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At least 19 records

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DOE OSTI2016

Accelerated testing of module-level power electronics for long-term reliability

This work has applied a suite of long-term-reliability accelerated tests to a variety of module-level power electronics (MLPE) devices (such as microinverters and optimizers) from five different manufacturers. This dataset is one of the first (only the paper by Parker et al. entitled “Dominant factors affecting reliability of alternating current photovoltaic modules,” in Proc. 42nd IEEE Photovoltaic Spec. Conf., 2015, is reported for reliability testing in the literature), as well as the largest, experimental sets in public literature, both in the sample size (five manufacturers including both dc/dc and dc/ac units and 20 units for each test) and the number of experiments (six different experimental test conditions) for MLPE devices. The accelerated stress tests (thermal cycling test per IEC 61215 profile, damp heat test per IEC 61215 profile, and static temperature tests at 100 and 125 °C) were performed under powered and unpowered conditions. The first independent long-term experimental data regarding damp heat and grid transient testing, as well as the longest term (>9 month) testing of MLPE units reported in the literature for thermal cycling and high-temperature operating life, are included in these experiments. Additionally, this work is the first to show in situ power measurements, as well as periodic efficiency measurements over a series of experimental tests, demonstrating whether certain tests result in long-term degradation or immediate catastrophic failures. Lastly, the result of this testing highlights the performance of MLPE units under the application of several accelerated environmental stressors.

14 SOLAR ENERGY↗

DOE OSTI2018

Integration of microinverter with photovoltaic module

Various technologies for integrating a microinverter with a photovoltaic module are disclosed. An alternating current photovoltaic (ACPV) module includes a photovoltaic module having a frame and a junction box including a direct current (DC) output connector, and a microinverter having a housing coupled to the frame and a DC input connector electrically mated with the DC output connector of the photovoltaic module.

Gilchrist, Phil↗

DOE OSTI2021

Integration of microinverter with photovoltaic module

Gilchrist, Phil↗

DOE OSTI2015

Module-Integrated Power Converters Based on Universal Dock

Solar power installations using alternating current photovoltaic (ACPV) modules have significant cost and performance advantages over systems using conventional solar modules and string inverters. ACPV modules have improved energy harvest due to module-level power point tracking and redundancy. More importantly, ACPV modules are easier and cheaper to install, lowering the total installed cost, indirect costs, and barriers to market entry. Furthermore, ACPV modules have communications and data logging capability, yielding module-level telemetry data that is useful in site diagnostics and other data applications. The products of these efforts were threefold. First, an advanced microinverter power topology was developed, modeled, simulated, and tested. Second, new microinverter enclosure concepts were developed and tested. Third, a new ACPV module prototype was constructed, combining the power topology and the enclosure concepts. SolarBridge filed for patents in each of these areas and is transitioning the project from a concept phase to full development.

14 SOLAR ENERGY↗

DOE OSTI2015

Orange County Government Solar Demonstration and Research Facility

Orange County Florida completed the construction of a 20 kilowatt Solar Demonstration and Research Facility in March 2015. The system was constructed at the Orange County/University of Florida Cooperative Extension Center whose electric service address is 6021 South Conway Road, Orlando, Florida 32802. The Solar Demonstration and Research Facility is comprised of 72 polycrystalline photovoltaic modules and 3 inverters which convert direct current from the solar panels to alternating current electricity. Each module produces 270 watts of direct current power, for a total canopy production of just under 20,000 watts. The solar modules were installed with a fixed tilt of 5 degrees and face south, toward the equator to maximize the amount of sunlight captures. Each year, the electricity generated by the solar array will help eliminate 20 metric tons of carbon dioxide emissions as well as provide covered parking for staff and visitors vehicles. The solar array is expected to generate 27,000 kilowatt hours of electricity annually equating to an estimated $\$$266 savings in the monthly electric bill, or $\$$3,180 annually for the Orange County/University of Florida Cooperative Extension Center. In addition to reducing the electric bill for the Extension Center, Orange County’s solar array also takes advantage of a rebate incentive offered by the local utility, Orlando Utility Commission, which provided a meter that measures the amount of power produced by the solar array. The local utility company’s Solar Photovoltaic Production Incentive will pay Orange County $\$$0.05 per kilowatt hour for the power that is produced by the solar array. This incentive is provided in addition to Net Metering benefits, which is an effort to promote the use of clean, renewable energy on the electric grid. The Photovoltaic Solar Demonstration and Research Facility also serves an educational tool to the public; the solar array is tied directly into a data logger that provides real time power generation accessible for public viewing on an interactive kiosk located in the Orange County/University of Florida Cooperative Extension Center’s lobby where visitors can review “real time” power generation, cost savings and environmental benefits of the system. Site commissioning with the software program was delayed due to Internal Security Software issues within Orange County that needed to be resolved, therefore the “real time” capture of the production data for the solar array using the software program commenced on May 1, 2015. In addition an educational flyer was developed and is available in the Orange County Education Center’s main lobby. The project completed under this grant award assisted Orange County in demonstrating leadership by installing the application of a renewable energy technology combined with energy efficiency measures; resulting in reduced energy costs for the Orange County University of Florida Cooperative Extension Center, and helping Orange County citizens and visitors move towards the goals of greater energy independence and climate protection. The addition of the new Solar Demonstration and Research Facility has advanced the Orange County/University of Florida Cooperative Extension Center’s mission of extending, educating and providing research-based information to residents and visitors of Orange County by demonstrating the application of renewable energy technology combined with energy efficiency measures; resulting in reduced energy costs, and helping Orange County move towards the goal of greater energy independence and climate protection. In 2014, the Orange County Cooperative Extension Center hosted nearly 10,800 visitors to their on-site Exploration Gardens plus 12,686 walk-in visitors to their office plant clinic and other services. The Education Center held 2,217 educational events that were attended by 46,434 adults and youth, but about half of those events occurred off-site. Based on the visitation numbers in 2014 the Orange County Cooperative Extension Center Education is a vital partner to Orange County’s continued outreach and education efforts concerning renewable energy technologies and greenhouse gas emission reduction well in the current 2015 year and future years of operation of the solar array to the future visitors of the Center which help stimulate market demand that will continue to advance the commercialization and the widespread application and use of renewable energy technologies in Orange County and the state of Florida. The project period performance date for this grant was November 1, 2009 through March 1, 2015. The Final Project costs to complete the project as reported in the FINAL SF 425 were $\$$195,512.50 (50% recipient cost share was satisfied as required by grant terms and conditions).

14 SOLAR ENERGY↗

DOE OSTI2015

Microinverters for employment in connection with photovoltaic modules

Microinverters useable in association with photovoltaic modules are described. A three phase-microinverter receives direct current output generated by a microsystems-enabled photovoltaic cell and converts such direct current output into three-phase alternating current out. The three-phase microinverter is interleaved with other three-phase-microinverters, wherein such microinverters are integrated in a photovoltaic module with the microsystems-enabled photovoltaic cell.

14 SOLAR ENERGY↗

DOE OSTI2023

Life-cycle costing assessment of back contact doping and encapsulation alternatives for increasing the life expectancy of CdTe PV modules (Final Report)

Contribution of Research to the State-of-Knowledge This research produced comparative sustainability evaluations of back contact doping and encapsulation alternatives considered by First Solar for decreasing degradation and increasing the life of the cadmium telluride (CdTe) photovoltaic (PV) modules. Technical Effectiveness and Economic Feasibility of Methods Investigated A holistic life-cycle-assessment of the alternatives considered for longer module operational lives, showed that they add between 0.2% and 2% to environmental impact indicators at the cradle-to-gate module level, but at the cradle-to-grave system level, alternative materials offer only benefits (i.e., environmental impact indicator decreases) to the public and the environment. Parallel experimental studies at First Solar showed that the use of the considered alternative materials did not impact the effectiveness of the current module recycling separations and material recovery processes. Furthermore, the increment on the module manufacturing cost due to using alternative materials was estimated to be negligible (i.e., >1%) and longer module lives more than compensate cost increases. Specifically, increase of the current warranted module life of 30 years to 50 years, would decrease the levelized cost of electricity (LCOE) from $40/MWh to $24/MWh for utility-scale installations in the US-SW, the economic feasibility of the considered alternatives is assured. Benefit to the Public With decreasing degradation from the current ~0.3%/year of Series 6 modules to less than 0.2%/year, the public will be benefited by longer photovoltaic operational lives, and therefore. In addition, the requirement for end-of-life management is shifted from 30 years to 40 or 50 years, with profound benefits to the public and the environment.

14 SOLAR ENERGY↗

DOE OSTI2023

Solar Canopy Expansion Project (Final Technical Report)

This project is a parking-lot canopy solar photovoltaic system, consisting of four canopy structures and 1,080 470-watt (W) modules. The nameplate rating of the project is 507.6 kilowatts direct current (kWDC) at Standard Test Condition (STC), and 448 kilowatts alternating current (kWAC). It is interconnected to the existing Tribe-owned medium-voltage micro-grid generation system via a step-up transformer and short medium-voltage line. This project offsets energy usage from more expensive existing sources, specifically the Tribe-owned gas-fired engine generators providing the primary power source for existing Tribal facilities and the electric utility, which provides an alternate source. The solar photovoltaic system is a renewable source, which has the benefit of reducing reliance on fossil-fuel burning sources. By reducing demand on existing Tribe-owned conventional generators, the project has avoided the need to add more conventional generation and has prolonged the lifespan of existing gas-fired engine generators. The project reduced energy costs and reliance on fossil-fuel burning power sources, increasing Tribe-owned generating sources and self-reliance, and prolonging the lifespan of existing generators. A side benefit to the project is the production of dozens of covered parking spaces in the existing parking lot.

14 SOLAR ENERGY↗

NASA NTRS1982

Cost estimates for flat plate and concentrator collector arrays

The current module and installation costs for the U.S. National Photovoltaic Program's grid-connected systems are significantly higher than required for economic viability of this alternative. Attention is accordingly given to the prospects for installed module cost reductions in flat plate, linear focus Fresnel concentrator, and point focus Fresnel concentrator candidate systems. Cost projections indicate that all three systems would meet near-term and midterm goals, provided that module costs of $2.80/W(p) and $0.70/W(p), respectively, are met. The point focus Fresnel system emerges as the most viable for the near term.

Shimada, K.↗

DOE OSTI2024

Performance Assessment of Photovoltaic Panels Using Impedance Spectroscopy

The goal of this project was to develop a technique for measuring internal characteristics of a PV module using light modulation under a fixed voltage bias while measuring the resulting alternating current. This technique, light-intensity modulated impedance spectroscopy (LIMIS), has the promise of detecting early signs of panel aging and degradation that could be used for example by solar farm operators to have early warnings to repair or replace panels to maintain reliability of the overall PV array. LIMIS would be complementary with the previously developed electrochemical impedance spectroscopy (EIS), which uses an alternating voltage applied electrically to a solar cell with a similar alternating current measurement. EIS has mostly been developed for individual PV cells rather than whole modules. The project was intended to assess what different information could be revealed by LIMIS, which may in some cases be more scalable to larger modules and potentially more practical to apply in field measurements without needing to electrically disconnect PV modules. We began with small 10 W PV modules and built a testbed capable of oscillating the light intensity with frequencies up to 50 kHz. In parallel, we built a large testbed for testing large 250 W PV modules. Meanwhile, we developed procedures for established measurement techniques: current–voltage (I–V), EIS, and electroluminescence (EL) imaging, where panels are subjected to forward bias while their infrared emission is recorded using a camera modified to be sensitive to IR wavelengths. In addition, we developed protocols for accelerated aging of PV modules in two ways. Thermal cycling from –40°C to +90°C simulates the diurnal temperature cycles on a rooftop. Mechanical stress by dropping a 227 g ball from a height of 1 m simulates damage such as that due to hail impacts.

14 SOLAR ENERGY↗

DOE OSTI2020

Cost estimates of production scale semitransparent organic photovoltaic modules for building integrated photovoltaics

Building integrated photovoltaics (BIPVs) are attached to commercial and residential structures to enable solar energy harvesting. While conventional Si photovoltaics (PVs) are dominant in the current market, second and third generation thin film solar cells based on amorphous Si, CdTe, CIGS, perovskites or organic photovoltaics (OPVs) are often considered as an alternative for BIPV applications since they may offer reduced costs compared to Si PVs. Indeed, recent advances in performance suggest that lightweight, flexible and visibly transparent OPVs can potentially be integrated into windows or other applications to which Si PVs are less well suited. Here, we estimate the cost of high efficiency, semitransparent OPVs (ST-OPVs) based on solution processing in a roll-to-roll (R2R) manufacturing line. Assuming modules with 10% power conversion efficiency (PCE), a 70% geometric fill factor (GFF), and 95% inverter efficiency, we anticipate a %1.6 per Wp module manufacturing cost that includes the cost of the microinverter to condition the OPV dc output to be compatible with the ac line voltage of the building. The materials and inverter cost comprise ~90% of the total module cost. Hence, with simplified material synthesis and a lower inverter cost, including marginally improved PCE and GFF, we expect the cost can be as low as $0.47 per Wp. Here, while the module costs ~60% of the average (uninstalled) double-pane window, we expect the payback period can be as short as 2 to 6 years, suggesting that OPVs can be an economic and attractive candidate for BIPV applications.

14 SOLAR ENERGY↗

DOE OSTI2018

Photovoltaic system with improved AC connections and method of making same

An alternating current (AC) harness for a photovoltaic (PV) system includes a wire assembly having a first end and a second end, the wire assembly having a plurality of lead wires, and at least one AC connection module positioned at a location along a length of the wire assembly between the first end and the second end. Further, the at least one AC connection module includes a first connection terminal electrically coupled to the plurality of lead wires of the wire assembly and constructed to electrically couple the wire assembly with an output of a first PV module of the PV system. The at least one AC connection module also includes a second connection terminal electrically coupled to the plurality of lead wires of the wire assembly and constructed to electrically couple the wire assembly with an output of a second PV module of the PV system.

14 SOLAR ENERGY↗

DOE OSTI2012

Electrical Bias as an Alternate Method for Reproducible Measurement of Copper Indium Gallium Diselenide (CIGS) Photovoltaic Modules: Preprint

Light-to-dark metastable changes in thin-film photovoltaic (PV) modules can introduce uncertainty when measuring module performance on indoor flash testing equipment. This study describes a method to stabilize module performance through forward-bias current injection rather than light exposure. Measurements of five pairs of thin-film copper indium gallium diselenide (CIGS) PV modules indicate that forward-bias exposure maintained the PV modules at a stable condition (within 1%) while the unbiased modules degraded in performance by up to 12%. It was additionally found that modules exposed to forward bias exhibited stable performance within about 3% of their long-term outdoor exposed performance. This carrier-injection method provides a way to reduce uncertainty arising from fast transients in thin-film module performance between the time a module is removed from light exposure and when it is measured indoors, effectively simulating continuous light exposure by injecting minority carriers that behave much as photocarriers do. This investigation also provides insight into the initial light-induced transients of thin-film modules upon outdoor deployment.

14 SOLAR ENERGY↗

NASA NTRS1983

Photovoltaic power - An important new energy option

A review of photovoltaic (PV) power technology is presented with an emphasis of PV as an economical and technically feasible alternative source of energy. The successful completion of the development and transfer of emerging low-cost technologies into a fully commercialized status are identified as the means to the realization of this option's full potential. The DOE National Photovoltaics Program, a significant sponsor of PV R&D, expects both flat-plate and concentrator collectors to meet established cost targets. Citing the DOE large flat-plate grid-connected system project of the Sacramento Municipal Utility District, current technology modules priced at near $5/Wp (1983 dollars) are steadily reducing costs. A recent DOE study suggests that PV-generated electricity produced at a 30-year levelized cost of 15 cents per kWh would represent a viable energy supply alternative for the nation.

Ferber, R. R.↗

DOE OSTI2021

Real-time Simulation Framework for Hardware-in-the-Loop Testing of Multi-port Autonomous Reconfigurable Solar Power Plant (MARS)

Multiport autonomous reconfigurable solar power plant (MARS) has been proposed for integrated development of photovoltaic (PV) and energy storage system (ESS) that can connect to high-voltage direct current (HVdc) and alternating current (ac) transmission grid. To de-risk the development of this complex integrated system that consists of hundreds to thousands of power electronics modules, a controller hardware-in-the-loop (cHIL) test setup will be extremely beneficial. The cHIL testing can be used for evaluation of modules as well as the hierarchical control system in MARS. With the unique configuration of power electronics modules in MARS, it becomes necessary to develop custom-designed real-time simulation models in the cHIL setup in absence of off-the-shelf models. In this paper, high-fidelity dynamic model of MARS, control algorithms at the lower level, and required communication algorithms are developed and optimized for real-time performance in the cHIL setup. Real-time experimental results from the cHIL are provided.

Dong, Zerui↗

DOE OSTI2017

Chapter 10.2: Encapsulant Materials for PV Modules

Encapsulant materials used in photovoltaic (PV) modules serve multiple purposes; it provides optical coupling of PV cells and protection against environmental stress. Polymers must perform these functions under prolonged periods of high temperature, humidity, and UV radiation. When PV panels were first developed in the 1960s and the 1970s, the dominant encapsulants were based on polydimethyl siloxane (PDMS). Ethylene-co-vinyl acetate (EVA) is currently the dominant encapsulant chosen for PV applications, not because it has the best combination of properties, but because it is an economical option with an established history of acceptable durability. Getting new products onto the market is challenging because there is no room for dramatic improvements, and one must balance the initial cost and performance with the unknowns of long-term service life. Recently, there has been renewed interest in using alternative encapsulant materials with some significant manufacturers switching from EVA to polyolefin elastomer-based (POE) alternatives.

14 SOLAR ENERGY↗

NASA NTRS1977

Energy requirement for the production of silicon solar arrays

The results of a study to investigate the feasibility of manufacturing photovoltaic solar array modules by the use of energy obtained from similar or identical photovoltaic sources are presented. The primary objective of this investigation was the characterization of the energy requirements of current and developing technologies which comprise the photovoltaic field. For cross-checking the energies of prevailing technologies data were also used and the wide-range assessment of alternative technologies included different refinement methods, various ways of producing light sheets, semicrystalline cells, etc. Energy data are utilized to model the behavior of a future solar breeder plant under various operational conditions.

Lindmayer, J.↗

DOE OSTI2022

Physics-Based Method for Generating Fully Synthetic IV Curve Training Datasets for Machine Learning Classification of PV Failures

Classification machine learning models require high-quality labeled datasets for training. Among the most useful datasets for photovoltaic array fault detection and diagnosis are module or string current-voltage (IV) curves. Unfortunately, such datasets are rarely collected due to the cost of high fidelity monitoring, and the data that is available is generally not ideal, often consisting of unbalanced classes, noisy data due to environmental conditions, and few samples. In this paper, we propose an alternate approach that utilizes physics-based simulations of string-level IV curves as a fully synthetic training corpus that is independent of the test dataset. In our example, the training corpus consists of baseline (no fault), partial soiling, and cell crack system modes. The training corpus is used to train a 1D convolutional neural network (CNN) for failure classification. The approach is validated by comparing the model’s ability to classify failures detected on a real, measured IV curve testing corpus obtained from laboratory and field experiments. Results obtained using a fully synthetic training dataset achieve identical accuracy to those obtained with use of a measured training dataset. When evaluating the measured data’s test split, a 100% accuracy was found both when using simulations or measured data as the training corpus. When evaluating all of the measured data, a 96% accuracy was found when using a fully synthetic training dataset. The use of physics-based modeling results as a training corpus for failure detection and classification has many advantages for implementation as each PV system is configured differently, and it would be nearly impossible to train using labeled measured data.

Hopwood, Michael W. (ORCID:0000000161901767)↗