Preparation of Junction Box Replacement in the Solar modules

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There is a massive solar modules installations are taking place at gigawatt (GW) scale across the globe and india is the thrid largest solar energy installation in the world reaching to a capacity of 81.8 GW as on mar’ 2024 as per CERC India (Central Electricity Regulatory Commission), focusing on increase in the renewable energy installation to minimise the carbon emissions and climate change.

Table of Contents:

    1. Parts of the Solar Module
    2. Key functions of Junction Box
    3. Common Reasons for Junction Boxes Failures

        Parts of Solar Module

        • Aluminium Frame
        • Tempered Cover Glass
        • Solar Cell
        • Encapsulation foil
        • Back Sheet
        • Junction Boxes

        A junction box is fixed at the backside of the solar panel which is the central point where cables are interconnected with all solar cells connected in series and parallel to the electrical systems that is pre-installed with silicon adhesive. It protects from the environment. 

        Key functions of Junction Box

        • Connecting the solar cells as a whole into a PV panel with the connect load
        • Protection to the outgoing line from the hot spot effect
        • Weather proofing against the external factors like moisture, dust, debris, etc. to increase integrity and longevity of the electrical system
        • Safety to meet the standard guidelines and prevent electrical hazards
        • Monitoring: some of the advanced junction boxes are capable of providing data like temperature, and communication

        With the gradually degradation of the solar modules, the major failure can be seen in the “Junction Boxes”. These junction boxes are available in the market at a lower prices that can be replaceable. Instead of throwing the complete solar module, we can be replace with the new junction boxes that are available in the local markets at a very cheaper price. By adopting to the Circular economy concept, we can help in minimising the e-waste and increase the life of the solar module (25 years and more w.r.t OEMs).

        With a well training electrical engineer, the junction boxes can be replaced carefully without damaging the solar cells. The failure rate of these junction boxes are low, some of the common reasons are as below:

        Common Reasons for Junction Boxes Failures

        • Poor Soldering connections
        • UV exposure
        • Temperature fluctuations
        • Mechanical Stresses
        • Manufacturing defects
        • Moisture infiltration and insulation breakdown


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