7/25/2019 C2_Werner Varro_Skript CE-Conformity of Stationary Electrical Storage Systems http://slidepdf.com/reader/full/c2werner-varroskript-ce-conformity-of-stationary-electrical-storage-systems 1/31 CE-Conformity of Stationary Electrical Storage Systems Varro Werner, TÜV-SÜD Product Service GmbH
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C2_Werner Varro_Skript CE-Conformity of Stationary Electrical Storage Systems
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7/25/2019 C2_Werner Varro_Skript CE-Conformity of Stationary Electrical Storage Systems
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1 Introduction
During the last years a lot of manufacturers have developed new energy storage systemsbased on different technologies and have introduced them or are introducing them into thecountries of the European Union. This products haw to fulfill a lot of requirements that come
from different parties, e.g.:
European Commission - legal requirements
power provider - technical specifications and requirements
residential user – technical specifications and requirements
The legal requirements are defined by the European legislation and belong to productsproduced in or imported to the European Union. As other products, storage systems mustcomply with the CE marking regulations and related directives and bear the CE-mark. Withthis mark, the manufacturer, his authorized representative or the importer indicate that the
product meets the legal requirements described in the applicable directive(s). Theserequirements are addressing system safety, health and environmental protection. Helpful forthe manufacturers are the harmonized product standards. Following this standards,compliance is presumed.
The user requirements refer to the function, the quality and the lifetime of the storage systemas well as to economical requirements, e.g. the price. Usually this requirements are definedat the product specification of the system.
The power provider requires values for power quality e.g.:
standby efficiency
storage efficiency
speed of response
performance curve
stability of voltage and frequency
interfaces to the grid and the management system
of such a storage system.Table 1 gives an overview of the different requirements and typical specifications for storagesystems.
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Table 1: Requirements and typical specification of electrical storage systems
Economic low investment costlow operating costs
Environmental low risks for manufacturinglow risks at operationrecycling
Lifetime energy cyclescalendar life
Power Quality high energy efficiencyhigh energy density/capacityhigh power densitylow energy inputlow energy losslow self discharge
low auxiliary energyGrid Quality requirements of power provider
Safety safety and securitylow potential damage
This presentation deals with small residential and utility storage systems and presents astrategy to achieve safety and CE-compliance. Following the same strategy it can be easilyadopted to large storage systems.
2 TÜV-SÜD Strategy All the different requirements mentioned before have to be considered when developing astorage system. There are a lot of European directives and harmonized standards forcomponents and subsystems but not for storage systems. Most of them are addressingapplications in vehicles, mobiles, power supplies or information technology equipment andare not completely applicable to storage systems.
The main problem is:
there are no product standards for stationary storage systems
requirements for mobile applications are „oversized“
The manufacturer of a energy storage system has to create his own specification/standardaccording to the applicable requirements listed before.One possibility to create such a specification and ensure compliance with the Europeanrequirements is the TÜV-SÜD strategy presented in this paper. It is based on a riskassessment and derived from the conformity procedures for well known products asmachinery, laboratory or medical equipment. The advantages are the following:
• proven in use strategy and methodology• based on the CE-marking procedure and EN/ISO/IEC standards
• risk assessment will become mandatory with the revised Low Voltage Directive.
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Basic steps of the TÜV-SÜD strategy are:
Step 1: Find the applicable directives, standards and regulations for your productStep 2: Determine the applicable conformity assessment moduleStep 3: Carry out a risk assessment and define measures based on harmonized standards
Step 4: Implement the measures defined at the risk assessmentStep 5: Create the technical file (TF)Step 6: Declare conformity and do the CE-marking
2.1 Step 1: Applicable directives, standards and regulations for your product
The “New Approach Directives” broadly describe the essential requirements for a lot ofproduct categories that these products have to comply. It is the responsibility of themanufacturer to indicate how the product complies to the essential directives and standards.Often European harmonized product standards (EN) are used, because they give precisely
the technical requirements that a product must meet. An advantage to apply harmonizedstandards is the presumption of conformity with the essential requirements of the applicabledirective(s).
Depending on the used technology for storage systems the European Directives listed intable 2 could apply.
Double-layer CapacitorSuperconducting magnetic coil
XX
XX
X X
Mechanical storage technology
Pumped HydroCAES (compressed air)Flyweel
XXX
XXX
XX X
X X X
X: EUP is applicable for subsystems or components used, e.g. motors
As shown in table 2 for electrical and electro-chemical storage systems the Low VoltageDirective 2006/95/EU and the EMC-Directive 2004/108/EU are the applicable directives.Based on these directives the conformity assessment and the harmonized standards have tobe selected and considered during the risk assessment and design of the storage system.
Because for most of the storage systems there are no harmonized product standardsavailable but there exists a lot of standards for the components and subsystems used, e.g.batteries, converters, or others, these have to be considered when developing a storage
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system. To select appropriate standards it is useful to take a look at the model of an energystorage system described at Fig. 1. The model describes a technology independent storagesystem and is helpful to select applicable standards. For mechanical storage technologywhere the Machinery Directive applies, the EN ISO 12100 is the basic standard to be
considered over the product life cycle. In addition for electrical safety, power management orcommunication the related product standards apply, e.g. EN IEC 60204-1, EN 61800 or EN61850.
For electro-chemical applications, the Low Voltage and EMC-Directive applies and e.g. thestandard for battery rooms EN 60272-1 has to be considered.
When software is part of the implemented safety functions, EN 61508 has to by considered.
Fig. 1: Applicable standards for subsystems and components of storage systems
Appendix 2 gives an overview of applicable standards for batteries and storage systems.
It is the responsibility of the manufacturer to identify the applicable standards and then todesign and construct the storage system according to this standards.
Power provider specifies the conditions to connect storage systems to the grid, to operate,control and maintain them. Typical values are the ratings for voltage, frequency, peak loadmanagement, net load ramping, communication, etc. The specifications are not harmonized
and could differ from one provider to another but the harmonization process is ongoing, thefirst results are specified in Germany e.g. at the VDE-AR-N 4105:2011-08.
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Conformity Assessment is a mandatory step for the manufacturer in the compliance processwith specific EU legislation. The purpose of conformity assessment is to ensure consistencyof compliance during all stages of the production process to facilitate acceptance of the finalproduct. EU product legislation gives manufacturers some choice with regard to conformityassessment, depending on the level of risk involved in the use of their product. These rangefrom self-certification, type examination and production quality control system, to full qualityassurance system. You can find conformity assessment bodies in individual Member Statecountry in this list by the European Commission.
The modules cover the design and production phases and are divided into eight assessmentprocedures (see table 3):
internal production control (module A);
CE type-examination (module B);
conformity to type (module C);
production quality assurance (module D);
product quality assurance (module E);
product verification (module F);
unit verification (module G);
full quality assurance (module H).
Table 3: conformity assessment modules
Design Phase Production Phase
M a n u f a c t u r e r
Module Ainternal production control
C E - M a r k i n g
Module B
CE type-examination
Module Cconformity to type
Module Dproduction quality assurance
Module Eproduct quality assurance
Module Fproduct verification
Module Gunit verification
Module Hfull quality assurance
For products like storage systems usually Module A is selected, CE-conformity is under thefull responsibility of the manufacturer.
2.3 Step 3: Risk assessment and measures based on harmonized standards
What is risk assessment?
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A risk assessment is a careful and systematic examination of locations and situations thatcould cause harm to people. Risk assessment requires the examination of a variety oftechnical aspects and needs the long-time professional experience and knowledge of safetyexperts and safety standards.
Please consider : Risk assessment is teamw ork!
The risk assessment is an overall process of risk identification,
risk analysis and
risk evaluation.
and includes the following (see ISO 31010 or ISO 12100):
Boundary definition Hazard identification
Risk estimation
Risk evaluation
Risk reduction
Documentation – record of results
The manner in which this process is applied is dependent not only on the context of the riskmanagement process but also on the methods and techniques used to carry out the riskassessment. There are a lot of technics that can be used, e.g. Check Lists, Brainstorming,
Hazard and Operability Study (HAZOP), Preliminary Hazard Analyse (PHA), Failure ModeEffect Analysis (FMEA), etc. For more details refer to IEC/ISO 31010. In this paper the PHA-method is used because it is a simple inductive method to identify hazards and hazardoussituations and is most commonly carried ou early in the development of a project.Nevertheless the PHA can be combined and enlarged easily with HAZOP or FMEA.
2.3.1.1 Boundary definition
Each risk assessment begins with the description of the product to be assessed and consiststhe following:
definition of the limits of the system (environment, dimensions, clearance, workingspace weight, etc.
definition of the intended use and think about misuse
definition of the time limits: probable lifetime under proper use, service intervals,preventive maintenance
2.3.1.2 Hazard identification
A hazard is anything that may cause harm, such as electricity, hot surfaces, moving parts,chemicals, radiation, electromagnetic fields, light,. Each conceivable hazard situation andeach hazard over the product lifecycle (PLC) has to be identified, e.g.:
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transport
assembly and Installation
set up
normal operation
service and maintenance decommitioning
dissasambly and disposal
For each phase of the PLC identify:
all conceivable hazards (electrical, chemical, mechanical, agronomical, radiation, …)
possible interaction between the system with the environment
possible malfunctions
the proper use
fix the requirements for personnel, e.g. protective equipment
2.3.1.3 Risk estimation
A risk is the chance - high or low - that somebody could be harmed by these hazards,together with an indication of how serious the harm could be and depends on. Estimate thelevel of risk for each identified hazard, establishing the probability of its occurrence(frequency) and the severity of potential harm using the table below.
Table 4: Levels of risk used for risk estimation
SeverityFrequency
catastrophic1
critical2
marginal3
negligible4
frequent A
probable B
occasional C
remote D
improbable E
Acute, unacceptable
High, undesirable
Moderate, acceptable with review
Low, acceptable without review
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2.3.1.4 Risk evaluation
The decision whether the residual risk is acceptable or whether risk reduction measures arenecessary requires experienced experts. EN ISO standards and others provide relevantguidance.
2.3.1.5 Risk reduction
Reduce the risk following this three guiding principles:
hazard elimination;
technical protective measures;
user information.
Evaluationresult
Reduction measure
Acute hazard elimination by design required
High hazard elimination or technical protective measuresrequired
Moderate protective measures and user information required, definepersonel protective equipment for user (PPE)
Low user information required.
Based on the directives and harmonized standards define at the risk assessment themeasures to be implemented by design or documentation. Keep the records of the risk
assessment to demonstrate compliance with the directives and to demonstrate that theprocess was conducted properly and in accordance with European legislation. A practicaltemplate is given in Annex 1.
2.4 Step 4: Implementing the measures
Working out the Risk Assessment is the basic requirement of the TUV strategy. But it isundesirable to verify if the measures are effective!
Apply the standards and implement the measures worked out at step 3. Review the riskassessment, to demonstrate that the measures are implemented, than test the performance
of the system as well as the safety functions, if any. Verify by test, e.g. at a testing laboratorythat the requirements of the standards are met and keep the test reports at the technical file.
2.5 Step 5: Technical file
The CE marking directives require the manufacturer of the product to create a technical file(TF) to demonstrate that the product complies with the requirements of the applicabledirectives.The TF includes the following:
the general description of the product; general arangement drawing the list of standards and essential requirements that are met;
the risk assessment to identify health and safety requirements on the applicableproduct; the design and fabrication drawings;
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detailed technical information on key aspects of the product; reporting of calculations and tests; description of control philosophy/logic wiring and circuit diagrams including part list certificates and test reports manuals for installation, user, maintenance, for series production, the internal rules that are adhered to ensure accordance with
the Directive(s) Declaration of Conformity, specifications, datasheets for sub-assemblies copies of any markings and labels quality control & commissioning procedures Declaration of Conformity (DoC) (see 6.1)
2.6 Step 6: Declaration of Conformity and CE-Marking
The conformity to the applicable directives has to be declared with the “EC Declaration ofConformity”. With this document the manufacturer, his agent or importer declares that the
product conforms to the essential requirements of the relevant New Approach Directive(s).
Please consider: The DoC is a legal compulsory document!
The Declaration of Conformity contains the following:
Company name, complete address of the manufacturer and, where appropriate, hisagent
Product identification (name, function, model, type, serial number and trade nameand any relevant additional information)
The directives concerned and where appropriate harmonized standards or othertechnical standards and specifications (see step 1 and 3)
Identity and signature of the person authorized to act on behalf of the manufacturer orhis representative to compile the declaration
The date on which the declaration is issued When Machinery Directive applies: the name and address of the person who is
responsible to compile the technical file in the Community, When a notified body is used: name, address and identification number of the
The CE marking symbolizes conformity to all requirements for the product according to theessential requirements out of the New Approach directives.
3 Certification for North America:
What is the difference between EU requirements and North America Requirements?The main difference is the listing of the equipment by a Nationally Recognized TestingLaboratory (NRTL) and the applicable codes and standards, e.g.:
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Code of Federal Regulations CFR
National Electrical Code (NEC) and/or Canadian Electrical Code
National or binational standards, e.g. ANSI, NFPA, UL, CAN/CSA.
Usually IEC and ISO standards are not applicable for listing of products for the North American market. Table 5 gives an overview of the different requirements between EuropeanUnion and North Amerika.
Table 5: comparison of requirements EU vs. North America
European Union North AmericaStep 1: Find the applicable directives,
standards and regulations for yourproduct
Find the applicable code (CFR),standards and regulations for yourproduct
Step 2: Determine the applicable conformity
assessment module
Listing of the product by an NRTL is
requiredStep 3: Conduct a risk assessment and definemeasures based on harmonizedstandards
Conduct a risk assessment and definemeasures based on CFR, NEC, CEC, ANSI, NFPA, UL, CSA standards
Step 4: Implement the measures defined at therisk assessment)
Implement the measures defined atthe risk assessment
Step 5: Create the technical file (TF) Create the technical file (TF withoutDoC)
Step 6: Declare conformity and do the CE-marking
print the listing mark onto the product
and voluntary
Once prepared, the same strategy and risk assessment can be used for certification forNorth America!
Machinery Directive 2006/42/EU / Low Voltage Directive 2006/95/EU
und harmonisierten europäischen Normen
and harmonized European standards
Projekt: ……………………….
Project: .
Diese Vorlage wurde von TÜV SÜD Product Service GmbH entworfen. Der Anwender ist für den Inhalt der Risikobeurteilung verantwortlich!This template is desig ned by TÜV SÜD Product Servic e GmbH. The appl icant of the hazard assessm ent is respons ib i l i ty for the co ntent !
EN 60993 Electrolyte for vented nickel-cadmium cells
EN 61440 Secondary cells and batteries containing alkaline or other non-acidelectrolytes. Sealed nickel-cadmium small prismatic rechargeablesingle cells
EN 62259 Secondary cells and batteries containing alkaline or other non-acidelectrolytes. Nickel-cadmium prismatic secondary single cells withpartial gas recombination
94/216281 DC Guide to the equipment manufacturers and users of alkalinesecondary cells and batteries on possible safety and health hazards.Part 1:Nickel-cadmium. (21A/163/CD)
IEC 1914. Technical report type 2. Alternative publication for vented nickel-cadmium prismatic rechargeable single cells
IEC 61959-1, ED.1 Mechanical tests for sealed portable alkaline secondary cells andbatteries. Part 1. Secondary cells
EN 60285. Ed.4. Secondary cells and batteries containing alkaline or other non-acid
electrolytes. Sealed nickel-cadmium cylindrical rechargeable singlecellsLead Acid Battery StandardsIEC/TR 62060 Monitoring of lead-acid stationary batteries User guide
EN 60896-1 Stationary lead-acid batteries. General requirements and methods oftest. Vented types
EN 60896-2 Stationary lead-acid batteries. General requirements and methods oftest. Valve regulated types
EN 60896-11 Stationary lead-acid batteries. General requirements and methods oftest. Vented types. General requirements and methods of tests
EN 61429 Marking of secondary cells and batteries with the internationalrecycling symbol ISO 7000-1135
EN 60896-1 Ed.2. Stationary lead-acid batteries. General requirements and methods oftest. Part 1. Vented types
IEC 60254-1 Lead-acid traction batteries. Part 1. General requirements andmethods of tests
EN 60095-1 Lead-acid starter batteries. General requirements and methods oftest
Photovoltaic Battery StandardsIEC 61427 Secondary cells for solar photovoltaic energy systems General
requirements and test methodsEN 50314-1 Photovoltaic systems. Charge regulators. Part 1. Safety. Test
requirements and procedures
EN 50314-2. Photovoltaic systems. Charge regulators. Part 2. EMC. Testrequirements and procedures
EN 50314-3. Photovoltaic systems. Charge regulators. Part 3. Performance. Testrequirements and procedures
EN 50315-1. Accumulators for use in photovoltaic systems. Part 1. Safety. Testrequirements and procedures
EN 50315-2. Accumulators for use in photovoltaic systems. Part 1. Performance.Test requirements and procedures
Subsystem and System level
IEC 61508 Functional safety of Electrical/Electronic/Programmable ElectronicSafety Related Systems
EN 45510-2-3 Guide for the procurement of power station equipment. Electricalequipment. Stationary batteries and chargers
EN 50272-2 Safety requirements for secondary batteries and battery installations.Stationary batteries
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AFNOR Association Française de Normalisation11 Avenue Francis de PressenséF93571 Saint-Denis La Plaine CedexTelefon: + 33 1 41 62 80 00Telefax: + 33 1 49 17 90 00
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