See all notes. I looked up (misspelling) to make sure I had it right but every online dictionary I went to immediately said “incorrect spelling, misspelled” so go figure.
AFTER soldering many cells I have found that this method is the easiest and most successful way, at least for me. Forgive the sometimes blurry images and the shaky hands. Having a camera positioned to capture many angles had me trying to solder in some very unnatural positions. I am trying to get the camera as close as possible so you can see the actual solder melting and what I call “Riding the Wave.” I have several steps. 1st. (I forgot this on the 2nd cell but the solder took okay) Always flux the solder points (white lines) on each cell just before soldering. Do not do this days in advance as the flux will attract dust. 2nd. Align your tabbing wire and secure one end with a 1/4″ solder. 3rd. With the tabbing wire aligned and secured at one end place the soldering iron tip against the tabbing wire while using your other hand to hold the other end of the wire in place. Move the soldering iron smoothly forward and watch the little wave of solder preceding the tip of iron. It is like a tiny bow wake from a ship. Do not outrun your wave. Force the wave along until it reaches the end of your soldering point and then go just a little bit further. I do not have to tell you when to remove your finger as the iron gets closer as you will figure rather quickly. Go a little past the soldering point also when initially securing, go just a little beyond like maybe 1/4″. This allows the solder behind the iron to cool and adhere to the cell before you lift the iron. Note. I am using a crappy worn out soldering tip. It doesn’t conduct heat well to the pre-soldered tabbing wire. To compensate you will see me apply a electrical solder to the tip. It only takes a tiny amount but it is enough to transfer the heat from the iron tip to the wire. When you see that little wave the same thing is happening on the underside of the tabbing wire but the wave is flattened out and spread across the solder points on the cell and really sticks well. I have never ever had to use additional solder and leave big thick globs like some others I have seen on Youtube. Actually when I have done a very good soldering run there will be a little excess solder from the tabbing wire roll off the end of the cell. Do not hold the iron in one place on the cell too long as it will cause the cell to warp and crack. Press lightly with iron or you’ll crack a cell in a split second. If you ever hear a tiny barely audible “tink” you just cracked a cell. It might not show up now but with any crack it will just get bigger the more it’s handled. Now, Now! No ex-wife or old girlfriend jokes please. You probably noticed that sometimes the tabbing wire is not always exactly centered on the white line on the cell. Two reasons for this. One I’m using cheap tabbing wire that often times comes off the roll slightly bent to one side or the other. You can try to straighten it but it never gets perfect. So I make sure I keep a finger on the other end of the wire and often have to adjust the wire slightly while moving the iron forward so the wire stays on the white line. Two: I’m getting old and I can’t see worth a crap anymore. But it’s okay. As long you have at least 3/4 the width of the wire on the white line it will stick just fine. A little tip for beginners. Take two cells and lay lengthwise one face up and the other face down about 1/4″ apart. Then measure the distance from the furthest point of the white solder line across the cell, across the 1/4″ gap and all the way across the last of the three soldering points on the back of the second cell. Now get a piece of cardboard about 3 inches wide X length of your measurement, approx 3″X 6 1/4″. Unwind your tabbing wire lengthwise around the cardboard in nice even rows side by side. When the board is wrapped lengthwise across the full three inches width cut the wire at a point that the tip end will fold over the edge of the board and secure it so it won’t get loose and unwind. Oh, yeah, when beginning to wind the wire around the board I secure the end with a small piece of tape. Now every wind of wire you unroll from the piece of cardboard will have a nice little bend where you cut the correct length. Make sure to test every cell before soldering it into the array. there is always either one bad or below average. I made a really tester do this quickly, easily and very inexpensive. If there are any requests I will do a video on how to make and use. Who knows, if enough people ask I might I might even build a whole panel on video. My entire house is powered by solar (except the clothes dryer). If your looking for a slick production you won’t find it here. Damn it Jim I’m a solar Panel engineer, not a movie director.
Post time: Jan-20-2017