The goal of any solar photovoltaic (PV) system is to generate maximum energy throughout its lifetime. The parameters that can affect PV module power output include: solar irradiance, temperature, soil accumulation, shading, encapsulant browning, encapsulant delamination, series resistance increase due to solder bond degradation and corrosion and shunt resistance decrease due to potential induced degradation, etc. Several PV modules together in series makes up a string, and in a power plant there are a number of these strings in parallel which can be referred to as an array. Ideally, PV modules in a string should be identically matched to attain maximum power output from the entire string. Any underperforming module or mismatch among modules within a string can reduce the power output. The goal of this project is to quickly identify and quantitatively determine the underperforming module(s) in an operating string without the use of an I-V curve tracer, irradiance sensor or temperature sensor. This goal was achieved by utilizing Radiovoltmeters (RVM). In this project, it is demonstrated that the voltages at maximum power point (Vmax) of all the individual modules in a string can be simultaneously and quantitatively obtained using RVMs at a single irradiance, single module operating temperature, single spectrum and single angle of incidence. By combining these individual module voltages (Vmax) with the string current (Imax) using a Hall sensor, the power output of individual modules can be obtained, quickly and quantitatively.

Demand for green energy alternatives to provide stable and reliable energy

solutions has increased over the years which has led to the rapid expansion of global

markets in renewable energy sources such as solar photovoltaic (PV) technology. Newest

amongst these technologies is the Bifacial PV modules, which harvests incident radiation

from both sides of the module. The overall power generation can be significantly increased

by using these bifacial modules. The purpose of this research is to investigate and maximize

the effect of back reflectors, designed to increase the efficiency of the module by utilizing

the intercell light passing through the module to increase the incident irradiance, on the

energy output using different profiles placed at varied distances from the plane of the array

(POA). The optimum reflector profile and displacement of the reflector from the module

are determined experimentally.

Theoretically, a 60-cell bifacial module can produce 26% additional energy in

comparison to a 48-cell bifacial module due to the 12 excess cells found in the 60-cell

module. It was determined that bifacial modules have the capacity to produce additional

energy when optimized back reflectors are utilized. The inverted U reflector produced

higher energy gain when placed at farther distances from the module, indicating direct

dependent proportionality between the placement distance of the reflector from the module

and the output energy gain. It performed the best out of all current construction geometries

with reflective coatings, generating more than half of the additional energy produced by a

densely-spaced 60-cell benchmark module compared to a sparsely-spaced 48-cell reference

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A gain of 11 and 14% was recorded on cloudy and sunny days respectively for the

inverted U reflector. This implies a reduction in the additional cells of the 60-cell module

by 50% can produce the same amount of energy of the 60-cell module by a 48-cell module

with an inverted U reflector. The use of the back reflectors does not only affect the

additional energy gain but structural and land costs. Row to row spacing for bifacial

systems(arrays) is reduced nearly by half as the ground height clearance is largely

minimized, thus almost 50% of height constraints for mounting bifacial modules, using

back reflectors resulting in reduced structural costs for mounting of bifacial modules

In the past, the photovoltaic (PV) modules were typically constructed with glass superstrate containing cerium oxide and EVA (ethylene vinyl acetate) encapsulant containing UV absorbing additives. However, in the current industry, the PV modules are generally constructed without cerium oxide in the glass and UV absorbing additives in EVA to increase quantum efficiency of crystalline silicon solar cells in the UV regions. This new approach is expected to boost the initial power output of the modules and reduce the long-term encapsulant browning issues. However, this new approach could lead to other durability and reliability issues such as delamination of encapsulant by damaging interfacial bonds, destruction of antireflection coating on solar cells and even breakage of polymeric backbone of EVA. This work compares the durability and reliability issues of PV modules having glass without cerium oxide and EVA with (aka, UVcut or UVC) and without (aka, UVpass or UVP) UV absorbing additives. In addition, modules with UVP front and UVC back EVA have also been investigated (aka, UVhybrid or UVH). The mini-modules with nine split cells used in this work were fabricated at ASU’s Photovoltaic Reliability Laboratory. The durability and reliability caused by three stress variables have been investigated and the three variables are temperature, humidity/oxygen and UV dosage. The influence of up to 800 kWh/m2 UV dosage has been investigated at various dosage levels. Many material and device characterizations have been performed to ascertain the degradation modes and effects. The UVC modules showed encapsulant discoloration at the cell centers as expected but the UVH modules showed a ring-shaped encapsulant discoloration close to the cell edges as evidenced in the UV fluorescence (UVF) imaging study. The PV modules containing UVP on both sides of cells with limited access to humidity or oxygen through backsheet (covered backsheet with adhesive aluminum tape) seem to experience encapsulant delamination as evidenced in the UVF images. Plausible explanations for these observations have been presented.

Global photovoltaic (PV) module installation in 2018 is estimated to exceed 100 GW, and crystalline Si (c-Si) solar cell-based modules have a share more than 90% of the global PV market. To reduce the social cost of PV electricity, further developments in reliability of solar panels are expected. These will lead to realize longer module lifetime and reduced levelized cost of energy. As many as 86 failure modes are observed in PV modules [1] and series resistance increase is one of the major durability issues of all. Series resistance constitutes emitter sheet resistance, metal-semiconductor contact resistance, and resistance across the metal-solder ribbon. Solder bond degradation at the cell interconnect is one of the primary causes for increase in series resistance, which is also considered to be an invisible defect [1]. Combination of intermetallic compounds (IMC) formation during soldering and their growth due to solid state diffusion over its lifetime result in formation of weak interfaces between the solar cell and the interconnect. Thermal cycling under regular operating conditions induce thermo-mechanical fatigue over these weak interfaces resulting in contact reduction or loss. Contact reduction or loss leads to increase in series resistance which further manifests into power and fill factor loss. The degree of intermixing of metallic interfaces and contact loss depends on climatic conditions as temperature and humidity (moisture ingression into the PV module laminate) play a vital role in reaction kinetics of these layers. Modules from Arizona and Florida served as a good sample set to analyze the effects of hot and humid climatic conditions respectively. The results obtained in the current thesis quantifies the thickness of IMC formation from SEM-EDS profiles, where similar modules obtained from different climatic conditions were compared. The results indicate the thickness of the IMC and detachment degree to be growing with age and operating temperatures of the module. This can be seen in CuxSny IMC which is thicker in the case of Arizona module. The results obtained from FL

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aged modules also show that humidity accelerates the formation of IMC as they showed thicker AgxSny layer and weak interconnect-contact interfaces as compared to Arizona modules. It is also shown that climatic conditions have different effects on rate at which CuxSny and AgxSny intermetallic compounds are formed.

Ethylene vinyl acetate (EVA) is the most commonly used encapsulant in photovoltaic modules. However, EVA degrades over time and causes performance losses in PV system. Therefore, EVA degradation is a matter of concern from a durability point of view.

This work compares EVA encapsulant degradation in glass/backsheet and glass/glass field-aged PV modules. EVA was extracted from three field-aged modules (two glass/backsheet and one glass/glass modules) from three different manufacturers from various regions (cell edges, cell centers, and non-cell region) from each module based on their visual and UV Fluorescence images. Characterization techniques such as I-V measurements, Colorimetry, Different Scanning Calorimetry, Thermogravimetric Analysis, Raman spectroscopy, and Fourier Transform Infrared Spectroscopy were performed on EVA samples.

The intensity of EVA discoloration was quantified using colorimetric measurements. Module performance parameters like Isc and Pmax degradation rates were calculated from I-V measurements. Properties such as degree of crystallinity, vinyl acetate content and degree of crosslinking were calculated from DSC, TGA, and Raman measurements, respectively. Polyenes responsible for EVA browning were identified in FTIR spectra.

The results from the characterization techniques confirmed that when EVA undergoes degradation, crosslinking in EVA increases beyond 90% causing a decrease in the degree of crystallinity and an increase in vinyl acetate content of EVA. Presence of polyenes in FTIR spectra of degraded EVA confirmed the occurrence of Norrish II reaction. However, photobleaching occurred in glass/backsheet modules due to the breathable backsheet whereas no photobleaching occurred in glass/glass modules because they were hermetically sealed. Hence, the yellowness index along with the Isc and Pmax degradation rates of EVA in glass/glass module is higher than that in glass/backsheet modules.

The results implied that more acetic acid was produced in the non-cell region due to its double layer of EVA compared to the front EVA from cell region. But, since glass/glass module is hermetically sealed, acetic acid gets entrapped inside the module further accelerating EVA degradation whereas it diffuses out through backsheet in glass/backsheet modules. Hence, it can be said that EVA might be a good encapsulant for glass/backsheet modules, but the same cannot be said for glass/glass modules.

The volume of end-of-life photovoltaic (PV) modules is increasing as the global PV market increases, and the global PV waste streams are expected to reach 250,000 metric tons by the end of 2020. If the recycling processes are not in place, there would be 60 million tons of end-of-life PV modules lying in the landfills by 2050, that may not become a not-so-sustainable way of sourcing energy since all PV modules could contain certain amount of toxic substances. Currently in the United States, PV modules are categorized as general waste and can be disposed in landfills. However, potential leaching of toxic chemicals and materials, if any, from broken end-of-life modules may pose health or environmental risks. There is no standard procedure to remove samples from PV modules for chemical toxicity testing in the Toxicity Characteristic Leaching Procedure (TCLP) laboratories as per EPA 1311 standard. The main objective of this thesis is to develop an unbiased sampling approach for the TCLP testing of PV modules. The TCLP testing was concentrated only for the laminate part of the modules, as they are already existing recycling technologies for the frame and junction box components of PV modules. Four different sample removal methods have been applied to the laminates of five different module manufacturers: coring approach, cell-cut approach, strip-cut approach, and hybrid approach. These removed samples were sent to two different TCLP laboratories, and TCLP results were tested for repeatability within a lab and reproducibility between the labs. The pros and cons of each sample removal method have been explored and the influence of sample removal methods on the variability of TCLP results has been discussed. To reduce the variability of TCLP results to an acceptable level, additional improvements in the coring approach, the best of the four tested options, are still needed.

Encapsulant is a key packaging component of photovoltaic (PV) modules, which protects the solar cell from physical, environmental and electrical damages. Ethylene-vinyl acetate (EVA) is one of the major encapsulant materials used in the PV industry. This work focuses on indoor accelerated ultraviolet (UV) stress testing and characterization to investigate the EVA discoloration and delamination in PV modules by using various non-destructive characterization techniques, including current-voltage (IV) measurements, UV fluorescence (UVf) and colorimetry measurements. Mini-modules with glass/EVA/cell/EVA/backsheet construction were fabricated in the laboratory with two types of EVA, UV-cut EVA (UVC) and UV-pass EVA (UVP).

The accelerated UV testing was performed in a UV chamber equipped with UV lights at an ambient temperature of 50°C, little or no humidity and total UV dosage of 400 kWh/m2. The mini-modules were maintained at three different temperatures through UV light heating by placing different thickness of thermal insulation sheets over the backsheet. Also, prior to thermal insulation sheet placement, the backsheet and laminate edges were fully covered with aluminum tape to prevent oxygen diffusion into the module and hence the photobleaching reaction.

The characterization results showed that mini-modules with UV-cut EVA suffered from discoloration while the modules with UV-pass EVA suffered from delamination. UVf imaging technique has the capability to identify the discoloration region in the UVC modules in the very early stage when the discoloration is not visible to the naked eyes, whereas Isc measurement is unable to measure the performance loss until the color becomes visibly darker. YI also provides the direct evidence of yellowing in the encapsulant. As expected, the extent of degradation due to discoloration increases with the increase in module temperature. The Isc loss is dictated by both the regions – discolored area at the center and non-discolored area at the cell edges, whereas the YI is only determined at the discolored region due to low probe area. This led to the limited correlation between Isc and YI in UVC modules.

In case of UVP modules, UV radiation has caused an adverse impact on the interfacial adhesion between the EVA and solar cell, which was detected from UVf images and severe Isc loss. No change in YI confirms that the reason for Isc loss is not due to yellowing but the delamination.

Further, the activation energy of encapsulant discoloration was estimated by using Arrhenius model on two types of data, %Isc drop and ΔYI. The Ea determined from the change in YI data for the EVA encapsulant discoloration reaction without the influence of oxygen and humidity is 0.61 eV. Based on the activation energy determined in this work and hourly weather data of any site, the degradation rate for the encaspulant browning mode can be estimated.

Bifacial photovoltaic modules are a relatively new development in the photovoltaic industry which allows for the collection and conversion of light on both sides of photovoltaic modules to usable electricity. Additional energy yield from bifacial photovoltaic modules, despite a slight increase in cost due to manufacturing processes of the bifacial cells, has the potential to significantly decrease the LCOE of photovoltaic installation. The performance of bifacial modules is dependent on three major factors: incident irradiation on the front side of the module, reflected irradiation on the back side of the module, and the module's bifaciality. Bifaciality is an inherent property of the photovoltaic cells and is determined by the performance of the front and rear side of the module when tested at STC. The reflected light on the back side of the module, however, is determined by several different factors including the incident ground irradiance, shading from the modules and racking system, height of the module installation, and ground albedo. Typical ground surfaces have a low albedo, which means that the magnitude of reflected light is a low percentage of the incident irradiance. Non-uniformity of back-side irradiance can also reduce the power generation due to cell-to-cell mismatch losses. This study investigates the use of controlled back-side reflectors to improve the irradiance on the back side of loosely packed 48-cell bifacial modules and compares this performance to the performance of 48 and 60-cell bifacial modules which rely on the uncontrolled reflection off nearby ground surfaces. Different construction geometries and reflective coating materials were tested to determine optimal construction to improve the reflectivity and uniformity of reflection. Results of this study show a significant improvement of 10-14% total energy production from modules with reflectors when compared to the 48-cell module with an uncontrolled ground reflection.

Performance of photovoltaic (PV) modules decrease as the operating temperatures increase. In hot climatic conditions, the operating temperature can reach as high as 85°C for the rooftop modules. Considering a typical power drop of 0.5%/°C for crystalline silicon modules, a performance decrease of approximately 30% could be expected during peak summer seasons due to the difference between module rated temperature of 25°C and operating temperature of 85°C. Therefore, it is critical to accurately predict the temperature of the modules so the performance can be accurately predicted. The module operating temperature is based not only on the ambient and irradiance conditions but is also based on the thermal properties of module packaging materials. One of the key packaging materials that would influence the module operating temperature is the substrate, polymer backsheet or glass. In this study, the thermal influence of three different polymer backsheet substrates and one glass substrate has been investigated through five tasks:

1. Determination and modeling of substrate or module temperature of coupons using four different substrates (three backsheet materials and one glass material).

2. Determination and modeling of cell temperature of coupons using four different substrates (three backsheet materials and one glass material)

3. Determination of temperature difference between cell and individual substrates for coupons of all four substrates

4. Determination of NOCT (nominal operating cell temperature) of coupons using all four substrate materials

5. Comparison of operating temperature difference between backsheet substrate coupons.

All these five tasks have been executed using the specially constructed one-cell coupons with identical cells but with four different substrates. For redundancy, two coupons per substrate were constructed and investigated. This study has attempted to model the effect of thermal conductivity of backsheet material on the cell and backsheet temperatures.

Solar photovoltaic (PV) deployment has grown at unprecedented rates since the early 2000s. As the global PV market increases, so will the volume of decommissioned PV panels. Growing PV panel waste presents a new environmental challenge, but also unprecedented opportunities to create value and pursue new economic avenues. Currently, in the United States, there are no regulations for governing the recycling of solar panels and the recycling process varies by the manufacturer. To bring in PV specific recycling regulations, whether the PV panels are toxic to the landfills, is to be determined. Per existing EPA regulations, PV panels are categorized as general waste and are subjected to a toxicity characterization leaching procedure (TCLP) to determine if it contains any toxic metals that can possibly leach into the landfill. In this thesis, a standardized procedure is developed for extracting samples from an end of life PV module. A literature review of the existing regulations in Europe and other countries is done. The sample extraction procedure is tested on a crystalline Si module to validate the method. The extracted samples are sent to an independent TCLP testing lab and the results are obtained. Image processing technique developed at ASU PRL is used to detect the particle size in a broken module and the size of samples sent is confirmed to follow the regulation.