starpower Solution 2

For a 100kW solar inverter, we recommend a T-type three-level NPC topology using GD100HFL120C2S IGBT modules: (1) DC-AC stage: T-type three-level inverter with 6x GD100HFL120C2S (2 per phase). This topology offers >98.5% efficiency with 1000V DC input. (2) MPPT stage: Interleaved boost using 2x GD50HFL120C1S for wide voltage range. (3) Grid filter: LCL filter designed for 16kHz switching frequency. Alternative: Use two-level topology with SiC modules (GDS100M12B1) at 32kHz for higher power density but slightly higher cost. The T-type NPC provides best efficiency and EMI performance for this power level with IGBT modules.

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Selection between IGBT and SiC modules for solar inverters depends on priorities: (1) Cost-sensitive applications: Use IGBT (GD100HFL120C2S) with 16kHz switching. Achieves >98% efficiency at lower cost. (2) Premium/high-density applications: Use SiC (GDS100M12B1) with 32-50kHz switching. Achieves >98.5% efficiency with 30-40% smaller magnetics. (3) Hybrid approach: Use SiC for MPPT boost (high-frequency) and IGBT for inverter (lower frequency) for cost-performance balance. (4) 1500V systems: SiC preferred due to lower switching losses at higher voltage. ROI analysis: SiC adds ~15-20% module cost but reduces system cost by 10-15% through smaller passive components and cooling. For 25-year life, SiC's higher efficiency provides additional energy revenue.

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Thermal design for solar inverters with Starpower modules: (1) Ambient temperature: Design for 60°C worst-case with full solar irradiance. (2) Heatsink design: Target RthSA of 0.15-0.25K/W for 100A modules at full load in 60°C ambient. (3) Cooling: Forced air cooling with 200-400CFM airflow typically required

natural convection only for low power (<10kW). (4) Thermal interface: High-performance TIM essential for reliable heat transfer over 25-year life. (5) Temperature derating: Plan for 80% current at 60°C ambient. (6) Hot spot management: Ensure uniform cooling across all modules

avoid temperature gradients >10°C between modules. (7) Thermal monitoring: Use module NTC for over-temperature protection at 100°C heatsink temperature. Example calculation: GDS100M12B1 at 100A, 60°C ambient, RthSA=0.2K/W: Tj = 60 + 120W × (0.4+0.2+0.1) = 60 + 84 = 144°C (acceptable with margin).

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MPPT boost stage design for wide voltage range (200-1000V) using Starpower modules: (1) Topology: Interleaved boost converter with 2 phases for >50kW to reduce current ripple. (2) Module selection: GD50HFL120C1S (50A) for boost switch

GDR200A12 (200A) for boost diode or use synchronous rectification with second IGBT. (3) Inductor design: Calculate for 20-30% current ripple at minimum input voltage. For 100kW, 200V input: L = V × dt / dI = 200V × 25μs / 15A = 333μH. (4) Switching frequency: 16kHz for IGBT, 50kHz for SiC. (5) MPPT algorithm: Perturb and observe with 0.5% voltage step for stable tracking. (6) Efficiency: Target >99% for boost stage alone. (7) Protection: Input overvoltage (1100V), overcurrent (150% rated), and reverse polarity protection. Starpower modules' low switching losses enable high-frequency operation for compact boost designs.

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This solution includes a complete BOM with carefully selected power modules and components, thermal design guidelines, and application documentation.

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