Module testing station
Unique combination of automation and top quality module characterization tools
QuickSun 550CE module testing station is a fully automated solar simulator for qualifying of PV modules with dimensions up to 105 x 205 cm2. High resolution EL imaging, Electrical Safety measurement tools are integrated in the same system. Throughput of 60–150 modules per hour is achieved depending on the applied EL and Electrical Safety testing parameters.
QuickSun 550CE is certified by TÜV Rheinland and a detailed test report is included with every simulator proving Class A+A+A+ performance with respect to spectrum, irradiance non-uniformity and short term instability (STI). Long term instability (LTI) is also within Class A+ tolerances during the 40 ms long flash pulse. IV characteristics are recorded with an electronic load and proprietary electronics unit which measures voltage, current and irradiance signals when module is swept e.g. from short circuit to open circuit or vice versa.
After reading the serial number either with a barcode scanner or through an industrial data bus like e.g. Profibus 550CE loads in the modules at ordinary conveyor line height and moves them to the testing position. 4-wire contacting probes are pushed automatically to the junction box contact pads or to the pads on the contact adapter plate. Frame contact probes are pushed to drainage holes. Automated switching unit contacts the module sequentially to IV, EL and Electrical Safety measurement instruments. Once all the tests have been completed the module is lowered down to conveyor line height for out feeding.
Irradiance non-uniformity is measured and adjusted automatically with a laminated c-Si cell which is moved over the test area by an internal X-Y stage. Number and location of test points can be selected freely.
Optional reference module loading unit enables automatic monitor cell gain adjustment and intensity level calibration. Omron PLC is used for automation control and nominal module infeed and out feed speed is 300–450 mm/sec.
EL-images having 200 μm pixel resolution can be recorded with six 8.3 Mpixel NIR ccd cameras. This enables sofware based automatic image analysis in order to identify and categorize small faults like microcracks and finger interruptions. If this accurate automatic analysis is not required cost effective 500 μm resolution EL picture can be recorded with two corresponding ccd cameras. 850 W power source source can be controlled to provide upto 14 A even to 72 cell modules. Typical exposure times vary between 5–20 seconds depending on the desired image quality.
QuickSun 550CE has the capability to perform insulation resistance, dielectric withstand and ground continuity tests as stipulated in the applicable UL and IEC standards.
Actual leakage current of PV modules is a few hundred nano amperes with a typical 4 KV test voltage while the ordinary dielectric withstand test acceptance criteria is 50 μA. QuickSun 550CE surpasses this minimum requirement and measures true insulation resistance and leakage currents accurately with sensitive enough instruments. This enables run time diagnosis of both contacting reliability and real module leakage characteristics.
|Contacting||J-Box / contact adapter; 4-wire / Kelvin||Frame; conical/pyramid pins to drainage holes|
|Load||feedback controlled MOSFET||adjustable bias 0–4.5 V|
|Voltage sweep||linear and double slope alternatives||Isc -> Voc, Voc -> Isc; average of both|
|Voltage measurement||1–100 V (other scales on request)||accuracy 0.2 % / 512 samples|
|Current measurement||0.5–25 A (other scales on request)||accuracy 0.2 % / 512 samples|
|Irradiance control||200–1000 W/m²||resolution 1 W/m² / 512 samples|
|Module temperature (IR)||0–75 ºC||accuracy 1 ºC|
|Monitor cell temperature||0–75 ºC||accuracy 1 ºC|
|Pmp repeatability||(max-min)/(max+min) < 0.25 %||std < +/- 0.1%|
|Average flash tube life time||300 000 flashes|
|Operation temperature||15–35 ºC|
|Mains utilities||3~, 400 Vac, 3 x 16 A, 50–60 Hz||CDA 4–6 bar|
|Total dimensions, weight||370 x 190 x 215 cm||1300 kg|