TEST PROCEDURES FOR SHS COMPONENTS

Transcription

1 Renewable Energy Test Station (RETS) (Collaboration among NAST, AEPC, ESAP, SEMAN & NBSM) TEST PROCEDURES FOR SHS COMPONENTS September 2001 First Revision: December 2002

2 First Revision: December

3 A. Test Procedures for Lamps and Ballasts (CFL and TL) S. No. Test Parameters Technical Requirements Instruments Required Test Methods A. Compulsory L1 Luminous yield (Lumens Per Watt, LPW) Luminous yield of the total ballast and fluorescent lamp system must be at least 35 lumens/watt within 15 minutes warm up time after switching on Lumen sphere (Integrating Sphere) and its accessories, Power supply, Multimeters, PC 1. Mount Calibration lamp assembly in lumen sphere. 2. Choose the correct power supply (CLS-LS-1475) for the calibration lamp in the control unit. 3. Record the output of the calibration lamp (S) when auxiliary lamp is OFF and calibration lamp is ON. 4. Choose the correct power supply (CLS-LS-1475) in the control unit for the calibration lamp. 5. Record the output of the auxiliary lamp when calibration lamp is OFF (As) 6. Replace the calibration lamp by Test lamp 7. Let the test lamp burn in for maximum of 15 minutes at nominal voltage of 12 VDC with auxiliary lamp in OFF condition. Check for specific instruction of manufacturer for placement of the lamp in the lumen sphere, if any. 8. Maintain external DC power supply voltage at 12 V DC 9. Record current (I), voltage (V) and output of test lamp (T) 10. Choose the correct power supply for auxiliary lamp (HLS ) in the control unit with the test lamp in lumen sphere in OFF condition 11. Record the output of the auxiliary lamp (At) with the test lamp in lumen sphere in OFF condition 12. Compute the lumen output of the test lamp using formula Lt = Ls * (T/S) * (As/At) where Lt = Total Lumen output of the test lamp and Ls = Luminous flux of reference lamp 13. Compute Lumen Per Watt (LPW) as (Lt / I * V ) First Revision: December

4 L2 L3 L4 L5 Life time and reduction in lumen Ignition Capability Lamp (Ballast and Tube combined) efficiency Reverse Polarity Protection Reduction in the output (reference lumen) must not exceed 10% after 1000 on/off cycles and must not exceed 50% after 5000 on/off cycles Stable light within 10 seconds, no flickering, in the voltage range 10.3 to 15.0 V over temperature range of -5 º C to + 40º C Electrical efficiency of the Lamp (Ballast and Tube combined) must be at least 70% at 12 V. Lamp must be protected against reverse polarity (Normal operation after test) Lamp Cycle Test Board with counterrelay & Power Supply, Lumen Sphere and its accessories, Power Supply, Multimeter, PC Pyranometer, Picologger, PC, Power supply, Multimeter, Climate Chamber Multimeters, Power Supply, Power Analyzer Power Supply, Test leads 1. Mount lamp (s) in Life Cycle Test bench after initial lumen measurement 2. Set programmable counter for 2 minutes ON and 4 minutes OFF for 1000 cycle 3. Start cycling, while observing all lamps at least 4 times daily 4. Note time and character of any failures of lamp (s) 5. After 1000 cycles, test the lamp (s) by test sequence L1 and note the reduction in initial lumen 6. Reinstall lamp (s) and continue cycling test 7. Take down lamps after 5000 cycles, notice any malfunctions 8. Test lamp (s) by Test Sequence L1 and note the reduction in initial lumen after 5000 on / off cycles. 1. Mount lamp in climate chamber 2. Set temperature at 5 deg C and wait for stabilization, at least 30 minutes 3. Connect the circuit as in figure with Pyranometer and data logger 4. Set power supply voltage at 10.3 V and turn the lamp on 5. Record the chart thorough the data logger in PC and calculate ignition delay by graph 6. Repeat step 4 with voltage set at 12 and 15 V 7. Repeat step 2-6 with increase in temperature in steps of 15º C until 40º C 1. Connect adjustable Power Supply to lamp terminals at 12 V DC 2. Connect DC Ammeter and Voltmeter to the input supply 3. Connect Power Analyzer at output of ballast as per figure 4. Measure input DC power and output active AC power and calculate efficiency. 1. Connect the lamp to the power supply with zero voltage with reverse polarity 2. Increase the voltage to 12 V slowly 3. Test the lamp in normal operation L6 Standby Consumption ( no tube operation) must be less than 20% of rated or nominal capacity (power consumption) Power supply, Multimeters 1. Connect the lamp with Ammeter and Voltmeter with power supply. 2. Set the power supply voltage at 12 V DC 3. Remove the tube and measure current consumption at 12V 4. Calculate standby consumption in watt First Revision: December

5 L7 Minimum Information B. Recommended L8 DC Component L9 L10 Radio Frequency Interference Crest factor and Wave shape symmetry The following minimum information must be included in the label of the Lamp: Brand name and model, Solar PV company name, Nominal power in Watt, Permitted tube size (s) in Watt, Nominal Voltage in Volt, Size of fuse (s) in Ampere (if applicable) DC component should be zero (less or equal to the instruments uncertainty) Should not produce radio frequency interference greater than 50 mv/m within 2 meters of distance Crest Factor should be less than 2.0 and Wave shape should be symmetrical in both half cycle for input voltage 11 to 12.5V at an ambient temperature of 25 o C Visual Inspection Power analyzer, power supply and Multimeter EMC probe, RF signal meter Power Analyzer Power Supply, Multimeter, Oscilloscope Inspect visually for following parameters in the label of the lamp Brand Name and model Solar PV company name Nominal power in Watt Permitted tube size (s) in Watt Nominal Voltage in Volt Size of fuse (s) if applicable 1. Connect power supply to lamp terminals at 12.0 V DC 2. Connect power analyzer at output of ballast 3. Measure the DC component 1. Connect the probe to the Signal meter 2. Measure the background RF noise 3. Connect the lamp to the power supply at 2 m distance from RF receiver 4. Measure the RF interference 5. Calculate the deviation 1. Connect adjustable power supply to lamp terminals and set the voltage at 11 VDC 2. Connect power analyzer at output of ballast 3. Record rms, maximum and minimum peak value and calculate crest factor 4. Use Pico Scope to measure the area in each half cycle 5. Increase the voltage by 0.5 and repeat step 3 and 4 until input voltage of 12.5V L11 Good Workmanship Lamp enclosure (housing) should display good workmanship and should provide protection against dust, water, oil and smoke. Visual Inspection Inspect the lamp visually for protections against dust, water, oil and smoke First Revision: December

6 B. Test Procedures for Tube for Compact Fluorescent Lamp (CFL) or Tubular Lamp (TL) No. L1 Test Parameters As per SHS DC lamp and ballast (L1 to L6) Technical Requirements As per SHS DC lamp and ballast (L1 to L6) Instruments Required As per SHS DC lamp and ballast (L1 to L6) Test Methods As per SHS DC lamp and ballast (L1 to L6) C. Test Procedures For Lamps used in Solar Lantern No. L1 Test Parameters As per SHS DC lamp and ballast (L1 to L11) Technical Requirements As per SHS DC lamp (L1 to L11) Instruments Required As per SHS DC lamp (L1 to L11) As per SHS DC lamp (L1 to L11) Test Methods First Revision: December

7 D. Test Procedures for AC Lamps For ISPS No. Test Parameters Technical Requirements Instruments Required L1 As per SHS DC As per SHS DC lamp (L1, As per SHS DC lamp lamp (L1, L2, L6, L2, L6, L7, & L8) (L1, L2, L6, L7 & L8) L7, & L8) Test Methods As per SHS DC lamp (L1, L2, L6, & L8). Note that the power supply used is AC in place of DC. L2 Ignition Capability Stable light within 10 seconds, no flickering, in the voltage range 220V ±10% and frequency 50Hz ±2% Lux sensor, Picologger, PC, Power Supply, Multimeter, Climatic Chamber 1. Mount lamp in climate chamber 2. Set temperature at 5 o C and wait for stabilization, at least 30 minutes 3. Connect the circuit as fig. 2 with Pyranometer and data logger 4. Set power supply voltage at 220V AC 50Hz and turn the lamp on 5. Record the chart thorough the data logger in PC and calculate ignition delay by graph 6. Repeat step 4 with voltage set at 5V AC deviation 7. Repeat step 2-6 with increase in temperature in steps of 15 O C until 40 o C First Revision: December

8 E. Test Procedures for Charge Controller No. Test Items Technical Requirements Instruments Required A. Compulsory C1 Low Voltage LVD for flat plate Adjustable Power Disconnect battery must not be less Supply, Ammeter, (LVD) and than 11.8 V and for Voltmeter or Low Voltage tubular plate battery Oscilloscope, Reconnect (LVR) LVD must not be less Variable Resistor or function than 11.4 V and the Electronic load setting must be within ± 2% of the manufacturer s claim at 25 C LVR must not be less than 12.5 V and the setting must be within ± 2% of the manufacturer s claim at 25 C C2 High Voltage Disconnect (HVD) and High Voltage Reconnect (HVR) function HVD must be within range of 14 V to 14.8 V and the setting must be within ± 2% of the manufacturer s claim at 25 C HVR must be greater than 13.5 V and the setting must be within ± 2% of the manufacturer s claim at 25 C Power Supplies, Multimeters, Oscilloscope, resistor Test Methods 1. Adjust the DC power supply (battery simulator) output voltage at the nominal voltage of the battery i.e. 12 V. 2. Adjust the output current of the charge controller (Load current) to 50% of the rated value with the variable resistor (VR) or electronic load 3. Decrease the voltage of the DC power supply gradually till the controller switches off the load connection automatically by indicating zero current through the ammeter (A), and note down the corresponding voltage in the voltmeter (V). This voltage is the Low Voltage Disconnect (LVD). 4. Increase the voltage of the DC power supply gradually until the battery is connected to the load again as indicated by the current through the ammeter (A), and note down the corresponding voltage in the voltmeter (V). This is the Low Voltage Reconnect (LVR). Note: This test can give erroneous results in the case of certain advanced charge controllers, using current dependent or thresholds depending on SOC. In such a case, manufacturer (s) should provide the necessary information at the time of sampling. ON/OFF Charge Regulator 1. Adjust the voltage of DC power supply1 (Module simulator) to module open circuit voltage, and current to nominal charging current. 2. Adjust the electronic load at 50% of max. input current of charge controller 3. Adjust the voltage of the DC power supply2 (battery simulator) to the battery nominal voltage, and increase it gradually. 4. Note down the voltage at power supply2 when the charge controller switches off the connection between the PV input and battery input i.e. open circuit (or short-circuits the PV array for a shunt-type controller). 5. Lower the voltage of the DC power supply2 and the reconnect First Revision: December

9 voltage will be determined when the controller causes the PV input to be reconnected to the battery. Shunt PWM 1.Insert Ammeter and oscilloscope probe at power supply 1 (PV module simulator). 2. The oscilloscope will show voltage pulse waveform. The HVD value is obtained when the voltage at PV input stays constant at zero. 3. Note down the voltage at power supply2. This is the HVD value. 4. Reduce the voltage at power supply2. The High Voltage Reconnect (HVR) is obtained when the oscilloscope shows the voltage pulse waveform. 5. Note down the voltage at power supply2. This is the HVR value. Series PWM 1. Connect 1Ohm, 10W resistor in series connection from the power supply 1 (module simulator) and connect Oscilloscope probe across that resistor as depicted in figure 2. When it almost reaches HVD, the charging current indicated by the ammeter (A) will start to decrease and the oscilloscope will show voltage pulse waveform. The HVD value is obtained when the charging current is zero. 3. Reduce the voltage at power supply2. The High Voltage Reconnect (HVR) is obtained when the oscilloscope shows the voltage pulse waveform. 4. Note down the voltage at power supply2. This is the HVR value. Note: 1. Depending on the charge controller under test, a capacitor of at least 50 µf must be connected parallel to the output terminals of the power supply2 (battery simulator) 2. It is advisable to discuss the test set up and the actual tests with the manufacturer. This test set- up is suitable for many charge controller on the market, but some charge controllers need a slightly modified set up or a specific preparation C3 Usage of Electromagnetic relay Usage of Electromagnetic relay is not permitted Visual Inspection Inspect Visually First Revision: December

10 C4 Quiescent current consumption ( Stand-by consumption) must not exceed 7 ma at nominal system voltage while the non-critical indicators are turned off Power supply, Ammeter 1. Connect a variable power supply to the charge controller battery terminals with Ampere meter inserted in series as depicted in figure. 2. Set voltage of 10.5 V at power supply and note down the current drawn by charge controller while non-critical indicators are turned off. 3. Increase the voltage in steps of 0.5 V till 15 V and note down the current drawn by charge controller 4. Reduce the voltage in steps of 0.5 V from 15 V till 10.5 V and note down the current drawn by charge controller while all the noncritical indicators are turned off. 5. Take the average value of current drawn by charge controller at 12 V in 3 and 4. This is the quiescent current consumption of charge controller. C5 Voltage drop For 12 V systems, voltage drop across the charge controller while charging (PV panel to battery terminals) must not exceed 1V and while discharging (battery to load terminals) must not exceed 0.5 V. For 24 V systems, voltage drop across charge controller while charging must not exceed 2 V and while discharging must not exceed 1 V. For 48 V systems, voltage drop across charge controller must not exceed 4 V during charging and must not exceed 2 V during discharging. C6 Rated Capacity Must withstand 90% of rated current in charging and discharging side Power supply, Electronic Load, Multimeters, Climatic chamber, Power supplies, Battery, Load, Charging Side 1. Connect the PV input terminals of the charge controller to power supply. Set the current at power supply to maximum charging current of charge controller. 2. Connect the electronic load at battery terminals of charge controller. 3. Turn on load and power supply to full rating of charging current of charge controller 4. Measure the voltage drop between PV and Battery terminals of the charge controller Discharging Side: 5. Connect the battery input terminals of the charge controller to power supply 6. Connect the electronic load to the load terminals of the charge controller 7. Adjust the electronic load current to maximum load current of the charge controller. Measure the voltage drop between load and battery terminals of the charge controller Discharging Side: 1. Connect the power supply at battery terminals and electronic load at load terminals of charge controller First Revision: December

11 C7 C8 Protection against reverse polarity Reverse leakage current protection within the temperature range of -5 o C to 40 o C Normal operation after test Reverse leakage current should be less than 500 micro amperes Multimeters Multimeter, power supply, Rheostat Adjustable power supply, Multimeter and Rheostat 2. Connect the circuit as in figure. 3. Place the Charge controller inside climatic chamber and set the temperature of climate chamber at -5 o C and wait for stabilization, at least 30 minutes 4. Set load at 90% of rated capacity of charge controller 5. Continue the test for half an hour 6. Increase temperature in steps of 15 o and repeat the test up to 40 o C Charging Side: 7. Connect the power supply at PV terminals and electronic load at battery terminals of charge controller 8. Set the current at power supply to 90% of charging current of charge controller. 9. Continue the test for half an hour 1. Connect a source of voltage (V1) with reverse polarity to the module input terminals of charge controller 2. Connect a voltage source (V2) with correct polarity to the battery terminals of charge controller 3. Slowly increase the voltage of voltage source (V1) from zero to maximum permissible open circuit voltage of the PV module 4. Connect a source of voltage (V2) with reverse polarity to the battery terminals of charge controller 5. Connect a voltage source (V1) with correct polarity to the module input terminals of charge controller 6. Slowly increase voltage of (V2) from zero to battery nominal voltage 7. Connect a source of voltage (V1) with reverse polarity to the module input terminals of the charge controller 8. Connect a voltage source (V2) with reverse polarity to the battery terminals of the charge controller 9. Slowly increase voltage from zero to maximum permissible open circuit voltage of PV module and battery nominal voltage 10. Check for normal operation of the charge controller 1. Connect the circuit as given in the fig (power supply, voltmeter, ammeter and a rheostat) 2. Adjust the DC power supply at nominal voltage 3. Vary the value of rheostat from maximum to zero 4. Measure reverse leakage current from battery to module 5. Note maximum value of reverse current First Revision: December

12 C9 Minimum Information Charge controller must have following information: Brand Name, type (Series or Shunt On / Off or PWM) and model, Solar PV company name, Maximum input current in Ampere, Maximum load current in Ampere, Nominal voltage in volt, Size of fuse(s) in Ampere (if applicable),type of battery to be used Visual Inspection Inspect visually for following things in the label of the charge controller : Brand Name, type (Series or Shunt On / Off or PWM) and model, Solar PV company name, Maximum input current in Ampere, Maximum load current in Ampere, Nominal voltage in volt, Size of fuse(s) in Ampere (if applicable), Type of battery (Tubular or Flat Plate) to be used The type of charge controller according to battery type (flat plate or tubular plate) must be printed in front cover of the charge controller as part of its specifications B. Recommended C10 Radio-frequency Interference C11 Good workmanship and protection against dust water, oil and smoke The charge controller should not produce radio frequency interference greater than 50mV/m within 2 metres distance. Charge controller boxes should display good workmanship and should provide protection against dust, water, oil, and smoke EMC probe, RF signal meter Visual inspection 1. Connect the probe to the Signal meter 2. Measure the background RF noise 3. Connect the charge controller to the power supply with load at 2 m distance from RF receiver 4. Measure the RF noise again 5. Calculate the deviation 6. Repeat no 2 to 5 for different location at 2m radial distance and different current setting (charging/discharging) of charge controller Inspect the charge controller visually for protections against dust, water, oil, and smoke First Revision: December

13 G. Test Procedures for Deep Cycle Battery No. Test Items Technical Requirements Instruments Required A. Compulsory B1 Type of The battery must be deep cycle battery type either Vented or Sealed Lead Acid Battery B2 Capacity The deviation of battery capacity from its rated capacity stated by the manufacturer must not exceed the limit of -10% to +10% (minus 10% to plus 10%) within 5 cycles of test Power Supply, Electronic load, PC with data logger, Programmable Logical Controller (PLC), Multimeter, Water bath, Hydrometer, Temperature Probe (Thermocouple) Test Methods Visual inspection Vented (Flat Plate or Tubular) and Sealed (Flat Plate or Tubular) 1. Charge the battery to its full charge (100 % SOC) at the 5- hour rate or 10-hour rate or 20 hour rate current (in which rate the battery capacity is provided) or Charge the battery to its full charge (100% SOC) as per the manufacturer s instruction. The battery is considered fully charged when during charging at constant current, the observed terminal voltage stabilizes at a constant value at least for 10 minutes. 1. In case of Vented (flooded) battery. the specific gravity of the electrolyte is corrected to 25 C by using the relation SG 25 = SG t (t-25) where SG 25 = specific gravity at 25 C SG t = specific gravity at t C t = temperature of the electrolyte 2. Place the battery in a water bath maintained at 25 C 3. Set the upper and lower limit of the battery voltage corresponding to 100 % and 0 % SOC in the controller of battery test arrangement 4. Discharge the battery at the 5 hour rate or 10 hour rate or 20hour rate (in which rate the battery capacity is provided) until the battery terminal voltage reaches 10.8 V unless otherwise specified by the manufacturer. 5. Battery terminal voltage, temperature of electrolyte are logged using data logger and PC 6. Discharging current is kept constant using electronic load 7. Compute Capacity at 25 C using the following relation: First Revision: December

14 Capacity in Ah = discharging current (A) X discharging time (hr) 8. If the temperature during discharge differs from the reference temperature of 25 C, the measured capacity shall be corrected to 25 C by the application of the following formula: Ca = Ct / (1+ λ (t 25)) Ah Where Ca = actual capacity at the reference temp of 25 C Ct = measured capacity at average temperature t C The temperature coefficient of capacity shall be taken as unless otherwise specified by the manufacturer. 9. Repeat the test (1 to 8) for maximum of 5 cycles 10. If the capacity observed is within the range of technical requirement at any cycle before 5 th cycle, that value of capacity shall be taken as initial capacity (C) of the battery. Further test may not be carried out. B3 Self discharge rate Must be less than 4 % per month (30 days) at 25 C Power Supply, Electronic load, PC with data logger, Programmable Logical Controller (PLC), Multimeter, Water bath, Hydrometer, Environment Chamber 1. The battery which has satisfied the requirements of capacity test shall be tested for the self discharge rate test. 2. Fully recharge the battery to the 100% state of charge 3. Leave battery on open circuit for a period of one month (30 days) without disturbance at 25 C 4. Measure electrolytic density for each cell and battery voltage in every week 5. After 30 days, discharge the battery at 25 C at the 5 hour rate or 10 hour rate or 20 hour rate until the battery terminal voltage reaches 10.8 V unless otherwise specified by the manufacturer. 6. Compute the capacity after 30 days of storage on open circuit (C1) 7. Compute the self discharge rate per month using the relation S =( (C C1) / C ) X 100 % Where C = initial capacity of the battery 8. If the temperature during discharge differs from the reference temperature of 25 C, the measured capacity shall be corrected to 25 C by the application of the following formula: Ca = Ct / (1+ λ (t 25)) Ah First Revision: December

15 B4 Battery life cycle Flat Plate 1. The operational life cycle of 12 V or 6 V battery must be at least 1,800 cycles at 20% DoD and 250 cycles at 80% DoD. 2. The operational life cycle of 2 V battery must be at least 3,000 cycles at 20% DoD and 1,000 cycles at 80% DoD. Tubular 1. The operational life cycle of 12 V or 6 V battery must be at least 3,000 cycles at 20% DoD and 1,000 cycles at 80% DoD. 2. The operational life cycle of 2 V battery must be at least 3,600 cycles at 20% DoD and 1,200 cycles at 80% DoD. Battery test arrangement with controller, load, power supply data logger, environment chamber, hydrometer and PC 1. The battery which has satisfied the requirements of capacity test shall be tested for the life cycle test 2. Charge the battery to 100% SOC as in B2 or as per the manufacturer s instruction 3. Set the upper and lower limit of the battery voltage corresponding to 80% and 0% DOD in the controller of battery life cycle tester 4. Place the battery in the water bath 5. Perform the test for required no of cycles 6. Follow the accelerated test, if required B5 Minimum Information The following minimum information must be included in the label of the battery: Brand and name of the manufacturer, Model and type, Rated capacity in Ampere-hours at the discharge rate C 20 or C 10 or C 5, Nominal voltage in Volt Visual Inspection Inspect visually for following things in the label of the battery: Brand and name of the manufacturer, Model and type, Rated capacity in Ampere-hours at the discharge rate C 20 or C 10 or C 5, Nominal voltage in Volt Recommended B6 Amount of Electrolyte B7 Electrolyte density Should exceed t 1.15 l per 100 Ah nominal capacity at C 20 Should not exceed 1.25 g/cl at 25 C Measuring Flask, Funnel Hydrometer 1. Take an unfilled battery 2. Fill the battery cell with water 3. Measure the content of cell with measurement flask 1. Charge battery to 100% SOC according to B2 or the manufacturer s instruction 2. Measure the electrolyte density by hydrometer B8 Protection Battery should have terminal caps Visual Inspection Inspect visually for the provision of protection against short First Revision: December

16 against short circuit to protect battery terminals from short circuit B9 Battery acid Should be certified according to NS standard B10 Battery water Should be certified according to NS standard Visual Inspection Visual Inspection circuiting of battery terminals Inspect the certificate of battery acid for NS standard Inspect the certificate of battery water for NS standard H. Test Procedures for PV modules No. Test Items Technical Requirements Instruments Required P1 IEC or Crystalline module must have IEC- Visual Inspection equivalent and Thin film must have certificate for IEC or equivalent national, Design regional or international standards Qualification and Type Approval P2 Minimum Information Name plate must be mounted on the PV Module containing the following details: Brand and Name of manufacturer, model, Manufacturers serial number, Maximum power in Watt peak, Open circuit voltage in Volt, Short circuit current in Ampere, Maximum rated voltage in Volt, Maximum rated current in Ampere Visual Inspection Test Methods Check the IEC or equivalent national, regional or international certification of the type of module Inspect visually the name plate mounted on PV module for following things: Brand and Name of manufacturer, model, Manufacturers serial number, Maximum power in Watt peak, Open circuit voltage in Volt, Short circuit current in Ampere, Maximum rated voltage in Volt, Maximum rated current in Ampere First Revision: December

17 P3 Electrical performance The deviation of maximum power from its nominal value stated by the manufacturer must not exceed the limit of -10 to + 20% (minus 10% to plus 20%) at STC The maximum rated voltage must be at least 16 V at STC P4 Bypass diodes The PV module of size 40 W p or above must have inbuilt bypass diodes. The modules of any rating to be used for ISPS and PVPS applications must have bypass diodes P5 Warranty Period The warranty period of solar PV module must be at least 10 years against maximum 10% reduction in output power at STC PVPM curve tracer ( Module Tester) Visual Inspection in junction box Visual Inspection 1. Mount reference PV module and reference sensor in the same plane of orientation facing the sun 2. Mount electrical wiring from module to PV tester 3. Wait at least 5 minutes for temperature stabilization 4. Run the PV-tester 5. Replace reference PV module by PV module to be tested 6. Repeat test from 1 to 4 7. If irradiance is less than 500 W/m2 reject the result 8. Transfer data to PC for printout of results 9. Compute the deviation of the parameters measured at STC. Visually inspect for bypass diode in junction box Check the certificate or document provided. First Revision: December

18 Annex-1 Block Diagrams for Tests Figure 1: Luminous Yield Test DC Power Supply A V Lamp Lumen Sphere Light Sensor Display Figure 2: Ignition Capability Test Circuit Data-logger with Display Pyranometer Lamp DC Power Supply

19 Figure 3: Electrical Efficiency of Lamp (ballast and tube combined) Test V DC Power Supply A Ballast Power Analyzer Tube Fig 4: Standby Consumption test of the lamp + Lamp A V + DC Power Supply First Revision: December

20 Figure 5: Low Voltage Disconnection and Reconnection Function Test Charge Controller SPV Battery Load V Load A Battery Simulator (DC Power Supply) First Revision: December

21 Figure 6: HVD Disconnection And Reconnection Functions Test Charge Controller SPV Battery Load r A R Oscilloscope For PWM Analysis C Load PV Module Simulator (DC Power Supply 1) V Battery Simulator (DC Power Supply 2) Figure 5: Quiescent Current Consumption (Standby Consumption Test) Charge Controller SPV Battery Load Dark Panel Simulator A Adjustable DC Power Supply First Revision: December

22 Figure 6a: Voltage Drop Test (Charging Side i.e. from Panel to Battery) Charge Controller SPV Battery Load V V Module Simulator Load Figure 6b: Voltage Drop Test (Discharging Side i. e. from Battery to Load) Charge Controller SPV Battery Load V V Power Supply Load First Revision: December

23 Figure 7: Reverse Leakage Test Adjustable Voltage Source A Potentiometer SPV Battery Load Charge Controller First Revision: December

24 Figure 8: Battery Test Assembly Timer and battery Status sensing circuit Recording Unit Data logger and PC Power Supply (Charger) Junction Box Electronic Load Battery First Revision: December

25 A. Sampling 1.1 Sampling Procedure Sampling shall be done on lot wise basis. Samples of every lot shall be tested as per standard The manufacturer will provide written information about quantity of products, brand, type, model, serial number etc. and appearance of the products in a lot to be tested When satisfied with the check, RETS will randomly select the samples from the lot in case of Random Sampling. In case of Product Introduction Test (PIT), the manufacturer should submit at least one sample to RETS There must be minimum of 25 and maximum of 1000 populations in a lot size for random sampling test There must be proper label as per revised NIPQA: 2005 in the samples Manufacturer / supplier must submit the IEC certificate, Warranty of PV modules and duly filled reception form at the time of sampling After the agreement signed between the manufacturer/supplier and RETS, these samples will be taken to the testing institution (RETS) The lot size, sample size and acceptable defective number of samples shall be as given in the table below: Lot Size, Sample Size and Acceptable Defective Number Table Lot Size Sample Size Acceptable Defectives Number B. Compliance with NIPQA Standard 2005 All the samples shall be subjected to whole of the test criteria as per NIPQA All samples must fulfil all the mandatory requirements of NIPQA for the samples to be compliance with NIPQA. However, the acceptable defective number of samples for a given lot size is as depicted in the table. C. Test Schedule for Random Sampling Test S. No. Component Maximum Time Required 1 PV Module 10 days 2 Charge controller 14 days 3 Lamp 45 days 4 Battery 60 days First Revision: December

26 D. Test Schedule for Product Introduction Test S. No. Component Maximum Time Required 1 PV Module 5 days 2 Charge controller 7 days 3 Lamp 30 days 4 Battery 20 days Note: 1. The above time schedule is for testing, data analysis and report submission. 2. If the products to be tested are already in queue, the time required increases accordingly 3. First preference is given to Product Introduction Test (PIT). 4. Preference will be given to SEMAN members paying test fee on subsidy based SHS. 5. Actual time schedule for each testing and reporting will be given at the time of sample collection. First Revision: December