PV panels

manufacturing ,
site issues and
IV curve test

WALEED AL AJLOUNI 165724

CONTENTS

01. PV module 02. Manufacturing

components process

Hotspot , micro-
03. cracks ,snail trails
04. IV-curve test
1. PV module components

aluminum frame
Ribbons / ( LRF )

glass
(EVA) film
solar cells
(EVA) film junction box ( bypass diodes , MC4 )

back sheet

Fig 1 : PV module components

2. Manufacturing process
Machine that
connect solar
cell to gather to
produce a sub-
String machine
string Electroluminescence )EL
( test

1 2 3 4
Solderng machine High pressure
Connecting ribbons to and
busbar
temperature
EL tset Framing Isolation test Sun simulation

5 6 7 8
Phenomenon occurs
when current pass a PV
cells
3.
Micro-cracks ,
Hotspot , snail trail
 EL image for a PV cells

Fig 2 : monocrystalline module Fig 3 : polcrystalline module

* NOT every cracks can lead to hotspot or a drop in output power
Crack free

Uniform distribution of
the heat , approximately
at STC ( 25 c° )

Micro-crack

Shade area

Uneven distribution of the

current flow in the busbars
which will increase the Temp.

Breakdown cell

Fig 4 : EL image of solar cell samples Fig 5 : Thermal image of solar cell
samples under STC condition
Solar irradiance vs output power of each crack

Crack free Micro-crack Shade area Breakdown cell

Fig 6 : Solar irradiance vs output power of each mode.
Shade ratio VS Temp. distribution

25%
The main reason of increase in cell
temperature is the uneven of current
40 %

distribution .
60 %
80 %

The most dangerous two cases are 40%

and 60% of shade , as the temperature
can reach 105 C°.
100%

Fig 7 : Shade ratio VS Temp.

distribution
 Fig 9 : busbar
deformation

snail
trail

Fig 8 : hotspots &

snail trail
Fig 10 : Burnt ribbon

Fig 11 : Burnt cell

Fig 12 : Normal Temp. distribution

Fig 13 : inner connection of PV panel

 Fig 16 : Hotspot
Fig 14 : 1 Bypass damaged

Fig 17 : Hotspot
Fig 15 : 2 Bypass damaged
4. IV CURVE TEST
 *
The PV test terminals maximum rating: 1000V DC open circuit voltage, 15A short circuit
current,10kW DC power.

Will appear when fill

factor < 60 %

Seaward PV 200
Fig 18 : Connection between SEAWARD PV200 and PV module

Solarcert software
 Table 1 : IV curve test for HOTSPO panel Table 2 : IV curve test for BYPASS panel

8
8

6
6
Current (A)

Current (A)
4 4

2
2

0 0
0 10 20 30 40 0 10 20 30 40
Voltage (V) Voltage (V)
THANK you
any questions?