Certificate No / FhG-ISE / 001

Transcription

1 Certificate No. 087 / FhG-ISE / 00 Manufacturer: phocos China Ltd. Charge regulator family: CXup 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 that are laid down in the measurement protocol (test report _Phocos_CXup_v5.pdf) 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 CXup charge controllers may require a repetition of some or all qualification tests to maintain type approval. Freiburg, August, 04 th, 207 Confirmed Dipl. Ing. (FH) Norbert Pfanner Head of Laboratory Dipl. Ing. Georg Bopp Head of 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 :200-2 Model/Type Phocos CXup 20 DuT Serial Number Reference number Date Update CXup_-phc CXup_2-phc /2

3 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 Overview Evaluation / Summary, page /2 DuT: Phocos CXup 20 Ref. nr.: CXup_-phc-047 CXup_2-phc-047 Tests based on standard / requirements: IEC / Ed..0 General remarks, recommendations The charge controller family CXup of phocos AG are professional manufactured charge controllers. The performance in all areas (efficiency, protection features, selfconsumption Overview etc.) is very high. The charge controllers are protected against short circuit and reversed polarity PV module, short circuited and reversed polarity battery using a reliable electronic fuse. tested? not tested (see commen IEC requirements value / claim ) tolerance measured value / result requirements fulfilled? comments Battery Lifetime Protection Tests PV leakage current test 0. % IN V; RPVLoop = 30 Ohm BCC Mode (battery) end of charge voltage boost mode 4.4 V 2,3 ± % 4.40 V end of charge voltage overcharge / equalization mode end of charge voltage floating mode low voltage 0. x I0 temperature compensation HVD Energy Performance Tests Model /Type Phoc os CX V to 5.3 V V 3 ± % 4.82 V 4, V V 3.7 V to 2.0 V - 5 mv/cell/ C ± % 3.80 V ± 2 %.50 V n. d. -4. to -4.7 mv/cell/ C self-consumption (including lights / LCD) 0. % IN n. d. 3.5 ma Vented battery charge efficiency n. d. n. d % at max. current From ISE perspective a range of -3 to -6 mv/cell/ C is o.k.! discharge efficiency n. d. n. d % at max. discharge current charging technology PWM/two point For information only ) Values in bold are recommended values according to IEC ) Vented battery 3) Sealed/VRLA battery ##### 3/2

5 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? protection against wrong polarity battery compulsory --- o.k. battery open circuit test compulsory --- o.k. protection against wrong polarity module compulsory --- o.k. protection against shorted load compulsory --- o.k. comments PV overcurrent protection test.25 x 25 C A Remarks see 4.2. User Interface Tests Load overcurrent protection test Thermal performance test.25 x 25 C for h A Remarks see o.k. test with max. currents at 40 C ambient temperature for hour display (charging, batt. charged, discharged) charging n. d. Signalled by LCD pictograms batt. charged n. d. Signalled by LCD pictograms discharg. batt. n. d. Signalled by LCD pictograms 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 Pretests. Information given by the manufacturer Manufacturer Country/Origin Model/Type Serial / Batch Nr. phocos AG Germany CXup (CXup_-phc-047) (CXup_2-phc-047) Mechanical data Dimensions (l * w * h) [mm] Weight [g] Case material Protection class (IP) Case mounting Connection type (terminal) Cable stress relief Cable diameter [mm²] Label 0*03*3 205 plastic 20 2 screws screws n.a. 6 yes Electrical data At ambient temperature of [ C] Rated voltage Automatic voltage adjustment 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 x 2 V x 24 V 48 V x yes no n.a. 0 to 40 depending on type 0 to 40 depending on type shunt x serial other: two point x PWM other: < 4 ma 3.8 / 27.6 (lead acid float voltage) 4.0 / 28.0 (LiFePO4) LED --- n.s..5 / 23.0 / 46.0 n.s. 2.8 / 25.6 (lead acid) 2.2 / 24.4 (LiFePO4) n.s. n.s. -30 up to +60 C x LCD LED & LCD 5/2

7 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 (e.g. USB-Port) 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 ) Electronic protection x yes no < 2.3 / / 28.8 (25 C), 2 h < 2. / / 29.6 (25 C), 2h x yes no -4.2 yes x no x yes 5.0 V, 500 ma no x yes no yes x no -- min. -- max. min. yes x no x yes ) no not specified x yes ) no not specified Protection against Over-Current, Over-Voltage, Over-Temperature, short-circuit and wrong polarity. 2 years datalogger and serial communication interface User friendly LC-Display and touch buttons Programmable nightlight function. Ext. Temperatur sensor max. Others Interfaces Price Service Warranty serial proprietary interface not available only manufacturer website no information 6/2

8 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: o.k. not o.k. x not available 2,5 4 6 x 6 2,5 4 6 x 6 very good x good bad x very good good bad x very good good bad x very good good bad x very good good bad very good good bad x n.a. ) x very good good bad very good quality yes x no Lettering of the charge controller Manufacturer x yes no Model / type x yes no Serial / batch number x yes no Nominal voltage x yes no Connectors x yes no Fuse yes no x n.a. ) LED, displays x yes no Comment labeling: o.k. Documentation Data sheet User manual Operating instructions Troubleshooting guide Safety instructions Installation instructions Calibration instructions Others Comment documentation 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, Spanish, Portugese, Chinese) o.k. Spare parts Fuse availabe Mounting parts availabe Connectors availabe Others Comment spare parts --- x not available ) x not available x not available Support Repair / Service address Warranty availabe availabe x x not available not available Others Comment support a support address should be given ) Electronic protection Is it possible to test the charge controller? x yes no IEC requirements fulfilled? x passed failed If failed, reason? 7/2

9 2 Battery Lifetime Protection Tests 2. Leakage Current Ambient temperature 28,0 C DuT Rated voltage 2,0 V Reference CXup_-phc-047 Inspector NP Test Behaviour / results Revers current [µa] Protection against night discharge of the battery (leakage current) 0,0 p leakage current was not measurable 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 2 Battery Lifetime Protection Tests 2.2 Set-points Ambient temperature Rated voltage 27,5 C DuT 2,0 V Reference CXup_-phc-047 Inspector NP Voltage thresholds Specification (manufacturer) [V] Measured [V] DuT DuT 2 p / f Remarks reg. start Cut-off End of charge voltage (floating) 3,8 3,76 3,80 p final voltage equalisation (gassing) 4,8 4,79 4,82 p Only if vented battery is selected. final voltage boost 4,4 4,35 4,40 p LVD Deep discharging cutoff voltage,50 p CC set to,5 V; mode = voltage Reconnect voltage load 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 2 Battery Lifetime Protection Tests 2.3 Temperature Compensation of the Set-points Ambient temperature see below C DuT Rated voltage 2,0 V Reference CXup_-phc-047 Inspector NP Voltage thresholds ambient temperature [ C] temp. comp [mv/k] / cell DuT End of charge voltage (float) [V] 25,0 C 3,76 3,80 Temp. C 40,5 40,5 3,38 3,36 4, 4,7 Equalization voltage [V] )2) Boost voltage [V] )2) Deep discharging cut-off voltage [V],50,52 Reconnect voltage [V] 2,78 2,70 ) PWM start 2) cut off Remarks 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 3 Energy Performance Tests 3. Self Consumption Tests Ambient temperature Rated voltage 24,5 C DuT 2,0 V Reference Inspector CXup_-phc-047 NP self consumption [ma] 4,0 3,9 3,8 3,7 3,6 3,5 3,4 3,3 3,2 Vbatt falling 3, 3,0 0,0,0 2,0 3,0 4,0 5,0 battery voltage [V] max. selfconsumption average selfconsumption DuT 3,52 0,2 V 3,49 ma Comment Used measurement equipment: Ibat: Ubat: Ta: Fluke 87 Maxim DS8S20 IEC requirements? If failed, reason? x passed failed /2

13 Measured data Nr. Batt. Volt. [V] Self consumpt. [ma] Self consumpt. [mw] DuT 2,6 3,47 43,7 2 2,0 3,48 4,8 3,4 3,49 39,8 4 0,8 3,50 37,8 5 0,2 3,52 35,9 Comment Deep discharge warning 2/2

14 3 Energy Performance Tests 3.2 Efficiency Tests Ambient temperature: 28,5 C DuT Rated voltage: Reference Rated max. charge current: 20,0 A Rated max. discharge current: 20,0 A Inspector: NP 2,0 V CXup_-phc Charging 0 % to 00 % rated charging current PV-Module Battery efficiency Vpv-Vbat DuT [V] [A] [W] [V] [A] [W] [%] [V] 3,239,95 25,8 3,207,95 25,8 99,8 0,032 3,305 4,04 53,8 3,259 4,04 53,6 99,7 0,046 3,323 6,53 87,0 3,259 6,53 86,6 99,5 0,064 3,370 8,02 07,2 3,295 8,02 06,6 99,4 0,075 3,333 0,6 4,5 3,239 0,6 40,5 99,3 0,094 3,380 2,0 6,9 3,276 2,0 60,6 99,2 0,04 3,440 3,99 88,0 3,322 3,99 86,4 99, 0,8 3,50 6,9 28,7 3,376 6,9 26,6 99,0 0,34 3,575 8,20 247, 3,425 8,20 244,3 98,9 0,50 3,647 20,39 278,3 3,479 20,39 274,8 98,8 0,68 99, Discharging 00 % rated load current Battery Load efficiency Vbat-Vload DuT [V] [A] [W] [V] [A] [W] [%] [V] 3,222 20,08 265,5 3,8 20,08 263,4 99,2 0,04 min. discharge efficiency [%]: Remarks: Used measurement equipment: Vbat: Ibat: Vpv: Ipv: Vload: Iload: Ta: Maxim DS8S20 IEC requirements? If failed, reason? x p f 3/2

15 Charge and discharge efficiencies Charge efficiency 00,0 0,80 efficiency [%] 99,8 99,6 99,4 99,2 99,0 98,8 0,60 0,40 0,20 0,00 0,080 0,060 0,040 0,020 deltau [V] DuT efficiency DuT deltau 98,6 0,000 0,0 5,0 0,0 5,0 20,0 25,0 charge current [A] 4/2

16 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: 20 A 20 A DuT Reference CXup_-phc-047 Inspector: NP 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] 3,3 20,5 3,2 0, 3, 20,4 45,2 45,0 5 3,3 20,5 3,2 0,2 3, 20,3 45,3 45, 0 3,2 20,6 3, 0, 3, 20,5 45,5 45,2 5 3,3 20,6 3,2 0, 3,0 20,5 45,5 45, 20 3,3 20,4 3,2 0, 3, 20,3 45,5 45,0 25 3,2 20,5 3, 0,0 3,0 20,5 45,6 45,2 30 3,3 20,6 3,2 0, 3, 20,5 45,4 45, 35 3,3 20,3 3,2 0, 3, 20,2 45,6 45,2 40 3,2 20,5 3, 0, 3,0 20,4 45,6 45, 45 3,3 20,5 3,2 0,2 3, 20,3 45,5 45,3 50 3,3 20,5 3,2 0, 3,0 20,4 45,6 45,2 55 3,2 20,5 3,2 0, 3, 20,4 45,6 45,3 60 3,2 20,5 3, 0, 3,0 20,4 45,7 45,3 Remarks: According manual:max.ambient currents is 45 C No problems occured during test. 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 4 Protection and Fail-Safe Tests 4.2 Overcurrent protection tests DuT Ambient temperature: see below C Rated voltage: Reference CXup_-phc-047 2,0 V Rated max. charge current: 20,0 A Rated max. discharge current 20,0 A Inspector: NP 4.2. PV overcurrent protection test time PV-module Battery Remark T heatsink T ambient DuT [min] [V] [A] [V] [A] [ C] [ C] 4,03 25,0 3,20 25,0 27,0 25,5 5 4,04 25,0 3,2 25,0 30,0 26,0 30 4,05 25, 3,2 25, --- 3,0 26,5 45 4,05 25, 3,20 25, 32,0 27,5 60 4,05 25, 3,20 25, 32,0 27, Load overcurrent protection test time Remark Battery Load T heatsink T ambient DuT [min] [V] [A] [V] [A] [ C] [ C] 2,05 25,2,9 25,2 28,0 27,5 5 2,04 25,2,90 25,2 29,0 27,5 5 2,03 25,2,9 25,2 30,5 28,0 30 2,02 25,3,9 25,3 3,0 28,5 45 2,02 25,3,9 25,3 32,0 29,0 60 2,0 25,3,9 25,3 33,0 30,0 No problems at all Used measurement equipment: Vbat: Ibat: Vpv: Ipv: Vload: Iload: Ta: Tc: Maxim DS8S20 Maxim DS8S20 IEC requirements? If failed, reason? x passed failed 6/2

18 4 Protection and Fail-Safe Tests 4.3 Protection Against Reversed Polarity and Short Circuits Ambient temperature Rated voltage 26,0 C DuT 2,0 V Reference Inspector CXup_-phc-047 NP Test Protection against short circuited PV ) Protection against reversed polarity PV Module Protection against short circuited load ) Behaviour / results DuT p/f remarks Vpv = 2,03 V p Ipv = 2,2 A Vpv = 22 V Vload = 2,0 V Iload = 2, A p p DuT didn't suffer any damage. DuT didn't suffer any damage. DuT didn't fed the reverse voltage to the load. DuT didn't suffer any damage. Operation with reversed polarity battery p DuT didn't suffer any damage. Buzzer alarm p/f: passed/failed ) Not mandatory according to IEC Remarks The charge controller is protected against short circuited PV, reversed polarity PV module, overload and reversed polarity battery. Used measurement equipment: Vbat: Ibat: Vpv: Ipv: Vload: Iload: Ta: Maxim DS8S20 IEC requirements? If failed, reason? x passed failed 7/2

19 4 Protection and Fail-Safe Tests 4.4 Battery Open Circuit Test Ambient temperature Rated voltage 25,3 C DuT 2,0 V Reference Inspector CXup_-phc-047 NP Test operating with disconnected battery Behaviour / results DuT didn't suffer any damage V load = 0,08 V p Passed/failed DuT removing battery during normal operation DuT didn't suffer any damage 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 5 User Interface Tests 5. Display Ambient temperature Rated voltage 25,3 DuT 2 V Reference Inspector CXup_-phc-047 NP DuT charging indication yes battery charged indication (charge status) yes load cut off warning battery discharged indication (load disconnection) yes /Buzzer yes / pictogram Remarks: Used measurement equipment: Vbat: Ibat: Vpv: Ipv: Vload: Iload: Ta: Maxim DS8S20 IEC requirements? If failed, reason? x p f 9/2

21 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- Zimmer LMG 95 Precision-wattmeter voltages, currents up to 40 A, power 42-DC-6 42-DC LI-5 Temperature sensors Maxim DS8S20 in combination with Arduino Mega datalogging 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 _Phocos_CXup_v5.xls /2