Cost effective second generation AC-modules: Development and testing aspects

In the framework of the European research project PV2GO, a new AC-module inverter was developed, taking into account all relevant aspects from a European market's point of view (standards, market, application, and research and development goals). The project goal was to achieve the overall system costs of 3 Euro per Wp for a modular plug-and-play photovoltaic system. For the photovoltaic-module, a standard 130-Wp Eurosolare module was chosen. The research and development (R&D) goal was to develop an advanced DC-control system consisting of a state-of-the-art programmable digital device and an Application Specific Integrated Circuit (ASIC) for the AC-control of the inverter. According to the topology concept, thermal and magnetic designs were optimized with regard to production technology and packaging for large-scale production. The new AC-modules were tested in a number of field-test sites in various parts of Europe and their reliability was assessed through Highly Accelerated Stress Tests. Efficiency and power quality have been tested in the laboratory. Further in the PV2GO project an optimization study of the manufacturing process of the new generation of AC-modules for high volume output was done. Another task was the pre-certification procedure to assure compliance with the European guidelines and standards.