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International 12-2010
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Power boosting
Spanish PV operators add modules to increase system yield and profits
Super grid-connection
Three inverters tested by PHOTON Lab all awarded A+ grades
International
REFUSOL 017K
None of the visible components in the REFUSOL 017K showed critical temperatures during thermographic imaging, although its multi-layer construction means that the power element cannot be seen clearly.
A+
12/2010
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International
REFUSOL 017K
A+
12/2010
www.photon-international.com
Highlights
RefuSol GmbHs REFUSOL 017K is a three-phase transformerless inverter with a DC nominal power of 16.8 kW The MPP range stretches from 460 to 850 V; the maximum MPP voltage is too close to the maximum input voltage of 1,000 V The units maximum conversion efficiency comes in at 98 percent, while the European efficiency is 97.7 percent and the Californian efficiency is 97.9 percent The PHOTON efficiency at medium irradiation was recorded as 97.4 percent, while it came in at 97.6 percent at high irradiation The device is suited for installation indoors and outdoors, and offers many options for expansion
etzingen, Germany-based RefuSol GmbH has another winner on its hands: the REFUSOL 017K has risen to the top of PHOTON Laboratorys test, just beating out a new contender from SMA Solar Technology AG (see article, p. 128). Based on medium irradiation, SMAs Tripower tied with a second device, a smaller member of the RefuSol series, the REFUSOL 013K (see article, p. 146). The manufacturer sent us both RefuSol devices in early August as part of the usual test agreement. The units are kitted out with above-average equipment and have a circuit topology that is more suitable for use with thin-film modules than most other transformerless inverters.
Construction
The RefuSol series includes products with AC nominal powers between 10,000 and 19,200 W. All of the models in this range are transformerless. The REFUSOL 017K is very compact and appears to be simple to manufacture. The device makes a good, high-quality impression
and is very small and light for a three-phase inverter in this power class. The internal set-up has several layers: on the upper layer is the control circuit board and the DC filter circuit board with the switched-mode power supply for auxiliary voltage. A large power element circuit board is located on the lower level. Three sinusoidal filter chokes and four storage chokes in the boost converter are cast into a separate section of the housing. The power element circuit board holds all of the input-side DC converters components, as well as the intermediate voltage circuit with the electrolytic capacitors, and the output bridges. The power semiconductors are located in three separate modules and are soldered to the bottom of the circuit board. For cooling, a large cooling element, without forced ventilation, is mounted to the back of the housing. The electrolytic capacitors in the power element and the control electronics have a temperature class of 105 C, and are therefore wellsuited to handle ambient temperatures.
International December 2010
A large, internal fan operates under the circuit board to prevent heat pockets from forming. Its lifespan is listed as 80,000 hours at 40 C that corresponds to an operating period of around 9 years, which should suffice for a typical inverter lifespan under normal circumstances. If, however, the fan malfunctions, it can be easily removed. The housing has an IP 65 protection type and is made of three pieces: the frame, the cover and a cooling element on the back. To ensure safe operation, the device uses an automatic grid-monitoring unit, which checks the grid for proper voltage and frequency. Moreover, the unit performs a test to check the insulation resistance between the solar generators connections and the ground, as well as inspecting the grid-side leakage current. The solar generator is hooked up using MC4 connectors from Multi-Contact AG, four pairs of which are included. The grid connection uses a large five-pole connector from Phoenix Contact GmbH & Co. KG. After assembly, this connector can be attached to the inverters housing with two screws. The REFUSOL 017K has a DC circuit-breaker situated underneath the housings frame, next to the DC connectors. The display circuit board is mounted on the housings cover and covered with a transparent film. The devices status is also shown via four LEDs. The inverter offers an array of connection possibilities for external devices, including irradiation and temperature sensors, relays (230 V, 2 A AC), RS485 (input and output), USB and Ethernet. Using the USB port or Ethernet connections, the device can communicate and update its firmware. Moreover, the device contains an internal datalogger, which can record up to 40 measurements. These have to be added individually, and the parameters set accordingly. The following configuration options are available: larger mains supply plugs, various PV connectors, remote monitoring with the help of different external monitoring devices, and a fan module to build inverter towers (called Powercap).
rent and AC frequency. Users can also see the cooler and internal device temperature as well as irradiation and module temperature, if the proper sensors are connected. The display can also show absolute and standardized yield data (daily, monthly, annual and total values). The daily amount of fed-in current can be shown in a bar graph. Thus, the device offers users a very wide range of values in a clear display.
Instruction manual
The device comes with a short version of the operating instructions in printed form and an extensive instruction manual as a PDF file on a CD-Rom in Czech, Dutch, English, French, German, Italian and Spanish. Recently, Korean has also been added to the list. The short version is designed for quick connection of the inverter. It includes technical data and general explanations, as well as tips for installation, connection and operation. Overview graphics explain how to navigate the menu. Moreover, the use of the display, grid connection and DC connection are also explained. The extensive instruction manual on the CD-Rom contains a lot of diagrams and a comprehensive presentation about the units menu structure. Both versions of the manual, as well as the technical data, can also be downloaded from the manufacturers website.
Circuit design
In principle, the REFUSOL 017K has a twostage circuit design, but doesnt have a classic topology. First, energy from the PV generator reaches the power stage via an EMI filter. The device has a split intermediate circuit capacitor, the center of which is connected with the grids neutral wire. It possesses two three-phase output bridges, which are connected in parallel on the output side. The first output bridge is directly connected to the DC input. The second bridge is supplied by two boost converters that are located in DC inputs positive and negative conductors, and which feed the second split intermediate circuit capacitor. The sinusoidal wave modulation is distributed between these two output bridges, so that both of them only transmit a portion of the voltage boost to the output chokes to produce the sinusoidal current. This reduces the losses in the power transistors and output chokes. Furthermore, every output in each phase has a free-wheeling path, which prevents energy stored in the output choke from flowing back into the intermediate circuit capacitor, which would cause greater losses. A successive filter smoothes the voltage blocks into sinusoidal voltage with a grid frequency of 50 Hz. An ENS disconnect unit separates the inverter from the grid as soon as grid voltage or grid frequency deviate from the designated limits, as well as if it detects residual current on the grid side. Insulation resistance is measured on the DC side. An output filter, installed directly in front of the grid clamp, eliminates any radio interference. 3
Operation
The device arrives at the customers home well packaged and protected by thick cardboard. The unit is hung on the wall with a bracket. At 40 kg, the unit is relatively lightweight. As long as the solar generator is properly designed and the DC disconnect is switched on, the inverter is ready for operation, and requires about 126 seconds to run a number of tests before it starts working. The white backlit display, flush with the front cover, is easy to read and offers the following languages: Czech, English, French, German, Italian and Spanish. Using eight buttons, operators can set parameters. A default display provides an overview of AC power, AC voltage, DC voltage and daily energy yield. There is also another menu stating DC power, DC voltage, DC current, AC power, AC voltage, AC curInternational December 2010
Manufacturers response
The measurements taken by PHOTON Lab match our results, taking measurement accuracy issues into account. In response to the critical appraisal of the MPP range's upper limit of 850 V, the most important factor for system design is the open-circuit voltage, which should not exceed the approved maximum DC voltage of 1,000 V. We haven't chosen to unnecessarily limit the MPP range of our device in order to allow the MPP to function optimally in the event of cloud cover and a cold generator. Furthermore, this equips us well to handle the next generation of modules with even better fill factors.
Although this variety of circuitry components makes the devices construction very elaborate, it has a high efficiency, good electromagnetic compatibility (EMC) and a DC potential at the DC connection terminal that is balanced with the ground.
Summary
The REFUSOL 017K is compact and appears easy to manufacture. The workmanship is impressive: it is small and light for a three-phase device in this power class. A very informative display, a number of integrated communications possibilities, and internal dataloggers round out the picture. The power elements topology makes it possible to distribute the potential of the DC connection symmetrically to the grounding conductor, and results in a very high efficiency. The manufacturer only approves the power element for open-circuit voltages of less than 960 V, which is why the simulators open-circuit voltage was limited to this range during the measurements. The MPP voltage range is very wide, but shows limitations in the upper range due to the insufficient distance between the maximum DC voltage and maximum MPP voltage. Conversion efficiency is consistent over the voltage and power ranges, and reaches a maximum of 98 percent. The unit also has a good European and Californian efficiency: the European efficiency is just 0.3 percentage points and the Californian efficiency just 0.1 percentage points lower than the maximum conversion efficiency. The very consistent and high MPPT adjustment efficiency allows for an overall efficiency course that only deviates slightly from the conversion efficiency. The MPP tracking only showed weaknesses at low powers and very high voltages. Despite the wide voltage range, the results show a very high PHOTON efficiency of 97.4 percent for medium irradiation and 97.6 percent for high irradiation: the best results seen in PHOTON Labs inverter tests so far. When selecting the MPP of a PV system, operators should choose voltages up to 740 V. The inverter has a very low overload range, but a very wide temperature range with minimal power limitations. The conversion efficiencys
International December 2010
Measurements
All of the following measurements are based on a grid voltage of 230 V. The REFUSOL 017Ks maximum DC voltage is 1,000 V; the DC nominal power is 16,800 W. During the measurements, the simulators open-circuit voltage was limited at MPP voltage ranges above 788 V, since a fill factor of 75 percent would result in voltages higher than 960 V, which is the upper limit specified by the manufacturer for the power element. Locating the MPP: At a predetermined IV curve with nominal power and an MPP voltage of 645 V, the inverter needs around 126 seconds to connect to the grid and another approximately 33 seconds to locate the MPP. When switching from 645 V to 624 V, the unit required 11 seconds, while a switch from 645 V to 665 V took around 13 seconds. MPP range: The MPP range stretches from 460 to 850 V, which is a wide range. Considering todays fill factors, the maximum MPP voltage of 850 V is too close to the maximum input voltage of 1,000 V. In the efficiency diagrams (covering conversion efficiency, MPPT adjustment and overall efficiency), there is a hatched area that represents limitations on the use of crystalline modules above about 805 V, and for thin-film modules above around 740 V. Conversion efficiency: In the diagram, the area of maximum efficiency is located in the middle of the MPP voltage range, reaching a very high level of 98 percent. The maximum level is achieved at 55 percent of nominal power and an MPP voltage of 583 V. The manufacturer specifies 98.1 percent. At higher MPP voltages, the conversion efficiency decreased by just 0.5 4
Conversion efficiency
Way up high: Conversion efficiency with this level of consistency across the entire MPP voltage and power ranges is rare.
= Overall efficiency
The diagram for overall efficiency is a pleasing picture and is an indication of the units excellent PHOTON efficiency.
dependence on temperature is very low at -0.2 percentage points. The display of output power is not as precise as the smaller REFUSOL 013K, but is still equivalent to that of a class B meter. All in all, the REFUSOL 017K is a top device, not only due to its exceptional PHOTON efficiency, but also thanks to its excellent equip-
ment and flexible usability it can even be used with thin-film modules, albeit with some limitations. According to Refu, the company has no problem issuing individual approvals for use with First Solar modules; GS Solar has issued a general approval for the use of its products with the RefuSol series (REFUSOL 010K to 020K),
and approvals from additional manufacturers (such as Abound Solar) are to follow.
Text Heinz Neuenstein, Jochen Siemer Further information Contacts page 233
International
REFUSOL 013K
A+
12/2010
While the REFUSOL 017K is the latest efficiency king in our inverter tests, the devices little brother, the REFUSOL 013K, is nipping at its heels; the REFUSOL 013K shares second place with SMAs STP 17000TL-10
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The Solar Power Magazine
International
REFUSOL 013K
A+
12/2010
www.photon-international.com
Highlights
The REFUSOL 013K is a three-phase transformerless inverter with a DC nominal power of 12.7 kW The devices MPP range stretches from 420 to 850 V Its maximum conversion efficiency is 98 percent, while its European efficiency is 97.6 percent and its Californian efficiency is 97.9 The inverters PHOTON efficiency for medium irradiation is 97.3 percent; its PHOTON efficiency for high irradiation is 97.6 percent
he REFUSOL 013K is a very compact and production-friendly inverter. It makes an excellent, high-quality impression and is very small and light for a three-phase device in its power class. It offers a large number of integrated communication possibilities and enables easy statistical analysis with its internal datalogger and graphics-capable display. The power elements topology makes it possible to distribute the potential of the DC connection symmetrically to the grounding conductor, resulting in a very high efficiency. During initial testing, the inverter was only able to reach 98.4 percent of its nominal power, but a firmware update addressed this error. The changes to the software have been integrated into the serially produced device, according to Refu. The manufacturer approves the units power element for maximum open-circuit voltages of up to 960 V. It should be noted that although the inverters MPP voltage range is very wide, there are limitations in the upper range: the distance between the maximum DC voltage and the maximum MPP voltage is too small. The REFUSOL 013Ks maximum conversion efficiency is 98 percent, and this efficiency is very consistent over the entire voltage range and power range. The same applies to its weighted efficiency: the European efficiency is just 0.4 percentage points below the maximum conversion efficiency at 97.6 percent, while the Californian efficiency is just 0.1 percentage points below the maximum conversion efficiency at 97.9 percent. The devices very consistently high MPPT adjust-
ment efficiency allows for overall efficiencies that are just slightly lower than conversion efficiencies. Only minor weaknesses emerge in the lower power range and at higher voltages. This results in a very stable overall efficiency path. Therefore, the test candidate received a grade of A+ for its PHOTON efficiency of 97.3 percent at medium irradiation and 97.6 percent at high irradiation despite its wide voltage range. When setting the MPP for a PV system, a range of up to 740 V should be selected. The inverters overload capacity is small, but its temperature range is very wide, so there are no limitations on power. The dependence of the units conversion efficiency on temperature is very low at -0.1 percentage points. Another excellent feature is the displays ability to measure output power very accurately. The REFUSOL 013K is therefore truly a topclass inverter. And whats more, it can also be used with thin-film modules despite its transformerless design with limitations. Refu says it has no problem approving the device for First Solar modules in individual cases, and GS-Solar has approved its modules for general use with the RefuSol series (REFUSOL 010K to 020K). Approvals from other module manufacturers (for instance, Abound Solar) are in the works.
Text Heinz Neuenstein, Jochen Siemer Further information Contacts page 233
*1 device no longer being produced, *2 prototype, *3 range at which the model was tested and to which the grade applies