PERFORMANCE IP, Workshop BIPV

30 October 2008, Nice, France

Fire Tests and Fire Risks

Ulrike Jahn

TÜV Rheinland Group

Renewable Energies
51101 Cologne, Germany
Phone: + 49 221 806 22 32
Email: ulrike.jahn@de.tuv.com
Outline

Safety Standards for PV Modules

International Standards for Building Products

New Test Procedures for BIPV

Fire Hazard due to Arcing

Assessments of Fire Risks

Methods for Risk Minimization

Summary
Safety Standards for PV Modules
Safety qualification testing acc. to IEC 61730-2

Preconditioning
IEC 61215 Ed. 2, IEC 61646

Fire Glass High voltage Component

test breakage test test tests

Ground Temperature backsheet

continuity test junction
box
Accessibility Reverse current Partial
test overload discharge

Preconditioning Conduit
IEC 61215 Ed. 2, IEC 61646 bending

Cut Impulse voltage Knock out

test test test

Accessibility
test
Tests with relevance for
Visual inspection
building construction

3
Safety Standards for PV Modules
Safety qualification testing

IEC 61730 was published in October 2005:

IEC 61730-1: Photovoltaic (PV) module safety qualification −
Requirements for construction
IEC 61730-2: Photovoltaic (PV) module safety qualification −
Requirements for testing

IEC 61730 combines “European” Safety Class II requirements and safety

requirements from UL 1703.

4
Safety Standards for PV Modules
Safety qualification testing

Test MST23: Fire Test (UL 790)

Purpose: To indicate the fire-resistance characteristics of PV modules
when exposed to a fire source originating from outside the building on
which they are installed…
Two different tests are described:

Burning brand test

Spread of flame test (gas flame is applied to the module)

NOTE: It is the intention of IEC Technical Committee 82 to use

international standards, such as ISO 834, for fire resistance testing of
PV modules. Until this standard is available, the tests described here
will be required as minimum safety qualification.

Test has been cut off from EN IEC 61730-2.

5
Safety Standards for PV Modules
Safety qualification testing acc. to EN IEC 61730-2

Preconditioning
IEC 61215 Ed. 2, IEC 61646

Fire Glass High voltage Component

test breakage test test tests

Ground Temperature backsheet

continuity test junction
box
Accessibility Reverse current Partial
test overload discharge

Preconditioning Conduit
IEC 61215 Ed. 2, IEC 61646 bending

Cut Impulse voltage Knock out

test test test

Accessibility
test
Tests with relevance for
Visual inspection
building construction

6
International Standards for Building Products
Test procedures for BIPV

Test procedures for characterisation of fire behaviour are divided into:

Fire behaviour of building products. The fire tests below are supporting
standards under the Construction Products Directive (CPD):
EN ISO 9239-1:2002 Reaction to fire tests. Horizontal surface spread of flame on floor-
covering systems – Determination of the burning behaviour using a radiant heat source
EN ISO 1716:2002 Reaction to fire tests for building products – Determination of the heat
combustions
EN ISO 11925-2:2002 Reaction to fire tests. Ignitability of building products subjected to direct
impingement of flame – Single-flame source test
EN ISO 1182:2002 Reaction to fire tests for building products – Non-combustibility test
EN 13823:2002 Reaction to fire tests for building products – Building products excluding
floorings exposed to the thermal attack by a single burning item

Fire resistance of components:

EN 1366:1999 Fire resistance tests on service installations

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International Standards for Building Products
Test procedures for fire behaviour

EN ISO 13501-5:2005 Fire classification of construction products and

building elements - Part 5: Classification using data from external fire
exposure to roofs tests

non-flammable

flame-resistant

normal flammable

highly inflammable

fire gases

draining of burning parts

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 Test Procedures for PV Building Products
Fire tests – Fire resistance tests

Fire test methods

(ENV 1187)

Single basket test

Fire resistant test

Fire spread test

Source: MPA Stuttgart (Material Testing Institute)

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Fire Hazards due to Arcing
Electrical arcs in PV modules
Investigations on Electric Arcing in PV Module
Willi Vaaßen, Jan Zornikau, TÜV Rheinland Group

Bus bar
Frame
Solar Cell
Back Sheet Foil String Connector

EVA Clamp

Glass Junction Box

Cable
 Investigations on Arcing in PV Modules
What causes electrical arcs or fires?

Direct electrical arc

When a direct current circuit is opened in the
• cell interconnects within the module
• junction box connectors
• plug-in connectors
• switches, inverter connection

Pre-requisite: sufficient current-voltage combination

55,0°C

50

SP01 40

30

20
20,0°C
Investigations on Arcing in PV Modules
What causes electrical arcs or fires?

Indirectly resulting electrical arcs (ignition, combustion)

Through significant increase in resistance, heating of the surrounding

materials until ignition temperature is reached.
Electric Arc Investigations
Circuits and voltages at electrical arc ignition when opening the electric circuit

Arc ignition
Lichtbogenzündung
No ignition
keine Lichtbogenzündung
I [A] Ignition limit
Zündgrenze
15
14
13
12
11
10
9
8
7 Arc
6
5
4
3
2
1
0
0 50 100 150 200 U [V] 250
 Electric arc investigations
Maximum electric arc length in dependence of voltage and current

30 V (25,1 V;27,7 V; 28,4 V)

Electric arc length d 100 V (97; 103,8; 106,6; 109,8; 106,3 V)
[mm] 220 V (198; 216; 224,6; 233,8 V)
25,00

20,00

15,00

10,00
15 mm

5,00

0,00
0,0 2,0 4,0 6,0 8,0 10,0 12,0 14,0
Current I [A]
Electrical arc investigations
Electrical arcs in junction boxes

Duration of electrical arc approx. 1 min

Duration of electrical arc approx. 1s

Risk Assessment
Probability and danger of electrical arcs

Connection: cell - cell:

Probability: very low, because two or three junctions must be damaged.
No punctual solder point.
Danger: high, because long-burning electrical arcs could occur.
Connection: cell – string connector:
Probability: low, because two or three connections exist. Small solder
joints. Systematic failures possible.
Danger: high, because long-burning electrical arcs could occur.
Risk Assessment
Probability and danger of electric arcs

Connection: string connector – clamp:

Probability: moderate. Very thin connection. Can easily break by
movement. Only one connection.
Danger: minor, because electrical arc extinguishes very fast
depending on construction.
Connection: clamp – connection line:
Probability: moderate. Due long time corrosion or lax connection.
Only one connection.
Danger: High, because long-burning electrical arc can arise.
 Assessment of Arc Risks
Different interconnects of PV modules

Interconnect Probability X
Danger =
Risk

Cell – cell 1 3 3
Cell – string
2 3 6
connector
String connector -
2 1 2
clamp
Clamp – cable 2 3 6

Average 1.8 2.5 4.4

Summary of electrical arc risks of different interconnects:
assessment: 1 = very low; 2 = moderate; 3 = high.
 Risk Assessment Measures

Risk analysis relating to each connection point

Principle analyses

• Secondary risk is dependent on the arc power x reaction time

• Arc power results from current-voltage combination
• Reaction time (arc lifetime) is determined from the
fault location (burn-out of the contact point) as well as mass,
conductivity and flammability of the ambient materials

Analyses of the impacts of electrical arcs

• Ignition, combustion of product (e.g. PV module) materials

• Ignition, combustion of ambient materials
• Dripping, hot or burning material
• Sparks
• Flaking and displacement of glowing or hot parts
Assessments of Fire Risks
Secondary risks in various system configurations

Type of Secondary risk Fire risk Building authority

system assessment relevant (in Germany)
BIPV facade Domestic fire High yes (general building authority
approval by DIBT)

BIPV roof Domestic fire High yes (general building authority

testing “Fire Rated Roofing”
acc. to Building Rules List A

Elevated Low No
flat roof Fire risk only in
individual cases
Elevated Low No
sloping roof
Ground- Risk of large-scale Low No
mounted fire in single cases
 Summary
Risk minimisation measures

1. As applicable constructive modifications, introduction of

new constructive requirements (design, material
flammability etc.)
Product

2. Quality assurance measures (also tests) during production

3. Development and introduction of new qualification tests

(electrical arc tests, material flammability)

4. Regular system inspections

System

5. Electronic electrical arc detection

6. As applicable restrictive installation specifications at BIPV

and/or fire-safe sub-construction