Testing Beyond IEC Traditional Standards and New Trend in ... · IEC 61215 / IEC 61730 such as:...

TÜV SÜDTÜV SÜD

Testing Beyond IEC TraditionalStandards and New Trend inIEC Standards Development

21/02/2014 Corporate Presentation Slide 1

Presented by Zhang ZhulinMar., 2014

TÜV SÜD

Topics

Slide 2Corporate Presentation14-02-21

IEC 61215 & IEC 61730-1/-2

Other Standards and Testing

Testing and Certification Trends

TÜV SÜD

Standard PV Module Certification

21/02/2014 Corporate Presentation Slide 3

IEC 61215, Crystalline silicon terrestrial photovoltaic (PV) modules – Design qualification and type approval

IEC 61730-1/-2, Photovoltaic (PV) module safety qualification – requirement for construction/testing

IEC 61646, Thin-film terrestrial photovoltaic (PV) modules – Design qualification and type approval

• Evaluate suitability of long-term operation in general open-air climates, as defined in IEC60721-2-1 (IEC 61215)

• All modules shall be able to operate under environmental condition type AB8 accordingto IEC 60364-5-51 (IEC 61730, identical with temp. range of IEC 60721-3-4, class 4K3 )

• Evaluate electrical shock, mechanical, fire resistance & propagation hazards• Verify evaluation through testing

TÜV SÜD 21/02/2014 Corporate Presentation Slide 4


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InitialMeasurement

Main tests includingintermediate tests

Final tests

IEC 61215 IEC 61730

Tests can be combined



General Inspection testVisual inspection

Preconditioning testsThermal cycling (TC50 or TC200)Humidity freeze (HF10)Damp heat (DH1000)UV preconditioningOutdoor exposure

Electrical shock hazard testsAccessibilityCut susceptibilityGround continuityImpulse voltageDielectric withstandWet leakage currentRobustness of terminations

Fire hazard tests

Temperature

Hot-spot

Fire

Bypass diode thermal

Reverse current overload

Mechanical stress tests

Module breakage

Mechanical load

Hail

Component tests

Partial discharge

Conduit bending

Terminal box knock out

Others (Evaluation/ comparison)

Measurement of temperature coefficient

Measurement of NOCT

Performance at STC and NOCT

Performance at low irradiance



Pass Criteria - IEC 61215 / IEC 61646If each test sample meets all the following criteria:a) maximum acceptable power losses (215 v.s. 646)b) no open circuit during the testsc) no visual evidence of a major defect, as defined in Clause 7d) pass insulation tests before and after some tests as prescribede) specific requirements of the individual tests are metIf test failure samples no. >= 2, the design shall be deemed not to have met thequalification requirementsIf one sample fail any test, another two samples shall pass the whole of the relevant testsequence from the beginning


Pass Criteria - IEC 61730


Construction requirements comply with IEC 61730-1

Test samples meet all of the criteria of each individual test

The nature of the failure will determine the extent of re-testing requirements

TÜV SÜD

Topics


IEC 61215 & IEC 61730-1/-2




Other Standards and Testing - Thresher

PV Module’s Durability and Reliability – 25 years warranty?


Thresher Mark Certification




What is it?Qualification program based on extended testing protocolFocused on critical Failure Modes for c-Si modules

ScopeProvide much higher confidence in lifetime prediction than IEC 61215 + IEC61730

How?By providing further insight on 1) Failure Mechanisms

2) Power Degradation Patterns3) Safety Degradation Patterns

Why?Failure rates in IEC testing have decreased but buyers whish a higher level of confidence


Other Standards and Testing - ThresherPreconditioning

20 kW/m2

Visual inspection10.1 + EL

Performance test10.2 & 10.7

Insulation test10.3

Wet leakage test10.15

Outdoor exposure test60 kW/m2 10.8

Bypass diode test10.18

Hot spot test10.9 5 times


TC 600


UV 453 x 15kWh/m2

TC 50

HF 30


DH 3000

Mechanical load test10.16


Hot spotsBypass diode

Broken interconnectsCell cracksSolder bond failuresOpen circuitThermal (bypass diode)

EncapsulantDiscolorationDelaminationCorrosionElectrical (j-box, conn.)Thermal (bypass diode)

DelaminationCorrosionMechanical failuresElectrical (jbox, conn.)Thermal (bypass diode)

Expected Failure Modes

7 MonthsA B C D EPID Test



Pass Criteria

Modules already certified acc. to IEC 61215 + IEC 61730-1, -2(certification still valid)

Modules shall undergo Thresher Test sequences successfully- no major visual defects,- pass insulation tests before and after some tests as prescribed- power degradation < 20 %- bypass diode functional

Factory Inspection – additional focus on internal reliability programs


Other Standards and Testing – Salt Mist

Environmental conditions not covered byIEC 61215 / IEC 61730 such as:

Marine environments with continuous highly corrosive wet atmospheres

Temporary corrosive atmospheres where salt is used in winter periods to meltice formation on street and roads

Which cause PV module components (metallic parts, non-metallic protectivecoatings and plastics) damaged and their functioning impaired.



Standard and Mark

IEC 61701, Salt mist corrosion testing of photovoltaic (PV) modules


(Originated from IEC 60068-2-52, Environmental testing – Part 2-52: Tests – Test Kb: Salt mist,cyclic (sodium chloride solution))

Severity 1: It is intended to be used in a marine environment.

Severity 2: Not suitable for PV modules as testing conditions are too weak.

Severity 3-6: Used in location where there could be a change between salt-laden and dryatmospheres, for example in places where salt is used to melt ice formations.

Test severities




Test time-scale



Test sequence



Pass Criteria

No major visual defects as described in IEC 61215 and IEC 61730-2

Max. power shall decrease by less than 5% of initial value

10.15 , MST 13 and MST 16 shall be fulfilled

Bypass diode functionality shall be also fulfilled


Other Standards and Testing – Ammonia

Agriculturalenvironment

Corrosive wetatmosphere

Corrosion of metallicparts

Assimilation ofammonia

Deterioration of theproperties of non-metallic materials




Standard and Mark

IEC 62716, Ammonia corrosion testing of photovoltaic (PV) modules


NH3 – Concentration 6667ppm

Temperature 60±3rel. Humidity 100%Cycles(24 Hours)

-exposure of NH3 for 8 h and 60±3with about 100% humidity

-drying for 16 h at normal atmosphere(18 ~28 and max.75% rel. humidity)

Duration 20 Cycles (480 Hours)


Test severity



Test sequence


Pass Criteria







Other Standards and Testing – Dust and Sand

Desert or desertization environments with high speed of wind

Which cause high speed dust and sand impact PV module, result in moduledamage or power degradation.




Standard and Mark

IEC 60068-2-68, Environmental testing – Part 2: Tests – Test L: Dust and sandLc2 + Insulation and power measurement tests from IEC 61215



Test severity

dust/sand type olivine or quartz or fledsparparticle size <75 um or < 150 um or < 850 umdust/sand concentration 1 g/m3 or 3 g/m3 or 10 g/m3air velocity 20 - 25 m/stest duration 4 hours each sidetemperature 40-60 degree Crelative humidity < 25 %



Test sequence


Pass Criteria







Other Standards and Testing – PID

Background

Potential-induced degradation(PID) of crystalline silicon solar cells was firstobserved by Sunpower in 2005.

It was found that leakage current through the frame, the front glass and encapsulationmaterial leads to accumulation of trapped negative charge on at the surface of the cells. Thesurface passivation provided by the front surface filed of these cells degraded. The fillfactor(FF),short-circuit current density and open-circuit voltage(Voc) were significantly reduced.

In 2010,NREL and Solon demonstrated that PID is a fundamental risk whenever state-of-the-art p-type crystalline silicon solar cells are used in standard modules at high negative bias.


Other Standards and Testing – PIDPossible PV array structure

EL pictures of multi c-Si string indicating shunting in the negative portion of a center-mounted orfloating string.



Standard and MarksIEC 62804 draft version 82/768/CD, System voltage durability test for crystallinesilicon modules – Qualification and type approval

And more…



Test sequence



Pass Criteria





Other Standards and Testing – Dynamic Load

Background

Mechanical load test in current IEC standards stipulates only a static mechanical load,it’s purpose is to determine the ability of the module to withstand wind, snow, static or iceloads

Hardly any fatigue stressing is carried out on cells, cell connectors or rigid componentparts such as the glass or framing by current method,

As regards oscillating or alternating forces, which may come from changing blast ofwind, judder and rain/wind-induced vibration, etc., dynamic mechanical loads addressmany more different requirements in the field than static loads



Standard and MarksIEC 62782 draft version 82/761/CD, Dynamic mechanical load testing forphotovoltaic (PV) modules + TÜV SÜD testing program



Test severity

Pressure + / - 1000 PaPressure applying duration 7 +/- 3 secondsCycles 1000Frequency 1 – 3 cycles / minute



Test sequence


Pass Criteria






Do you really know your power measurement system?

Other Standards and Testing – Power Measurement SystemValidation


Other Standards and Testing – Power Measurement SystemValidation

What contributes to the power measurement uncertainty?

Solar simulator (class AAA?)

Reference device (traceability)

Environment control

Intermediate check

Technician (training, authorization)


What’s our service?cooperate with NIM

validation from equipment to personnel to systemcontinuous measurement data comparison

Other Standards and Testing s – Power Measurement SystemValidation

TÜV SÜD

Topics


IEC 61215 & IEC 61730-1/-2




Test and Certification Trends

Prequalification of PV materials

No qualification requirements in current PV module IEC standards

Requirements of materials in current PV module IEC standards are not sufficient

IEC TC 82 established PV materials working groups

Several draft standards for PV materials are available



PV module rating to multiple climates



PV module fire resistance rating

Fire accidents occurred from time to time, especially for BIPV

It’s difficult to extinguish the fire when PV module is still generating electricity

Current draft says it should be done in accordance with local or nationalrequirements, which varies from nation to nation

UL proposes test for combined system of module/rack/roof

EU tests are under discussion



PV module reliability and ageing test

outdoor testing is a must but it takes too long, reliability or ageing is necessary topredict module’s lifetime

initial investment of PV plant is higher than traditional energy resources, how tocompete?

25-year warranty guarantee

power degradation pattern



Some draft standards statusNo. Name Statu

sIssuedate

IEC 61215Ed. 3.0

Crystalline silicon terrestrial photovoltaic (PV) modules – Design qualification and typeapproval

Draft M 2Q,2015

IEC 61215-1Ed. 1.0

Terrestrial photovoltaic (PV) modules – Design qualification and type approval – Part 1:Requirements for testing

ACDV 2015-06

IEC 61215-1-1Ed. 1.0

Terrestrial photovoltaic (PV) modules – Design qualification and type approval – Part 1-1:Special requirements for testing of crystalline silicon photovoltaic (PV) modules

ACDV 2015-05

IEC 61215-1-2Ed. 1.0

Terrestrial photovoltaic (PV) modules – Design qualification and type approval – Part 1-2:Special requirements for testing of cadmium telluride (CdTe) photovoltaic (PV) modules

AMW 2015-06

IEC 61215-1-3Ed.1.0

Terrestrial photovoltaic (PV) modules – Design qualification and type approval – Part 1-3:Special requirements for testing of amorphous silicon (a-Si) and microcrystalline silicon(micro c-Si) photovoltaic (PV) modules

AMW 2015-06

IEC 61215-1-4Ed. 1.0

Terrestrial photovoltaic (PV) modules – Design qualification and type approval – Part 1-4:Special requirements for testing of copper indium gallium selenide (CIGS) and copperindium selenide (CIS) photovoltaic (PV) modules

AMW 2015-06

IEC 61215-2Ed. 1.0

Terrestrial photovoltaic (PV) modules – Design qualification and type approval – Part 2:Test procedures

ACDV 2015-05

IEC 62892-1Ed. 1.0

Comparative testing of PV modules to differentiate performance in multiple climates andapplications – Part 1: Overall test sequence and method of communication

ANW 2015-12


Some draft standards statusNo. Name Statu

sIssuedate

IEC 61730-1Ed. 2.0

Photovoltaic (PV) module safety qualification – Part 1: Requirements for construction 2CD 2014-05

IEC 61730-2Ed. 2.0

Photovoltaic (PV) module safety qualification – Part 2: Requirements for testing 2CD 2014-05

IEC 61853-2Ed. 1.0

Photovoltaic (PV) modules performance testing and energy rating – Part 2: Spectralresponse, incidence angle and module operating temperature measurements

ADIS 2014-05

IEC 61853-3Ed. 1.0

Photovoltaic (PV) modules performance testing and energy rating – Part 3: Energy ratingof PV modules

NWIP -

IEC 61853-4Ed. 1.0

Photovoltaic (PV) modules performance testing and energy rating – Part 4: StandardReference Climatic Profiles

NWIP -

IEC 62109-3Ed. 1.0

Safety of power converter for use in photovoltaic power systems – Part 3: Particularrequirements for PV modules with integrated electronics

ANW 2014-12

IEC 62759-1Ed. 1.0

Transportation testing of photovoltaic (PV) modules – Part 1: Transportation and shippingof PV module stacks

CCDV 2015-02

IEC 62782Ed. 1.0

Dynamic mechanical load testing for photovoltaic (PV) modules ACDV 2015-04

IEC 62804Ed. 1.0

System voltage durability qualification test for crystalline silicon modules 1CD 2014-12



Some draft standards status


No. Name Status

Issuedate

IEC 60904-11Ed. 1.0

Photovoltaic devices – Part 11: Measurement of initial light-induced degradation ofcrystalline silicon solar cells and photovoltaic modules

ANW 2014-03

IEC 62788-1-2Ed. 1.0

Measurement procedures for materials used in photovoltaic modules – Part 1-2:Encapsulants – Measurement of volume resistivity of photovoltaic encapsulation andbacksheet materials

1CD 2014-12

IEC 62788-1-3Ed. 1.0

Measurement procedures for materials used in photovoltaic modules – Part 1-3:Encapsulants – Measurement of dielectric strength

ANW 2014-10

IEC 62788-1-4Ed. 1.0

Measurement procedures for materials used in photovoltaic modules – Part 1-3:Encapsulants – Measurement of optical transmittance and calculation of the solar-weighted photon transmittance, yellowness index, and UV cut-off frequency

ANW 2014-12

IEC 62788-1-5Ed. 1.0

Measurement procedures for materials used in photovoltaic modules – Part 1-3:Encapsulants – Measurement of change in linear dimensions of sheet encapsulationmaterial under thermal conditions

ACDV 2016-01

IEC 62788-2Ed. 1.0

Measurement procedures for materials used in photovoltaic modules – Part 2: Polymericmaterials used for frontsheets and backsheets

ANW 2015-12

IEC 62790Ed. 1.0

Junction boxes for photovoltaic modules – Safety requirements and tests ADIS 2014-06

IEC 62852Ed. 1.0

Connectors for DC-application in photovoltaic systems – Safety requirements and tests ADIS 2014-06

TÜV SÜD

TÜV SÜD GroupPresented by Zhang ZhulinMar., 2014

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Testing Beyond IEC Traditional Standards and New Trend in ... · IEC 61215 / IEC 61730 such as:...

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