A Cost-effective Method for PV Module Field Test

Using an Electronic Load

Jin-Ho Ahn, Eun-Chel Cho, Myung-Ick Hwang, Seung-Min Shin and Hyun-Il Kim

Green Energy Division, Hyundai Heavy Industries Co., Ltd., Eumseong, 369-872, KOREA

Abstract - To analyze the electrical performance of individual analyze the electrical performance of many individual PV
PV modules in the field, I-V curve tracers or micro inverters are modules in the field at the same time.
typically used with the associated shortcomings. In this study, we
used a precision electronic load to analyze the electrical
performance of individual PV modules. The electronic loads have II. EXPERIMENTAL METHODS
been used for empirical field studies on 12 PV modules installed
in Hyundai Heavy Industries test site (Eumseong factory). Three
sets of the electronic loads and controllers have been installed,
A. Block Diagram
with each set capable of handling 4 PV modules in a time-divided
The main apparatus of this study consist of electronic loads,
manner.
main controllers, 4-channel port changers, analog to digital
The main advantages of the electronic load are its low price, converters and PC logger program. Fig. 1 shows a block
high precision, wide input ranges for voltage, current and power,
diagram of the field performance testing facility for individual
and easy control by electrical communication. Initially, the
biggest drawback of the electronic load was the slow control PV module using the electronic loads.
speed, but we resolved the issue by applying a new tracking
algorithm.

Index Terms - Electronic load, field test, performance test,

photovoltaic module, cost-effective method, I-V curve tracer,
micro-inverter, MPPT (Maximum Power Point Tracking).

I. INTRODUCTION

I-V curve tracers or micro inverters are the most common

methods for the field test of individual PV modules [I]. Both
methods have their advantages and disadvantages, shown in
TABLE I.
TABLE I
THE MAIN FEATURES OF PV MODULE FIELD TESTERS
Type Advantages Disadvantages
- IV curve data is - Long acquisition time
available - High cost
IV-Curve Analog to Digital
- The power grid is - Only a single channel
Tracer Converter (8ch)
not required support
Q
- High accuracy
Q
- Lower cost - Limited input/output voltage, Q
- High durability current, power and frequency Analog to Digital
- Electrical power is ranges Converter (8ch)
Micro fed into the grid - Low accuracy

Inverter - The power grid is required RS485 #1 RS485 #2

- No function to measure PC Logger Program
Voc( open-circuit voltage) and

Isc (short-circuit current)

In order to overcome these shortcomings while keeping the Fig. 1. The block diagram of the field performance testing facility

benefits, a cost-effective and high-precision solution was for individual PY module using the electronic loads.

developed, utilizing electronic loads. The device was used to

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 B. Apparatus components
l) Electronic Load
The electronic load can control the voltage, current and
power of a load on manual or by communication [I]. When we
need electrical parameters of PV modules, it can be easily
obtained by controlling the voltage and current with some
algorithms. The input voltage, current, and power ranges are
very wide. Therefore, various types of modules that have
various voltage and current can be tested without especial
caution. To keep high accuracy, 4-wire measurement method
is used. And we achieved obtaining the accurate electrical data
without additional meter (Table II). Also, we can easily
change the input power limitation by only replacing the
electronic loads that use the same communication protocol.
The measurement errors can be managed and reduced by
regular calibration.
Due to using of the general purpose electronic load, the
speed of control is too slow. However, it was overcome by
applying a new tracking algorithm.
TABLE II
ELECTRICAL SPECIFICATIONS OF ELECTRONIC LOADS
Maximum Input
Accuracy
Model Rating
Volt Amp Watt Voltage (%) Current
Type A 500 15 300 ±(0.02+0.025FS) ±(0.2+0.3FS)
Type B 120 120 600 ±(0.02+0.025FS) ±(0.2+0.15FS)
* FS: Full scale
2) Main Controller
To obtain electrical parameters of the PV modules, the main
controller controls the electronic load by a RS232
communication. The main controller sends the collected
electrical parameters of PV modules by a RS485
communication when the PC logger program requests. Also,
by controlling the 4-channel port changer in a time division
manner, 4 PV modules can be analyzed by the single
electronic load in the system. The main controllers have their
own unique ID, if we connect each of the controllers in a
RS485 daisy chain method, it can be monitored up to 255
controllers. And maximum 1 020 PV modules can be measured.
A cost-effective, high performance 8 bit micro-processor
(ATmega256 1 , 1 6Mhz) was used. The circuit was simplified
by using built-in memory, port, etc.
3) 4-Channel Port Changer
Individual 4 PV modules can be measured by switching the
each port in a time division manner. The ports are controlled
by the main controller. l6A DC relays were applied for
switching the power lines.
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4) Analog to Digital Converter
It converts from analog data of pyranometer, temperature,
humidity, wind speed and wind direction sensor to digitized
data and transmits data by the RS485 communication when PC
logger program requests.
5) PC Logger Program
It commands the main controllers to start measurement and
collects the electrical parameters, weather data from all main
controllers and analog to digital converters. It displays the
measured data and saves the data as a CSV computer file.
Using monthly sunrise and sunset average time, the logging
function can be automatically stopped or started to save the
storage space. This program is possible to monitor and log 30
PV modules, 2 weather sensors per PV module, 4 external
weather sensors.
III. RESULTS
A. Functions & Operations of Developed Field Tester
I) MPPT (Maximum Power Point Tracking)
This function always operates at Vmpp (voltage at
maximum power point) of the PV module similar to a micro
inverter. The different thing is that when the main controller
(%)
receives the measurement start command, it measures
additional Isc and Voc including Pmax (power at maximum
power point), Impp (current at maximum power point), Vmpp
[2, 3]. This function overcame the disadvantage of the micro
inverter that cannot measure Isc and Voc. And only a single
channel is available in this operation.
"'"' MPPT t'lode(2/2) **
Pr�ax; 59.45, FF: 64.46
lJoe: 40.36, UPf'l: 37.99
Ise:2.257, Ip'I:!.565
Fig. 2. Display monitoring during MPPT operation.
2) Parameter Scan
This operation is designed to fine out Pmax, Voc, Vmpp, Isc,
Impp, FF (fill factor) and Wh (watt hour) correctly as soon as
possible using a new tracking algorithm [2, 4]. This mode is
the fastest and the most economic among the operations.
Because I-V curve raw data is not needed, the electrical
parameters can be found quickly and 4 PV modules can be
measured using 4-channel port changer. It takes approximately
2.5 seconds per PV module to obtain the electrical parameters.
1: .,2. 46W, 54009.9Wh
» 7 . 0 8W , 435G7.2(Jh
3: 3.55W, 68222.1Wh
4'65.57W, 733:;i9.4Wh',
Fig. 3. Display monitoring during parameter scan operation.
001283
 5) New Tracking Algorithm for Parameter Scan Operation
3) I-V Curve Trace
It took approximately 50-lOOms for the used electronic load
This function operates like an I-V curve tracer. 1 00 samples
to change current/voltage and send feedback to the main
of voltage, current and power are measured. Using these data,
controller. It is too slow to sweep the voltage from Voc to zero
it is easy to recognize the I-V curve shape. However, it is not
voltage for finding out the electrical parameters. In order to
enough to obtain the electrical parameters correctly. Therefore,
overcome, we used the fact that there is no significant change
parameter scan runs at the end of sampling the I-V curve raw
of VmppNoc ratio in a similar environment. And it is easier to
data to seek the correct data. This mode is useful, when we
scan from voltage higher than Vmpp to Zero, because of
want to know the shape of the I-V curve graphs. 4 PV modules
higher value of b,P/b,V. The PV module parameter can be
can be measured using the 4-channel port changer. It takes
easily and rapidly found using the algorithm below.
approximately 6 seconds per PV module to obtain I-V curve
raw data and the electrical parameters.
------------ - Voc is measured to determine the start voltage.
... IV_CU'WI ..o'lrPH r:-L�'r.;:
- Start voltage Voc(measured)*(VmppNoc Ratio)* 1 .05
=

(VmppNoc Ratio is the measured real value before this

scan. initially 0.85)
- Power at start voltage is measured.
- Power at start voltage minus b,V is measured to determine
the scan direction.
(b,V Voc / constant)
=

- Voltage change in the determined direction is given.

Maximum power value will be refreshed when bigger power
value is obtained.
- This scan will stop when gathered value is lower than
maximum power value 5 times in a row.
- Isc and Voc are measured at the end
Fig. 4. PC logger program during I-V curve trace operation.
It takes only approximately 2.5 seconds to obtain Pmax, Voc,
Vmpp, Isc and Impp using this algorithm.
4) Current Control for Hot Spot Diagnosis

This function can be easily used to measure the degree of 6) Field Logged Data
hot spot (abnormal temperature rise of solar cell by reason of
cell crack, shading, etc.) of PV modules by changing current Three newly developed devices have been installed in the
of the PV modules [5]. Every 5 seconds or when voltage or testing facility of Hyundai Heavy Industries in Korea. 12 PV
current significantly changes, the main controller measures and modules are being analyzed using the parameter scan
refreshes Isc value and makes the operating current Isc x ratio operation successfully. Fig. 6 is a real data related to
(set by user, 0.00- 1 .00) like equation 1 . WIWp* 1 00, Wh/Wp of 12 PV modules and Fig. 7 is a real
operation screen shot of the PC logger program. Fig. 8 is a
!(PV) = !SC(measured) X RCset) (1) testing facility photograph.
Where I(Pv) i s the P V module current controlled b y the -(A)W/Wp-IOO
electronic load, Isc(measured) is the measured value of Isc, R(set) is t------::-Ji'�=_--:::<:���= 6
-(B) W/Wp�l00
-(C)W(Wp·I(Xl

the setting ratio by user. -(D)W/Wp-IOO

-(E)W!Wp-IOO
-(F)W!Wp*l00
-«(;)W/Wp.100
-(H)W(Wp-lOO
- <I- -0) W/Wp-IOO

I -;�:;:::::
- 3ii: (LjW!Wp-l00
� -(A)wtlfVio
� -(B)wtl/1"p
-(C)wt1/V'p
-(D)wt./Ylp
-(E)Wtl/'{t'p
-(F)wtl/'('p
-(G)wn/If'p
-(H)'Nh/lllp
-(l)'VttI/'('p
(J)'Htl/'f.'fJ
-(l()VY'tl/1"p
(llwn/lflp

Time

Fig. 6. Logged data of 12 PV modules installed in the testing

Fig. 5. Infrared images according to the R(sel)' O.85(Left),
facility of Hyundai Heavy Industries, Korea
O.95(Right).

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 Industries. The expensive equipment in the market could be
replaced with the cost-effective equipment enough. Also, high
usability has been confirmed by adding a variety of functions.

REFERENCES

[1] Yingying Kuai and Yuvarajan. S., "An electronic load for testing
photovoltaic panels", Journal of Power Sources, 2006, pp. 308-

II II I I I I I II I I! I 313.
[2] Jae Ho Lee, HyunSu Bae and Bo Hyung Cho, "Advanced

iI ! II II IIII 1111
Incremental Conductance MPPT Algorithm with a Variable Step
Size", Power Electronics and Motion Control Conference, 2006,

""11111111111
pp. 603-607
[3] Jantsch, M. , et ai, "Measurement of PV Maximum Power Point
Tracking Performance", Proceedings of the 26th European
Photovoltaic Energy Conference, 1997.
[4] A. Hunter Fanney, Mark W. Davis, Brian P. Dougherty, David L.
Fig. 7. The PC logger program in the testing facility of Hyundai King, William E. Boyson, and Jay A. Kratochvil D. I. King, J. A.
Heavy Industries, Korea Kratochvil, "Comparison of Photovoltaic Module Performance
Measurements", J. Sol. Energy Eng., 2006, pp. 152-160.
[5] W. Herrmann, W. Wiesner, W. VaaBen . "Hot Spot Investigations
on PV Modules - New Concepts for a Test Standard and
Consequences for Module Design with Respect to Bypass
Diodes", Photovoltaic Specialists Conference, 1997, pp. 1129-
1132.
[6] B. Lindgren "A Power Converter for Photovoltaic Applications"
Department of Electric Power Engineering, Chalmers University
of Technology, 2000

Fig. 8. The testing facility of Hyundai Heavy Industries, Korea

IV. CONCLUSIONS

When PV module makers develop new types of PV modules,

typically indoor and outdoor tests are performed. There is a
number of dedicated indoor test equipment [6]. However,
regarding the outdoor test, it is not easy to find the equipment
that satisfies price and functions.
In this study, we developed the new equipment that has 4
functions using a cost-effective electronic load. Especially, we
invented new algorithm that find out electrical parameters of a
PV module within 2.5 seconds to overcome low control speed
of the electronic load. If this algorithm is applied to I-V curve
tracer in the market, multi input channel could be easily
implemented, because measurement speed will be remarkably
improved. Also, 4 PV modules can be measured using a single
electronic load by means of 4-channel port changer. The
electronic load is cost-effective, accurate enough and input
voltage, current and power is so wide that variety types of PV
modules can be measured without any caution.
Now, newly developed field testing devices using the
general electronic loads are being used successfully for the
purpose of outdoor performance test and daily power output
analysis in the PV system testing facility of Hyundai Heavy

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