PV Module Production-Line Testing Solution

Ensure Stable 25-Year Service Life for Solar Panels

A qualified photovoltaic module goes through battery sorting, soldering, lamination, framing and final testing. Hidden risks such as poor material performance, virtual soldering, micro-cracks and insulation degradation may occur in every procedure.

Our complete production-line testing solution covers Incoming Quality Control (IQC), In-Process Testing, Finished-Product Final Inspection, QC Reliability Sampling and Tooling Calibration & Maintenance. It helps manufacturers detect defects in advance, comply with IEC 61215 and IEC 61730 standards, and guarantee long-term outdoor reliability of PV modules.

1. Incoming Quality Control (IQC) — Block Defects at Source

Prevent unqualified raw materials from entering production lines with full-item inspection for key materials:

• Solar Cells: HP3542-Y / HP3545-Y 4-probe resistance tester, test sheet resistance and diffusion doping uniformity of silicon wafers.
• PV Glass / Conductive Glass: Check TCO conductive-film sheet resistance and film uniformity by 4-probe tester and HP1035-FGG scribing inspection system.
• EVA / POE Encapsulant & Backsheet: HP3530 / HP3530A ultra-high-resistance insulation tester for surface and volume resistivity measurement.
• PV Junction Box: CHT9960 junction-box comprehensive tester. Test diode forward voltage, reverse leakage current, reverse withstand voltage, conduction resistance and junction temperature.
• Aluminum Frame & Structural Parts: CHT9931A high-current continuity tester to verify frame conductivity and grounding-loop resistance.

2. In-Process Testing — Capture Hidden Defects During Manufacturing

Laser Scribing Procedure

Use HP1035-FGG scribing inspection system to test sub-cell resistance and scribing-groove insulation after laser scribing, avoiding implicit power loss caused by defective scribing craftsmanship.

Post-Lamination Pre-Test (After Framing & Junction-Box Mounting)

• Safety pre-screening: CHT9951A/B PV high-voltage safety tester performs DC withstand-voltage and insulation-resistance tests.
• Junction-box soldering validation: Re-check diode performance and busbar soldering resistance with CHT9960 tester, screen virtual-soldering risks.

3. Finished-Product Final Inspection — Mandatory Full Test Before Shipment

Every PV module must pass strict final inspection before delivery:

1. IV Power Performance TestHP1040-55 rod-type IV test fixture applies Kelvin 4-wire principle for accurate power measurement. Cooperate with HP1035-IV 4-wire reliability monitoring system, real-time monitor tooling contact resistance, give early warning for oxidation and poor contact to secure test repeatability & accuracy.
2. All-in-one Safety Compliance TestHP9914 PV-specific safety comprehensive testercompletes 4-in-1 tests: AC/DC withstand voltage, insulation resistance, grounding resistance and bypass-diode characteristics, fully meeting IEC 61215 & IEC 61730 certification requirements.
3. Grounding Continuity TestCHT9931A high-current continuity tester carries out full inspection for frame grounding-loop resistance to satisfy lightning-protection safety requirements for outdoor deployment.

4. QC Reliability Sampling — Simulate Harsh 25-Year Outdoor Environment

Reliability sampling reproduces complex field working conditions to evaluate long-term durability:

• PID Performance Sampling: HP1092-25C24 PID test system simulates high-temperature, high-humidity and high-voltage environment to measure potential-induced degradation ratio.
• Wet-Leakage-Current Sampling: HP1070-SLD wet-leakage-current test system assesses insulation performance under humid conditions.
• Environmental Reliability Test: TC200 continuity monitoring system cooperates with environmental chambers, monitors circuit status during thermal-cycle & humidity-freeze tests, and locates micro-cracks & virtual-soldering failure points.
• Aging Insulation Verification: HP3530 / HP3530A ultra-high-resistance insulation tester detects insulation resistance attenuation after aging.

5. Production-Line Tooling Calibration & Maintenance

IV / EL test tooling will degrade after long-time repeated usage, which brings deviation for power test results.

• Regular Calibration: HP1042-ITJK cross-bar tooling offline inspection station detects contact resistance and deformation of tooling, quantifies performance degradation, ensures test-data traceability and meets CNAS laboratory requirements.
• Daily Maintenance: HP1041-SXJK automatic tooling polishing system removes oxidation and contaminants on contact copper sheets, restores conductive performance and extends tooling service life.

Why Our PV Production-Line Testing Solution?

✅ Full-process coverage: IQC → in-process → final test → reliability sampling → tooling management ✅ Standard compliance: Strictly follow IEC 61215, IEC 61730 for PV module certification ✅ Real-world-oriented: Target actual pain points of PV manufacturing plants and third-party labs ✅ Data traceability: Support laboratory system docking, meet CNAS quality-management demands ✅ Automation-friendly: Equipped with communication interfaces, easy to integrate into existing production-line MES system

FAQ

Q: Does your solution comply with IEC 61215 and IEC 61730 standards?

A: Yes. All test items are designed in accordance with IEC 61215 & IEC 61730 for PV module safety and reliability certification.

Q: Can your equipment realize full-line testing from raw-material incoming to finished-product delivery?

A: Absolutely. We cover raw-material IQC inspection, in-process defect capture, finished-product safety & performance test, reliability sampling as well as tooling calibration & maintenance.