The Effects of Modified Production Method and New Parts Integration on CPV Modules.

King Abdulaziz City for Science and Technology (KACST) in collaboration with IBM has developed the first manually manufactured concentrator photovoltaic (CPV) modules. A single CPV module is rated at 120 W at nominal operating test condition (NOTC) of 1000 W/m2 direct normal insolation (DNI) and 25 °C ambient temperature. Two trackers are installed and operated in the solar village outside Riyadh and one located in the eastern coastal city of Alkhafji. Figure 1 shows the trackers in Solar Village and Alkhafji. Valuable lessons were learned after three years of operating the systems on sites with different environmental characteristics. A production process flaw that caused cell material weakening and falling of light pipes from the cell have caused huge output degradation. Other factors that improved module performance are modification of production methods, integrating and replacing new parts. The Fresnel lens was replaced with a higher transmission efficiency lens of the same make as the former. Focal length of the new lens was determined and a new aluminum casing with different dimension was produced. This paper discusses in details the manufacturing process of two modules. The modules are essentially the same except for the cell used in each one. Both modules were manufactured using the modified process. New parts have been incorporated. The modules were then installed in the solar village. Data are being collected at a time interval of 10 minutes. I-V curve tests are also being acquired at different environmental conditions. Analysis and comparisons of these modules with one old module shall be presented. [ABSTRACT FROM AUTHOR]