Certificate No / FhG-ISE / 001

Transcription

1 Certificate No. 055 / FhG-ISE / 00 Manufacturer: phocos China Ltd. Charge regulator type: CMLsolid 30 The above mentioned family of charge controllers have been subjected voluntarily to the qualification tests according to IEC / Edition.0 "Battery Charge Controllers for Photovoltaic Systems Performance and Functioning". On the basis of the test results (CMLsolid 30) that are laid down in the measurement protocol (test report) dated herewith we confirm that the tested charge controller type fulfils or exceeds controller specifications required by IEC / Edition.0. Remarks. This certificate is only valid in combination with above mentioned test report. 2. Any change in the electronic design, materials, components or processing of the CMLsolid 30 charge controllers may require a repetition of some or all qualification tests to maintain type approval. Freiburg, May 27 th, 205 Confirmed Dipl. Ing. (FH) Norbert Pfanner Head of Laboratory Dipl. Ing. (FH) Friedemar Schreiber Head of Testing Team Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.v., München Vorstand Prof. Dr.-Ing. habil. Prof. E.h. Dr.-Ing. E.h. mult. Dr. h.c. Reimund Neugebauer, Präsident Prof. Dr. rer. nat. Ulrich Buller Prof. (Univ. Stellenbosch) Dr. rer. pol. Alfred Gossner Dr. rer. publ. Alexander Kurz

2 Test and Measurement Protocol - Charge Controllers - Tests according to IEC :200 Model/Type Phocos CMLsolid30 DuT Serial Number Reference number Date Update CML30-phc CML302-phc-503 /2

3 charge controller, tests and measurements according to IEC / Ed..0 Table of Contents Overview page 3 Pretests page 5 Battery Life Time Protection Tests page 8 Energy Performance Tests page Protection and Fail-Safe Tests page 5 User Interface Tests page 9 ISO 900 Certification page 2 2/2

4 charge controller, tests and measurements according to IEC / Ed..0 Overview Evaluation / Summary, page /2 DuT: Ref. nr.: Phocos CMLsolid30 CML30-phc-503 Tests based on standard / requirements: IEC / Ed..0 tested? not tested (see commen Overview IEC requirements value / claim ) tolerance measured value / result requirements fulfilled? comments Battery Lifetime Protection Tests PV leakage current test 0. % I N ,7 2.6 V; R PVLoop = 48 Ohm end of charge voltage boost mode 4.4 V ± % 4,42 V end of charge voltage overcharge / equalization mode Model /Type Phoc os CX V 5.3 V ± % 4,84 V end of charge voltage floating mode 4. V ± % 3,86 V low voltage 0. x I 0 temperature compensation HVD Energy Performance Tests.7 V 2.0 V - 5 mv/cell/ C ± 2 %,00 V n. d. -3,8 to -4,3 mv/cll/ C values are within ± % of manufact. statement values are within ± % of manufact. statement values are within ± % of manufact. statement values are within ± 2 % of manufact. statement From ISE perspective a range of -3 to -6 mv/cell/ C is o.k.! self-consumption (including lights / LCD) 0. % I N n. d. 4,5 ma max. self consumption charge efficiency n. d. n. d. 98, % at max. current discharge efficiency n. d. n. d. 98, % at max. current charging technology PWM For information only ) Values in bold are recommended values according to IEC next page ##### 3/2

5 charge controller, tests and measurements according to IEC / Ed..0 Overview Evaluation / Summary, page 2/2 tested? not tested (see comment) IEC requirements Protection and Fail Safe Tests Value / claim tolerance measured value / result requirements fulfilled? comments protection against wrong polarity battery compulsory --- o.k. battery open circuit test compulsory --- o.k. Load voltage 0 removed battery protection against wrong polarity module compulsory --- o.k. protection against shorted load compulsory --- o.k. PV overcurrent protection test.25 x I 25 C ,5 A User Interface Tests Load overcurrent protection test.25 x I 25 C Thermal performance test I PVmax and I max for h A --- o.k. test with max. currents at 50 C ambient temperature for hour display (charging, batt. charged, discharged) charging n. d. available Signalled by LED batt. charged n. d. available Signalled by LEDs discharg. batt. n. d. available Signalled by LED The following lettering / labelling should be available: manufacturer, model/type, serial no, rated voltage, max. charge current, max. load current, terminals, display, fuses Complete documentation should be available: data sheet, user manual, installation instructions, operation instructions, trouble shooting guide, calibration instructions (if on site calibration is possible), safety instructions, warranty, information about spare parts must be durable --- o.k o.k. The availability of lettering/labelling is not postulated by IEC From perspective a labelling should be available. Visual test The availability of documentation is not postulated by IEC From perspective a documentation should be available. Visual test. n.d. = not defined T max = manufacturer's specified max. rated ambient operation temperature I N = nominal current I PVmax = manufacturer's specified max. PV current I Loadmax = manufacturer's specified max. load current 4/2

6 charge controller, tests and measurements according to IEC / Ed..0 Pretests. Information given by the manufacturer Manufacturer Country/Origin Model/Type Serial / Batch Nr. Mechanical data Dimensions (l * w * h) [mm] Weight [g] Case material Protection class (IP) Case mounting Connection type Cable stress relief Cable diameter [mm²] Label Electrical data 2 phocos AG Germany CMLsolid *40* metall 20 screws screws n.a. 6 yes At ambient temperature of [ C] Rated voltage Automatic adjustment 2/24V Max. module power [W] Max. charge current [A] Max. discharge current [A] Type of controller Technique of regulation Self consumption [ma] End of charge voltage [V] return switch-on voltage (two point regulation) [V] load disconnect warning on [% SOC] load disconnect voltage [V] time delay at load sheding [s] Reconnection voltage load [V] time delay at reconnection [s] load reconnection manually [V] operation temperature range [ C] display 25 C 2V 24V x 2 & 24V x yes no C 45 C shunt x serial other: two point x PWM other: / 27,6 (float voltage) x LED / 22.0 no information 2.8 / 25.6 no information no -40 up to +50 LCD LED & LCD 5/2

7 charge controller, tests and measurements according to IEC / Ed..0 Information given by the manufacturer (continued) Additional functions boost/gassing function boost activation voltage [V] final boost voltage [V] equalization activation voltage [V] final equalization (gassing) voltage [V] Temperature compensation temperature compensation [mv/k*cell] Battery voltage sensor DC/DC-Converter MPPT adjustable for different battery types adjustable thresholds end of charge [V] load disconnect [V] selectable priority at load disconnection Protection against reversed battery polarity Protection against reversed PV polarity Others x yes no < 2.3 / / 28.8 (25 C), 2 h < 2. / / 29.6 (25 C) 2 h x yes no 4,2 yes x no yes x no yes x no x yes no yes x no min. max. min. max. yes x no x yes ) no not specified x yes ) no not specified USB-Charger Remote Terminal for inverter DIP switches for Alarm, LVD and Battery type ) Electronic protection listed values rated for x 2V x 24V Others Interfaces Price Service Warranty yes not available only manufacturer website no information 6/2

8 charge controller, tests and measurements according to IEC / Ed..0 Pretests.2 Visual Inspection Connection type Cable stress relief Cable diameter stranded [mm²] Cable diameter solid [mm²] Case quality Connector quality Electronic quality Packing of charge controller Lettering of packing Fuse changing Mounting of charge contr. Others: Comment quality Damages plug x screw other: cables o.k. not o.k. x not available 2,5 4 6 x 6 2,5 4 6 x 6 x very good good bad very good x good bad x very good good bad very good x good bad x very good good bad very good good bad x n.a. ) very good x good bad very good quality yes x no Lettering of the charge controller Manufacturer Model / type Serial / batch number Nominal voltage Connectors Fuse LED, displays Comment labeling: Documentation Data sheet User manual Operating instructions Troubleshooting guide Safety instructions Installation instructions Calibration instructions Others Comment documentation x yes no x yes no x yes no x yes no x yes no yes no x n.a. ) x yes no o.k. x o.k. not o.k. not available x o.k. not o.k. not available x o.k. not o.k. not available x o.k. not o.k. not available x o.k. not o.k. not available o.k. not o.k. x not available user manuals in different languages (german, english, french, spainish, portugese, chineese) o.k. Spare parts Fuse Mounting parts Connectors Others Comment spare parts availabe availabe availabe --- x not available ) x not available x not available Support Repair / Service address Warranty Others Comment support ) Electronic protection availabe availabe Is it possible to test the charge controller? x yes no IEC requirements fulfilled? x passed failed If failed, reason? x x a support address should be given not available not available 7/2

9 charge controller, tests and measurements according to IEC / Ed..0 2 Battery Lifetime Protection Tests 2. Leakage Current Ambient temperature 25,5 C DuT Rated voltage 2,0 V Reference CML30-phc-503 Inspector bg Test Behaviour / results DuT p/f remarks Revers current [µa] Protection against night discharge of the battery (leakage current) 67,7 p Vbatt: 2.6 V PV loop resistor: 48 Ohm Used measurement equipment Vbat: Ibat: --- Vpv: --- Ipv: Fluke 87 Vload: --- Iload: --- Ta: Maxim DS8S20 DuT = device under test p/f = passed / failed IEC requirements? If failed, reason? x passed failed 8/2

10 charge controller, tests and measurements according to IEC / Ed..0 2 Battery Lifetime Protection Tests 2.2 Set-points Ambient temperature Rated voltage 25,0 C DuT 2,0 V Reference CML30-phc-503 Inspector bg Voltage thresholds Specification (manufacturer) [V] Measured [V] DuT DuT 2 p / f Remarks PWM start Cut-off End of charge voltage (floating) 3,8 3,7 3,86 p final voltage equalisation (gassing) 4,8 4,7 4,84 p Only if flooded battery is selected. final voltage boost 4,4 4,3 4,42 p Load disconnect warning on Deep discharging cutoff voltage,0,00 p Alarm before Cut-Off Reconnect voltage load 2,8 2,78 p Time delay load disconnect [s] Time delay load reconnect [s] Type of controller equal to manufacturer data appr. min. 0 serial / PWM x yes no Used measurement equipment Vbat: Ibat: Vpv: Ipv: Oscilloscope Agilent DSO-X-304A Vload: Iload: Ta: Maxim DS8S20 DuT = device under test p/f = passed / failed IEC requirements / recommendations? x passed failed If failed, reason? 9/2

11 charge controller, tests and measurements according to IEC / Ed..0 2 Battery Lifetime Protection Tests 2.3 Temperature Compensation of the Set-points Ambient temperature see below C DuT Rated voltage 2 V Reference CML30-phc-503 Inspector bg Voltage thresholds ambient temperature [ C] temp. comp [mv/k] / cell DuT End of charge voltage (float) [V] )2) Equalization voltage [V] )2) Boost voltage [V] )2) Deep discharging cut-off voltage [V] Reconnect voltage load [V] ) PWM start 2) cut 25,0 C 3,7 3,86 4,7 4,84 4,3 4,42,0 2,78 Temp. C 3,36 3,50 4,36 4,5 3,94 4,07 39,5 39,5 39,5 39,5 39,5 39,5,06 39,5 stable 2,72 39,5 stable -4,0-4, -4,0-3,8-4,3-4,0 Remarks Equalization charge only in flooded battery mode. Used measurement equipment Vbat: Ibat: Vpv: Ipv: Vload: Iload: Ta: Oscilloscope Agilent DSO-X-304A Maxim DS8S20 IEC requirements? If failed, reason? x passed failed 0/2

12 charge controller, tests and measurements according to IEC / Ed..0 3 Energy Performance 3. Self Consumption Tests Ambient temperature Rated voltage 25,5 C DuT 2,0 V Reference CML30-phc-503 Inspector bg self consumption [ma] 5,0 ref ref2 Overv Batt.V rising falling Batt.V rising falling 2,6 4, #### ##### #BEZUG! #### 2 4,2 #### ##### #BEZUG! ####,4 3,3 #### ##### #BEZUG! #### 0,8 4,5 #### ##### #BEZUG! #### 0,2 4,3 #### ##### #BEZUG! #### #NV #NV #### ##### #BEZUG! #### #### #### #### ##### #BEZUG! #### #### #### #### ##### #BEZUG! #### #### #### #### ##### #BEZUG! #### #### #### #### ##### #BEZUG! #### #### #### #### ##### #BEZUG! #### #### #### #### ##### #BEZUG! #### #### #### #### ##### #BEZUG! #### 4,5 4,0 3,5 3,0 2,5 2,0,5,0 0,5 0,0 0,0,0 2,0 3,0 4,0 5,0 battery voltage [V] Vbatt falling max. selfconsumption average selfconsumption DuT 4,5 0,8 V 4, V Comment Used measurement equipment Ibat: Ubat: Ta: HP 3440A Maxim DS8S20 IEC requirements? If failed, reason? x passed failed /2

13 charge controller, tests and measurements according to IEC / Ed..0 Measured data Nr. Batt. Volt. [V] Self consumpt. [ma] Self consumpt. [mw] DuT 2,6 4, 5,7 2 2,0 4,2 50,4 3,4 3,3 37,6 4 0,8 4,5 48,6 5 0,2 4,3 43,9 Comment 3 State of charge Leds On State of charge Led On State of charge Led flashing Load status Led On Load status Led On 6 2/2

14 charge controller, tests and measurements according to IEC / Ed..0 3 Energy Performance 3.2 Efficiency Tests Ambient temperature: 27,0 C DuT Rated voltage: 2,0 V Reference Rated max. charge current: 30,0 A Rated max. discharge current: 30,0 A Inspector: CML30-phc-503 bg 3.2. Charging 0 % to 00 % rated charging current Vpv-Vbat PV-Module Battery efficiency [V] [A] [W] [V] [A] [W] [%] [V] 3,23 3,5 4,67 3,20 3,06 40,39 96,9 0,03 3,25 6,7 8,75 3,20 6,09 80,39 98,3 0,05 3,27 9,9 2,95 3,20 9, 20,25 98,6 0,07 3,29 2,23 62,54 3,20 2,5 60,38 98,7 0,09 3,32 5,25 203,3 3,20 5,9 200,5 98,7 0,2 3,34 8,28 243,86 3,20 8,23 240,64 98,7 0,4 3,36 2,3 284,70 3,20 2,26 280,63 98,6 0,6 3,39 24,34 325,9 3,20 24,30 320,76 98,4 0,9 3,42 27,36 367,7 3,20 27,33 360,76 98,3 0,22 3,44 30,38 408,3 3,20 30,36 400,75 98, 0,24 DuT Discharging 00 % rated load current Battery Load efficiency Vbat-Vload [V] [A] [W] [V] [A] [W] [%] [V] 2,60 30,23 380,90 2,45 30,00 373,50 98, 0,5 3,20 30,6 398, 3,05 29,95 390,85 98,2 0,5 min. discharge efficiency [%]: 98, DuT Remarks: very high efficiencies Used measurement equipment: Vbat: Ibat: Vpv: Ipv: Vload: Iload: Ta: Maxim DS8S20 IEC requirements? If failed, reason? x p f 3/2

15 charge controller, tests and measurements according to IEC / Ed..0 Charge and discharge efficiencies efficiency [%] Charge efficiency 99,0 0,30 98,5 0,25 98,0 0,20 0,5 97,5 0,0 97,0 0,05 96,5 0,00 0,0 0,0 20,0 30,0 40,0 charge current [A] deltau [V] DuT efficiency DuT deltau 4/2

16 charge controller, tests and measurements according to IEC / Ed..0 4 Protection and Fail-safe Tests 4. Thermal Performance Tests Ambient temperature: see below Rated voltage: 2 V Rated max. charge current: Rated max. discharge current: 30 A 30 A DuT Reference Inspector: CML30-phc-503 bg Test at extented ambient temperature time PV-module Battery load T heatsink T ambient DuT Comment [min] [V] [A] [V] [A] [V] [A] [ C] [ C] 0 2,77 30,00 2,53 0,00 2,39 30,00 52,0 50,0 5 2,78 30,00 2,54 0,00 2,39 30,00 55,5 50,0 0 2,78 30,00 2,54 0,00 2,39 30,00 56,0 50,0 5 2,78 30,00 2,54 0,00 2,39 30,00 56,0 50,0 20 2,78 30,00 2,54 0,00 2,39 30,00 56,0 50,0 25 2,78 30,00 2,54 0,00 2,39 30,00 56,0 49,5 30 2,78 30,00 2,54 0,00 2,39 30,00 56,0 50,0 35 2,78 30,00 2,54 0,00 2,39 30,00 56,0 49,5 40 2,78 30,00 2,54 0,00 2,39 30,00 56,0 49,5 45 2,78 30,00 2,54 0,00 2,39 30,00 56,0 49,5 50 2,78 30,00 2,54 0,00 2,39 30,00 56,0 50,0 55 2,78 30,00 2,54 0,00 2,39 30,00 56,0 49,5 60 2,78 30,00 2,54 0,00 2,39 30,00 56,0 50,0 Remarks: Used measurement equipment: Vbat: Ibat: Vpv: Ipv: Vload: Iload: Ta: Tc: Maxim DS8S20 Maxim DS8S20 IEC requirements? If failed, reason? x p f 5/2

17 charge controller, tests and measurements according to IEC / Ed..0 4 Protection and fail-safe tests 4.2 Overcurrent protection tests DuT Ambient temperature: see below C Rated voltage: 2,0 V Reference CML30-phc-503 Rated max. charge current: 30,0 A bg Rated max. discharge curre 30,0 A Inspector: 4.2. PV overcurrent protection test time PV-module Battery Remark T heatsink T ambient DuT [min] [V] [A] [V] [A] [ C] [ C] 0 3,50 37,65 3,20 37,58 27,5 26,0 5 3,5 37,62 3,20 37,57 33,5 27,0 30 3,52 37,63 3,2 37,57 34,0 28,0 45 3,52 37,63 3,2 37,56 34,5 28,0 60 3,52 37,64 3,2 37,56 34,5 28, Load overcurrent protection test time Remark Battery Load T heatsink T ambient DuT [min] [V] [A] [V] [A] [ C] [ C] 0 2,00 37,76,8 37,5 28,0 27,0 5 2,0 37,75,8 37,50 3,5 29,5 30 2,00 37,76,8 37,50 32,5 29,5 45 2,00 37,76,80 37,50 38,0 30,0 60 2,00 37,76,80 37,50 4,0 3,0 Used measurement equipmvbat: Ibat: Vpv: Ipv: Vload: Iload: Ta: Tc: Maxim DS8S20 Maxim DS8S20 IEC requirements? If failed, reason? x passed failed 6/2

18 charge controller, tests and measurements according to IEC / Ed..0 4 Protection and Fail-Safe Tests 4.3 Protection Against Reversed Polarity and Short Circuits Ambient temperature Rated voltage 25,5 C DuT 2,0 V Reference CML30-phc-503 Inspector bg Test Behaviour / results DuT p/f remarks Protection against short circuited PV ) test ok p Protection against reversed polarity PV Module test ok p Protection against short circuited load ) test ok p Operation with reversed polarity battery test ok p Load status Led indicates the reverse battery voltage.the reverse voltage was fed to the load. The charge controller didn't suffer any damage. According to the manual there is a warning to reverse the polarity. p/f: passed/failed ) Not mandatory according to IEC Remarks the charge controller is protected against short circuited PV, reversed polarity PV module, short circuited load, overload and reversed Used measurement equipment Vbat: Ibat: Vpv: Ipv: Vload: Iload: Ta: Maxim DS8S20 IEC requirements? If failed, reason? x passed failed 7/2

19 charge controller, tests and measurements according to IEC / Ed..0 4 Protection and Fail-Safe Tests 4.4 Battery Open Circuit Test Ambient temperature Rated voltage 27,0 C DuT 2,0 V Reference CML30-phc-503 Inspector bg Test operating with disconnected battery Behaviour / results Load will be switched off; V load = 0,0 V p Passed/failed DuT removing battery during normal operation V load = 0,0 V p Passed/failed Remarks Used measurement equipment Vbat: Ibat: Vpv: Ipv: Vload: Iload: Ta: Maxim DS8S20 IEC requirements? If failed, reason? x p f 8/2

20 charge controller, tests and measurements according to IEC / Ed..0 5 User Interface Tests 5. Display Ambient temperature Rated voltage DuT Reference CML30-phc-503 Inspector bg charging indication yes, green LED DuT battery charged indication (charge status) yes, 3 Leds load cut off warning battery discharged indication (load disconnection) yes, acoustic signal yes, red LED on Remarks: Used measurement equipment: Vbat: Ibat: Vpv: Ipv: Vload: Iload: Ta: Maxim DS8S20 IEC requirements? If failed, reason? x p f 9/2

21 charge controller, tests and measurements Overview of measurement equipment used (following DIN ISO 900:2000) device type measured dimensions reference number following DIN EN ISO 900:2000 HP 3440A Precision system-multimeter voltages, currents up to 3 A 42-DC-0 42-DC- 42-DC-6 Zimmer voltages, Precision-wattmeter 42-DC-25 LMG 95 currents up to 40 A, power 42-LI-5 Temperature sensors Maxim DS8S20 temperatures Agilent DSO-X 304A 4-channel-digital oszilloscope control of PWM behaviour Fluke 87 multimeter voltage, current, resistor 42-DC-7 / 42-DC-8 20/2

22 charge controller, tests and measurements Phocos_cmlsolid /2