for Distributed Power Generation

Dmitri Vinnikov, Indrek Roasto, Tanel Jalakas

Department of Electrical Drives and Power Electronics
Tallinn University of Technology
Tallinn, Estonia
dm.vin@mail.ee


Abstract This paper presents a new step-up DC/DC converter
topology intended for the distributed power generation systems.
The topology utilizes the voltage fed quasi Z-source inverter with
continuous input current on the primary side, a single-phase
isolation transformer and a voltage doubler rectifier. To increase
the power density of the converter, implementation of the three-
phase auxiliary AC-link (three-phase inverter and three-phase
isolation transformer) and the three-phase voltage doubler
rectifier are proposed by the authors. The paper describes the
operation principles of the proposed topologies and analyzes the
theoretical and experimental results.
Keywords- fuel cell powered systems, distributed power
generation, DC/DC converters, control algorithms
I. INTRODUCTION
Distributed power generation, when fully implemented, can
provide reliable, high-quality, and low-cost electric power. As
a modular electric power generation close to the end user, it
offers savings in the cost of grid expansion and line losses. If
connected to the power grid, the bi-directional transactions
between the grid and the local generation result in grid capacity
enhancement, virtually uninterrupted power supply, and
optimum energy cost due to the availability of use/buy/sell
options [1].
Distributed power is a concept that covers a wide spectrum
of schemes used for local electric power generation from
renewable and non-renewable sources of energy in an
environmentally responsible way. Basic schemes are mainly
based on solar energy, wind energy, fuel cells, and
microturbine engines.
A fuel cell (FC) is potentially the most efficient and modern
approach to distributed power generation. The efficiency of the
conversion, i.e., the ratio of the electrical output to the heat
content of the fuel, could be as high as 65-70% [1]. In fact, its
electrical efficiency could be greater than 70% in theory. The
current technology has only been capable of reaching
efficiencies of around 45%. Combined cycles are envisaged to
bring the electrical efficiency of plants based on high
temperature cells up to around 60% [2].
For the interconnection of a low DC voltage producing fuel
cell (40...80 V DC) to the residential loads (typically, 230 V
AC single phase or 3x400 V AC), a special voltage matching
converter is required. A typical structure of the two-stage
interface converter is presented in Fig. 1. Due to safety and
dynamic performance requirements, the interface converter
should be realized within the DC/DC/AC concept. This means
that low voltage from the fuel-cell first passes through the
front-end step-up DC/DC converter with the galvanic isolation;
afterwards the output DC voltage is inverted in the three-phase
inverter and filtered to comply with the imposed standards and
requirements (second DC/AC stage).
=
=
=
~
STEP-UP
ISOLATED DC/DC
CONVERTER
THREE-PHASE
FOUR-WIRE
INVERTER
600
VDC
RESIDENTIAL
LOAD
(230 VAC 1 Ph.
or
400 VAC 3 Ph.)
FUEL CELL
(40...80 VDC)
TWO-STAGE INTERFACE CONVERTER

Figure 1. Typical structure of the interface converter for the residential
fuel cell powered systems.
The given paper is devoted to the new power circuit
topology to be implemented in the front-end DC/DC converter
for the distributed power generation. The topology proposed
(Fig. 2) utilizes the voltage-fed quasi-Z-source (qZSI) inverter
with the continuous input current at the converter primary,
high-frequency step-up isolation transformer, bridge rectifier
and output filter assembly. In contrast to earlier presented
topologies [3-5], the novel converter provides such advantages
as increased reliability, isolation transformer with drastically
reduced turns ratio, reduced impact on the fuel cell and simple
control strategy. Finally, to improve the power density of the
978-1-4244-5172-2/09/$26.00 2009 IEEE
An Improved High-Power DC/DC Converter
converter, the topology with a three-phase intermediate AC-
link is discussed in the final section of the paper.
II. DESCRIPTION OF PROPOSED TOPOLOGY
The qZSI with continuous input current implemented at the
converter input side (Fig. 2) has a unique feature: it can boost
the input voltage by introducing a shoot-through operation
mode, which is forbidden in traditional voltage source
inverters (VSI). Thus, the varying output voltage of the fuel
cell is first preregulated by adjusting the shoot-through duty
cycle; afterwards the isolation transformer is being supplied
with the voltage with a constant amplitude value. Although the
control principle of the ZSI is more complicated than the
traditional VSI, it provides a potentially cheaper, more
powerful, reliable and efficient approach to be used for fuel
cell powered systems.
Figure 2. Simplified power circuit diagram of the . topology proposed with
the voltage-fed quasi-Z-source (qZSI) inverter with the continuous input
current.
The voltage-fed qZSI with continuous input current was
first presented in [6] as a modification of a currently popular
voltage-fed Z-source inverter (ZSI) [7]. The ZSI has such a
significant drawback as discontinuous input current during the
boost mode, which could have a negative influence on the fuel
cell. The discussed qZSI shown in Fig. 2 features continuous
current drawn from the fuel cell as well as lower operating
voltage of the capacitor C
Z2
, as compared to the ZSI topology.
The operating dc voltages of the capacitors C
Z1
and C
Z2
could
be estimated as:
IN
Z
Z
CZ
U
D
D
U

=
2 1
1
1
, (1)

IN
Z
Z
CZ
U
D
D
U

=
2 1
2
, (2)
where D
z
is the duty cycle of the shoot-through state:

T
t
D
Z
Z
= , (3)
where t
Z
is the duration of the shoot-through state and T is the
operation period. The shoot-though state here is the
simultaneous turning on of both switches of the same phase
leg of the inverter (Fig. 3). This operation state is forbidden
for the traditional VSIs because it causes the short circuit of
the dc link capacitors. In the discussed qZSI, the shoot-
through state is used to boost the magnetic energy stored in the
dc side inductors without short-circuiting the dc capacitors.
This increase in inductive energy in turn provides the boost of
voltage seen on the transformer primary winding during the
traditional operating states of the inverter. Thus, coupled with
the qZSI network, the traditional VSI could realize both the
voltage buck and the boost functions without any additional
switches using special control algorithms only.
Figure 3. Equivalent model of the inverter during the shoot-through
state.
The simplified equivalent model of the VSI during the
shoot-through state is presented in Fig. 3. During this
operation mode the peak current through the inverter switches
reaches its maximum. In the presented scheme the switches
are represented as resistors. The short current is distributed
between both inverter arms. During the shoot-through state,
the voltage of the isolation transformer drops to zero, thus
changing the operation duty cycle of the transformer (Fig. 4c).
A. Control Principle of the qZSI-Based Single-Phase DC/DC
Converter
As was discussed earlier, compared with a traditional VSI,
the quasi Z-source inverter has an extra switching state: shoot-
through, when the top and bottom switches of the inverter legs
are simultaneously turned on. Fig. 4 presents the control
principle of the single-phase qZSI in the shoot-through state.
Fig. 4a shows the theoretical switching pattern of the
traditional single-phase VSI based on the triangular carrier. To
control the shoot-through states, the two straight lines (U
p
and
U
n
) were introduced (Fig. 4b). When the triangular waveform
is greater than the upper envelope U
p
or lower than the bottom
envelope U
n
, the inverter switches turn into the shoot-through
state (Fig. 4b). The resulting voltage waveform of the primary
winding of the isolation transformer during the shoot-through
states is presented in Fig. 4c.
Figure 4. Operating principle of the proposed DC/DC converter in the
shoot-through state.
Each operating period of the proposed topology consists of a
shoot-through state t
Z
and an active state t
A
:

A Z
t t T + = . (4)
In the active states, one and only one switch in each phase
leg conducts. The (4) could also be represented as
1 = + = +
A Z
A Z
D D
T
t
T
t
, (5)
where D
Z
is the duty cycle of the shoot-through state and D
A
is the duty cycle of the active state. The duty cycle of the
shoot-through state could never exceed 0.5.
It should be noted here that in the presented control scheme
the switching frequency of the transistors as well as the
operation frequency of the quasi Z-source network will be four
times higher than the frequency of the fundamental harmonic
of the isolation transformers primary voltage (Fig. 4c). That
fact is always to be considered during selection of proper
components and operating frequencies of the proposed
converter.
B. Operation of the of the Single-Phase qZSI
This section discusses the simulation and experimental
results of the 500 W qZSI-based single-phase DC/DC
converter. The desired operating parameters are presented in
Table I.
TABLE I. Desired Operating Parameters of the Investigated Converter
Parameter Value
Minimal input voltage, U
IN,min
40 V
Minimal input voltage UIN,max 80 V
Desired DC-link voltage amplitude U
DC
80 V
Output power P 500 W
Switching frequency, f
sw
20 kHz
Fundamental frequency of the isolation transformers
primary voltage, fTR
5 kHz
Capacitance of Cz1 and Cz2 330 uF
Inductance of Lz1 and Lz2 50 uH
Type of primary switches IGBT
In the given application, the desired value the DC-link
voltage U
DC
was selected to be 80 V. It is assumed that the
converter is always operating with the rated load and between
two boundary operating points, which correspond to the
minimal and maximal input voltages. In the first case, the
shoot-through state should be used to boost the input voltage
to the predefined DC-link voltage level. In the second case,
when the input voltage is equal to the desired DC-link voltage,
no shoot-through is applied and the qZSI operates as a
conventional VSI.
If the input voltage is below the predefined DC link voltage
level, the converter utilizes the shoot-through states, thus
ensuring the corresponding boost ratio B of the input voltage:

IN
DC
U
U
B = (6)
For the current application, the maximal boost ratio could be
achieved at the minimal input voltage and rated load:
. 2
40
80
min ,
max
= = =
IN
DC
U
U
B (7)
The duty cycle of the shoot-through state could be found
by

( )
2
1
1

=
B
D
Z
. (8)
The maximum shoot-through duty cycle in the discussed
application is

( )
25 . 0
2
1
1
max
max
=

B
D
Z
. (9)
To confirm the above presented assumptions a series of
simulations were performed. The operation of the single-phase
qZSI was verified in the boundary operating points U
IN,min
and
U
IN,max
. To provide a better appearance, simulation waveforms
are shown with the timescale corresponding to one full period
of the operating voltage of the isolation transformer. The
inverter is operated with no dead-time. The operating
frequency seen on the isolation transformer windings is 5 kHz,
while the inverter switching frequency as well as the
frequency seen by the quasi impedance network is 20 kHz.
The first simulations (Figs. 5-7) were performed with an
input voltage U
IN,min
= 40 V and with the shoot-through mode
(D
Z
=0.25). The operating duty cycle of the isolation
transformer is D
A
=0.75.
Figure 5. Input voltage (VIN) and DC link voltage (VDC) during the
minimal input voltage and maximal boost ratio (D
z
=0.25).
Figure 6. Voltage profiles of the capacitors Cz1 and Cz2.
Figure 7. Primary voltage of the isolation transformer (DA=0.75).
The results of simulations were verified on the experimental
setup of the qZSI-based single-phase DC/DC converter. As the
experiments show (Figs. 8 and 9), the simulated and measured
results are in full agreement for the operating point with
minimal input voltage and rated load when the shoot-through
duty cycle reaches its maximum. Moreover, it was stated that
the discussed topology ensures continuous input current
during the voltage boost mode (Fig. 8b), thus reducing
negative impact on the proton exchange membrane of the fuel
cell module. The peak-to-peak current ripple could be further
decreased by the implementation of qZ-inductors with
increased inductance values.
(a) (b)
Figure 8. Input and DC link voltages (a) and input current (b) with
Dz=0.25.
(a) (b)
Figure 9. Voltage profiles of dc capacitors (a) and primary voltage of the
isolation transformer (b) with D
z
=0.25.
The second group of simulations (Figs. 10-12) was
performed with an input voltage U
IN,max
= 80 V. In that
operating point, the shoot-through mode was eliminated
(D
Z
=0). The operating duty cycle of the isolation transformer
is D
A
=1. As can be seen from Fig. 11a, without the shoot-
through state, the voltage of capacitor C
z1
is equal to the input
voltage and the voltage of the capacitor C
z2
is zero. This
demonstrates that a single-phase qZSI can be operated as a
traditional PWM inverter without any modifications in
hardware.
Figure 10. Input voltage (VIN) and DC link voltage (VDC) during the
maximal input voltage and no-boost mode (DZ=0).
Figure 11. Voltage profiles of the capacitors C
z1
and C
z2
.
Figure 12. Primary voltage of the isolation transformer (D
A
=1).
The results of simulations were verified on the experimental
setup of the qZSI-based single-phase DC/DC converter. As the
experiments show (Figs. 13 and 14), the simulated and
measured results are all in agreement for the operating point
with maximal input voltage and rated load, when the shoot-
through operating mode is eliminated.
(a) (b)
Figure 13. Input and DC link voltages (a) and input current (b) with D
z
=0.
(a) (b)
Figure 14. Voltage profiles of dc capacitors (a) and primary voltage of the
isolation transformer (b) with D
z
=0.
III. DESIGN OF THE OUTPUT STAGE AND STEP-UP
ISOLATION TRANSFORMER
A specific feature of the proposed topology is that it utilizes
the qZSI as the primary side inverter of the isolated DC/DC
converter. Earlier applications of the ZSI and the qZSI were
UIN
IIN
UDC
UCZ2
UCZ1
U
TR,pr
U
IN
I
IN
UDC
U
CZ2
U
CZ1
UTR,pr
only connected with the single-stage DC/AC applications
(motor drives). Since there is a need of the isolation
transformer in the proposed topology, certain adjustments are
to be made in the design of the power circuit. It is well-known
that the transformer is the main contributor to the size of any
switching-mode power supply since it contributes about
2530% of the overall volume and more than 30% of the
overall weight [8]. In order to design a small and compact
converter, it is essential to reduce the size of the isolation
transformer (as well as output filter components). Moreover,
the output rectifier should have reduced power dissipation to
ensure better efficiency of the converter. Thus, the design of
the output stage and the isolation transformer implies a great
challenge for the designer.
One of the most widespread topologies for the output stage
of a single-phase DC/DC converter is a full-bridge rectifier
(FBR) with the LC-filter (Fig. 16a). In that case the output
voltage of the converter U
OUT
depends on the operating duty
cycle D
A
, which, in turn, depends on the duty cycle of the
shoot-through state D
Z
:
( )
Z ,sec TR A ,sec TR OUT
D U D U U = = 1 , (10)
where U
TR,sec
is the amplitude voltage value of the secondary
winding of the isolation transformer It means that in the
conditions of varying input voltage, the output voltage of the
converter will also vary with the discussed control
methodology. The nominal output voltage will be achieved
only at the minimal input voltage, when the shoot-through
duty cycle is maximal. In all other operating points it will
exceed the predefined nominal value of the output voltage
(Fig. 15).
1
1,05
1,1
1,15
1,2
1,25
1,3
1,35
Input voltage
O
u
t
p
u
t

v
o
l
t
a
g
e

o
f

c
o
n
v
e
r
t
e
r

w
i
t
h

f
u
l
l
-
b
r
i
d
g
e

r
e
c
t
i
f
i
e
r

(
p
.
u
.
)


Uin,min Uin,max
Figure 15. Demonstration of the output voltage rise with the rise of the
input voltage of the investigated converter with a full-bridge rectifier (caused
by the rise of the DA).
To resolve that problem, some modifications should be done
in the control algorithm of the converter, thus increasing its
complexity. Namely, the conventional zero states (when the
primary winding of the isolation transformer is shorted
through either the top or bottom inverter switches) should be
added to the control algorithm for controlling of the magnitude
of the output voltage.
The simplest method to cope with the above-discussed
problem will be to implement the voltage doubler rectifier
(VDR) on the output stage of the converter (Fig. 16b). In that
case the output voltage of the converter is
2 =
sec , TR OUT
U U . (11)
From (11) it is seen that the output voltage of the converter
with the VDR does not depend on the duty cycle of the active
state anymore. It improves the control flexibility of the
proposed converter with no modifications in the control
algorithm.

(a) (b)
Figure 16. Full-bridge rectifier with LC-filter assembly (a) and voltage
doubler rectifier (b).
Fig. 17 shows the experimental results of the VDR. The
converter was tested in two boundary operating points: with
input voltages 40 and 80 V and at the rated load. The shoot-
through duty cycle was set for each case study personally to
ensure 80 V on the DC link. The isolation transformer has the
turns ratio 1:1. As seen from the diagrams, despite the
variation of the shoot-throug duty cyle (and, in turn, duty cycle
of the active state), the voltage on the converter output
remains unchanged for any operating point. Thus, it is
concluded that the VDR proposed for the current application
could provide an output voltage without intolerable ripple and
with a magnitude twice the amplitude voltage value of the
secondary winding of the isolation transformer.
(a) (b)
Figure 17. Operation waveforms of the voltage doubler rectifier at
different input voltage conditions: input voltage UIN=40 V, DZ=0.25 (a) and
input voltage UIN=80 V, DZ=0 (b).
Other benefits of the VDR rectifier implemented on the
secondary stage of the proposed converter could be listed as
follows:
1) improved rectification efficiency due to reduced
voltage drop (twice reduced number of rectifying
diodes and full elimination of the smoothing
inductor);
2) turns number of the secondary winding of the
isolation transformer could be reduced by 62% (turns
ratio 1:3.75 in the case of VDR instead of 1:10 of
FBR) due to the voltage doubling effect available
with the VDR.
Finally, it could be stated that the proposed qZSI-based
single-phase DC/DC converter with a high-frequency step-up
transformer and a voltage doubler rectifier could be positioned
as a new alternative for the front-end DC/DC converter for
residential power systems with the operating power up to
10 kW.
IV. QZSI-BASED DC/DC CONVERTER WITH THREE-PHASE
INTERMEDIATE AC-LINK AND VOLTAGE DOUBLER RECTIFIER
Modern trends in residential power systems are aimed to
increase the efficiency and power density of electronic
UOUT
UTR,sec
U
OUT
UTR,sec
80 V
160 V
converters to enhance the feasibility of the whole system. For
the discussed application, an increase in power density (more
power for the same volumetric space of the converter) could
be achieved by the implementation of the three-phase
intermediate AC-link instead of the single-phase one. The new
topology for the front-end DC/DC converter proposed by the
authors for the high-power applications is presented in Fig. 18.
It utilizes the three-phase qZSI with continuous input current,
a three-phase isolation transformer stack (winding could be
connected in different configurations to obtain the desired
output voltage) and a three-phase voltage doubler rectifier.
Figure 18. Proposed power circuit layout of the three-phase isolated DC/DC
converter with a qZ-source inverter and paralleled voltage doubler rectifiers.
For every operating point within the predefined boundaries
[U
IN,min
; U
IN,max
], the output voltage of the converter at the
shoot-through mode could be estimated as

|
|
.
|

\
|

=

=
Z
IN IN
OUT
D n
U
n
B U
U
2 1
1 2 2
, (12)
where n is the turns ratio of the three-phase isolation
transformer.
(a) (b)
Figure 19. Experimental waveforms of the proposed converter operating at
minimal input voltage (UIN=40V) and maximal shoot-through duty cycle
(D
Z
=0.25): input voltage, current and DC-link voltage (a) and line voltages of
the primary winding of the three-phase transformer stack.
(a) (b)
Figure 20. Operation waveforms of the voltage doubler rectifier at different
input voltage conditions: input voltage U
IN
=40 V, D
Z
=0.25 (a) and input
voltage UIN=80 V, DZ=0 (b).
Fig. 19 presents the experimental waveforms of the
proposed three-phase converter. As seen from Fig. 19a, the
three-phase qZSI operates with continuous input current. The
operating frequency of the quasi Z-network is six times higher
than the fundamental harmonic frequency of the isolations
transformer.
As in the case of the single phase VDR discussed earlier, the
proposed three-phase VDR could provide output voltage
without intolerable ripple and with the magnitude twice the
amplitude voltage value of the secondary winding of the
isolation transformer in all operating points of the converter
(Fig. 20).
V. CONCLUSIONS
This paper has presented two new isolated step-up DC/DC
converter topologies with quasi-impedance-source inverters.
The topology is intended for applications with widely varying
input voltage and stabilized output voltage and when the
galvanic separation of the input and output sides is required.
The high-frequency transformer stack is responsible for
providing the input/output galvanic isolation demanded in
many applications. The paper is focused on an example of the
step-up DC/DC converter with high-frequency isolation for
the distributed power generation systems. The operating
principle, converter design methodology, simulation and
experimental results are presented and analyzed. Moreover, to
improve the power density and reliability, the updated
converter topology with the three-phase auxiliary AC link and
the three-phase voltage doubler rectifier was proposed and
verified.
ACKNOWLEDGMENT
Authors thank Estonian Science Foundation (Grant
ETF8020 Research of Advanced Control and Diagnostics
Systems for the High-Power IGBT Converters) for their
financial support.
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U
OUT
U
ab
80 V
160 V
U
OUT
Uab
UAB
U
AC
UBC
IIN
UIN
U
DC