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DOE OSTI2020

Potential Vorticity Mixing in a Tangled Magnetic Field

A theory of potential vorticity (PV) mixing in a disordered (tangled) magnetic field is introduced. The analysis is in the context of β -plane MHD, with a special focus on the physics of momentum transport in the stably stratified, quasi-2D solar tachocline. A physical picture of mean PV evolution by vorticity advection and tilting of magnetic fields is proposed. In the case of weak field perturbations, quasi-linear theory predicts that the Reynolds and magnetic stresses balance as turbulence Alfvénizes for a larger mean magnetic field. Jet formation is explored quantitatively in the mean field–resistivity parameter space. However, since even a modest mean magnetic field leads to large magnetic perturbations for large magnetic Reynolds number, the physically relevant case is that of a strong but disordered field. We show that numerical calculations indicate that the Reynolds stress is modified well before Alfvénization—i.e., before fluid and magnetic energies balance. To understand these trends, a double-average model of PV mixing in a stochastic magnetic field is developed. Calculations indicate that mean-square fields strongly modify Reynolds stress phase coherence and also induce a magnetic drag on zonal flows. The physics of transport reduction by tangled fields is elucidated and linked to the related quench of turbulent resistivity. We propose here a physical picture of the system as a resisto-elastic medium threaded by a tangled magnetic network. Applications of the theory to momentum transport in the tachocline and other systems are discussed in detail.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2025

UV + Damp Heat Induced Power Losses in Fielded Utility N-Type Si PV Modules

A recent trend in commercial PV modules is a transition to n-type silicon cells, including passivated emitter rear totally diffused (n-PERT), tunnel oxide passivated contact (TOPCon), and silicon heterojunction (SHJ). There is evidence via lab studies that some of these cells are more susceptible to UV induced degradation (UVID), yet there is a lack of confirmation that such degradation occurs in the field. Current IEC standards designed to screen for early module failures require only minimal UV exposure (15 kWh/m2 280-400 nm, ~2-3 months equivalent outdoor exposure). Here, we investigate fielded n-PERT silicon (Si) modules from a commercial utility that show power losses of ~2%/year. We present a comprehensive picture of the physics and chemistry of degradation supported by both module and cell electronic characterization (EL, PL, IV, EQE, and DLIT) and materials-level morphological and chemical analysis (SEM, EDS, XPS, FTIR, and HPLC). All sampled site modules show short circuit current (Isc) and open circuit voltage (Voc) losses when compared to unfielded spares, with the most severely degraded also having losses in fill factor (FF). We identify two different degradation modes contributing to overall power loss: (1) external quantum efficiency (EQE) measurements show losses in the blue range of the spectra, indicative of cell surface recombination losses, and (2) variations in high series resistance (Rs) at the cell level that are correlated with compositional differences in cell metallization. Using unfielded spares, we were able to reproduce Voc, Isc, and EQE losses via a minimum UV stress of 67.5 kWh/m2 (280-400 nm), 4.5x the exposure currently required in IEC 61215-2 (MQT 10). Degradation continued with additional UV dosage equivalent to the fielded modules (405 kWh/m2 total), with power loss leveling out at an average of 6.1%. Subsequent 1000 h of 85% RH/85degrees C damp heat testing showed that cells exposed to UV underwent additional severe series resistance degradation, even those without the susceptible paste composition seen in the field, whereas non-UV exposed cells saw little change. We attribute this to higher concentrations of acetic acid generated on the UV exposed area of the module, leading to degradation of the gridline/cell interface and high Rs. This study is unique in that it reproduces field observed utility scale UVID with an accelerated test and supports the need for standards development for longer UV exposure combined with other stress factors to catch materials interplay within a module package.

14 SOLAR ENERGY↗

DOE OSTI2022

PV Reference Cells for Outdoor Use: Comparison of First-Year Field Measurements

Reference cells are widely used in the photovoltaic (PV) industry to measure irradiance. For field applications and outdoor use, a variety of products are on the market, and they are often perceived as low-cost alternatives to thermopile pyranometers. But reference cell characteristics, such as directional and spectral response, fundamentally differ from pyranometers, and measurements made by the former cannot be substituted for or directly compared with the latter. The National Renewable Energy Laboratory's (NREL's) Solar Radiation Research Laboratory is currently in a multiyear effort to develop guidance and recommendations for the design and use of outdoor reference cells, with a view to reducing inconsistencies and measurement uncertainty. The core of this effort is the long-term deployment of multiple products from different manufacturers that are mounted at a fixed tilt, on a single-axis tracker, and on a dual-axis tracker. This report provides an analysis of the data collected during the first year of operation at the NREL location. An overall assessment is made by comparing the total energy measured by each instrument to the other instruments having the same orientation. These totals are calculated for three different scenarios: (1) using the factory calibration factors, (2) using the previously determined NREL Cell Lab calibration factors, and (3) using the newly determined field calibration factors derived from the recorded measurements. Because the true or correct measurement values are unknown, pair-wise comparisons are made. The results show that the difference between the highest and lowest measured energy can exceed 3% when using the factory calibration factors. Consistency among instruments improves when Cell Lab calibrations are used, and it further improves when using field calibration factors.

14 SOLAR ENERGY↗

DOE OSTI2024

Field‐representative evaluation of PID‐polarization in TOPCon PV modules by accelerated stress testing

Abstract Potential‐induced degradation‐polarization (PID‐p) can reduce module power, but how to project the extent to which PID‐p may occur in field conditions considering the factors of system voltage, condensed moisture, temperature, and illumination has not been clarified. Using tunnel oxide passivated contact (TOPCon) modules, this work demonstrates a method to test full‐size crystalline silicon PV modules for PID‐p to provide field‐representative results. In initial screening tests with positive or negative 1000 V electrical bias applied at 60°C for 96 h using Al foil electrodes on the glass surfaces, the module type exhibited reversible PID‐p only on the front face when the cell circuit was in negative voltage potential. No PID was detected on the rear after testing in either polarity. We then evaluated the PID‐p sensitivity on the front side under different UV irradiances while maintaining the glass surface wet to estimate real‐world susceptibility to PID‐p. The magnitude of the observed behavior was fit using a previously developed charge transfer and depletion by light model. Whereas power loss with −1000 V applied to the cell circuit at 60°C for 96 h in the dark was about 30%, testing the module front under 0.051 W·m −2 nm −1 at 340 nm UVA irradiation using fluorescent tubes, the mean degradation was only 3%. When the modules were tested in the dark for PID‐p with in situ dark current–voltage (I‐V) characterization, the thermal activation energy for degradation was 0.71 eV; for recovery in the dark, it was 0.58 eV. Whereas recovery from the degraded state at 60°C in the dark without voltage bias was 5% absolute in 38 h, rapid recovery of about 5% absolute was observed with 1000 W·s/m 2 exposure at 25°C using a flash tester.

14 SOLAR ENERGY↗

DOE OSTI2021

Nanomechanical and Fluorescence Characterizations of Weathered PV Module Encapsulation

Nanoindentation and fluorescence spectroscopy provide spatially resolved mechanical and chemical characterization for degradation of poly (ethylene-co-vinyl acetate) (EVA) encapsulants aged under accelerated weathering and in field deployed photovoltaic (PV) modules. For the accelerated weathering tests, two different EVA formulations in the glass/EVA/glass-laminated coupons were exposed to ultraviolet (UV) light for 180 days at three different temperatures (40, 60, and 80 °C) and UV intensities (0.4, 2.2, and 2.9 W/m2/nm at 340 nm). The fluorescence spectra and moduli were uniform through the cross section of both EVA formulations at the lowest temperature and UV intensity; however, under the highest temperature and UV intensity, the UV irradiated sides showed lower moduli and higher fluorescence compared to the opposite sides. For EVA obtained from PV modules deployed 27 years in Sacramento, CA, USA, changes in fluorescence intensity across the thickness were relatively greater than changes in modulus. On the other hand, for EVA obtained from the same type of module stored in the shed for 27 years, no fluorescence was observed, and a uniform modulus was seen through the EVA layer, but with substantially higher values than those obtained from the field-deployed modules. The different extent of changes between laboratory and field exposures suggests the importance of considering effects of temperature and UV intensity for designing a reliable accelerated testing. This study uniquely demonstrates the capability of microscale characterization using nanoindentation and fluorescence microscopy to monitor mechanical and chemical degradation of EVA encapsulants in PV modules.

14 SOLAR ENERGY↗

DOE OSTI2023

PV Inverter Testing for Momentary Cessation and Rate-of-Change-of-Frequency Events

To understand the power system stability and develop better electromagnetic transient (EMT) models of field deployed photovoltaic (PV) inverters, it is important to characterize inverters' response to abnormal voltage and frequency scenarios. Because EMT models are not typically available for small distribution-connected PV inverters, and because inerterconnection standards historically did not specify desired ride-through behaviors, we tested two such inverters in the lab to characterize their responses to severe undervoltage events and high rate-of-change-of-frequency (ROCOF) conditions. The inverters tested were pre-IEEE 1547-2018 residential PV inverters widely used in the Hawaiian Electric territory and many other areas. The testing results for undervoltage scenarios showed that the inverter from one vendor exhibited momentary cessation while the inverter from the other vendor did not exhibit momentary cessation behavior or tripping for most of the events below the 120 ms undervoltage trip threshold duration set by IEEE 1547-2003. The testing results for ROCOF scenarios showed that the inverter from one vendor temporarily lost synchronization during ROCOF conditions while the inverter from the other vendor did not lose synchronization or cease generation for any ROCOF conditions. Both the inverters were also tested for EMT-simulated grid events with severe changes in frequency and voltage. The observed responses of the inverters were different from the simulated response of PV inverters represented the best available assumptions from pre-existing information. The results from these experiments can be used to update the inverter models used in bulk power system studies.

aggregates↗

DOE OSTI2023

PV Inverter Testing for Momentary Cessation and Rate-of-Change-of-Frequency Events: Preprint

IEEE 1547 2018↗

DOE OSTI2023

Field studies of PERC and Al-BSF PV module performance loss using power and I-V timeseries

We have studied the degradation of both full-sized modules and minimodules with PERC and Al-BSF cell variations in fields while considering packaging strategies. We demonstrate the implementations of data-driven tools to analyze large numbers of modules and volumes of timeseries data to obtain the performance loss and degradation pathways. This data analysis pipeline enables quantitative comparison and ranking of module variations, as well as mapping and deeper understanding of degradation mechanisms. The best performing module is a half-cell PERC, which shows a performance loss rate ( PLR ) of −0.27 ± 0.12% per annum (%/ a ) after initial losses have stabilized. Minimodule studies showed inconsistent performance rankings due to significant power loss contributions via series resistance, however, recombination losses remained stable. Overall, PERC cell variations outperform or are not distinguishable from Al-BSF cell variations.

Curran, Alan J.↗

DOE OSTI2025

Ecovoltaic solar energy development can promote grassland bird communities

Ecologically informed photovoltaic (PV) developments that co-prioritize PV electricity generation with ecosystem function (‘ecovoltaics’) have emerged as a promising land sharing strategy to minimize ecological conflicts associated with PV solar energy development. While habitat-focused ecovoltaic designs can conceptually benefit biodiversity by offsetting or enhancing impacts of PV development, foundational field research is needed to examine how wildlife respond to these novel ecosystems. We conducted passive acoustic monitoring (PAM) in 2023 and 2024 at 13 solar facilities and paired control sites to investigate avian community responses to ecovoltaic facilities in the Midwestern United States. Compared to control sites (row crop agricultural fields), we found that ecovoltaic sites supported more grassland bird species throughout a 17-week monitoring period between May and September. Grassland bird communities on ecovoltaic sites were also more stable than on agricultural controls, as measured by the Jaccard dissimilarity index. We also used PAM-based weekly species occurrences in an occupancy-modelling framework to investigate the influence of PV development and other landscape variables on grassland bird occupancy. 10 out of 13 modelled grassland bird species had greater predicted occupancy probabilities (ψ) on PV sites than control sites. Synthesis and applications. Our findings suggest that properly sited and developed ecovoltaic solar facilities in human altered landscapes can improve habitat for birds and other wildlife, but further research is needed to understand which species may benefit most from these novel ecosystems.

14 SOLAR ENERGY↗

DOE OSTI2023

Supply Chain Cybersecurity Recommendations for Solar Photovoltaics

Solar photovoltaic (PV) cybersecurity is a growing field of research. As deployments of solar PV has increased, cyber risk has also increased. However, utility solar PV installations are not required to comply with North American Electric Reliability Corporation (NERC) Critical Infrastructure Protection (CIP) unless they meet a minimum generation threshold of 75 Megawatts (MW). Individual residential scale solar PV deployments will not meet that generation threshold and are therefore excluded from NERC CIP requirements. With most solar installations below 75MW, solar PV has been deployed with minimal oversight and highly variable cybersecurity maturity. The resources that make up the digital supply chain can include software, code, data, as well as other digital components. However as clean energy technology advances, cybersecurity threats and vulnerabilities continue to evolve and grow in sophistication. Solar PV faces a unique challenge in which it can be deployed in residential buildings and purchased by a consumer directly. This makes the supply chain of PV a unique challenge, where responsible parties for cybersecurity vary widely depending on the type of solar PV being deployed. Supply chain cybersecurity for solar PV represents a critical area for ensuring safe operations as the U.S. moves towards a clean energy future.

14 SOLAR ENERGY↗

DOE OSTI2023

DER Digital Supply Chain Gap Analysis

Solar photovoltaic (PV) cybersecurity is a growing field of research. As deployments of solar PV have increased, cyber risk has also increased. Utility solar PV installations, however, are not required to comply with the North American Electric Reliability Corporation (NERC) Critical Infrastructure Protection (CIP) plan unless they meet a minimum generation threshold of 75 MW. Individual residential-scale solar PV deployments will not meet that generation threshold and are therefore excluded from the NERC CIP requirements. With most solar installations less than 75 MW, solar PV has been deployed with minimal oversight and highly variable cybersecurity maturity. The resources that comprise the digital supply chain can include software, code, data, and other digital components. But as clean energy technologies advance, cybersecurity threats and vulnerabilities continue to evolve and grow in sophistication. Supply chain cybersecurity represents a critical area for ensuring safe operations as the U.S. moves toward a clean energy future.

cybersecurity↗

DOE OSTI2026

Failure Mode and Effects Analysis (FMEA) for Photovoltaic Inverter

Photovoltaic (PV) inverters are critical yet vulnerable components in modern energy systems, often acting as reliability bottlenecks that increase the levelized cost of energy (LCOE). To address this, this paper presents a comprehensive Failure Mode and Effects Analysis (FMEA) tailored for PV inverters. Leveraging field data and literature, we identify failure-prone components, such as capacitors,, and relays, and prioritize their risks based on quantitative Risk Priority Numbers (RPNs). The analysis reveals that surge-induced MOV short circuits, capacitor degradation, and environmental cooling fan failures dominate the risk profile. These findings provide a targeted framework for reliability improvement, guiding future efforts in predictive diagnostics, design optimization, and accelerated life testing strategies.

14 SOLAR ENERGY↗

DOE OSTI2022

Investigating Local Carrier Dynamics in PERC Patterned CdTe Solar Cells

Remarkable progress has been achieved in CdTe photovoltaics (PVs) to further improve cell performance while reducing manufacturing costs. Researchers optimized the front contact that leads the short-circuit current density (J sc ) over 31mA/cm 2 (e.g., (Zn, Mg)O buffer layer and/or alloying CdTe with Se). Reese et al. reported an open-circuit voltage (V oc ) over 1 V with group-V doped single crystal, showing the feasibility of increasing V oc in CdTe PV that is fixed to less than 900 mV in most cases. Recent studies suggested that the V oc improvement in polycrystalline CdTe PVs requires well-passivated back contact. One possible strategy is to use CdMgTe alloy (E g > 1.8 eV), where the band-gap offset (ΔE CB ≈ 0.2 eV) reflects minority carrier electrons, thereby decreasing surface recombination. Another strategy is to utilize a stable Al 2 O 3 layer as an electron reflector; experimental works confirmed the improved performance with a conformal Al 2 O 3 layer. In this configuration, the precise control of Al 2 O 3 (≈1 nm) over the entire CdTe layer is essential because the J sc greatly depends on the tunneling current. While promising, both CdMgTe and Al 2 O 3 passivation on CdTe introduce unfavorable valence band offset that blocks the hole transport. Kephart et al. proposed a patterned passixc vation layer (≈ 20 nm Al 2 O 3 ) with point contacts (≈ 3 μm in diameter) that extract hole carriers. This configuration is similar to the passive emitter and rear contact (PERC) design that has been extensively studied in Si PVs. While remarkably high carrier lifetime and photoluminescence (> 10 X) were measured, consistent improvement in V oc and efficiency in this CdTe PERC were not yet observed. At this time, it is unclear how the surface potential is distributed in the presence of patterned Al 2 O 3 reflectors and how this additional field impacts the PV performance for Cu-doped and group-V doped CdTe PERC devices. To tackle this challenge, we develop robust nanofabrication and characterization platform to study CdTe PERC devices consisting of a patterned Al 2 O 3 layer on CdSe( 1-x )Te x (Cu-doped, GrV-doped; x = 0 to 1; CST). First Solar supplies high-quality CST materials. The dark and light I-Vs under 1-sun illumination are extracted for a series of each set of devices. We perform quantitative and qualitative PV analysis for a series of Cu-doped and Gr-V doped PERC devices, showing notably different V oc changes for GrV-doped compared to Cu-doped PERC devices. This project attempts to produce individual contacts on single grains and grain boundaries to measure lateral transport. As a model system, we use a CdSe( 1-x )Te x film on glass prepared by a colossal grain growth (CGG) technique at National Renewable Research Laboratories (NREL). Our preliminary results confirm that intergranular transport is hindered by the electrical barrier formed near grain boundaries. The PERC fabrication and the lateral transport measurement platform developed in this project can easily be applied to other types of advanced CdSe( 1-x )Te x architectures to better understand local photocarrier transport, in turn, providing the fundamental knowledge to improve the performance of CdTe PVs.

14 SOLAR ENERGY↗

DOE OSTI2025

OPET Firmware (Open PV Electrical Tool Firmware) [SWR-25-43]

The main application of OPET is long term performance measurements of PV devices in field or under controlled environmental conditions. This repository contains everything relating to the firmware of the OPET device including source code. If you are looking for the hardware or control software repositories, links are below: https://github.com/NREL/opet-hardware https://github.com/NREL/opet-control

McDanold, Byron [National Renewable Energy Laborat↗

DOE OSTI2022

Network Models of Active Degradation Mechanisms and Pathways for Service Life Prediction of Indoor and Outdoor PV Modules

ct: PV service lifetime prediction (SLP) enables accurate calculation of levelized cost of energy (LCOE), which is crucial to rationalizing PV investment and installation. However, SLP is challeging since PV reliability in the field is affected by many combined factors, including various environmental stresses and module quality. In order to map out the active degradation mechanisms and pathways that best resemble real world conditions, we introduce the framework of a study protocol and use network models fitted to data, to enable analysis and SLP of complex PV systems with multiple active degradation mechanisms. The study protocol is the experimental design, including module variants and different exposure conditions, selection of evaluation methods, time-series data acquisition and training of network models to these data. We present SLP of minimodules in the lab and PV systems in the field. For lab SLP, minimodules with 8 variants based on manufacturer, architecture, and encapsulation were prepared and aged in modified damp heat with or without full spectrum light exposure. Stepwise I-V and Suns-Voc data acquisition tracks changes in electrical properties including Rs,IV, Isc,IV, Vmp,PIV providing insights into power loss of minimodules. Network structural equation modeling (netSEM) was utilized to construct degradation pathway models that identify active degradation mechanisms and predict power loss over time. For field SLP, datastreams of Pmp values and I-V curve datastreams of two types of modules installed in three distinctly different Köppen-Geiger climate zones for 9 years were acquired. With power loss modes corresponding to uniform current loss (ΔPIsc), recombination (ΔPVoc), series resistance (ΔPRs), and current mismatch (ΔPImis) determined, the performance loss rates (PLR) were determined using PVplr. We show how to establish a study protocol framework to ensure appropriate parametric variations and valid data collection from the variants of your complex systems. Then the data-driven netSEM model fitting provides a comprehensive mapping of multiple active degradation mechanisms, and accurate service life prediction.

network model, degradation, photovoltaic, solar↗

DOE OSTI2025

Ultraviolet Fluorescence Imaging for Photovoltaic Module Metrology: Best Practices and Survey of Features Observed in Fielded Modules

As the photovoltaics (PV) industry grows in sophistication, so must the extent to which systems are characterized. UV Fluorescence (UVF) imaging is a valuable, easy-to-perform, high-throughput, nonintrusive technique for characterizing modules in the field and in the lab. However, UVF is still a relatively new technique, and many in the PV industry are still unaware of its potential. We provide a guideline for obtaining, processing, and interpreting UVF images. We have provided a list of considerations for imaging hardware and settings, a suggested pipeline for image processing, and details on a survey of features shown in UVF images. As a result, a new database with UVF images of 7190 modules and another database curated by BrightSpot Automation are publicly available.

14 SOLAR ENERGY↗

DOE OSTI2024

Rapid Characterization and Statistical Analysis of High-Volume Field-Harvested Photovoltaic Connectors

Photovoltaic (PV) installations heavily depend on connectors for efficient module and string interconnections without requiring skilled labor. Yet this seemingly innocuous component of PV systems is a leading cause of module failures, multiple high-profile fires, and lawsuits in the PV industry. This work aims to answer critical questions regarding why connectors fail and the contributing factors to their failure. The study involves collecting and analyzing more than 17,000 field-harvested connectors from various solar installations across the United States. The vast dataset, which includes connector metadata, visual inspections, and resistance measurements, provides unprecedented insight into the state of health of PV connectors across the US, including the geographic locations, connector types, and installation practices most prone to failures. The work presented here describes a novel rapid characterization method for processing large numbers of connectors and is supported by parallel forensic analysis to discern the root causes of failures as well as a levelized cost of lifetime model to determine the economic ramifications of connector failure. Ultimately, the findings may inform PV developers about the best practices to extend connector longevity and lead to more resilient and reliable PV systems.

connectors↗

DOE OSTI2023

Thermal behaviors of ethylene vinyl acetate encapsulants in fielded silicon photovoltaic modules

Aging of silicon photovoltaic (PV) module packaging is one of the greatest limiters of PV module service lifetimes. Module characterization typically focuses on power degradation metrics, which do not convey the complexities of often simultaneous degradation mechanisms. In this work, PV modules with pristine references and known fielding histories were investigated by non-destructive and destructive methods. Modules from Canadian Solar, Mission Solar, and Hanwha Q-Cells were fielded for up to three years; select modules were removed from fielding each year for coring to allow for characterization of the encapsulant. Modules are commonly encapsulated with two protective layers of partially-crystalline ethylene vinyl acetate (EVA) polymer that must undergo a crosslinking reaction to achieve desired properties. The extent of crystallinity of the encapsulants as studied by differential scanning calorimetry showed differences between manufacturers and over time. Some encapsulants showed different magnitudes of crystal sizes which changed after fielding; encapsulants with the monodisperse crystal sizes did not change with fielding. This is due to differences in thermal history. In conclusion, these results have implications for stress development during module aging, since EVA crystal melting and crosslinking reactions can result in encapsulant density changes.

36 MATERIALS SCIENCE↗