FY 2004 ANNUAL REPORT DOE Solar

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FY 2004 ANNUAL REPORT DOE Solar ( fy-2004-annual-report-doe-solar )

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thermal management, highly integrated controls and drivers, advanced surge protection, innovative packaging, full systems integration, intelligence, communications, and consumer-friendly products. A third and critical approach is to provide benchmarking and analytical testing and evaluation of emerging inverter and BOS hardware and technologies through SNL’s Distributed Energy Technologies Laboratory (DETL). 2.2 Systems-Driven Approach Inverter Workshops The R&D initiative, 5-year strategy, and laboratory work at the DETL are based on the results of well-attended DOE workshops where the inverter industry, the PV industry, systems designers, utilities, universities, and laboratory experts assembled to provide valuable inputs and prioritization for needed R&D. All competitive contract awards are based on proposals, statements of work, and end products that meet the priorities for the workshops. The contracts for the high-reliability inverter work are listed below. perspectives from each. Figure 1 shows the results of a components and materials session of the first workshop and from a high-reliability perspective. It shows the passive components (capacitors, transformers, connectors) as a topic needing the most attention from a high-reliability perspective. Automated Assembly Advanced Packaging dvanced Control Algorithms Testing/QC eliable (low cost)Switchgear Passive Components High Reliability Priorities (Average Normalized) Components & Materials 0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 Average Score (Maximum = 5.0) FY 2004 Budget ($K) 2,055* 430 3.1 The High-Reliability Inverter Initiative The High-Reliability Inverter Initiative was initiated in 2001, with the first contracts issued in 2002. The initiative was begun as a response to reports of unacceptable high percentages of inverter malfunctions and outright failures in PV installations. The schedule included three phases. The initiative focused on developing designs that could be mass-produced while improving reliability to at least 10 years (mean time before failure [MTBF]). Costs were to be improved or at least held in line. The work was coupled to market analysis and prospects for systems integration resulting in high (>10,000 units per year) production rates. One theme of the first workshop and the initiative was to examine inverter improvement issues with respect to cost and reliability and to provide Fig. 1. Components and materials prioritization for high-reliability inverter development Figure 2 shows another set of priorities based on low-cost considerations for inverters. Capacitors were identified as the highest priority. Thermal management that can be tied to components and packaging followed. All of the high-reliability initiative contractors carefully considered the results of the inverter workshop while designing their next-generation, high-reliability inverters. The Phase I final reports were reviewed by inverter-cognizant personnel at ORNL, NREL, and SNL. This resulted in the three Phase II contracts. The three high-reliability inverter contractors are now in the final stages of Phase II. Deliverables consist of prototype development, follow-on market analysis, product layout, drawings and working prototypes. All contractors have initiated the testing for safety and UL listing. Some highly accelerated lifetime testing (HALT) has been conducted, but it is required of all. The three contractors will be submitting prototype inverter hardware to SNL for characterization and evaluation in December 2004. Phase II reports will be used in combination with hardware- evaluation results to determine which contractors can be funded for Phase III work. Phase III will take products to commercialization. Task Title High Reliability Inverter Initiative Inverter and BOS Development *Includes $830K of FY 2003 carryover funds. 3. Results and Accomplishments

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