Online Diagnostics as a First Step in the Safe Use of Damaged Photovoltaic Modules

Although solar photovoltaic (PV) technology is a well-known sustainable energy source, as glass-on-glass bifacial modules have dominated the market during the rapid scaling of the PV industry, glass breakage has become an environmental concern. This study explores the reuse of broken modules to further improve PV sustainability through case studies of 3.45 MWp and 1.4 MWp solar farms, comprising over 12,700 modules. After cleaning and testing, 1.45% of PV modules were physically damaged due to glass breakage during transport or handling at the solar farms in Brazil. Recycling of PV modules is infrequent; therefore, the reuse of modules under these conditions was explored. Nine modules with glass damage were connected to the electricity grid using a carport-type structure, and 36 diagnostic current–voltage (I-V) tests were carried out over an 18-month experimental period. Tests to detect faults and low system insulation resistance indicated that the implementation of non-invasive, remote, online, and periodic monitoring enabled the system to operate and enabled the reuse of damaged modules. Although the electrical results were promising, future work is needed to evaluate methods to ensure the broken glass is sealed to prevent electric shock hazards and to maintain long-term safe performance.