X International Symposium on Lightning Protection

9th-13th November, 2009 Curitiba, Brazil

Surge protection for PV generators: Requirements, testing procedures and practical applications
Josef Birkl1, Peter Zahlmann2, Ottmar Beierl3
1,2

DEHN + SHNE GMBH + Co. KG, 92318 Neumarkt, Germany - E-mail: Josef.Birkl@technik.dehn.de
3

Georg Simon Ohm University Nuremberg, Germany system is also described as an insulated LPS. When a PV array is protected by a LPS, the minimum separation distance between the conductive parts of the PV array and the external lightning protection systems should be kept to prevent partial lightning currents flowing through the metal parts of the PV-array. For PV arrays installed on the roof of buildings the necessary separation distance can not be fulfilled in all cases, due to the limited space. In this case a direct connection between the LPS and the metal PV module frame is necessary. This has also implications on the possible installation of SPDs. Depending on the presence of an external LPS, the future European Application Standard on SPDs connected to Photovoltaic installations [6] describes different cases for the possible installation of SPDs: Building without external LPS Building with external LPS separation distance s is kept - Building with external LPS separation distance s is not kept This results in the different protection schemes, as laid down in table 1.
Table 1: Possible Installation of SPDs depending on the LPS.

Abstract The general methods of lightning and surge protection, as laid down in the lightning protection standards of the IEC 62305 series [1] can be applied also in photovoltaic installations. This paper describes the general requirements of a coordinated surge protection in PV-applications. We mainly focus on the specific application of SPDs on the DC side of a PV generator. Up to now, both the installation standards, such as IEC 60364-5-53 and IEC 61643-12 [2] [3]. Also the product standards for SPDs, such as IEC 61643-1 [4] and UL 1449 [5] cover only AC-applications of SPDs. In this paper the special requirements on SPDs in PV applications will be evaluated by computer simulation and laboratory testing. Also the implications on the specific testing methods for such SPDs will be discussed..

INTRODUCTION

Due to the exposed arrangement and the extended surface of photovoltaic systems, a high risk of direct and indirect lightning strikes arises for such systems. The lighting current of a lightning discharge can influence PV installations by inductive and capacitive voltages as well as lightning surges in the upstream power supply system. Avoiding system failures due to damage caused by lightning surges requires a good coordination of a lightning and surge protections concept. The general methods described in the lightning protection standards IEC 62305 can also be applied for photovoltaic systems. In general the lightning protection system for a PV generator also includes External Lightning Protection System (LPS) Earthing and bonding Magnetic shielding and line routing Coordinated SPD protection

Lightning Protection No LPS external

Figure 1 gives an example of the principal lightning and surge protection measures of a grid connected PV generator in an installation with an external LPS. In this example the separation distance s is kept by an external LPS, isolated from the structure. Such a

External LPS; Separation distance kept External LPS; separation distances not kept

SPDs on ACoutput of converter SPD Class II tested recommended SPD Class I tested SPD Class tested I

SPD on DCoutput of converter SPD Class II tested recommended SPD Class II tested SPD Class tested I

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wind sensor s s

s: separation distance is kept (insulated LPS) SPD: Surge Protective Device ACU: Acquisition and Control Unit

a.c. output

d.c. input

SPD Type 2 for PV application SPD Type 2

equipotential bonding bar

additional earthing connector

SPD Type 1 Combined SPD for low voltage power supply and signal line acc. to EN 61643-11 and EN 61643-21 SPD (test impulse D1) for signal line acc. to EN 61643-21 Air termination system

meter/main distribution

main earthing bar

signal line low voltage power line

Down conductor Earth termination system

Fig. 1 Lightning and surge protection measures of a grid-connected PV generator Protection by an external, insulated LPS [6]

COORDINATED SURGE PROTECTION MEASURES OF A GRID-CONNECTED PVGENERATOR

LIGHTNING REQUIREMENTS ON SPDS ON THE DC-SIDE OF PV APPLICATIONS

In general the coordinated surge protection measures of a grid-connected PV generator include, as shown in the example of figure 1, Surge protective devices, both on the DC side and AC side of the PV installation. If the length of the circuit between the SPD and the DC-AC-converter is too long, propagation of surges can lead to an oscillation phenomenon. This can increase the overvoltage at the input terminals of the inverter up to two times of the SPDs protection level. Moreover lightning flashes close to the PV installation induce an overvoltage in the wiring between the SPD and the inverter, that adds to the protection level of SPD and reduces the protection efficiency of the SPD. Therefore additional SPDs as close as possible to the PV inverter are recommended, if the distance between PV array and DC-AC converter or DC-AC converter and origin of installation

The special requirements on SPDs installed on the DCside of PV applications will be evaluated by computer simulation and laboratory testing. Also the implications on the specific testing methods for such SPDs will be discussed. 3.1 Impulse current (Iimp) for Class I tested SPDs As already pointed out, when a PV array is protected by a LPS and when the separation distance cannot be kept direct bonding of the LPS and the metal part of the PV array is necessary. In this case partial lightning currents are flowing via the metal parts of the PV system. Figure 2 shows the possible lighting current distribution in such a system. In case of a direct lightning flash to the LPS a substantial voltage difference between the equipotential bonding at the roof level and the remote earth of the plus- and minus-line occurs. Due to this potential difference the SPDs installed at the DC terminals of the PV-array, become activated and partial lightning currents flow via the SPDs and plus- and minus-line towards remote earth of the DC-AC converter. Apparently the SPDs, installed at both ends of the DC line have to carry partial lightning currents. The impulse current rating Iimp for these lightning current arresters, according to the terminology of IEC 61643-1 classified as Class I tested SPDs has to withstand the expected stress at the point of installation. The lightning current sharing can be calculated according to the methods, described in part 1 and part 4 of IEC 62305. Computer simulations can be a helpful tool to evaluate the lightning current dispersion. Therefore it is necessary to convert the real world system, as shown in the example of figure 2 into an equivalent

exceeds 10 meters. If the PV-system is equipped with data acquisition and control equipment it is necessary to protect also the communication circuits by suitable SPDs [7]. Up to now, both the installation standards, such as IEC 60364-5-53 and IEC 61643-12 and also the product standards for SPDs such as IEC 61643-1 and UL 1449 cover only AC-applications of SPDs. Therefore this paper mainly focuses on the specific application of SPDs on the DC side of a PV generator.

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electrical circuit diagram. This results for the example of figure 2 in the equivalent circuit diagram of figure 3. When conducted to earth, the lightning current is divided between the down conductors and the electrical lines via the SPDs connected to them. In order to calculate the lightning current distribution within the system of figure 2, following paths to earth have to be considered: - Four down conductors of the LPS - The earthing connection of the PV-array - The two DC lines

Neglecting the impedance of the SPDs and assuming that the length of the LPS down conductors and the electrical lines is the same, the current sharing can be evaluated by following simplified approach [8]: I (1) I imp total
n

n being the total number of parallel paths. Based on this approach the values of Iimp for the SPDs, given in table 2 can be determined for different Lightning Protection Levels (LPL) and different n.
Table 2: Determination of Iimp of SPDs on the DC side of PV generators

LPL

I (200kA) II (150kA) III/IV (100kA)

n=7 (4 down conductors and earthing Iimp 28,6kA 21,4kA 14,3kA

n=4 (2 down conductors; no additional earthing ) Iimp 50 kA 37,5 kA 25 kA

Fig.2 Lightning current distribution in PV-system

3. 2 Discharge current (In) for Class II tested SPDs As pointed out it is the basic aim of a lightning protection system for PV-systems to prevent any partial lightning current flowing within the PV-system. In a system, equipped with an insulted LPS only the induction effects due to lightning electromagnetic impulse (LEMP) have to be considered. Therefore it is sufficient, according table 1, to install Class II tested SPD , on the DC side of the PV generator. According to figure 4 the magnetic field H created by the lightning currents flowing in the neighboring LPS can induce considerable voltages in any conductor loop, which result in corresponding impulse currents, if these conductor loops are closed. These induced surges are the primary threat parameters for the Class II tested SPDs, installed at the terminal of the PV array. Laboratory tests on a PV module with shunted output terminal have been carried out to evaluate the necessary surge current rating In of the SPDs [9].

Fig.3 Equivalent circuit diagram to evaluate Iimp

Fig.4 Induced surges in PV-arrays due to the magnetic field of a nearby lightning current

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Figure 5 shows the main results of these induction tests on a single PV module, which are summarized below: a) The induced current decreases almost proportional to the distance between PV module and air-termination conductor and increases with steepness of the primary lightning current impulse. b) The induced current has a shorted wave shape which corresponds almost to an 8/20 impulse current at a 10/350 primary lightning current. Based on this measurement of a single PV-module the total load of a PV array has been estimated with a maximum induced current of 10kA. It can be concluded that for Class II tested SPDs installed at the DC-side of PV systems a nominal discharge current In = 20 kA (8/20) per mode of protection is sufficient.
I10/350 [kA] 50 40 30 20 10 0 -10 1.0 0.8 0.6 0.4 0.2 0.0 -0.2 0 0.25 0.5 0.75 1.0 1.25 1.5 1.75 Time [ms] Distance 0,5 m Distance 1 m Distance 2 m

Fig.6 Test set-up on induced surges in PV arrays due to the magnetic field of nearby lightning currents

Primary lightning currents in copper wire 10/350 s at different distances

Iinduced [kA]

Induced impulse currents at different distances

Fig.5 Induced surge current in a single PV-module

Figure 6 shows the further development of these tests on induced surges in PV-modules. In a second test not only the behavior of single module but a complete PV array has been examined. In this case the lightning current was shared between several paths of the module frame. These tests confirmed the general finding of the previous tests. Considerable surges damaged the equipment installed in PV sub-array junction box, which was not protected by SPDs. The decisive test parameter for surges due to induction effects is the steepness of the lightning current flowing in air-termination conductors of the LPS. Due to the impedance of this relatively large test object, the average current steepness was limited to di dt 10kA s , which represents the current steepness of LPL III for the first short stroke as described in IEC 62305-1. To evaluate the induced surges for the subsequent short strokes, which are defined with 200kA/s for LPL I in Part 1 of IEC 62305 further computer simulations will be performed. First results of these computations on induced surges in PV arrays due to subsequent short strokes will be presented at the X SIPDA conference.

3.3 Coordination SPD protection level Up and immunity of DC-AC-converter The protective performance of an SPD is described by its voltage protection level Up, as given in IEC 61643. The surge immunity of equipment is described by its immunity level according IEC 61000-4-5 [10] and its withstand level according IEC 60664-1 [11]. In order to identify the needed protection level Up of the SPDs it is necessary to establish the surge immunity of the DC-ACconverter. It has to be considered that not only the maximum voltage level Umax to be expected across the terminals of the SPD has to be compared with the withstand of the equipment. A number of further additional parameters might be relevant for effective protection, such as - Maximum impulse current Imax flow into equipment - Maximum energy Wmax transferred into equipment - Maximum voltage-time integral u dt Maximum voltage change du
dt

These criteria have to be fulfilled, both for SPDs installed at the AC and DC input of the converter. These requirements also have to be fulfilled both by Class II tested SPD, when only inductive effects are considered, but also by Class I tested SPDs in case lightning flash directly into the LPS of the PV installation are taken into account. A lightning current test of SPD and DC-AC converter under real service has been proposed in [12]. The basic idea of such a test is to combine the standard test philosophy of an equipment immunity test with the increased stress parameters, needed for advanced lightning and surge protection. Figure 7 shows the test assembly of the impulse current test of a central DC-AC converter, with Class II tested SPDs installed on the DC side and Class I tested SPDs on the AC side of the converter. The results of such system tests deliver also an import input for the design of new and advanced surge protection technologies.

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Fig.6 Test set-up on Induced surges in PV-arrays due to the magnetic field of a nearby lightning currents

Fig.7 Voltage-current characteristic of a PV module at different cell temperatures

SYSTEM REQUIREMENTS ON SPDS ON THE DC-SIDE OF PV APPLICATIONS In the previous paragraphs important parameters for the selection of SPDs on the DC-side of PV-generators have been described, which are all related to the lightning and surge events. For a save and reliable operation of SPD also some important system requirements have to be observed, which take into account also the special source characteristic of a PV array. 4.1 Continuous operating voltage UC of the SPDs An important parameter for the selection of an SPD is the maximum continuous operating voltage UC. The following general rule also applies for SPDs on the DCside of PV-applications: UC must be higher than the maximum open circuit voltage of the PV-generator. This criteria has to be fulfilled under normal operation conditions and for all modes of protection (plus to minus, plus to earth and minus to earth). In order to describe the open circuit voltage of a PV-array, the future IECstandard CD-IEC 62548 Installation and safety requirements for PV generators introduced the term UOC Array, the open circuit voltage of a PV array at standard conditions [13]. These standard conditions, used for testing and rating of photovoltaic modules are defined with a PV cell temperature of 25C, an irradiance in the plane of the PV module of 1000W/m and light spectrum corresponding to an atmospheric air mass of 1,5. However these standard conditions are in conflict with the basic requirement, that the Uc must be higher than the open-circuit voltage of the PV array under all normal operation conditions. Figure 7 show the voltage-currentcharacteristic of a PV-cell at 1000W/m with the PV-cell temperatures as a variable parameter. The open circuit voltage of a PV-cell increases with a decreasing celltemperature. In the given example the voltage of ~ 42 V at a standard temperature of 25C increases to ~ 52 V at - 25C. Therefore this voltage rise due to lower cell temperatures also has to be considered when selecting Uc of a SPD installed PV array.

It is also important to notice that the real maximum opencircuit voltage of PV modules differs to its nominal value. Especially in PV application with thin film module the tolerance of the open-circuit voltage has to be observed. Thus the selection of Uc for SPDs installed on the DC side of PV application, based on UOC Array, seems not reasonable. A new definition UPVmax, describing the admissible maximum PV voltage under normal operation conditions has been introduced for the new design of surge protective devices for photovoltaic systems [14]. Based on this value, the design engineer of the PV-system is able to select the correctly dimensioned SPDs, as a similar definition is also used for the correct selection of the admissible input voltage of DC-AC converters [15]. 4.2 Overload behavior of SPD in PV-Arrays Clause 4.1 describes criteria for the correct selection of SPDs under normal operation conditions. However SPDs also have to cope with abnormal conditions such as: - Earth fault on the DC-side of an unearthed PVsystem - Excessive number of lightning strikes or impulse currents In these cases, the SPDs might turn into an overload status. This status has to be save, without any conflict in terms of fire protection and personal protection. a) Earth fault on the DC-side of an unearthed PVsystem Figure 8 describes the basic conditions in case of an earth fault on the DC side of an unearthed PV-System. Many PV systems require, that neither plus nor minus are connected to earth, especially if DC-AC converters without transformer are applied. In this case, the "maximum system voltage of the PV system" is applied plus to minus. If none of both DC lines is earthed, the voltage line to earth is only 50 % of the "Maximum system voltage of the PV system". SPDs are connected in general line to earth as lightning surges are in general surges to earth. Under normal operation conditions for the

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mode of protection line to earth a Uc which is above this "50 % of the "maximum system voltage of the PVsystem" would be sufficient. However in case of an insulation fault, the full "maximum system voltage of the PV system" is applied across this SPD. So if the maximum continuous operating voltage is chosen according to this 50%-criteria, as explained above, SPDs might be overstressed. SPDs including a non-linear protection-component, might create an inadmissible fault current due to the V-I-characteristic of the MOV. Doubling the UC of the SPD results in a higher protection level Up at the same discharge current, which might be in conflict with the immunity level of the converter.

b) Excessive number of lightning strikes or impulse currents Despite the advanced fault-resistant Y-configuration SPDs
on the DC side of PV Systems might be overloaded due to a excessive number of partial lightning or impulse currents. During the Class I and II preconditioning and operating duty tests SPDs have to withstand in total 20 impulses. Following this complete test sequence the protection level UP shall still within the tolerance of a new SPD. A higher, excessive number

of lightning strikes or impulse currents, not exceeding the characteristic of SPD might lead to a slow degradation and finally destruction of its internal components. This might result in a so called end of life scenario. In contrast to applications of SPD on the AC side the disconnection of SPDs on the DC side of PV systems by upstream overcurrent protection device is difficult, as the nominal current and the short circuit current in PV-arrays is within the same range. The usual SPDs disconnector, which provide a reliable disconnection in case of this end-of-life-scenario are designed for AC applications. The disconnection mechanism in DC circuits is different to AC applications. It is necessary to implement a specific DC disconnector, The general rule to interrupt the DC-fault current is that the arc-voltage of the disconnector has to be above the open circuit voltage of the DC source. For the specific application in PV circuits additionally the specific voltage-current-characteristic of the PV source as shown in figure 10 has to be considered .
U [V]

UDC PV-Generator Uarc = f (i)

Fig.8 Insulation fault in an unearthed PV system

The scenario described in figure 8 was the background for the SPD design with a so-called fault-resistant Yconfiguration ,as shown in figure 9. This design ensures, that the SPD is not overstressed even in case of an insulation fault. On the other hand it provides a lower protection level between plus and minus and ensures the coordination with immunity of the DC input of the converter.

Conventional DC-source with two-pole characteristic

x ISC

I [A]

Fig.10 Comparison of the static voltage-current characteristic of a conventional DC source and a PV generator

Fig.9 SPD with fault-resistant Y-configuration

A PV-array has in contrast to a conventional DC-source with two-pole characteristic almost the behavior of constant-current source. A conventional DC-source has a linear decreasing voltage-current-characteristic. The different static voltage-current-characteristic of these different DC- sources results in the different oscillograms of figure 11. In this figure the voltage across a disconnection device and the corresponding DC current have been recorded for a comparison test of a conventional DC source with the described two-pole characteristic and a real PV generator. The real PV generator delivers the above described constant current

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during the disconnection period, despite an increasing arcvoltage across the disconnector switch. This constant current results in a much higher energy dissipation in the switch during the disconnection period. Furthermore the voltage across the switch has to exceed the open-circuit voltage of the PV-generator, when almost the total DC fault current is flowing.
1.0 voltage [kV] 0.8 0.6 0.4 0.2 0.0 -0.2 10 9 current 8 [A] 7 6 5 4 3 2 1 0 -1

6 REFERENCES
[1] IEC 62305-1: 2006-01: Protection against lightning - Part 1 to Part 4 [2] IEC 61643-1: 2005-03: Low-voltage surge protective devices Part 1: Performance requirements and testing methods [3] IEC 60364-5-53:2001 + A1:2002: Selection and erection of electrical equipment: Clause 534 Devices for protection against overvoltages [4] IEC 61643-12: 2002: Low-voltage surge protective devices Part 12: Surge Protective devices connected to lowvoltage power distribution systems Selection and application principles [5] UL 1449: 2006: Third Edition: Standard for Surge Protective Devices [6] pr TS 50XXX-12: Low-voltage surge protective devices Surge protective devices for specific us including d.c. part 12: Selection and application principles SPDs connected to photovoltaic installations [7] IEC 61643-21: 2000: Low-voltage surge protective devices Part 21: Surge Protective devices connected to telecommunication and signaling networks Performance requirements and testing methods [8] DIN EN 62305-3 Bbl 5 (VDE 0185-305-3 Bbl 5) Blitzschutz Teil 3: Schutz von baulichen Anlagen und Personen Beiblatt 5: Blitz und berspannungsschutz fr PV-Stromversorgungssysteme [9] J. Birkl and B. Schulz, "Lightning and Surge Protection for Photovoltaic applications Performance tests of PVmodules and DC-AC-converters", Proceedings of the 28th International Conference on Lightning Protection, pp. 12921297, Kanazawa, Sep. 2006. [10] IEC 61000-4-5 Ed. 2.0: 2005-11 Electromagnetic Compatibility (EMC)- Part 4-5: Testing and measurement techniques - Surge immunity test [11] IEC 60664-1: 2002 Insulation coordination for equipment within low-voltage systems- Part 1: Principles requirements and tests [12] J. Birkl and P.Zahlmann, "How to verify lightning protection efficiency for electrical systems? Testing procedures and practical applications, Proceedings of the IX International Symposium on Lightning Protection, pp. 450455, Foz do Iguacu, Nov. 2007 [13] 1st CD on IEC 62548 Installation and safety requirements for Photovoltaic (PV) generators 82/514/CD 2008-02-08 [14] J. Ehrler: Design of surge protective devices for photovoltaic systems in compliance with the requirements for surge protection, fire protection and personal protection Proceedings of the 8. VDE-ABB-Blitzschutztagung, NeuUlm, Oktober 2009 [15] H. Hberlin Photovoltaik, AZ-Verlag, Arau-CH, 2007

Conventional DC-current source

Real Photovoltaic generator

Linear decreasing current

constant current

5 time [ms]6

Fig.10 Comparison test of a DC disconnection of a conventional DC source and a real PV generator

It can be concluded, that testing the DC disconnection of SPDs in PV applications for a end-of-life-scenario requires a realistic simulation of the specific voltagecurrent characteristic of a PV generator. This conclusion has not only an impact on a realistic test of SPD disconnectors but on all devices, based on switching arcs. A future test on Class I tested SPDs for PV applications based on spark gap technology also has to consider the specific voltage-current characteristic of a PV generator. These findings of extensive laboratory testing and additional field tests on real PV generators have been also considered in the specific SPD design, shown in figure 9.

5 CONCLUSIONS Due to the very specific characteristic of PV-installations on the DC side, only SPDs especially designed and tested for application on PV arrays should be used. Both the specific requirements for lightning protection and also the special conditions of a PV generator have to be considered. The specific characteristic of PV installations also has implications on specific requirements for future test standards for SPD in PV generators.

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