Detailed Inverter Specifications, Testing Procedure,

and Technical Approach and Testing Application

Requirements for the Little Box Challenge

Introduction

ThankyouforyourinterestintheLittleBoxChallenge.Youmayhaveseenabriefdescriptionof
theinverterprizespecificationsneededtowinonthewww.littleboxchallenge.comwebsite.This
documentisamoreindepthdescriptionofthosespecifications,alongwithsomeinformation
regardinghowtheinverterswillbetested.Yourinvertermustconformtotheformfactor,
connectorandsafetyrequirementslistedinthisguideinordertobeconsideredfortesting,so
pleasereadtheseinstructionscarefully.Alsoincludedinthisdocumentaretherequirementsfor
whatmustbesubmittedfortheTechnicalApproachandTestingApplicationdocumenttobe
submittedonorbeforeJuly22,2015.Thelegallybindingtermsandconditionsforthe
competitionarefoundontheregistrationpage.Thesemustbecarefullyreadandagreedupon
beforeenteringthecompetition.

QuestionsaboutthisdocumentcanbesubmittedbyfillingouttheformontheFAQsectionof
thewww.littleboxchallenge.comwebsite.Asdescribedonthesite,anyquestionthatisanswered
willbereproducedonthesite,withoutidentifyingtheasker,andpostedinapdfforeveryoneto
seeinordertoensurefairnessforallcompetitors.

Thisdocumentmaybemodifiedperiodicallytoreflectquestions/clarificationscitedonthe
websiteortoreflectupdatedinformationandtestingprocedures.Anyoneregisteredforthe
competitionwillreceiveanemailindicatingthatthereisarevisedversion.

Table Of Contents

Introduction
TableOfContents
HighLevelPrizeSpecifications
DetailedRequirementsandTestingProcedure
VolumeandEnclosureRequirements
VoltageInput
VoltageOutput
FrequencyOutput
LoadProfile
TotalHarmonicDistortion+Noise
Efficiency
InputRippleCurrentandVoltage
MaximumExposedOuterDeviceTemperature
ElectromagneticCompliance
GroundCurrentLimit
Grounding,DeviceConnectionsandSafetyRequirements
Grounding
DeviceConnections
SafetyRequirements
TechnicalApproachandTestingApplicationRequirement
TechnicalApproachDocument
TestingApplication
AppendixA:TestingApplicationTemplate/Example

High Level Prize Specifications

Thewinninginverterwillbetheunitwhichachievesthehighestpowerdensity,i.e.fitsinthe
smallestrectangularenclosure,whilemeetingthefollowingspecificationsundertestingfor100
hours.Apanelofjudgeswilldeterminewhichinvertershavemetthespecifications(e.g.ifany
deviationsaresubstantialenoughtowarrantadisqualification)andmayrequestfurthertestingat
theirdiscretionbasedonthedatagathered.Intheeventofatieonvolume,efficiencywillbe
usedtodeterminethegrandprizewinner.

Parameter

Requirement

Comment

Maximumload

2kVA

Loadwillbeadjustedsothatatmost2kVAis
sourcedat240VRMSACoutputat60Hz

Powerdensity

>50W/in3

Inaccordancewithmaximumloadandvolume
requirements

<40in3

Requirerectangularenclosure,maxdimension
20in.,min0.5in.

Volume
Voltageinput

450VDC,10
Resistor

Seevoltagesourcedescription

Voltageoutput

240+/12VAC

Singlephase.Seedescriptionbelow

Frequencyoutput

60+/0.3Hz

Singlephase

Powerfactorofload

0.71

Leadingandlagging,loaddescriptionbelow

VoltageoutputTHD+N

<5%

Totalharmonicdistortion+noise

CurrentoutputTHD+N

<5%

Totalharmonicdistortion+noise

Efficiency

>95%

Measuredbyweightedaverageatdifferentloads
avariationontheCECmethod,seesectionbelow

Inputripplecurrent(120Hz)

<20%

MeasuredasIpeakpeak/Iaveragefroma450Vsupplyin
serieswitha10resistor

Inputripplevoltage(120Hz)

<3%

MeasuredasVpeakpeak/Vaveragefroma450Vsupplyin
serieswitha10resistor

<60C

Testedat15C30Cambient.Anypointthat
maybetouchedfromtheoutsidemustbe<60C

Maximumouterinvertertemperature
Electromagneticcompliance
Maximumcurrentonchassisground
connection

FCCPart15B

Seesectionbelow
Measureddirectly,orasthedifferenceincurrent
betweentheAChotandneutralwires

<5mA

Detailed Requirements and Testing Procedure

Volume and Enclosure Requirements

Theinvertermustbecontainedwithinarectangularmetalenclosurewithavolumeoflessthan
40inches3.Itistoyouradvantagetomakeeachfaceoftheenclosureflat,sinceanybulgingon
afacewillresultinanincreasedassessmentoftherelevantdimensionofheightwidthordepth
asshowninFigure1.Thevolumewillbecalculatedasifitwerearectangularprismwith
HxWxD,thusanydeviationfrombeingflatwillsubstantiallyincreasethevolumeattributedtothe
device.

Figure1:Invertercrosssectiontoillustratecalculationofheightandwidth
(depthcalculatedsimilarly)
Themaximumdimensionmaynotexceed20inchesandtheminimumdimensionmaynotbe
lessthan0.5inches.Thedimensionsoftheenclosurewillbemeasuredwithdigitalcaliperstoa
precisionof0.05inches.Thebottomoftheinvertermustbelargeenough(eachdimension>=1
inch.)toaccommodatethefoursupportpostsdescribedintheMaximumExposedOuterDevice
Temperaturesectionbelow.

Openingsintheenclosurearepermitted(e.g.fortheexitandstrainreliefoftheAC,DCand
groundwireconnections,aswellasholestopermitairtoenterandexitforcoolingpurposes).
Anyopeningintheenclosuremustbefingersafe,i.e.mustnotallowacylinderofdiameter
orgreatertopassthroughit.Anymeshusedshouldberecessedtofitwithintherectangular
enclosure.Aprotrudingmeshwilladdtotheeffectivedimensionoftherectangularenclosure,
thusincreasingtheassessedvolumeofthedevice.

Thevolumeofthewiresandstrainreliefexitingtheenclosurewillnotbecountedtowardsthe
totalvolumeoftheenclosure.

Voltage Input

Theinverterwillbetestedusinganearidealvoltagesupplysetat450V.Thispowersupplywill
befloating.Itspositiveterminalwillbeconnectedtoa10wirewoundresistorwhichwillinturn
beconnectedtothepositiveDCinputterminaloftheinverter.Thevoltagesourcewillbevery
closetoripplefree.

Voltage Output

Thevoltageoutputmustbe240VRMSsinglephaseAC,withina+/12Vband.Afteratransient
changeintheloadthevoltageshouldreturntowithinacceptablebandsin0.1secondsorless
andnotleavethebandagainuntilthenextloadchange.Thevoltagewillbemeasuredatthe
outputoftheinvertertoensureitremainswithinacceptablebands.

Frequency Output

Thefrequencyoutputmustbe60HzsinglephaseAC,withinabandbetween59.7to60.3Hz.
Afteratransientchangeintheloadthefrequency,ifitchanges,shouldreturntowithinthe
acceptablebandin0.1secondsorlessandnotleavethebandagainuntilthenextloadchange.
Thefrequencywillbemeasuredattheoutputoftheinvertertoensureitremainswithin
acceptablebands.

Load Profile

Theinverterwillbetestedunderdynamicloadconditions.Theloadwillbeprovidedbyan
electronicloadbankwhichcanswitchinandoutaseriesoflinearreactive,inductiveand
capacitiveloadsinsmall(<50VA)increments.Themaximumloadwillbe2kVA.Thepower
factorswillvarybetween0.7and1,leadingandlagging.Theloadchangeprofilewillbesimilarto
thatseeninaresidentialsetting,althoughonlyusinglinearloads.Entrantscanexpecttheloadto
varybetween0and2kVAwithindividualloadjumpsashighas500VA,andtheloadmay
changeasfrequentlyasonceeverysecond.

Total Harmonic Distortion + Noise

Totalharmonicdistortionplusnoise(THD+N)isameasureofhowmuchtheoutputofthe
invertervariesfromanidealsinewaveattheprimaryfrequency(60Hz).Themeasurementfor
voltageTHD+Nisdefinedas:

V THD+N

i=

V i2+V N oise2

i=2

V1

(1)

WhereV1istheamplitudeofvoltageatthefundamentalfrequency(at60Hz)andVi=V2,V3,
V4aretheamplitudesoftheharmonics.V2istheamplitudeat120Hz,V3at180Hz,V4at240
HzandVnbeingtheamplitudeatnx60Hz.VNoiseistheRMSvalueofthenoise(e.g.all
componentsnotatamultipleofthefundamental)withinthemeasurementbandwidth.

Similarly,thecurrentTHD+Nisdefinedas:

I THD+N

j=

I j2+I N oise2

j=2

I1

(2)

WhereI1istheamplitudeofcurrentatthefundamentalfrequency(at60Hz)andIi=I2,I3,I4
aretheamplitudesoftheharmonics.I2istheamplitudeat120Hz,I3at180Hz,I4at240Hzand
Inbeingtheamplitudeatnx60Hz.INoiseistheRMSvalueofthenoise(e.g.allcomponentsnot
atamultipleofthefundamental)withinthemeasurementbandwidth.

BothVTHD+NandITHD+Nmustremainbelow5%atallloadlevels.TheTHD+Nwillonlybe
measuredduringsteadystateoperationatdifferentloads.Duringanychangeinload,transient
behaviorandTHDmeasurementswillbeignoredfor1secondpriortotheloadchangeand1
secondaftertheloadchange.

Efficiency

Theinvertermustdemonstrateanefficiencyof>95%.Theefficiencyisdefinedas:

Efficiency = ACPowerOutput
DCPowerInput

(3)

andwillbedeterminedbymeasuringtheinputvoltageandcurrentandoutputvoltageand
current,usingtherealcomponentofthepoweratthefundamentalfrequency.

EfficiencymeasurementswillbetakenusingavariationontheCaliforniaEnergyCommission
(CEC)efficiencydeterminationmethod.Theinverterefficiencywillbedeterminedbytaking
measurementsat6differentloadlevelsasshowninTable1.

OutputAC
10%
PowerLevel (200VA)
Weighting
Factor

0.04

20%
(400VA)

30%
(600VA)

50%
(1kVA)

75%
(1.5kVA)

100%
(2kVA)

0.05

0.12

0.21

0.53

0.05

Table1:WeightingFactorsforCECefficiencycalculation

IntheCECefficiencymethodthesemeasurementsaretakenatthreedifferentvoltagelevels.
UnliketheCECmethod,thevoltageoftheDCinputinthiscompetitionwillbetiedtothepower
outputsinceweareusingavoltagesource+resistorsetup,asdescribedintheVoltageSource
section.Therefore,eachpartloadmeasurementwilltakeplaceatasingleinputvoltage.Eachof
themeasurementswillbetakenusingapurelyresistiveload.Themeasurementswillbetaken
atdifferenttimesduringthedynamicloadtestswiththeloadsspecifiedabove.Eachinverterwill
havethesameloadprofileappliedforthetestsandefficiencycalculation.

Inadditiontotherequirementslistedabovetheinvertermustalsohaveanefficiencyof
>95%atfull2kVAload.Thereasonforthisissothatateamcannotuseaforcedconvection
orotherwiseparasiticmeansofcoolingonlywhenoperatingatornearfullload,thusobscuring
theparasiticcoolingmethodseffectonefficiency.

Input Ripple Current and Voltage

Theinputripplecurrentandvoltagelimitsaredependentonthevoltagesourceconfiguration
beingusedtotestthedevice.Participantsmustplanandtesttheirdesignsaccordingly.The
inputripplecurrent(IRipple)isdefinedas:

I Ripple =

I P eakP eak(@120Hz)
I Average

I M axI M in(@120Hz)
I Average

(4)

Similarly.thevoltageripple(VRipple)isdefinedby:

V Ripple =

V P eakP eak(@120Hz)
V Average

V M axV M in(@120Hz)
V Average

(5)

ThedefinitionofIPeakPeak(@120Hz)andVPeakPeak(@120Hz)isshowninFigure2.As
illustrated,thepeaktopeakvalueistakenoftheenvelopeofthe120Hzoscillations(whichare
notnecessarilyperfectsinusoids)andnarrowspikesordeviationsathigherfrequenciesdonot
countinthemeasurement.

Figure2:DemonstrationofdefinitionofIPeakPeak(@120Hz)andVPeakPeak(@120Hz)forthe
ripplecurrentandvoltagemeasurements

BoththecurrentandvoltageripplewillbemeasuredbetweenthepositiveandnegativeDCinput
terminalsoftheinverter,ontheinvertersideofthe10wirewoundresistor.

ThelimitfortheinputripplecurrentisIRipple<20%atallloadlevels.Becausethevoltageand
currentrelationshipissetbythe(near)idealvoltagesourcesetat450Vinserieswitha10
wirewoundresistor,thecorrespondingVRipplefollowsfromtheallowableIRippleandrequires
VRipple<3.0%(allowingforsomeadditionallossesinthesystem)atallloadlevels.

Maximum Exposed Outer Device Temperature

Thedevicemustbeconstructedsuchthatallfingeraccessiblelocationsstaybelow60C.We
willtestthisthroughacombinationofthermal(IR)imageryandplacementofthermocouples.
Forourdefinitionoffingeraccessible,seetheenclosuredefinitionabove.

Notethatitisnotsufficientmerelytoensurethatallfingeraccessibledevicesurfacesstaybelow
60C.Wemayalsomeasurethetemperatureathermocouplereachesinafingeraccessible
locationthatisnotonadevicesurface(e.g.,justaboveaheatvent).

Theplacementofthethermocoupleswillbesimilaracrossalldevices,buttestersmayalsovary
theirplacementlookingforhotspots.Temperaturemeasurementsofopeningsonthe
enclosureforcooling,suchasholesorameshtoallowforairtoenterandexit,willbetaken
usingthermocouplesasareadingusingIRcamerasmayshowthetemperatureoftheinternal
sectionsoftheinverter.Thethermocoupleswillbesmallenoughandplacedinsuchawayasto
notmeaningfullyimpedeairflowinandoutofholesintheenclosure.

Theambienttemperatureofthetestingenvironmentwillremainbetween15Cand30C.
Therearenorequirementsforthetemperaturereachedbycomponentswithintheenclosure.
Thebottomsideoftheinverter(thesidetobeparalleltothefloorofthetestinglab)willbe
supportedonfourposts,1oneachcorner,1inchhigh,andwithatopareawhichmakes
contactwiththebottomoftheinverterofdimensions0.5x0.5inches.Therewillbenosignificant
heatconductedthroughtheseposts.

Electromagnetic Compliance

ThedevicemustconformtoFCCPart15Brulesintheunintentionalradiatorscategory.More
informationaboutFCCPart15BrequirementscanbefoundintheElectronicCodeofFederal
Regulationsandelsewhere.

TheFCCPart15Bcompliancewillbetestedatcertifiedelectromagneticcompliance(EMC)
testinglaboratoryintheUnitedStatesnearthetestingfacility.MoredetailsregardingtheEMC
testingfacilitywillfollowduringthecompetitioninanupdatedversionofthisdocument.

DuetothedifficultyofreachingcompliancewithFCCPart15B,especiallywithprototypes,we
encourageyoutosubmityourinverterfortestingevenifitmaynotreachfullFCCPart15B
compliance.IntheeventthatnoinvertersreachfullFCCPart15Bcompliance,thejudgesmay
doarelativecomparisonofEMCperformancebetweeninvertersandstillawardtheprize.

Ground Current Limit

Asdescribedinthegrounding,safetyandconnectionssectionbelow,therewillbeawire
connectingthechassisoftheinvertertoearthgroundinthetestinglaboratory.Thecurrent
flowingacrossthewiretogroundcannotexceed5milliAmpsatanytimeduringthetesting.The
currentflowingacrossthewiretogroundwillbeestablishedeitherbymeasuringthecurrenton
thegroundchassisconnectiondirectly,orbymeasuringthedifferenceincurrentbetweenthe
hotandneutralorhot1andhot2ACoutputconnections.

Grounding, Device Connections and Safety Requirements

Grounding

Theinverterdoesnotneedtoprovidegalvanicisolation.TheDCsupplywillbefloating.Inorder
toaccommodatethemostprevalentgroundingconventionsaroundtheworld,twodifferent
groundingconfigurationsarepermissible.Thegroundingconfigurationthattheteamwishes
tousemustbespecifiedbothduringtheTechnicalApproachandTestingApplication
Submissionandduringthesubmissionoftheinverteritself.Nopreferencewillbegivento
entriesbasedontherequestedgroundingconfiguration.

GroundingConfiguration1:240Vsplitphaseconfiguration

Thegroundingconfigurationforthe240VsplitphaseconfigurationisshowninFigure3.

Figure3:240Vsplitphasegroundingconfiguration

Inthisconfiguration,the240VRMSACoutputoftheinverterisbetweenterminalsdesignated
AC(Hot1)andAC(Hot2).Theseterminalsconnecttoeachotherthroughanisolation
transformerwhoseothercoilisconnectedtotheACloadbankthatwillapplytheloadprofileas
discussedintheloadprofilesection.Theisolationtransformeriscentertappedontheinverter
sideandconnectedtoground.ThishastheeffectoffixingbothoftheAC(Hot1)andAC(Hot2)
linestobe120VRMStoground,180degreesoutofphase,similartowhatwouldbefoundina
NorthAmericanhousehold.

Thepurposeofthe100resistorandswitchontheoutputoftheAC(Hot1)istolimittheinrush
currentsintothetransformeruponstartup.Theswitchwillbeleftopenforaperiodof10
secondsuponstartup,andthenwillbeclosed.

10

Aseparatewireisrequiredtoconnectthechassisoftheinvertertoearthground.Theresistance
betweenthiswire,asmeasuredinthechassisgroundreceptacleontheNEMA615
connector,andthemetalenclosureontheinvertermustbe<1.

Thevoltageandcurrentmeasurementstakentomeasureefficiencyandotherparameterswill
betakenontheinvertersideofthetransformertoensurethatanytransformerlossesdonot
adverselyaffecttheresults.

GroundingConfiguration2:240Vtogroundconfiguration

Thegroundingconfigurationforthe240VtogroundconfigurationisshowninFigure4.

Figure4:240Vtogroundgroundingconfiguration

Inthisconfiguration,the240VRMSACoutputoftheinverterisbetweenterminalsdesignated
AC(Hot)andAC(Neutral).Theseterminalsconnecttoeachotherthroughanisolation
transformerwhoseothercoilisconnectedtotheACloadbankthatwillapplytheloadprofileas
discussedintheloadprofilesection.Onesideoftheisolationtransformerisconnectedto
ground.ThishastheeffectoffixingtheAC(Hot)tobe240VRMStogroundandtheAC(Neutral)
tobeheldatground,similartowhatwouldbefoundinaEuropeanandotherhouseholdsaround
theworld.

Thepurposeofthe100resistorandswitchontheoutputoftheAC(Hot)istolimittheinrush
currentsintothetransformeruponstartup.Theswitchwillbeleftopenforaperiodofat10
secondsormoreuponstartup,andthenwillbeclosed.

Aseparatewireisrequiredtoconnectthechassisoftheinvertertoearthground.Theresistance
betweenthiswire,asmeasuredinthechassisgroundreceptacleontheNEMA615
connector,andthemetalenclosureontheinvertermustbe<1.

Thevoltageandcurrentmeasurementstakentomeasureefficiencyandotherparameterswill
betakenontheinvertersideofthetransformertoensurethatanytransformerlossesdonot
adverselyaffecttheresults.
11

Device Connections

Itistheresponsibilityofthecompetitortowirethedeviceexactlyasspecifiedbelow.Any
damageordecreaseinperformancethatresultsfromimproperwiringwillbethe
responsibilityofthecompetitorandnotthatofeitherthetestingfacilityorGoogle.

Thedevicesubmittedfortestingmustbearectangularmetalenclosurewith5wiresexitingfrom
it.Eachofthewiresmusthaveadiameterof10AWG,alengthofbetween1012inchesand
haveadequatestrainrelief.

Ononeoftheupright/verticalfacesperpendiculartothetestingsurface,twoDCconnections
wiresmustexittheenclosure,onedesignatedDC+andtheothermarkedDC.TheDC+
connectionmustbearedwire,theDCmustbeablackwire.TheredDC+wiremustconnect
toaredAndersonpowerproductsPP75DCconnector,theblackDCwiremustconnectto
ablackAndersonpowerproductsPP75DCconnector.TheredDC+connectionwillbe
attachedtothepositiveterminalofthepowersupply,ontheothersideofthe10wirewound
resistor.TheblackDCconnectionwillbeconnectedtothenegativeterminalofthepower
supply.ThetwoAndersonpowerproductsPP75connectorsshouldnotbeglued,stuck,or
otherwisepermanentlyfastenedtogether.

Ontheupright/verticalfaceoppositeandparalleltothefacewiththeDCwiresexiting,twoAC
wireconnectionsandonechassisgroundconnectionmustexittheenclosure.Thechassis
groundwiremustbeagreenwire.

Forthe240Vsplitphaseconfiguration,onewireshouldbedesignatedAC(Hot1)andmust
beabluewire,andanothershouldbedesignatedAC(Hot2)andmustbeabrownwire.For
the240VtogroundconfigurationonewiremustbedesignatedasAC(Hot)andmustbea
bluewire,andanothershouldbedesignatedasAC(Neutral)shouldbeawhitewire.

ThesethreewiresmustbeconnectedtoaFemaleNEMA615ACelectricalconnector.The
connectionsontheFemaleNEMA615ACelectricalconnectorwillbedependentonthe
groundingspecificationchosen:240Vsplitphaseconfiguration,or240Vtoground
configuration.

NEMA615connectionsforgroundingconfiguration1:240Vsplitphase

ThetwoACconnectionsandthechassisgroundconnectionmustbeattachedtotheFemale
NEMA615connectorinthefollowingway:whenlookingstraightaheadintotheoutletsofthe
connector,withthesinglesemicircularflattenedopeningorientedtowardsthebottomandthe
twoflatrectangularopeningsaboveitequidistantoneitherside,theAC(Hot1)wiremustbe
connectedtotheleftrectangularoutlet,theAC(Hot2)wiremustbeconnectedtotheright
12

rectangularoutletandthechassisgroundconnectionmustbeconnectedtothesemicircularand
flatoutletonthebottom.ThisisshowninFigure5.

Figure5:ACandchassisgroundconnectionrequirementsonfemaleNEMA615connectorin
the240Vsplitphaseconfiguration

TheAC(Hot1)andAC(Hot2)pinswillbeconnectedoneithersideofacentertapped
transformertoground,asshowninFigure3.Theothersideofthetransformerwillbeconnected
toaprogrammableloadbankandthechassisgroundwillbeconnectedtoearthgroundas
showninFigure3.

NEMA615connectionsforgroundingconfiguration2:240Vtoground

ThetwoACconnectionsandthechassisgroundconnectionmustbeattachedtotheFemale
NEMA615connectorinthefollowingway:whenlookingstraightaheadintotheoutletsofthe
connector,withthesinglesemicircularflattenedopeningorientedtowardsthebottomandthe
twoflatrectangularopeningsaboveitequidistantoneitherside,theAC(Neutral)wiremustbe
connectedtotheleftrectangularoutlet,theAC(Hot)wiremustbeconnectedtotheright
rectangularoutletandthechassisgroundconnectionmustbeconnectedtothesemicircularand
flatoutletonthebottom.ThisisshowninFigure6.

TheAC(Hot)andAC(Neutral)pinswillbeconnectedtoeithersideoftheisolationtransformer
asshowninFigure4andtheAC(Neutral)willbeconnectedtoearthground.

Safety Requirements

On/OffSwitch,LEDindicatorandTurnonDelay

Thedevicemusthaveaclearlylabelledon/offtoggleswitchontheenclosure.Whenthetoggle
switchisintheoffposition,novoltageorcurrentistobepresentontheACsideevenwhenthe
DCsideislive.
13

Figure6:ACandchassisgroundconnectionrequirementsonfemaleNEMA615connectorin
the240Vtogroundconfiguration

Whentheswitchisintheonposition,thedevicemustdetectthattherehasbeenavoltageof>
300Voltsforatleast5secondsbeforeoutputtingtotheACside.Thereshouldbenovoltageor
currentoutputontheACsideuntilthistime.

WhenthereislivevoltageontheACside,agreenindicatorlightlocatednexttotheon/offswitch
shouldbeilluminated.WhenthereisnovoltageontheACside,theLEDshouldbeoff.

FuseConfigurationforTestingSetup

Inordertoprotectboththeinvertersbeingtestedandtheequipmentbeingusedforthetest,the
followingfuseswillbeusedatthedifferentlocationsinthetestingsetup:

BetweentheresistorattheoutputofthevoltagesupplyandthepositiveDC+terminalof
theinverter:10A,500VDCslowblowfuse.
BetweenthenegativeterminalofthepowersupplyandthenegativeDCterminalofthe
inverter:10A,500VDCslowblowfuse.
BetweenthetheAC(hot)or(hot1)terminaloftheinverterandtheAC(hot)or(hot1)
inputtotheisolationtransformer:12A,240VAC,slowblowfuse.
BetweenthetheAC(neutral)or(hot2)terminaloftheinverterandtheAC(neutral)or
(hot2)inputtotheisolationtransformer:12A,240VAC,slowblowfuse.

Thesefusesarenottobeprovidedbythecontestparticipants.Theywillbeincorporatedintothe
testsetup.Theirvaluesareincludedsothatparticipantswillunderstandwhatcircumstances
mayleadtoablownfuse.

FurtherInverterSelfProtectionMeasures

[Tobeincludedbytestingpartnerinupdatedversionofthisdocument]
14

Technical Approach and Testing Application Requirement

Inorderfortheirinvertertobeconsideredfortesting,theteamsmustsubmitatechnical
approachandtestingapplicationdocumentonorbeforeJuly22,2015.Thoseregisteringforthe
competitionwillreceivemoreinformationbyemailaboutthesubmissionguidelinesinearly2015.
Thisapplicationwillbereviewedbyapanelofjudgesandnomorethan18finalistswillbe
selectedfortesting,andachancetowintheGrandPrizeof$1million.Thecriteriabywhich
thesubmissionswillbeevaluatedis:

Didtheteamsadequatelyandclearlypresentthehighleveloverviewoftheapproach
theyweretaking,meetingalltherequirementsforcontentlistedbelow?
Didtheirapproachmakesenseintermsofbeingabletoachievewhattheyclaim?
Didtheysubmittherequireddataandsafetyinformationrequiredinthetesting
application?
Didthatdatavalidatetheperformancetheyareclaiming?
Forthetechnicalapproachandtestingapplicationsthatmeetallofthecriteriaabove,is
theteamclaimingtoachieveoneofthe18highestpowerdensitiesofallthequalifying
applicants?

Teamsmeetingalloftheserequirementswillbeinvitedtobringtheirinvertersinpersontothe
testingfacilityintheUnitedStatesinOctober2015.

Technical Approach Document

Inordertobeconsideredfortesting,participantsinthecompetitionmustsubmitatechnical
approachdocumentnottoexceed4pages.Thisdocumentshoulddescribeatahighlevelwhat
approachandinnovationstheteamareusingtoachievethehighpowerdensitiesclaimedfor
theirinverters.Inaddition,a1pageappendixwithbiographicalinformationaboutthekey
membersofyourteammustalsobeincluded.

Thepurposeofthisdocumentistwofold.First,itwillallowapanelofjudgestoassessthelikely
viabilityofyourinverterdesignanddecidewhetherthesubmissionshouldqualifyasafinalistfor
testing.Second,asubsetofthetechnicalapproachdocumentssubmittedwillbemadepublicby
Googlesothattheworldmayseethenewtechniquesandinnovationswhicharenowmaking
thesehighdensitiespossible.

Thelevelofdetailrequiredinthetechnicalapproachdocumentismeanttobehighlevelandnot
divulgeanytradesecrets.Thecontentanddescriptionsofthedeviceshouldbecomparabletoa
shortIEEEpapermeanttoexplainconceptuallyhowanewdevicecanworkwithoutrevealingall
thedetailsabouttheexactvaluesofcomponentsused,norgoingintodetailsaboutthecontrol
algorithmsandothermoredetailedaspects.Generalcontentguidelinesinclude:
15

Powerdensityachieved:thevolumeoftherectangularenclosureusedandthusthe
resultingpowerdensityachievedataloadof2kVAshouldbespecified.
Switchlevelschematics:schematicsshouldbedetailedenoughtorevealwhatgeneral
topologyisbeingused,butnotincludeeverypassivecomponentorothercircuitdetail.
Orderofmagnitudepassivecomponentvalues:Forpassivecomponentswhichtypically
takeupalargevolume,orareotherwisecriticaltothetheconceptualdesignofthe
circuit,anorderofmagnitudevalueforwhatwasused(e.g.10sofmicrofaradsvs.100s
ofmicrofarads)isacceptable.
Orderofmagnitudefrequencyvalues:Forswitchingfrequenciesusedincreatingan
alternatingcurrentoutputfromadirectcurrentthroughapulsewidthmodulationorother
technique,specifyingtheorderofmagnitudeoffrequencyused(e.g.10sofkilohertzvs.
100sofkilohertz)isacceptable.
Semiconductordevicetype(s):Participantsshouldspecifythetypeofsemiconductor
switchingdevicesthattheyareusing(e.g.silicon,galliumnitride,siliconcarbide,etc.).
Participantsmayormaynotspecifythevendorsandprovidersofthesesemiconductor
switchingdevicesattheirdiscretion.Thesameistrueofanynovelpassivecomponents
used.

Participantsarefreetoincludemoredetailthanthisattheirdiscretion.Thetechnicalapproach
documentshoulddescribeanyandallofthekeyinnovationsbeyondthecurrentstateoftheart
whichenabledtheinvertertoachievethesehighpowerdensities.Inadditiontoanygeneral
contentabouttheinnovationsused,theymustprovideclearlyindicatedsectionsonwhat
innovationstheyhaveusedtoconfrontthefollowingchallengestoincreasinginverterpower
density:

120Hzinputcurrent/voltageripplerequirement:Thetypicalsolutiontominimizethe
inputcurrentrippleontheDCsideoftheinverter,whichisdetrimentaltotheoperationof
PV,batteryandothersystems,hasbeentoincludelargeamountsofenergystoragein
theformofoftenunreliable,largevolumeelectrolyticcapacitors.Participantsmust
describewhatmeansthathaveusedtomeettheinputripplecurrent/voltage
requirementswhileminimizingthevolumerequired.

MiniaturizationofcomponentsforDCACconversion:Thetypicalmethodsof
switchingafixedvoltageDCsignalintoAC,suchaspulsewidthmodulation(PWM),
requiretheuseofpassivecomponentstosmoothsquarewavepulsesintoasinewave
withminimalharmonicdistortion.Theenergystoragerequirement,andthusthesize,of
thesepassivecomponentscandiminishasthefrequencyofthesesquarewavepulses
isincreased.Thesehigherfrequenciesmaynowbeattainableeitherthroughtheuseof
widebandgapsemiconductorssuchasGalliumNitride(GaN)andSiliconCarbide(SiC),
orthroughnewtopologiesusingtraditionalsiliconsemiconductors.Participantsmust
elaborateonwhichofthesemethods,orothers,theyhaveusedtominimizethesizeof
theDCACswitchingcomponents,andwhyitisthepreferredsolutionforachievinghigh
16

powerdensities.Theymayalsoincludeanyadvancesinthepassivecomponents
themselves.

Thermalmanagement:Theamountofheatgeneratedbythesystemwilldecreaseas
theefficiencyofthesystemincreases,butevenattherequiredefficiencyof>95%atfull
loada2kVAinvertercangenerateupto100Wattsofheatwhichmustbedissipatedin
ordertopreventanunacceptabletemperaturerise.Thehigherthepowerdensityofthe
inverter,thelesssurfaceareaisavailableforthisheattobedissipatedacross.

Thelocalthermalmanagementrequirementsinthesystemmayberelaxedbyusing
devices(e.g.widebandgapsemiconductors)thatcanoperatereliablyatelevated
temperatures.Newpassiveoractivethermalmanagementapproachesmaybeusedto
managetheheatthatdoesgetgeneratedanddistributeitevenlyacrossthesurfacearea
oftheenclosuretoavoidthepresenceofhotspotsabove60C.Thetechnicalapproach
documentmustdescribewhatinnovationsinthermalmanagementarebeingusedto
achievetherequiredspecificationsatthesehighpowerdensities.

ElectromagneticCompliance(EMC):Thepossibleuseofhigherfrequencies,new
componentsinasmallerformfactoroffersbothchallengesandopportunitiesforlimiting
boththeconductedandradiatedelectromagneticinterferencewithinacceptablelimitsfor
FCCPart15Bcompliance.Participantsmustdescribethestepstakentolimitthe
electromagneticinterferenceofthedevicewhileconsumingtheminimumpossible
volume.

Biographicalinformationappendix(maximum1page):Inadditiontothetechnicalmaterial
listedabove,competitorsmustsubmita1pageappendixwithbriefdescriptionsofthekey
membersofyourteam.Thismustcontainonetotwoparagraphsperteammemberwith
informationontheirprofessionalandacademicbackground,beginningwiththeteamspointof
contact.DescriptionsshouldbesimilartowhatwouldbefoundattheendofanIEEEpaperina
journalsuchasIEEETransactionsonPowerElectronics.Photosareoptional.

Thetechnicalapproachdocumentshouldconformtothefollowingformattingguidelines:

Mustbewritteninenglish
Musthavetheteamnameandregistrationcodeclearlyindicatedatthetopofthefirst
pageofthedocument
Use8.5x11inchpagesize
Minimum12pointfontforbodytext
Minimum9pointfontinfigures,tablesandcaptions
Minimum1inchmarginsonallsides
Notexceed4pagesinlength+1pagebiographicalappendix
Citationsarewelcome,butentrantsshouldnotexpectjudgestodoathorough
examinationofseveralcitationstoevaluatethemeritoftheapproach
17

Technicalapproachdocumentswhichsimplyrefertothecontentofexternalcitationswithout
brieflyexplainingtheircontentandspecificrelevancetothehighpowerdensityinverter
applicationarefrowneduponandmayresultinadisqualificationfrombeingafinalistfortesting.

Testing Application

Atestingapplicationdocumentmustbesubmittedalongsidethetechnicalapproachdocument.
Thisdocumentpresentsdatatakenbyeachteamontheirinvertersasaproofoftheirviability,
alongwithasafetyquestionnaireneededfortesting.Atemplateofthetestingapplicationis
includedinAppendixAofthisdocument.Participantsdonotneedtofollowtheexact
color/formattingschemelistedbutshouldfollowthegeneralguidelinesandprovidethedataina
veryclear,legibleformat.Failuretodosomayresultindisqualification.Thesafetyquestionnaire
willbeprovidedinanupdatedversionofthisdocumenttobepostedduringthecompetition.

Thetestingapplicationconsistsof:

Maximum1pageTechnicalspecificationsheet:Inthisdocument,competitorswill
listtheperformanceoftheinvertertheythemselveshavemeasuredonthefollowing
metricswhiletestingtheirinverterona2kWpurelyresistiveloadat240+/12VAC
output.Theinvertershouldberunforlongenoughtoallowittoreachthermalequilibrium
priortothesemeasurementsbeingtaken.

Asdescribedabove,theinvertershouldbetestedwhilereceivinganinputfroma450V
nearidealpowersupplyinserieswitha10wirewoundpowerresistor.

Thespecificationsmeasuredandreportedshouldbe:

Groundingspecification:Theteammustspecifyiftheirinverteristobetestedin
the240Vsplitphaseconfigurationor240Vtogroundconfiguration.Seethe
groundingsectionaboveformoredetails
Maximumloadtested(mustbe2kVAorabove,correspondingto~28.8loadat
240VAC)
Volumeoftherectangularenclosure(inch3)
Dimensionsofrectangularenclosure(LxWxH,inches)
Resultingpowerdensityat2kWload(watt/inch3)
DCvoltagemeaninput(volts)
DCcurrentmeaninput(amps)
ACvoltageRMSoutput(volts)
ACcurrentRMSoutput(amps)
DCtoACefficiency(%)
Voltagetotalharmonicdistortion+noise(%)
Currenttotalharmonicdistortion+noise(%)
18

Inputripplecurrent(%)Ipeakpeak/Iaverage(@120Hz)
Inputripplevoltage(%)Vpeakpeak/Vaverage(@120Hz)
Maximumtemperaturereachbytheenclosure(C)
Ambienttemperatureoftestingenvironment(C)

TheseshouldbeorganizedinatableasshownintheexampleinAppendixA.

Maximum2pagesWaveformscreencaptures:Participantsmustprovidesample
waveformimagesoftheDCinputandACoutputoftheirinvertersatfulloutputona
purelyresistiveload.Thewaveformtracesshouldbetakenwithasamplingrateofat
least10kHz.

Eachimageshouldbebetween45inchesinwidthand34inchesinheight.
Thereshouldbe1traceperimage(currentorvoltage)foratotalof4images,2
oneachpage.
DCinputwaveforms:Mustshowbetween4660Hertzcyclesofbothinput
currentandvoltageatfullloadwithclearindicationofthevoltageandcurrent
divisions.Thiscorrespondstoa66100millisecondoscilloscopetrace.
ACoutputwaveforms:Mustshowbetween4660Hertzcyclesofbothinput
currentandvoltageatfullloadwithclearindicationofthevoltageandcurrent
divisions.Thiscorrespondstoa66100millisecondoscilloscopetrace.

Maximum2pagesExtendeddevicetesting:Participantsmustprovideaplotof1
secondmeasurementsofthefollowingquantitiesoverthecourseof3hoursoftesting
andtwodifferentloadconditions:2kVApureresistiveload,and1kVApureresistiveload.

DCvoltagemeaninput(volts)
DCcurrentmeaninput(amps)
ACvoltageRMSoutput(volts)
ACcurrentRMSoutput(amps)
Eachimageshouldbebetween46inchesinwidthand12inchesinheight.
Thereshouldbe1traceperimage(currentorvoltage)foratotalof8images,4
oneachpage

Maximum2page:Devicepictures:Theparticipantsmustsubmit3picturesofthe
invertertobesubmittedfortesting.

Apicturefromthetopofthedevicewiththeenclosureremoved.Theentiretyof
thedevicemustbewithintheboundsofthepicture.Thetoplevelcircuit
componentsshouldbevisible.Thisisonlyusedtoestablishthatyouhavean
actualviabledevicefortesting.Thispictureshouldbebetween46inchesinboth
widthandheight.
19

Apicturewiththeenclosureinplace,takenfromthetop.Thewiresexitingthe
deviceandtheproperconnectors(NEMA615andAndersonPowerProducts
PP75perinstructionsabove)mustbeclearlyvisible.Ameasuringtapeorruler
shouldbepresentinthepicture,withthemarkingslegible,forscaleandto
validatethedimensionsstated.Thispictureshouldbebetween46inchesinboth
widthandheight.
Apictureofthedevicewiththeenclosureinplacetakenfromtheside.A
measuringtapeorrulershouldbepresentinthepicture,withthemarkings
legible,forscaleandtovalidatethedimensionsstated.Thispictureshouldbe
between46inchesinbothwidthandheight.

Maximum[X]pages:Safetyquestionnaire(tobeprovidedbytestingpartnerin
updatedversionofthisdocument).Participantsmustanswerthequestionsrelatingto
safetyandhazardousmaterialsinformationneededtoconductthetestingatthetesting
facility.

20

Appendix A: Testing Application

Template/Example

21

TestingApplication:TechnicalSpecificationSheet

TeamName:TemplateTeam

RegistrationCode:*******************

Parameter

Value(TemplateExampleOnly!)

GroundingConfiguration
Maximumloadtested

240Vtoground

2.06kVA/28

Volumeoftherectangularenclosure

35in3

Dimensionsofrectangularenclosure

7inchx5inchx1inch

Resultingpowerdensityat2kWload

57.1W/in3

DCvoltage(RMS)input

395.8V

DCcurrent(RMS)input

5.4A

ACvoltage(RMS)output

240.2V

ACcurrent(RMS)output

8.6A

DCtoACefficiency(CECMethod)

95.5%

Voltagetotalharmonicdistortion+noise

4.4%

Currenttotalharmonicdistortion+noise

4.4%

Inputripplecurrent

16.1%

Inputripplevoltage

2.2%

MaxTemperatureofEnclosure

56C

AmbientTemperatureofTest

28C

22

TestingApplication:WaveformScreenCaptures

TeamName:TemplateTeam

RegistrationCode:*******************

DCInputVoltage

DCInputCurrent

23

ACOutputVoltage

ACOutputCurrent

24

TestingApplication:ExtendedTestingData

TeamName:TemplateTeam

RegistrationCode:*******************

2kVALoadDCVoltageInput

2kVALoadDCCurrentInput

2kVALoadACVoltageOutput

2kVALoadACCurrentOutput

25

1kVALoadDCVoltageInput

1kVALoadDCCurrentInput

1kVALoadACVoltageOutput

1kVALoadACCurrentOutput

26

TestingApplication:DevicePictures

TeamName:TemplateTeam

RegistrationCode:*******************

TopViewEnclosureOff:

TopViewEnclosureOn:

27

SideViewEnclosureOn:

28

TestingApplication:SafetyQuestionnaire

TeamName:TemplateTeam

RegistrationCode:*******************

[Tobeincludedinupdatedversionofthisdocument]

29