Renewable Energy Test Station (RETS) TEST PROCEDURES FOR SOLAR TUKI

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1 Renewable Energy Test Station (RETS) TEST PROCEDURES FOR SOLAR TUKI March 2007

2 A. Test Procedures for Solar Tuki Lamp S. No. Test Parameters Technical Requirements Instruments Required Test Methods A. SOLAR TUKI LAMPS L1 Type of LEDS and their number The Lights must be White LEDs cluster and each cluster must consist of twelve identical high intensity (2000 mcd, milky diffused ) WLEDs. These lamps must include reflector and cover L2 Viewing angle A viewing angle of each WLEDs must be equal or greater than 2*25 o L3 Luminous efficiency The luminous efficiency of WLEDs cluster must not be less than 20 Lumen/watt. Visual observation 1. See the technical specification of WLED supplied by the manufacturer 2. Count the number of WLEDS in the Solar Tuki Lamp Sets. Visual inspection WLED Specification Lumen sphere specific for WLED measurement (Integrating Sphere) and its accessories, Power supply, Multimeters, PC See the technical specification supplied by the manufacturer of White LEDs used in Solar Tuki Lamp Sets. Testing facility not available at RETS Lab currently. L4 Lux Output The Lux value at the centre of circle of 2m diameter circle with lamps fixed at 2m height from the illumination surface must be at least 6 Lux. L5 Reduction of output The WLED lamps must be operational for at least 500 hours continuously with reduction in luminous efficiency and lux not Lux Meter, Dark room, Multimeter, measuring tape Power supply, life cycle board,multimeter 1. Mount lamp at a stand 2 meter height in a dark room with voltmeter and ammeter in circuit. 2. Keep the Lux meter at centre of 2m diameter circle perpendicular distance form the WLED of Lamp. 3. Set the power supply for lamp at nominal voltage. 4. Note the reading of Lux meter. 1. Mount lamp (s) in Life Cycle Test bench after initial lumen and lux measurement 2. Start continuous burning test for 500 hours 3. Note time and character of any failures of lamp (s) 4. After cycles, test the lamp (s) by test sequence L3 and L4 2

3 exceeding 30% of its initial value and note the reduction in initial lumen and lux output L6 Life cycle The mean time between failures must not be less than 50,000 hours. L7 L8 L9 L10 Rated voltage and current Resistance of wires Luminous intensity Colour Rendering Index The value of current at rated voltage must be maintained at rated value for at least one hour of continuous burning The combined resistance of wires, switches, sockets (between battery terminals and WLEDs) must not exceed 20 milli Ohms excluding dumping resistor. Current and luminous intensity at specified voltage of individual WLEDs used in the lamp must not differ by more than 10%. The Colour Rendering Index (CRI) of the WLEDs should be not less than 60 at Correlated Colour Temperature of 5000 degree Kelvin. Power supply, Multimeter RLC Meter Lumen sphere specific for WLED measurement (Integrating Sphere) and its accessories, Power supply, Multimeters, PC of specification provided by the manufactures of WLED used in Lamp sets mentioning operational for at least 50,000 burning hours. 1. Switch ON the lamp for one hour at rated voltage of lamp 2. Take reading of current initially and at every 20 minutes 3. Note the difference in value of current 1. Bypass WLEDs and Keep RLC meter in the path of wires, switches, sockets (between battery terminals and WLEDs ). 2. Check the resistance value of the path. Full Testing facility not available in RETS Lab currently. Visually inspect the specification provided by the WLED lamp manufacturer for the CRI value at specified temperature. L11 Reverse Polarity Lamp must be protected Power Supply, Multimeter 1. Connect the lamp to the power supply with zero voltage with reverse polarity 3

4 against reverse polarity. L12 Height of lamp Height of lamp using NiMH or Li-ion battery must be within the range of 10 inches to 15 inches L13 Workman Ship The lamp and its enclosure should display good workmanship and should provide protection against dust, oil, and smoke. L14 Casing Mechanical Strength Metal box or molded plastic must be used as light casing. Measuring tape 2. Increase the voltage to nominal voltage slowly 3. Test the lamp in normal operation Measure the height of lamp Inspect the lamp for protections against dust, water, oil and smoke Check the casing of the lamp 4

5 B. Test Procedures for Battery, Battery Mounting and Charge controller. No. Test Items Technical Requirements Instruments Required Test Methods B1 Type of battery The battery must be maintenance free rechargeable Nickel Metal Hydride or Lithium ion or VRLA (with control circuit) matching with specified module. Visual inspection 1. Visual inspection of specification of battery used in solar tuki lamps sets provided by the company. B2 Voltage of battery For each WLED based lamp, NiMH or Li-ion must be of 3.6 V and VRLA battery must be of 12 V Visual inspection Visual inspection of specification of battery used in solar tuki lamps sets provided by the company. B3 Battery Capacity 1. In case of NiMH and Li-ion battery, nominal capacity expressed in C5 discharge rate at 20 o C must be at least 2300mAh. In case of VRLA battery, nominal capacity expressed in C10 discharge rate at 20 o C must be at least 4Ah 2. 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 Visual inspection, Power Supply, Electronic load, PC with data logger, Programmable Logical Controller (PLC), Multimeter, Water bath, Temperature Probe (Thermocouple) VRLA or NiMH / Li-ion 1. Inspect visually the capacity of the battery 2. Charge the battery to its full charge (100 % SOC) with 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 remains constant at least for 10 minutes. 3. Place the battery in a water bath maintained at20 C or 25 C 4. Set the upper and lower limit of the battery voltage corresponding to 100 % and 0 % SOC in the controller of battery test arrangement 5. Discharge the battery at the 5 hour rate or 10 hour rate or 20 hour rate (in which rate the battery capacity is provided) until the battery terminal voltage reaches 1 V (NIMH) or 10.8 V (VRLA) unless otherwise specified by the 5

6 plus 10%). manufacturer. 6. Battery terminal voltage, time, temperature of electrolyte are logged using data logger and PC 7. Compute Capacity at 25 C using the following relation: 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 Repeat the test (1 to 8) for maximum of 5 cycles 9. 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 shall not be carried out. B4 B5 Battery life cycle Minimum Information Operational life cycle of the battery must be at least 500 cycles at 50% DoD The following minimum information must be included in the label of the battery: Brand and name of the Visual Observation of specification of provided by the manufacturer s 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 50% 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 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 6

7 manufacturer Model and type Rated capacity in Amperehours at the discharge rate C5 or C10 Nominal voltage in Volt B6 B7 Battery connector Provision for Battery over charge and under charge protection The battery connector resistance must not exceed 5 mill-ohms and must be rust free type in case of NiMH and LI-ion battery Charge controller with over charge protection features must be used in Nickel Metal Hydride or Lithium ion or for VRLA battery both over charge and deep discharge protection features should be used. RLC meter Visual inspection of manufacturer s claim Measure the resistance value of battery connector using RLC meter. Visually observe the provision for battery over charge and undercharge protection in the charge-controller used in Solar Tuki Lamp Sets. B8 Voltage Threshold Charge controller must have HVD of V in case of Nickel Metal Hydride or Lithium ion battery and in case of VRLA battery HVD must be in the range of V. For VRLA battery, LVD must be in the range of V and LVR must not be less than 12.5V Adjustable Power Supply, Ammeter, Voltmeter, Oscilloscope, Variable Resistor or Electronic load LVD & LVR 1. Adjust the DC power supply (battery simulator) output voltage at the nominal voltage of the battery 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 Load Reconnect Voltage (LVR). 7

8 B9 Charge controller Type Charge controller used in Solar Tuki Lamp Sets must be Pulse width Modulation (PWM)Type Power Supplies, Multimeters, Oscilloscope, resistor HVD 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). 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. 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. Note: Follow the instructions of the manufacturer during the testing of deep cycle battery, if any. 8

9 C. Test Procedures for PV modules No. Test Items Technical Requirements Instruments Required P1 The PV module must be of the Mono Module Types and Crystalline Silicon Type or Poly Certification Crystalline Silicon Type P2 P3 P4 P5 P6 Maximum Rated Power (W p ) Minimum Information Maximum Rated Voltage (V) Warranty Period IEC or Equivalent certificate The peak power rating of PV module must be 5Wp. The deviation of maximum power from its nominal values stated by the manufacturer must not exceed the limit of -10% to +20% (minus 10% to plus 20%) at STC. A nameplate must be mounted on the PV module frame containing the following details: Brand and name of the manufacturer, Maximum power in Watt Peak, Maximum rated voltage in Volt, Maximum rated current in Ampere, Supplier company engrave number The rated voltage (V mp ) must be greater than by 20% of end of charge voltage of battery system at STC The warranty period of Solar PV Module must be at least 10 years against maximum 20% reduction in output power at STC. The PV module must be used from the PV module manufacture that has IEC certification in its larger sized module PVPM curve tracer ( Module Tester) in junction box Test Methods Make observation to distinguish the type of Module under test. 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. Inspect visually the name plate mounted on PV module for following things: Brand and name of the manufacturer, Maximum power in Watt Peak, Maximum rated voltage in Volt, Maximum rated current in Ampere, Supplier company engrave number Calculate Vmp reading to find out that the module output voltage is above 20% of end of charge voltage of battery at STC condition. Check the certificate or document provided. Check the IEC or equivalent national, regional or international certification of the type of module in its larger sized module. 9

10 D. Sampling 1.1 Sampling Procedure The manufacturer will provide written information about quantity of products, brand, type, model, serial number 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 300 and maximum of 1000 populations in lot size for random sampling test There must be proper label as per technical standard of Solar Tuki: 2063 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 for Solar Tuki system shall be as given in the table below: Lot Size, Sample Size and Acceptable Defective Number Table Lot Size Sample Size Acceptable Defectives Number RETS will issue the test report in 30 days from the date of testing. E. Compliance with Technical Standard for solar Tuki (TSST) 2063 All the samples shall be subjected to whole of the test criteria as per Technical Standard of solar Tuki (TSST) All samples must fulfil all the mandatory requirements of TSST for the samples to be compliance with TSST. However, the acceptable defective number of samples for a given lot size is as depicted in the table.

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