The operating lifespan of a solar panel, which doesn't have any moving parts (a primary source of reliability issues in other types of power generation systems), is typically determined by the stability and corrosion resistance of the materials used in the solar panel. However, there are several failure modes and degradation mechanisms that can reduce power output or cause solar panels to fail. Almost all of these mechanisms are related to water ingress or temperature stress.
Degradation mechanisms may involve a gradual reduction in power output over time of the solar panel or an overall decrease in power due to failure of individual solar cells in the solar panel.
Shorted Cells
Shorts can occur at the interconnection of cells, and this is a common failure mode for thin-film cells because the top and back contact points are closer together and more susceptible to areas of pinholes or cell material corrosion or damage.
Open Cells
This is a common failure mode, although redundant contact points and "interconnect buses" allow the cells to continue to function.
Shattering of the top surface may occur due to damage, thermal stress, handling, wind or hail.
Solar panel delamination
Delamination of modules was a common failure mode in early modules and is no longer a problem. It is usually caused by a reduction in bond strength, either from environmentally induced moisture or photothermal aging, and stress caused by varying thermal and humidity expansion.
Hot spot failures
Mismatched, cracked or shadowed cells can lead to hot spot failure.
Bypass diode failure
The bypass diode itself, used to overcome cell mismatch problems, can fail, usually due to overheating, usually due to undersizing. If the junction temperature is kept below 128°C, this problem will be minimized.
Failure of encapsulants
UV absorbers and other encapsulant stabilizers ensure the long life of solar module encapsulants. However, slow depletion does occur through leaching and diffusion, and once the concentration falls below a critical level, rapid degradation of the encapsulant material occurs. In particular, browning of the EVA layer, accompanied by the accumulation of acetic acid, has led to a gradual reduction in the output of some arrays, particularly those in concentrated systems.
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