Energies, Vol. 19, Pages 472: Simulation-Based Analysis of the Heating Behavior of Failed Bypass Diodes in Photovoltaic-Module Strings
Energies doi: 10.3390/en19020472
Authors:
Ibuki Kitamura
Ikuo Nanno
Norio Ishikura
Masayuki Fujii
Shinichiro Oke
Toshiyuki Hamada
With the expansion of photovoltaic (PV) systems, failures of bypass diodes (BPDs) embedded in PV modules can degrade the power-generation performance and pose safety risks. When a BPD fails, current circulates within the module, leading to overheating and eventual burnout of the failed BPD. The heating characteristics of a BPD depend on its fault resistance, and although many modules are connected in series in actual PV systems, the heating risk at the module-string level has not been sufficiently evaluated to date. In this study, a numerical simulation model is constructed to reproduce the operation of PV modules and module strings containing failed BPDs, and its validity is verified through experiments. The validated numerical simulation results quantitatively illustrate how series-connected PV modules modify the fault-resistance dependence of BPD heating under maximum power-point operation. The results show that, under maximum power-point operation, the fault resistance at which BPD heating becomes critical shifts depending on the number of series-connected modules examined, while the magnitude of the maximum heating decreases as the string length increases. The heat generated in a BPD at the maximum power point decreases as the number of series-connected modules increases for the representative string configurations analyzed. However, under open-circuit conditions due to power-conditioner abnormalities, the power dissipated in the failed BPD increases significantly, posing a very high risk of burnout. Considering that lightning strikes are one of the major causes of BPD failure, adopting diodes with higher voltage and current ratings and improving the thermal design of junction boxes are effective measures to reduce BPD failures. The simulation model constructed in this study, which was experimentally validated for short PV strings, can reproduce the electrical characteristics and heating behaviors of PV modules and strings with BPD failures with accuracy sufficient for comparative and parametric trend analysis, and serves as a practical tool for system-level safety assessment, design considerations, and maintenance planning within the representative configurations analyzed.