterOutput KWH meter

Status (liital)

Verified

Off

Off---l tfi' ic l t Solar Powor

Of f--Shut Down

Off--Error |R'cyc le

A36

APPENDIX B

EMI TESTS ON COMPARABLE

POWER CONVERSION EQUIPMENT

BI

HOFKINS ENGINEERING COMPANY QTR-556.5-425.

28 JAN 1975

QUALIFICATION TEST REPORT

ELECTROMAGNETIC INTERFERENCE TESTS

ON

UNINTERRUPTABLE POWER SUPPLY SYSTEM

t

Prepared For:

STATIC POWER INC.300 Campus BoulevardNewport Beach, California

by

HOPKINS ENGINEERING COMPANY12900 FoothIll Boulevard

Seri Fernando, Calif. 91342

Prepared by:.-rltd yo n A t

ar T T

m roEMI Specialist Vice Pr.e ntrope n-

1Hopkins Engineering CompanyA1proved2

ice Preside QOuality Control

HOPKINS ENGINEERING COMPANY QTR-55635-425-1

TABLE OF CONTENTS

SECTION TITLE PAGE

-- REPORT SUMMARY

1.0 SCOPE 1

2.0 APPLICABLE DOCUMENTS I

3.0 GENERAL 1

3.1 TEST SAMPLE IDENTIFICATION I

3.2 SUMMARY OF TEST METHODS PERFORMED 1

3.3 TEST DATES 2

4.0 TEST PROCEDURES 2

4.1 TEST SITE 2

4.2 OPERATIONAL PROCEDURES 2

4.3 TEST INSTRUMENTATION 2

5.0 TEST RESULTS 2

5.1 CE02 CONDUCTED EMISSIONS 14KHz to 50MHz 2

5.2 RE02 RADIATED EMISSIONS 14KHz to 1000 MHz 2

5.3 REO4 RADIATED EMISSIONS H Fields 20Hz to 50KHz 2

6.0 CONCLUSIONS 3

113

HOPKINS ENGINEERING COMPANY QTR-55635-425-1

REPORT SUMMARY

PURPOSE: Electromagnetic interference tests were performed on theUninterruptaole Power Supply (UPS) to verify that the UPSsystem provides adequate compliance with the applicableelectromagnetic compatibility control requirements.

TEST ITEMS: Uninterruptable Power Supply62.5 KVA

MANUFACTURED BYz ,Static Poter Inc.

Newport Beach, California

SPECIFICATION: MIL-STD-461A,/462 Notice 3

TEST PIRFORMED BY: HOPKINS ENGINEERING COMPANYSan Fernando, California 91342

TEST PERFORMED AT: STATIC POWERNewport Beach, California

AUTHORIZED BY: STI Purchase Order #4864 dated 12-11-74

TEST CIMPLETION: 12-18-74

SECURITY CLASSIFICATIONt Unclassified

SUMMARY OF RESULTS: The Uninterruptable Power Supply was foundto be in compliance with all applicableelectromagnetic control requirements whentested in accordance with MIL-SLD-461ANotice 3, Para. C E 0 2, R E 0 2 & R E 0 4.

B14

HOPKINS ENGINEERING COMPANY QTR-55635-425-1

QUALIFICATION TEST REPORT

1.0 SCOPE

T is report presents the results of the electromagnetic interferencetest performed on the UPS 62.5KW manufactured by SPI, Newport Beach,California, and compares these results with the applicable require-ments of the specification.

2.0 APPLICABLE DOCUMENTS

Military Standards

mIL-STD-461A Electromagnetic Interference Characteristics,tOctice 3 requirements for Equipment.

MIL-STD-462 Electromagnetic Interference Characteristics,Notice 3 Measurement of.

APPROVED TEST PROCEDURE

Prfor to conducting the Radiated Emissions Test the perifery of thesfstem was probed to determine the position of maximum radiationaccording to approved test procedure of MIL/STD-462. The antennaeswere then positioned as specified and all radiated measurement takenat this locition. Conducted measurements were made using a currentprobe on input and output power 3 phases and neutral.

3.0 GENERAL

3.1 TEST SAMPLE IDENTIFICATION

The test sample system consisted of one console and applicable load.

3.2 SUMMARY OF TEST METHODS PERFORMED

The test sample system was subjected to the following applicabletest methods of MIL/STD-461Ai2 62 Notice 3.

METHOD TYPE or TEST Freq. Range

CE02 Conducted Emissions, Power Lines 1/4KHz-5OMHz(Input & output)

RE02 Radiated Emissions, E Field 14KHz-IOOOMHz

REO1. Radiated Emissions, H Field 20Hz - 50KHz

B5

HOPKINS ENGINEERING COMPANY QTR-55635-425-1

3.3 TEST DATES

These tests wore started on 12/18/74 and completed on 12/18/74.

4.o TEST PROCEDURES

4.1 TEST SITE

The test prograr was conducted at S.T.I. facility at 3800 CampusBoulevard, Newport Beach, California. Since the test sample couldnot feasibly be housed in a shielded enclosure, radiated tests wererun after 11:00 PM because of day time Hi Ambient fields. Conductedtests were run after factory shut down.

4.2 OPERATIONAL PROCEDURES

All test sequences were performed with the UPS operating load,50 KVA.

4.3 TEST INSTRUMENTATION

The test instruments used during this test program are listed inAppendix A along with their applicable model numbers, serialnumbers and calibration dates.

5.0 TEST RESULTS

5.1 CEO2 Conducted Emissions, Phase A.B.C. & Neutral input andoutput 14KHz-r0MHz.

5.1.1 Broadband emissions on both Input & output all phase werewithin specification limits.(See Graphs Fig. #1 thro 8)There were no measureable Narrowband Emissions.

5.2 RE02 RADIATED EMISSIONS; E-FIELD (14KHz-10OOtz)

Broadband radiatad emission were within specification limitsall frequencies. (See Graphs Fig. 9 )There were no measureable Narrowband Emissions.

5.3 REO4 RADIATED EMISSIONS; H-FIELD (20Hz - 50KHz)

There was no measureable H-Field emission.

B6

HOPKINS ENGINEERING COMPANY QTR-55635-425-1

6.0 CONCLUSIONS

When tested in accordance with mrL-STO-462 the UninterruptIblePower Supply conplied with all applicable Class I C requiremuntsof MIL-STD-461A Notice 3 Test Method CE02, RE02 and REO4.

B7

HOPKINS ENGINEERING COMPANY QTR-55635-425-1I

APPENDIX A

TEST EQUIPMENT

The following primary meters were used during this test program:

RECEIVERS/METERS

Noise and Field Intensity Meter, Singer/Empire Model NF105 S/N 2083Calibration date 2-5-75. Stoddart N M 40 S/N 1Calibration date 5-17-75.

CURRENT PROBE

Stoddart Radio No. - 91550-1 S/n BF231

ANTE N NAS

Singerlmpire VX - 105

S inger/Empi re VA - 105

Honeywell Bi Conical Model 7825

Electro Magnetics Conical Log Spiral Model CLP-lA

Loop Antenna Model 90114-3

B8

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4/1

31

4' 4

C33

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1,4

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4. 4.A l

HOPKINS ENGINEERING COMPANY

ELECTROMAGNETIC INTERFERENCE DATA SHEET

TIEST CQUIPMKN ETE 8DT-2

STYPE i~sROAO3Amp ortONOUCTtO IZ1SION SlIgAL 0ORCEcIVEoDBY C KNITTEO MY

OF ONANRR@WIAND ONADIAT90 SCEucPTIBILITY jL!dfURENT PROGE 0ig, Caoo CO~l 1 IPOLZTEST 0 09-ONICIAL OSPINAL OwoO,. OLOOP

tF___S____________ STEADY STATE OTRANSIENT 0 _ _______________

L~~j1A~ ,'0' AIE_ 1 L& J ± ./00~~~~~~ eo. 9 2,iI± d

~,o ;~ L q/jj __

d.U I9Q go 5"d /1_

CIO 972 9_ 77 y di 7__ _6

__35__ V~ go ko q3j

77 0

.LLI2~~ c( ~ S ~ ~ j (~ 'l__k 10 7 -

rMe-,CT OP

B19

HOPKINS ENGINEERING COMPANY

ELECTROMAG#4UTIC INTERFERENCE DATA MHEET

PROJECT ___ ESITM .'V ii;J4

TEST SP9C. 14LI I ~ PAR AGRAPH _____ _ -TEST POINT_________

~TET Qup::?~AF o~.... T E T ESTD:Y DATE

or I2ARROWSANO (: AITO CSXCPII Y cu FRIENT P OCISN DNOO ClOtPOLE

ES gL3 0 JOSI-C')MICAL OSPIRAL CMORN OLOOP

_______________ OSI EADY STATE 0 TRANSIENT 0[I _____________

M14

q4 ______J7~~' _

____ 3k,3 5 __ '

1 2-_ 6 -1 ,__ _

241 2f

9I-- IT or~___ )-J224~iJ)O____ B2

HOPKINS ENGINEERING COMPANY

ELECTROMAGNETIC INTERFERENCE DATA SHEET

PROJECT ~V~ ~~ TEST ITEM LO (_LOA) -S-~~a

TEST SPEC......._ ___ PARAGRAPH _ ______TEST POINT ______

TEST EQUIPMUNT ___________ __________ _ DAT

Of C~ARR~@::o014ADIATELD CSLSCEPTISILITY QfURRNENT 101O111 0CLISN CR00 CIPOLE9

TaST 0 c 0t1CONICAL OSPIRqAL ONoRN CLOOP

I MooNf EI-lADY STATS 0 TRAWSIENT 0-

4 1-1

L~~~Z r/ _ , __ _

/7 -2-'. 'o j 6 7~ .'

____ L, -6 -

12 Al

5-- _ 6 7) ~ 3a- 1_

_ i __ 1 -K 1'163f. Orc.

A!L ~ A Z toe-Al l.£~ 2. L __ _

_~~~~"a or q 52 6 .i

_ _ ~ L 4~ B21

'1Lo6_

HOPKINS ENGINEERING COMPANY

ELECTROMAGNETIC INTERFERENCE DATA SHEET

Rpojgtr~ S2AT . CO% I_ TEST ITUM ki U44S ~Li)

_____$PICe PAR kGNAPN _ TEST POINT_________

yggT EQUIPMIENT -I~ I.)TZ BY DATE

tyE TYP 60OAOUNO m(cooouvygO 0 EMISSION4 SI04AL CEcIVED my 0 XMITvrg mY

Of ONARNOVSAND ONADIAT&O 0GUICIEPTIMILITY f3feiJRRENT PROSI OLISN 0DOR0 QOIPOLE

VsT 0 3 U 00hCONICAL OSPINAL 014oRN O3LOOe

TEST UO009 ______ LSIAOY $TATE OTNlAmsIEI ____

,A01 4 7

~~ /dj~~7 35 C _ _ __ _

4j_ _o

1122

HOPKINS ENGINEERING COMPANY

ELECTROMAGNETIC INTERFERENCE DATA SHEET

TCST SPEC. ti/A/# P A~ _ PAAGRA P HT d ee

ILtst dkupm" T' $TED@ ZS',-( A ,

TVp9 i6,'RnOAornA~o 0- D~UCTED QI9missIOw SIGNAL 0 9CEIV90 MY 0 XMIT(O gY

OF 100ARROSAND IO1ADIATED O)SUSCEPTIuILyTY C CURRENT PROS LJLSk CriOo Co1uOo.9TEST 10 0 oribI-CONICAL OSPIRAL. ONORN DLOOP

TEST 6$eDR _ C STEADY STATE 0 TRANSIEN T 0 _______3_______

191

~~~. ~ 2 ____ ___