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Sun Sumlator SMT A Manual

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Sun Simulator Instruction manual

Sun Simulator

(SMT-A)

Instruction Manual

Wuhan Sunic Solar Technology CO.,LTD


Sun Simulator Instruction manual

Content
① Preface..........................................................................................................................2
1. Abstract...................................................................................................................2
2. Technical features...............................................................................................2
3. Technical parameter...........................................................................................3
4. Working environment...........................................................................................4
5. Standard terminology...........................................................................................5
② Safety instructions............................................................................................5
③ Product structure...................................................................................................6
3.1 Introduction.........................................................................................................6
3.2 Test theory...........................................................................................................7
3.3 Structure introduction......................................................................................8
3.3.1 Electrical cabinet.........................................................................................8
3.3.2 Light source box.............................................................................................8
3.3.3 Other components.............................................................................................9
④ Installation and use.........................................................................................10
4.1. Install...............................................................................................................10
4.2. Equipment use.....................................................................................................11
4.3. Xenon lamp replacement...................................................................................13
⑤ Software system.....................................................................................................15
5.1 Introduction to software interface...........................................................15
5.2 Introduction of menu bar...............................................................................16
5.2.1 Communication status...................................................................................16
5.2.2 Capacitor charge and discharge...............................................................17
5.2.3 Xenon lamp status.........................................................................................18
5.2.4 Start test.......................................................................................................19
5.2.5 Historical data query.................................................................................19
Historical data query figure...............................................................................20
5.3 System settings.................................................................................................21
5.4 Calibration and correction...........................................................................22
5.5 Language change.................................................................................................24
5.6 Production information...................................................................................25
5.7 Grading setting.................................................................................................27
5.8 Print settings...................................................................................................28
⑥ Maintenance and problems................................................................................29
6.1 Maintain...............................................................................................................29
6.1.1 Before...............................................................................................................29
6.1.2 Regular maintenance.....................................................................................29
6.2 Fault handling...................................................................................................30
⑦ Other operating precautions......................................................................31
⑧ contact us...............................................................................................................31

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Sun Simulator Instruction manual

① Preface

This manual is used to provide relevant application knowledge of


installation, operation and maintenance of long pulse width solar
module tester (A +, A +, A +).
Customers are advised to read this manual carefully before
installing and operating the equipment.

1. Abstract

Long pulse width solar cell module tester (A +, A +, A +) is a


special equipment for solar cell module test with high reliability
and precision developed and produced by Wuhan Sunic Solar Technology
Co., Ltd.The equipment use high-power and long-life imported
straight tube pulse xenon lamp as the simulator light source, the
power supply use microcomputer control and closed-loop feedback
control, the nonlinear and linear electronic loads ensure the
accuracy of test results. It is suitable for manufacturers to test
solar cell modules.

2. Technical features

 Ensure the light intensity stability in the test range, and


ensure the authenticity and reliability of the test data.
 Digital control to ensure test accuracy; Programmable control of
hardware parameters simplifies equipment debugging and
maintenance.
 Curve fitting is used to accurately reflect the actual working
condition of the tested module.
 Infrared temperature measurement is adopted to truly reflect the
temperature change of the module and automatically complete the
temperature compensation.

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 Automatic control throughout the test.


 Detect the working status of module and main unit circuits in
real time, and provide software / hardware protection to ensure
the reliable operation of the equipment.
 Forward scanning Isc→Voc,reverse scanning Voc→Isc.

3. Technical parameter

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Equipment model SMT-A


I-V、P-V
curve、Isc、Uoc、Pmpp、Eff、FF、Impp、Umpp、Rser
、Rshunt、module surface
Measurable parameters
temperature、Iuld(Current corresponding to
fixed-point voltage)、Puld(Power corresponding
to
fixed-point voltage)
Maximum measurable component size 2400mm×1400mm
Test speed 240 pcs/h
Flash time 10-150ms
Xenon lamp life >100,000 flashes
Light intensity range 500-1200W/㎡
Solar spectrum matching 0.875-1.125(A+)
STI ≤0.25%(A+)
LTI ≤1%(A+)
Intensity inhomogeneity ≤1%(A+)
Solar spectrum range(IEC 300-1200nm class A
60904-9:2020)
Repeat test accuracy <0.3%
Power Measuring range 10 W to 350 W
Measuring range Voltage: 1v/10v/50v/100v/150v/200v
Current: 0.25A/1A/5A/10A/20A
Measurement resolution 16bit(Measurement resolution 0.003%)
Lamp type Straight tube xenon lamp
Working mode Single pulse
Working power supply 200-240V ,10A, 50/60HZ,single phase
Size of Light source box (L x W 2900X1800X1050mm
x
H)
Size of electric control 600x800x1800mm
cabinet(L x W x H)
Equipment weight Light source box: 500kg
Electric control cabinet:280kg

4. Working environment
 Environment temperature : 25℃±2℃

 Relative humidity :≤75

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 Lighting :Sufficient use needs.

 No strong magnetic interference ; No corrosive gas

5. Standard terminology
Mark Definition Unit
Isc short-circuit current Ampere(A)
Voc Open circuit voltage Voltage(V)
Pm maximum power Watt(W)
Ipm Current at maximum power Ampere(A)
Vpm Voltage at maximum power Voltage(V)
Series resistance of
Rs solar Ohm(Ω)
module
Parallel resistance of
Rsh solar module Ohm(Ω)
Eff efficiency=Pm/area*P %
FF Filling factor= %
Pm/Voc*Isc
Short circuit current 2
Jsc density A/m
Light 2 2
intensity P=500W-1200W/m W/m
Temperatu Working environment
re temperature ℃

② Safety instructions

Please read this manual carefully before using this machine for
your installation and use. Please pay special attention to the
precautions and warning words on the instructions, which must be
understood and followed, otherwise it will violate the safety
requirements and rules for product manufacturing, design and use.
FYA:Our company shall not be responsible for any liability accident
caused by failure to perform safety matters.

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Safety signs:

High voltage hazard symbol

Warning!
▲ The power input of the equipment must comply with the electrical
parameters marked on the equipment nameplate, and the product must
be installed and connected in strict accordance with the safe power
use specification.
▲ This product is a precision testing equipment. Please ensure that
the input power supply of the equipment is free from interference
sources, and put the equipment in a good electromagnetic
environment.
▲ There are high-voltage devices inside the equipment. Improper
operation will endanger life safety. Please pay attention to the
warning board on the equipment before operation. Non professionals,
please communicate with our company and obtain authorization before
opening the cabinet.
▲ There are energy storage devices inside the equipment. Do not
operate immediately after shutdown. The cabinet can be opened for
inspection only after 2min discharge.

③ Product structure

3.1 Introduction

The long pulse width solar module tester is mainly composed of two
parts: light source box and electrical cabinet. The light source box
is composed of xenon lamp light source, filter, monitoring battery
cell, fan and

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Sun Simulator Instruction manual

trigger alarm circuit board. The electrical cabinet contains


industrial control system, battery module detection and monitoring
system, constant light system, charge system and energy storage
system. In addition, it also includes some accessories: industrial
computer, display screen, mouse and keyboard, simple conveyor,
infrared thermometer, heavy-load connecting line, signal line, test
line and power line.

Equipment panorama

3.2 Test theory


Firstly, the user gives instructions through the PC, and the
power supply charges the energy storage capacitor to provide the
energy required by the light source. When receiving the test signal
sent by the PC, the energy storage capacitor discharges to the xenon
lamp in the light source box through the light intensity control
circuit to generate constant irradiance, and then the electronic
load part synchronously collects the IV, temperature and other

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Sun Simulator Instruction manual

parameters of the test module,

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After processing, it is transmitted to the PC software. The software


processes the data through the algorithm, calculates the module
parameters, and finally draws the IV curve.

3.3 Structure introduction

3.3.1 Electrical cabinet


The electrical cabinet mainly includes charging, energy storage,
optical control and acquisition devices, and its structure is as
follows: (1)Storage capacitor layer:Xenon lamp energy storage
capacitor; (2)Charging layer:Energy storage capacitor charging
power supply; (3)Charge control layer : Energy storage capacitor
charging control circuit;
(4) Light intensity control layer:Xenon lamp light intensity control
circuit;
(5) Electron load layer:Module parameters acquisition and electronic
load;
(6) PC layer:Mini PC inside.
3.3.2 Light source box
The light source box mainly contains xenon lamp light source and
its supporting structure, filter, xenon lamp trigger plate,
monitoring battery, etc.

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3-3 light source box

3.3.3 Other components


Infrared thermometer : The equipped high-precision infrared
thermometer is used to monitor the module surface temperature, and
its measured value is used for module temperature correction.

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④ Installation and use


4.1. Install

 Ensure that the 220V power supply is connected(The power socket


must be grounded and the test equipment must be grounded
independently).
 Ensure that the equipment operates at a constant temperature of
25 ℃.
 Several standard battery modules.
 Tools (internal hexagonal socket, multimeter, screwdriver, etc.).
 Our company will train 1 equipment supervisor and 1-2 operators
for the user manufacturer, and the above personnel shall be in
place in time.
Before installation, please check the packing list to confirm
whether the equipment components are complete. The components
include: electrical cabinet, light source box, infrared thermometer
and installation support, electrical cables (load connection line,
heavy load connection line, power line and data connection line),
simple conveyor; Connection method: connect electric cabinet and
light source box with heavy load connection line and data connection
line, and pay attention to the difference between data connection
lines; The load connecting line connects the No. 2 box of the
electrical cabinet and the tested module; The infrared thermometer
is fixed on the bracket on the light source box; The power line is
connected to the single-phase power supply of the user's electrical
system.

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As indicated in the above two figures, connect the light source


box and the electric control cabinet accordingly.

4.2. Equipment use

Power on: connect the power supply, pull on the breaker, after
confirming that the wiring is correct, turn on the key switch on
NO.1

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box of the electric control cabinet, and the equipment starts up. At
this time, the industrial control opportunity will automatically turn
on (the mini PC has been set to power on automatically in BIOS), turn
on the software, and carry out the charging operation after confirming
that the communication is correct, After the instrument of the
electrical cabinet shows that the capacitor voltage rises to 240V and
stops (the voltage can be set by the upper computer software), the
test can be started.
Power off: turn the key switch on the electric control cabinet
again to shut down the equipment, turn off the industrial computer
operating system by yourself, and then pull down the breaker to
avoid PC error. Shut down and wait for 2min before operating the
electrical cabinet.

Schematic diagram of LED tube of electric cabinet

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4.3. Xenon lamp replacement

A guide rail groove is designed on both sides of F and B sides of


the light source box to facilitate the replacement of xenon lamp or
filter. Open the baffles on both sides of the light source box,
remove the guard plate, extend your hand into the light source box
under the condition of complete power off, and then take out the
device where the xenon lamp is located from both sides through the
guide rail. be careful:
 As a filter is installed at the bottom of the xenon lamp device,
please wear gloves during operation to avoid polluting the
filter;
 Handle with care during operation. Xenon lamp and filter are
fragile. Do not reckless;
 Based on the working environment, please clean the xenon lamp
device regularly as appropriate, and wipe the dust attached to
the xenon lamp and filter with special cleaning cloth;

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Xenon light as the core component of the long pulse width solar
module tester, the working voltage and xenon ratio of the pulse
xenon lamp are separately customized by the equipment manufacturer
and the xenon lamp manufacturer, and then matched with a customized
filter to output the spectrum matching and life commitment that meet
the requirements of IEC60904-9. Wuhan Sunic Solar Technology company
makes the following description for the xenon lamp:
1 、 Xenon lamp are consumables. If xenon lamp need to be replaced
outside the warranty period, users need to purchase them by
themselves;
2 、 In order to ensure the technical indicators of the equipment,
xenon lamps can only be provided by the original factory of Wuhan
Sunic Solar Technology company!
3、In order to ensure the service life of xenon lamp, xenon lamp can
only be provided by the original factory of Wuhan Sunic Solar
Technology company!
4、Xenon lamp is a precision accessory. It is forbidden to touch the
lamp tube directly by hand. Gloves should be worn when touching the
lamp tube! 5、Red line:It is the positive pole of xenon lamp, and
the red thin wire on the same side is the high-voltage trigger wire;
6、Black line:Negative electrode of xenon lamp;
Special note: if the customer privately purchases xenon lamps that
do not meet the equipment use requirements, Wuhan Sunic Solar
Technology company has the right not to fulfill the warranty
commitment。

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⑤ Software system

5.1 Introduction to software interface

Double click the desktop icon to open test software.The test


software interface appears.

The main interface is mainly composed of the following points:


 1:Menu bar;
 2:Test result curve display bar;
 3:Test result display bar;
 4:Real time selection view bar of current test results;
 5:System working status bar;

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5.2 Introduction of menu bar

5.2.1 Communication status

Before starting the test, it is necessary to confirm whether the


communication status is normal, and click the button in the working

status bar of the system “ ”,The prompt box as shown in the figure
below appears. Code = 0 indicates that the communication is normal
and the software can work normally.

Communication prompt block figure

If the communication fails, check whether the communication is

in the column of communication serial port settings ,If it

fails,

is displayed.
At this time, you need to check the computer device manager to
confirm whether the serial port number of the communication port and
the COM port set by the software is COM8; Then determine whether the
USB cable connected between box 1 and box 2 of the electric control
box is in good contact.

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5.2.2 Capacitor charge and discharge

The equipment adopts test software to control charging and


shutdown automatic discharge (to save energy, capacitor discharge is
changed to suspend charging). When the communication is normal,
click the "capacitor charging" button to control the charging of the
equipment. When the capacitor reaches 240V, the charging will be
stopped automatically. Note: if the equipment switch is turned off
without clicking the "capacitor discharge" button, the energy
storage capacitor will discharge automatically. It is must to wait
for more than 2min to ensure the complete discharge of the energy
storage capacitor.

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5.2.3 Xenon lamp status

Click " " in the menu bar to pop up the prompt box as shown
in the figure below.

Xenon lamp voltage status figure

The system charges to the test voltage of 240V by default. When


clicking the "capacitor charging" button, the "xenon lamp status"
prompt box will display the current equipment capacitor voltage in
real time. If there is no abnormality in the test equipment, the
feedback code 0. If there are other numbers in code, it indicates
that the equipment has problem and the test needs to be suspended.
here the following table for specific codes:

Fault code description


Fault code Definition
0 No fault
1 L1 Lamp charging fault
2 L2 Lamp charging fault
20 CAN Bus communication failure
21 L1 CAN Bus communication failure
22 L2 CAN Bus communication failure
33 Fan control plate CAN Bus communication failure
50 Fan 1 over speed fault
51 Fan 1 Low speed fault
52 Fan 2 over speed fault
53 Fan 2 Low speed fault
54 Fan 3 over speed fault
55 Fan 3 Low speed fault
56 Fan 4 over speed fault
57 Fan 4 Low speed fault
The fault codes in data acquisition are processed each time. Refer to "data
format

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(acquisition error)"
1:Light intensity detection error: insufficient light intensity;
2:Voltage detection error: no test module, short circuit or damage of test module,
too large or too small range setting, etc;
3 : Current detection error: scanning circuit fault, too small range setting,
etc The hardware detects before the electronic load works to prevent the
circuit from burning.

5.2.4 Start test


After confirming that the communication is normal and the
capacitor is charged, start the test. Click the "start test" button
to start the flashing test of the corresponding light source box. Be
careful:
 Before starting the test, ensure that there is load and the
wiring is firm, otherwise the test cannot be carried out and
will alarm .
 Before starting the test, ensure that the test gear is selected
correctly, otherwise the test cannot be performed and will alarm
.
 When starting the test, do not walk around to avoid interfering
with the test results.
 When starting the test, remember not to look directly into the
interior of the light source box. Its xenon flash lamp will bad
for the eyes.
When the equipment is in the scheduled test, click the "start test"
button again, its status will change from "scheduled test" to "start
test", and the test will stop at this time.

5.2.5 Historical data query


When you need to view historical test data, click "historical
data query" in the menu bar, and the following figure will appear.

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Historical data query figure

The operator can quickly query the test data of the required
time period by adjusting the test start time and test end time.
Click the "export query results" button to quickly generate the
excel table of the required time period.
Double click a single piece of test information to view the test
image corresponding to this piece of test information, as shown in
the following figure:

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5.3 System settings

When testing solar cell modules with different indicators, it is


necessary to set corresponding data acquisition indicators. Click
"quick setting" and select "communication function" in the list.

Data acquisition setup figure

Adjust the current and voltage bin according to the basic


parameters of the measured solar module. Example: the current value
of the solar module to be tested is about 6A and the voltage value
is about 11V. Then the current range to be selected is 10A and the
voltage range is 50V.
The scanning time can be adjusted from 10ms to 150ms as needed.
Irradiance can be set from 50-120mw/cm². Password of all changed
parameters: 1234.
In the scanning mode, set 0 to represent the forward scanning
mode ISC → VOC, and set 1 to represent the reverse scanning VOC →
ISC.

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5.4 Calibration and correction

The equipment includes 5 kinds of correction,ISC, VOC, Pmax,


test temperature correction, irradiance correction and module area
correction. As shown in the figure below.

Calibration and correction operation figure

Calibration and correction is to set the necessary options


before the test, mainly including calibration, temperature setting
and irradiance setting. Each setting process is as follows:

Calibration

 Before starting the one click calibration, it is necessary to connect the

standard battery module as a reference to the equipment for a measurement


in order to obtain the actual measured value of the standard battery
module in the current test environment and input it into the measured
value column.

 Then you need to enter the nominal value on the nameplate label
of the standard battery module into the column of standard
value.

 After completing the above two steps, click one key to complete the

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correction.

 Note: due to the changes of the environment during the use of


the equipment, such as temperature, humidity, external light,
etc., in principle, the equipment needs to be corrected once
with standard battery modules after working for two hours to
ensure the accuracy of the test values.

Correction
The software default temperature is corrected to 25 ℃.
Set relative current temperature coefficient and relative
voltage temperature coefficient. The value of relative current
temperature coefficient corresponds to different solar module to
be tested. The corresponding relative current temperature
coefficient and relative voltage temperature coefficient must be
input. The relative current temperature coefficient and relative
voltage temperature coefficient reflect the sensitivity of the
internal current and voltage parameters of a single solar module
to temperature changes. The calculation formula is as follows:
Relative current temperature coefficient = absolute current
temperature coefficient / short circuit current
Relative voltage temperature coefficient = absolute voltage
temperature coefficient / open circuit voltage
The short-circuit current and open circuit voltage are the
values of the single chip to be tested under standard test
conditions. For example, when the short-circuit current of the solar
cell is 8A, the open circuit voltage is 0.6V, the absolute current
temperature coefficient is 0.0016 A / ℃, and the absolute voltage
temperature coefficient is
-0.0022 V / ℃, the relative current temperature coefficient and
relative voltage temperature coefficient are:
Relative current temperature coefficient =(0.0016 A/℃)/8A = 0.0002 /℃

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Relative voltage temperature coefficient =(-0.0022 V/℃)/0.6V =-0.0037 /℃

Irradiance correction options, no calibration and correction


options. If irradiance correction is checked, the test results will
be corrected according to the irradiance value after the test. If no
calibration and correction is checked, its none calibrated and
corrected data will be displayed after the test. If it is not
checked, it is the opposite.
The light intensity correction coefficient will affect the
displayed light intensity value on the screen, but will not really
change the light intensity.
The module area option is directly related to the change of EFF
value. When it is necessary to accurately obtain the EFF value of
the solar module, it is necessary to accurately measure the measured
effective area of the tested module and input it into the item of
module area.

5.5 Language change

In this option,the operator can select two type of language to


show. Operator can set the Chinese and English switching of the
operation interface. After the application,need to restart the
program to take effect. The interface is shown in the figure below.

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Language change figure

5.6 Production information

Production information figure

In the production information setting block diagram, operator


name setting and equipment number setting can be set. When external
speakers are needed, check the voice reading option, and the reading
parameters are adjustable. The setting supports automatic or manual

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generation of

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serial number and docking with the code scanning gun of automatic
production line. It should be noted that when docking the automatic
production line, the number corresponding to the barcode length
needs to be input for different barcode lengths, and the barcode
prefix can be customized when outputting. The barcode prefix does
not occupy the barcode length. Example: when the bar code on the
next component to be tested is 22 bits long, and the tested bar code
needs to be prefixed with SCT. Then you can enter 22 in the barcode
length on the operation page as shown in the above figure, and enter
SCT automatically for barcode prefix.
Barcode label printing is supported, and the customer name can
be customized.
The database export directory can be customized. Whether this
function is enabled corresponds to whether access data export
function is required. The default state is off. After this function
is enabled, the data of each test will be automatically saved to the
selected directory. You need to pay attention to clearing disk space
regularly.

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5.7 Grading setting

Grading setting figure

Grading setting includes two functions: grading parameters and


grading setting;
The grading operation process is as follows:
 Build a grading scheme first;
 Select the grading parameters. The options include:
Pmax、Isc、Voc、Eff、Imax;
 Select the required series;
 Enter the corresponding maximum and minimum values;
 Click the confirm button, then click Save scheme, select the
path to save, and enter the file name to save;

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5.8 Print settings and Access data

Print setting figure

In this function,the operator can customize various printed


information. In Access database settings,the operator can customize
various types of information to be displayed.

On the accessDB page, you can customize the data imported into
the access table.

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Note that you need to create a directory to export access data.


The default directory is the result directory on disk D.

Ⓐ Maintenance and problems

6.1 Maintain

6.1.1 Before
Ensure that the equipment is powered off before maintenance;
After the equipment is powered off, the two pole voltage of the
capacitor in the electrical cabinet is lower than 10V, and the light
source box must stand for at least 2min before maintenance.

6.1.2 Regular maintenance


6.1.2.1 Weekly maintenance
(1) Wipe the dust on the upper surface of the reference battery with
a dust-free cloth;
(2) Use standard modules to calibrate the equipment regularly.

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6.1.2.2 Monthly maintenance


Users can open the lamp box,turn it down and lay it flat to
clean the internal dust.Dust free cloth can be used to wipe the
positions that affect the irradiation intensity of the light
source,spectrum and test non-uniformity,such as the surface dust of
xenon lamp, reflector, filter and so on.

6.1.2.3 Annual maintenance


According to the international standard (IEC 60904-9-2020),the
overall inspection is carried out for the equipment, and the test
focus is spectral mismatch; Irradiation non-uniformity; Irradiation
instability. Determine whether it meets the requirements through the
results. In case of any problems, please contact the manufacturer in
time.

6.2 Fault handling

 No flashing
Treatment method : Check whether the high-voltage trigger plate is
faulty; Check that the xenon lamp wiring in the light source box is
firm and correct; Check whether the monitoring module is wired
correctly and damaged or not; Check whether the software test bin
setting is correct.
 Flashing but no test data
Treatment method : Check whether the load line is firmly connected to
the module board to be tested.
 Xenon lamp always on
Treatment method : If this happens, please press the emergency stop
button at the first time to prevent damage to the xenon lamp; Check
the load plate in box 2 for failure.

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⑦ Other operating precautions

1. Ensure that the equipment is operated at a constant


temperature of 25 ℃ (± 2 ℃) and a humidity of less than 75%
RH.
2. Ensure constant indoor light.
3. When the equipment is not used for a long time, pay attention
to the power off of the equipment.
4. In order not to affect the test results, clean the test table
with anhydrous alcohol regularly.
5. The set parameters cannot be adjusted at will.
6. It is strictly prohibited to non-load test of equipment to
prevent short circuit.
7. Non operators are not allowed to open the equipment.
8. It is forbidden to insert external USB flash disks and optical
discs into the computer to prevent viruses in the computer. It
is recommended to install anti-virus software and check and
kill regularly.
9. The equipment shall be re-calibrated at least once every 24 hours.
10. Some parameters of the test software have been set before
trade, and non professionals are strictly prohibited to adjust
them. (important)

Contact us

(D)2022,Wuhan Sunic Solar Technology CO,.LTD page33 total 34


Sun Simulator
Instruction manual

Wuhan Sunic Solar Energy Technology Co.,Ltd.


Address : No. 4, Huanglongshan North Road, DongHu New
Technology Development Zone, Wuhan, China
Code:430000
Phone:86-27-59722666
Fax:86-27-59722966
Customer service telephone:86-27-59723880
Customer service fax:86-27-59723887
E-mail:info@sunic.com.cn Website:www.sunic.com.cn www.sunicsolar.com

(D)2022,Wuhan Sunic Solar Technology CO,.LTD page34 total 34

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