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MCS Certification The end to end process

MCS Certification the end to end process

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About MCS:

• Industry led Quality Assurance scheme

• Certificates Microgeneration Products and Services against consistent, robust and high quality standards

• MCS is a pre-requisite for financial incentives such as the Feed In Tariff (FITs) or the Renewable Heat Incentive (RHI)

• Provides a route to market for MCS Certified Products and installation via the on-line directories

Introduction

Using this never before published guide to the MCS Certification Process, you can get on the inside track to faster certification. Knowing what standards apply, the documentation and testing that is required in advance and what to expect from Intertek as your Certification Body, you can make the process more efficient and get your products to market faster.

First let’s have a look at some of the frequently asked questions about MCS Certification and Certification Bodies to put the material in this paper into context:

What is the MCS Certification Mark?

The Microgeneration Certification Scheme (MCS) is an independent scheme that certifies microgeneration products and installers in accordance with a range of MCS standards. In turn, these standards reference EN/IEC and relevant industry test standards. It is designed to evaluate microgeneration products and installers against robust criteria providing greater protection for consumers.

The Intertek MCS Certification Mark as shown may be applied to a micro-generation product that has been tested and found to be in compliance with the applicable MCS Standards.

The Microgeneration Certification Scheme (MCS) is a UK Government ‘owned’ certification scheme under the Department of Environment and Climate Change (DECC).

An independent company, Gemserv, was appointed by DECC to operate the Microgeneration Scheme. Gemserv is the scheme licensee and is responsible for scheme administration and maintaining the on-line listings of approved products.

In order for the end user to be eligible for the various UK Government financial incentives for renewable energy, the installation must utilise MCS Certified Products and be installed by a MCS Certified installer.


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When a product is MCS Certified its basic identity details are then added to the ‘MCS Product Directory’ maintained on the Microgeneration Certification Scheme website

http://www.microgenerationcertification.org/mcs-consumer/product-search.php

Gemserv maintains the product listing directory based on information submitted by the Certification Bodies, where users, retailers, exporters, wholesalers, installers, contractors and the authorities - can check that the product carries an approval.

Certification is then maintained through annual product and manufacturing site inspection, to check production continuity between the current production run and the sample that was originally tested.

What form does the Microgeneration Scheme take?

The MCS operates according to the principles of the EN45011 Standard. This is the standard that covers all general requirements for bodies operating certification schemes.

The MCS Governance is administered by Gemserv and takes the form of a MCS Steering Group, MCS Working Groups and Scheme Documents which include standards and guidelines.

Gemserv administration comprises:

• Licences the Mark to CB’s • PR and Promotion of the scheme • Meeting secretariat • MCS Website • Data management and on-line directories • Email and phone helpdesks

The Certification Bodies (CB’s) must be accredited by UKAS and the applicable MCS standards must be covered under the CB Accreditation Scope

The Certification Bodies (CB’s) are responsible for the technical evaluation, review and issue of certification under the scheme requirements


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What gives a Certification Body the right to MCS certify a product?

A Certification Body (CB) has to demonstrate their expertise in a particularly product or field to the relevant accreditation body before they can start issuing Certifications for that area or product. Once this expertise has been deemed acceptable by the accreditation body the CB receives an accreditation acceptance (from the Accreditation Body) and a licence (from Gemserv) to issue the MCS Certification Mark.

Certification Bodies may be accredited by an Accreditation Body such as the United Kingdom Accreditation Service (UKAS) or similar. CB’s are accredited to the standard EN45011 – General Requirements for Bodies Operating Certification Schemes.

Currently there are 14 Certification Bodies offering MCS – each with a particular scope covering certain product technologies or installer categories.

What types of products are certified?

The MCS covers 3 principle technologies:

Electricity generating Solar Photo voltaic (PV)

Micro and Small Wind Turbines

Micro Hydro

Heat generating Solar Thermal

Heat Pumps

Biomass

Co-generating (Heat and Electricity) Micro Combined Heat and Power (CHP)

Each of the product categories listed are covered by specific MCS Product Standards and MCS Installation Standards. These standards are available from the MCS Website: http://www.microgenerationcertification.org/installers/product-manufacturer

Intertek is accredited to certify the following categories of product:

• Solar Thermal (MCS-004) • Solar PV (MCS-005) • Micro and Small Wind (MCS-006) • Heat Pumps (MCS-007)


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In addition to the MCS Product Standards listed, 2 other standards are covered under our UKAS scope:

• MCS-010 – Factory Production Control Requirements • MCS-011 – Microgeneration Certification Scheme - Testing Acceptance Criteria

These are key standards underpinning the MCS scheme.

How can I get my product tested for MCS?

The MCS Certification Body (CB) may accept test data based on the criteria defined in MCS-011. In summary the following test routes are available to product manufacturers:

1. Testing by independent, third party test laboratories accredited by the United Kingdom Accreditation Service (UKAS) or equivalent accreditation body to perform testing to the applicable test standards.

2. Testing by independent, third party test laboratories that are not accredited to perform testing to the applicable test standards or were not so accredited at the time the testing was conducted. Testing is permissible providing that the CB conducts an ISO17025 (General Requirements for the competence of Testing and Calibration Laboratories) assessment of the laboratory to determine equipment, calibration, procedures and competence amongst others and witnesses the same or similar tests.

3. Testing conducted at the manufacturers test facilities. Testing is permissible providing that the CB conducts an ISO17025 assessment of the laboratory to determine equipment, calibration, procedures and competence amongst others. The CB must witnesses a representative sample of each product family under test. There is no requirement for the manufacturer’s laboratory or test site to have independent accreditation for the lab.

4. Testing has already been conducted at the manufacturers test facilities. Under exceptional conditions, this test data may be accepted at the discretion of the CB, providing that the CB conducts an ISO17025 assessment of the laboratory to determine equipment, calibration, procedures and competence amongst others. Additional evidence and test data relating to the products performance in the field and records of test work and methods will be required.


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Intertek can support all of the test routes outlined above, including testing performed in Intertek’s own laboratories which are located in a variety of locations around the world. Please contact us for further details.

SATELLITE™

Manufacturers test facilities may also be covered under Intertek’ SATELLITE™ program. SATELLITE™, Intertek’s exclusive data acceptance program, gives you control of your product certification program and delivers market-leading speed, market access and flexibility. Conduct testing in your own labs, on your own schedule, and obtain Intertek’s market-leading certifications for your products.

The SATELLITE™ Scheme:

Satellite is a scheme run by Intertek to accept testing conducted by a manufacturers own laboratory to help reduce costs and further increase speed to market. We can recognise the expertise of the laboratory and the validity of the test results they produce. 4 Levels of acceptance are available: Level 4 - Manufacturer conducts testing and prepares report without Intertek presence Level 3 - Manufacturer conducts testing without Intertek presence; Intertek prepares report Level 2 - Intertek engineers witness tests conducted by the manufacturer and prepare reports Level 1 - Intertek engineers conduct full testing at the manufacturer’s site and prepare reports If you would like to participate in the Satellite scheme and use your own test laboratory to conduct product assessment against relevant Standard, call us today on 01372 370900 or email us at [email protected]

Renewable Energy Testing Solutions:

Demand for clean renewable energy is experiencing exponential growth, being driven by the rising costs of traditional energy sources, increased recognition of environmental issues and political support. Intertek works with regulatory bodies; provides a broad range of integrated services, and has a global footprint in more than 100 countries to turn your project from potential energy to revenue quickly and proficiently. We provide testing and certification for the following products:

• Solar Panel Testing (Photovoltaic Modules)

• Solar Thermal System Testing

• Building-Integrated Photovoltaics (BIPV)

• Wind Energy Services

• Inverters and Converters for Traditional and Renewable Energy

• CoGen Products

• Fuel Cells/Hydrogen Generation and Dispersion

• Energy Storage and Battery Testing


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European Directives:

The Essential Health & Safety Requirements of the Machinery Directive are comprehensive and require compliance with other applicable European Directives. Intertek is also notified for the following Directives:

• Machinery Directive

• Low Voltage Directive

• EMC Directive (2004/108/EC)

• Gas Appliance Directive

• ATEX Directive (94/9/EC)

• Medical Device Directive (93/42/EEC)

• Outdoor Noise Directive

• R&TTE Directive

Is there any other testing or certification that I need to consider in addition to MCS?

The MCS scheme is largely focussed on providing performance assurance.

In addition to requiring MCS certification to be eligible for the financial incentives such as FITs or the RHI, the manufacturer of renewable energy products must ensure compliance with the relevant European Directives such as the Low Voltage Directive, EMC Directive and the Machinery Directive in order to produce a Manufacturers Declaration of Conformity and then CE Mark the product.

This means that major components such as generators, grid-tie inverters, cables and connectors, control and protection systems need to be assessed in order to meet the Essential Health and Safety Requirements of these directives

Each of the directives listed are supported by numerous standards which may be used to demonstrate a presumption of conformity with the relevant directive.

Intertek has testing laboratories across the globe that can provide the relevant electrical safety, EMC compliance and machinery evaluation and risk assessments. Please contact us for further details.

Additionally, the inverters used to connect products such as PV modules or wind turbines to the electrical grid will need to comply with the Energy Network Association (ENA) Engineering Recommendation G83 (or in the case of wind G59). Whilst described as ‘Recommendations’ these documents form an integral part of the Distribution Code within the UK and Distribution Network Operators (DNO’s) will insist on compliance with these documents. Please contact us for further details.


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Does the MCS include factory inspection?

Yes, this is an integral part of the robust criteria set out in the MCS scheme.

In order to ensure the continued quality and performance of the product over the life of the certification, the CB will conduct an initial audit of the factory. This is described as the initial Factory Production Control visit. This audit will assess the main factory (and other manufacturing locations) for compliance with the MCS-010 Standard. This is similar in form to an ISO9001 audit but places great emphasis on technical knowledge of the manufacturing techniques and technology employed within the product being assessed.

This FPC report may identify non-compliances (NC’s) with the standard. The NC’s must be resolved prior to the issue of the MCS licence.

To ensure that the product (and manufacturing process) remains in compliance over the life of the certification, the CB will conduct an annual audit of the manufacturing facility.

The deliverable from an FPC audit is an FPC report. This must be completed and passed prior to the issue of the MCS licence to use the certification mark.

I have a complete range of products with similar design. Do I need to test and certify all of them for MCS?

Applications for a range of common products (product families) will be dealt with on a case by case basis. For example, where one or more characteristics are the same for products with similar design, construction and functionality then it may be possible that the results of tests for these characteristics on one product may be applied to other similar products. This will be determined by the Certification Engineer.

Information relating to product groups and families is requested as part of the Intertek MCS Application Form and supporting documentation. This information is used to determine product groups and families.

Any products submitted for MCS and not covered by existing test data will be reviewed following completion of Declaration of Product Similarity which is completed by the applicant. This information will be reviewed by the Certification Engineer and based upon this review, further information or limited testing may be required for certification.

Any product that is to be sold as MCS certified and listed within the MCS Product Directory will need to be covered by the MCS licence.


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ETL Listed Mark:

The ETL Listed Mark from Intertek is the fastest growing product certification mark in North America with more than 60,000 product listings. With shorter queue times and faster turnaround (15 days), immediate response to your inquiries and request for quotes, and testing expertise across a global network of laboratories, Intertek can help you gain the certifications you need. The ETL Listed Mark is proof of product compliance (electrical, gas and other safety standards) to North American safety standards. Authorities Having Jurisdiction (AHJ’s) in 50 states and Canada and retailers accept the ETL Listed Mark as proof of product safety. Manufacturers are choosing ETL because it gives them a competitive advantage in the marketplace.

MCS Certification Process

There are 2 ways to obtain MCS Certification:

1. Contact your MCS Certification Body to discuss your requirements and agree the testing route. In most cases, the MCS CB will be able to advise costs for testing and certification and can arrange for this testing to be performed.

2. Arrange to test your product at the test laboratory of your choice. Complete the testing and then present the test reports and other data to the MCS Certification Body

Intertek encourages early contact with Certification Body, as this enables all test requirements to be defined and agreed at an early stage. The risk of taking the latter approach is that review of test reports and documentation may then require additional testing and/or clarification.

Always involve your CB at the start of the project.

It is also important to consider that the MCS standards are based upon IEC/EN standards and in many cases it may be possible to deliver other certification such as IECEE CB Certification or ETL Certification for the USA and Canada by conducting additional testing at the same time. Often, there is significant crossover or similarity between North American and IEC standards so it makes sense to consider future market entry requirements at the time that testing is carried out.


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New Application

Stage 1 – Getting a Quotation Approach us with as much information as you have on the product to obtain a quotation for MCS Certification and if required, testing. The application data to supply should typically include:

• Drawings/Product Photographs (if available) • Product Specifications (dimensions, power ratings, materials and components list etc)

• Product description (intended use) • Model name, model number(s) • If the model is part of a series, the rationale for model similarity if ALL models are not covered by the test reports

• Details of any approved/certified sub assemblies or components that will be used in the finish product e.g. Junction Boxes, generator etc.

• Details of the Applicant, Licence Holder and Manufacturer • Details about the manufacturing process for the MCS Factory Production Control (FPC) audit

• Copies of the Quality Manual and details of how the product compliance will be maintained

• If the product is Building Integrated (for Solar thermal and Solar PV modules)

• Details of the test laboratory (if known) • Test reports (if available)

We will review the material you send us, taking into account any previously approved components or sub-assemblies which will be used in the product, then select the applicable MCS standard and EN/IEC standards for testing then identify


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a suitable laboratory in our network to conduct the work and a qualified reviewer to assess the results. We will then consult with them about the project and then provide a quotation – which will detail the number of samples we need, list the Standards involved, their edition numbers and relevant revision dates.

We will also issue you with a MCS Application Form. This will detail all of the information we require in order to provide you with a complete and accurate quotation.

Once that quotation is signed off by you and a purchase order is returned, we will acknowledge your order and define the testing schedule and then the project moves onto stage 2.

Stage 2a: The Product Technical Evaluation Now the Product and test documentation that has been issued to us will be evaluated against the criteria outlined in the appropriate MCS standards. This includes full review of any test reports submitted against the standards referenced in the MCS standards.

Upon successful completion of the technical evaluation, a certification recommendation will be issued pending successful completion of the FPC.

Stage 2b: The Factory Production Control (FPC) Audi t and Report In parallel with the Technical Evaluation, we will begin preparations for the FPC audit. We will review the Quality Manual and other information on how product compliance will be maintained in manufacture and how design changes will reviewed and informed.

Prior to the FPC audit the MCS Pre-Licence questionnaire must be completed.

Section 1 of the Pre-licence questionnaire must be completed by the MCS Licence Holder, (this may be the same as the MCS Applicant)

Section 2 of Pre-licence questionnaire is completed by the final manufacturing/assembly facility.

If manufacturing/assembly of the microgeneration product takes place at more than one facility please complete and return Section 2 of this document for each manufacturing location involved in the production/assembly process.

We also require evidence of any QMS Certification (ISO 9001) for each manufacturing location. Evidence of ISO 9001 may allow us to reduce the length of time and audit plan needed for the FPC assessment.


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Section 3 of Pre-licence questionnaire provides a checklist for the documentation pack required to be sent to Intertek with this questionnaire for review in preparation for the Factory Production Control audit.

Factory Production Control (FPC) guidance and further explanation of clauses/requirements are detailed in Intertek Doc 40 – Guidance for the manufacturer / factory site. A copy is available from Intertek upon request.

Intertek has also produced a set of guidelines to assist customers with the FPC process.

Stage 3: Resolution and closure of any non-complian ces Any NC’s identified during the initial FPC must be resolved and signed off by the CB prior to the issue of the licence allowing the use of the MCS mark. In certain cases, there maybe a requirement for a second audit visit but the majority of NC’s are cleared by submitting documentary evidence only.

Once satisfied with the documented solutions the CB will sign off the FPC report.

Follow Up Services Intertek will conduct annual FPC audits in accordance with MCS-010 to ensure ongoing compliance with the requirements.

In addition, the MCS certified product will be audited as part of the annual FPC follow-up. Intertek will

A) review the product technical data files including materials, B) review of end of line tests in accordance with the manufacturer’s quality plan,

C) if necessary to confirm that the product continues to meet the requirements, conduct repeat testing of elements of the applicable product standards.

MCS Certification from a CEN Solar Keymark

The MCS is an EN45011 certification scheme which complies with the government criteria for eligibility to access financial incentives. There is another scheme covering Solar Thermal Products which is equivalent to MCS and this is operated as the CEN Solar Keymark Scheme.

The 2 schemes operate separate Product Listing directories. This means that a product that is covered under the CEN scheme will not automatically appear in the MCS Product Listing directory unless a specific application is made for MCS certification to an MCS CB.


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The 2 schemes are broadly similar and the test standards used are identical. However, the basis for Factory Audit is ISO9000 for the CEN scheme whereas the requirements for MCS are covered by MCS-010. This builds on the requirements of ISO9001 with particular emphasis on end of line test and product compliance.

An MCS CB is therefore likely to accept the CEN Solar Keymark certification as the basis for MCS Certification but it will be necessary to perform the MCS FPC (initial and annual) in order to comply with MCS requirements.

The advantage of this ‘dual listing’ is that s Solar Thermal product will be visible in the MCS Product Listing Directory and there is strong evidence to suggest that consumers and installers look to the MCS website as a major resource when selecting products. Please contact Intertek for further details.

Glossary

FPC Factory Production Control. This is a factory audit in accordance with the requirements of MCS-010

MCS Microgeneration Certification Scheme

CB Certification Body, for example Intertek, accredited by a National Accreditation Body to EN45011

NC Non-compliance – this may apply to the FPC audit or Technical Evaluation and testing

NRTL Nationally Recognised Test Laboratory, a body accredited by OSHA to award Certification/Listing on the US & Canada

UKAS United Kingdom Accreditation Service – The UK National Accreditation Body, responsible for the assessment of competence of Certification Bodies and Testing Laboratories in the UK

QMS Quality Management System

ETL Intertek’s ETL Mark denotes that a product meets the safety requirements to be placed on the North American market

IECEE IEC Electrotechnical Equipment conformity testing and certification scheme

CEN Comitie Europeen de Normalisation – The European Committee for Standardization


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Contacts

Your local MCS managing office:

Intertek Leatherhead Intertek House Cleeve Road Leatherhead Surrey KT22 7SB T: +44 1372 370900 F: +44 1372 370999

For more information on specific testing and certification information, please contact Intertek at 1-800-WORLDLAB, email [email protected], or visit our website at www.intertek.com.

This publication is copyright Intertek and may not be reproduced or transmitted in any form in whole or in part without the prior written permission of Intertek. While due care has been taken during the preparation of this document, Intertek cannot be held responsible for the accuracy of the information herein or for any consequence arising from it. Clients are encouraged to seek Intertek’s current advice on their specific needs before acting upon any of the content.