Inspection ,Testing and

Certification of PV Power
Plants.

Nearly 140 Years of Innovation. TUV (Technical

Uberwachungs Verein )
Your advantage: our experience.
1872

1957

2009

Entrepreneurs take the initiative

and set up the DV to ensure the
safety of their manufacturing plants

Commitment to environmental
protection: dust register in Cologne

Worlds largest
photovoltaic lab

2006

1918
Activities in the energy
and mining sectors

Joined the
UN Global Compact

1926

1975

First material analysis

laboratory

Medical work

1900

1969

2007

Vehicle inspection and driving

license tests

International product
tests and certifications

Represented on all
continents

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At Home on All Continents.

220 offices in Germany more than

500 locations in 61 countries.

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Sales by Business streams.

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TUVR Services for Safety Of Power Plant

TV Rheinland has the expertise of testing PV modules, having been in the
solar business for over 30 years. It has a market share over 70 percent, and
has seven PV labs spread across Germany, China, Taiwan, US, Japan (two labs),
and now, India. Its testing focus is on safety, efficiency, quality and durability of
solar systems. TV Rheinlands test laboratory in Electronics City, Bangalore, is
spread over an area of 20,000sqft., including 5,000sqft. outside exposure
testing area. We have invested close to $3 million in setting up the lab,

PV Lab Service

PV modules testing as per

IEC 61730
IEC 61215
IEC 61646
UL 1703

PV Power Plant Service

Grid connected PV System Testing

& Verification IEC/EVS EN 62446
Owner Engineer Service
Lenders Engineer Service

TUV R Services For Safety and

Quality

IEC 61730
IEC 61730: Photo Voltaic

Part 1: Requirement of Construction

Part 2 : Requirement for Testing

Testing in Lab
Visual test
Accessibility test
Cut Susceptibility Test
Ground continuity Test
Impulse Voltage Test
Dielectric With Stand Test
Temperature Test
Reverse Current overload test
Module breakage test
Fire test

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Module (PV) Safety Qualification

Photovoltaic Module Safety Qualification IEC 61730 ed1 2004

Visual
inspection

Performance test
(IEC 61215, IEC 61646
Component tests

Fire
test

Module
breakage test

Dielectric
withstand test

Bypass diode
thermal test

Ground
continuity test

Temperature
test

Accessibility
test

Reverse current
overload test

foil

Partial
discharge test

Test Sequences
Precondition: compliance with
IEC 61215 (ed2 2005), IEC 61646
Cut susceptibility tests

Impulse
voltage test

Accessibility
test
Visual inspection
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junction
box

Conduit
bending test
Terminal box
knock out test

Fire Test
Spread of Flame Test
For Roof top PV Solar as per A,B and C
Class
For A&B class burner rating 325KW and time
period of 10 min
For C class burner rating 325 KW and time
period of 4min
Result : No glowing or burning parts of PV
module fall on test rig
Flame spread not to exceed Class A
1.2M,Class B 2.4M and Class C 3.9M

Burning Brand Test

As per class A or B or C different mass of
wooden brands between( 10 to 2000gms) are
ignited to test if external fires causes PV
modules to burn.

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Photovoltaic Module Safety Qualification IEC 61730 ed1 2004

Module breakage test

The impactor bag, filled with lead shot,

weighs approximately 45,5 kg and will be
capable of delivering 542 J of kinetic
energy when swung through a 1,2 m
vertical drop.
The bag is dropped sequentially from a
height of 300 mm, 450mm and 1220mm
from the surface of the module, if no
breakage occurs before.
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Photovoltaic Module Safety Qualification IEC 61730 ed1 2004

Cut test:
A blade with a definite weight is moved
over the back side foil of the PV-module..

..subsequently the impairment

of the insulation is measured.
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Photovoltaic Module Safety Qualification IEC 61730 ed1

2004
Impulse voltage test and high voltage test:
The PV-module is enfolded with a copper foil.
Impulse voltage : 8000 V
High voltage : 4 x nominal system voltage + 2000 V

Possible defects:
Disruptive discharge from live parts of the PVmodule to the outer copper foil.

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Photovoltaic Module Safety Qualification IEC 61730 ed1

2004
Terminal box knockout tests:

a force of 44,5 N is applied to the

knockout of the terminal box for 1 min.
after 1 hour the displacement between
the knockout and the box shall be less
than 0,75mm
a removed knockout shall not leave sharp
edges or cause damage to the box

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Hail Impact test

Hail impact test: The PV - module must withstand the impact
of hail stones (weight: 7.5g, size: 2.5cm in diameter) at a
speed of approx. 82 km/h damage free.

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PID Potentially Induced Degradation (IEC 62804 Draft)

PID is loss of system power caused due to leakage current at higher voltages.
Performance loss can be high as 20%
Caused by temperature and relative air humidity
To make modules anti PID cell design changes is required in ARC, Cell metallization,
emitter design and doping.
Testing at 60deg C,85% RH ,1000 V for 96hrs degradation of power output between
initial and final out put should be less than 5%

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TCO - Corrosion
Caused at edges especially in Thin film modules by reaction of moisture and sodium
present in the glass
Modules with cells made of a-Si and CdTe with superstrate technology are affected the
most
Happens in high temp and high humidity conditions
TCO becomes milky and losses its conducting property and thereby efficiency of module

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Risks at PV Power plant systems

For costumer/operator (Banks, investors, insurances, etc..) AND for Installers/distributors
- Economic risks
- Delivery delay
- Low performance
- Defects and loss of energy yield
- High costs for maintenance, repair or replacement
- Theft, vandalism
- At building integrated PV installations: negative effects on or damage of the structure
of the building
- Safety risks
- Electric shock
- Fire
- Statics
- Danger of falling
- Common accident danger
- Environmental risks
- Storm
- Lightning impacts
- Snow, ice
- Hail
- Rock fall, landslide, earthquake, flooding
- Weather during installation

PV Power plant testing & verification EVS- EN 62446 2010

IEC/EVS EN 62446 Grid connected photovoltaic systems Minimum requirements
for system documentation, commissioning tests and inspection

1 ) System Documentation
2) Verification as per IEC 60364-6
- Normative references for the above standard:
IEC 60364 (all parts) - Low-voltage electrical installations
IEC 60364-6 - Low-voltage electrical installation Part 6: Verification
IEC60364 7 712 - Electrical installations of buildings Requirements for
special installations or locations Solar Photovoltaic (PV) power supply systems

IEC/TR 60755 General requirements for requirements for residual current

operated protective devices

IEC 61557 (all parts) Electrical safety in low voltage distribution system up to
1000 V AC and 1500 V DC Equipment for testing, measuring or monitoring of
protective measures

IEC 61730 1 Photovoltaic (PV) module safety qualification Part 1:

Requirements for construction
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PV Power plant testing & verification IEC/EVS EN62446

Testing Equipments

1. IV curve tracer

2. Insulation resistance
tester

3. Voltmeter
4. Clamp meter

3
5

5. Switches
6. Infrared Camera
4

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PV Power plant testing & verification IEC/EVS EN62446

String IV curve
measurement
Insulation Resistance
testing

Current, voltage
measurement of the
string

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PV Power plant testing & verification IEC/EVS EN62446

Thermograph
images taken from
IR camera

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Defects that leads to failure

Thermograph images

Module JB failure due to

higher temperature rise at
the interconnection inside
the JB.

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Defects that leads to failure

Thermograph Images
Temperature rise at the
interconnection inside
the JB due to lose
connection/improper
crimping of the wire

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Defects that leads to failure

Thermograph images

Hot Spot on the

module due to
shading by the
lightning
arrestor

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EL Image

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Corrosion on Frame

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Examples of Failures

Melting of the JB from inside

due to high temperature at
the interconnection

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Junction Box failure

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Junction Box and Module Failures

Module failure due to arching

EVA Discolouration

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Observed defects in the field

Bad quality modules

Delaminating

Arcing effect Structure failure

between the cells

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Module Failure ( Thin Film )

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Defects that leads to failure

Broken module
By the vehicle
Movement in the site

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Defects that leads to failure

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Structure Failures

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OSHA Standard ( Green Job Hazard)

OSHA has many standards that cover them.
Falls
Lockout/Tagout
Crane and Hoist Safety
Electrical
Heat/Cold Stress
Personal Protective Equipment

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IV curve characteristics of the string

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Overview Solar Power Plant

Solar thermal power plants
- Parabolic trough type
- Power tower concept

- Dish sterling type

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Solar PV Power Plant Site Layouts

Solar PV Power Plant Site Layouts

Site visuals

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Transformer, substation and switchyard visuals

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Accreditation for Type and Component Certification for On

shore and Offshore wind turbine

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Thank you for your attention

B.S.Arun Kumar
TV Rheinland India Pvt. Ltd.,
Industrial Services
# 17B, Electronics City, Phase II, Industrial Area, Begur Hobli,
Bangalore 560 100
Tel. # +91 80 30554337; Fax. # + 91 80 3055 4342; M # + 91 9620288804
E-Mail: arunkumar.bs.@ind.tuv.com
www.ind.tuv.com