EN 62093:2005

STANDARDSistemska tehnika fotonapetostnih sistemov - Ocena zasnove za naravna okolja (IEC 62093:2005)Balance-of-system components for photovoltaic systems – Design qualification natural environments (IEC 62093:2005)©
Standard je založil in izdal Slovenski inštitut za standardizacijo. Razmnoževanje ali kopiranje celote ali delov tega dokumenta ni dovoljenoReferenčna številkaSIST EN 62093:2005(en)ICS27.160

EUROPEAN STANDARD
EN 62093 NORME EUROPÉENNE EUROPÄISCHE NORM
May 2005 CENELEC European Committee for Electrotechnical Standardization Comité Européen de Normalisation Electrotechnique Europäisches Komitee für Elektrotechnische Normung
Central Secretariat: rue de Stassart 35, B - 1050 Brussels
© 2005 CENELEC - All rights of exploitation in any form and by any means reserved worldwide for CENELEC members.
Ref. No. EN 62093:2005 E
ICS 27.160
English version
Balance-of-system components for photovoltaic systems –
Design qualification natural environments (IEC 62093:2005)
Composants BOS des systèmes photovoltaïques –
Qualification et essais d'environnement (CEI 62093:2005)
BOS-Bauteile für photovoltaische Systeme –
Bauarteignung natürliche Umgebung (IEC 62093:2005)
This European Standard was approved by CENELEC on 2005-04-01. CENELEC members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this European Standard the status of a national standard without any alteration.
Up-to-date lists and bibliographical references concerning such national standards may be obtained on application to the Central Secretariat or to any CENELEC member.
This European Standard exists in three official versions (English, French, German). A version in any other language made by translation under the responsibility of a CENELEC member into its own language and notified to the Central Secretariat has the same status as the official versions.
CENELEC members are the national electrotechnical committees of Austria, Belgium, Cyprus, Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Slovakia, Slovenia, Spain, Sweden, Switzerland and United Kingdom.

at national level by publication of an identical
national standard or by endorsement
(dop)
2006-01-01 – latest date by which the national standards conflicting
with the EN have to be withdrawn
(dow)
2008-04-01 Annex ZA has been added by CENELEC. __________ Endorsement notice The text of the International Standard IEC 62093:2005 was approved by CENELEC as a European Standard without any modification. __________

- 3 - EN 62093:2005
Annex ZA
(normative)
Normative references to international publications
with their corresponding European publications The following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies. NOTE Where an international publication has been modified by common modifications, indicated by (mod), the relevant EN/HD applies. Publication Year Title EN/HD Year IEC 60068-1 - 1) Environmental testing Part 1: General and guidance
EN 60068-1 1994 2) IEC 60068-2-6 - 1) Part 2: Tests - Test Fc: Vibration (sinusoidal)
EN 60068-2-6 1995 2) IEC 60068-2-21 - 1) Part 2-21: Tests - Test U: Robustness of terminations and integral mounting devices
EN 60068-2-21 1999 2) IEC 60068-2-27 - 1) Part 2: Tests - Test Ea and guidance: Shock
EN 60068-2-27 1993 2) IEC 60068-2-30 - 1) Part 2: Tests - Test Db and guidance: Damp heat, cyclic (12 + 12-hour cycle)
EN 60068-2-30 1999 2) IEC 60068-2-75 - 1) Part 2-75: Tests - Test Eh: Hammer tests EN 60068-2-75 1997 2) IEC 60068-2-78 - 1) Part 2-78: Tests - Test Cab: Damp heat, steady state
EN 60068-2-78 2001 2) IEC 60068-3-6 - 1) Part 3-6: Supporting documentation and guidance - Confirmation of the performance of temperature/humidity chambers
EN 60068-3-6 2002 2) IEC 60410 - 1) Sampling plans and procedures for inspection by attributes
- - IEC 60529 - 1) Degrees of protection provided by enclosures (IP Code)
EN 60529 + corr. May 1991 2) 1993
IEC 60721-2-1 - 1) Classification of environmental conditionsPart 2: Environmental conditions appearing in nature - Temperature and humidity
HD 478.2.1 S1 1989 2)
1) Undated reference. 2) Valid edition at date of issue.

EN 60904-3 1993 IEC 61215 - 1) Crystalline silicon terrestrial photovoltaic (PV) modules - Design qualification and type approval
EN 61215 2005 2) IEC 61345 - 1) UV test for photovoltaic (PV) modules
EN 61345 1998 2) IEC 61427 2005 Secondary cells and batteries for photovoltaic energy systemes (PVES) - General requirements and methods of test
EN 61427 - 3) IEC 61646 - 1) Thin-film terrestrial photovoltaic (PV) modules - Design qualification and type approval
EN 61646 1997 2) IEC 61683 - 1) Photovoltaic systems - Power conditioners - Procedure for measuring efficiency
EN 61683 2000 2) IEC 62262 - 1) Degrees of protection provided by enclosures for electrical equipment against external mechanical impacts (IK code)
EN 62262 2002 2) ISO/IEC 17025 - 1) General requirements for the competence of testing and calibration laboratories
EN ISO/IEC 17025 2000 2)
3) To be published.
NORMEINTERNATIONALECEIIECINTERNATIONALSTANDARD62093Première éditionFirst edition2005-03Composants BOS des systèmes photovoltaïques –Qualification et essais d'environnement Balance-of-system components for photovoltaic systems – Design qualification natural environments Pour prix, voir catalogue en vigueur For price, see current catalogue© IEC 2005
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Web: www.iec.ch CODE PRIX PRICE CODE WCommission Electrotechnique InternationaleInternational Electrotechnical Commission

62093 ¤ IEC:2005 – 3 –
CONTENTS FOREWORD.7 1Scope and object.112Normative references.113Sampling.134Marking.155Documentation.155.1General.156Testing.216.1Service use.216.2Test sequence.217Pass criteria.277.1General pass criteria.277.2Specific requirements for charge controllers.297.3Specific requirements for secondary batteries.298Major visual defects.359Report.3510Modifications.3511Test procedures.3511.1Visual inspection.3511.2Functioning tests.3711.3Specific performance tests for components.4511.4Insulation test.4911.5Outdoor exposure test.5111.6Protection against mechanical impacts (IK-code).5311.7Protection against dust, water and foreign bodies (IP-code).5311.8Shipping vibration test.5511.9Shock test.5511.10UV test.5711.11Thermal cycling test.5911.12Humidity-freeze test.6311.13Damp heat test.6711.14Robustness of terminals test.6911.15Damp heat, cyclic test.71 Annex A (informative)
Switching thresholds for charge controllers using the battery voltage as the main parameter for the switching algorithm.75Figure 1 – Qualification test sequence.27Figure 2 – Cycling conditions of the efficiency test procedure.33Figure 3 – Diagram of the test set-up without measuring equipment.41Figure 4 – Thermal cycling test.61Figure 5 – Humidity-freeze test.65

62093 ¤ IEC:2005 – 5 – Table 1 – Summary of test levels.23Table 2 – Temperature limits for thermal cycling test.61Table 3 – Temperature limits for humidity-freeze test.63Table 4 – Temperature limits for damp heat test.67Table 5 – Temperature limits for damp heat, cyclic test.73

62093 ¤ IEC:2005 – 7 – INTERNATIONAL ELECTROTECHNICAL COMMISSION ___________BALANCE-OF-SYSTEM COMPONENTSFOR PHOTOVOLTAIC SYSTEMS – DESIGN QUALIFICATION NATURAL ENVIRONMENTS FOREWORD1) The International Electrotechnical Commission (IEC) is a worldwide organization for standardization comprising all national electrotechnical committees (IEC National Committees). The object of IEC is to promote international co-operation on all questions concerning standardization in the electrical and electronic fields. To this end and in addition to other activities, IEC publishes International Standards, Technical Specifications, Technical Reports, Publicly Available Specifications (PAS) and Guides (hereafter referred to as “IEC Publication(s)”). Their preparation is entrusted to technical committees; any IEC National Committee interested in the subject dealt with may participate in this preparatory work. International, governmental and non-governmental organizations liaising with the IEC also participate in this preparation. IEC collaborates closely with the International Organization for Standardization (ISO) in accordance with conditions determined by agreement between the two organizations. 2) The formal decisions or agreements of IEC on technical matters express, as nearly as possible, an international consensus of opinion on the relevant subjects since each technical committee has representation from all interested IEC National Committees.
3) IEC Publications have the form of recommendations for international use and are accepted by IEC National Committees in that sense. While all reasonable efforts are made to ensure that the technical content of IEC Publications is accurate, IEC cannot be held responsible for the way in which they are used or for any misinterpretation by any end user. 4) In order to promote international uniformity, IEC National Committees undertake to apply IEC Publications transparently to the maximum extent possible in their national and regional publications. Any divergence between any IEC Publication and the corresponding national or regional publication shall be clearly indicated in the latter. 5) IEC provides no marking procedure to indicate its approval and cannot be rendered responsible for any equipment declared to be in conformity with an IEC Publication. 6) All users should ensure that they have the latest edition of this publication. 7) No liability shall attach to IEC or its directors, employees, servants or agents including individual experts and members of its technical committees and IEC National Committees for any personal injury, property damage or other damage of any nature whatsoever, whether direct or indirect, or for costs (including legal fees) and expenses arising out of the publication, use of, or reliance upon, this IEC Publication or any other IEC Publications.
8) Attention is drawn to the Normative references cited in this publication. Use of the referenced publications is indispensable for the correct application of this publication. 9) Attention is drawn to the possibility that some of the elements of this IEC Publication may be the subject of patent rights. IEC shall not be held responsible for identifying any or all such patent rights. International Standard IEC 62093 has been prepared by IEC technical committee 82: Solar photovoltaic energy systems. The text of this standard is based on the following documents: FDIS Report on voting 82/374/FDIS 82/380/RVD Full information on the voting for approval can be found in the report on voting indicated in the above table.
This publication has been drafted in accordance with the ISO/IEC Directives, Part 2.

62093 ¤ IEC:2005 – 9 – The committee has decided that the contents of this publication will remain unchanged until the maintenance result date indicated on the IEC web site under "http://webstore.iec.ch" in the data related to the specific publication. At this date, the publication will be
• reconfirmed; • withdrawn; • replaced by a revised edition, or • amended.

62093 ¤ IEC:2005 – 11 – BALANCE-OF-SYSTEM COMPONENTSFOR PHOTOVOLTAIC SYSTEMS – DESIGN QUALIFICATION NATURAL ENVIRONMENTS 1 Scope and object This International Standard establishes requirements for the design qualification of balance-of-system (BOS) components used in terrestrial photovoltaic (PV) systems. This standard is suitable for operation in indoor, conditioned or unconditioned; or outdoor in general open-air climates as defined in IEC 60721-2-1, protected or unprotected. It is written for dedicated solar components such as batteries, inverters, charge controllers, system diode packages, heat sinks, surge protectors, system junction boxes, maximum power point tracking devices and switch gear, but may be applicable to other BOS system components. This standard is based on that which is specified in IEC 61215 and IEC 61646 for the design qualification of PV modules. However, changes have been made to account for the special features of the balance-of-system components, and to add different levels of severity for the different service environments. Dust, fungus, insects, shipping vibration and shock, and protection class have been added to the appropriate environmental categories. The high and low temperature and humidity limits have also been modified for the appropriate service environments.
This standard does not apply to photovoltaic modules. These are covered by IEC 61215 or IEC 61646. Also, this standard does not apply to concentrator modules or to complete PV systems. Specific electrical safety aspects are not part of this standard.
This standard is applicable to lead-acid and nickel-cadmium cells and batteries. Other electrochemical storage systems will be included when they become available. The object of this test sequence is to determine the performance characteristics of each BOS components and to show, as far as possible within reasonable constraints of cost and time, that the component is capable of maintaining this performance after exposure to the simulated service natural environmental conditions for which it is intended to be applicable as specified by the manufacturer. The actual life expectancy of components so qualified will depend on their design, their environment and the system conditions under which they are operated. 2 Normative references The following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies. IEC 60068-1, Environmental testing – Part 1: General and guidance IEC 60068-2-6, Environmental testing – Part 2: Tests – Test Fc: vibration (sinusoidal)IEC 60068-2-21, Environmental testing – Part 2-21: Tests – Test U: Robustness of terminations and integral mounting devices

62093 ¤ IEC:2005 – 13 – IEC 60068-2-27, Environmental testing – Part 2: Tests. Test Ea and guidance: ShockIEC 60068-2-30, Environmental testing – Part 2: Tests. Test Db and guidance: Damp heat, cyclic (12 + 12-hour cycle) IEC 60068-2-75, Environmental testing – Part 2-75: Tests – Test Eh: Hammer tests IEC 60068-2-78, Environmental testing – Part 2-78: Tests – Test Cab: Damp heat, steady state IEC 60068-3-6, Environmental testing – Part 3-6: Supporting documentation and guidance – Confirmation of the performance of temperature/ humidity chambers IEC 60410, Sampling plans and procedures for inspection by attributesIEC 60529, Degrees of protection provided by enclosures (IP Code) IEC 60721-2-1, Classification of environmental conditions – Part 2-1: Environmental conditions appearing in nature – Temperature and humidity IEC 60904-3:1989, Photovoltaic devices – Part 3: Measurement principles for terrestrial photovoltaic (PV) solar devices with reference spectral irradiance data IEC 61215, Crystalline silicon terrestrial photovoltaic (PV) modules – Design qualification and type approval
IEC 61345, UV test for photovoltaic (PV) modules IEC 61427:2005, Secondary cells and batteries for solar photovoltaic energy systems – General requirements and methods of test IEC 61646, Thin film silicon terrestrial photovoltaic (PV) modules – Design qualification and typeapprovalIEC 61683,Photovoltaic systems – Power conditioners – Procedure for measuring efficiencyIEC 62262, Degrees of protection provided by enclosures for electrical equipment against external mechanical impacts (IK code) ISO/IEC 17025, General requirements for the competence of testing and calibration laboratories3 Sampling For qualification testing a quantity of at least three samples of a component (plus spares as desired) shall be taken at random from a production batch or batches, in accordance with the procedure given in IEC 60410. The components shall have been manufactured from specified materials and components in accordance with the relevant drawings and process sheets and shall have been subjected to the manufacturer's normal inspection, quality control and production acceptance procedures. The components shall be complete in every detail and shall be accompanied by the manufacturer's handling, mounting and connection instructions, including the maximum permissible system voltage. In the case of items, for example wires and cables, that do not have previously defined measures, a sufficient amount for the testing purposes shall be taken at random from a production batch or batches, in accordance with the procedure given in IEC 60410.

62093 ¤ IEC:2005 – 15 – 4 Marking Each component shall carry the following clear and indelible markings: – name, monogram or symbol of manufacturer/supplier; – type or model number; – serial/batch number, if practical; – the design service use of this component; outdoor unprotected, outdoor protected, indoor unconditioned and indoor conditioned; – polarity of terminals or leads (only colour coding is not permissible); – maximum system voltage for which the component is suitable; – nominal and minimum values of the power consumption, as specified by the manufacturer for the product type. The date (and preferably time) and place of manufacture shall be marked on the component or be traceable from the serial or batch number. NOTE Small components such as wires, connectors, fuses, etc. need not have these elaborate markings. The minimum information is name/monogram/symbol of manufacturer or supplier and the type or model number. 5 Documentation 5.1 General The documentation shall contain the following information (if relevant): − compliance with relevant standards (this is especially important with respect to European Directives and the related CE marking); − installation and disconnection instructions; − operating instructions; − service use of the component (see 6.1); − technical data (circuit diagram and technical specifications); − troubleshooting instructions; − safety warnings and instructions;
− information on spare parts; − warranty; − instructions for decommissioning and disposal. In particular, the documentation shall indicate (if relevant): a) Conditions of surroundings 1) Range of operating temperature 2) Range of storage temperature 3) Maximum relative humidity b) Physical properties of the component 1) Dimensions of the enclosure 2) Weight 3) Properties of the enclosure (material) 4) Fasteners 5)
Protection class (IP and IK Code)

62093 ¤ IEC:2005 – 17 – 6) Connecting terminals 7) Cables (inlet, pull relief, cross-sections)
8) Spare parts c) Electrical properties of the component 1) For charge controllers − Listing of incompatible and compatible battery types − Nominal voltage of input and output (V) − Maximum module current (A) − Maximum load current (A)
− Type of controller (series controller, shunt controller, etc.) − Working principle (PWM, two-point-regulation, state of charge algorithm, etc.)
− All used thresholds (V)
− Temperature compensation for the thresholds (mV/°C/cell)
− Quiescent current − Curve indicating input and output power/current vs. ambient temperature − Power consumption to be measured during operation immediately after deep discharge disconnection − Power consumption during operation at nominal voltage − Overload protection − Reverse-polarity protection − Definition of the allowable voltage area at the input and at the output side − Warning before load disconnect − Definition of the output behaviour in the case of no battery connection − Delayed load disconnection − Displays (LEDs, display, accuracy) − Additional functions (MPP tracking, etc.) − Maximum AC ripple on the battery charging current NOTEIf the negative terminal of the battery, module and load cannot be linked together, this must be clearly stated and the behaviour in such a case must be defined. 2) For batteries − Type of battery: NiCd, lead-acid, vented (flooded), valve-regulated, gas-tight sealed (NiCd only), tubular plate, flat plate, etc. − Nominal voltage − Specific gravity of the electrolyte − Capacity expressed in C120,C20,C10,C5− Charge retention expressed as a percentage: monthly self-discharge/nominal capacity − Endurance in cycles, measured according to IEC 61427 − Charging efficiency (see IEC 61427) − Instructions for starting up (the manufacturer must advise if there are special considerations for the initial charging with only the solar generator available as the power source), maintenance, and safety. − Transportation restrictions

62093 ¤ IEC:2005 – 19 – 3) For inverters − Maximum input current (A) − Maximum output current (A)
− Nominal input voltage and range (V) − Nominal output voltage and range (V) − Absolute maximum solar voltage (Voc)− Number of phases − Frequency (Hz) − Output voltage: sine wave, square wave or modified square wave, etc. − Galvanic separation
− Overload capability curve − Curve indicating output power at nominal input voltage vs. ambient temperature − Curve indicating maximum output power at nominal input voltage vs. ambient air-pressure (may be expressed in height of installation above sea-level) − Maximum ambient temperature − Type of load allowed, for example maximum cos(phi), regenerative loads − Earthing requirements − For standalone inverters: power consumption to be measured during operation immediately after deep discharge disconnection and in standby-mode (there may be several standby modes, e.g. sleep-mode, no-load mode, etc.) − Power consumption in standby-mode (there may be several standby modes, e.g. sleep-mode, low-solar-input-mode, etc.) − Efficiency curve according to IEC 61683 − Fuse required on the AC-side of the inverter: size and class − If applicable, recommended fuse on the DC-side of the inverter, size and class − Definition of the behaviour of the inverter during an overload situation and overload protection − Reverse-polarity protection on the DC-side − Warning before load disconnect, if relevant − Delayed load disconnection, if relevant − Displays (LED's, display, accuracy) − Additional functions (MPP tracking, etc.) − Total harmonic output distortion on a linear load at nominal conditions − Total harmonic output voltage distortion on non-linear loads at nominal conditions with a crest factor of 2,5 % − List of generic appliances, known to be incompatible with the inverter All data shall be verified in the course of the following test sequences. Data, which are missing or do not conform to the indications of the manufacturer, shall be conscientiously recorded.

62093 ¤ IEC:2005 – 21 – 6 Testing 6.1 Service use The test severities are based on the service use (to be indicated by the manufacturer) of the component. These are defined as follows. a) Outdoor, unprotected
The component is fully exposed to direct rain, sun, wind, dust, fungus, ice, radiation to the cold night sky, etc.
b) Outdoor, protected
The component is partially covered to protect it from direct rain, sun, wind-blown dust, ice, fungus, and radiation to the cold night sky, etc.
c) Indoor, unconditioned
The component is fully covered by a building or enclosure to protect it from direct rain, sun, wind-blown dust, fungus, and radiation to the cold night sky, etc, but the building or enclosure is not conditioned in terms of temperature, humidity or air filtration. d) Indoor, conditioned
The component is fully covered by a building or enclosure to fully protect it from rain, sun, wind-blown dust, fungus, and radiation to the cold night sky, etc, and the building or enclosure is generally conditioned in terms of temperature, humidity and air filtration. The test conditions for these different services are summarized in Table 1. 6.2 Test sequence The components shall be divided into three groups and subjected to the qualification test sequences in Table 1, carried out in the order laid down. Each box refers to the corresponding subclause in this standard. Test procedures and severities, including initial and final measurements where necessary, are detailed in Clause 11 and summarised in Table 1. Three groups of components shall first be subjected to basic environmental testing, after which a damp heat, cyclic test (see 11.15) shall be done. After each basic environmental test, a visual inspection (VI), a functioning test (FT) and an insulation test (IT) shall be done. All groups/pieces shall be subjected to their individual functioning test before and after each qualification test. Table 1 contains a summary of test levels. For electronic equipment all tests apply. For batteries certain tests do not apply, a summary can also be found in Table 1. NOTE 1 Where the final measurements for one test serve as the initial measurements for the next test in the sequence, they need not be repeated. In these cases, the initial measurements are omitted from the test.NOTE 2 In the case where the component under test has already been subjected to a certain test in another qualification sequence by an accredited test lab, this test may be omitted if it does not have an influence on the whole testing sequence.In carrying out the tests, the tester shall strictly observe the manufacturer's handling, mounting and connection instructions. The test report shall state the basis for any test omission.

62093 ¤ IEC:2005 – 23 – Table 1 – Summary of test levels Test Title Test conditions Secondary batteriesOther electronic equipment11.1 Visual inspection See detailed inspection list in 11.1.2 Yes Yes 11.2 Functioning test Ambient temperature: 25 °C; 40 ± 20 % RH Yes Yes
Specific component parameter
11.4 Insulation test 500/1 000 V DC + twice the open-circuit voltage of the system or 1 min. Insulation resistance of not less than 50 MΩ at 500 V DC.No Yes 11.5 Outdoor exposure test
No Yes
- outdoor, unprotected 60 kWh⋅m–2 total solar irradiation
- outdoor, protected Not required
- indoor, unconditioned Not required
- indoor, conditioned Not required
11.6 Protection against mechanical impact (IK)
Yes Yes
- outdoor, unprotected IK05
- outdoor, protected IK05
- indoor, unconditioned IK05
- indoor, conditioned IK05
11.7 Protection against dust, water and foreign bodies (IP-code)
Not relevant Yes
- outdoor, unprotected IP44
- outdoor, protected IP44
- indoor, unconditioned IP20
- indoor, conditioned IP20
11.8 Shipping vibration test 10 Hz to 11,8 Hz; 11,9 Hz to 150 Hz Amplitude: 3,5 mm, acceleration: 2 g1 octave/min, Duration on each axis: 2 h; overall: 6 h Yes Yes 11.9 Shock test Yes Yes 15g, half-sine, Duration: 11 ms;
Sequence: 1 s Number of shocks: 18 (6 × 3)

62093 ¤ IEC:2005 – 25 – Table 1(continued)Test Title Test conditions Secondary batteriesOther electronic equipment11.10 UV test
Not relevant Yes
- outdoor, unprotected As in IEC 61345
- outdoor, protected Not required
- indoor, unconditioned Not required
- indoor, conditioned Not required
11.11 Thermal cycling test
Yes Yes
- outdoor unprotected - outdoor, protected 50 and 200 cycles from –20 °C to +85 °C 50 and 200 cycles from −20 °C to +75 °C
- indoor, unconditioned 50 and 200 cycles from
0 °C to +55 °C
- indoor, conditioned Not required
11.12 Humidity freeze test
No Yes
- outdoor, unprotected 10 cycles from +85 °C, 85 % RH to −20 °C
- outdoor, protected 10 cycles from +75 °C, 85 % RH to −20 °C
- indoor, unconditioned 10 cycles from +55 °C, 85 % RH to 0 °C
- indoor, conditioned Not required
11.13 Damp heat test
No Yes
- outdoor, unprotected 1 000 h at +85 °C, 85 % RH
- outdoor, protected 1 000 h at +75 °C, 85 % RH
- indoor, unconditioned 1 000 h at +55 °C, 85 % RH
- indoor, conditioned Not required
11.14 Robustness of terminals test As in IEC 60068-2-21 Yes Yes 11.15 Damp heat cyclic test
No Yes
- outdoor, unprotected 3 cycles from +75 °C, 95 % RH to 25 °C
- outdoor, protected 3 cycles from +55 °C, 95 % RH to 25 °C
- indoor, unconditioned 3 cycles from +40 °C, 95 % RH to 25 °C
- indoor, conditioned Not required

62093 ¤ IEC:2005 – 27 – 3 piecesVisual inspection (VI) - all pieces Functioning test (FT) - all pieces Specific performance tests - 1 piece Insulation test (IT)1 piece1 piece1 pieceOutdoor exposure testUV test FT, IT, VIFT, IT, VIShipping vibration testThermal cycling test, 50 cycles FT, IT, VIFT, IT, VIDamp heat test Handling shock testHumidity freeze test FT, IT, VIFT, IT, VIFT, IT, VIThermal cycling test, 200 cyclesRobustness of terminals test
FT, IT, VIFT, IT, VIIK classIP class Basic environmental testing Repeat visual inspection, functioning,insulation Damp heat, cyclic test - 1 piece Performance environmental testing IEC
511/05 Figure 1 – Qualification test sequence7 Pass criteria 7.1 General pass criteria The component design shall be judged to have passed the design qualification tests if each test sample meets all the following criteria: a) the component passes its specific performance tests; b) after the final test of each test sequence, the component passes the functioning test; c) no sample has exhibited any irreversible open-circuit or ground fault during the tests: allowed are such situations which are induced by the component itself for the sake of protecting itself or any other connected device or load (and can hence normally be reset);

62093 ¤ IEC:2005 – 29 – d) there is no visual evidence of a major defect, as defined in Clause 8; e) the component passes the insulation test. If any component does not meet these test criteria, nor the specific criteria for the component, the design shall be deemed not to have met the qualification requirements, and another two components meeting the requirements of Clause 3 shall be subjected to the whole of the relevant test sequence from the beginning. If one or both of these also fail, the design shall be deemed not to have met the qualification requirements. If, however, both components pass the test sequence, the design shall be judged to have met the qualification requirements. 7.2 Specific requirements for charge controllers 7.2.1 Switching thresholds/operation algorithm Many charge controllers use the battery voltage as the main parameter for the switching algorithm. However, some charge controllers use other parameters, for example state of charge. Annex A contains some recommended switching voltages for lead-acid batteries. The manufacturer shall clearly specify to the test lab the operating algorithm of the charge controller. If the battery voltage is used as the main parameter for the switching algorithm, the manufacturer shall specify these thresholds. 7.2.2 Output voltage of a charge controller after battery disconnection The charge controller shall protect the load from the open-circuit voltage of the PV-array, in case the battery has been disconnected from the system. This is an important feature of good charge controllers, since many loads can be destroyed when they are exposed to the open-circuit voltage of the PV-array. The manufacturer shall supply a definition of the output behaviour in the case of no battery connection. 7.2.3 User feedback The charge controller shall provide at least: – an indication of charging state;
– an indication of load-disconnect state;
– an indication of the state-of-charge of the connected battery. Certain special purpose charge controllers, for example dedicated controllers for industry applications do not have a user feedback. The manufacturer shall state this. 7.3 Specific requirements for secondary batteries
Lead-acid and nickel-cadmium batteries can only be qualified according to this standard for the conditions ‘indoor conditioned’ and ‘indoor unconditioned’. This implies that many tests are not relevant. Table 1 contains an overview of the tests that apply to the design qualification for secondary batteries.

62093 ¤ IEC:2005 – 31 – 7.3.1 Charge retention of secondary batteries at high temperatures 7.3.1.1 Purpose The purpose of this test is to determine the charge retention of batteries during storage at higher temperatures. 7.3.1.2 Procedure – Condition the battery – Do an initial capacity test, determine C10, before– Keep the battery at 40 °C for 30 days – Do a new capacity test, determine C10, after– Calculate the loss in charge: Closs = C10, after – C10, before7.3.1.3 Requirements The loss in charge shall not be more than 15 % for lead-acid batteries and not more than 30 % for nickel-cadmium batteries. 7.3.2 Cycling ability 7.3.2.1 Purpose The purpose of this test is to determine the capability of the battery to withstand the typical cycling conditions occurring in PV systems. 7.3.2.2 Procedure According to IEC 61427. 7.3.2.3 Requirements The test method described in IEC 61427 shall be performed once. The loss compared to the rated capacity (C10) shall be less than 20 %. 7.3.3 Ah-cycling efficiency of secondary batteries 7.3.3.1 Purpose The purpose of this test is to determine the Ah-cycling efficiency of secondary batteries at low state of charge.
The efficiency of a battery at low state of charge shall be sufficient to enable all energy provided by the PV modules to be converted into usable energy stored in the battery.

62093 ¤ IEC:2005 – 33 – 7.3.3.2 Procedure The Ah-cycling efficiency can be expressed as: (Ah)capacityRecharge(Ah)capacityDischarge)efficiency(Ahefficiencycycling-Ah=The test shall be carried out at 20 °C± 3 °C.The test procedure is as follows:Initial cycle : – charge at 0,1 C10 until 100 % of SOC (state of charge), – discharge at 0,1 C10 (= initial capacity), until 1,8 V per cell (= 100 % of SOC)Cycling: – charge at 0,1 C10 until 50 % of the initial C10 capacity value, – discharge at 0,1 C10 (initial capacity) until 1,8 V per cell. This cycle is performed four times. The efficiency test procedure is presented in Figure 2.
Potential
V SOC
% 100 % 1,8 Vpc Initial charge Discharge 0,1 C1010hRest 2 h Charge 0,1 C10(rated) 5 h 5 h 1 cycle 50 % Rest 2 h Rest 2 h Discharge0,1 C10(rated) 5 h 4 cycles Charge0,1 C10(rated) IEC
512/05 Figure 2 – Cycling conditions of the efficiency test procedure To calculate the Ah-cycling efficiency value the values of the 4thcycle and the 5th cycle are averaged.
(This range has been selected because the corresponding efficiency values are mostly stable.)

62093 ¤ IEC:2005 – 35 – 7.3.3.3 Requirements For flat-plate lead-acid batteries, the Ah-cycling efficiency (at 20 °C) shall be at least 94 %. For tubular plate lead-acid batteries, the Ah-cycling efficiency (at 20 °C) shall be at least 92 %. For nickel-cadmium batteries, the Ah-cycling efficiency (at 20 °C) shall be at least 90 %. 8 Major visual defects For the purposes of design qualification, the following are considered to be major visual defects: a) broken, cracked, bent, misaligned or torn external surfaces; b) corrosion of any part of the component, inside or outside; c) dust, water or fungus intrusion into the electrically active interior of the component; d) loss of mechanical integrity, to the extent that the installation and/or operation of the component would be impaired. 9 Report Following design qualification, a report of the qualification tests, with measured performance characteristics and details of any failures, re-tests or omissions shall be prepared by the test laboratory. The report shall meet the requirements laid down in ISO/IEC 17025. A copy of this report shall be kept by the manufacturer for reference purposes. 10 Modifications Any change in the design, materials, components or processing of the component may require a repetition of some or all of the qualification tests. 11 Test procedures 11.1 Visual inspection 11.1.1 Purpose The purpose of this test is to detect any visual defects in the component. 11.1.2 Procedure Carefully inspect each component for the following conditions:– broken, cracked, bent, misaligned or torn external surfaces; – faulty interconnections or joints; – visible corrosion of any part of the active circuit;

62093 ¤ IEC:2005 – 37 – – visible corrosion of output connections, interconnections and bus bars; – visible corrosion of the enclosure surface; – cracked or damaged wire or cable; – faulty terminals, exposed energised electrical parts; – any other conditions which may affect functioning, performance or safety.
Make note of and/or photograph the nature and position of any defects which may worsen and adversely affect the component functioning in subsequent tests. 11.1.3 Requirements Visual conditions other than the major visual defects listed in Clause 8 are acceptable for the purpose of design qualification. 11.2 Functioning tests 11.2.1 Functioning test procedure – charge controllers for lead-acid batteries 11.2.1.1 Overview This procedure comprises charge controllers for lead-acid accumulators with liquid electrolyte (vented and valve regulated). The tests described in this procedure are valid for charge controllers, which use the accumulator terminal voltage as a criterion for operation as well as modern control procedures (e.g. state of charge algorithms). In the case where all or some of these tests are not relevant for a specific type of charge controller, the manufacturer shall state this. The following symbols are used in this document: Ichmax: maximum charge current permissible
Ilmax:
maximum load current permissible UNominal: nominal voltage of the charge controller Ubat: battery voltage Umax: maximum system voltage ≥ highest battery voltage permitted by charge controller (for example, gassing voltage) Umin: minimum system voltage ≥UlcdUhcd: voltage at high charge disconnect Uhcr: voltage at high charge reconnect Ulcd: voltage at low charge disconnect Ulcr: voltage at low charge reconnect Uoc: open-circuit voltage of the photovoltaic solar module(s) 11.2.1.2 Determination of thresholds 11.2.1.2.1 Purpose The purpose of this test is to determine all switching thresholds of the charge controller.

62093 ¤ IEC:2005 – 39 – 11.2.1.2.2 Apparatus A resistor (Rx) with a magnitude Umin/(Ichmax× 1,1) and an allowed power consumption of at least Umax×Ichmax× 1,1. This resistor is intended to keep the current from being fed into the power supply. In the worst case (maximum module current when load is switched off), the power supply will still supply a current of 0,1 ×Ichmax. If a four-quadrant power supply is utilised, this resistor is not necessary. A current/voltage source that can supply at least Ichmax at open-circuit voltage (Uoc) of the PV-generator connected (power supply 1). Current and voltage shall be capable of being set separately from each other and have limitations. Another current/voltage source which can supply at least a current with a magnitude (Umax/Rx) + Ilmax at maximum system voltage (power supply 2). Current and voltage shall be capable of being set separately from each other and have limitations. If a four-quadrant power supply is utilised, a maximum possible current of Ilmax is sufficient at maximum system voltage. In this case, the resistor described above (Rx) is no longer necessary. A variable resistor (RL) with a power consumption of at least Umax×Ilmax or a corresponding electronic load. An oscilloscope for visualising the pulse width modulation when end-of-charge voltages are reached.
Various ammeters and voltmeters. 11.2.1.2.3 Procedure The system components shall be inspected for visible damage.
Any peculiarities observed shall be conscientiously documented, if necessary by means of photography. The charge controller is mounted according to the manufacturer's instructions and hooked up as shown in Figure 3. If there are any voltage sensor lines on the charge controller, they shall be connected to power supply 2. Between power supply 1 and the charge controller a minimum of 10 m of the prescribed cable shall be installed to simulate a real system.
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