Title of Topic : PV Modules

Delivery Mode : Theory Lecture

Duration : 2 hours

Version Control
Version : 1.2
Created/ Revised on : 10 August 2016
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Topic: PV Modules

What is Photovoltaics?

 The direct method of converting sunlight into electricity

using a device called SOLAR CELL.
 PV utilizes the ‘LIGHT’ of sunlight.

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Topic: PV Modules

Working of a Solar Cell

Physical Mechanisms:
1. Absorption
2. Transport
3. Collection Current
External Current!
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Topic: PV Modules

Strength of a PV Module

 A solar cell is very thin and brittle.

 However, a PV module is designed to perform for 25 years
under harsh weather conditions…
 Heat, wind, rain, hail, dust, vibrations, etc.

 Hence, a PV module is designed and constructed to be very

sturdy and protects the solar cell inside.
 The glass on front is tempered to strengthen it and absorb
mechanical and weather-related temperature shocks.
 The solar cells are sandwiched between ethyl vinyl acetate (EVA),
which is transparent and gel-like, and absorbs external mechanical
shocks and impacts.
 The back sheet, which is usually a polymer called Tedlar®, protects
the PV module from the backside.

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Topic: PV Modules

Components of a Crystalline Silicon PV Module

Front side. Back side.

Frame
Junction Box

Label

Solar Cell
EVA
Glass
Cable
Connector
Back Sheet
Busbar
Tab

SHOW & TELL: Identify the components in different (mono and poly) crystalline silicon
photovoltaic modules.
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Topic: PV Modules

Component: Frame (1/2)

Front side.
Frame

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Topic: PV Modules

Component: Frame (2/2)

 Material: Aluminium
 Aluminium is a very good conductor of heat and electricity.
 However, surface of the aluminium frame is anodized.
 Anodized aluminium is insulating, and hence, surface of the
frame does not conduct electricity.
 Uses of the frame:
 Protects edges of PV module from air, moisture, water, etc.
 Holes provided in the frame can be used for bolting the PV
module to a module mounting structure; the frame can also
be tightly clamped to a mounting structure.
 Provides additional mechanical strength to the PV module.
 Additional holes provided in the frame are for earthing the PV
module.
 IMPORTANT: Mounting and earthing instructions are always
provided in the manual of the PV module.

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Topic: PV Modules

Component: Junction Box (1/2)

Back side.

Junction Box

Top Cover.

Bypass Diode

Conducting Strips
(which are internally
connected to the module)

Cable Gland
Inside the Junction Box. (for external cable)
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Topic: PV Modules

Component: Junction Box (2/2)

 The junction box contains the electrical
terminals of the PV module, which come
from inside of the PV module.
 The junction box also contains bypass
diodes, which are connected in parallel
to the series of cells inside the PV
module.
 These bypass diodes are used to divert
current in case a series of cells are not
able to conduct current due to any shading
or damage.
 The junction box is adhered to the back-
side of the PV module, which should last
throughout the life (25+ years) of the
module.
 The junction box is rated IP65 or higher,
so that there is no ingress of dust or
moisture inside it.

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Topic: PV Modules

INFORMATION:
What is IP Rating?
 The IP Rating (“International Protection” Solid Object Moisture
Rating, sometimes also interpreted as Protected against solid Protected against
“Ingress Protection” Rating) classifies the 1 objects greater than
50 mm. 1 vertically dripping
water.
degree of protection against both solids and
Protected against solid Protected against


liquids in electrical enclosures.
IP ratings are defined in the international
2 objects greater than
12.5 mm. 2 dripping water when
tilted up to 15°.
Protected against solid Protected against


standard IEC 60529.
The standard aims to provide users more
3 objects greater than
2.5 mm. 3 spraying water at up
to 60° from vertical.
Protected against solid Protected against
detailed information than vague marketing
terms such as ‘dust-proof’ and ‘waterproof’. 4 objects greater than
1 mm. 4 water splashed from
all directions.
Dust protected. Protected against jets
 Note that if one drills a hole in an IP-rated
enclosure, then its IP rating may be 5 Limited ingress of
dust permitted. 5 of water.

compromised or lost if proper procedures Dust tight. No Protected against

are not followed. 6 ingress of dust
permitted. 6 strong jets of water.

 For example, if one drills a hole in an IP65 Protected against

enclosure to insert a wire, then an appropriate
cable gland should be used to ensure that no
Example: 7 temporary immersion
in water.
Protected against
IP65 8
dust or moisture can enter the enclosure
continuous immersion
through the hole. in water

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Topic: PV Modules

Component: Label

Back side.

Label

 The label is printed immediately after a PV module is

tested during manufacturing, and is stuck on the back-side
of the PV module.
 It typically contains the following information:
 Manufacturer and model number
 Electrical rating such as VOC, ISC,VMP, IMP, PMAX, maximum system
voltage, etc.
 Physical characteristics such as weight, dimension, etc.
 Certification information such as IEC, CE, etc.
 The label should last throughout the life (25+ years) of the
module even in harsh climatic conditions.
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Topic: PV Modules

Component: Solar Cell (1/3)

Front side.

Solar Cell

A solar cell.

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Topic: PV Modules

Component: Solar Cell (2/3)

 A ‘solar cell’ (also known as a

‘photovoltaic cell’ or ‘PV cell’) is a
device that directly converts sunlight
into electricity.

 A solar cell produces a voltage and

current when exposed to sunlight.

 The voltage and current output of a

solar cell depends on various
parameters, such as:
 Type and size of the solar cell
 Load connected to the solar cell
A solar cell.
 Radiation incident on the solar cell
 Temperature of the solar cell

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Topic: PV Modules

Component: Solar Cell (3/3)

 Polycrystalline and crystalline silicon solar
cells are used in 85% of the solar PV plants
globally.

 Standard metrics of a typical solar cell:

 Area: 156 mm x 156 mm (i.e. 6 inch x 6 inch)
 Typical Thickness: 180 µm (micrometre)
 Typical Current: ~8 Amperes A crystalline silicon
 Typical Voltage: ~0.5 Volts (DC) solar cell.
 Typical Power: 4 Watts
 Top Surface: Negative Terminal
 Bottom Surface: Positive Terminal

 Dependency on size of solar cell

 The output current of a solar cell is directly
proportional to its area.
 The output voltage of a solar cell remains A polycrystalline silicon
constant irrespective of its area. solar cell.

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Topic: PV Modules

SHOW & TELL:

Different types of solar cells
Busbars Busbars Busbars

Type of Cell Crystalline silicon Polycrystalline silicon Polycrystalline silicon

(Monocrystalline silicon) (Multicrystalline silicon) (Multicrystalline silicon)
Shape Usually pseudo-square Usually Square Usually Square
Top Surface Single shade of Multiple shades of Multiple shades of
dark blue/ black dark blue/ black dark blue/ black
Number of 2 or 3 2 or 3 2 or 3
Busbars (In picture: 3) (In picture: 2) (In picture: 3)

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Topic: PV Modules

Component: Ethylene Vinyl Acetate (EVA)

Front side.  EVA is a thermoplastic,

which is used to
encapsulate the solar
cells from front and back
sides.

EVA  EVA is transparent and

hence, allows light to
pass through it and
reach the solar cell.

 EVA, due to its gel-like

properties, mechanically
protects the solar cell
from shocks.

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Topic: PV Modules

Component: Glass

Front side.
 The glass on the front-side
provides mechanical strength to
the PV modules and protects
the brittle solar cells inside.
 Typical solar glass is:
 3 mm to 4 mm thick,
 Tempered, which makes it 4
Glass times stronger compared to
regular glass,
 Low in iron impurities so that it
can transmit more light.
 The glass is strenuously (vigorously) tested
for weight loading and impact resistance.
 Glass surface is usually smooth, because
textured surface could enhance dust
accumulation on the surface.
 Glass is the majority contributor to the
weight of the PV module.

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Topic: PV Modules

Component: Cable
 Cables of a PV module have to follow the same Back side.
standard as all the other DC cables of the PV system.
 The cable should be a ‘PV Cable’, typically with the
following characteristics:
 Single-core multi-stranded flexible tinned
copper cable
 Double-insulated UV-resistant PVC or
cross-linked polyethylene (XLPE).
 Resistant to UV, flame, weather,
ozone, acids, ammonia; Cable
and should be halogen-free.
 Conductor cross section area
of at least 4 mm2.
 Working DC Voltage
 Maximum permitted DC voltage of 1.8 kV.
 Working temperature: -40°C to +90 °C.

 Additionally, the cables should be clearly marked as positive or negative.

 More information on cables will be provided in subsequent lectures.
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Topic: PV Modules

Component: Connector

 Connectors of a PV module are also known as Back side.

‘quick-connects’
 PV connectors do not require tools to connect.
 However, it is highly recommended to use a tool to
disconnect such connectors to avoid any damage
to them.
 Connectors should be at least IP65 rated.
 Typical Makes:
 Multi-Contact (MC) 4,
 Tyco,
 Radox, Connector
 Amphenol, etc.
 It is important to specify the type of connector
to ensure its compatibility with other equipment
of the PV system.
 More information on electrical and other
properties of connectors will be provided in
subsequent lectures.
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Topic: PV Modules

Component: Back Sheet

 Tedlar (which is a Back side.

polyvinyl fluoride film, a
plastic) is a common
back sheet material.

 It protects the solar

cells from
environmental
penetration. Back Sheet

 It is delicate and should

not be scratched.

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Topic: PV Modules

Component: Busbars and Tabs (1/3)

Front side.

 Tabs and busbars are copper

strips that conduct
electricity from one cell to
another within a PV module.
Busbar
Tab  These copper strips are
typically coated with tin or
its alloy for easy soldering.

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Topic: PV Modules

Component: Busbars and Tabs (2/3)

Busbar

 Busbars connect one cell to

another in a string.

 A typical polycrystalline silicon

solar module of 200-300W
contains either 10 or 12 solar cells
connected in a string.

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Topic: PV Modules

Component: Busbars and Tabs (3/3)

 Tabs connect one string of solar cells to another.

 A typical polycrystalline silicon solar module has 6 such string connected

in series using tabs.

Tabs

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Topic: PV Modules

Different Shapes and Sizes of

Mono and Poly-crystalline Silicon PV Modules

 Various mono and poly-

crystalline silicon PV
modules are typically used
for domestic applications
such as rooftop, solar
streetlights, lanterns, etc.

 Current of a PV module depends on the area of each solar cell.

 Voltage of a PV module depends on the number of solar cells

connected in series.

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Topic: PV Modules

Available Crystalline Silicon PV modules

Cross-section of a crystalline Silicon PV module. Different types of

crystalline silicon
PV modules.

 Construction of most mono-crystalline poly-crystalline silicon PV modules

are similar.
 However, they come in various shapes and sizes depending on the size and
number of solar cells inside them.
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Topic: PV Modules

Connecting solar cells in series

N N N
Solar Cell Solar Cell Solar Cell
P P P

 The top (negative terminal) of one cell is connected to the bottom

(positive terminal) of the next cell by soldering a metal strip.

SHOW & TELL: Look at an actual crystalline silicon PV module and verify how the solar
cells are connected in series all the way up to the junction box.
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Topic: PV Modules

How is a crystalline silicon PV Module

constructed?
F LA S H

Glass
EVA

Solar Cell Solar Cell Solar Cell

Tedlar

1. Solar Cells from 2. Tabbing & 3. Layup of Glass,

STEPS: Tester Stringing EVA* and Tedlar®

4. Lamination in 5. Trimming of 6. Sealant on edges 7. Aluminium

Vacuum Edges (Silicone or tape) Framing
8. Installation of 9. I-V (Flash) Testing 10. Labelling on PV 11. Other Testing
Junction Box of PV Module Module (Hi-Pot, EL, etc.)
*EVA: Ethyl Vinyl Acetate
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Topic: PV Modules

QUICK EXERCISE:
Achieving desired current and voltage (1/2)

Given: Calculate: Calculate:

Current : 8A Current : 4A Current : 2A
Voltage : 0.5 V Voltage : 0.5 V Voltage : 0.5 V
Power : 4W Power : 2W Power : 1W

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Topic: PV Modules

PV Module Parameters

Parameter Significance
Open-circuit Voltage (VOC) • Maximum output voltage of a PV module,
given when no current is flowing.
• Should be considered when complying
with maximum voltage limitations of
other equipment e.g. inverters, switches.
Short-circuit Current (ISC) • Maximum output current of a PV module,
given when the module is shorted.
• Should be considered when sizing
elements like fuses, switches, etc.
Maximum Power (PMAX) • Maximum power that can be extracted
out of a PV module at Standard Testing
Condition (STC).
Voltage at Maximum Power Point (VMP) • Voltage of the PV module when it is giving
maximum power at STC.
Current at Maximum Power Point (IMP) • Current of the PV module when it is
giving maximum power at STC.
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Topic: PV Modules

Series Connection of PV Modules

 Voltage of the circuit

increases as PV
modules are
connected in series.

I(A)
Isc

Voc 2 x Voc 3 x Voc V (V)

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Topic: PV Modules

Parallel Connection of PV modules

I(A)
3 x Isc

2 x Isc

Isc

 Current increases
when PV modules
are connected in
parallel. V (V)
Voc
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Topic: PV Modules

Efficiency of a PV Module
Efficiency
= PV Module Area:
Electricity
Output: 
Output 1m x 2m
Input

 Incident Power:
=1kW/m2 x 2m2
= 2kW
Input: Light

 Vmp: 35VDC
 Imp: 8A
 Pmax: 280W

 PV Module Efficiency:
η = 280 / 2000
= 14%
Solar Simulator with I-V Tester
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Topic: PV Modules

Shading Effect and Bypass Diode

+
_

Performance: 0%
50%
100%
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Topic: PV Modules

Quick Exercise
Efficiency of a PV Module (3 minutes)

Take a datasheet of a PV Module.

1. Verify that PMAX = VMP X IMP

2. Find out the efficiency of the PV module using its

electrical characteristics and physical dimensions.

3. How many bypass diodes does the PV module have?

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Topic: PV Modules

Ambient Temperature vs. Cell Temperature

 Cell (or module) temperatures are always higher than ambient
temperatures during daytime.

 The cell temperature depends on ambient air temperature and

irradiance:
Tcell = Tamb + (0.031 * Irradiance in W/m2)

 All deration calculations with respect to temperatures should be

done with respect to cell (or module) temperatures.

 Example: At 1000 W/m2 irradiance (bright sun) and ambient

temperature of 24oC, the cell temperature is approximately:
Tcell = 24 + (0.031 * 1000) = 55oC

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Topic: PV Modules

Dissimilar PV Modules in Series

 When dissimilar PV modules are connected in series,

the voltages still add, but the current is limited by the
lowest current output device in series

Pos (+) (-) (+) Neg (-)

A B

Vseries = VA + VB
Pos (+) Iseries = IA < IB Neg (-)

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Topic: PV Modules

Dissimilar Modules in Parallel

 When dissimilar devices are connected in parallel, the

individual currents add, and the voltage is the average
of devices

A
Vparallel = (VA + VB) / 2
Iparallel = IA + IB
Neg (-) Pos (+)

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Topic: PV Modules

Degradation of a PV Module

 A typical PV module degrades approximately 1% per year.

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Topic: PV Modules

PV Module Warranty

 Performance
 90% for the first 10 years
 80% for the next 15 years

 Workmanship
 5 years

 For larger plants, performance warranties are also backed

by bank guarantees.
 This is an added comfort to ensure customer service in case
the manufacturer ceases to exist or cannot service the
customer.

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Topic: PV Modules

Certifications in a PV Module

Component Standard Description

c/mc-Si Terrestrial PV Module: Design qualification and

PV Module IEC 61215
type approval.
Thin-Film Terrestrial PV Module: Design qualification and
IEC 61646
type approval.
CPV Modules & Assemblies: Design qualification and type
IEC 62108
approval.

IEC 61730 PV Module: Safety qualification.

Connectors EN50521 Connectors for Photovoltaic Systems: Safety.

Power J-Box / IEC 62208 Empty Enclosures for Low-Voltage Switchgear and
Enclosures IP65 / IP12 Control gear Assemblies: General requirements.

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Topic: PV Modules

Buying a PV Module

What should I consider when buying a PV module?

 Cost: What is the rate in terms of Rs. per Watt?

 Power: Range OR Specific?
 Size: (Mono/ Poly-crystalline silicon) 60 OR 72 Cell OR smaller?
 Type: Mono/ Poly-crystalline silicon OR thin-film?
 Bypass Diodes in Junction Box: 3 OR 6 OR 12 OR other?
 IEC Certification available?
 Warranty on Performance and Workmanship available?
 Payment terms: How much advance?
 Delivery time: Readily available or months?
 Reputation and Bankability of Manufacturer

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Topic: PV Modules

REFERENCE/ SUPPLEMENTARY READING

1. Datasheet: Polycrystalline silicon PV module Titan M6-60 Series
2. Datasheet: Polycrystalline silicon PV module Titan M6-72 Series
3. Datasheet: Polycrystalline silicon PV module Waaree WS-230/ WS-240
4. Datasheet: Polycrystalline silicon PV module Moser Baer eLite 60 Series
5. Datasheet: Polycrystalline silicon PV module Moser Baer power Series
6. Datasheet: Thin film CdTe PV module First Solar Series 3
7. Installation Manual: Polycrystalline silicon PV module Canadian Solar
8. Installation Manual: Polycrystalline silicon PV module Jinko Solar
9. Installation Manual: Polycrystalline silicon PV module Moser Baer
10. Installation Manual: Polycrystalline silicon PV module Trina Solar
11. Installation Manual: Thin film CdTe PV module First Solar Series 4
12. IEC 61215 Certificate: Polycrystalline Silicon PV module Titan M6-72 Series
13. IEC 61215 Certificate: Polycrystalline Silicon PV module Moser Baer CAAP Series
14. IEC 61701 Certificate: Polycrystalline Silicon PV module Moser Baer CAAP Series
15. IEC 61646 Certificate: Thin film CIS PV module Solar Frontier PV Module S Series
16. Warranty Document: Polycrystalline silicon PV module CSUN EnverQ Series
17. Warranty Document: Polycrystalline silicon PV module Moser Baer eLite and eco Series
18. Warranty Document: Polycrystalline silicon PV module Titan M6-72 Series

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