SOLAR FRAME

IEC 61215: What it is and isn’t

NREL/PR-5200-54714

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 PV Module

IEC 61215: What it is and isn’t

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 Back Sheet

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 Back Sheet

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 Back Sheet

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 Back Sheet

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 Back Sheet

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 Back Sheet

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 Back Sheet

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 PV Module

Average composition of a PV module

~ 78%

Glass Aluminum Plastics Metals &

Semiconductors

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 Solar frame from aluminum body to plastic body

1) Plastic material Name & grade

2) Is this material UL certified?

What Customer 3) How are you doing frame processing Injection moulding or extrusion ?
Wants from
Jyoti ?? 4) Mould type 3 plate or 02 Plate.

5) How many Gates and Gate type you will provide in this frame.

6) Also, we need mould flow analysis report.

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  Solar Module Size : 2274x1134x30mm
Glass Size : 2267x1128 x2.0mm (Front & Back)
Module Weight : Approx 33kg with AL frame
Frame weight approx. 3.5 Kg ( 2.7kg from customer purchase dept )
AL frame material -6063T5. ( Rs. 450 / kg ) (Source - https://connect2india.com/Aluminium
6063#:~:text=The%20avg.,India%20is%20Rs%20450%2F%20Kilogram.)

 We need your standard Plastic Frame Cross section drawing which sustain
below mention testing as per IEC 61215 & 61730 :2016
Customer
Input  Mechanical :
Static load test : 5400Pa
Wind Speed : 2400Pa
Dynamic Mechanical Load test : 2000 Cycle

 Environmental testing:
Damp Heat – 2000Cycle
TC – 400 Cycle
UV preconditioning test (MQT 10) - 90 kW/m 2.
HF -20

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 LEXAN™ Copolymer_SLX2271T Adobe Acrobat
Document

Suggestions
LG CHEM LUPOY EU5201 FS Adobe Acrobat
for plastic Document

Raw material
NORYL™ Resin_SE1GFN1 Adobe Acrobat
Document

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 Weight Comparison of plastic vs aluminium solar frame panel

Material Density Weight Rate/kg Outer panel Anodizing Rare / piece

prize/piece rate / kg
Aluminium 6063T5 2.7 2.77kg 450 ₹1246.5 ₹60 / kg

LEXAN 1.2 1.22kg 300 ₹366

NORYL 1.16 1.20kg 384 ₹461

LG CHEM LUPOY EU5201 FS 1.32 1.36kg

Customer prize $8.7 / Aluminium panel

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Aluminium 6063T5 Anodise

NOTE-6063 T5 natural colour anodized aluminium profile extruded for window. Silver, bronze,
champagne, titanium, nickel, golden yellow, etc. Anodizing thickness is up to 25um. Powder coating
thickness is more than 60um.
(http://www.forchunaluminum.com/info/?127.html#:~:text=6063%20T5%20natural%20color
%20anodized%20aluminum%20profile%20extruded%20for%20window,-
2016%2D06%2D29&text=Silver%2C%20bronze%2C%20champagne%2C%20titanium,thickness
%20is%20up%20to%2025um.&text=Powder%20coating%20thickness%20is%20more%20than
%2060um. )

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Tests required to qualify

• Wind test
- need to do computational fluid dynamic test.
- Structural analysis test of frame.
- software required – STADD Pro.
• Need to calculate FOS ( Factor of safety)
• CFD and FEM analysis.
• Ansys CFX is computational fluid dynamic test.
• Simulate the flow of air over a panel and determine the generated lift force.
• 140mph is the wind limit for solar panel.
• ASTM-E1830-D1
• Hail Testing.
• Snow load testing.
• Salt mist corrosion test.
• Mechanical stress analysis through STADD pro software.

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Tests required to qualify

• Wind test.
• Damp heat test.
• Impact test.
• Mechanical load test.
• Outdoor exposure test.
• Salt mist test.
• UV test.

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Solar Panel Assembly Test standards

•The commercial success of PV is based on long term reliability of

the PV modules.
• These modules are typically qualified/certified to:
 IEC 61215 for requirements for the design approval and
qualification process.
 IEC 61730-1:2016 specifies and describes the fundamental
construction requirements for photovoltaic (PV) modules in
order to provide safe electrical and mechanical operation.
•These qualification tests do an excellent job of identifying
design, materials and process flaws that could lead to
premature field failures.

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Mode of failure of solar panel

• Broken interconnects.
• Broken cells.
• Corrosion.
• Delaminating and/or loss of elastomeric properties of encapsulate.
• Encapsulate discoloration.
• Solder bond failures.
• Broken glass.
• Hot Spots.
• Ground faults.
• Junction box and module connection failures.
• Structural failures.
• Bypass Diode failures.
• Open circuiting leading to arcing.

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Mode of failure of solar panel

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Mode of failure of solar panel

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 Tests procedures

Hail test procedure: Humidity Freeze test procedure:

Typically test labs use a pneumatic ice ball launcher,  The purpose of this test is to determine the ability
which is capable of launching ice balls at specified of the PV module to withstand humidity penetration
speeds and various weights. The PV module will be hit at extreme temperatures. It may be considered as
with ice balls at over 10 specified spots. After the test, a combination of two other tests - Damp Heat and
there should be no visible damage at the front of the Thermal Cycling.
solar panels caused by the hailstones. Possible  Humidity Freeze Test is performed according to
effects and problems that can be identified after the IEC 61215. PV modules are subjected to cycling
hail impact test are: between temperatures 85°C with relative humidity
1. Broken cells 85 % and -40°C. PV modules are subjected to 10
2. Broken glass complete cycles in the closed climatic chamber in
3. Micro cracks accordance with the profile on the picture bellow.
4. Dysfunctional cells The purpose is to determine the ability of the
5. (Slight) structural deformation/ mechanical data module withstand against humidity penetration.
nonconformity

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 Tests procedures

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Qualification Tests

Test I II III IV V

Thermal 100 50 50 50 200

Cycles -40 to +90C -40 to +90C -40 to +90C -40 to +90C -40 to + 90C

Humidity 70C,90% 5 cycles 5 cycles 5 cycles 10 cycles

68 hrs 40 to 23C 40 to 23C 54 to 23C 85 to -40C
90% 90% 90% 85%

Hot Spot 3 cells

(intrusive) 100 hrs

Mechanical 100 cycles 100 cycles 10000 10000

Load ± 2400 Pa ± 2400 Pa ± 2400 Pa ± 2400 Pa

Hail 9 impacts 10 impacts

¾” –45 mph 1” – 52 mph

High Pot <15 µA < 50 µA < 50 µA < 50 µA

1500 V 1500 V 1500 V 2*Vs+1000

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Examples of Field of Failures

Broken Cells
Broken Interconnects Ground Fault

Delamination
Corrosion

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Opportunities

Potential Products From Solar Industries to Explore

Solar cells Connectors Junction Box Microinverters Solar Mountings

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Leading Companies

These are few leading companies in the field of Solar energy:

 SunPower (https://us.sunpower.com/products/solar-panels)
 Dhash technology – TUV approved product (https://dhashtec.com/products/solar-pv-connectors/).
 Vishakha solar panels (https://vishakharenewables.com/ ).
 Euro photovoltaic (biggest importer of junction boxes ) (
http://www.euromultivision.com/photovoltaic/pv_home.html).
 QC solar (http://www.qc-solar.com/).
 First solar (https://www.firstsolar.com/en-IN/).
 Jinko Solar (https://jinkosolar.eu/).
 Sicame (http://www.sicame.in/ ).
 Enphase micro inverter (https://enphase.com/installers/microinverters)

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 MOM 29/09/23
Meeting with Mitesh Shah and Sachin sir ( SABIC)

 SunPower solar energy company uses grade Noryl SE1GF2 to manufacture solar panels .
 LG Lupoy 5216 ( RD sir suggestion)
 Jyoti will get 2-3 references of China from SABIC team who manufacture solar frame in plastic material
of same size which we required.
 Plastic solution for solar frame may not work for land installation and that too maximum with 10 years
warranty.
 China is making 11.2kg of solar frame only.
 EU5201 FS KA02, Jyoti using this grade in their products.
 LG Lupoy have certification of required standard.
 Enphase invertors modifies their micro invertors design in few years.
 Junction + connectors = micro invertors.
 Junction box weight – 50gm.
 3 panels – 1kw power generation.
 1 panel – 330 watts power generation.
 India is at 4th position in solar industry after China, Germany and US.
 Solar cells mounting devices cost 3 to 3.5 Rs / watt

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 THANK YOU
CORPORATE OFFICE:
94, Bombay Talkies Compound,
Malad (W). Mumbai - 400 064.
India.
T: +9122 2882 4448 / 3385 7400

KHADKI PLANT:
Survey No. 178/1, 178/1/Paiky-1,
Bhramdev Industrial Park,
Pardi Paria Road, Village – Khadki,
Tal. Pardi, Dist. – Valsad,
Udwada - 396 185. India.
T: +0260 3918200 / 2337237

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