IEC TS 62257-9-5:2013

Recommendations for small renewable energy and hybrid systems for rural electrification - Part 9-5: Integrated system - Selection of stand-alone lighting kits for rural electrification

IEC/TS 62257-9-5:2013(E) applies to stand-alone rechargeable electric lighting appliances or kits that can be installed by a typical user without employing a technician. This technical specification presents a quality assurance framework that includes product specifications (a framework for interpreting test results), test methods, and standardized specifications sheets (templates for communicating test results). The intended users of this technical specification are:
- market support programmes;
- manufacturers and distributors;
- bulk procurement programmes;
- trade regulators. The main changes with respect to the first edition are:
- overall, shifted from narrow focus on the needs of bulk procurement programmes to a wider framework for structuring quality assurance using appropriate methods for a range of stakeholders including governments, manufacturers, buyers, and others;
- revised structure of document with modular methods (located in annexes) that are applied using four distinct test regimes;
- added a framework for categorizing products based on the arrangement of components.
This publication is to be read in conjunction with IEC/TS 62257-1:2003, IEC 62257-2:2004, IEC 62257-3:2004, IEC 62257-4:2005, IEC 62257-5:2005 and IEC 62257-6:2005

General Information

• Status: Published
• Publication Date: 02-Apr-2013
• ICS: 27.160 - Solar energy engineering
• Technical Committee: TC 82 - Solar photovoltaic energy systems
• Drafting Committee: JWG 1 - TC 82/JWG 1
• Current Stage: DELPUB - Deleted Publication
• Completion Date: 30-Jun-2016

Standards Content (Sample)

IEC/TS 62257-9-5
®

Edition 2.0 2013-04
TECHNICAL
SPECIFICATION

colour
inside


Recommendations for small renewable energy and hybrid systems for rural
electrification –
Part 9-5: Integrated system – Selection of stand-alone lighting kits for rural
electrification

IEC/TS 62257-9-5:2013(E)

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IEC/TS 62257-9-5

®


Edition 2.0 2013-04




TECHNICAL



SPECIFICATION








colour

inside










Recommendations for small renewable energy and hybrid systems for rural

electrification –

Part 9-5: Integrated system – Selection of stand-alone lighting kits for rural


electrification
























INTERNATIONAL

ELECTROTECHNICAL

COMMISSION

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ICS 27.160 ISBN 978-2-83220-733-8



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® Registered trademark of the International Electrotechnical Commission

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– 2 – TS 62257-9-5  IEC:2013(E)
CONTENTS
FOREWORD . 9
INTRODUCTION . 12
1 Scope . 13
2 Normative references . 14
3 Terms and definitions . 15
4 System limits . 19
4.1 System description . 19
4.1.1 Components . 19
4.1.2 Product categories. 20
4.1.3 Lighting kit parts . 22
4.1.4 Additional system elements . 23
4.2 System measurements and observations . 23
4.2.1 General . 23
4.2.2 Product design, manufacture, and marketing aspects . 24
4.2.3 Product durability and workmanship aspects . 26
4.2.4 Lighting durability aspects . 29
4.2.5 Battery performance aspects . 30
4.2.6 Solar module aspects . 31
4.2.7 Run time aspects . 31
4.2.8 Light output aspects . 33
4.2.9 Battery-charging circuit efficiency . 33
4.2.10 Self-certification aspects . 34
4.2.11 Water protection integrated assessment . 34
5 Product specification . 35
5.1 General . 35
5.2 Applications . 35
5.3 Quality assurance principles . 36
5.3.1 General . 36
5.3.2 Rationale for dividing quality, warranty, and performance . 36
5.4 Product specification framework description . 37
5.4.1 General . 37
5.4.2 Blank product specification document . 37
5.4.3 Tolerances . 41
5.4.4 Quality standards criteria . 42
5.4.5 Warranty requirements criteria . 47
5.4.6 Performance targets criteria . 47
6 Quality test method . 50
6.1 General . 50
6.2 Applications . 50
6.3 Sampling requirements . 51
6.4 Laboratory requirements . 51
6.5 Testing requirements . 51
6.6 Recommended tests programme . 53
6.6.1 General . 53
6.6.2 Product sampling . 54
6.6.3 Test preparation . 54

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TS 62257-9-5  IEC:2013(E) – 3 –
6.6.4 Batch A tests . 55
6.6.5 Batch B tests . 56
6.6.6 Batch C / potentially destructive tests . 56
6.6.7 Report preparation. 57
6.7 Reporting . 57
7 Market check method . 57
7.1 General . 57
7.2 Applications . 58
7.3 Sampling requirements . 58
7.4 Laboratory requirements . 58
7.5 Testing requirements . 58
7.6 Recommended tests programme . 60
7.7 Report requirements . 60
8 Initial screening method . 60
8.1 General . 60
8.2 Applications . 60
8.3 Sampling requirements . 60
8.4 Laboratory requirements . 61
8.5 Testing requirements . 61
8.6 Recommended tests programme . 63
8.7 Reporting . 63
9 Field screening method . 64
9.1 General . 64
9.2 Applications . 64
9.3 Sampling requirements . 64
9.4 Laboratory requirements . 64
9.5 Testing requirements . 64
9.6 Recommended tests programme . 66
9.6.1 General . 66
9.6.2 Product sampling . 66
9.6.3 Test sample preparation . 67
9.6.4 Manufacturer information request . 67
9.6.5 Visual screening . 67
9.6.6 Light output . 67
9.6.7 Full-battery run time . 67
9.6.8 Solar-day run time . 67
9.6.9 Water protection assessment . 67
9.6.10 Durability testing . 67
9.6.11 Results check and report generation . 67
10 Standardized specifications sheets . 67
10.1 General . 68
10.2 Applications . 68
10.2.1 General . 68
10.2.2 Guidance . 68
10.2.3 Framework for SSS guidelines document . 68
Annex A (informative) Recommended quality standards and performance targets for
off-grid lighting market support programme qualification . 73

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– 4 – TS 62257-9-5  IEC:2013(E)
Annex B (informative) Example quality standards, warranty requirements, and
performance targets for bulk procurement qualification (“sample tender”) . 77
Annex C (informative) Recommended SSS guidelines . 82
Annex D (normative) Manufacturer self-reported information . 91
Annex E (normative) Product sampling . 95
Annex F (normative) Visual screening . 98
Annex G (normative) Sample preparation . 107
Annex H (normative) Power supply setup procedure . 109
Annex I (normative) Light output test . 113
Annex J (normative) Lumen maintenance test . 118
Annex K (normative) Battery test . 126
Annex L (informative) Battery testing recommended practices . 133
Annex M (normative) Full-battery run time test . 136
Annex N (normative) Full discharge preparation . 144
Annex O (normative) Grid charge test . 147
Annex P (normative) Electromechanical charge test. 150
Annex Q (normative) Outdoor photovoltaic module I-V characteristics test . 153
Annex R (normative) Solar charge test . 160
Annex S (normative) Charge controller behaviour test . 174
Annex T (normative) Light distribution test . 185
Annex U (normative) Physical and water ingress protection test . 197
Annex V (normative) Level of water protection . 201
Annex W (normative) Mechanical durability test . 208
Annex X (informative) Example test report templates . 216
Annex Y (informative) Photometer box for relative luminous flux measurements . 244
Annex Z (informative) Photometer tube for relative luminous flux measurements . 249
Annex AA (normative) Field testing methods . 250
Annex BB (informative) Battery durability test . 256

Figure 1 – Fixed Separate (fixed indoors) system—example arrangement of
components . 20
Figure 2 – Portable Separate system—example arrangement of components . 21
Figure 3 – Portable integrated system—example arrangement of components . 21
Figure 4 – Fixed integrated (fixed outdoors) system-example arrangement of
components . 22
Figure 5 – Division of a lighting kit into subsystems—illustrative example . 23
Figure 6 – Recommended sequence of testing for QTM . 54
Figure 7 – Recommended sequence of testing for FSM . 66
Figure 8 – First portion of example SSS . 71
Figure H.1 – 4-wire test configuration with input filter capacitors . 110
Figure I.1 – Conceptual schematic of the light output test setup, including the 11 × 11
grid, Cartesian coordinate axes for rotation reference, and the DUT . 115
Figure J.1 – Schematic of a photometer tube . 120
Figure J.2 – Example lumen maintenance plot . 125

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TS 62257-9-5  IEC:2013(E) – 5 –
Figure L.1 – Battery testing flowchart for the battery test (Annex K) . 134
Figure M.1 – Interior view of photometer box with suspended light . 138
Figure M.2 – Plot of example results from the full-battery run time test . 140
Figure Q.1 – PV module I-V curve testing rack . 156
Figure R.1 – Schematic of the power supply and DUT connection for the solar charge
efficiency test . 162
Figure R.2 – Example “true” and simulated I-V curves plotted with the deviation ratio . 164
Figure R.3 – Example time series plot of the solar charging cycle showing the
maximum power available from the PV simulator, actual power supplied by the PV
simulator, and power delivered to the batteries . 172
Figure R.4 – Example time series plot of the solar charging cycle showing the
instantaneous battery-charging circuit efficiency and solar operation efficiency . 173
Figure S.1 – Schematic of the DC power supply-DUT connection using a series
protection resistor . 177
Figure T.1 – Schematic of a task light suspended 0,75 m above a photometer . 189
Figure T.2 – Schematic of “rotary disk” setup, with the DUT shown . 191
Figure T.3 –Side view of desktop light measuring setup . 192
Figure T.4 – Example plot of usable area as a function of minimum illuminance . 194
Figure T.5 – Example of resulting surface plot of light distribution from the brightest
“face” of the multi-plane method or illuminance on a plane method . 195
Figure T.6 – Example of resulting polar plot of illuminance from the multi-plane or
rotating disk method . 196
Figure W.1 – Three-dimensional Cartesian coordinate system for drop test reference . 211
Figure W.2 – Cable strain angle (γ) schematics for a PV module junction box (left) and
a separate light point (right) . 213
Figure Y.1 – Interior view of completed photometer box . 244
Figure Y.2 – Exterior view of completed photometer box . 245
Figure Y.3 – Photometer box dimensions (in cm) . 246
Figure Y.4 – Photometer box assembly pieces and list of materials (dimensions in cm) . 247
Figure Z.1 – Completed photometer tube . 249

Table 1 – Applications of product specifications . 36
Table 2 – Qualification as separate PV module . 38
Table 3 – Truth-in-advertising tolerance . 38
Table 4 – Safety and durability standards . 39
Table 5 – End-user support standards . 40
Table 6 – End-user support requirements . 40
Table 7 – Run time criteria for performance targets . 40
Table 8 – Lighting service criteria for performance targets . 40
Table 9 – Additional features criteria for performance targets . 41
Table 10 – Truth-in-advertising criteria for quality standards . 43
Table 11 – Notes on common truth-in-advertising aspects . 44
Table 12 – Safety and durability criteria for quality standards . 45
Table 13 – Recommended level of water protection by product category . 46
Table 14 – End-user support criteria for quality standards . 47

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– 6 – TS 62257-9-5  IEC:2013(E)
Table 15 – Criteria for warranty standards . 47
Table 16 – Run time criteria for performance targets . 48
Table 17 – Run time benchmarks . 48
Table 18 – Lighting service criteria for performance targets . 49
Table 19 – Lighting service benchmarks . 49
Table 20 – Additional function criteria for performance targets . 50
Table 21 – Applications of product specifications . 50
Table 22 – QTM testing requirements . 52
Table 23 – Applications of product specifications . 58
Table 24 – Typical MCM testing guidelines . 59
Table 25 – Applications of product specifications . 60
Table 26 – ISM testing requirements . 62
Table 27 – Applications of product specifications . 64
Table 28 – FSM testing requirements . 65
Table 29 – Applications of product specifications . 68
Table 30 – Recommended precision requirements for metrics on a continuous scale . 70
Table A.1 – Qualification as separate PV module . 73
Table A.2 – Truth-in-advertising tolerance . 74
Table A.3 – Safety and durability standards . 75
Table A.4 – End-user support requirements . 76
Table A.5 – Run time criteria for performance targets . 76
Table A.6 – Lighting service criteria for performance targets . 76
Table B.1 – Product classes qualified for bulk procurement . 77
Table B.2 – Qualification as separate PV module . 77
Table B.3 – Truth-in-advertising tolerance . 78
Table B.4 – Safety and durability standards . 79
Table B.5 – End-user support requirements . 80
Table B.6 – Run time criteria for performance targets . 80
Table B.7 – Lighting service criteria for performance targets . 80
Table B.8 – Run time criteria for performance targets . 80
Table B.9 – Lighting service criteria for performance targets . 80
Table B.10 – Additional features criteria for performance targets . 81
Table C.1 – Requirements for retesting to update SSS . 82
Table C.2 – Recommended precision requirements for metrics on a continuous scale . 83
Table C.3 – Elements in the header / overall performance SSS section . 84
Table C.4 – Elements in the general information SSS section . 86
Table C.5 – Elements in the performance details section . 87
Table C.6 – Elements in the light output SSS section . 88
Table C.7 – Elements in the special features SSS section . 88
Table C.8 – Elements in the durability SSS section . 88
Table C.9 – Elements in the solar module details SSS section . 89
Table C.10 – Elements in the battery details SSS section . 89
Table C.11 – Elements in the marks and certifications SSS section . 89

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TS 62257-9-5  IEC:2013(E) – 7 –
Table C.12 – Elements in the SSS information section . 90
Table D.1 – Manufacturer self-reported information outcomes. 91
Table E.1 – Product sampling outcomes . 95
Table F.1 – Visual screening test outcom
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