Type approval qualification of Photovoltaic Modules Procedures and test experiences We Advise. Develop. Facilitate. Inspect. Certificate. Precisely Right. For You. 1
Type approval qualification of Photovoltaic Modules Standards EN IEC IEC 61215 61215 (2005): (1993): Crystalline silicon terrestrial photovoltaic (PV) modules Design qualification and type approval Edition 2 EN IEC IEC 61646 61646 (2008): (1997): Thin-film terrestrial photovoltaic (PV) (PV) modules Design qualification and type approval Edition 2 IEC 61730-1 (2004): IEC 61730-2 (2004): PV modules safety qualification - Requirements for construction PV modules safety qualification - Requirements for testing 2
IEC 61215, Ed. 2 (April 2005) Crystalline silicon terrestrial PV modules - Design qualification and type approval Preconditioning (5 kwh/m²) Visual Inspection, Performance, Insulation, Wet leakage Electrical Parameters UV preconditioning Damp Heat Test Thermal cycling (200 cycles) Outdoor Test Thermal cycling (50 cycles) Bypass Diode Test Humidity freeze Test Hot-Spot Test Terminations Test Mech. Load Hail Test Visual Inspection, Performance, Insulation, Wet leakage 3
IEC 61215 Pass Criteria Extract from IEC 61215: 4
Measurement of modules Solar simulators 5
Determination of electrical parameters Temperature coefficients Open circuit voltage V OC Short circuit current I SC Maximum Output Power P MPP 6
Determination of electrical parameters Nominal operation cell temperature (NOCT) 7
Determination of electrical parameters IV-curves at NOCT-conditions and low irradiance (200 W/m²) 8
Outdoor exposure Test Outdoor exposure dose: 60 kwh/m² 60 9
Bypass diode thermal test Possible problem in field installation Active by-pass diode (closed connection box) 37,0 캜 30 84,1 캜 20 80 10 60 3,8 캜 40 24,7 캜 Active by-pass diode (connection box with open lid) 10
Hot-Spot endurance test Problem Irradiation Reduced Irradiation Solar-cell IV-curves Cell Current Module Current Cell Voltage Forward- Voltage Reverse- Voltage Forward- Voltage Infrared images 11
UV-preconditioning test TÜV test chamber Browning effects of EVA - Dose UV-A (320 nm - 400 nm): > 15 kwh/m² - Dose UV-B (280 nm - 320 nm): = 5.5 kwh/m² - Module temperature: 60 C 12
Climatic-Tests TÜV test facilities 13
Climatic-Tests Thermal cycling test 200 (50) temperature cycles from -40 C to 85 C Edition 2: Current flow (I MPP ± 2%) through modules (t > 25 C) 14
Climatic-Tests Humidity-Freeze test 15
Climatic-Tests Damp heat test Module temperature / C 85 Test temperature: 85 C ± 2 C Relative Humidity: 85% ± 5% Test duration: 1000 hours 0 500 1000 Time / h 16
Climatic tests Test failure IV-curves Reduction of Fill-Factor due to increasement of series resistance Power loss of strings due to interrupted interconnects 17
Mechanical load test Test performance 3 load-tension cycles: 2400 Pa, 1 hour Optional: 5400 Pa 18
Mechanical load test Test failures 19
Module Frame Mounting of PV-Modules Example of mechanical stress calculation (STC) using clamp fixture Example of a frameless module using clamp fixtures front end fixture alongside fixture source: www.pv-wirefree.com 20
Cut test A knife is pulled over the back sheet with a defined weight pushing it down. The influence on the insulation properties is checked afterwards. 21
Test failures How to continue? If one qualification test is failed, the following procedure applies: The failed test sample(s) will be shipped back to the manufacturer for investigation. The manufacturer provides us with a detailed failure analysis report: What exactly was the reason for the failure? What measures will be taken to avoid such failures? With this evaluation report at hand, TÜV decides what tests have to be repeated with new test samples. If the repetition of the selected tests is passed, TÜV will issue the certificate. If the test-repetition is failed again, the module design has to be rejected! If the test samples fail in several different qualification tests (i. g. damp-heat, thermal-cycling and hot-spot) we have to reject the complete module design! The manufacturer can then reapply with an improved design. 22
Photovoltaic-Components 1. Applying Specifications: 23
Which PV-Components could be tested? PV-Junction box PV-Connector PV-Cables T-Distributor Y-Distributor Splice cables etc... 24
Current valid PV-Component-Standards PV Back Sheet - Partial discharge test - Previous version : EN 60664-1: 1992+A1+A2, EN 60664-1: 2003 - Current valid standard : EN 60664-1: 2007 PV Cable - Previous version : 2 Pfg 1169: 2004 - Current valid standard : 2 Pfg 1169: 2007 2 Pfg 1169: 2004 + Halogen free + Shrinkage test 25
2 PfG 1161 2 PfG 1161 = Code for Testing and Certification body in Germany = Prüfgrundlage für Gerätesicherheit (Test Specification for Product safety) = Consecutive number 26 TÜV Rheinland Korea 26 2008/10/1
Current valid PV-Component-Standards Junction Box - Previous version : 2PfG 1162: 2007-07 2PfG 1162: 2003-09 + Add. Requirements Bypass diode thermal test according to Clause 10.18 of IEC 61215: 2005 - Current valid standard : DIN V VDE V 0126-5: 2008-05 PV Connector - Previous version : 2 PfG 1161:2004 2 PfG 1161: 2006 - Current valid standard : DIN V VDE V 0126-3: 2006-12 27
History and development of PV-Component-Standards - First inquiries from TIE concerning SCII-Tests for Components. - Evaluation of appropriate standards for Components (acc. to SCII). - Adjusting to PV-Requirements. - Creation of first 2 PfG for Connector (2PfG1161) - Following creation of 2PfG1162 for Junction box and 2 PfG 1169 for cables. - Publication of IEC 61730. - Modification/adjusting of existing 2 PfG according to relevant clauses of IEC 61730. - Interest from DKE (national German committee for standardization) for creation of PV-Component-Standards. - Publication of DIN V VDE V 0126-3 for PV-Connector and forwarding to TC82 of CENELEC (Dec. 2006) - Publication of DIN V VDE V 0126-5 for PV-Junction box (May 2008) - Publication of Fpr EN 50521 for PV-connector (28.08.2008) 28
History and development of PV-Component-Standards - First inquiries from TIE concerning. SCII-Tests for Components. - Evaluation of appropriate standards for Components (acc. to SCII). - Adjusting to PV-Requirements. - Creation of first 2 PfG for Connector (2PfG1161) - Following creation of 2PfG1162 for Junction box and 2 PfG 1169 for cables. - Publication of IEC 61730. - Modification/adjusting of existing 2 PfG according to relevant clauses of IEC 61730. - Interest from DKE (national German committee for standardization) for creation of PV-Component-Standards. - Publication of DIN V VDE V 0126-3 for PV-Connector and forwarding to TC82 of CENELEC (Dec. 2006) - Publication of DIN V VDE V 0126-5 for PV-Junction box (May 2008) - Publication of Fpr EN 50521 for PV-connector (28.08.2008) 29
IEC 61730-1 30
History and development of PV-Component-Standards - First inquiries from TIE concerning. SCII-Tests for Components. - Evaluation of appropriate standards for Components (acc. to SCII). - Adjusting to PV-Requirements. - Creation of first 2 PfG for Connector (2PfG1161) - Following creation of 2PfG1162 for Junction box and 2 PfG 1169 for cables. - Publication of IEC 61730. - Modification/adjusting of existing 2 PfG according to relevant clauses of IEC 61730. - Interest from DKE (national German committee for standardization) for creation of PV-Component-Standards. - Publication of DIN V VDE V 0126-3 for PV-Connector and forwarding to TC82 of CENELEC (Dec.2006) - Publication of DIN V VDE V 0126-5 for PV-Junction box (May 2008) - Publication of Fpr EN 50521 for PV-connector (28.08.2008) 31
History and development of PV-Component-Standards IEC 61730-1 Component-Standards 32
History and development of PV-Component-Standards Connector IEC 61730-1 IEC 61984 45 pages, therefrom 27 pages requirements and tests 33
History and development of PV-Component-Standards cables IEC 61730-1 IEC 60245-4 25 pages, therefrom 17 pages requirements. Tests are described in several other standards. 34
History and development of PV-Component-Standards Junction box IEC 61730-1 3 pages (for Fieldwiring compartment with cover ) IEC 60670 63 pages, therefrom 47 pages requirements and tests. 35
History and development of PV-Component-Standards Environmental conditions IEC 61730-1 Component/PV-Standards All modules shall be able to operate under environmental condition type AB8 according to IEC 60364-5-51.... must be suitable for the durable use outside in an ambient temperature area from -40 C to +85 C. AB8 acc. to IEC 60364-5-51 = -50 C bis +40 C (15 100%rH) 36
History and development of PV-Component-Standards Connectors IEC 61730-1 Component/PV-Standards No requirements for durability No requirements for the maximum temperature limit neither for connectors nor for their contacts Requirements for durability (Operating cycles/ Contact resistance) Sum of Ambient temperature + temperature rise during operation shall not exceed upper limit temperature 37
History and development of PV-Component-Standards Junction box IEC 61730-1 Component/PV-Standards Requirements for wall thickness of junction boxes No general requirements for wall thickness of junction boxes Requirements for inner volume depending on the capacity of terminals General requirement for sufficient space within the junction box 38
History and development of PV-Component-Standards Junction box IEC 61730-1 Component/PV-Standards No requirements for protection against ingress of water and rigid objects (IP-code) Minimum degree of protection against ingress of water and rigid objects: IP55 39
History and development of PV-Component-Standards Cables IEC 61730-1 Component/PV-Standards No specified requirements Requirements for mechanical and electrical characteristics of materials 40
Photovoltaic-Components 2. Actual status of standardization: 41
Photovoltaic-Components Basic requirements according to IEC 60364-7-712 712 712.4 Protection for safety 712.41 Protection against electric shock PV equipment on the DC side shall be considered to be energized, even when the system is disconnected from the AC side. The selection and erection of equipment shall facilitate safe maintenance and shall not adversely affect provisions made by the manufacturer of the PV equipment to enable maintenance or service work to be carried out safely. 712.413.2 Protection by use of class II or equivalent insulation should preferably be adopted on the DC side. 42
Photovoltaic-Components PV-Connector (pre-standard) DIN V VDE V 0126-3 (since Dec. 2006) Based on 2 PfG 1161/01.2006 of TÜV Rheinland Composed of requirements from standards: IEC 61984 IEC 61730 IEC 61215 IEC 61646 IEC 60364-7-712 EN ISO 4892-standards 43
Photovoltaic-Components PV-Connector (pre-standard) EN 50521:2008, based on the requirements of DIN V VDE V 0126-3, was published in autumn 2008 44
Photovoltaic-Components PV-Connector 1 Scope This Standard applies to connectors of application Class A according to EN 61730-1 for use in photovoltaic systems with rated voltages up to 1 000 V d.c. and rated currents up to 125 A per contact. This standard applies to connectors without breaking capacity but might be engaged and disengaged under voltage. NOTE: For connectors according to Class B and C of EN 61730 as well as for protection for Class II equipment intended for use between 0 V and 50 V d.c. in photovoltaic-systems this standard may be used as a guide. 45
Photovoltaic-Components PV-Connector 46
Photovoltaic-Components PV-Connector Main Characteristics: Warning notice Do not disconnect under load 47
Photovoltaic-Components PV-Connector Main Characteristics: - Suitable for ambient temperature -40 to + 85ºC - unipolar; multipole under definite conditions allowed - Protection against electric shock during insertion and withdrawal - Termination according to relevant standards - Mounted cable must be suitable for PV-systems - Sufficient cord anchorage - min. IP 55 - Mechanical strength even at low temperatures - Requirements for withdrawal force 48
Photovoltaic-Components PV-Connector Main Characteristics: 5.16 Connector without locking device Connectors without locking device or without snap-in device shall withstand a withdrawal force of at least 50 N Compliance shall be tested according to clause 6.3.13 5.17 Connector with locking device Connectors with locking device or with snap-in device shall withstand a load of at least 80 N Compliance shall be tested according to clause 6.3.14 49
Photovoltaic-Components PV-Connector Main Characteristics: - Creepage distances and clearances according to IEC 60664-1 - Sufficient rated impulse voltage - Sufficient insulating materials - Outer materials, serving as enclosure - Flammability class: HB, V-2, V-1 or V-0 - Resistance to weathering according to ISO 4892-standards - Inner materials, serving as support for current carrying parts - Flammability class: HB, V-2, V-1 or V-0 - CTI relevant to rated values 50
Photovoltaic-Components PV-Connector Extract from test requirements: - Heating test and storing at ULT for 1000h - Climatic test (one sample, in following sequence) - Thermal cycling test (+85 C to -40 C, 200 cycles) - Damp heat test (+85 C, 85%, 1000h) - Corrosion test (Sulphur dioxide-atmosphere) - subsequent measurement of contact resistance and - Impulse withstand test 51
Photovoltaic-Components PV-Connector Extract from test requirements: - Test at insulation material - Weather resistance test according to ISO 4892-standard - Flammability test according to IEC 60695-11-10 - Glow-wire-test with 650 C / 750 C 52
Photovoltaic-Components PV-Junction box (pre-standard) DIN V VDE V 0126-5 (since May 2008) Based on 2 PfG 1162/07.2007 of TÜV Rheinland Composed of requirements from standards: IEC 60670 IEC 61730 IEC 61215 IEC 61646 IEC 60364-7-712 EN ISO 4892-standards 53
Photovoltaic-Components PV-Junction box 1 Scope This standard applies to junction boxes up to 1000 V DC for use on photovoltaic modules according to application class A of IEC 61730-1. Note For junction boxes according to application classes B and C of IEC 61730 in photovoltaicsystems this standard can be used as guideline. 54
Photovoltaic-Components PV-Junction box Requirement from IEC 60364-7-712 712 712.536.2.2.5.1 All junction boxes (PV generator and PV array boxes) shall carry a warning label indicating that active parts inside the boxes may still be live after isolation from the PV inverter. 55 55
Photovoltaic-Components PV-Junction box Main Characteristics: - Suitable for ambient temperature -40 to + 85ºC - Termination according to relevant standards - Cord anchorage - min. IP 55, Category 1 - Mechanical strength even at low temperatures - Creepage distances and clearances according to IEC 60664-1 - Double or reinforced insulation between live parts and accessible surfaces 56
Photovoltaic-Components PV-Junction box Main Characteristics: - Sufficient rated impulse voltage - Sufficient insulating materials - Outer materials, serving as enclosure - Flammability class: HB, V-2, V-1 or V-0 - Resistance to weathering according to ISO 4892-standards - Inner materials, serving as support for current carrying parts - Flammability class: HB, V-2, V-1 or V-0 - CTI relevant to rated values 57
Photovoltaic-Components PV-Junction box Main Characteristics: - Wall thickness (for polymers) min. 3,0mm or reduced under condition that additional tests will be passed (test of flammability class 5, at complete Junction box) 58
Photovoltaic-Components PV-Junction box Main Characteristics: 59
Photovoltaic-Components PV-Junction box Main Characteristics: - Number and type of bypass-diodes - Type and kind of adhesive for mounting on backsheet material 60
Photovoltaic-Components PV-Junction box Main Characteristics: 5.2.5 Unless otherwise specified in the test schedule, all tests shall be made on the specimen completely assembled according to the manufacturer s instructions. A sufficient number of specimen must be mounted on a mounting surface as in normal use. The mounting surface must consist of the same material like the backsheet material of the module, the box is intended to be fixed. If the box is intended to be fixed with several adhesive on several backsheet materials a sufficient number of specimen for each material must be tested. The cell connections will be bent down and fixed such that they have a conductive connection to mounting surface. For some tests it is necessary to connect the cell connections. 61
Photovoltaic-Components PV-Junction box Extract from tests: - Check of documents - Weather resistance test according to ISO 4892-2 or -3 (500h) - Glow-wire-test with 650 C / 750 C - Mechanical strength at -40 C with 1 Joule - Wet leakage current test - Thermal cycling test (+85 C to -40 C, 200 Cycle) - Damp heat test (+85 C, 85%, 1000h) - Humidity freeze test - Flammability test according to IEC 60695-11-10 at complete sample 62
Photovoltaic-Components PV-Junction box Extract from tests: - Thermal Bypass-diode-test - Heating treatment of sample up to 75 C - Operation of diode in direction of current flow - Applying rated current of junction box - After one hour evaluation of temperature of diode temperature - Increasing of current to 1,25-times rated current of junction box - After one hour verifying that diode is still operational 63
Photovoltaic-Components PV-cables 2 PfG 1169/08.2007 Based on: EN 50395 and EN 50396 Requirements from PV- world ISO 4892-standards Test requirements according to IEC 60811-standards 64
Photovoltaic-Components Basic requirements according to IEC 60364-7-712 712 712.52 Wiring systems 712.522 Selection and erection in relation to external influences 712.522.8.1 PV string cables, PV array cables and PV DC main cables shall be selected and erected so as to minimize the risk of earth faults and short-circuits. NOTE This may be achieved for example by reinforcing the protection of the wiring against external influences by the use of single-core sheathed cables. 712.522.8.3 Wiring systems shall withstand the expected external influences such as wind, ice formation, temperature and solar radiation. 65
Photovoltaic-Components PV-cables Main Characteristics: - Max number of cores: 1 - Suitable for ambient temperature from -40 C to + 90ºC - Rated Voltage : AC U 0 /U 0,6/1 kv - Maximum permitted voltage: DC 1,8 kv - Material of conductor: Copper (tinned) - Class 5 (flexibel) according to IEC 60228 - Maximum temperature at conductor: 120 C - Expected period of use is 25 years 66
Photovoltaic-Components PV-cables Main Characteristics: - No specified wall thickness of insulation and sheath depending on the diameter - but minimum wall thickness of insulation and sheath each 0,5mm - Halogenfree material of insulation and sheath (and seperation layers) - Temperature index of 120 C for 20.000h according to IEC 60216-2 for insulation and sheath - Mechanical strength even at low temperatures - No different requirements depending on several materials - Optimized fire hesitation according to IEC 61332-1-2 67
Photovoltaic-Components PV-cables Main Characteristics: - Resistance against acid and alkaline solution - Resistance against shrinkage 68
Photovoltaic-Components PV-cables Extract from tests: - Electrical tests at complete cable (High voltage test with 6kV AC or 15kV DC - Pressure test at high temperature at complete cable (140 C) - Damp heat test at complete cable (+90 C, 85%, 1000h) - Test of influence - Mechanical tests at low temperatures - Weathering resistance test acc. to ISO 4892-2 or -3 (720h) - Ozone resistance test according to IEC 50396, method B - Notch propagation test 69
Photovoltaic-Components PV-cables Extract from tests: - Flammability test according to IEC 60332-1-2 with 1kW-flame - Test of long term resistance of insulation to DC - Material test before and after ageing - Test of resistance against acid and alkaline solution - Hot set test - Assessment of halogen 70
Photovoltaic-Components PV-cables Extract from tests: - Thermal endurance properties - Test with minimum 4 different temperatures - Longest test sequence: minimum 5.000h NOTE: An Infrared-Analysis from the tested samples (insulation- and sheath-material) should be performed for further compliance-tests during routine factory inspections. 71
Photovoltaic-Components Further PV-Components Main characteristics: - Suitable for ambient temperatures -40 to + 85ºC (90 C) - min. IP 55 - Mechanical strength even at low temperatures - Termination according to relevant standards - Cable must be suitable - Cord anchorage - unipolar; multipole under definite conditions allowed - Protection against electric shock during insertion and withdrawal 72
Photovoltaic-Components Further devices for use in PV-systems Inverter: IEC 62109-1 Disconnector: IEC 60947-3 PV-Generator-junction-box: IEC 60439-1 Cable trays: IEC 61537 73
74 Thank you for your kind attention
75 Dipl.-Ing. Soo-Bong Lim TÜV Rheinland Korea Ltd. E&C Venture Dream Tower 6, 197-28, Guro-dong, Guro-gu, Seoul, Korea Tel.: 02/ 860 9958, Fax 02/860 9862 E-Mail: soobong.lim@kor.tuv.com, www.kor.tuv.com