Solar Power World

Follow these seven tips to ensure that your new product designs for the photovoltaic industry meet certification standards so that you can get to market fast.

You won’t be able to sell that new PV module into certain countries and regions around the world if it does not meet specific certification standards. As more companies seek proof of certification, the wait time is increasing at accredited testing labs. You can significantly reduce certification delays by making smart choices early in the design of the products.
1: Start Early

Begin certifying a new PV module before its design is complete. Identify your potential geo-graphic target markets as soon as possible. Different countries around the world and regions or states within those countries, such as the U.S., have their own requirements.

Generally speaking, however, you will want your modules to satisfy two major routes – ANSI/UL for the U.S. and Canada and CB Scheme for the EU, parts of Asia (including China and India), and other countries that participate in the program. Knowing early in the module design process which standards must be met will save time during the certification.

2: Only Use Certified Components

Each component that goes into the finished module – from wiring to adhesives – must comply with certain standards. These standards can be different in North America, the EU, and Asia, so make sure the components you select meet the requirements of your target markets. While in some cases it is relatively easy to test an unapproved component for its intended application or use, such as with encapsulants and backsheets, using materials with the correct certifications is always an easier route.

Most component manufacturers have their products certified, but some don’t. We at Intertek (an accredited testing lab) have found that one of the most frequent causes of module non-compliance is the use of components that aren’t properly certified. Labs that perform design reviews (see step #4) help ensure that you only select components and materials that are certified and rated properly for the application in the PV module.

Some module components that require certification include:

· PV connectors
· PV junction box
· Leads
· PV polymeric materials such as substrates, encapsulants, adhesives and sealants

3: Select the Right Lab

Select a testing lab that is accredited to certify modules in the markets of interest. You can gain access to more than 40 countries after completing one set of tests. The use of a lab can cut certification time down to as little as one-third what it can be when using multiple labs in different countries. These labs achieve the savings in time by designing a test plan that takes advantage of the overlap between the different crediting standards so that fewer tests need to be done. Such labs are accredited to certify modules under both of the major routes (ANSI/UL and CB Scheme). The accrediting body for ANSI/UL is OSHA and the accrediting body for CB Scheme is the IECEE.

It is also important that the selected lab has expertise in PV technology. The current certification requirements are generic and written for existing PV technology, but many manufacturers are looking to certify modules with innovative technology that is unlike any previously on the market. That means new module technology might not fit neatly into the requirements of the current standards. A lab with PV expertise is better equipped to develop the right test plan and apply generic requirements to the new technology.

4: Do a Design Review

Engage a lab for a design review. During this review, lab technicians’ experience will help ensure that materials and electrical components are certified in the desired geographic markets, that components have the necessary rating and proper spacing between electrical equipment, that materials are compatible, that framing is properly grounded, and can help develop satisfactory installation instructions. By working with a lab in a design review, problems are identified early and the eventual certification testing can move more quickly.

5: Develop a Smart Test Plan

A smart test plan will save time and money. The test sequences for safety and performance in the two major routes have some overlap, so a lab with both accreditations can conduct the certifications concurrently. Where there is overlap, the lab will pick the more stringent requirement and, with one test, satisfy both.

6: Take Advantage of your lab

Most major labs allow for what is called a “data acceptance program.” Under such a program, some testing done at your internal lab can be used toward certification.
Because many of you are using innovative technology, your in-house staff may have more intimate knowledge about it than outside labs. You can take advantage of your internal expertise by doing some of your own testing and developing justifications for why some testing should be done differently than conventional methods. By joining and taking advantage of these data acceptance programs these modified test plans could be used to do the testing and the data could be used for certification. At Intertek, we refer to it as the “Satellite Program”.

7: Retest only what is Necessary

Modifications to standard compliant components can invalidate the components’ certification and require re-testing. The IECEE has published retesting guidelines that most labs have adopted, and in certain cases modified to accommodate certain standards. In some cases, the retesting guidelines require modified modules to be completely recertified, but in other instances only limited tests need to be redone. If you are aware of the retest guidelines for any modified components, you can design so as to modify and retest as little as necessary.
The PV industry has been growing fast in recent years, and module manufacturers are constantly making advances in the technology. Certification can take months, but you can take steps that will ensure your products are certified as quickly as possible.
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Relevant ANSI/UL Standards
The following standards are for the U.S. only, however Canada has similar requirements.
• UL 1703: Standard for flat-plate PV modules and panels
• UL 790: Standard for standard test methods for fire test of roof coverage
• AC 365: Standard for building-integrated PV modules (BIPV)

Individual U.S. State Requirements
• California: California Energy Commission (CEC)
• Florida: Florida State Energy Center (FSEC) and county specific building requirements.
Other states are in the process of adopting individual requirements.

Relevant CB Scheme Standards (Europe, parts of Asia and other countries)
• IEC 61730: Standard for PV module safety
• Part 1: requirements for construction
• Part 2: requirements for testing
• IEC 61215: Standard for crystalline silicon terrestrial PV modules
• IEC 61646: Standard for thin-film terrestrial PV modules
• IEC 60904-X: Standard for PV devices (measurement procedures and requirements)

Intertek
www.intertek.com