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The Module Reliability Project consists of the following tasks. materials (e.g., encapsulants) and designs. Module-level packaging R&D includes: • Alternatives to double glass for thin films (soft backsheets and hard-coat barrier films) • EVA substitutes that are cheaper/better, not requiring transparency. • Field and stress survival including adhesion, cohesion, and water-diffusion barriers • Detailed measurements and characterization of moisture transmission properties of polymers and coatings • Modeling of moisture ingress and egress into module structures. The SNL tasks include the continued development and use of module-performance characterization methods; and, the collection and performance- degradation rate analyses using long-term exposure data from SNL, the Florida Solar Energy Center (FSEC), and the Southwest Technology Development Institute (SWTDI). SNL uses a module-performance characterization (i.e., calibration) apparatus that is capable of deriving the module power output (i.e., I-V curve) as a function of solar irradiance, optical air mass (i.e., spectral), solar irradiance incident angle, atmospheric temperature, and module temperature. Using this apparatus, SNL provided PV module baseline performance characterizations prior to the deployment of modules at the long-term exposure sites at FSEC, SWTDI, SNL, and NREL. At periodic intervals, SNL repeats such measurements to establish module performance-degradation characteristics. This database was also used to continue the improvement of existing software that accurately models the expected power and energy production from PV systems in site-dependent applications. The SNL tasks also include investigations, jointly with NREL, of observed module field (either at the FSEC/SWTDI and/or from industry sites) failures. 3. Results and Accomplishments • Completed accelerated testing program (thermal cycling, UV exposure, humidity- freeze cycling, damp heat, and light soaking) for several CdTe modules and provided results and conclusions to the manufacturer. Task Title Exploratory Reliability & Performance (NREL) Module Packaging Research and Reliability (NREL) Long-term Outdoor Durability Test & Failure (SNL) Module Reliability Characterization (SNL) Module Manufacturing and Process R&D (SNL) FY 2004 Budget ($K) 1,292 1,252 462 110 393 The NREL Exploratory Performance Task includes accelerated indoor and outdoor environmental stress testing, and long- term outdoor performance and reliability testing and analyses of most (if not all) PV module technologies. The emphasis is on the module technologies being addressed by the NREL PV Manufacturing R&D and Thin Film PV Partnership Projects. The NREL Outdoor Test Facility (OTF) is used for these purposes. Accelerated testing uses specialized environmental chambers and facilities to conduct tests that include thermal cycling, UV exposure, humidity-freeze cycling, damp heat exposure, and light-soaking. Accelerated outdoor testing includes a specialized apparatus called the Outdoor Accelerated-weathering Testing System (OATS), which allows module exposure to solar irradiance at an intensity of nearly 3 suns. The long-term module performance and reliability uses a specialized test bed called the Performance and Energy Ratings Testbed (PERT). This test bed holds up to 45 PV modules that are kept at maximum power; it periodically (every 15 to 30 minutes) measures full I-V curves, along with other measurements such as incident solar irradiance, outdoor temperature, and module temperature. These data are used to determine performance ratings (e.g., kWhrdc/Wp) and performance degradation rates for several module technologies and manufacturers. The NREL Module Packaging Research and Reliability Task includes efforts to address the long-term reliability aspects of module packaging Reliability &PDF Image | FY 2004 ANNUAL REPORT DOE Solar
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