Benefits of Non-Isolated Inverters
As we will show, ungrounded PV systems have additional BOS requirements compared to conventional grounded PV systems. Ungrounded PV systems also require special inverters specifically designed and listed for use with ungrounded arrays. So why would anyone choose to go this route?
It turns out that many of the potential benefits of deploying ungrounded PV systems are specifically associated with the use of non-isolated inverters. The advantages most commonly attributed to non-isolated inverters include higher efficiency, improved economics and increased ground-fault sensitivity.
Higher efficiency. Advanced Energy has sold its bipolar transformerless inverters into commercial and utility-scale PV applications since August 2007. According to Tucker Ruberti, the company’s director of segment marketing, “The most obvious benefit of a transformerless architecture is higher inverter efficiency.” As an example, the weighted CEC efficiency of Advanced Energy’s transformerless Solaron 250 kW inverter is 97.5%, which is 1% higher than that of the company’s transformer-isolated PVP250kW inverter.
While modern transformers are exceptionally efficient, losses that can never be entirely eliminated occur in the core and in the windings. These losses are dissipated as waste heat, which is one of the reasons that 60-Hz transformer-based inverters often have relatively large heat sinks.
Since large transformers are generally more efficient than smaller ones, it is not uncommon to see a higher efficiency differential between isolated and non-isolated inverters at smaller inverter capacities. For example, SMA America’s 8 kW transformerless inverter (SB 8000TL-US) has a CEC efficiency of 98%, which is a full 2% higher than the efficiency of its 8 kW transformer-isolated inverter (SB 8000US). Generally speaking, non-isolated inverters are 1%–2% more efficient than equivalent isolated inverters.
Improved economics. Since non-isolated inverters are more efficient, they have the potential to increase a PV system’s specific yield and improve a customer’s return on investment as a result. In theory, non-isolated inverters should also cost less to purchase, ship and install than isolated inverters. As Wiles explains in Home Power magazine, “The transformer is usually heavy, costly and bulky—decreasing efficiency and increasing the inverter’s size and shipping costs.”
Eliminating the isolation transformer in a utility-interactive inverter may also enable additional savings. Verena Arps is the director of technical sales at REFUsol, an inverter manufacturer with a line of transformerless 3-phase string inverters ranging in capacity from 16 kW to 24 kW. Arps points out that REFUsol’s transformerless inverter topology does not require active cooling: “Because the inverters are more efficient, the internal heating losses are decreased, which allows for the elimination of active cooling components.”
Even when active cooling components are included, non-isolated inverters generally have a lower parts count than their isolated counterparts. A reasonable claim can be made that they have less embodied energy than transformer-isolated inverters since they are smaller and lighter. These same attributes could make them easier to install.
The extent to which the raw material reductions associated with non-isolated inverters translates to up-front cost savings still remains to be seen. In today’s market, a non-isolated inverter may cost about the same as an equivalent isolated inverter from the same manufacturer. However, non-isolated inverters have yet to achieve manufacturing efficiencies of scale. They are still a specialty or niche product compared to isolated inverters. Most industry experts agree that transitioning to non-isolated inverters will eventually drive inverter costs down in North America.
SolarEdge has developed a unique utility-interactive PV system that consists of module-level dc-to-dc power optimizers coupled with proprietary non-isolated inverters. According to John Berdner, the company’s general manager for North America: “Non-isolated inverters offer the best chances for future cost reductions since they do not include the large transformers found in low-frequency transformer-isolated inverter designs and have far fewer components than highfrequency transformer-isolated designs.”
Increased ground-fault sensitivity. When people refer to the safety benefits associated with ungrounded PV systems, they are almost certainly referring to the fact that non-isolated inverters are more sensitive to ground faults than isolated inverters. In a SolarPro magazine article (February/March 2011) identifying the limitations of GFDI systems used in listed isolated inverters, Brooks points out, “The only way to get ground-fault detection below 1 amp as part of the GFP scheme for large PV systems is to unground or resistively ground the array circuit, just as they do in Europe and Japan.” He continues: “Contemporary European inverters, for example, can detect changes in ground current as low as 300 mA, which is an order of magnitude lower than our solidly grounded systems.”
While the differential is less pronounced in residential applications, non-isolated string inverters are still three times as sensitive to ground faults as isolated string inverters. At present, transformer-isolated string inverters up to 15 kW in capacity typically use a 1 A GFDI fuse to provide ground-fault protection. UL 1741 allows higher-capacity inverters to use GFDI fuses with higher ratings. For example, inverters rated more than 250 kW in capacity are allowed to use a 5 A fuse. Since a fuse located between the grounded current-carrying conductor and the ground bond most commonly provides this protection, the time required to open this fuse is determined by the physical response time of the fuse itself, which varies depending on temperature and the amount of current flowing across it during the fault event.
The electronic GFP strategy employed by non-isolated inverters used on ungrounded PV arrays allows for much lower and more consistent current and trip-time settings. Non-isolated inverters 30 kW and below sold on the market today are tested to the current UL CRD requirements of 300 mA maximum fault current and 0.3 second maximum trip time. Additionally, there is a “sudden ground-fault current change and response time” requirement that causes the operation of this protection circuit at levels as low as 30 mA and as quickly as 0.04 seconds. Besides reducing the potential shock hazard in a PV array, this means that ground faults are identified and the fault current is stopped more quickly, before it turns into an arcing fault capable of starting a fire.
Furthermore, since non-isolated inverters test for ground-fault currents at the start of each day— before the inverter goes online—they can detect potential ground-fault conditions before a fault occurs. For example, compromised conductor insulation may first manifest as a high-resistance fault and only later as a low-resistance fault. The groundfault protection scheme used in transformer-isolated string inverters may respond to the low-resistance fault only, whereas the scheme used in non-isolated string inverters is more likely to identify the highresistance fault condition.
SMA America was the first manufacturer to certify non-isolated inverters to UL 1741, using UL as its Nationally Recognized Testing Laboratory (NRTL). Greg Smith, a technical training specialist with the SMA Solar Academy, notes, “Plan checkers and inspectors may mistakenly think that a non-isolated inverter is unsafe because it doesn’t have the isolation transformer in it.” The reality is just the opposite, Smith explains: “Because non-isolated inverters check for PV isolation resistance before connecting to the grid and producing power, current is never flowing in a potentially unsafe array with ground faults.”