Certification Training Course

CONFIDENTIAL

SESSION -1: PV Modules – Part 2 LIMITED USE

1. Introduction
2. Solar Fundamentals
3. PV Technologies
4. PV Modules – Part 2
5. Inverters
6. Benefits of the PV

DRRG – Training on Standards and Regulations

PV Modules

Goal
The goal of this module is to present the IEC
requirements for,
• Design qualification and type approval of PV
modules (performance standard) and
• Safety qualification of PV modules.

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Design
qualification and
type approval of
PV modules

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Design qualification and type approval of PV modules
With the consistent growing of PV industry, two questions captures attention:
1- What is the ‘good quality’ PV module?
2- How ‘reliable’ will be this module in the field?
Rather than waiting 25 years to answer these questions, standards IEC 61215 and
61646 have been developed (UL 1703 only as reference)
• Develop accelerated stress tests for the design qualification and type approval of
terrestrial PV modules designed for long-term operation in open air climates.

IEC IEC UL
61215 Crystalline silicon 61646 Thin-film 1703
terrestrial terrestrial Standard for
photovoltaic (PV) photovoltaic (PV) Flat-Plate
modules – modules - Photovoltaic
Design Design Modules and
qualification and qualification and Panels
type approval type approval

IEC standard – IEC standard – UL standard –

April 2005 May 2008 March 2002

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Design qualification and type approval of PV modules
IEC 61215 – list of stress tests
Performance

Performance Performance

Electrical
Performance

Mechanical

Irradiance Mechanical

Electrical
Irradiance

Environment

Thermal
Environment

Thermal
Environment

Irradiance
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Design qualification and type approval of PV modules
Sampling and marking

Sampling
• 8 module samples for qualification testing shall be taken
randomly from a production batch or batches, in
accordance with the procedure given in IEC 60410.
• The 8 module samples go through the test sequences of
the IEC 61215 & IEC 61646 in parallel, as shown on next
slide.

Marking
• Each module shall carry the following markings: name,
monogram or symbol of manufacturer; type or model;
serial number; polarity of terminals; maximum system
voltage for which the module is suitable

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Design qualification and type approval of PV modules
IEC 61215 Outline

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Design qualification and type approval of PV modules
Pass criteria

Each test sample shall meet all the following criteria:

• the degradation of maximum output power does not exceed the
prescribed limit after each test nor 8% after each test sequence.
• no sample has exhibited any open circuit during the tests.
• no visual evidence of a major defect.
• the insulation test requirements are met after the test sequences.
• the wet leakage current test requirements are met at the beginning
and the end of each sequence and after the damp heat test.

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Design qualification and type approval of PV modules
Measurement of nominal operating cell temperature (NOCT)
Performance at STC and NOCT

NOCT is the temperature reached by open circuited cell

in an open- rack mounted PV module under the
following reference environment:
• tilt angle: 45° from the horizontal
• total irradiance: 800 W/m2
• ambient temperature: 20 °C
• wind speed: 1 m/s
• electrical load: nil (open circuit)

Performance at STC and NOCT

• To determine how the electrical performance of the module varies
with load at STC (1000 W/m2, 25 °C cell temperature and at NOCT
and an irradiance of 800 W/m2

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Design qualification and type approval of PV modules
Using NOCT to estimate the PV cell temperature

Tc = Ta + (NOCT–20)  I / 800

Where:
Tc = PV cell temperature [°C]
Ta = Air temperature [°C]
I = Solar Irradiance normal to
the PV module [W/m2]

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Design qualification and type approval of PV modules
Standards IEC 61215 and 61646

 IEC 61215 has to be applied to Silicon-

crystalline modules
 IEC 61646 has to be applied to Thin-Film
modules
 Date of issue of the test certificate must be
recent (not older than 2 years)
 Tests must be made by an accredited
Practical laboratory that fulfil the requirements of
recommendations (ISO/IEC 17025)
 All tests in the standard must be performed
successfully and according to the given
sequence
 The certificate must refer to the given
module (manufacturer, model) without any
changes in dimensions, materials, etc.

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Safety
qualification of
PV modules

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PV module safety qualification
Standards IEC 61730-1 and 61730-2 (UL 1703 only as reference)
• Defines requirements for construction (IEC 61730-1) and testing (IEC
61730-2) for PV modules in order to provide safe electrical and
mechanical operation during their expected lifetime.
• Test sequence can be combined with those of IEC 61215 or IEC 61646, so
that test samples that have already passed the tests of IEC 61215 and
IEC 61646 can be used for the safety tests of the IEC 61730.

IEC IEC
UL
61730- 61730-
1703
1 Photovoltaic (PV) 2 Photovoltaic (PV)
Standard for
module safety module safety
Flat-Plate
qualification - qualification -
Photovoltaic
Part 1: Part 2:
Modules and
Requirements for Requirements for
Panels
safe construction safe operation

IEC standard – IEC standard – UL standard –

March 2013 November 2012 March 2002

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PV module safety qualification
Standard IEC 61730 – Application classes Only Class A is suitable for
grid-connected applications

Class A: General access, hazardous

voltage, hazardous power applications
• Used in systems operating at voltage greater than 50 V DC. Modules should meet
the requirements for safety class II (double insulation or reinforced insulation)

Class B: Restricted access, hazardous

voltage, hazardous power applications
• Restricted to systems protected from public access by fences, location, etc.
Modules should meet the requirements for safety class 0 (single insulation with no
protective earthing)

Class C: Limited voltage.

• Restricted to systems operating at less than 50 V DC. Modules should meet the
requirements for safety class III (Applied to equipment supplied from Extra Low Voltage
(ELV) source).

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PV module safety qualification
Standard IEC 61730-1

Construction requirements
• General (Modules completely assembled, need no alteration upon installation,
contain connection means, maintain ground continuity, parts prevented form risky
loosening, and friction free).
• Metal parts (endured or protected against moisture and corrosion),

Polymeric materials
• Serve as an enclosure for live parts (such as junction box)
• Serve to support live parts (such as integrated terminals)
• Serve as an outer surface (such as front-sheet & back-sheet)
• Serve as barriers between live parts.
• Should have a minimum temperature endurance of 20 oC higher than the
maximum measured operating temperature,

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PV module safety qualification
Standard IEC 61730-1

Bonding and grounding

• A module with accessible conductive parts (frame) shall have provision for
grounding. (Frames usually covered by a non-conductive anodizing or clear-coating to inhibit
corrosion)
• Modules may be provided with provisions for functional grounding. Such
grounding means shall be isolated from live parts by reinforced insulation

Creepage and clearance distances

• Separation between conductive terminals shall not be less than the

values specified in the Tables.

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PV module safety qualification
Standard IEC 61730-1

Required documents of PV module

• Installation instructions describing the methods of electrical and

mechanical installation and the electrical ratings of the module.
• When the fire rating is dependent on a specific mounting
structure, details of the specific parameters shall be included in
the instructions.
• Detailed description of the wiring method to be used, including
grounding, series/parallel configurations, overcurrent protection,
type of bypass diodes, minimum cable diameters, etc.
• The mechanical installation instructions for roof mounting shall
include:
• The minimum mechanical means for securing the module to
the roof
• indication of any slope required for maintaining a fire class
rating

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PV module safety qualification
IEC 61730-2 – Preconditioning tests
IEC 61730-2 – General inspection test
To assess the prevention against electrical shock, fire hazards, and injury due to mechanical & environmental
stresses.

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PV module safety qualification
IEC 61730-2 – Electrical shock hazard tests

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PV module safety qualification
IEC 61730-2 – Cut susceptibility test MST 12

A test fixture as shown designed to draw a

shaped object, a 0,64 mm ± 0,05 mm thick
carbon steel blade (for example the back of a
hacksaw blade) over the surface of the module
with an applied force of 8.9 N ± 0.5 N.

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PV module safety qualification
IEC 61730-2 – Impulse voltage test MST 14

Cover the whole module with a copper

foil. Connect the foil to the negative
terminal of the impulse voltage generator.
Then, connect the shorted output
terminals of the module to the positive
terminal of the impulse voltage generator.
With no illumination, apply the surge
impulse voltage for 3 successive pulses.
Change the polarity and repeat.

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PV module safety qualification
IEC 61730-2 – Fire hazard tests

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PV module safety qualification
IEC 61730-2 – Fire test MST 23

Fire resistance classes (ANSI/UL 790)

• Class A (highest fire resistance)
• Class B (medium fire resistance)
• Class C (fundamental fire resistance)

Tests
• Spread-of-flame test
• Burning brand test

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PV module safety qualification
IEC 61730-2 – Fire test MST 23 – Spread-of-flame test

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PV module safety qualification
IEC 61730-2 – Fire test MST 23 – Burning brand test

Wooden blocks (brands) are

burned then placed onto the
module

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PV module safety qualification
IEC 61730-2 – Mechanical stress tests
IEC 61730-2 – Component tests

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PV module safety qualification
IEC 61730-2 – Module breakage test MST 32

The purpose of this test is to provide

confidence that cutting or piercing injuries
can be minimized if the module is broken

Conduit bending test

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PV module safety qualification
Standards IEC 61730-1 and 61730-2 (UL 1703 is also used)

 Date of issue of the test certificate must be

recent (not older than 2 years)
 Tests must be made by an accredited
laboratory (ISO/IEC 17025)
 All the tests in the given standard must be
performed successfully and accordingly with
Practical the sequence indicated in the standard IEC
recommendations 61730-2
 The certificate must refer to the given
module (manufacturer, model) without any
changes in dimensions, materials, etc.

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Other
requirements for
PV modules

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Other requirements for PV modules
Standards IEC 61701, IEC 61345, IEC 62716, IEC 60068-2-68

• Resistance of different PV modules to corrosion from salt mist containing Cl-

• Resistance of the module when exposed to ultra-violet (UV) radiation
• Resistance of PV modules to ammonia (NH3)
• Effects of dust and sand suspended in air, on electrotechnical products

IEC
IEC IEC IEC
60068-
61701 61345 62716
Salt mist Photovoltaic 2-68 Environment
al testing -
corrosion UV test for (PV) modules
Part 2-68:
testing of photovoltaic - Ammonia
Tests - Test
photovoltaic (PV) modules corrosion
L: Dust and
(PV) modules testing
sand

IEC standard IEC standard IEC standard

IEC standard
– December – February – August
– June 2013
2011 1998 1994

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Other requirements for PV modules
Standards IEC 61701, IEC 61345, IEC 62716, IEC 60068-2-68

 Tests must be made by an accredited

laboratory (ISO/IEC 17025)
 IEC 61701, IEC 61345 and IEC 60068-2-68
have to be always used in consideration of the
harsh conditions in Dubai
Practical
recommendations  IEC 62716 is to be used when PV modules
are mounted on stables or analogous
structures

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