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Design and Implementation of Flyback MPPT

Converter for PV-applications


P. Suskis, Member, IEEE (Riga Technical University), I. Galkin, Member, IEEE (Riga Technical
University), J. Zakis, Member, IEEE (Riga Technical University),

 MPPT converters or PV-modules [1]. Galvanic isolation


Abstract— One of major problems related with PV- eliminates the connection between grounded grid and PV-
applications is common mode currents. The issue can be solved panel leakage capacitance. The benefit of this solution is
in two ways: galvanic decoupling of AC-grid and chopping the eliminating the reason of occurring the common mode
common mode currents by additional actively controlled currents, while chopping the currents is just struggle of the
circuitry. Flyback converter is good solution for MPPT consequences. In case of malfunction of current choppers
tracking for PV-modules up to 100-150 W with galvanic
the human or animal being can be damaged while galvanic
decoupling. The problem of designing of this type of converter
is that most of design guides and literature is dedicated to
decoupling provides safer solution. In papers [4] [5], [6] this
consumer electronics applications. MPPT converter design problems are eliminated due to galvanic isolation, but with
have different starting points of calculations. The paper different converter topology.
contains the suggested approaches to the calculations, design The fly-back converter was chosen as MPPT converter
recommendations, considering the specific nature of PV- for photovoltaic modules because of simple structure, low
sources and NOCT model of PV-module. production issues and, therefore, prospective of a good
The approach calculations, design guidelines, power density in case of efficient design. Acceptable energy
recommendations and simulation of power electronics part of conversion efficiency is obtained for this type of converters
MPPT converter and experimental results with implemented for power up to 150 W that matches most of the BIPV
circuit are presented and discussed. In order to increase the
(Building Integrated PhotoVoltaic) modules. [6], [7], [8].
efficiency during tests the circuit was upgraded with active
clamp. After the tests active clamp was upgraded to the
The correct approach for calculations is necessary for the
forward active clamp topology. The efficiencies and key proper design of converter. The most of the scientific
waveforms of voltages are compared and analyzed. sources considers it as a converter that have constant output
and relatively stable input. In case of MPPT converter for
PV-panels the input and output are dependent on many
Index Terms—active clamp, flyback, forward, MPPT, conditions [8]. All above makes the start of design hard.
photovoltaic. This paper is dedicated to the calculations of power part of
the fly-back. Several MPPT converters of this type can be
I. INTRODUCTION easily cascaded in system as in [10].
Nowadays the renewable sources of energy gets more
popular. The solar energy is one of them. However, most of II. THE APPROACH OF CALCULATIONS ON FLYBACK MPPT
the solar systems are not stand-alone. Grid-tied photovoltaic CONVERTER FOR PV-MODULES
systems are very common. One of the main problems for The design for PV-Panel must be started with estimation
this kind of systems are common mode currents. of extreme operation points. This is the way the designed
The origin of the common mode currents are strict converter will avoid over-load conditions. First of all NOCT
regulation rules that prescribes necessity of the grounding of (Nominal Operating Cell Temperature) model must be used
metal frames of photovoltaic modules, large leakage to calculate the power points for maximal irradiation (and
capacitance of photovoltaic modules and grounding of this means the maximal generated power within conditions)
neutral of AC-grid. If the system has no galvanic decoupling and extreme temperatures for given climatic zone. The
between the PV-panel and AC-grid this kind of currents values used for calculations overlaps the ones that real
occurs. The grid with grounded neutral, MPPT (Maximum MPPT converter can meet in real life, but certainly will give
Power Point Tracking) converter and leakage capacitance of higher margin of safety.
photovoltaic module makes a closed loop. 50 times per The example of calculations will be for climatic zone of
second the leakage capacitance of the module gets the high Latvia and for PV-module SPR-90-WHT-I produced by
and low potentials of the AC-grid [1], [2], [3]. SunPower. The parameters of the PV-panel are listed in
There are several ways to avoid this problem. The Table 1. [7]
inverter topologies like HERIC and H5 for grid-inverter that
chops-off the currents on the stage of AC-forming. Other A. NOCT-Model
way is introducing current interrupters at the section of The rated parameters of photovoltaic solar cell array are
obtained within laboratory conditions. For better reflection
This research work has been supported by Latvian Council of Science of power module behave NOCT-model must be used.
(Grant 673/2014). Formula (1) is for calculation of real temperature of the cell
P. Suskis, I. Galkin and J. Zakis are with Institute of Industrial
Electronics and Electrical Engineering, Riga Technical University, and formulae (2), (3), (4) for calculations of parameters
Kronvalda blv., Riga, Latvia (e-mail: pavels.suskis@rtu.lv, under calculated temperature conditions [9]:
gia@eef.rtu.lv, janis_zakis@yahoo.com)
TNOCT  20C  Choice of maximal duty cycle
 Tcell  Tamb  Irr  
800W / m 2  Current ripple coefficient choice
 Assuming of efficiency for further calculations
where Tamb is actual ambient temperature, Irr is actual
In this example we will use the switching frequency of
irradiation that been assumed as 1000W/m2 to get maximal
100 kHz (fsw), Dmaxap maximal duty cycle of 0.45 for first
converted power value.
calculation, current ripple equal coefficient to 25%. The
 VOCx  VOC  V Tcell  25C    choice of prospective efficiency must be done after some
experimental draft-design for the approximately equal
 I SCx  I SC  I Tcell  25C    parameters [7], [11]. In this case we take 82% value. The
 PMPPx  PMPP  PTcell  25C    output voltage is important value. Most of the design guides
are based on the constant output while the input can have
where VOCx, ISCx and PMPPx are the open circuit voltage, some pulsation of voltage. The difficulty of the MPPT fly-
short-circuit current and maximal power point power of the back converter design is that the input voltage and output
module for calculated cell temperature. voltage are variable. In this case it was decided to take 10
MPPT converters and connect them in series. The voltage of
TABLE I. PARAMETERS OF SUNPOWER SPR-90-WHT PANEL
DC-grid is varying from 540V to 660 V. The reserve for
Parameter Description Abbreviation Value malfunction or irradiation disturbance of one or few MPPT
Maximum Power Point at 1000W/m2 converters can be considered as option. In this case for
PMPP 90
and 25ºC, AM1.5 [W]
calculation simplification this option is skipped. Injecting
Open Circuit Voltage (VOC) [V] VOC 21.2
energy to the DC-grid when the voltage of 650V must be
Short Circuit Current (ASC) [A] ISC 5.5
avoided for overvoltage protection. So, the single converter
Maximum Power Point Voltage
(VMPP) [V]
VMPP 17.7 output is 65V. For more deep analysis and explanation on
Maximum Power Point Current decisions is explained below.
IMPP 5.1 The circuit of flyback converter is shown in Fig.1.
(AMPP) [A]
Voltage change by temperature
ΔV -60.8
increase [mV/ºC]
Current change by temperature Csn Dout
ΔI 2.2 Rsn
increase [mA/ºC] Vin Cout Vout
Maximal power change by Dsn
temperature increase [%/ºC]
ΔP -0.38 Cin
NOCT cell-temperature TNOCT 48,5º C Qmain
NOCT conditions: Irradiation of 800W/m², wind velocity 1m/s and
20º C of Ambient temperature Fig. 1. Flyback converter circuit diagram.

For the climatic zone of Latvia two extreme conditions As the voltage is smaller and current is larger in case of
are chosen +35º C and -40º C and maximal irradiation of low-temperature conditions these values will be used for
1000W/m2. These are extreme temperature points for the calculations as default. However, in some cases the high-
region and will be used as two reference points as there is temperature condition reference-values must be used as
different currents and voltages are expected in each of cases. well.
The calculation results for the panel are given in Table 2: The turn ratio of fly-back transformer is:
Dmax ap VMPP1
TABLE II. REFERENCE VALUES FOR TWO TEMPERATURE  N pts     ap  
CONDITIONS Dmax ap  1 Vout
Ambient temperature
Parameter Description where Npts is ratio of turns of primary to secondary winding,
+35 -40
Dmax is the maximal duty cycle, ηap is approximate
Open Circuit Voltage (VOC1, VOC2) [V] 18.426 22.986
efficiency of converter. The forward voltage of output diode
Short Circuit Current (ISC1, ISC2) 5.6 5.435
of classic equation is not included as the efficiency ratio is
Maximum Power (PMPP1, PMPP2) 75.649 100.046
included and the output voltage is relatively high comparing
Approximate Maximum Power Point
Voltage (VMPP1, VMPP2)
15.4 19.2 to the voltage drop on diode. Usually the obtained value gets
Approximate Maximum Power Point rounded (to integer number) for easier approach and new
4.92 5.22 maximal duty ratio is calculated, but using the modern
Current (IMPP1, IMPP2)
calculation software the use of the precise value is not
The values of approximate maximum power point voltage problem anymore. For inductance calculation the current
and current can be used as reference numbers for converter ripple must be obtained, according to [11], [12], for better
input calculation. Both of values will be needed in further efficiency it must be for most of the design cases:
approach as the converter must be able to handle the  i1  25%  I MPP1  
generated energy in both of cases that have different input.
In the same manner gets calculated Δi2 for different
B. Flyback Converter Approach conditions with IMPPT2. In the case of low temperature
Once the input reference values are estimated following conditions the PV-output voltage is higher that means the
decisions must be made: duty cycle is lower:
 Choice of frequency
 Choice of output voltage
N pts So it get assumed as some part of total converted energy.
 DMPP 2    In the considered example maximal converted power is
V MPP 2
N pts  about 100 W. We take 2% or 2 W to be dissipated in both
Vout windings of fly-back transformer. The reference [7] contains
Now the inductance for both of cases can be calculated. the table of geometrical constants for common ferrite core
The larger value will be able to keep current pulsations at geometries in Appendix 2 that is defined as:
the rated ripple limit [12], [13]. The chosen one value get Ac2W A
 kg   
V MPP1 D max MLT
 L p1   
2 f SW i1 where Ac is the core cross-sectional area, WA is the window
The secondary inductance is equal to [14]: area, and MLT is the winding mean-length-per-turn. The
geometrical constant of the core must have larger than the
2
 1  estimated value in formula (15). But choice of core with too
 L sek    L p   large geometrical constant than estimated one leads to
 N pts 
  increase of core losses according to equation [7]:
Transformer input RMS current is equal to [14], [15]:  PFe  k Fe B  Ae l e  
iin2 Coefficient kFe is expressing relative losses for the
 I inRMS  DI in2  D   corresponding frequency, ΔB is flux density ripple, β is core
3
loss exponent, le is effective magnetic path, Ae effective
The equation for output RMS current [13]: cross-section of magnetic path. The best core that fits the
estimated values is P 2213. But this kind of cores has small
iin2 material list in the retail. Therefore, due to the popularity the
 I outRMS  (1  D) I in2  (1  D)  
3 chosen core size for the considered example is ETD29 (that
has larger geometrical constant). As the core geometrical
Currents for both of cases must be calculated. In case of
constant is larger than estimated, the total copper loss will
high-temperature conditions the duty cycle D has the value
be smaller than 1W. To avoid core saturation and energy
of Dmax, Iin is equal to the IMPP1 and Δiin is equal to the Δi1.
storage the lg air gap must be calculated.
In case of calculation for low-temperature operation DMPP2,
2
IMPP2 must be used. Current pulsation must be recalculated  0 L p I sat
for chosen primary induction value.  lg   
Bsat Ae
For fly-back transformer the value of maximal current
must be estimated. For the safety reserve reasons the sum of The minimal turn number of the primary winding is:
short-circuit current value and current ripple is used as
saturation current. Using of this variable in equation is L p I over
 N p min   
making a reserve that will never be reached at any case. Bsat Ae
Even if the MPPT converter control system is failed, the
saturation current is never reached. Note, the current ripple The obtained number of turns is minimal and expected as
decreases in the PV-module current-source region as the non-integer number. The number of turns of secondary
voltage of the source gets smaller. Saturation current for this winding is equal to the same number divided by primary to
case: secondary turn ratio. The numbers are 8 turns and 45.

 I sat  I SC 2  i 2   C. Spread of Transformer Losses


The losses in the core can be found both from material
Further approach refers to the fly-back calculation
datasheet and from the core losses graph from material
mentioned in the [7], [16]. Magnetic current Itot is needed technical specification. [7]
for estimation of geometrical constant of core. The copper losses of windings are defined by formula:
I outRMS
 I tot  I inRMS      MLT
k  n 2j I 2j 
N pts  PCuTot 
WA ku  
 j
j 1 
 


Once both total currents for both of magnetic currents are 
calculated, the largest value should be used in geometrical The copper losses of windings and total copper loss are
constant (kg) calculation: shown in the Fig. 2.
L2p I tot
2 2
I over
 kg   
k u Bsat PCu
where ρ is the resistivity of copper at room temperature
equal to 1.724∙10-6 [Ω∙cm]; ku is winding window utilization
ratio or fill factor that commonly gets assumed as 0.3; Bsat is
saturation flux density for corresponding material, PCu is
assumed copper loss. Calculation of this value is
complicated and is strongly dependent on the choice of the
core geometry that has not been done at this approach point.
Fig. 2. Diagram of winding loss as the function of allocation factor
There is common opinion, that the copper loss is minimal +15

in the point where the copper losses of windings (cross-


point of loss functions) are equal. As it is obvious from the PWM
figure, the point of minimal total copper losses is close but A)
is not exactly in the same. For this reason (22) derivation by
α (fraction of allocation of winding and α1 is allocation
fraction of a primary winding, secondary winding allocates GND
the rest of window area) must be equated to the zero. The
solution of the equation is the minimum of the function and, GND
therefore, the optimal winding allocation that leads to the
optimal cross-section of wires [7]:
PWM
I inRMS
 1  1    B)
N pts I outRMS  I inRMS
The estimated value for the example is 0.427. This means -15
the part of winding window for the secondary winding is Fig. 4. Gate Driver A) optocoupled field transistor.
0.573.
The cross-section of the winding conductors are Both of solutions has the advantages and disadvantages.
calculated by formula: A) is good for the MOSFETs with low gate charge. Due to
reduced costs and easy circuit structure. On the other side
 1k uW A most of MOSFET transistor with low RDSOn have large gate
 AW   
Np charge. Circuit A is not able to carry enough energy to
provide proper semiconductor device switching. For this
The cross-section of conductor is not always value that purpose circuit B) is shown. Drawbacks of this topology is
can be used for wire choice. Due to the skin effect the power supply needed for negative voltage and
winding must be wound of couple of isolated wires. The recommended complementary pair of npn/pnp transistors.
effective wire size of winding working on 100 kHz Most of opto-coupling drivers are not good enough to pull-
frequency is # 33 AWG according to [7]. Therefore must be up gate potential of the ground. On the other hand the
used several wires which cross-section sum is equal to the currents flowing through the P-channel MOSFET are
values estimated using formula (22). significant and reducing the conduction losses is able to
increase circuit overall efficiency.
III. THE EXPERIMENTAL VERIFICATION The other way to increase efficiency of the converter is
The flyback converter has been designed according to the change of flyback topology to actively clamped forward
calculations. After several experiments the topology showed converter. The circuit diagrams are close enough and there
net enough satisfactory efficiency. The semiconductor parts is no large mismatch in circuit work principles.
required additional cooling. For this reason the circuit has Both testing for conventional and active clamp flyback
been upgraded by active clamping technique. This allowed are made with equal capacitance on output and input of the
to take the overvoltage spikes and provided ability of converter. The output part of active clamp forward converter
switching the transistor in the decreased voltage periods. is different to the two mentioned above.
Using active clamp technique allow to skip chopping the
current off and get the energy kept in clamp- capacitor till Dout1 Lout
next cycle start. The flyback with active clamp topology is
shown in Fig. 3.
Cin Dout2 Cout Vout
Vin
Dout Cclamp
Cin Cout Vout Qmain
Qclamp
Qmain Cclamp Fig. 5. Active Clamp Forward converter circuit diagram

Active clamp allows the use of duty ratios above 50%


Qclamp that are restricted for flyback with RCD-snubber. The same
transformer coilformer with the same winding was used for
Fig. 3. Active clamp flyback converter circuit diagram. three tests. The active clamp forward converter have
As seen from the image the converter has two switches: different relationship between input voltage, output voltage,
main switching N-channel MOSFET, active clamp switch duty ratio and turn ratio than other two. For these reasons
P-channel MOSFET. There is two ways for driving P- the maximum duty ratio for active clamp forward was
channel switch that are shown in Fig. 4. changed to higher. [17], [18].
Time period of reduced voltage is relatively short. This
makes the switch control signal timing a significant
problem. If the main switch is not switched on in right time
the losses are rising very dramatically. Taking in account
efficiency diagram of topologies in Fig. 6 and Fig. 7. the
implementation of this topology becomes irrational. [17]

VgsMain

VdsMain
Fig. 6. Efficiency for three types of converters (conventional flyback with
RCD snubber, active clamp flyback and active clamp forward) for voltage
of 15.4 V VgsClamp
Three topologies were tested, efficiency values estimated
by the Precision Power analyzer PPA5530 KinetiQ.

Fig. 10. Oscillograms for forward converter with active clamp, Drain-
Source voltage and gate-source and drain-source voltage of active clamp
switch voltage for voltage of 19.2 V and current 3.5 A

For the test in diagram in Fig. 10. the same coilformer


with the same windings was used as the transformer. Only
difference to the previous two tested converter topologies
was the lack of air gap. The air gape in core is essential for
the flyback topology as the transformer is working rather as
the two-winding inductor. In forward topology the
Fig. 7. Efficiency for three types of converters (conventional flyback with transformer is functioning rather as the HF-transformer, not
RCD snubber, active clamp flyback and active clamp forward) for voltage inductor.
of19.2 V
Next issue of forward converter is the relationship
The oscillograms for all three converters at the same input between input voltage (Vin), output voltage (Vout), turn ratio
conditions are shown in Fig. 8, Fig. 9, Fig. 10. (N) and duty ratio (D) [18]:
 V  V DSon 
 Vout   in  VQrec   D  
 N 
VdsMain VgsMain
There is two additional variables VDSon and VQrec that are
that stands for the voltage drop on main switch drain-to-
source voltage drop and rectifier semiconductor voltage
drop. As the relationship is different the maximum duty
cycle duration has been changed to the larger value. The
maximum ratio of flyback is strictly limited by 0.5. [7], [13]
Forward converter with Active Clamp has big
opportunities for synchronous rectification due to
rectangular waveforms of the transformer voltage.
Introducing this technique is able to rise the overall
Fig. 8. Oscillograms for flyback converter with RCD snubber, Drain- efficiency.
Source voltage and gate-source voltage for voltage of 19.2 V and current As seen from the oscillogram in Fig. 10. the reduced
3.5 A. voltage region is longer. Duration and degree of voltage
reduction is strictly related to the leakage inductance of
VdsMain VgsMain primary side. Rising stray inductance on primary side is able
to reduce the voltage to the zero and achieve ZVS [17], [18].
Increase of stray inductance can be achieved by: designing
the transformer, adding the inductor to the circuit, design of
PCB. On the other side this parameter is decreasing the
VgsClamp voltage that is provided to the magnetic inductance. If the
design has too high stray inductance on primary side, the
required power flow between input and output can be
disturbed.
The design of the correct transformer is sophisticated
Fig. 9. Oscillograms for flyback converter with active clamp, Drain- question that different research can demand the individual
Source voltage and gate-source and drain-source voltage of active clamp research, respecting the NOCT model and attach to the
switch voltage for voltage of 19.2 V and current 3.5 A. certain photovoltaic module as it is done in this paper.
Respecting arguments expressed above the topology is Photovoltaic Modules," Power Electronics, IEEE Transactions on ,
vol.27, no.7, pp.3221,3233, July 2012
recommended rather to the applications that require higher
[9] Suskis, P.; Galkin, I., "Enhanced photovoltaic panel model for
input voltage. MATLAB-simulink environment considering solar cell junction
capacitance," Industrial Electronics Society, IECON 2013 - 39th
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voltage reduction and power flow. As the leakage
inductance dependent on the transformer design is affecting BIOGRAPHIES
both of these parameters significantly. Pavels Suskis has presented his Bachelor
Science degree and Master degree in Riga Technical
University, Faculty of Electrical Technologies in
ACKNOWLEDGMENT 2008 and 2010, respectively. His bachelor thesis
was focused in “Frequency converter applying to
This research work has been supported by Latvian crane drive” while master thesis and engineering
Council of Science (Grant 673/2014). project was devoted to to research and development
of control system for voltage source inverter.
Research interests of Pavels Suskis are in the field
REFERENCES of intelligent microprocessor control of electric
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Ph. D. Thesis is dedicated to Photovoltaic energy sources.
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modulation techniques for Z-Source inverter used in photovoltaic applications of matrix converters. In particular it
systems," Power Electronics, Drive Systems and Technologies regards integrated designs with the matrix
Conference (PEDSTC), 2013 4th , vol., no., pp.459,464, 13-14 Feb. converters, smart control of their semiconductor
2013. switches, thermal and conductor‟s design.
[3] Habib Khan, M.N.; Khan, S.; Gunawan, T.S.; Shahid, Z., "DC-AC Another research field includes smart power
inverter with perspective of common mode and wave-shaping," Smart supplies for various applications, for example, for
Instrumentation, Measurement and Applications (ICSIMA), 2013 LED lighting.
IEEE International Conference on , vol., no., pp.1,5, 25-27 Nov. The working experience of Ilya Galkin includes 6 year of practical
2013. engineering job at research and manufacturing enterprise “Lasma” (Latvia)
in the field of elaboration and development industrial automatics, as well as
[4] A. Blinov, A. Andrijanovits "New DC/DC Converter for Electrolyser 14 years of research and educational job at Riga Technical University. At
Interfacing with Stand-Alone Renewable Energy System", Electrical, the given time he is a professor at the Department of Power Electronics and
Control and Communication Engineering. Volume 1, Issue 1, Pages Electrical Technologies of RTU-EEF-IEEI. Ilya Galkin is the author of
24–29, ISSN (Online) 2255-9159, ISSN (Print) 2255-9140, DOI: various publications.
10.2478/v10314-012-0004-1, January 2013 Ilya Galkin is IEEE member since 2006 in societies of Power
[5] Husev, O.; Stepenko, S.; Roncero-Clemente, C.; Romero-Cadaval, E.; Electronics, Industrial Electronics, Automatic control and Education.
Strzelecki, R., "Experimental Investigation of high frequency 3L-
NPC qZS inverter for photovoltaic application," Industrial Electronics Janis Zakis (M’10) received B.Sc., M.Sc. and
Society, IECON 2013 - 39th Annual Conference of the IEEE , vol., Dr.Sc.ing. degrees in electrical engineering from
Riga Technical University, Riga, Latvia, in 2002,
no., pp.5969,5974, 10-13 Nov. 2013 2004 and 2008, respectively.
[6] Mingzhi Gao; Min Chen; Chi Zhang; Zhaoming Qian, "Analysis and He is presently a Senior Researcher in the
Implementation of an Improved Flyback Inverter for Photovoltaic AC Institute of Industrial Electronics and Electrical
Module Applications," Power Electronics, IEEE Transactions on , Engineering, Riga Technical University.
vol.29, no.7, pp.3428,3444, July 2014 He has over 30 publications and is the holder of
[7] R. W. Ericson, D. Maksimovic, Fundamentals of Power Electronics, one Utility Model in power converter design. His
Second edition, Kluwer Academic Publishirs, 2001, Sixth Printing research interests include flexible ac transmission
2004. systems (FACTS), simulation of power systems,
switching mode power converters, applied design
[8] Nanakos, A.C.; Tatakis, E.C.; Papanikolaou, N.P., "A Weighted- of power converters and energy storage systems.
Efficiency-Oriented Design Methodology of Flyback Inverter for AC

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