tÜv rheinland solar energy report factory inspection€¦ · refer to certificate pv 50371126 page...

TÜV Rheinland Solar Energy

Report

Factory Inspection

as part of the Photovoltaic Module qualification according to IEC 61215/IEC 61730/ANSI/UL 1703/

CAN/CSA-C22.2 No.61730-1/-2

TÜV Report No.: 15102643.004

January, 2020

Publication or transfer of this report to third parties is only permissible in its complete an unabridged form. Publication or dissemination of extracts, appraisals or any other revision and adaptation hereof, in particular

for advertising purposes, is only permissible on receipt of prior written agreement by TÜV Rheinland.

Protocol no.: 170125932

Inspector: Lei C.L. Chen

FI report_ZNSHINE_2020_15102643.004.docx / 43

Inspection of photovoltaic (PV) module manufacturing site

☐ Initial inspection

☒ Follow-up inspection

Date and time of inspection: from: 08/01/2020 until: 08/01/2020

9:00 a.m. 17:00 p.m.

Participants of the opening meeting:

Name Company Position

Wang wei ZNSHINE PV-TECH CO.,Ltd. Technical Director

Rui Xingjuan ZNSHINE PV-TECH CO.,Ltd. Certification Supervisor

Fang Yihong ZNSHINE PV-TECH CO.,Ltd. DCC specilist

Huang Lupin ZNSHINE PV-TECH CO.,Ltd. QC manager

Lei C.L. Chen TÜV Rheinland (Shanghai) Co., Ltd.

Inspector

Participants of the closing meeting:

Name Company Position

Wang wei ZNSHINE PV-TECH CO.,Ltd. Technical Director

Rui Xingjuan ZNSHINE PV-TECH CO.,Ltd. Certification Supervisor

Fang Yihong ZNSHINE PV-TECH CO.,Ltd. DCC specilist

Huang Lupin ZNSHINE PV-TECH CO.,Ltd. QC manager

Lei C.L. Chen TÜV Rheinland (Shanghai) Co., Ltd. Inspector

Company/applicant details:

Name/Description: ZNSHINE PV-TECH CO.,Ltd. Street: No.1, Zhengxing South Road, Zhixi Industrial Zone Postcode/City: Jintan Changzhou, Jiangsu Province 213251 Country: P.R.China Phone: +86 519 68220253 Fax: +86 519 68220233 E-mail: [email protected] Web address: www.znshinesolar.com

Quality manager/nominee details:

Name: Rui Xingjuan Department: Quality dept. Phone: +86 519 68220250 Fax: +86 519 85322976 E-mail: [email protected]




Inspector’s details:

Name: Lei C.L. Chen Department: Solar/ Fuelcell Technology Greater China Phone: +86 86 21 60811779 Fax: +86 21 6108 1199 E-mail: [email protected]

Production at several sites: ☐ Yes ☒ No

Address of the inspected site:

Name/Description: ZNSHINE PV-TECH CO.,Ltd. Street: No.1, Zhengxing South Road, Zhixi Industrial Zone Postcode/City: Jintan Changzhou, Jiangsu Province 213251 Country: P. R. China Type of production: Crystalline PV module production Additional manufacturing sites:

N/A




List of contents

Inspection of photovoltaic (PV) module manufacturing site ...........................................................2 1 Ambit of the inspection......................................................................................................6 2 Inspected production areas ...............................................................................................6 3 Existing accreditations, certificates, permissions, approvals....................................................6

3.1 Main licenses...........................................................................................................6 3.2 Co licenses .............................................................................................................6

4 Production in the considered period ....................................................................................6 5 Components and materials for the production.......................................................................8

5.1 General...................................................................................................................8 5.2 Solar cell .................................................................................................................8

5.2.1 Solar cell .............................................................................................................9 5.2.2 Solar cell .............................................................................................................9

5.3 Front cover ............................................................................................................ 10 5.4 Backside cover ...................................................................................................... 10 5.5 Interconnection circuit ............................................................................................. 11

5.5.1 Cell connector .................................................................................................... 11 5.5.2 String connector ................................................................................................. 11 5.5.3 Soldering material ............................................................................................... 11

5.6 Electrical connection ............................................................................................... 12 5.6.1 Junction box, bypass diode, cable, connector .......................................................... 12 5.6.2 ............................................................................................................................ 14 5.6.3 Junction box adhesive ......................................................................................... 16 5.6.4 Potting material of junction box ............................................................................. 16

5.7 Cell encapsulation .................................................................................................. 16 5.7.1 Encapsulation material......................................................................................... 16 5.7.2 Edge sealing ...................................................................................................... 17

5.8 Frame and frame adhesive ...................................................................................... 17 5.8.1 Frame ............................................................................................................... 17 5.8.2 Frame adhesive (tape/silicone) ............................................................................. 18

5.9 Mounting and attachment parts................................................................................. 18 5.10 Markings ............................................................................................................... 19 5.11 Other components .................................................................................................. 19

Remark: No available invoice or contract copies on FI. Based on the declaration, components used for prototype samples are provided by the suppliers free of charge. .................................................. 19 6 Production process ........................................................................................................ 20

6.1 Incoming inspections and preparation of materials....................................................... 20 6.2 Solar cell tabbing and connection to strings ................................................................ 20 6.3 Interconnection of strings......................................................................................... 21 6.4 Compilation of material layers (module sandwich) ....................................................... 21 6.5 Lamination process................................................................................................. 21

6.5.1 ............................................................................................................................ 21 6.5.2 ............................................................................................................................ 21 6.5.3 ............................................................................................................................ 22 6.5.4 ............................................................................................................................ 22

6.6 Electrical connection ............................................................................................... 22 6.7 Framing ................................................................................................................ 24 6.8 Safety tests ........................................................................................................... 24

6.8.1 Hi-pot test .......................................................................................................... 24 6.8.2 Insulation test ..................................................................................................... 24 6.8.3 Wet leakage test ................................................................................................. 24 6.8.4 Ground continuity test.......................................................................................... 25

6.9 Control of output power (100 %) ............................................................................... 25 6.10 Final visual control.................................................................................................. 25

7 Quality assurance/control ................................................................................................ 26 7.1 Premises and environmental conditions ..................................................................... 26

7.1.1 Storage and handling of materials ......................................................................... 26 7.1.2 Production areas ................................................................................................ 26




7.1.3 Staff training....................................................................................................... 27 7.1.4 Complaints ........................................................................................................ 27

7.2 Methods for output power measurement .................................................................... 27 7.3 Handling of test and calibration equipment ................................................................. 28 7.4 Regular quality assurance tests ................................................................................ 29 7.5 Documentation of process data ................................................................................ 29 7.6 Directing of faulty products....................................................................................... 29

8 Summary ...................................................................................................................... 30 Annex 1: Module type family sheet.......................................................................................... 31 Annex 2: List of the existing and surveyed documents ............................................................... 32




1 Ambit of the inspection

An overview of produced module types is to be presented in annex 1. Here a module type family is defined by the design and the list of components and materials. Within a module type family only module size and power class may change.

This is a follow-up factory inspection requested by license holder “ZNSHINE PV-TECH CO., Ltd.”. Scope of inspection: No. 2 workshop as an representative. During the inspection, the modules (6” poly, 72 cells) were in production. Refer to certificate PV 50371126 page 1-2, PV 50401141 page 1-2, PV 50408499 page 1-3 for the details of scope module types.

2 Inspected production areas

Material preparation, solar cell sorting, cell tabbing and stringing, lay-up, EL imaging, lamination, electrical connection, framing, electrical safety tests, output power control, final visual inspection, warehouse

3 Existing accreditations, certificates, permissions, approvals

3.1 Main licenses

ISO9001:2015, Certificate No.: 35387, Valid until: 04/09/2020, Certified by NQA Certification Limited. ISO14001:2015, Certificate No. E4056, Valid until: 04/09/2020, Certified by NQA Certification Limited. OHSAS18001:2007, Certificate No. H1621, Valid until: 04/09/2020, Certified by NQA Certification Limited.

3.2 Co licenses

Please refer to respective main licenses.

N/A

4 Production in the considered period

Number of production staff per shift: 50 Number of production lines: 4 workshops (Workshop 1: 2 lines with 6 laminators; Workshop 2: 3 lines with 12 laminators; Workshop 3: 2 lines with 9 laminators; Workshop 4: 2 lines with 6 laminators.) Number of shifts: 2

Production capacity: 2.0 (500MW for each workshop)

GWP per year

Serial number: from ZX87123419330550 until ZX75713519192098

Period: from 23/01/2019 until 08/01/2019

No modules with TUV Rheinland test mark was produced during 2019.01-2020.01. Refer to Annex 2.6 for detialed declaration.




Explanation for serial number coding:

According to QES/ZX-TD-III0004C (version C, effective date: 18/01/2016) supplied by Znshine: ZX X X X X XX XX XX XXXX A B C D E F G H I A= Product brand; B= Cell type; C= Cell detailed information; D= Work order code; E= Workshop code; F= Year code; G= Month code; H= Date code; I= Running serial number.

Example for traceability supplied by a bill of materials for one module recently tested at TÜV Rheinland:

Refer to annex 2.8 for more details.

Serial number of tested module:

N/A

Bill of materials and process data (can be supplied by corresponding documents in the annex):

Confirmation that the certification marks were only found on products for which a test mark was granted:

TÜV Rheinland test mark: ☒ Confirmed ☐ Not confirmed ☐ Not applicable

BRE Global and MCS mark: ☐ Confirmed ☐ Not confirmed ☒ Not applicable




5 Components and materials for the production

The certification according to IEC 61215 determines the usable materials for the production. Modules, that are based on the same materials, components and processing and that only differ in size and electrical out-put power, form a so-called product family or type family. The larger the diversity of products from a manufacturer, the more materials and material combinations must be tested / certified. All changes in the module design and used materials must be declared to TÜV Rhein-land. Depending on the type of change an extension of the IEC certification to the new module type may require the repetition of certain tests. In this section the conformity of the current module production with the certified materials and material com-binations will be verified by means of random sampling of delivery notes or invoices during the past period and by inspection of current inventory. In the following each module component is represented by one item. If different type specifications or materi-als are used add sub-items.

5.1 General

This section should be used to record evidence of compliance with MCS 010 Table 1 clause 6 (ordering) and clause 7 (purchasing).

Orders, contracts and tenders shall be reviewed to ensure that - the requirements are adequately defined for each product for quantity, packaging, deliver, etc., - the company has the resource and capability to meet the order/contract requirements. Where the

time scales cannot be met, the company shall detail when the order/contract will be fulfilled.

Records of this activity shall be maintained for all orders/contracts and tenders and presented for inspection. A process shall also exist for managing amendments to contracts/orders.

Description of processes:

The order and contract do contain quantity, specification, type, delivery date and those requirements are

documented in the QM documentation. QES/ZX-PS-III001C

A master list of suppliers shall be established to identify their address, location, contact details and the ser-vice or products/materials supplied. The method of adding or removing suppliers and products/materials from the master list shall be established, e.g. previous dealings/past history, product approval. Purchase orders for products shall clearly identify the part number, class, grade, size, finish, trade name and any other details quoting (where necessary), tolerances or relevant product standards. Description of processes:

A master list of suppliers is available, which contains the address, location, contact details and the services or materials from each supplier. Documented in QES/ZX-PS-III003B

Contract related records must as a minimum contain details of the customer reference, dates, quantities and details of all products supplied. Does the company keep these records for a minimum of five years?

Yes, contract related records are kept for a minimum of 5 years.

5.2 Solar cell

Use one item per manufacturer and cell type. If necessary add sub-items. Note all power classes of the cell types that are used in production.




5.2.1 Solar cell

Type/Specification Manufacturer/Remarks

Technology (mono/poly Si, etc.): mono –si

Type designation: ZX6MR1-4

Dimensions mm x mm: 156x156

Active area cm²: 238.95

Thickness µm tolerance: 200±30

Power classes:

Name and location of manufacturer:

ZNSHINE PV-TECH Co.,Ltd.

1# Zhengxing South Road, Zhixi Industrial Zone, 213251, Jintan, Changzhou, P.R.China

Name and location of supplier (if applicable):



Validation by invoice/delivery note no.: N/A dated: -

5.2.2 Solar cell


Technology (mono/poly Si, etc.): poly-si

Type designation: ZX6PR1-4

Dimensions mm x mm: 156x156

Active area cm²: 243.36

Thickness µm tolerance: 200±30

Power classes:











5.3 Front cover


Material (glass, etc.): glass

Type designation: Coated glass

Thickness mm: 3.2

Kind of surface treatment: hexagon、Quad

Tempering method (if tempered glass):


JIANGSU SUOLATE PHOTOVOLTAIC SCIENCE AND TECHNOLOGY DEVELOPMENT C0.,LTD. NO8.Yijing Road,Jintan City,Changzhou City,Jiangsu,China


JIANGSU SUOLATE PHOTOVOLTAIC SCIENCE AND TECHNOLOGY DEVELOPMENT C0.,LTD. NO8.Yijing Road,Jintan City,Changzhou City,Jiangsu,China




Type designation: semi-tempered glass

Thickness mm: 2




Chang zhou Hongxie Safety Glass Co.,Ltd.




5.4 Backside cover



Type designation: semi-tempered glass

Thickness mm: 2









Type designation: Cynagard205A

Backsheet structure (layers): PVDF/PET/Flourine film

Thickness mm: 22.5/275/4

Max. system voltage [V]: 1500


Cybird Technology lnc.

Yegang Road 369#,Wujiang,Jiangsu 215200 P.R.China


Cybird Technology lnc.

Yegang Road 369#,Wujiang,Jiangsu 215200




P.R.China


5.5 Interconnection circuit

5.5.1 Cell connector


Dimensions mm: 1.2x0.25

Composition of alloy: Base Cu.Coating Sn60pb40

Article/specification no.:


XiAn Telison New Material Co., Ltd.




5.5.2 String connector


Dimensions mm: 6x0.35

Composition of alloy: Base Cu.Coating Sn60pb40

Article/specification no.:






5.5.3 Soldering material


Soldering of the cell: cell interconnector

Fluxing agent/paste: SF56


Singapore Asahi Chemical﹠Solder Industries Pte Ltd.






Connections of the strings, junction box, etc.:

Soldering tin: string connector

Fluxing agent/paste: ANX3012






5.6 Electrical connection

5.6.1 Junction box, bypass diode, cable, connector

Junction box type/Specification Manufacturer/Remarks

Type designation:PV-JX1203

Nominal current A: 13

Nominal voltage V: 1500

Certificate no.: R 50337606 0001


Taizhou jinxiu Electrical Science ﹠Technology Co.，Ltd. Zhugang Town Yucheng Street, Yuhuan County, Zhejiang 317600, P.R. China



Name and location of supplier (

Bypass diode type/Specification Manufacturer/Remarks

Type (pn/Schottky): Schottky

Type designation: SPA2040


Max. junction temperature Tj [°C]: 200

Max. foreward voltage [V] at IF = 20 A: 0.62

Max. blocking voltage [V]: 40


Taizhou jinxiu Electrical Science ﹠Technology Co.，Ltd. Zhugang Town Yucheng Street, Yuhuan County,

Zhejiang 317600, P.R. China







Cable type/Specification Manufacturer/Remarks

Type designation: H1Z2Z2-K 1x4.0mm2

Cross section mm²: 1x4.0mm2

Max. nominal current A:

Max. operating voltage V: 1500V

Max. temperature rating °C: 120

Certificate no.: R 50164036


Ningbo Followray Solartech Co., Ltd

NO.38 HuiMao Road,Economic &Technological De-velopment Zone FengHua City,ZheJiang Prov-ince,China




Connector type/Specification Manufacturer/Remarks

Type designation: LJQ-3

Max. nominal current A: 30

Max. operating voltage V: 1500













5.6.2

Junction box type/Specification Manufacturer/Remarks

Type designation: PV-JX1201H


Nominal voltage V: 1500

Certificate no.: R 50276972 0002





Name and location of supplier (

Bypass diode type/Specification Manufacturer/Remarks

Type (pn/Schottky): Schottky

Type designation: SPA2040-1


Max. junction temperature Tj [°C]: 200

Max. foreward voltage [V] at IF = 20 A: 0.62

Max. blocking voltage [V]: 40







Cable type/Specification Manufacturer/Remarks

Type designation: H1Z2Z2-K 1x4.0mm2

Cross section mm²: 1x4.0mm2

Max. nominal current A:

Max. operating voltage V: 1800V












Connector type/Specification Manufacturer/Remarks

Type designation: LJQ-1

Max. nominal current A: 30

Max. operating voltage V: 1500













5.6.3 Junction box adhesive


Type designation: ZQ-5612 Name and location of manufacturer:

Liyang tomorrow New Marterials Co.，Ltd.

Hexi Village Daibu Town Liyang, Jiangsu China


Liyang tomorrow New Marterials Co.，Ltd. Hexi Village Daibu Town Liyang, Jiangsu China


5.6.4 Potting material of junction box


Type designation: ZQ-5622 Name and location of manufacturer:

Liyang tomorrow New Marterials Co.，Ltd.

Hexi Village Daibu Town Liyang, Jiangsu China




5.7 Cell encapsulation

5.7.1 Encapsulation material


Frontside of cells

Type designation: EV1050G1

Thickness [mm]: 0.5


Jiangsu Lushan Photovoltaic Technology Co.,Ltd.

East Road No.2229 South Ring Jintan, Economic Develoment Zone, Jiangsu(213200)




Backside of cells

Type designation: EV1050G2

Thickness [mm]: 0.5

Colour: White











5.7.2 Edge sealing


Type designation: EV1050G1、EV1050G2 Name and location of manufacturer:







5.8 Frame and frame adhesive

5.8.1 Frame

Type/Specification/Drawing No. Manufacturer/Remarks

Material: 6063T-5

Coating (type & thickness): Anodized Aluminum

Drawing no.:

Assembly components (screws, rivets, etc.): assembled by key corners


Changzhou Yihe Aluminum Industry Co.,Ltd.


Changzhou Yihe Aluminum Industry Co.,Ltd.





5.8.2 Frame adhesive (tape/silicone)


Type designation: ZQ-5611

Thickness:

Name and location of manufacturer: Liyang tomorrow

New Marterials Co.，Ltd. Hexi Village Daibu Town Liyang, Jiangsu China




5.9 Mounting and attachment parts


Type: 6063-T5 Name and location of manufacturer: Zhangjiagang Hanlong New Energy Technology Corp.






5.10 Markings

To ensure compatibility with all Canadian jurisdictions, products meeting CAN/CSA-C22.2 No.61730-1/-2 requirements shall be bilingual – English and French.


Type label: 50 micron Matte Silver PET TC/S333(a)(b)


AVERY DENNISON CHINA CO.,LTD



Barcode or serial number label: 50 micron Matte Silver PET TC/S333(a)(b)






5.11 Other components


Fixing of cells (tape): 5 Electrical Tape Name and location of manufacturer: 3M

Electrical Products Division

6801 River Place Blvd.

Name and location of supplier (if applicable): 3M

Electrical Products Division

6801 River Place Blvd.


Remark: No available invoice or contract copies on FI. Based on the declaration as shown in Annex 2.6.




6 Production process

The certification according to IEC 61215 also determines the sequence of the production process as well as the main process parameters.

6.1 Incoming inspections and preparation of materials

Description of methods, sample size, demands for suppliers, etc.:

Backsheet, EVA, cell & string interconnector, solar cell and adhesive are required to be kept at 15-30°C, RH 30%-70%.

Visual inspection, dimension and type name are checked in most case.

Cell thickness is checked, sampling: 3%

EVA: Gel-content test, peel-off test between EVA and backsheet.

Pull test between solar cell and cell interconnector is performed.

The controlled documentation defines methods, sample sampling.

The temperature in cell power measurement room is 25±2℃.

Preparation of materials (cleaning of glass, cutting of foils, pre-soldering of tabbing, etc.):

Glass is prewashed by supplier and cleaned with lint-free cloth and alcohol 100% during lay-up station.

The margin of fluxing agent is checked every 4 hours.

6.2 Solar cell tabbing and connection to strings

☐ Manually ☐ Semi-automatically ☒ Automatically

Type, make and quantity of equipment:

No. 1 workshop:

CH526 (4 sets) from Ningxia xiaoniu Automatic Equipment Co.,Ltd.

No. 2 workshop:

CH518 (4 sets) from Ningxia xiaoniu Automatic Equipment Co.,Ltd.

No. 3 workshop:

CH526 (4 sets) from Ningxia xiaoniu Automatic Equipment Co., Ltd.

Number of soldering points: 4 busbars / 12 busbars

Soldering technology (contact, IR, hot air, induction, laser, etc.):

Induction for equipment types from Ningxia xiaoniu

Preheating (temperature): 80-100℃ for equipment types from Ningxia xiaoniu

Process parameters (soldering temperatures, etc.): 180-240℃ for equipment types from Ningxia xiaoniu

Min. distance between cells (incl. tolerances): 1~3mm

Quality control tests:

Pull test is checked every 12 hours.

Soldering temperature check is performed every 2 weeks.

Remark:

The below listed new equipments is not in the scope of certification of TÜV Rheinland, refer to decla-ration as documented in Annex 2.9 for details.

No. 1 workshop:

CHD150-M4000 (5 sets) from Wuxi Autowell technology Co., Ltd




No. 3 workshop:

CHD150-M4000 (4 sets) from Wuxi Autowell technology Co., Ltd

No. 4 workshop:

5xLDTS4000A from Wuxi Lead Intelligent Equipment Co., Ltd.

6.3 Interconnection of strings

☐ Manually ☐ Semi-automatically ☒ Automatically


DH120

No.1 workshop: 2 sets

No. 2 workshop: 3 sets



Soldering technology (contact, IR, hot air, induction, laser, etc.):

Induction

Process parameters (temperatures, etc.): Current: 4.5-5A

Min. distance between cells: 2±0.5mm

Min. distance between strings: 3±1mm

Remarks: temperature check is performed every shift.

check for inducting current and time on the automatic machine for interconnection of strings only by pull off test.

6.4 Compilation of material layers (module sandwich)

☐ Manually ☒ Semi-automatically ☐ Automatically

(Processing, positioning, training of personnel, min-imum distances of conducting parts and edge of module)

Glass, EVA (between glass & solar cell) and cell strings are laid automatically.

The operators adjust the position of cell string with template, solder the string connector by soldering iron, stick fixing tape & serial number, lay the EVA (be-tween solar cell & backsheet) & backsheet.

100% EL image check is performed.

6.5 Lamination process

6.5.1

Parameter/Specification Value/Remarks

Type, make and quantity of equipment: No. 1 workshop:

CYDSC-2448DGM from SECO 6 sets

Quantity of modules per lamination: Depending on the module area

Pressure of membrane [kPa] (evacuation/lamination/cooling phase):

-60/40/-20

Lamination temperature [°C] (evacuation/lamination/cooling phase):

130-150°C

Lamination time min (evacuation/lamination/cooling phase):

330 / 10, 10, 550 / -




Uniformity of the temperature %: 1.5

Requirement for Gel content %: 70-90

Maintenance interval (oil, membrane, etc.):

Pump oil is performed once a week.

Heating oil is performed once a year

membrane is performed every 2 months

Process recording: yes

Quality control tests: Temperature uniformity check is performed daily under close laminator cover. Gel-content test is checked: 1 position/laminator/shift

6.5.2


Type, make and quantity of equipment: No. 2 workshop:

CYDSC-2448DGM (6 sets) from SECO


Pressure of membrane [kPa] (evacuation/lamination/cooling phase):

-100; -60/-40/-20; -


145 for SVECK; 148 for Lushan

Lamination time min (evacuation/lamination/cooling phase):

360/10, 10, 580/-



Maintenance interval (oil, membrane, etc.):

Pump oil is performed once a week.

Heating oil is performed once a year

membrane is performed every 2 months



6.5.3



No.3 workshop:

SYDSQ-3623DGM-B (9 sets) from Shanghai Senco Technology Corp. Ltd.

(heating character: electrical heating )


Pressure of membrane [mbar] (evacuation/lamination/cooling phase):

The 1st phrase: -100; -60/-40/-20; -

The 2nd phrase: -100; -50/-30/-10; -


The 1st phrase:132;

The 2nd phrase:136




(for EVA from SVECK and Lushan)

Lamination time s

(evacuation/lamination/cooling phase):

The 1st phrase: 300/20,20,120/-

The 2nd phrase: 10/20, 20, 410/-




Maintenance interval (oil, membrane, etc.): N/A



6.5.4



No.4 workshop:

CYD-SCSM4824DGM from (6 sets) from Shanghai Senco Technology Corp. Ltd.

(heating character: electrical heating )


Pressure of membrane [mbar] (evacuation/lamination/cooling phase):

The 1st phrase: -100; -60/-40/-20; -

The 2nd phrase: -100; -50/-30/-10; -


The 1st phrase:125;

The 2nd phrase:141


Lamination time s

(evacuation/lamination/cooling phase):

The 1st phrase: 330/10,10,100/-

The 2nd phrase: 10/10, 10, 440/-




Maintenance interval (oil, membrane, etc.): N/A



6.6 Electrical connection


Description of single process steps

- Junction box is attached after framing. - The sealant is injected by automated machine. - Soldering temp: 440 ± 15 ºC




6.7 Framing


Description of single process steps Manufacturer/Remarks 1. The frame is pre-filled with frame adhesive. 2. Laminate modules are transported to the position and get aligned. 3. The four corners are pressed with the framing machine. Remark: To make sure the suitable amount adhesive injected into the frame slot, 2 times weighting daily. To make sure the good framing, there has routine test (size checking) is performed daily. Visual inspection is performed with 100% sampling.

6.8 Safety tests

6.8.1 Hi-pot test


Type, make and quantity of equipment: 3154 from Everyman

Sample rate [%]: 100

Test voltage V: 3600

Duration of tests s: 1

Pass criteria: Leakage current <0.05mA

Remarks:

Recommendation from TÜV Rheinland: VTEST = (1000 V + 2 x VSYS) x Y,

where Y = 1 for a minimum test duration of 1 minute, Y = 1.2 for a minimum test duration of 1 second.

6.8.2 Insulation test


Type, make and quantity of equipment: 3154 from Everyman

Sample rate [%]: 100

Test voltage V: 1000

Duration of tests s: 3

Min. insulation resistance M: 400 M.m2/module area

Pass criteria: 400 M.m2/module area

Remarks: Recommendation from TÜV Rheinland: test performance acc. to IEC 61215 conditions.

6.8.3 Wet leakage test



N/A

Sample rate [%]:

Test voltage V:

Duration of tests s:

Min. insulation resistance M:




Pass criteria:

Remarks: Recommendation from TÜV Rheinland: test performance acc. to IEC 61215 conditions.

6.8.4 Ground continuity test



N/A

Sample rate [%]:

Duration of tests s:

Applied current [A]:

Pass criteria:

Remarks: N/A

6.9 Control of output power (100 %)


Type, make and quantity of equipment: XJCM-11A+ (3 sets in workshop 3) from Gsola

DLSK-SOL8 (7 sets in workshop 4) from Delicacy

Type of simulator (flash type (short/long-pulse; multi flash); continous):

short pulse flash

Max. test area [m²]: 1mx2m

Non-uniformity of irradiance [±% or class]: A

Spectral match [±% or class]: A

Temporal instability of irradiance [±% or class]: A

Duration of measurement [ms]: 10

Temperature sensors (PT100, IR, etc.): IR

Correction factors (temperature coefficients, internal series resistance, irradiance coefficient, etc.):

Temperature coefficients are applied

Acceptance protocol: yes

Measurement uncertainty %: 3%

Light induced degradation considered? N/A

Remark: 16/05/2019 for XJCM-11A+ and 10/08/2019 for DLSK-SOL8 by Fujian MeTROLOGY institute.

6.10 Final visual control

Description of single process steps The products are checked by EL 100% sampling. The final visual check includes the check of backsheet, serial no. , junction box, cable, connection, edge sealing material, frame, the front view of module. If pass, there will have QC pass mark on each product, otherwise, it will be put on separate area.




7 Quality assurance/control

Quality management system type: ISO9001:2015 Since: 01/12/2019

Quality manual: Yes ☐ No Number/last revision: QES/ZX-102C

Are regular internal review meetings taking place to review the status of the quality system? At what fre-quency?

Yes, once a year. The internal meeting with quality function is performed weekly.

Method used to control quality relevant documents (document number/data base/master list/revision num-bers etc.); storage/backup of documentation. (Awareness of relevant international and national standards to be fulfilled).

Document number and revision number are used to control the document; The quality department is respon-sible for storage / backup of documentation.

7.1 Premises and environmental conditions

It must be assured that the environmental conditions in the production and storage rooms do not have a negative influence on the quality of the PV modules. The technical requirements for the production areas and the environment should be laid down in a written form.

7.1.1 Storage and handling of materials

Regulation of storage processes, definition of storage periods and transportation guidelines, material han-dling guidelines, packaging instructions:

- FIFO executed in the warehouse.

- The warehouse is air-conditioned, temperature controlled at 15~30°C and RH≤70%.

- Carts are ready to transport critical materials and semi-finished products in warehouse and production line.

- Refer to QES/ZX-WH-III01Edocument.

Is each process, part or material which is to be used, identified, along with specification tolerances, methods and any other specifications that may be required by contract?

Yes ☐ No ☐ Not applicable

7.1.2 Production areas

Description of conditions (measures to maintain order and cleanliness, health and safety issues):

- The temperature and humidity were controlled by air-conditioning.

- The production line was clean and tidy.

- Safety line was marked on the floor.

- Steel barriers were ready nearby the laminator area.

- All operator worn hairnets and clean uniform.

Are there any health and safety issues for the employees? ☐ Yes No

Is personal protective equipment needed in the production line? ☐ Yes No

Description: N/A




7.1.3 Staff training

Are work instructions available at the location where the processes take place?

☐ No ☐ Parts of the line Total line

Have a competence matrix and training records for all personnel been established?

Yes ☐ No Refer to QES/ZX-PD-III032A document.

7.1.4 Complaints

The company shall manage complaints under controlled condition and shall keep a log/register of any com-plaints received and the corrective and preventative actions taken to satisfy the complaint and where neces-sary the complainant. Complaints must be dealt within a timely and effective manner.

Are these requirements accounted for?

Yes ☐ No ☐ Not applicable Refer to QES/ZX-MD-III001F documents.

7.2 Methods for output power measurement

Within quality control the manufacturer is obliged to use adequate methods for the testing and calibration. This includes methods for the temperature and irradiance correction of the measured module characteristics to STC as well as the calibration of the solar simulators in terms of non-uniformity of irradiance, spectral match and temporal instability of irradiance. It has to be verified, that these methods are suitable for the in-tended purpose.

For the determination of the production tolerance the manufacturer has to dispose methods for the estima-tion of the measuring uncertainty and make use of them. For the estimation of the measurement uncertainty all contributing components have to be taken into account. Adequate methods for the calculation of the over-all measurement uncertainty have to be used.

Usage of reference modules (primary/secondary reference modules, verification and adjustment of flasher, reproducibility, etc.):

- The primary reference modules are checked at TUV SÜD with reference report No. 70461908305.

- The secondary reference modules are reproduced by the primary reference module and applied in the production line; Cross check between primary reference module and secondary reference module is performed once a week;

Temperature correction procedures (measurement temperature, max. range, correction parameters [acc. to IEC 60891], etc.):

Temperature coefficients are used and the measurement is performed 23-27°C (measured on the module).

Simulator classification (acc. to IEC 60904-9):

Flasher classification is class AAA, and it is calibrated at external accredited lab once a year.

Determination of measurement uncertainty:

N/A




7.3 Handling of test and calibration equipment

The production line has to be equipped with measuring and testing equipment that allows a satisfactory qual-ity control (control of output power, insulation test and control of process parameters). All equipment that is used for tests and/or calibrations has to be calibrated/checked on regular basis. There have to be set meth-ods and cycles for calibration/check-up. The equipment has to be documented in a way that shows clearly the calibration status and its cycle.

List of the used measurement and test equipment (calibration modules, temperature and pressure sensors, IV-curve measuring equipment, regulation for storage of measuring equipment):

Calibration stickers are available on calibrated equipment, list of the used measurement and test equipment is available. Refer QES/ZXQA-III031A and QES/ZX-QA-IV068B document.




7.4 Regular quality assurance tests

Are regular off- or in-line test programs used to maintain the quality of the products? If so, which are these?

Pull-off test performed.

Gel content test performed.

Uniformity of laminator performed. Safety tests performed.

7.5 Documentation of process data

For the processing, storing and back tracing of test and process data, these must be documented in an ade-quate way. The recording of the data should allow a process monitoring which shows possible tendencies.

Description of the methods (data base, power classes, serial no.):

Working slip is used to record the product information and can be traced back according to the serial num-ber.

Records shall be kept for a minimum of two years. Are production records examined regularly? By whom?

Records will be kept at least 5 years by administration department.

7.6 Directing of faulty products

The production process must dispose of regulations and methods, which have to be applied, if the quality control shows a faulty product or a product is outside the production tolerances.

How is the course of events determined, if a faulty product is found?

All faulty products are classified to different classes, faulty products & materials can be reworked, repaired, scrapped or sent back to suppliers.

Do procedures for the application of corrective and preventive actions exist?

Yes, refer to QES/ZX-QA-III037A document.




Annex 1: Module type family sheet

Refer to constructional data form (CDF) 50146732 003 and 50123455 002 issued by TUV Rheinland.




Annex 2: List of the existing and surveyed documents

(Accreditations, certificates, declarations, licenses, data sheets, quality control verifications)

No. Ident./version no. Description

1 2.1 ISO certificate

2 2.2 Example of IV curve

3 2.3 Verifications for Gel content test and pull test

4 2.4 Organization chart

5 2.5 Declaration

6 2.6 Serial No. coding rule

7 2.7 Bill of materials and process data of tested module

8 2.8 Declaration from ZNSHINE




Annex 2.1 ISO certificate




Annex 2.2 IV curve




Annex 2.3 Verifications for pull test




Annex 2.4 Org. Chat




Annex 2.5 Declaration




Annex 2.6 Serial no. coding rule




Annex 2.7 Bill of materials and process data of produced module




Annex 2.8 Declaration from ZNSHINE

tÜv rheinland solar energy report factory inspection€¦ · refer to certificate pv 50371126 page...

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