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Investing in solar panels is a bright idea, but like any technology, they can sometimes have manufacturing flaws or develop defects over time. Understanding these potential problems can help you make informed decisions and ensure long-lasting solar power generation. Electrifying Australia is here to help you identify solar panel defects, what causes them, and ways to prevent or mitigate them.
1. Microcracks
Photo Credit: Winaico Australia
They are identified by tiny, often invisible, cracks in a solar cell's silicon wafers, disrupting electron flow.
Causes: Mishandling during manufacturing, transport, installation (bending, dropping), or extreme temperature fluctuations.
Impact: Reduced energy output as affected cells produce less power. It's not always immediately noticeable.
Prevention: Choosing reputable brands with stringent quality control, demands careful handling throughout the supply chain.
2. Hot Spots
Photo Credit: Winaico Australia
Identified by localized areas of excessive heat on the panel, appearing brighter in thermal imaging.
Causes: Shading (debris, bird droppings, nearby objects) or faulty bypass diodes (meant to mitigate shading effects).
Impact: Accelerated cell degradation in the hot spot, potentially damaging the entire panel and posing fire risks.
Prevention: Regular panel cleaning, choosing panels with module-level optimization (reduces the impact of shading on individual cells), and periodic inspections with thermal imaging cameras.
3. Delamination
Photo Credit: MJK Power
Delamination can be identified by the separation of the different layers within the panel - glass, encapsulant (usually EVA), cells, and back sheet.
Causes: Poor manufacturing, low-quality materials (especially encapsulant), exposure to high humidity/temperature swings.
Impact: Reduced efficiency as layers detach, eventually leading to panel failure due to moisture ingress and cell corrosion.
Prevention: Opt for reputable brands known for durability and check product warranties specifically covering delamination.
4. Potential Induced Degradation (PID)
Photo Credit: GSES
Identified by gradual performance decline caused by voltage differences between the solar cells and the frame, leading to current leakage.
Causes: High system voltages, particularly in humid environments, coupled with inadequate grounding, allowing leakage.
Impact: Significant power loss over time, affecting the overall system's output and ROI.
Prevention: Ensure proper grounding during installation, and use high-quality inverters with built-in anti-PID features.
5. EVA Browning/Yellowing
Photo Credit: MDPI
Identified by discoloration of the encapsulant material (usually EVA), which bonds and protects the cells, hindering light transmission.
Causes: UV exposure, moisture penetration into the panel, or degradation of low-quality EVA that's prone to yellowing.
Impact: Reduced efficiency as less light reaches the cells to be converted into energy.
Prevention: Choose panels with UV-resistant, high-quality EVA encapsulant and ensure proper panel sealing during manufacturing.
6. Snail Trails
Photo Credit: PV-Manufacturing
Identified by brownish or discolored patterns on the solar cells, often appearing like snail tracks, not always indicative of a problem.
Causes: Not fully understood, potentially linked to silver oxide formation within the cell due to humidity and micro-defects.
Impact: Mostly cosmetic in many cases, but some types can indicate cell damage and potential long-term performance decline. Monitoring is key.
Prevention: Difficult to prevent completely, choosing reputable brands reduces risk, and performance monitoring helps identify if it's more than cosmetic.
7. Burn Marks
Photo Credit: Winaico Australia
Identified by visible discoloration or darkening on the cell, indicating localized overheating and damage.
Causes: Faulty wiring, malfunctioning bypass diodes (meant to handle current safely), or untreated, concentrated hot spots.
Impact: Irreversible cell damage, significant power loss in the affected area, potential fire hazard requiring immediate attention.
Prevention: Ensuring proper installation by qualified professionals, conducting regular system checks, and addressing any hot spots promptly.
8. Glass Breakage
Photo Credit: PV Magazine
Identified by cracks or shattering of the protective glass layer, most common in hail-prone areas.
Causes: Impact from hail, debris (tree branches, objects blown by wind), or extreme temperature changes causing thermal stress.
Impact: Reduced energy output as light is obstructed, safety hazard due to exposed electrical components and potential water ingress.
Prevention: Choosing panels with impact-resistant tempered glass, trimming overhanging branches, and considering additional hail protection if needed.
9. Backsheet Deterioration
Photo Credit: Eco Generation
Identified by cracking, peeling, or delamination of the protective back sheet (often made of polymers) at the rear of the panel.
Causes: Prolonged UV exposure, extreme temperature swings, low-quality materials that degrade faster, or improper installation stressing the panel.
Impact: Reduced panel lifespan as moisture can penetrate, corroding internal components and compromising fire resistance.
Prevention: Select panels with durable, UV-resistant backsheets, ensuring proper installation to avoid undue stress or bending of the panel.
10. Junction Box Failures
Photo Credit: Syonyk's Project Blog
Identified by issues within the junction box, located on the back of the panel, which houses the electrical connections (diodes, wiring).
Causes: Poor sealing leading to water damage, corrosion from humidity, rodent damage, or overheating due to loose connections.
Impact: Power loss as current flow is disrupted, potential safety hazards like short circuits, arcing, and even fire risks.
Prevention: Regular system inspections, ensuring proper sealing during installation, implementing rodent control measures, and using high-quality components within the junction box.
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Together, let's power a brighter future for NSW!
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