Introduction to Photovoltaic Modules and 21 Common Quality Issues -2

　　【 Cause of component junction box fire 】

　　1. The lead wire is not tightly clamped in the slot, causing ignition and fire;

　　2. The welding area of the lead and junction box solder joints is too small, resulting in excessive resistance and causing ignition;

　　3. If the lead wire is too long and in contact with the plastic parts of the junction box, prolonged heating can cause a fire.

　　Component impact:

　　1. A fire can directly cause the components to be scrapped, and in severe cases, it may lead to a fire together.

　　Preventive measures:

　　1. Strictly follow the SOP operation to fully insert the lead wire into the card slot;

　　2. The welding area of the lead wires and junction box solder joints should be at least 20 square millimeters;

　　3. Strictly control the length of the lead wire to meet the requirements of the drawing and operate according to SOP Avoid contact between the lead wires and the plastic parts of the junction box.

　　Reasons for battery cracking

　　1. Improper operation during the welding process leads to cracking;

　　2. Improper lifting and lowering techniques by personnel resulted in component fragmentation;

　　3. The fault of the laminating machine resulted in component fragments.

　　Component impact:

　　1. Failure of fragmented parts affects component power attenuation;

　　2. The power attenuation or complete failure of a single battery cell affects the power attenuation of the component.

　　Preventive measures:

　　1. The welding and rework areas of the busbar shall be strictly operated according to the SOP method;

　　2. Personnel must strictly follow the process requirements when lifting and placing components;

　　3. Ensure regular maintenance of the laminating machine Every replacement of equipment accessories must be strictly confirmed as OK before production;

　　4. EL testing strictly controls the inspection and prohibits any defects or omissions.

　　Reasons for excessive use of battery soldering flux

　　1. The excessive amount of flux spraying caused by adjusting the welding machine;

　　2. Personnel applied too much soldering flux during the repair process.

　　Component impact:

　　1. Affects the EVA delamination at the position of the main gate line of the component;

　　2. After a long period of time on the power generation system, components may develop lightning streaks and black spots, which can affect the power attenuation of the components and reduce their lifespan or cause them to be scrapped.

　　Preventive measures:

　　1. Adjust the flux spraying amount of the welding machine Regular inspection;

　　When replacing battery cells in the repair area, please use the designated soldering aid pen and do not use a large head brush to apply soldering flux.

　　Reasons for virtual soldering and over soldering

　　1. Excessive welding temperature or insufficient application of flux or too fast speed can lead to virtual soldering;

　　Excessive welding temperature or welding time can lead to over welding phenomenon.

　　Component impact:

　　1. Virtual soldering can cause delamination between the solder strip and the battery cell in a short period of time, affecting the power attenuation or failure of the component;

　　2. Over welding causes damage to the internal electrodes of the battery cell, directly affecting the power attenuation of the component, reducing its lifespan, or causing it to be scrapped.

　　Preventive measures:

　　1. Ensure the parameter settings for welding machine temperature, flux injection amount, and welding time And regular inspections should be conducted;

　　2. The repair area should ensure the temperature of the soldering iron, welding time, and the use of the correct soldering aid pen to apply flux;

　　3. Strengthen EL inspection efforts to avoid defective products from missing the next process.

　　Reasons for offset of welding tape or warping and fragmentation after welding

　　1. Abnormal positioning of the welding machine can cause displacement of the welding strip;

　　2. The deviation of the main grid line of the battery cell raw material will cause the welding strip to deviate from the main grid line after welding;

　　3. The high temperature and excessive hardness of the welding strip cause the battery cells to bend after welding.

　　Component impact:

　　1. Offset can lead to reduced contact between the solder strip and the battery area, resulting in delamination or affecting power attenuation;

　　2. Over welding causes damage to the internal electrodes of the battery cell, directly affecting the power attenuation of the component, reducing its lifespan, or causing it to be scrapped;

　　3. Bending after welding causes battery cell fragments.

　　Preventive measures:

　　1. Regularly check the positioning system of the welding machine;

　　2. Strengthen the incoming inspection of battery cells and welding strip raw materials.

　　Reasons for component tempered glass explosion and wire breakage in junction box

　　1. The components were severely impacted by external forces during transportation, resulting in glass explosion;

　　2. Impurities in glass raw materials cause the raw materials to self destruct;

　　3. The wire was not placed in the designated position, resulting in back pressure damage to the wire.

　　Component impact:

　　1. Glass blasting components are directly scrapped;

　　2. Damaged wires can lead to component power failure or dangerous electrical leakage accidents.

　　Preventive measures:

　　1. Components should be handled with care during lifting and placement Avoid external collision;

　　2. Strengthen the inspection and testing of glass raw materials;

　　3. The wires must be strictly coiled according to the requirements Avoid scattering on components.

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