When a CPV manufacturer completes a design and assembly of a solar product, their work has just started. In order to properly get their product to market they must address the obstacle of certifying their product according to the regulatory requirements set by the installation site’s country and regional location.
The European standard for Concentrator Photovoltaic Modules and Assemblies, IEC 62108, for example, was recently published in 2007 and is in the process of adding a stronger emphasis on safety to its current performance emphasis. Meanwhile, the United States standard for Concentrator Photovoltaic Modules and Assemblies, UL 8703, is currently in the process of being published.
Unlocking the mysteries presented by the safety certification of CPV modules, especially for companies new to this type of process, requires a comprehensive understanding of the safety investigation required and this is where solar certification consulting companies, such as Solar Compliance LLC, step in to offer solar compliance assessment and solar certification project management to improve product time to market.
Typical CPV module safety investigations performed by certification laboratories can be summarised into the following stages: Preliminary Investigation, Construction Review¸ Test Program, Final Review, and Production Inspection.
1. Preliminary Investigation – A preliminary safety investigation involves the submittal of one CPV module sample (final production version is not typically required – a prototype will suffice) to the certification laboratory for examination and analysis. A certification engineer will provide a report, covering all findings of non-compliance as well as areas of concern which are likely to affect the safety certification investigation as well as an anticipated test program for the module system. The report will also identify key applicable standards for the module end product as well as any components within the end product, such as polymeric materials, tracker, wiring, connector, and printed wiring board standards. Key parameters are established during the Preliminary Investigation, including defining the module enclosure, establishing the module and component electrical and mechanical ratings, outdoor exposure considerations, etc. A preliminary investigation is not required by the certification laboratory (although it is highly recommended for a company submitting their product for the first time). This phase of the evaluation will provide a manufacturer with a comprehensive approach and strategy for the safety investigation.
2. Construction Review - The construction review phase is a more detailed version of the preliminary investigation in that final production samples are to be submitted to the certification laboratory for a comprehensive and detailed breakdown of all applicable end product and component requirements of the CPV module. A construction review report is then provided to the manufacturer to provide a comprehensive list of all non-compliant findings for both the end product and components of the CPV module. Consideration is given to not only the applicable end product requirements, but also how the component requirements relate to the end product. Understanding the component/end product relationship is one of the key concepts which will maximize the chances of success as well as avoiding any unwanted last minute surprises during the investigation. The anticipated test program will also then be solidified in the construction review report as well. This phase of the investigation is the most critical because it sets the tone for the entire investigation for it will become the foundation of the final review phase described in Item 4.
3. Test Program – The test program phase builds on the construction review by coordinating and executing the anticipated test program. Anticipated testing includes environmental chamber, outdoor, mechanical, electrical, and abnormal condition testing. In the event of non-compliant test results, consideration will be given to the construction changes employed on the unit to address the non-compliant issues as well as how the construction change(s) will affect the existing test program. If the construction change is deemed by the certification engineer to render the revised construction no longer representative of the version that was previously tested, additional repeated testing may be required. This is the reason why it is critical to ensure pre-testing is conducted, per the test requirements, prior to submitting the samples for testing to the certification laboratory.
4. Final Review – The final review phase builds on the momentum achieved by the construction review and test program phases by addressing all outstanding issues during the investigation. A descriptive report for the product is solidified in preparation for the Production Inspection described in Item 5. The traceability of the entire bill of materials is finalized. Traceability refers to the ability to establish a paper trail for all components and materials in the build of a product in order to document where all components come from and ensure the construction of the product does not change in a manner different from that of the originally tested construction. All additional applicable requirements (such as the instruction manual, marking, etc.) are also addressed in the final review phase. If all outstanding issues are proactively addressed throughout the investigation, the final review should be relatively straightforward.
5. Production Inspection – The production inspection phase is typically done after the completion of the first certification for the manufacturer. The inspection evaluates the manufacturer’s ability to build the product in a workmanlike manner per the descriptive report. Manufacturer production line tests (dielectric withstand, grounding continuity, input tests, etc.) are also conducted on the CPV module and applicable components. Upon successful completion of the Production Inspection, the product is allowed to bear the laboratory’s certification mark.
“The certification process is painstaking and time consuming, but with diligent and proactive preparation, it is a rewarding process,” says Kenny Villegas, President of Solar Compliance LLC, who provided this article. “There are other regulatory obstacles beyond the safety certification of a CPV module, such as preparing a permitting package for the installation site and environmental regulations, but successfully completing the safety certification of a CPV module will solve a key piece of the puzzle en route to driving a manufacturer’s CPV module to market”.
For additional information:
