Online Training Program

for officials of
ISA member Countries
Session III
• Solar Module characterization

Presented by
Abhinav Shukla
Master trainer, Skill Council For Green Jobs
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 Content

• Concept of SPV Module

• IV Curve , PV Curve, Efficiency & fill factor
• STC & NOCT and its significance
• Effect of temperature, intensity of light & partial Shadow on generation
• Interconnection of SPV panels
• Series
• Parallel
• Different SPV technologies
• ON Grid
• OFF Grid
• Hybrid
• Remote monitoring system for Solar Plants / pumps

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 The Photovoltaic Effect & Solar Cell
• The direct method of converting sunlight into electricity using a device called SOLAR CELL.
• PV utilizes the ‘LIGHT’ of sunlight.

• With the ‘standard’ (156mm x 156mm) P-type multi crystalline and monocrystalline wafers rapidly becoming obsolete,
210mm x 210mm P-type mono wafer size with PERC (Passivated Emitter Rear Cell) technology that would be in production

• Top Surface: Negative Terminal

• Bottom Surface: Positive Terminal
• The output current of a solar cell is
directly proportional to its area
• The output voltage of a solar cell
remains constant irrespective of its
area.

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 Different types of Solar cells

Mono

Multi
flexible

Thin film
Colored cells

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 Working of a Solar Cell

Physical Mechanisms:
1. Absorption
2. Transport
Current
3. Collection External
Current!
DC power flows from negative to positive.

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 (I-V) Characteristics of PV Module

 Initial condition:
 Open circuit, OR
Isc
 Infinite Resistance
I  V = Voc, I = 0
(A)
 Resistance decreases:
 I increases
 V slightly decreases

 Resistance decreases:
 I saturates
 V decreases
 Resistance becomes zero:
Voc V (V)  Short circuit
 V = 0, I = Isc

6
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 PV Module Parameters
If the resistance of the load is equal to the characteristic resistance of the solar cell, then the maximum power is transferred
to the load, and the solar cell operates at its maximum power point.
I (A) P (W)
Max. Power
Isc Point

Imp

Pmax
Pmax

Vmp Voc V (V)

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 Effect of MPPT with Example

Normal Solar Charge Controller:

Solar Panel works at point A state, the solar
panel working voltage is a little higher than
battery voltage.
Charge Voltage: UA=13.2V
Charge Current: IA=9.8A
Charge Power: PA=13.2*9.8=129.36w
Area in drawing: 1 + 3
MPPT Solar Charge Controller:
Solar Panel works at point B state, the solar
panel working voltage much higher than
battery voltage.
Charge Voltage: UB=18.4V
Charge Current: IB=9.3A
Charge Power: PB=18.4*9.3=171.12w
Area in drawing: 1 + 2

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 Solar cells are current source
• Voltage source is one which gives constant voltage irrespective what is connected to it while current source
gives constant current, it doesn't matter what is connected across it.
• Batteries are good example of voltage source as it provide constant voltage.
• solar cell exhibit the property of current source but when operated near its open circuit voltage.

• Area: 156 mm x 156 mm (i.e. 6 inch x 6 inch)

• Typical Thickness: 180 µm (micro-metre)
• Typical Current: ~8 Amperes
• Typical Voltage: ~0.5 Volts (DC)
• Typical Power: 4 Watts
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 Connecting solar cells in series

N N N
Solar Cell Solar Cell Solar Cell
P P P

• The top (negative terminal) of one cell is connected to the bottom (positive terminal) of the next cell by
soldering a metal strip.

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 Cut-section view of solar module

Polyvinyl fluoride

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 Components of a crystalline silicon PV module

Front side. Back side.

Frame
Junction Box

Label
Solar Cell
EVA
Glass
Cable
Connector
Back Sheet
Bus bar
Tab

SHOW & TELL: Identify the components in different (mono and poly) crystalline silicon PV modules.
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 How is a crystalline silicon PV module constructed?
FLASH
Glass
EVA

Solar Cell Solar Cell Solar Cell

Tedlar

1. Solar Cells from 2. Tabbing & 3. Layup of Glass,

STEPS: Tester Stringing EVA* and Tedlar®
4. Lamination in 5. Trimming of 6. Sealant on edges 7. Aluminium
Vacuum Edges (Silicone or tape) Framing
8. Installation of 9. I-V (Flash) Testing 10. Labelling on PV 11. Other Testing
Junction Box of PV Module Module (Hi-Pot, EL, etc.)
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 Bus bar and its effect

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 Standard IP rating
Solid Object
Protected against solid
1 1
objects greater than 50 mm.
Protected against solid
2 2
objects greater than 12.5 mm.
Protected against solid
3 3
objects greater than 2.5 mm.
Protected against solid
4 4
objects greater than 1 mm.
Dust protected. Limited
5 5
ingress of dust permitted.
Dust tight. No
6 6
ingress of dust permitted.
7
Example:
IP65
8
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Moisture
Protected against vertically
dripping water.
Protected against dripping water
when tilted up to 15°.
Protected against spraying water at The IP Rating (“International
Protection” Rating, sometimes
up to 60° from vertical.
also interpreted as “Ingress
Protected against water splashed Protection” Rating) classifies
from all directions. the degree of protection
Protected against jets of water. against both solids and liquids
in electrical enclosures.
Protected against strong jets of
water.
Protected against temporary
immersion in water.
Protected against continuous
immersion in water
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 Efficiency & Fill factor of module

fill factor (FF): This factor is a measure of quality of a solar cell. This
is the available power at the maximum power point (Pm) divided by
the open circuit voltage (VOC) and the short circuit current (ISC):
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 Efficiency

More the efficiency

lesser the size of
module & lesser the
BOM cost

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 Different efficiency levels in Solar Modules

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 Area required for different technologies

More the efficiency lesser the size of module & lesser the BOS cost
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 QUICK EXERCISE: Achieving desired I and V (1/2)

Given: Calculate: Calculate:

Current : 8A Current : Current : 2A

4A
Voltage : 0.5 V Voltage : 0.5 V Voltage : 0.5 V

Power : 4W Power : 2W Power : 1W

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 QUICK EXERCISE: (2/2)

Current : 4A Current : 8A
Voltage : 2V Voltage : 1V
Power : 8W Power : 8W

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 Half Cut cell module
Twin cell solar market share is expected to 60 and 72 solar cell panels become a 120
increase from 18% in 2018 to 40% by 2028. and 144 solar cell panels

half-cut cells or multi-cut cells with multi

bus-bar (MBB) technologies or stacking
and shingling interconnect technologies
to limit sheet resistance and provide high
cell output.

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 Half cut mono PERC cell module & Its advantages

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 Less impact of inter row shadow

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 Advantages …..

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 Different types of Solar Modules & their efficiency

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 Bifacial solar module

• More efficient and more overall • Solar tracking of PV array can result • A larger distance from the ground
output in up to 50% bifacial energy yield increases the bifacial gain. In
• Difficult to install/handling/ Maintain gain between 1-2 m

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 Test conditions & IEC standards
For mono facial modules

For bi facial modules

Defined in the same environment as defined in IEC 60904-3 with 1m ground clearance of bifacial PV modules

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 Effect of ambient temperature on module out put

More sunlight on collector more the power output, less the cell temperature more the output

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 Effect of ambient temperature on module out put

• Cell (or module) temperatures are always

higher than ambient temperatures during
daytime.

• The cell temperature depends on ambient air

temperature and irradiance:
Tcell = Tamb + (0.031 * Irradiance in W/m2)

• All deration calculations with respect to

temperatures should be done with respect to
cell (or module) temperatures.

• Example: At 1000 W/m2 irradiance (bright sun)

and ambient temperature of 24oC, the cell
temperature is approximately:
Tcell = 24 + (0.031 * 1000) = 55oC

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 Shadow and its ill effects

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 Shading Effect and Bypass Diode

+
_

Performance: 0%
50%
100%
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 Shadow effect on current

a. 5.60 Amp b. 3.89 Amp

c. 2.30 Amp d. 0.77 Amp

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 Shadow ill effect; Hot Spot

Thermal imaging of SPV panels

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6d02c2350d428f0cb79ffd533c517b87.jpg Shadow & hot spot generation
14-11-2019 06:17:06

FLIR Thermal Image

Report
14-11-2019 06:17:06

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 Interconnection of SPV modules
Series connection of modules

• Voltage of the circuit increases as

PV modules are connected in
series.

I(A)
Isc

Voc 2 x Voc 3 x Voc V (V)

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 Parallel connection of modules

I(A)
3 x Isc

2 x Isc

Isc

• Current increases
when PV modules
are connected in
parallel.
Voc V (V)

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 MC-4 series & branch connectors

MC4 stands for the manufacturer Multi-Contact USA and a 4 mm2 contact assembly pin

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 Series and Branch connector

MC4 in Parallel Connection

Low Voltage, High current (Up to 69 A)

MC4 in Series Connection,

High Voltage (up to 1500 V), Low Current

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 For bigger plants (String)

• String is panels are connected in series

• There should not be any potential difference in between strings

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 Degradation of a PV Module

• A typical PV module degrades approximately 1% per year.

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 PV Module Warranty

• Performance
• 90% for the first 10 years
• 80% for the next 15 years

• Workmanship
• 5 years

• For larger plants, performance warranties are also backed by bank guarantees.

• This is an added comfort to ensure customer service in case the manufacturer ceases to
exist or cannot service the customer.

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 Radio Frequency Identification

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 Quality measures in Solar Modules
• Module manufacturers are only required to meet
the UL and or IEC safety standard.
• For example; Each module of 72 cells in general has
2,016 soldering points.
• Quality BOM and manufacturing process is highly
critical for best performance against harsh weather
conditions and UV rays.
• Fill factor is also a quality indicator for SPV modules
• Degradation
• LID
• PID
• Generation reduction in life cycle

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 Different standards for modules
Compliances Comply with
IEC 61215 (Edition 2005) Crystalline silicon terrestrial photovoltaic (PV) modules - Design qualification-Performance Standards
IEC 61646 Thin-film terrestrial photovoltaic (PV) modules – Design qualification -Performance Standards
IEC 61730 Module safety Qualification – Safety Standards
UL 1703 Fire classification rating
ISO 9001:2008 Module manufacturing unit Quality compliances
ISO 14001 Environmental Management System Certification
OHSAS 18001 Occupational health and Safety
IEC 60891 PV - Procedures for temperature and irradiance corrections to measured I-V characteristics
IEC 61701 Salt mist corrosion testing
IEC 62716 Ammonium corrosion testing
IEC 60364 Protection Against Electric Shock for low-voltage electrical installations in PV modules
ASTM E1171 - 15 Test Methods for Photovoltaic Modules in Cyclic Temperature and Humidity Environments
IEC 60904 Measurement of current-voltage characteristics of bifacial photovoltaic devices
IEC 60721 PV module’s performance capability under prolonged exposure to standard climates
IEC60068-2-2 Test to evaluate the ability of the module for use/storage under high temperature
IEC 61853 Validation of Models using Outdoor Test Methods
IEC TS 62782 test method for performing a cyclic (dynamic) mechanical load test
Test to evaluate the durability of crystalline (PV) modules to the effects of short-term high-voltage stress including
IEC TS 62804-1:2015
potential-induced degradation (PID
IEC61646 or IEC61625- Wet Leakage Test to test the electrical isolation of the housing
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 Solar module Inspection & maintenance
Solar module Inspection

MC 4 connector failure

Cable & JB Gland failure Diode failure

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 Defects in solar cell / Module
Snail trails

Delamination caused by poor silica gel & Cross hidden

cracks of solar cell
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 Defects in different parts of solar modules

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 Panels defect

Cell damage due to hot spot Hot spots destroy the panel PV Yellowing

Yellow and Corroding Solar Panel Foreign particle Track short circuit
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 Panels defect

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 Modules on site test

Instructions to Installer:
• Please. fill the following details of the solar panel
• Please Note: Raise your complain with in 5 days from the date of receiving
modules.

Dispatch/ Complaint Date

Sr. Customer Product Material
Invoice No Quantity Complaint Transport from the
No. Name Description Receipt date
Detail customer

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 EL Test & PID detection

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 Module EL Test for Micro cracks & PID

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 EL test at 100% Isc

EL image at 100% ISC of a test module with a

defective cell interconnection in the original state.

..\..\..\..\founi odisa\videos\NREL Dont stand on panels.mp4

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 Partial Shading Due to Improper Cleaning

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 Bird Repellent

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 Temperature test for all contacts & equipment

Placed against the back of a module, a

sensor (attached to a
meter) can be used to measure cell
temperature. Be sure to
take readings on several spots and average
the results.
Heating of contacts at JB
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 Hot spot detection

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 Plant inspection with the help of drone

Flying Robots are the Future of

Solar O&M

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 Arial inspection fault finding and trouble shooting

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 Arial view of a solar plant

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 Cleaning the module

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 Tools for Module cleaning

• Good quality brush

• Soft water
• Cleaning agent

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 Good brush and the regular interval

Dry cleaning
“Don’t clean like this, it may
scratch the SPV after
sometime”

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 Water arrangement for construction & cleaning

• Availability / Quantity required

• For constructing footing 30 litters of water per bag of cement is required in PCC/ M20/M 15
• For cleaning 3-5 litters per module, depending upon the type of cleaning, frequency & soiling level
• Dry cleaning or automatic robotic cleaning is also very popular these days

• Quality/hardness level
• To avoid stain & scaling during cleaning purposes minerals and a total hardness of less than 75 mg/L
may be used
• High iron content in the water must avoid for cleaning
• Water pressure should not exceed more than 75 Bar at the nozzle
• The temperature of the water should ideally be equal to the module temperature
• It should be cleaned in low sunlight with a soft microfiber brush

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 Thank-You

Abhinav Shukla
Master Trainer SCGJ
abhinav.saveearth@gmail.com
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+91-9179818192