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Fig. 1. Xantrex high-reliability 5-kW alpha prototype Results of the upgraded prototype testing at SNL were transferred to each contractor along with suggested engineering changes, which resulted in improved performance and compliance with applicable codes and standards. Figures 1 and 2 show the Xantrex and GE alpha prototypes, respectively. Both prototypes were found to need modifications or upgrades to meet the requirements of the initiative and the contractor’s marketing needs. On its 3.6-kW, two-input design, GE used a design for reliability (DFR) process that has been proven accurate on a variety of GE products. The Xantrex design was analyzed using Design Failure Mode Effects and Criticality Analysis (DFMECA) to uncover components and operating modes in which additional work was required to improve long-term reliability. Xantrex established a Highly Accelerated Life Test capability as part of its contract cost share. Beta units are being constructed by each company. Following SNL evaluations and verifications of compliance with the NEC, UL standards, performance and operating characteristics, the evolution to commercialized products will begin. Photovoltaic R&D Advanced Materials and Devices 68 Advancements in a micro-inverter development provided proof of concept for an innovative circuit using no electrolytic capacitors. The calculated MTBF was over 250,000 hours, the performance was better than expected, and the distribution of heat was as calculated. The cost of the inverter was estimated at less than $.30/W in 10,000 quantities. One important characteristic of the innovative topology is the elimination of AC ripple on the PV array through high-speed, feed-forward control. Figure 3 shows the measured PV array ripple along with simultaneous half-sine waves generated within the inverter. The ripple is measured here at about 60% rated operating level and represents 0.3% of average DC current. The low ripple will improve maximum-power-point tracking effectiveness. The innovative topology appears to be applicable to higher power inverters and could significantly impact future designs. Figure 4 shows the internal components of the micro-inverter as designed for a detailed thermal Ripple Current Half- Sine 4 3 Fig. 3. Inverter half-wave current and ripple current Note: Form-factor Design Is Intended To Fit Within a Frame or Mounting Structure Of PV Module This Bench Prototype was Constructed for Initial Assessment of Losses, Performance and Thermal Analysis. It Uses Discrete Control Components Fig. 4. Micro-inverter thermal analysis prototype Fig. 2. GE high-reliability 3.6-kW alpha prototypePDF Image | DOE Solar Energy Technologies Program
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