Frequently Asked Questions

Who is PowerFilm Solar?

• PowerFilm Solar is a U.S.-based solar manufacturer located in Ames, Iowa. We design and manufacture thin-film solar panels using roll-to-roll semiconductor processes and assemble crystalline panel systems using automated cell stringing and collaborative robotic automation for transportation and other commercial applications.

Where are PowerFilm solar products made?

• PowerFilm thin-film solar panels are manufactured in Ames, Iowa, using roll-to-roll semiconductor deposition processes.

• Crystalline solar panels are assembled in Ames, Iowa, using automated cell stringing and robotic assembly processes.

• All manufacturing and assembly operations are performed at our U.S. facility.

What is thin-film amorphous silicon?

• Thin-film amorphous silicon is a photovoltaic technology deposited onto a flexible polyimide substrate. It enables lightweight, low-profile solar panels that deliver strong performance under diffuse and variable lighting conditions.

What is crystalline silicon solar technology?

• Crystalline silicon solar technology uses wafer-based silicon cells to convert sunlight into electrical energy.

• Cells are electrically interconnected into strings and encapsulated within a structural panel assembly.

• PowerFilm crystalline panels utilize high-efficiency Maxeon monocrystalline silicon cells to deliver high power density for transportation and other commercial applications.

How are PowerFilm’s amorphous silicon solar panels manufactured?

• Thin-film solar material is produced using a proprietary roll-to-roll vacuum deposition process. Manufacturing steps include:

• Back metal deposition

• Amorphous silicon deposition

• Transparent top contact deposition

• Laser scribing

• Busbar attachment

• Encapsulation

• Die cutting

• The process is continuous.

What voltages are available?

• Thin-film outdoor products are available in power point voltages including 1.2V, 2.4V, 3V, 3.6V, 4.2V, 4.8V, 6V, 7.2V, 9.6V, and 15.4V.

• Crystalline panels are available in higher voltage configurations suitable for 12V, 24V, 36V, 48V, and larger battery systems, depending on panel architecture and charge controller pairing.

• Custom voltages are available for OEM programs.

What determines solar panel life expectancy?

• Life expectancy is determined primarily by encapsulation type and environmental exposure.

• ETFE encapsulation supports permanent outdoor exposure. Polyester encapsulation is intended for protected environments.

• The photovoltaic semiconductor device itself has no intrinsic wear mechanism when properly protected.

Why do amorphous silicon panels vary in color?

• Color variation is a natural result of the thin-film deposition process and does not affect electrical performance.

How should PowerFilm panels be disposed of?

• PowerFilm thin-film panels contain no heavy metals and are non-toxic. Disposal should follow local electronic waste regulations where applicable.

• PowerFilm crystalline panels consist of silicon cells encapsulated within laminated structural assemblies using polymer backings, conductive materials, and copper interconnects. Disposal or recycling should comply with applicable electronic waste and photovoltaic recycling regulations.

Are PowerFilm solar panels intended for residential rooftop installation?

• PowerFilm does not offer residential rooftop or building-integrated solar systems. We focus on lightweight, portable, transportation, and OEM-integrated solar solutions.

How thin are PowerFilm thin-film solar panels?

• Thin-film amorphous silicon panels range approximately from 0.22 mm (8 mil) to 1.22 mm (44 mil), depending on laminate configuration and environmental rating.

• Crystalline panels range from 0.76mm (30 mil) to 2.54mm (100 mil), depending on the laminate configuration and environmental rating. Crystalline panels are thicker than thin-film laminates because of their cell-and-backing construction. Thickness varies by product series and structural design.

What is the minimum light level required for PowerFilm solar panels to operate?

• Outdoor PowerFilm amorphous and crystalline panels begin producing usable output at approximately 5,000 lux.

• Indoor Light Series panels are specified at 1,000 lux nominal operating conditions and can function down to approximately 200 lux depending on spectral distribution and load.

• Performance depends on irradiance, spectrum, temperature, and electrical loading.

How is solar panel wattage measured (STC)?

• Rated wattage is measured under Standard Test Conditions (STC):

• Cell temperature: 25°C

• Irradiance: 1000 W/m²

• Air mass: 1.5

• Panel oriented perpendicular to sunlight

• Actual field performance varies with environmental conditions.

What is the efficiency of PowerFilm solar panels?

• Efficiency depends on panel architecture and active area utilization.

• Thin-film amorphous silicon panels are approximately 6% efficient under Standard Test Conditions (STC). Maxeon crystalline silicon panels exceed 24% under STC.

• Crystalline silicon provides higher conversion efficiency. Amorphous silicon may provide improved energy harvest in diffuse or variable light conditions.

How should a solar panel be positioned for maximum performance?

• Panels generate maximum output when oriented perpendicular to incoming sunlight.

• Output decreases as the angle of incidence increases.

How does temperature affect solar panel output?

• As cell temperature increases, panel voltage decreases and power output declines.

• Thin-film amorphous silicon panels exhibit a temperature coefficient of approximately −0.16%/°C.

• PowerFilm crystalline panels utilize Maxeon cell architecture with a temperature coefficient of approximately −0.29%/°C.

• System sizing should account for expected operating temperature and installation environment.

What is the recommended operating temperature range?

• Most encapsulated outdoor panels, including both thin-film and crystalline constructions, are rated for operation between -40°C and 85°C.

• Certain laminate or structural configurations may carry different limits. Refer to product-specific documentation for exact ratings.

How does partial shading affect panel performance?

• Typically, output is reduced proportionally to the shaded area for thin-film panels. Crystalline panels may experience more pronounced power reduction depending on string configuration.

When is a charge controller required with a solar panel?

• A charge controller is required when the panel output exceeds approximately 1/100th of the battery's watt-hour capacity.

• Controllers regulate charging and prevent overcharge conditions.

  
  

Are PowerFilm solar panels compatible with lithium batteries?

• Compatibility depends on system architecture and charge regulation.

• Both amorphous and crystalline panels may be used with lithium battery systems when paired with a lithium-compatible charge controller matched to panel voltage and battery chemistry.

• Charge controller configuration must support the target battery voltage, charging profile, and protection requirements.

What does an integrated charge controller mean?

• An integrated charge controller is built into the panel assembly and electrically matched to the panel output to regulate battery charging.

What is the difference between PWM, MPPT, and PowerBoost charge controllers?

• PWM controllers regulate voltage through pulse modulation, connecting the panel directly to the battery each cycle. This means the panel operates at the battery's current voltage rather than at its maximum power point.

• MPPT controllers track the maximum power point of the solar panel to collect the maximum amount of energy.

• PowerBoost charge controllers are application-optimized devices configured for a specific panel voltage and battery charge profile. When matched to known system parameters, they deliver MPPT-level performance at a cost comparable to traditional PWM controllers.

Can multiple PowerFilm solar panels be connected in parallel?

• Panels may be connected in parallel when voltage ratings match and wiring is properly sized.

• Connector and cable current limits must not be exceeded.

Can multiple PowerFilm solar panels be connected in series?

• Panels may be connected in series when system voltage requirements exceed the output of a single panel.

• Total open-circuit voltage must remain within the maximum input rating of the charge controller and all downstream components.

• Voltage matching and controller compatibility must be verified before integration.

Can PowerFilm crystalline and amorphous panels be connected?

• Panels may be connected in parallel if the voltage characteristics are compatible.

• Electrical matching should be confirmed before integration.

What connectors are used on PowerFilm solar panels?

• Connector type varies by product family.

• Thin-film portable panels commonly use Aptiv Weather Pack connectors.

• Crystalline Foldable panels use SAE connectors.

• SemiFlex panels use Aptiv Weather Pack connectors.

Does cable length affect system performance?

• Longer cable runs increase resistance and may reduce the voltage delivered to the load.

• The cable gauge should be selected based on current and distance.

What cable gauge should be used for solar panel connections?

• Cable gauge must support maximum system current with minimal voltage drop.

• 14 AWG or heavier is typically required for higher-current systems.

What cable gauge is required for higher-wattage panel systems?

• Systems above approximately 200W should use 14 AWG or heavier conductors to minimize voltage drop and prevent thermal losses.

• Cable sizing must match the maximum system current and run length.

What current limits apply to PowerFilm accessory cables?

• The RA-6-HD Daisy Chain Cable is rated for up to 20A.

• Most other standard accessory cables are rated for approximately 7A continuous current.

• Higher system currents require appropriately sized custom cabling.

Can a solar panel remain permanently connected to a battery?

• Panels with integrated blocking diodes or charge controllers may remain connected.

• Permanent installations should include appropriate regulation.

What happens if a charge controller is connected with reversed polarity?

• Reverse polarity may damage internal controller components.

• Immediately disconnect the controller and inspect the inline fuse. Replace the fuse only with the same rating. If output does not resume, the controller may require replacement.

How can I verify that a solar panel is producing power?

• Measure open-circuit voltage at the panel output using a voltmeter while under illumination.

• The measured voltage should be within approximately 20% of the published open-circuit voltage under similar temperature conditions.

How do I determine the appropriate panel wattage for my application?

• Panel wattage is determined by load profile, daily energy consumption, available sunlight, battery capacity, and allowable depth of discharge.

• System sizing should be based on measured load data whenever possible. Engineering consultation is recommended for custom programs.

How should PowerFilm solar panels be cleaned?

• Use a damp cloth with mild soap. Avoid abrasive materials. Allow panels to dry before storage.

How should PowerFilm solar panels be stored?

• Store clean and dry in a cool environment.

• Thin-film rollable panels should be rolled with the solar surface facing outward. Rolling the panel too tightly will likely reduce its effectiveness. The inner roll should measure at least 3” across (42 Watt Rollable (R-42) and 60 Watt Rollable (R-60) at least 5”).

• Battery-integrated systems should be stored at a state of charge above 50%.

Are PowerFilm solar panels waterproof?

• Ingress protection depends on the product family and construction.

• Rollable thin-film panels carry an IP67 rating. Other thin-film and crystalline products are designed for outdoor exposure but are not submersible unless specifically rated for submersion.

• Refer to product documentation for ingress protection classification and environmental limits.

What is the shelf life of butyl-backed panels?

• Butyl-backed panels have a 2-year shelf life when stored between 10°C and 27°C and at relative humidity below 75%.

How should a mounting surface be prepared for installing a butyl-backed panel?

• Clean the surface using greater than 90% isopropyl alcohol and ensure it is dry before installation.

Can I walk on a solar panel?

• Walking on solar panels is not recommended. Crystalline panels, including SemiFlex and other crystalline assemblies, contain silicon cells that point loads may damage. Thin-film amorphous silicon panels do not contain crystalline cells, but concentrated loads may still damage the laminate or electrical layers. Avoid applying body weight or localized pressure to any panel unless specifically designed for foot traffic.

Do you provide installation services?

• Installation services are not provided. Installation instructions and videos are available in product documentation.

What military or environmental standards do certain panels meet?

• Certain panels have been tested to MIL-STD-810G environmental conditions.

• Refer to product documentation for specific test parameters and certifications.

What operational impacts can solar have on transportation equipment?

• Solar may offset parasitic loads, reduce battery depth of discharge, reduce jump-start frequency, and reduce engine idle time.

• Documented field data is available upon request.

What size solar panel is typical for transportation applications?

• Panel size depends on the load profile.

• Common configurations range from 24W to 480W, depending on application and duty cycle.

How does solar perform in northern climates?

• Solar panels generate power whenever irradiance is present.

• System sizing should account for seasonal variations in irradiance and reduced winter daylight hours.

Will solar power an all-electric tractor or trailer?

• Solar panels are not capable of powering full electric propulsion systems.

• They are designed to support auxiliary loads and battery maintenance.

Does solar charge batteries independently of the alternator?

• Solar systems operate independently and regulate based on battery voltage.

• They do not interfere with alternator regulation.

Are charge controllers used in transportation systems waterproof?

• Transportation charge controllers are fully potted and may carry IP68 ratings depending on configuration.

• Refer to specific product documentation for ingress protection details.

How are Electronic Component Solar Panels electrically connected?

• Electrical connection methods include hand-soldered wire leads, conductive adhesive, spot-welded tabs, conductive epoxy, and mechanical connectors.

• Panels may be connected in series or parallel using wire jumpers.

• Electronic Component Solar Panels are not compatible with standard PCB reflow processes due to laminate encapsulation.

How can Electronic Component Solar Panels be mounted?

• Mounting methods depend on application and environmental requirements.

• Common methods include adhesive backing, epoxy, mechanical fasteners, heat shrink, vacuum lamination, or PCB attachment via conductive interfaces.

• Mounting strategy should account for thermal expansion, environmental exposure, and electrical isolation requirements.

Can Electronic Component Solar Panels be bent or formed?

• The allowable bend radius depends on the laminate selection.

• Typical limits are approximately 1-inch fixed radius and 3-inch repetitive bend radius.

• Improper bending may cause permanent electrical damage.

Are Electronic Component Solar Panels suitable for indoor or outdoor use?

• Suitability depends on product series and laminate selection.

• Indoor Light Series panels are optimized for artificial lighting.

• Classic Application Series panels are optimized for sunlight exposure.

• WeatherPro Series panels include UV-protected laminate and weather-sealed borders for outdoor use.

Can I purchase custom-sized Electronic Component Solar Panels?

• Custom sizes and configurations are available, including die-cut geometry, busbar exposure, laminate selection, adhesive backing, and contact configuration.

• Minimum order quantities and NRE fees vary by design complexity.

Can Electronic Component Solar Panels go through a PCB reflow process?

• Electronic Component Solar Panels cannot withstand standard PCB reflow soldering temperatures.

• Alternative attachment methods, such as hand soldering or conductive adhesives, must be used.

Where can Electronic Component Solar Panels be purchased?

• Electronic Component Solar Panels can be purchased in small quantities (100s) via DigiKey and Mouser, and in larger quantities (1,000s) directly from PowerFilm Solar.

• Engineering consultation is recommended for OEM programs.

What does semi-flexible mean?

• SemiFlex panels use crystalline silicon cells bonded to a structural fiberglass backing.

• Panels may be installed on surfaces with curvature no tighter than approximately 3-foot diameter.

• Panels must be installed against structurally stable mounting surfaces.

What type of solar cells are used in SemiFlex panels?

• SemiFlex panels use high-efficiency Maxeon crystalline silicon cells selected for electrical reliability and consistent performance.

What does an integrated charge controller mean for SemiFlex systems?

• An integrated charge controller is built into the panel assembly and electrically matched to the panel output to regulate battery charging.

• Controller configuration is specific to battery voltage and chemistry.

Are SemiFlex panels compatible with lithium batteries?

• SemiFlex systems with integrated 12V lead-acid charge controllers are compatible only with lithium batteries designed as drop-in lead-acid replacements with internal BMS.

• SemiFlex panels without integrated regulation require a lithium-compatible external controller.

Can I walk on a SemiFlex panel?

• Walking on SemiFlex panels is not recommended.

• Point loads may cause microfractures in crystalline cells.

Can multiple SemiFlex panels be connected?

• SemiFlex panels may be connected in parallel when voltage ratings match and wiring is properly sized.

• Connector and cable current limits must not be exceeded.

How can multiple PRESS panels be connected?

• Series connection is not recommended due to elevated open-circuit voltage.

• Parallel connection is permitted within specified limits and wiring ratings.

What charge controller should be used with the PRESS unregulated output?

• The selected charge controller must support at least 47.1V at the maximum power point and 58V at the open-circuit voltage, and be configured for the target battery chemistry.

• MPPT controllers are recommended.

What is the maximum number of PRESS panels that can be connected?

• Up to two units may be connected via a regulated output.

• Up to three units may be connected via the unregulated output, provided the connector current limits are not exceeded.

Can the PRESS be set at different deployment angles?

• The PRESS includes an adjustable stand allowing multiple deployment angles to optimize solar incidence.

Does the PRESS meet military environmental standards?

• PRESS panels have been tested to MIL-STD-810G environmental conditions.

• Refer to product documentation for specific parameters.

Which battery chemistries are compatible with the PRESS’s regulated output?

• PRESS regulated outputs are configured for 24V lead-acid battery systems.

• Lithium batteries designed as drop-in 24V lead-acid replacements are compatible.

What type of solar technology is used in Foldable panels?

• Foldable panels are available in both thin-film amorphous silicon and crystalline silicon configurations.

• Technology selection depends on the intended deployment environment and performance requirements.

Can Foldable panels be connected to Rollable panels?

• Panels may be connected in parallel only when the voltage characteristics match.

• Amorphous and crystalline panels typically have different operating voltage profiles and should not be connected unless electrical compatibility is confirmed. Mismatched voltages can reduce output and interfere with proper charge regulation.

What batteries can Foldable panels charge?

• Amorphous and crystalline foldable panels, when paired with a properly configured buck or boost charge controller, can charge 12V, 24V, 36V, 48V, and other voltage battery systems of varying chemistries.

• Battery chemistry compatibility depends on the charge controller configuration.

How should Foldable panels be deployed for best performance?

• Deploy panels flat and oriented perpendicular to incoming sunlight.

• Avoid shading and ensure ventilation during operation.

What is the allowable bend radius for Foldable panels?

• Foldable panels are designed to fold only along designated hinge seams.

• A safe bend radius for foldable panels would be greater than three inches.”

• The photovoltaic surface itself should not be creased.

What type of solar technology is used in Rollable panels?

• Rollable panels use thin-film amorphous silicon technology.

How should a Rollable panel be rolled and stored?

• Roll with the solar surface facing outward.

• Store clean and dry.

• Avoid tight radii beyond specified limits.

What batteries can Rollable panels charge?

• Rollable panels are designed for 12V lead-acid battery systems when used with appropriate regulation.

• Lithium batteries are compatible when paired with the proper charge controller.

What is the allowable roll diameter for Rollable panels?

• Rollable panels should not be rolled tighter than the minimum diameter specified in product documentation to prevent laminate damage.

What environmental rating applies to Rollable panels?

• Rollable panels carry an IP67 ingress protection rating.

What batteries are compatible with the PowerDrive panel?

• PowerDrive panels are designed for flooded, gel, and AGM lead-acid batteries.

• Lithium drop-in replacements for lead-acid with internal BMS are compatible.

What system voltages are supported by PowerDrive panels?

• PowerDrive panels support 36V and 48V battery configurations.

• Additional voltages may be available for custom programs.

Can the PowerDrive panel be installed on an existing canopy?

• PowerDrive panels use a snap-on mounting system and are designed for compatible existing canopies.

Does the PowerDrive panel charge independently of the vehicle charger?

• The PowerDrive panel charges independently of the vehicle’s plug-in charging system.

• Both regulate based on battery voltage.

How does the PowerDrive panel affect vehicle operating range and energy consumption?

• Under controlled testing conditions, supplemental solar charging extended operating time between plug-in charging cycles.

• By contributing energy directly to the battery system during vehicle operation or idle periods, the panel reduces the external energy required for recharging.

• Actual impact depends on irradiance, duty cycle, battery condition, and geographic location.

Does the PowerDrive system include charge regulation?

• PowerDrive panels charge through an external charge controller installed within the battery compartment.

• The controller regulates voltage to prevent battery overcharge.

How long does it take to charge the LightSaver from solar?

• Full solar charge typically requires one full day of direct sunlight (6-8 hours).

• Charge time increases under low irradiance conditions.

How long does it take to charge the LightSaver from a wall outlet?

• A full charge via micro-USB typically takes 3–4 hours, depending on the charger's output.

What devices can the LightSaver charge?

• The LightSaver charges USB-powered devices, including phones, cameras, lights, and similar electronics.

Can the LightSaver charge a 12V battery?

• The LightSaver is not designed to charge 12V battery systems.

• Use a regulated solar panel system designed for 12V battery charging.

What do the LightSaver indicator lights signify?

• Solid Red: Less than 10%

• Blinking Red: 10–50%

• Blinking Green: 50–90%

• Solid Green: 90–100%

• Blinking Green and Red: Thermal protection active

• Indicator LEDs illuminate during charging only.

How should the LightSaver be stored long-term?

• Store at a state of charge above 50%.

• Recharge at least every six months.

• Store in a cool, dry environment.

What temperature range is supported for LightSaver operation?

• Optimal operating range is 2°C to 45°C (35°F to 115°F).

• Lithium battery chemistry limits performance outside this range.

Can LightSaver products be transported on commercial flights?

• Battery capacity is below the 100Wh threshold commonly referenced in airline lithium battery policies.

• Confirm carrier restrictions before travel.

How should the LightSaver Max be charged?

• The LightSaver Max may be charged via the integrated solar panel, a 12V input, or a USB-C input.

• Ensure the solar panel is fully rolled when charging via wall or 12V input.

How long does it take to charge the LightSaver Max?

• Full charge typically requires 1-1.5 days of direct sunlight (10-12 hours), 3–4 hours via a 12V input, or 4–12 hours via USB-C, depending on the source current.

What USB and 12V devices can the LightSaver Max power?

• USB-powered electronics and 12V devices up to 30W continuous load are supported.

Are there limitations on USB chargers used with the LightSaver Max?

• The LightSaver Max draws 5V from USB sources and does not support USB-C power delivery protocols.

• High-voltage rapid chargers may not fully charge the unit.

What is the maximum input voltage for the LightSaver Max?

• Maximum input voltage is 28V.

What is the battery voltage when fully charged?

• The internal lithium-ion battery pack reaches approximately 8.4V when fully charged.

Why does the 12V output measure below 12V under load?

• A DC-DC boost converter generates the 12V output.

• Output voltage varies with load current and cable resistance.

How should the LightSaver Max be stored long-term?

• Store at a state of charge above 50%.

• Do not store under constant charge.

• Recharge every six months.

Can the LightSaver Max battery be replaced?

• The internal battery pack is not user-replaceable.

• Attempted replacement voids the warranty.

What are the 12V input and output connector sizes on the LightSaver Max?

• 12V input barrel connector: 1.3 mm ID × 3.5 mm OD

• 12V output barrel connector: 2.1 mm ID × 5.5 mm OD

What protection features are built into the LightSaver Max?

• The system includes internal protection circuitry for overcharge, over-discharge, overcurrent, and thermal protection.

What is the expected service life of the LightSaver Max battery?

• Lithium-ion battery life depends on charge cycles, storage conditions, and depth of discharge.

• Capacity gradually decreases over time with normal use.