Solar Lattice

Symptom

Cracked front glass

ID
symptom:cracked-glass
IRI
https://solarlattice.org/kb/symptom/cracked-glass
Status
active
Also known as
Glass breakage, Front glass breakage, Breakage of front glass, Broken PV module glass, Shattered (tempered)

The module glass is cracked in one spot or across the whole module. Tempered glass shatters into small pieces, while annealed glass breaks into large pieces. On non-tempered glass the impact point is easy to find because the glass does not fragment. This helps you tell a surface impact apart from a break that started at the edge. Common causes are hail, stones or other impacts, bad clamps or over-tightened screws, transport damage, and heat from hot spots or arcing. A defective mounting structure can also put extra stress on the glass. Thin glass/glass bifacial modules often crack on the rear glass first, so check the back of the modules as well as the front. Module power often does not drop right away. An inverter isolation or ground fault alarm may be the first sign, especially in wet weather. Visual inspection is the simplest way to find broken glass. IR imaging shows hot spots or hot broken cells, and EL or UV fluorescence shows the cell cracks behind them. Over time, moisture getting in corrodes the cells and circuits. A fully broken module can reduce current in the whole string, so replace modules that pose a safety or insulation risk.

<!-- review notes

Claims

observed_as

c1 drafted · lead Hot cell in IR image

Damaged front glass often leaves broken cells that show up hot in thermography; tempered glass that shatters usually breaks the cells too.

c2 drafted · lead Localized IR hotspot

Glass breakage causes hot spots that can overheat the module. Infrared imaging picks up temperature anomalies linked to the breakage.

c3 drafted · lead Crack pattern in EL image

EL and UV fluorescence can show cell cracks caused by the glass breakage, for example in hail-damaged modules.

c4 drafted · lead Low insulation resistance alarm

An isolation failure may be the first fault the inverter reports, especially in wet conditions. A ground fault and inverter shutdown can follow.

c5 drafted · lead String current below average

A module whose glass is completely broken reduces current and power in the whole string.

time_to_onset

c6 drafted · lead ≤ 9 MO

Conditions: Published case: half of the bifacial 2 mm/2 mm glass/glass modules on rack and tracker mounts had broken glass within 9 months of outdoor exposure. Mostly the rear glass broke.

review note: support check: partial - u8 gives 50% of modules broken within 9 months, with most breaks on the rear glass, but it doesn't say the onset time is 'up to 9 months'. The modules cracked at a constant rate over the 9-month test period, so 9 months is the length of the exposure test.

Referenced by

Data