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• SNLs work with the dark I-V measurement • procedure as a lab diagnostic capability and a production line quality-control tool is ongoing with joint efforts with PowerLight and RWE Schott Solar. Success at PowerLight • motivated its major module suppliers (Sharp, Sanyo) to implement similar production line test equipment. • By request, SNL diagnosed field reliability and • Laminate and perform accelerated testing of CdTe-based devices using a variety of encapsulants/processing cycles to determine failures affecting device performance. Evaluate the adhesive and cohesive strength of the layers within the thin-film module structures for the principal technologies and report to industry. Deposit and measure properties of barrier coatings to protect thin-film module cells from moisture and report results. manufacturing issues for four major c-Si module manufacturers using a combination of dark IV analysis and infrared imaging. Long- term reliability of multi-megawatts of modules was being affected. 4. Planned FY 2006 Activities One of the top research priorities identified by the PV industry year after year is module performance and reliability, as an essential ingredient for product credibility and consumer confidence. The plans for FY 2006 are to perform module reliability and packaging research and testing, produce technical reports of results, and interact and collaborate with the PV industry module manufacturers to address the long-term goals of the Solar Program—which are to commercialize PV modules having at least 30-year service lifetimes and less than 0.5% annual performance degradation, at target costs consistent with market-required levelized cost of electricity. Specific activities to support these goals include the following proposed milestones for completion by 9/30/06, subject to funding levels: • Report analyses of outdoor module performance of ~34 modules under test in the Performance and Energy Ratings Testbed showing effective efficiency and energy production compared to nameplate. • Report comparisons of module degradation/ failure for 2.5X exposure versus 1X exposure using the Outdoor Accelerated Weathering Tracking System to assess accelerated exposure testing capability. • Report results of high-voltage stress testing (module leakage currents) using the High- Voltage Stress Testbed for potential high- voltage applications by industry. • Continue support of data archiving and data analysis of thin-film hot and humid outdoor exposure testing and other in-house and subcontracted module research. • Enhance accelerated module testing and certification capabilities essential to industry partners. • Working with industry, develop new packaging formulations and provide adhesion and water vapor transmission values, water ingress modeling results, and assessment of cracking and shunt problems. • Prepare a comprehensive summary of degradation rates and diagnostic evaluation of 10 commercial module types using 5–15-year outdoor exposure data at SNL, FSEC, or SWTDI. • Implement and demonstrate production line module dark I-V diagnostic procedures with two manufacturers. • Conduct high-reliability cell-ribbon solder-bond experiment. • Initiate the next generation of long-term exposure testing of the latest high- performance commercial modules from two manufacturers at FSEC and SWTDI, with baseline tests at SNL. • In support of SNL’s System Evaluation and Optimization project, perform baseline performance characterization and modeling of eight new 3–6-kW PV arrays, which will initiate an effort to accurately quantify performance- degradation characteristics of inverters and arrays in continuously operating systems. • Implement Systems-Driven-Approach and stage-gate processes in project activities, in support of the MYTP. 5. Major FY 2005 Publications B. Marion, S. Rummel, and A. Anderberg, “Current-Voltage Curve Translation by Bilinear Interpolation,” Prog. Photovolt: Res. Appl., 2004, 12:593-607. C.R. Osterwald, J. Adelstein, J.A. del Cueto, W. Sekulic, D. Trudell, P. McNutt, R. Hansen, S. Rummel, A. Anderberg, and T. Moriarty, “Resistive Loading of Photovoltaic Modules and Arrays for Long-Term Exposure Testing,” submitted to Prog. Photovolt.: Res. Appl., July 2005. Photovoltaic R&D Advanced Materials and Devices 63PDF Image | DOE Solar Energy Technologies Program
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