JIS Q 8901 Introduction

JIS Q 8901 and Its Certification
November 27th 2012
Katsuaki Shibata
PV Module Certification Bodies' Council (PVCBC)
JAPAN ELECTRICAL SAFETY & ENVIRONMENT TECHNOLOGY LABORATORIES
BACK GROUND
Existing IEC 61215 Product Certification Change in PV market structure in Japan FIT Act (Duration and Requirements)
Copyright JAPAN ELECTRICAL SAFETY & ENVIRONMENT TECHNOLOGY LABORATORIES. All Rights Reserved
Existing IEC 61215 Product Certification -1

Combination of Product Testing and Factory Inspection Product Testing
Full testing to basic model in accordance with sampling rule of IEC 61215 clause 3 To certify family models after having conducted necessary additional tests using Retesting Guideline (IECEE/CTL) Appropriate valid period of test data in order to avoid some complexity in retesting
Factory Inspection
Initial and annual Follow-up Factory Inspection as a condition of continuance of certification. Manufacturers are expected to ensure that all certified products are identical, within accepted manufacturing tolerances, to the sample against which the product certification was granted. Manufacturers shall maintain appropriate records to demonstrate conformance with the Factory Inspection requirements. If necessary, reexamination samples are picked up from the production line or stock.

Sampling rule for Product Testing IEC 61215 (2nd edition 2005-04) 3 Sampling
Eight modules for qualification testing (plus spares as desired) shall be taken at random from a production batch or batches, in accordance with the procedure given in IEC 60410. When the modules to be tested are prototypes of a new design and not from production, this fact shall be noted in the test report.

Retesting rule for Product Testing IEC 61215/61646 Retesting Guideline (IECEE/CTL)
http://www.iecee.org/ctl/retest_guidelines/RetestGuideline_IEC61215_61646def.pdf.pdf
This document sets forth a uniform approach to maintain the certification of products that have, or will, undergo modification from the articles originally certified. It should not be used as a guideline to certify new product submittals. Changes in material selection, components and manufacturing process can impact electrical performance and reliability of the modified product. The recommended test sequences given below have been selected to identify adverse changes to the modified product. Those products meeting the requirements of the relevant standard after retesting are considered to be compliant and will be issued an amended CB Conformity Assessment Certificate and an Amended Technical Report Form
61215 Ed 3 Draft I
Modifications
Changes in material selection, components and manufacturing process can impact the qualification of the modified product. Material in direct contact with each other shall be tested in all applicable combinations unless equality can be proven. The recommended test sequences given below have been selected to identify adverse changes to the modified product. The number of samples to be included in the retesting program and the pass/fail criteria are to be taken from the relevant sections of this standard. For the modifications listed below, the re-test program shall be used as a guideline to maintain product certification. Each test shall meet the individual pass criteria.

Requirement for Factory Inspection IECEE OD-4003 Guide to Certificate Holders and Manufacturers
http://www.iecee.org/Operational_documents/iecee_documents/od-4003_ed.1.1.pdf
At least the following records shall be maintained as far as applicable:

Incoming inspection of components (including Certificates of Conformity) Routine Tests Periodic Product Verification Tests Functional checks of test and measuring equipment Calibration of test and measuring equipment Results of self-assessment Customer complaints and corrective action
Selection and Shipping of Re-Examination Sample(s)

If required by the NCB the manufacturer shall assure that re-examination samples can be selected by the inspector from the production line or from stock. If the re-examination sample(s) are not transported by the inspector the manufacturer shall assure that no modifications are made to the sample(s) selected and shall send the samples to the NCB in accordance with the Certification Bodys requirements.
Change in PV market structure in Japan

MW
before and after FIT

MW
2,500
2,000 1,600 1,400 1,200 1,000 800 600 400 200 0

(Until September)
1,500 74% 1,000

86%
PV 10kW PV 10kW
Other Residential 77% 0 Jul Aug Sep Oct

(End of each month)
500 26%
FY2012
Fiscal year
(Source: JPEA)
Shipped PV modules in Japan
Cumulative capacity of PV systems recognized under the new FIT scheme (Approved facilities)
(Source: METI)
Outline of FIT Act

The Act on Purchase of Renewable Energy Sourced Electricity by Electric Utilities was approved at the 177th session of the Diet. This Act obliges electric utilities to purchase electricity generated from renewable energy sources (Solar PV, Wind power, Hydraulic power, Geothermal and Biomass) based on a fixed-period contract with fixed price. It started on July 1st, 2012. Costs incurred by the utility in purchasing renewable energy sourced electricity shall be transferred to the entire electricity customers, who pay the Surcharge for renewable energy in general proportional to electricity usage. Electricity generated from solar PV, wind power, hydraulic power (below 30MW), geothermal and biomass shall be purchased.
For small-scale PV systems at residences or the like, excess electricity exported back to the grid will be purchased as in the current scheme. (Duration: 10 years)
The certification by the Minister of Economy, Trade and Industry on power generator and generation method shall be required (e.g. Whether the generator can stably work shall be checked). Electricity supplied from the certified generator shall be purchased.
Requirement for FIT Facilities

I. The facility must be capable of stably and efficiently generating electricity during the guaranteed period. II. The facility must be capable of transparently and fairly measuring the amount of the electricity produced from renewable energy that is supplied to the electric utility. III. The facility to be used for power generation must be specified in detail.
(Article 6 of the Act)
[Common standards for all energy sources]

1. Maintenance system must be secured for the facility.
Inspection and maintenance service network over the FIT period in Japan (with a lead time of maximum 3 months for repair)
2. The facility must have a structure that is capable of making proper measurements using a measuring instrument 3. The power generation facility must be specified in detail (e.g., the manufacturer and the model code of the product) 4. The renewable energy producer must record and periodically submit the breakdown of the costs for installing the facility (the facility cost, the land cost, the cost for access to the electric power system, the maintenance cost, etc.) and the breakdown of annual fiscal costs for operating the system.
Tariffs and Durations
Solar PV 10 kW or more Less than 10 kW (purchase of excess electricity)
Tariff ( per kWh) 42.00 yen 42 yen(*)
Duration 20 years 10 years
(*) Solar PV power generation using systems for residences The price for solar PV power generation of less than 10 kW is seemingly the same as that for solar PV power generation of 10 kW or more. However, considering the subsidy of 35,000 yen per kW (FY2012) granted for power generation using systems for residences, the price will be 48 yen in effect.
10
JIS Q 8901
Pre-history Requirements
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Pre-history of JIS Q 8901

July 15th , 2011
(1st International PV Module Quality Assurance Forum, San Francisco, USA)
JEMA's Proposal -- Module Makers Perspective
Management system of design review of PV module structure Product warranty system including after-sales service JEMA: Japan Electrical Manufacturers Association
August 30th , 2011

New FIT Act Act on Purchase of Renewable Energy Sourced Electricity by Electric Utilities was promulgated.
Supplementary resolutions were adopted by both of upper and lower houses.
To require long-term quality assurance and maintenance contract
September 16th , 2011

(1st Local TG1) Local TG1-5 were set up.
Draft guideline to realize JEMA's proposal was deliberated.
December 8th , 2011

(2nd International PV Module Quality Assurance Forum, Tokyo, Japan) Session III. Forum Task Group Reporting: Task-1 Region JP Reporting
Proposal for Requirement of PV module Design Proposal for Requirement of After-sales service
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JEMA's Proposal -- July 15th , 2011

Module Makers Perspective 1st International PV Module Quality Assurance Forum, San Francisco, USA Presenter: Yoshihito Eguchi, SHARP CORPORATION
Proposals for Quality Assurance Program

Management system of design review of PV module structure Product warranty system including after-sales service
Program consists of product quality assurance authorized by the independent certification body in accordance with the manufacturers declaration on the following items;
A) Process quality controls approved on process quality audit B) Quality management system covering warranty of PV modules. (Including the management system of design review of PV module structure) C) Product warranty system including after-sales service
The independent certification body conducts

Inspections of the system on which design and warrant of PV modules can be relied based on the self declaration of PV manufacturers. Process quality audit (such as ISO 9001) and certifies the PV manufacturers.
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Task-1 Region JP Reporting -- December 8th , 2011

2nd International PV Module Quality Assurance Forum, Tokyo, Japan Session III. Forum Task Group Reporting Reporter: Yoshihito Eguchi, SHARP CORPORATION
Well-harmonized combination of design review manufacturing consistency and after-sales services could be quite helpful to ensuring reliability of PV modules until validated test methods are developed. Proposal for Requirement of PV module Design
Setting of target for long-term use: Functional lifetime The rule or management system for PV module design review and validation Suitable examination item and validation methodology for evaluating
Proposal for Requirement of After-sales service

The contents of product warranty certificate and the internal rule about the warranty shall be fitted. Product warranty certificate: disclosure, control system for after-sales service
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JIS Q 8901 (Published on 29th
February 2012)
JIS Q 8901:Terrestrial photovoltaic (PV) modules-Requirement for reliability assurance system (design, production and product warranty)
Objectives: To require a consistency between design, production and product warranty of PV modules (the combination of reliability of product itself and warranty services ) through the party for product liability from the view point of long-term liability so as to increase the liability of PV systems and realize the popularization and user protection
Response to troubles, replacement after lifetime A business entity that has primary liability for PV module products (design, production, and power output performance warranty)
In order to conform to the requirement of JIS Q 8901,

The party for product liability shall set functional lifetime and verify the structure of the PV modules is so designed that specified power output performance is expected over the functional lifetime.
Design target period when PV modules is expected to satisfy specified power output performance under specified conditions
The party for product liability shall manage manufacturing of the PV modules in accordance with Clause 7.5 (manufacturing and offer of service) of JIS Q 9001 based on the above design. The party for product liability shall ensure consistency between functional lifetime and power output performance warranty so that power output performance of the PV module is ensured over the period of warranty. In case the functional lifetime is shorter than the power output performance warranty period, the warranty shall be secured by the services .
operational rules and systems for the warranty services consistent with the contents of power output performance warranty of the PV modules
English JIS Q 8901 is available at the JSA Web Store.

http://www.webstore.jsa.or.jp/webstore/Top/html/en/september2012.htm
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JIS Q 8901 CERTIFICATION

Certification Bodies' Council Outline of Certification Unified Guideline for Inspectors
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PV Module Certification Bodies' Council (PVCBC)

1. Activities
Consultation on certification criteria for improving the quality of PV module certification Collection and sharing of relevant information and documents on PV module certification Liaison between relevant government sections and organizations Communication to stakeholders Other necessary activities
2. Members
Regular members:
JAPAN ELECTRICAL SAFETY & ENVIRONMENT TECHNOLOGY LABORATORIES (JET) TUV Rheinland Japan Ltd. UL Japan, Inc. VDE Global Services Japan Co., Ltd
Special members:
Ministry of Economy, Trade and Industry (METI) National Institute of Advanced Industrial Science and Technology (AIST) Photovoltaic Power Generation Technology Research Association (PVTEC) Japan Electrical Manufacturers' Association(JEMA) Japan Photovoltaic Energy Association (JPEA)
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Outline of JIS Q 8901 Certification

JET and other three PVCBC certification bodies started Reliability Assurance System PV module certification service using JIS Q 8901.
As an additional requirement to existing IEC 61215 certification
All certified models by both of IEC 61215 (61646) and JIS Q 8901 are described on the certificate.
Extended factory inspection (incl. design/ product warranty) is needed.

Both of follow-up factory inspection for IEC 61215 product certification and for JIS Q 8901 assurance system certification can be conducted at a time by the same inspector (PV expert).
Loose linkage to the requirement of New Feed-In Tariff scheme

As an evidence to prove the existence of domestic inspection and maintenance service network System integrators are expected to require their PV modules conforming to the standard.
So far, certifications were issued by JET, TUV-Rheinland Japan and VDE Global Services.
Unified Guideline for Inspectors was shared among PVCBC member bodies.
Stakeholders opinions had been input through special members of PVCBC and face to face meetings with customers. An excerpt of the guideline can be downloaded on JET Website.
http://www.jet.or.jp/products/solar/JISQ8901.html
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Excerpt of JIS Q 8901 Guideline -1

JIS Q 8901 Mini-Guideline (Requirements of the Standard & Explanation of their Concrete Meanings) 4.3.2.1 Provisions of reliability design and verification method
(Requirement(s)) The rules and systems for managing and controlling the design process and verification method of the design output to ensure reliability of the PV modules shall be defined. (Explanation) The inspector checks if the auditee has test methods (necessary to be described in QMS documents) which prove that the functional lifetime is effective The inspector evaluates supporting data of the tests above as evidence. Data type is fine as well, such as data of similar product of the company, or such as literature that has been widely cited in the industry. In either case it's necessary to explain basis for the functional lifetime by showing logical linking to supporting data (evidence).
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4.3.2.3 Notification of items concerning reliability
(Requirement(s)) The party for product liability shall notify installers of the PV modules of precautions for use and/or installation, if necessary, so that the requirements for functional lifetime should be met. (Explanation) Instruction and/or installation manuals for the modules need to be written in Japanese and those manuals for overseas (other than Japan) need to be written in appropriate local language. Contents of clause 12 in IEC61730-1 need to be described in instruction and/or installation manuals for the modules. Each installation manual for the modules needs to be put into product package, or method of distributing manuals to installation contractors needs to be set down.
4.4 Quality management for production

(Requirement(s)) The party for product liability shall manage the manufacture of the PV modules in accordance with 7.5 of JIS Q 9001. (Explanation) The inspector checks if the auditee is certified JIS Q 9001 (ISO9001) in the scope. (If so, it is conforming.) If the auditee is not certified JIS Q 9001 (ISO9001) in the scope, the inspector checks if the auditee's PV modules' production is managed based on clause 7.5 of the standard.
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4.5.2 Product warranty
(Requirement(s)) The party for product liability shall disclose contents of the performance warranty to the purchasers of PV modules, including warranty conditions pertaining to it and matters necessary for after-sales services specified in the warranty. (Explanation) The following contents need to be described in the warranty (or the attached document) Object to warrant (output of the module, electricity generated over a period of time) Warranty period Definition of warranty start date Warranty criteria, judgment criteria Compensation method (replacement, monetary compensation, etc.) (In the case of replacement : if the same products or similar products are available) (In the case of replacement : if it costs, and range of costs) (In the case of monetary compensation : method of estimation) Service center (contact information, how to contact, opening hours) Procedures for compensation Warranty disclaimer (use and handling in severe condition areas)
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4.5.3 Operation of warranty service
(Requirement(s)) The party for product liability shall organize warranty service system to securely implement the warranty. The operational rules and/or systems shall be defined for acceptance of consultation requests from purchasers when some problems occur, diagnosis to identify the problem, compensation after the problem is identified, and measures for preventing the recurrence of the problem. (Explanation) The inspector checks the following :
procedure concerning customer service when customer makes inquiries about the product procedure concerning diagnosis for problems/failures on the product procedure concerning compensation (repair, replacement, etc.) methods after cause of problem is identified procedure concerning period for taking action (repair/replacement of modules) against the problems/failures procedure concerning corrective/preventive actions including feedback to design and production procedure concerning business support at the time of withdrawal from present business (If there is a case that withdrawal without any problem in the past, you can show it in place.)
Service centers for after-sales service need to respond to customers in Japanese. Concretely speaking, telephone numbers and e-mail addresses for customers use need to be available in Japanese. Framework of after-sales services organization (for specifying problems, repair and replacement of modules) shall be located in Japan. This is confirmed by organization chart, diagram and/or regulations.
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5 Retention of records
(Requirement(s)) The party for product liability shall keep and manage properly the records necessary for the operation of warranty services over the period of the performance warranty. (Explanation) The inspector checks regulation for records (including records retention period list). Traceability system which can trace product's information by its serial number is necessary. System to make a backup copy of necessary information for service operation including customers' information (electronic media) is necessary, and it needs to be implemented. Over performance warranty period, readable product identification information needs to be on the product. If applicable, evidence (supporting data) for endurance of label printing/label sticking on the product for performance warranty period is necessary. Records necessary for service operation need to be stored for performance warranty period plus one year or more than that.
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JIS Q 8901 Introduction

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JIS Q 8901 Introduction

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JIS Q 8901 and Its Certification

November 27th 2012

JAPAN ELECTRICAL SAFETY & ENVIRONMENT TECHNOLOGY LABORATORIES

Existing IEC 61215 Product Certification -1

Existing IEC 61215 Product Certification -2

Existing IEC 61215 Product Certification -3

Existing IEC 61215 Product Certification -4

At least the following records shall be maintained as far as applicable:

Selection and Shipping of Re-Examination Sample(s)

Change in PV market structure in Japan

before and after FIT

2,000 1,600 1,400 1,200 1,000 800 600 400 200 0

1,500 74% 1,000

Other Residential 77% 0 Jul Aug Sep Oct

Shipped PV modules in Japan

Outline of FIT Act

Requirement for FIT Facilities

[Common standards for all energy sources]

Tariffs and Durations

Solar PV 10 kW or more Less than 10 kW (purchase of excess electricity)

Tariff ( per kWh) 42.00 yen 42 yen(*)

Duration 20 years 10 years

Pre-history of JIS Q 8901

August 30th , 2011

September 16th , 2011

December 8th , 2011

JEMA's Proposal -- July 15th , 2011

Proposals for Quality Assurance Program

The independent certification body conducts

Task-1 Region JP Reporting -- December 8th , 2011

Proposal for Requirement of After-sales service

JIS Q 8901 (Published on 29th

In order to conform to the requirement of JIS Q 8901,

English JIS Q 8901 is available at the JSA Web Store.

JIS Q 8901 CERTIFICATION

PV Module Certification Bodies' Council (PVCBC)

Outline of JIS Q 8901 Certification

Extended factory inspection (incl. design/ product warranty) is needed.

Loose linkage to the requirement of New Feed-In Tariff scheme

Excerpt of JIS Q 8901 Guideline -1

Excerpt of JIS Q 8901 Guideline -2

4.4 Quality management for production

Excerpt of JIS Q 8901 Guideline -3

Excerpt of JIS Q 8901 Guideline -4

Excerpt of JIS Q 8901 Guideline -5

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