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www.globalsolartechnology.comGloabl Solar Technology Volum

e 5 Number 1

January/February 2012

Volume 5 Number 1 January/February 2012

www.globalsolartechnology.com

The Global Journal for Solar and PV Manufacturing Professionals

Ferro coNducTiVe PaSTe deVeloPMeNTS iN coNTexTeFFicieNcy aNd yield iMProVeMeNTS • iMProViNG Solar Power iNVerTer efficiencies • Ge Gives thin film a really biG vote of confidence • smart sensinG of SeleNiuM

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Contents

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contentsVolume 5, No. 1

January/February 2012

EDITORIAL2 Goodbye 2011, hello 2012! Alan Rae

TECHNOLOGY FOCUS10 Critical factors to advances in solar battery storage Brent Ekiss, Fabrico technical specialist18 The future of the solar junction box: Intelligent and modular?20 Rapid-installation system for frameless thin-film photovoltaic modules Armin Barth and Michael Littig, Simrit, Solar Clip22 Increasing performance in anti-reflective coatings30 Performance and reliability testing of photovoltaic modules—insurance for your investment Sunny Rai and Dr. Paul Robusto, Intertek25 Efficiency and yield improvements with fab-wide process management software David Genova, Rudolph Technologies, Inc. SPECIAL FEATURES 6 ArrayPower—Inverting conventional wisdom8 Sollega racks up impressive performance figures9 CPV: Concentrating on excellence13 COP 17—What does it mean for Solar PV? A perspective from Noemie Bourdin of Upsolar14 Hanwha SolarOne—International integration15 And as the market goes more international, so does Power-One 16 Solar Frontier’s vision: Performance, reliability and sustainability

OTHER REGULAR FEATURES4 Industry news34 New products for integrators & installers36 New products for manufacturers 40 International diary

Visit www.globalsolartechnology.com for the latest news and more, every day.

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Alan RaeTechnical Editor

Editorial

Goodbye 2011,hello 2012!

This was another tough year for the solar PV industry internationally. Economic crises, changing government policies, FIT changes undermining solar installation economics, loan guarantee issues, high profile bankruptcies, including Solyndra and Evergreen, crises at industry leaders like First Solar—and many solar stocks down catastrophically on the year, losing two thirds of their value or more.

Global economics have a huge effect on the industry and the level of uncertainty is as high as it has ever been. The slowing economy in China, the Euro crisis, unrest and regime change in the Middle East and an election year in the USA which may have a huge influence on energy policy.

So what do we expect for 2012? Well, the hangover of subsidies that helped us limp through 2011 are evaporating. That’s the bad news. The good news is that module prices have dropped so far that solar power is really becoming an economic alterna-tive to traditional sources in an increasing number of areas.

There is a lot more good news.

Let’s talk about economics. The cost of solar installations is falling and continues to fall. This is the only energy source that is actually getting cheaper! Truly “clean” coal is uneconomic (and we are still not sure where to put the carbon dioxide when we capture it), nuclear is challenged by the fallout from Fukushima, wind energy is actually getting more expensive as we move offshore. Natural gas is both a friend to solar (balancing output variations) and a foe (used as a political tool to halt alter-native energy subsidies) as more and more countries realize their previously uneco-nomic gas reservoirs can be accessed by horizontal drilling and hydraulic frac-turing “fracking”—but even this practice is controversial due to environmental management issues. Oil—too expensive now unless there is no alternative—and bets are off as to the situation in the Middle East next year. Hydro—we’ve dammed

about all we can dam. Tidal and other sources—still under development.

It’s not just about cells—module costs, installation costs, and paperwork (some-times costing as much per watt as the module itself!) are all being challenged.

We see a big vote of confidence for thin film PV modules in the Department of Energy’s SunShot program and in GE’s new 400MW thin film plant in Aurora, Colorado. We see creative solutions in the partnerships between module manufac-turers, inverter and micro-inverter makers, and racking suppliers to reduce cost and ease installation. And integrated solar shingles for roofing are now appearing on new construction. The SunShot program is looking at how to smooth the paperwork issues to reduce time and cost.

The other realization that is coming to the surface is that solar does not always have to be in a remote location (although solar farms will have a strong role to play). Decentralized commercial rooftop loca-tions in and near cities can make a huge contribution to supplying peak summer loads without requiring new grid infra-structure and can be a relatively rapid way to balance supply and demand.

Bearing these considerations in mind, the consensus view of companies I talked to recently was that we need to get through 2012—but 2013 will be where we really see the uptick.

If GE and Warren Buffett are both investing big in solar—and they are—that’s really positive! Neither are short term players.

Here at Global Solar Technology we wish all our readers a successful 2012. You will find great information in these pages that will help you make the success you deserve. Hang in there!

— Alan Rae

Heraeus PV silver paste. Make your profits rise like the sun.Heraeus’ industry-leading silver pastes are especially formulated to increase the efficiency, performance and output of your solar cells—while reducing your cost-per-watt. Our R&D staff continues to reduce the silver content and improve paste coverage of our front-side and back-side pastes, thereby lowering your production costs.

Our front-side pastes are customizable to meet your individual requirements. We also introduce several new formulations each year for advanced cell designs, such as MWT, High Sheet Resistance, Selective Emitter and N-Type cells, as well as a new series of pastes for low temperature processing. Our back-side pastes also provide low cost and optimized adhesion characteristics.

With production facilities in Asia, Europe and North America, Heraeus is capable of supplying your production needs—whenever and wherever you need us.

Visit our booth at these upcoming trade shows: International Green Energy Expo Korea 2012 March 28 – 30 • Booth A-510

SNEC 6th (2012) International Solar Industry and Photovoltaic Exhibition May 16 – 18 • Hall W3, Booth 250

Heraeus PV Business Unit www.pvsilverpaste.com +1 610-825-6050 [email protected]

12-HMT-012 • Global Solar Southeast Asia Magazine • 8” x 10.8” • Insertion: January/February 2012

12-HMT-012_Global Solar Southeast Asia-JanFeb.indd 1 2/1/12 9:39 AM

Heraeus PV silver paste. Make your profits rise like the sun.Heraeus’ industry-leading silver pastes are especially formulated to increase the efficiency, performance and output of your solar cells—while reducing your cost-per-watt. Our R&D staff continues to reduce the silver content and improve paste coverage of our front-side and back-side pastes, thereby lowering your production costs.

Our front-side pastes are customizable to meet your individual requirements. We also introduce several new formulations each year for advanced cell designs, such as MWT, High Sheet Resistance, Selective Emitter and N-Type cells, as well as a new series of pastes for low temperature processing. Our back-side pastes also provide low cost and optimized adhesion characteristics.

With production facilities in Asia, Europe and North America, Heraeus is capable of supplying your production needs—whenever and wherever you need us.

Visit our booth at these upcoming trade shows: International Green Energy Expo Korea 2012 March 28 – 30 • Booth A-510

SNEC 6th (2012) International Solar Industry and Photovoltaic Exhibition May 16 – 18 • Hall W3, Booth 250

Heraeus PV Business Unit www.pvsilverpaste.com +1 610-825-6050 [email protected]

12-HMT-012 • Global Solar Southeast Asia Magazine • 8” x 10.8” • Insertion: January/February 2012

12-HMT-012_Global Solar Southeast Asia-JanFeb.indd 1 2/1/12 9:39 AM

4 – Global Solar Technology – November/December 2011 www.globalsolartechnology.com

industry newsIndustry news

industry newsIndian CSP heavyweights gearing up for New Delhi summitGodawari Green Energy Limited (GGEL) and Reliance Power are two companies leading the way in commercializing CSP in India, with 150MW in progress. Both will be providing exclusive updates on their Phase I projects under the National Solar Mission at the 3rd CSP Today India Summit 2012 (14-15 March, New Delhi).

From an industry perspective, the overall progress made by project developers in Phase I has been heavily scrutinized in recent months, and with the project completion deadline now almost a year away, the impact that current projects have had on future industry growth will form a critical part of the debate in New Delhi. www.csptoday.com/india

Failure of government appeal creates solar gold rushSolarlec is experiencing a gold rush after the government lost its second appeal to reduce subsidies paid to consumers.

The court of appeal ruled that the govern-ment acted unlawfully by attempting to reduce the feed-in tariff ahead of the original April deadline.

This has left consumers with a possible window of opportunity to take advantage of cheaper panel prices, as the feed-in tariff may remain at its highest ever rate, before it is halved on March 3rd. Consumers who buy now will potentially secure the high rate for 25 years. www.solarlec.com

North American utility-scale PV installations surge in Q4’11Sharp reductions in market prices, combined with the impact of regional and national policies, pushed the North American photovoltaic (PV) market to a new quarterly peak with 0.93 GW installed in Q4’11, according to the latest North American PV Markets Quarterly report issued by NPD Solarbuzz. The solar incen-tive policy mix in both the United States and Canadian markets drove up demand in large-scale ground-mount systems, which was 59% of this total. Regionally, the New Jersey, California, Arizona, and Ontario accounted for two-thirds of Q4’11 demand. www.solarbuzz.com

California remains number 1 in the US solar industryWith around a gigawatt of newly installed capacity, the state of California was last year’s leader in the US solar industry. The sunshine state will continue to play a leading role—not least because of numerous technological innovations that originate here. However, it is vital for any companies that want to engage in the Californian market to be active locally. The “Inverter and PV System Technology Forum—USA 2012” conference, taking place on 27 and 28 February 2012 in San Francisco offers an ideal opportunity for discussion and forging new contacts.

PPG to make SOLARPHIRE PV glass at Fresno plantPPG Industries’ flat glass business will expand production capability at its Fresno, California plant to accommodate the manufacture of Solarphire PV glass, an ultra-low-iron glass used to make compo-nents for the solar power industry.

Richard A. Beuke, PPG vice president, flat glass, said the production of Solarphire PV glass at the Fresno Works will make PPG the first and only manufacturer of low-iron glass on the West Coast and dramatically enhance the company’s ability to serve the region’s burgeoning solar power market. www.ppgideascapes.com

Solar industry announces awards for excellence in utility-scale solar power generationSolar Power Generation USA has announced the winners of its Solar Power

Generation Awards. The 2012 winners in the four categories are First Solar, Inc. for PV Project of the Year, the Ivanpah Solar Electric Generating System for CSP Project of the Year, Kaua’i Island Utility Cooperative for Solar Utility of the Year, and Soitec for CPV Breakthrough Achievement of the Year. These awards, chosen by the industry, recognize achievements in the field of utility scale solar power generation in the US. www.solarpowergenerationusa.com

Novel cell designs for more efficient solar cellsScientists of the Fraunhofer Institute for Solar Energy Systems (Fraunhofer ISE) developed a crystalline solar cell with efficiency greater than 20 percent using Heraeus metallization pasteInnovation and material technology are the keys to success for increasing the efficiency of solar cells. For the first time ever, scien-tists accomplished the development of an industry-scale c-Si solar cell with an effi-ciency greater than 20 percent. The record cell is based on the combination of two cell design technologies: MWT and PERC. www.ise.fraunhofer.de

Chinese PV equipment suppliers grab further market-share gainsAmbitious PV manufacturing capacity investments across the Asia Pacific region during 2011 have provided substantial revenue growth for local PV equipment suppliers, according to the latest NPD Solarbuzz PV Equipment Quarterly report.

Beneficiaries of these record investments include Japanese wire-saw producer

Industry news

Global Solar Technology – November/December 2011 – 5www.globalsolartechnology.com

Industry news

Komatsu-NTC and an emerging group of Chinese tool suppliers that includes (Fujian) Apollo, 48th Research Institute (CETC-48), (Zhejiang) Jinggong, and Jingyuntong (JYT). Collectively, these four Chinese companies have posted a CAGR metric in excess of 200 percent for PV-specific equipment revenues covering the period from 2008 to 2011.

Applied Materials (AMAT) is forecast to retain the top spot as leading PV equipment supplier by recognized revenues. AMAT’s c-Si specific PV revenues for CY’11 are forecast to grow by more than 60 percent, as process tools for wafer and back-end cell production were widely implemented throughout all geographic regions and tier categories. www.solarbuzz.com

Wells Fargo to fund $100 mn for solar PV projects developed by EnfinityWells Fargo & Company and Enfinity America Corporation have got into a joint program through which Wells Fargo will provide up to $100 million for solar photo-voltaic (PV) projects developed by Enfinity. Financing provided by Wells Fargo will enable Enfinity to cost-effectively provide a clean and reliable source of electricity to its customers and support its growing pipeline of distributed generation and utility-scale projects throughout the United States. www.enfinitycorp.com

SolarCity allows homeowners and businesses in Connecticut to install Solar for freeSolarCity, a national leader in clean energy services, is expanding to Connecticut to make it possible for many homeowners and businesses to install solar panels for free and pay less for solar electricity than they pay for utility power. SolarCity is expanding to Connecticut in large part due to the efforts of the state—through programs at Connecticut Clean Energy Finance and Investment Authority (CEFIA) and the Department of Energy and Environmental Protection (DEEP) to promote, develop and invest in clean energy and energy effi-ciency projects. www.solarcity.com

npower installs solar power at Birmingham Airportnpower will help Birmingham Airport to save 22 tonnes of carbon dioxide each year with the installation of 200 solar panels on the roof of its terminal. The 1.6 m x 1 m panels will generate 40,000 kWh a year; sufficient to power 12 average sized houses.

The airport has worked in partnership with npower to install the 50 kpw solar photo-voltaic (PV) systems to provide renewable green energy on-site as it reduces its depen-dency on mains power electricity. www.npower.org

Honda begins installation of solar power generation Systems at automobile dealership locations in JapanHonda Motor Co., Ltd. has a 9 kilowatt-capacity solar power generation system at the Adachi Odai location of the Honda Cars Tokyo Chuo dealer network. The installation kicks off a project to install Honda Soltec solar power generation systems with a total capacity of 1 megawatt at Honda automobile dealership locations in Japan by March 31, 2014.

Striving to realize a low carbon society, Honda has been installing solar power generation systems at Honda operations in Japan. The combined capacity of solar power generation systems installed to date has reached 3.3 megawatts, the largest in Japan among all automakers oper-ating. www.honda.com

Growth in PV brings new opportunities for the solar industry2011 was a record year both for Intersolar Europe and the international solar industry, with the expansion of newly-installed photovoltaic capacity reaching a new high. With 18 billion kilowatt hours (kWh) of solar power generated during the year, 2011 saw photovoltaics conquer a larger share of the German energy production market than hydropower for the first time. The increasing market share occupied by solar power highlights the opportunities that could be enjoyed by the technology in future energy supply. In order to exploit these opportunities effectively, the solar industry is working at full steam to create new solutions, such as grid integration and energy storage systems.

South Africa: Solar investment appealThe recent increase in South Africa’s power tariffs in, together with greater policy and regulatory certainty has made the country a more attractive renewable energy invest-ment prospect than ever. Independent Power Producers (IPPs), both in Europe and on the greater African continent, are clamoring to enter the next big CSP market. For its part, South Africa’s government is energetically encouraging

external investment into its local renewable energy industry.

The South African Government’s commit-ment to the liberalization of the elec-tricity supply industry is reflected in the Department of Energy’s (DoE) mandate that IPPs contribute 30 percent of new generation capacity by 2030. www.csptoday.com/southafrica

Solar thermal technology developed by Southwest Solar Technologies, Inc.Southwest Solar Technologies Inc. informed its development program for a solar thermal technology that will serve industrial needs for process heat and steam. The solar thermal application leverages the company’s solar dish and other core competencies and will be a new addition to its product portfolio.

The system uses a parabolic solar concen-trating dish to focus sunlight into a high temperature thermal cavity receiver which heats water or thermal oil to transfer heat to conventional heat exchangers located on the ground. The system would typically be used to reduce costs by supplementing or displacing another fuel source such as natural gas. One or more dishes can be commissioned depending on user needs. www.swsolartech.com

Potential for photovoltaics in Germany could be up to 200 Gigawatts“Nobody had expected that the German solar market for 2011 would turn out so well”—this was the unanimous verdict of those at the “2nd Inverter and PV System Technology Forum 2012” that took place January 23-24. At the end of the year, of the total installed capacity of 24 GWpeak in Germany, 7.5 gigawatts were added in just the last year. This doesn’t only bring new challenges for the grid infrastructure—as extensively discussed in the media—but also for the entire photovoltaic system. Technical solutions for dealing with the rapid growth of solar energy were discussed by around 200 experts in Berlin.

6 – Global Solar Technology – January/February 2012 www.globalsolartechnology.com

We talked to Wendy Arienzo, CEO and Nick Cravalho, VP of business development at

ArrayPower to understand their new and different inverter technology.

Tell us a bit about the companyIt was founded—in a garage—in 2008 by a ham radio enthusiast, a telecom expert and a power electronics expert. It received its first funding in 2009 and we changed the name from Array Converter to ArrayPower to underscore the fact that we are really a power electronics company. Our IP is all internally generated.

TechnologyOur emphasis is to simplify and use well proven technology from other industry areas to maximize efficiency and reliability, and to use a leading EMS contract manu-facture to ensure reliable low-cost perfor-mance.

Existing inverter technologies are inher-ently complex and failure-prone, relying on components that can wear out or break—including electrolytic capacitors, optocouplers, varistors and cooling fans. Conventional systems contain hundreds of single points for possible failures, each of which can bring down an entire instal-lation.

Our sequenced inverter is radically different from these technologies in that each sequenced inverter in a system operates autonomously. The high-frequency, amplitude-modulated current pulses from the sequenced inverters synchronize with the frequency of the grid and then are sequenced by time-shifting relative to one another. They are connected in parallel and thus eliminate the risk of a single point of failure. When combined, the result is a smooth, synthesized AC wave— grid-quality, three-phase power suitable for commercial and industrial applications.

By distributing the inverter function across the full array of equipped AC modules in a system, the work of each s e q u e n c e d inverter is simplified. This creates an overall system architecture that is less costly and more reliable. The ArrayPower sequenced unverter is also designed to vastly reduce the amount of energy storage required for operation, replacing expensive and failure-prone capacitors used in conven-tional inverters with rugged iron-and-copper inductors. Sequenced Inverters are thermodynamically optimized to ensure cool operation, and are made from industrial-strength components to reduce heat sensitivity and eliminate the need for cooling fans. Unlike conventional inverters, sequenced inverters offer exceptional surge survivability and are designed to last for decades. Because of their robust design and durable components, Sequenced inverters have projected lifetime failure rates comparable to those of solar modules, based on extensive expert review and third-party testing.

With a truly parallel architecture and a distributed design with no single point of failure, systems incorporating sequenced inverters are highly tolerant of shade and module mismatches, improving overall energy yield and system reliability. The design is also inherently safe, with a low-voltage operation that reduces risk for installers, maintenance workers and first responders.

cost eliminationWith an integrated design that does away with the DC junction box and the associ-ated cables and connectors required for a conventional DC module, ArrayPower’s technology makes it possible to produce modules that arrive at the job site precon-figured and preassembled, needing only to be linked together and connected to the grid. The benefits of this simplicity cascade

ArrayPower—Inverting conventional wisdom

Up to 40 ArrayPower sequenced inverter-equipped AC modules can be connected in parallel on a single three-phase AC branch circuit. The amplitude-modulated current from all AC mod-ules is combined in a sequenced manner to synthesize grid-quality, three-phase AC current.

arrayPower—inverting conventional wisdom

Wendy Arienzo Nick Cravalho


down through the value chain: Module manufacturers can reduce their parts count and offer installers faster and easier system setup. Installers do not need to deal with high voltage DC.

The distributed architecture also greatly increases design and installation flexibility while simplifying cable management. An ArrayPower-based system can accommo-date up to 40 Sequenced Inverter-equipped AC modules on a single branch circuit, making scalability simple and reducing the number of cables in a system. The design flexibility of sequenced inverter-equipped AC modules allows for maximum utiliza-tion of the available rooftop area, resulting in more installed solar capacity per rooftop.

ScalabilityOur “sweet spot” is commercial installa-tions that use a 3-phase supply. Our system is extremely scalable to match clients’ infrastructure limitations and power needs.

efficiencyThat’s a really interesting question as most microinverter companies are vying for energy harvesting bragging rights! It’s not easy to make apple to apple comparisons. You obviously need to be above 95% but you need to incorporate the losses from the whole system, not just the inverter and

include uptime and other factors.how will your product be rolled out?We have partnered with a leading module manufacturer and will be selling product in 2012. We already have systems in the field in Frankfurt, Germany and Davis CA with more on the way.

To learn more about ArrayPower’s novel approach, visit www.arraypower.com.

Wendy Arienzo has extensive experience in the technology development sector, bringing 30 years of technical and management expe-rience in the semiconductor industry to her current position.

Previously, Arienzo worked at some of the leading companies in the technology industry, including IBM, Phillips and NXP Semiconductors. Arienzo began her career in the solar technology development field developing polycrystalline silicon cells in Florence, Italy.

Arienzo has received numerous accolades for her accomplishments and is a sought-after public speaker in the technology sector. She has been recognized by the New York State Department of Environmental Conservation and the Center for Economic Growth, a non-profit based in New York state promoting

economic growth throughout the state’s capital region.

Arienzo holds a doctorate in materials science and engineering from Stanford University. She received her combined bach-elor’s/master’s degree in materials science engineering from Brown University.

Nick Cravalho brings extensive knowledge of the solar industry and key markets in Asia to his position at ArrayPower. He has expertise bringing innovative technologies to market both as a technologist and as a business professional.

Prior to joining ArrayPower, Cravalho was vice president of business develop-ment and marketing at Innovalight. He has also worked at Miasolé, Kiva Systems and Applied Materials.

Cravalho received his master’s degree in management and engineering from the Sloan School of Business and the School of Engineering at Massachusetts Institute of Technology, and he received his bachelor’s degree in mechanical engineering from the University of California at Berkeley.

A solar PV system based on AC modules equipped with ArrayPower sequenced inverters™ eliminates the complexity found in conventional DC systems. This reinvisioned system produces grid-quality AC power internally, meaning it can be connected to the grid simply by connecting an AC cable.

The smallest increment of solar modules that can be added to a DC system is typically fourteen. For an ArrayPower enabled AC system, the smallest increment of modules that can added to the system is one. Therefore, the ArrayPower system allows a commercial roof to be fully packed with modules and greatly reduces the design and installation time.

ArrayPower—Inverting conventional wisdom


how did you enter this business?We started by distributing other’s products and saw a need for a high performance easy-to –install ballasted system. We talked to membrane manu-facturers and determined what was needed to make the right interface with the membranes to preserve roof integ-rity and maintain membrane warranties. We spent a lot of time on the roof with installers learning their issues.

can you describe the system?It’s available in 10 degree and 15 degree versions and is adaptable to modules of different sizes, for example the 15-degree system fits lengths between 65 and 69 inches and widths between 30 and 42 inches. Each panel has two HDPE supports that are ballasted with ASTM C1491 roof pavers.

how is it easier to use?The module is front hinged so can be carried and mounted by one person.

The back attachment is threaded so that applying the retaining nut is also easy. Only one tool is needed. Labor costs are cut by 50% and the use of standard pavers as ballast is another cost and time savings.

and green?The HDPE is 35% reground and fully recyclable. All metal parts are galva-nized, stainless steel or aluminum. There’s a 25-year warranty.

how about your wind rating of aSce 7-05, 120 mph?Roof conditions vary, with lower wind speeds at roof center and highest loads at the edges. If we are installing in areas with extremely high wind speeds the

racks can be bolted down if necessary along the roof edge.

Now that the module cost is typically about 1/5 of the cost of an installed system in the USA, the pressure to reduce installation costs will increase and Sollega’s solution is a clever way of addressing the problem by meeting both installers and roof membrane manufacturers’ needs.

Sollega racks up impressive performance figures

Sollega racks up impressive performance figures

At SPI we saw a strong focus on racking solutions. We had an opportunity to talk to John

Humphret, Sollega’s president and co-founder, about their InstaRack™ ballasted system.

The InstaRack ballasted solar racking system is designed to reduce labor and shipping costs for low-slope flat roof solar installations. It’s manufactured from HDPE (high-density polyethylene) utilizing 35% recycled content with a built in UV inhibitor. InstaRack is available in tilt angles of 10° and 15°. The modular design ensures

compatibility with all solar panels 30 inches to 44 inches in width. Its

one-piece molded unit design requires only one tool for installation, and uses readily available rails. The Sollega QuickSnap,

a new attachment method for PV modules developed in partnership, clips on the edge of the module with no hardware and snaps into the strut. The InstaRack is wind tunnel tested to 120mph. Sollega provides array layout, design engi-neering services, as well as wind and ballast calculations.


how is your product different than most cPV systems?We have chosen our materials for high durability, using aluminum and glass. Our panel back is a single pressing, ensuring low cost of production and high dimensional stability as it is also a heat sink. Because of our mirror concentration system, we have a high light acceptance angle of 1.6˚, much higher than the normal 0.25 to 0.5˚. This is important in manufacturing, deploy-ment and use in say, windy conditions. Our primary and secondary mirror system reduces the depth of the modules, reducing shipping cost, weight and materials cost. Finally our system can incorporate future cell structures readily whereas Fresnel systems may need modification.

what is your manufacturing process?Highly automated. Three robots attach the mirrors to the glass and the cells to the panel back, then they are brought together

to form the modules. We manufac-ture in Southern California and are expanding there.

how about trackers?We bought a Spanish tracker company that was not yet industri-alized and have incorporated that into our designs.

what is your installed base?8 MW in the ground, with 50 MW in construction, 30 MW coming on stream in San Diego in December/January. We expect a total of 150 MW in 2012. SolFocus products can be seen operating in Arizona, Colorado, California, Hawaii, Italy, Portugal, Greece, Spain, Australia, Saudi Arabia, South Africa and Malaysia. SolFocus CPV systems are certified to the rigorous standards of IEC 62108, and are backed by Munich Re performance insur-ance.

what is the panel output?Each panel in our recently announced SF-1136SX system is 432W, 30% efficient and they are arrayed 9 x 4 on the tracker to give a total of 15.6 kW per tracker. Our new systems require about four acres / MW, down from six acres per MW with the previous version.

how about maintenance?We have an analytical team measuring performance and we are averaging 100.2% of nameplate performance. Washing is needed about four times a year, mainly in the summer, with four gallons of water per MW. We have been pleased to see the natural ecosystem being restored rapidly under the trackers after the normal construction disruption.The SolFocus display and the quality of the modules was in sharp contrast to some of the other CPV booths at SPI. If you are considering CPV, SolFocus is worth serious consideration.

cPV: concentrating on excellence

The concentrated photovoltaics (CPV) area is a growing area and we had the opportunity at SPI to talk to one of the most innova-tive companies in this field, SolFocus. Nancy Hartsoch, their VP of marketing and business development, took us through their booth and products.

CPV: Concentrating on excellence


As integration of renewable energy into the electrical grid evolves, one of the major challenges is the vari-

ability of renewable energy sources. It’s not just the magnitude of the change—from full power to zero power—it’s also the time—sometimes mere seconds. To solve this, energy storage technologies are receiving close scrutiny.

Energy storage options include transmis-sion level storage, such as pumped hydro-electric, compressed air electric storage, and flywheels. Distribution level storage includes conventional batteries, electro-chemical flow batteries, and supercon-ductor magnetic energy storage.

At the grid level, the current breakdown in the types of storage technologies includes about 21 gigawatts of pumped hydro, a few hundred megawatts using compressed air electric storage, and tens of megawatts of battery storage.

Storage provides both energy manage-ment and spike power. Spike power may only occur for short periods of time to assure continuity of power quality, or to bridge power levels when switching from one power source to another. In managing energy, storage is used to decouple the generation of power from the consump-tion of power. For example, in solar appli-cations, power is generated during the day but is also consumed at night when no power is being generated.

Typical utility energy storage applications can include: peak shaving, load leveling, demand response, outage protection, and grid power quality control. Peak shaving minimizes demand charges for a commer-cial customer or reduces peak loads experi-enced by the utility. Peak shaving requires that the renewable energy source provide the power above a certain threshold and

offer adequate energy storage to fill the gap if renewable is not available. To accom-modate peak shaving, power from energy storage must be available when the renew-able/solar system is unable to meet load.

Load balancing, or load shifting, requires that stored power be available during peak loads that occur after peak solar genera-tion hours have passed, for example at night or late in the day. Demand response allows utilities to meet the needs of high-demand devices, for example air condi-tioners, during high-demand periods. Energy storage is critical to implementing demand response strategies to ensure that adequate power is available.

Outage protection ensures that stored energy is available when for some reason, the grid experiences and outage. Grid power quality control uses energy storage to ensure constant voltage, phase angle adjustment, and the removal of extraneous harmonic content from the grid. Efficient energy storage can help deliver high quality power and avoid problems, such as voltage sag.

For renewable energy sources including solar, new advances in battery technology are being investigated for use in grid and off-grid applications. The global energy storage market is estimated to grow from approximately $329 million in 2008 to $4.1 billion by 2018, according to a Pike Research report. This makes the topic of energy storage of extreme importance to generators and users alike.

Those engaged in renewable energy projects are looking for batteries to become more powerful and less costly. In general, batteries need to be able to hold more charge and last through more charge/discharge cycles.

Critical factors to advances in solar battery storage

critical factors to advances in solar

battery storage Brent Ekiss, Fabrico technical specialist

As renewable energy sources, including solar, continue to connect to the grid, balancing power supply and demand becomes ever critical. Energy storage becomes key in offset-ting the fluctuating nature of PV and wind generation. Without improved energy storage capabilities, renew-able energy tied to the grid remains a limited resource that will require back-up from traditional, fossil fuel-based generation facilities. Improvements in battery storage technology require addressing thermal manage-ment, electrical insulation, and EMC/EMI shielding issues. An experienced con-verter can work with battery manufacturers to provide the right materials to meet these needs.


Effective energy storage that can match total generation to total load will allow utilities to compensate for changes in solar and other renewable energy contribu-tions over both the short and long-term. Fossil fuel plants have to scramble to come online and can take as long as 10 minutes in an emergency. Stored renewable energy would be available in seconds and produce no emissions.

Battery typesThere are several battery technologies in use or being investigated for renewable energy applications. All of these technolo-gies are deep-cycle in nature; they can be discharged thousands of times. They include:• Sealed lead acid • Nickel cadmium• Nickel metal hydride• Nickel iron• Zinc-air• Lithium-ion• Lithium polymer

Sealed lead acid (SLAs) batteries are a familiar technology, essentially car batteries. They are maintenance free, but have a shorter lifespan than other batteries. They are deep-cycle batteries and are the oldest battery technology in use. SLAs are inexpen-sive, charge more slowly than other battery technologies, provide larger amounts of power, and are very tolerant of overcharging and undercharging. A bank of SLAs might need to be replaced every ten years or less. SLAs represent cost-effective, mature tech-nology that is relatively efficient.

Nickel cadmium and nickel metal hydride technologies are similar, with nickel cadmium the older technology. While a

“greener” technology, nickel metal hydride batteries have a higher rate of self-discharge than nickel cadmium, with approximately 30% power lost within one month. They also take twice as long to charge as nickel cadmium or lithium-ion. Nickel cadmium and nickel metal hydride both provide good energy density, have a long shelf-life, and can take abuse, but are fairly expensive.

Nickel iron batteries can last as long as 40 years, contain no environmentally damaging or poisonous elements; however, they fell out of use due to their high cost of manu-facture. Now they are being investigated again, primarily due to their long cycle life. No emissions, high energy density, and low maintenance make this technology inter-esting despite the high price tag.

Zinc-air batteries are non-rechargeable but have a long life. Zinc chemistry provides, for low cost, high energy density and stable power output. Zinc-air batteries are arguably the “greenest” battery technology available.

Lithium-ion and lithium polymer batteries have very high charge densities which allow them to pack a lot of power into a very small size. Lithium-ion and lithium polymer batteries are beginning to grow in popularity due to the following character-istics:

• Twice the energy density of nickel-cadmium;

• Good load characteristics;• High individual cell voltage;• Low maintenance and long life;• Millisecond response time

and power capability in charge and discharge;

• Rechargeable and can be safely disposed.

However, despite their overall advantages, there are some drawbacks. Lithium-ion is fragile and requires a protection circuit to maintain safe operation. Cell temperature

must be monitored to prevent extremes. Beyond the acceptable range, lithium-ion batteries have a tendency to break down. Aging can also be a concern.

T h e r m a l m a n a g e m e n t , electrical insulation, and eMi/eMc shieldingIn general, all battery technologies require thermal management, electrical insula-tion, and EMI/EMC shielding. By working with an experienced converter such as Fabrico, battery manufacturers can gain insight into adapting their technologies to meet the unique requirements of the solar market.

Designing a battery to perform at optimal levels in a renewable energy application requires dealing with critical considerations, such as:

• Using interface material to remove/dissipate heat;

• Introducing an electrical insula- tor;• Maintaining proper electrical

contact;• Shielding from debris and envi-

ronmental conditions.


Lithium-ion batteries provide twice the energy density of nickel-cadmium, but require close thermal management.



Thermal managementFabrico converts a wide variety of ther-mally conductive materials for the disper-sion of heat in temperature-sensitive battery applications. Thermal manage-ment material helps transfer heat away from components into heat sinks or the ambient environment, or spread excessive heat in one area across the surface of an assembly where it can be further dissipated. Fabrico teams with device engineers early in the design process to determine the proper material(s) and process necessary to fully manage the thermal challenge. For example, lamination with other materials is frequently required for structural and elec-trical insulation purposes, or to provide a multi-purpose thermal and moisture management layer. Materials can also be custom die-cut to fit the design footprint. Fabrico also specializes in creating retrofit solutions for thermal management needs that become evident once the device is in the production process.

For example, in one battery application, Fabrico applies silicon sponges to the battery pack’s cooling bar tube or heat sink to improve heat transmission between the cells and cooling bar. The sponge material improves the contact surface between the rounded cell and the flat metallic cooling bar. In addition, the sponge material is

compression set resistant to protect the cells from shock and vibration over an extended product life. The material also has good dielectric properties.

Heat absorption is especially critical in battery pack applications as batteries become larger and more powerful. Lithium-ion batteries require stringent temperature controls to keep them from failing. The sponge material is able to withstand high temperatures—up to 400°F (204°C). Its excellent thermal conductivity enhances battery performance, extends the useful life of the battery, and increases safe operation.

As batteries and battery packs become more condensed and more powerful and the solar industry investigates different battery technologies, heat absorption and dissipation become critical to keep batteries from failing.Fabrico stocks numerous thermally conductive materials from 3M™, DuPont, Chomerics, Laird, and Von Roll. These products can be electrically conductive or electrically isolating.

electrical insulationFabrico can provide a broad range of elec-trical insulation materials that are die-cut to meet a variety of size/shape require-

ment for battery applications. After inves-tigating, testing, and acquiring the proper quantities of raw material for a given appli-cation, Fabrico processes them with close-tolerance slitting, sheeting, cut-to-length, die cutting, edge taping, traverse winding, heat forming, cuffing, and printing.

Insulation products, which include both discrete and multilayer custom parts, are designed and manufactured to meet material specifications such as dielectric strength, temperature resistance, and resis-tance to tearing and puncturing during the assembly process. Fabrico provides end products to battery manufacturers in various forms, including sheets, slit rolls, traverse-wound spools, and fabricated parts, from electrical grade papers, films, coated fabrics, laminates, and electrical tapes specifically for electrical insulation.

eMc/eMi/rFi shieldingFabrico assists electronic engineers in complying with EMI/RFI shielding requirements for increased product func-tionality. Materials include electrical tape with aluminum and copper backings for grounding, bonding, and EMI shielding. Conductive and nonconductive adhesive systems are available. Fabrico offers numerous EMI and RFI shielding converted materials. These mate-rials are die-cut into shapes or laminated to other products to meet the requirements of the application, including a range of thermal management and electrical insula-tion properties required for battery appli-cations.

conclusionSolar battery storage technology is a critical component in every solar power system that hopes to penetrate the grid. Whichever battery technology becomes dominant, effective electrical and EMC insulation materials and heat dissipation materials are key to successful implemen-tation. Flexible materials converters can help solar battery manufacturers in three key areas: electrical insulation, thermal management, and EMC/EMI shielding.

Fabrico works with design engineers to include effective EMI/EMC shielding.


Countries meeting in Durban, South Africa in December delivered what appeared to be a breakthrough agreement on the future of the international commu-nity’s response to climate change at the Durban UN Climate Change Conference (COP17/CMP7).

In Durban, governments decided to adopt a universal legal agreement on climate change as soon as possible, but no later than 2015. Work will begin on this imme-diately under a new group called the Ad Hoc Working Group on the Durban Platform for Enhanced Action.

Many governments, including 35 indus-trialized countries, agreed a second commitment period of the Kyoto Protocol from January 1, 2013. To achieve rapid clarity, Parties to this second period will turn their economy-wide targets into quantified emission limitation or reduction objectives and submit them for review by May 1, 2012.

A significantly advanced framework for the reporting of emission reductions for both developed and developing countries was also agreed, taking into consideration the common but different needs and responsi-bilities of different countries.

Whilst pledging to make progress in a number of areas, governments acknowledged the urgent concern that the current sum of pledges to cut emissions both from devel-oped and developing

c o u n -tries is not high enough to keep the global average temperature rise below two degrees Celsius.

We talked with Noemie Bourdin of Upsolar, who recently returned to her office in Paris from South Africa.

were you part of a delegation to coP 17?Yes, I was there with two colleagues from China to meet delegates, politicians and potential clients. We also met with NGO’s and organizations interested in sponsoring new projects in developing countries including education and training.

what are the obstacles to solar PV becoming a major part of initiatives in developing countries?Alternative energy options are complex and many politicians and regulators don’t see the full picture of costs and benefits of the different options. For example, solar PV is seen as expensive for developing

econo-mies, which is no longer the case. We need to concentrate on educating the key people involved.

what about upsolar and what is your involvement?We are a Chinese company with an office in Paris that has been open for 2 years. We differentiate ourselves by producing high quality products. We outsource all manu-facturing but perform intensive quality control and performance testing. This gives us a unique low cost and high quality product.

For more information on Upsolar, see www.upsolar.com

For more details on the conference, visit www.cop17-cmp7durban.com. The next major UNFCCC Climate Change Conference, COP 18/ CMP 8, is to take place November 26-December 7, 2012 in Qatar, in close cooperation with the Republic of Korea.

COP 17—what does it mean for Solar PV? A perspective from Noemie bourdin of Upsolar

coP 17—what does it mean for Solar PV? A perspective from Noemie Bourdin of Upsolar


Hanwha SolarOne is a vertically integrated manufacturer of silicon ingots, wafers, PV cells and PV modules. A top-10 solar panel module manufacturer globally and top five in China, Hanwha SolarOne sells under its own brand and serves as an original equipment manufacturer. The company sells its solar products to its broad base of customers directly and through distribu-tors. Hanwha SolarOne’s North American headquarters are located in Costa Mesa, Calif.

We met with Sungsoo Lee, Hanwha SolarOne’s CSO and Board member, on their impressive booth at SPI.

Hanwha SolarOne is a tightly integrated business?

Yes we have 1 GW capacity in Ingots, 1.5 GW in cells and 1.7 GW in modules.

Hanwha SolarOneis an international firm?

Yes, Hanwha Chemical is based in Korea, Hanwha SolarOne is based on China, and we are quoted on the Nasdaq(HSOL).

How did you get into Solar?

Hanwha chemical is one of the biggest

petrochemical companies in the Asia-Pacific region. It acquired polysilicon capacity from Dow in the 1960’s and expects to produce 10,000 mt in 2013. We developed this market presence and moved downstream into cells and modules.

Where are your markets?

50-55% Europe, primarily Germany and Italy. We have a strong OEM partnership with Q.cells and Schüco. 25% of the market is in the USA and Canada and about 10% in China. We see growth in the Americas and China.

How about Korea?

The market has not yet developed in Korea.

How far downstream do you plan to go?

Through partnerships we are able to supply our customers with balance of system components such as inverters, racking, DC maximizers and batteries. We have a task force listening to customers’ needs in the various markets so we can develop the appropriate products internally or with partners such as Enphase ,Tigo and Zep Solar. Our aim is to be the “one stop shop.”

Hanwha SolarOne—International integration

hanwha solarone—international integration


about Power-oneThe company is based out of Italy and has a US office in Camarillo, California. We have been developing our range by talking to installers, finding out what they like and don’t like.

how does that help you in the market?Installers are key in the decision process. It’s a tight-knit community, and if an inverter is tricky to install, the word gets around and back to the customers, and sooner or later those inverters will not be recommended.

where is your biggest market?Historically, it has been in Germany. It’s a demanding market, and technical benefits are also important in that market—for example MPPT (maximum power point tracking), which optimizes

output throughout the day. As a result of our focus on ease of installation and performance, we have built our product range and our brand, and last year we moved from #9 to #2 in the world.

what is your range?From residential <27 kW single phase to our Ultra at 1.4 MW, we cover the market. And as the market goes more international, so does Power-One.

And as the market goes more international, so does Power-One

and as the market goes more

international, so does Power-one

UNO 2.0 Power-One outdoor power inverter

At SPI, Power-One had an impressive booth and introduced several new products to the Power-One Aurora range. To date, Power-One has an installed base totaling more than 4 GW of power globally.

The smallest of the residential inverters, the new UNO 2 kW single phase inverter, has been redesigned. A new look inverter from both a style and technology standpoint, it is high performing, extremely robust, easily installed and features a new user interface.

Other important products two new string inverters for large roof top applications, TRIO-27.6 and TRIO-20.0, three-phase inverters outputting 27.6 kW and 20.0 kW respectively. These products fill a gap between the previous 10.0 kW and 12.5 kW three-phase products and the smallest central inverter products (50kW and 55 kW). This new design of inverter benefits from three-phase inverter technology perfected in the PVI-10.0 and 12.5, probably the world’s most commonly used three-phase inverter, which led the way in best-in-class efficiency.

Power-One is also launching the new ULTRA, their biggest inverter with an output of up to 1.4 MW featuring passive liquid cooling. This new concept in large-scale utility inverter features an IP65 enclosure, high performances, minimum footprint, low maintenance and Power-One’s traditional modular approach.

We talked to Jason Nicholls, Power-One’s global marketing communications director.


We met with Brooks Herring, exec-utive officer and vice president of communications and operations,

to discuss Solar Frontier’s unique approach to the market and their expansion plans.

Tell us about Solar Frontier.

Solar Frontier’s mission is to create the most economical, ecological solar energy solutions on Earth—on the world’s largest scale. The proprietary CIS technology (for key ingredients copper, indium, and selenium) combines compelling economics and energy conversion efficiency today—and greater potential for tomorrow—with superior reliability, stability, sustainability, non-toxicity, design, and lower overall energy consumption in the manufacturing

process to yield a faster energy payback time. The new 900 MW production plant in Miyazaki, Japan, commenced opera-tions in 2011 and is the world’s largest CIS factory.

Tell us about the CIS Modules.

The CIS modules produced in the plant offer the highest conversion efficiency of any mass-produced thin-film module, up to 12.6%. The 155W modules feature the light-soaking effect unique to Solar Frontier’s CIS technology, which provides higher output than the 150W rating suggests. The light soaking and aperture characteristics are equivalent to another 2% performance. The modules also have a lower temperature coefficient than silicon,

0.31 vs. 0.46, which means better oper-ating performance under hot conditions. So we are really not selling peak watts, we are selling kWh, much more relevant to customers!

The panels have passed all salt mist and ammonia resistance tests devised by TÜV Rheinland and received the relevant certifications proving this. It is a distinc-tion few PV manufacturers have. In agri-cultural areas it is vital that the glass, frame and connections of the modules are not corroded by ammonia generated by live-stock, while near seashores, resistance against the corrosive attributes of salt mist is essential. TÜV Rheinland’s tests showed that even high concentrations of salt mist and ammonia did not affect Solar Frontier’s modules or lead to accelerated degradation.

Solar Frontier’s vision: Performance, reliability and sustainability



Tell us about your production.

Solar Frontier’s globally distributed CIS thin-film modules are produced at its new gigawatt-scale Kunitomi plant in Miyazaki, Japan. We are bringing it online in 3 phases, with the next two phases commis-sioning in February and April with strong support from our research center outside Tokyo which can do bench scale, pilot scale and full size module development. The high level of automation allows us to produce panels cost-effectively in japan with extremely high quality and consis-tency.

Solar Frontier also has a reputation for a strong commitment to the environment.

All modules are RoHS (European Community Reduction of Hazardous

Subst ances ) c o m p l i a n t and cadmium- and lead-free. We use zinc oxide, not the cadmium oxide that is c o m m o n l y used in GIGS cells. Solar Frontier is one

of the few manufacturers able to meet the requirements and has completed volun-tary testing by TÜV Rheinland to make it official. The Restriction of Hazardous Substances act adopted by the European Union in 2003 sets a 0.01% concentration limit on cadmium, and a 0.1% limit on lead, mercury and three other hazardous substances, for any component of a certi-fied electronic device.

In addition, Solar Frontier announced last year that it joined the European asso-ciation PV Cycle. Founded in 2007, the Brussels-based interest group is devel-oping an industry-wide, voluntary waste-management and recycling program for end-of-life photovoltaic modules. By joining PV Cycle, Solar Frontier reaffirmed its responsibility for its CIS modules

throughout their entire lifecycle. End-of-life modules are still scarce compared to the number of modules still in operation, as significant photovoltaic systems began ramping up in the early 1990s.

The average photovoltaic module is expected to produce energy for over 25 years. PV Cycle intends to have its program in place by 2015, when a large number of modules have to be replaced. To this end, PV Cycle supports research to minimize recycling costs and provides information for owners, installers and distributors of PV modules. Solar Frontier’s parent company, Showa Shell Sekiyu K.K., has partnered with Kitakyushu City to build Japan’s first PV system recycling facility in a project with Japan’s New Energy Development Organization (NEDO). It is cooperating with NEDO and universities to co-develop appropriate processes to recycle all kinds of solar panels.

Solar Frontier is certainly ahead of many module companies in looking at the full life cycle of their innovative products.



For many years, Huber+Suhner has been combining core competences in radio-frequency technology, fiber

optics and low-frequency technology. The company has also been serving the solar market for several years with an exten-sive range of products. With Radox solar cables, the company has set the benchmark for cables. In 2003, they also launched the first Radox connectors. Since 2006, they have also been successfully developing, producing, and selling junction boxes for applications in the PV solar industry. Today, the company has developed into one of the leading suppliers of complete connectivity solutions—from the solar module through to the inverter.

Trends in the marketWith its products, Huber+Suhner pursues high quality requirements. The company offers a wide range of quality products, in particular for applications exposed to the elements in solar technology.

“Together with our customers, we develop solutions that are ideally tailored to their needs and can later be made available as a series product,” explains Max Göldi, product unit manager at Huber+Suhner.

“We constantly observe, test, and assess the

trends on the market. Only in this way, can we constantly come up with innovative products.”

Currently, local regulations are increas-ingly influencing certification in indi-vidual markets. These regulations are thus increasingly becoming cost drivers. This development opposes the latest low-cost trend and affects the market, and there-fore also Huber+Suhner. In addition, the company often discusses with its customers the critical question as to when price is more important than quality. A high level of performance as well as safe, reliable, and maintenance-free solutions must be ensured for decades. The aim of Huber+Suhner is to provide the proper balance between quality and price.

Successful entry into the junction-box businessIn 2006, Huber+Suhner went to market with its first solar junction box, the HA3. An initial order was received from a major module manufacturer, thereby justifying the development of a specific junction box. The USP, which ensures the thermal sepa-ration between junction box and module by uprating all power-carrying parts, was patented by Huber+Suhner. This design

The future of the solar junction box: Intelligent and modular?


Prototype of the new modular system from Huber+Suhner with variable “blue box”As a leading international manufacturer and sup-plier of components and systems for electrical con-nectivity, Huber+Suhner provides complete con-nectivity solutions with junction boxes, solar cables and solar connec-tors. The company is set-ting a new standard with a new modular system in the junction box market.


separates the module from the junction box, which ensures improved heat dissi-pation in the bypass mode of the diodes. Thanks to the air circulation between the junction box and the module, the junction box remains about 10 degrees cooler than the back of the module. Furthermore, there is no heat build-up at the module as with conventional solutions. As a result, the effi-ciency of the cells is not negatively impacted and the risk of micro-cracks in the cells is minimised. The large cross sections and excellent cable contacting ensure low and constant losses over the entire service life. The junction boxes feature a high degree of reliability and performance for the entire service life. They are suitable for manual and automated production processes and can be installed quickly and easily. As of this year, Huber+Suhner has also been producing junction boxes for thin-film modules and crystalline PV modules with lower power output. The HO1 junction box and the HF0/HF1 solar box system were also developed in cooperation with customers and successfully introduced onto the market.

over 1.5 million junction boxes each monthTo meet the rising demand for Huber+Suhner solar junction boxes, new plants were commissioned at various production sites around the world, or existing plants were modernised and the capacity increased. The company now produces in modern production facilities at these locations: Switzerland, Poland, China, and Malaysia. Production capacity is well over 1.5 million junction boxes per month worldwide and, in addition to Europe, also serves customers in Asia and the US.

intelligent junction boxesHuber+Suhner observes and tests devel-opments in the junction box business. Intelligent junction boxes, i.e. solar junction boxes with integrated smart electronics, are currently penetrating the market via different companies. Based on the proven connectivity technology, Huber+Suhner is developing the latest generation of junction boxes in coopera-tion with leading smart-electronics manu-facturers. With these solutions, the effi-ciency and reliability of photovoltaic plants can be improved.

The future: the modular systemHuber+Suhner sees the future in customer-specific, individual solutions or the modular system. The company is currently working on a modular system consisting of a basic junction box, a “blue box” (smart electronics) and a connec-tivity system. Market launch is planned for the second quarter of 2012. For OEMs and PV installers, the system provides more options in selecting electronics suppliers and the complexity of the electronics functions. Moreover, the junction box can easily be retrofitted and enables simple maintenance. These advantages also open the door to cost savings. To this end, Huber+Suhner has two main objectives:

“We offer quality at competitive prices. The focus must remain on quality despite price pressure,” explains Max Göldi. “Solar modules must last between 20 and 30 years. The market still does not see the conse-quences that may arise from inexpensive offers in the coming years.”

Furthermore, the company is testing the smart electronics offered by various renowned partner companies and intends to go to the market with complete solu-tions in the near future.

For more information, visit www.huber-suhner.com.



Freudenberg Simrit’s Solar Clip comprises only two parts. This completely new rapid connection system works entirely without screwed joints. Because the lower part of the Solar Clip contains a specially designed connection for the carrier system, it is inserted into the racking system profiles and rotated by 90°. Based on the same principle as a quarter-turn fastener, this clamp connection with positive locking system creates a whole new connection to the lower structure.

Now the photovoltaic module is inserted into the lower part of the Solar Clip which, depending on the installation position, has up to four positive engage-ment clamps. Then the upper part of the Solar Clip is manually inserted into the lower part, automatically connecting the photovoltaic module reliably and securely with the carrier system. This is made possible by a central plastic bolt that acts as an installation guide and an additional lock. By pressing this plastic bolt into the central opening of the lower part of the Solar Clip, both components are securely connected to one another. At the same time, six notches engage securely on both components. This ensures that the photo-voltaic modules are clamped by means of a defined force and also that the rapid-instal-lation system is doubly securely attached to the elevation profile (the belt-and-braces principle). Moreover, it acts as a reliable anti-theft device.

Plastic and s i l i c o n e instead of aluminumThis highly economical rapid-installation system is made possible by a completely new combina-tion of materials. Both carrier parts that make up the Solar Clip are made of high-quality, weather-resistant plastic (Ultramid A3WG10 with 50% GF). The contact surfaces that come in contact with the photovoltaic module are both coated with a specially developed silicone profile structure. The silicone cushions on the upper and lower sections ensure gentle yet reliable clamping of the photovoltaic modules and compensate for up to 1.2 mm thickness tolerances caused by the manu-facturing process without causing any damage to the photovoltaic modules. This optimized pressing ensures not only that the modules remain permanently attached to each other in all temperatures, but can also withstand the pressures exerted by heavy snow or high winds. This product offers a uniquely secure and at the same time elastic connection.

The symbiosis of a high-quality thermo-plastic and silicone is the key to this inno-vative connection solution. To this end, Freudenberg has perfected the so-called

“two-component technology.” This tech-nology allows for more than just inexpen-sive production, it also makes it possible to reduce the number of components and the space required. These completely new two-component attachment systems offer great potential for savings in terms of installa-tion and logistics. Moreover, the fact that the amount of cell surface area covered by the clip has been minimized, optimizes the use of the frameless thin-film modules.

All of this paves the way for the fascinating technical and economical benefits offered

Solar Clip makes the installation of photovoltaic modules child’s play: Rapid-installation system for frameless thin-film photovoltaic modules

Solar Clip makes the installation of photovoltaic modules child’s play:

rapid-installation system for frameless thin-film photovoltaic modules

The photovoltaic module fixing system of the future: the Solar Clip.

Armin Barth and Michael Littig, Simrit

The new Solar Clip, which is used to secure frame-less thin-film photovoltaic modules, is as simple to use as a conventional press fastener. This new product is set to revolutionize the installation of photovol-taic modules. The exertion of even, defined surface pressure prevents damage during installation. Not only is the patented Solar Clip incredibly good value for money, it will also help drastically reduce labor costs because it allows modules to be installed much faster and without tools.


by this clip system, for which a patent application has been made:• the solar modules can be installed

manually, without the need for any tools;

• assembly is extremely simple; assembly time is drastically reduced;

• the risk of damage being caused during assembly as a result of excessive clamping pressure is minimized;

• and the ergonomic design with integral anti-theft locking mechanism will

comply with all conventional indus-trial standards and certifications in the near future.

Moreover, being a technical plastic compo-nent, the clip also offers countless design, color, and system integration opportuni-ties. This in turn offers manufacturers of thin-film modules quick and inexpensive opportunities for securing modules.

Solar Clip makes the installation of photovoltaic modules child’s play: Rapid-installation system for frameless thin-film photovoltaic modules


comparing ar glass coatingsAnti-reflective glass coatings are manu-factured by applying a single or multiple layers of material onto a highly transmis-sive, ultra-clear glass. Coatings are engi-neered to reduce reflection at the air/glass interface so that more electricity producing photons can enter the solar cell.

By enhancing solar transmittance, these coatings enable devices equipped with AR glass to convert solar energy into electricity more efficiently. Anti-reflective coatings increase module power output and lower the cost-per-watt, which is the key value measure for any solar powergenerating system.

Sol-gel and other ar coatingsMost commercial AR coated glasses for the solar industry feature a layer of uniform or graded low-density material that is applied to a glass substrate by various deposition processes, including wet techniques—such as sol-gel, spray, dip, and flow—or dry processes, such as vacuum deposition.

Sol-gel-based coatings are one of the most popular types for AR glass because they are highly transmissive across a broad range of the solar spectrum. That makes them especially effective for solar-thermal applications where the collection of heat energy has equal or greater primacy than

the collection of energy in the visible range of the solar spectrum.

One major drawback with low-density AR coatings, including those made with the sol-gel process, is that they are relatively soft, which can lead to processing and handling difficulties. Soft coatings placed

“side-down” during assembly can adhere to conveyor rolls and other processing equip-ment. This not only deposits damaged coating residue on the rolls themselves, but also leaves roll marks on the finished glass, which can diminish the effectiveness of the coating. They also scratch easily during shipping and handling.

Another shortcoming associated with low-density AR coatings is a porous structure that, when deposited on a glass substrate, tends to densify during heat-treating. Later, during field use, the coatings have propen-sity to collect environmental contami-nants due, again, to their porosity. Both phenomena make the coating less trans-missive, which ultimately results in lower performance for the AR-glass equipped solar module.

For these reasons, many AR coatings cannot pass all of the environmental testing proto-cols established in IEC 61215, the standard for predicting field durability of solar glasses.Solarphire ar glass

Increasing performance in anti-reflective coatings

increasing performance in anti-reflective coatings

Solar module manufactur-ers measure the performance of glass products according to two primary factors: solar transmittance and durabil-ity. While anti-reflective (AR) glasses often are used on solar modules to maximize solar transmittance, they tradition-ally have been handicapped by coatings that cannot with-stand the rigors associated with processing and long-term field performance. Solarphire AR glass by PPG is a new gen-eration of anti-reflective glass that, due to a proprietary, per-manent, protective overcoat, combines high solar trans-mittance with exceptional durability. The following document examines common types of AR glass and explains why the durability of the glass enables it to outperform and deliver better long-term value than other AR glasses for many solar applications.


Solarphire AR glass is a new solar glass by PPG that provides both exceptional solar transmittance and revolutionary break-throughs in durability and long-term performance. With its unique formulation and coating characteristics, Solarphire AR glass provides the following processing and performance advantages over sol-gel and other wet-applied AR glass products:• The AR coating optimizes module

performance in two ways: first, by increasing transmittance of the glass in the spectral range where common photovoltaic (PV) conversion mate-rials, such as silicon and cadmium telluride, need it; and second, by reflecting infrared (IR) rays not converted by these materials into electrical energy. This reduces heat build-up in solar modules and makes them more energy-efficient.

• The glass can run “coated side down” on processing conveyors. That means customers require no special handling equipment to switch from an uncoated product to the AR glass.

• Because of its unsurpassed durability, manufacturers can apply the coating on the first surface of a PV module and have high confidence that it will perform well throughout its service life. As the test results demonstrate, Solarphire AR coatings survive exposure tests well in excess of those prescribed in IEC 61215 testing.

• The glass requires heating to achieve the best optical performance and durability test results. At 1185°F, there is a chemical reaction in the coating that makes it less energy-absorbing. Consequently, in applications that require heat-treating or bending, the glass actually outperforms those that do not have heat-treated glass.

• Solarphire AR glass is available with the AR coating on both sides of the glass substrate (Solarphire 2XAR glass). In applications where both surfaces of Solarphire 2XAR glass are exposed, such as cover plates for concentrated photovoltaic (CPV) modules or receivers, the resulting 4 to 5 percent increase in transmittance can substantially improve the overall efficiency of the module.

Performance testingTo measure the durability and long-term transmissivity of Solarphire AR glass, PPG subjected product samples to standard IEC 61215 and Taber abrasion tests.

Taber abrasion testAlthough the Taber abrasion test is not

commonly done on solar glass products, it is recognized as an especially rigorous method for measuring the wear resistance and durability of specific products and/or materials.

To complete the test, two abrasive wheels were rotated over the surface of glass with varying levels of pressure to simulate the physical effects of abrasion.

The purpose was two-fold: first, to gauge the susceptibility of the glass surface to scratching during handling and fabrica-tion and, second, to assess its ability to maintain transmittance after repeated exposure to a wear mechanism that was significantly more abrasive than any it would encounter in processing or actual

field service.

Final results showed that, even after strin-gent abrasion testing, Solarphire AR glass maintained virtually undiminished solar transmittance.

iec 61215 industry standard testingThe IEC 61215 protocol specifies 1,000 hours of damp heat exposure (85°C/85% relative humidity) and 10 cycles of humidity-freeze testing. PPG testing far exceeded these standards by exposing glass samples to one full year of damp heat exposure, 60 cycles of humidity-freeze testing and 17 weeks of salt-fog




testing as prescribed by the American Society of Testing and Materials (ASTM) B-117 procedures.

When measured after each of these indi-vidual tests, Solarphire AR glass showed decreases in transmittance of less than 0.5 percent in the PV range of the solar spectrum (400 to 1100 nm).

The glass also passed sulfuric and abrasion testing for EN 1096-2, the European standard for glass coating performance.

Summary• Taber abrasion and other industry-

standard testing shows that, due to its proprietary, permanent, protective overcoat, Solarphire AR glass maintains original transmittance when subjected to conditions far beyond what would be typically expected during processing and in the field.

• Because of its proprietary formulation and coating technology, heat-treated glass increases solar transmittance 2 to 2.5 percent in the PV range of the solar spectrum. When the AR coating is applied to both sides of the glass substrate (Solarphire 2XAR glass) in heated-treated applications, solar trans-mittance levels increase by 4 to 5 percent in the PV range.

• The glass can be run “coated sidedown” on processing conveyors without causing a build-up of coating materials on the contact surfaces or damage to the coating itself.

• Solar manufacturers require no special equipment to process the glass.

• Unlike some AR glass products that lose performance when heat-treated, Solarphire AR performance actually increases in such applications.

• The glass increases the reflection of heat produced in the IR range of the solar spectrum that is not useful to the creation of electric energy. This reduces the heat load on the solar module, resulting in an increase to its peak performance thresh-olds and long-term output.

To learn more about Solarphire AR glass and the entire line of PPG solar glass solu-tions, call 1-888-PPG-SUN1 (774-7861) or visit www.ppgsolarphire.com.


efficiency and yield improvements with fab-wide

process management software

Increases in conversion efficiency and yield of a fraction of a percent can have a huge impact on profitability. Process

monitoring and yield management tech-nologies provide a powerful weapon in the battle to increase both. These techniques collect and analyze performance data from all stages of the manufacturing process—ingot growth, wafer production, cell fabri-cation, module assembly—to allow process engineers to rapidly identify and correct problems that cause drops in efficiency and process yield.

Two considerations dominate the economics of PV manufacturing. First, wafer cost is fixed relative to cell fab perfor-mance, so that any increase in process yield reduces production costs as a percentage of earnings. Second, the selling price of a cell or module is determined by its power output, so that any improvement in effi-ciency contributes directly to increased margins and profitability. Both of these factors, process yield and efficiency, are highly leveraged, providing large returns for even minor increases, as the examples described in this article demonstrate.

The discipline of yield management includes collecting and analyzing data from all stages of manufacturing to optimize process yield and conversion efficiency. Possible sources of data include module testing, cell testing, wafer inspection, tool operation, metrology, wafer tracking (individual and lot), and process events (tool maintenance, material changes, and process alarms). Analyzing this data allows manufacturers to quickly find and correct the root cause of yield excursions; increase average cell efficiency; share data and analytical conclusions among wafer, cell and module factories; gain visibility of work in progress (WIP); and monitor tool performance.

Event-related problems are significant causes of efficiency downturns. Detection

of these events as they occur, rather than when their effects appear as a drop in efficiency at cell testing, can dramati-cally reduce their negative impact. Real time tracking of efficiency trending allows engineers to see and address low points to increase average cell efficiency. As Table 1 illustrates, an increase of 0.1 percentage points can generate a 0.65 percentage point increase in profitability, adding millions of dollars annually to the bottom line. Additional benefits accrue from reductions in engineering time and cost, and improved training and proficiency of off-shift staff.

Much of the power of a well-designed yield management system comes from its ability to quickly analyze vast amounts of data and present the results in readily inter-preted visual format. A brief visual tour of some of the capabilities of a yield manage-ment system (Discover Solar, Rudolph

Technologies) is perhaps the best way to illustrate its benefits.

Statistical process controlStatistical process control (SPC) provides a means to monitor process parameters over time to detect excursions beyond established control limits. Typical SPC charts include mean and range, mean and standard deviation, mean and moving range, count of defects and more. SPC typi-cally includes provisions for sending alarms automatically to the process engineer when a monitored parameter exceeds the speci-fied limits. Alarms may also be based on a set of rules. Western Electric rule set is widely used to track statistical anomalies, such as the number of times the measured value falls consecutively on the same side of the mean.

Table 1. Gains in conversion efficiency are highly leveraged. Slight improvements yield signifi-cant increases in revenue, margin and profitability.

Efficiency and yield improvements with fab-wide process management software

David Genova, Rudolph Technologies, Inc.


SPC in a high-volume PV manufacturing operation has specific challenges, perhaps the greatest being the large number of data points and the high degree of random variability. The yield management system treats SPC alarms like any other monitored event (maintenance, material changes, etc.), allowing them to be included in charts and high level analyses.

alarm reviewWhen an alarm occurs, the system can quickly chart the history of measurements leading up to the event. In this example the alarm was made when the thickness of a layer deposited by a specific tool fell on the same side of the median value more than

eight consecutive times (Western Electric Rule 4). Along with the alarm the system can send a predetermined out-of-control action plan (OCAP) to assist the recipient in diagnosing the problem and executing appropriate corrective actions.

Multivariate analysisStatistical analysis for yield management focuses on identifying points that are significantly different from the main popu-lation. Traditional univariate techniques, such as SPC, can miss significantly different points because they do not include correla-tions between parameters. Multivariate analysis looks simultaneously at multiple parameters and does include correlations

among them. The primary challenge in multivariate analysis is determining which points are different, and why; that is, which parameter(s) caused a point to be flagged. A number of tools are available to help. Analysis of variance provides an objective means to evaluate observed differences. Clustering, which groups data based on the parameters that caused it to be flagged, helps the process engineer know where to direct additional analysis. For example, the observation of both low short circuit current (ISC) and low open circuit voltage (VOC) might point to a materials issue. Comparing the paths that different groups followed through the process or looking for correlations of differences with material


Figure 1. A plot of daily average efficiency allows quick identification of highs and lows to direct further analysis. More than a million data points are included in this analysis, with each daily average representing tens of thousands of cells.

Figure 2. Historical data leading up to the triggering of an alarm when thickness values from a particular tool exhibit anomalous behavior


vendors could then be used to test hypoth-eses about root causes.

Determining whether observed differ-ences are significant requires an analysis of variance. Hotelling (t2 analysis) is a specific technique that extends the univariate student’s t test to multivariate analysis. It provides a method for evaluating whether an observed difference is significant or simply the result of variability within the compared populations.

automated reportsAutomated reports can be configured by the process engineer to drill down into the data in a specific way. The reports may be

generated on demand, on a schedule or on the occurrence of an alarm. They may include electrical, tool, material, metrology data and more. They may be layered and interactive, allowing the user to click on a chart to drill down to a more detailed analysis mode.

examplesCase 1: Edge isolation problemApproximately 7,000 wafers per day (5.7% of the population) exhibited laser edge isolation problems. Monitoring of tool performance and SPC alarms isolated the problem to one of two lasers in one of six modules. Corrective action reduced the occurrence of the problem to 2000 wafers/

day. The diagnosis was based entirely on historical data and did not require process experiments that would have consumed engineering resources, displaced produc-tion and delayed the solution. The improvement (5,000 wafers/day) repre-sents an annual cost savings of $7.2 million and additional annual revenues of $9 million.

Case 2: Incoming wafer qualityA drop in efficiency was observed while all process tools were operating within specification and control lots showed no problems. Analysis of efficiency by wafer supplier demonstrated a significant differ-ence among vendors. Analysis of the same

Figure 3. Pareto charts help to direct attention to the most significant problems by plotting process excursions in order from most frequent to least frequent. They may also include a plot of cumulative frequency. In this example half of all alarms are the result of the first two causes.

Figure 4. Regression analysis can determine the strength of a correlation within a population or a selected group by generating the Pearson coefficient. With a single click, the system can fit linear, quadratic or cubic regression formulas to the data and evaluate the goodness of fit.




Figure 5. Vendors show similar variability and range (top) but wafers from vendor 8 appear to produce consistently lower average efficiency. With more than 150,000 measurements, wafers from vendor 8 yielded cells with significantly lower efficiencies (bottom).



population by production line showed consistently lower performance for vendor 8 on all lines.

Case 3: Metallization contact problemEngineers observed periodic contact problems at metallization. They suspect a problem with the metallization process. They selected a group of points with low fill factor and high shunt resistance and observed that the same group exhibited high series resistance. Drilling down, they tracked the problem to the diffusion process where they found significant differences in series resistance values correlated with specific furnace tubes. High sheet resis-tivity values were creating Ohmic contact problems after firing. What was presented initially as a metallization problem was, in fact, a problem in the diffusion process. The analysis was able to identify the furnace tubes that were causing the problem without costly process experiments.

conclusionProfitability in PV manufacturing is driven by cell efficiency and process yield. Slight increases in these parameters can generate significant improvements in revenue, margin and profitability. Improvements in cell efficiency can also confer competi-tive advantage and gains in market share. Yield management technologies give PV

manufacturers visibility of both process yields and cell efficiency on a near real-time basis, offering substantial benefits for the economic performance of the manufac-turing process and the competitive perfor-mance of products in the marketplace.

Figure 7. Case 1 shunt resistance before and after the laser in one edge isolation module was fixed (at about 03:00 on 12/13/08).

Figure 6. Path analysis allows the user to compare populations that followed different paths through the process. The system can compare process lines, tools, lots, raw materials, and more to quickly gain an understanding of non-conforming data. This example compares measure-ments made on wafers that went through three different SIN tools. Using path analysis, work centers can be connected, optimum processes understood, and best practices proliferated from factory to factory.

30 – Global Solar Technology – January/February 2012 www.globalsolartechnology.com30 – Global Solar Technology – October 2011 www.globalsolartechnology.com

The sun shines brightly on the solar industryAs reported by the U.S Solar Market Insight, today, grid-connected solar electric instal-lations can generate enough electricity to power 600,000 homes. This solar produc-tion amounts to 2.85 GW (gigawatts).1 As illustrated in Figure 1, technology prices have been falling at a steady pace for the past 25 years. That, combined with rising government programs and subsidies, has set the stage for solar’s market growth. For example, in 2007 a commercial and utility system would cost $7 per watt to install, in 2010 the cost had dropped to $3 per watt.2

As mentioned, this industry also benefits from government support. Currently, the Department of Energy (DOE) has distrib-uted $30.7 billion via their loan guarantee program. As shown in Figure 2, the market for PV installations has grown exponen-tially year-over-year for the past 6 years. In 2005, there were only 79 MW (megawatt) installed compared to 886.6 MW in 2010.3

According to Frost & Sullivan, the solar market has grown 120% in the last year

and is expected to continue on this growth curve.4 Currently Europe, with Germany in the lead, is the largest PV market followed by Japan and the US. China is the main manufacturer of PV cells. However, the US is on its way to taking the lion’s share of the market in the next few years as manufacturers are looking to the US due to decreasing feed-in tariffs in Europe and increasing government incentives in the US.3

This sector is rapidly evolving and as it matures and more players join the solar market, there can be a sense of urgency felt by manufacturers to get their product on the market first and to be seen as leaders. Often this can come at the cost of offering a product that has not been fully tested and that can potentially create harm to both the manufacturer (who is liable) and the user (if property is damaged). Adopting national and international standards set forth by the industry can alleviate a manu-facturer’s last hurdle in the product devel-opment cycle. In order to comply with these standards, partnering with the right

certified labo-ratory is a key factor. Third party laboratories can ensure that all-inclusive safety, performance and reliability testing and certification are achieved.

overview of certificationWhether using crystalline silicon (c-Si), thin film cells or concentrators, all products must be tested according to established standards to ensure safety. Manufacturers must obtain their North American certification covering safety and performance of the PV product from a Nationally Recognized Test Laboratory (NRTL). Requirements such as UL1703 and UL/ORD1703 in the US and Canada must be met in order to sell products in North America. The product can bear a recognized certification mark once it meets the required standard.

A certification laboratory can audit, inspect and test for certification before the PV modules hit the global marketplace. Many of these tests not only substantiate product claims, but also provide independent veri-

Performance and reliability testing of photovoltaic modules—insurance for your investment

Performance and reliability testing of photovoltaic modules—insurance for your investmentSunny Rai and Dr. Paul Robusto, Intertek

This article outlines the solar industry and particularly the pho-tovoltaic modules current trends and market data. Among the many tests that are offered to ensure safe and reliable products entering the market, the reliability and per-formance tests will be showcased. Finally, the benefits of partnering with a global testing and certifi-cation agency are detailed in the article.


fication of product performance. In the solar industry, third party laborato-ries will test various modules according to the following UL and IEC standards:

• UL 1703 and cUL 1703: Safety for flat-plate photovoltaic modules and panel

• IEC 62108: Concentrator photovol-taic (CPV) modules and assemblies—design qualification and type approval

• IEC 61730-1 & 2: Construction and safety qualification and testing stan-dards for all types of flat plate modules

• IEC 61215: Crystalline silicone photo-voltaic modules—design qualification and type approval

• IEC 61646: Thin film terrestrial photo-voltaic modules—design qualification and type approval

• Subject 8703: Outline of investigation for concentrator photovoltaic modules and assemblies

Currently the top stakeholders in the industry, including manufacturers, test laboratories and investors etc., are looking to agree to a new standard of perfor-mance that would develop a QA rating for

the durability of the module design and develop a guideline for QA of the manu-facturing process. This effort in the photo-voltaic industry is being led by, amongst others, the National Renewable Energy Lab (NREL) and the DOE to achieve consensus on a standard to set a minimum test criteria so the product can carry an additional “Quality Assurance QA” rating.

As stated by the International PV Module Quality Assurance Forum “A rating system that provides comparative information about the durability of PV modules to a variety of stresses will be a useful tool to PV customers and will provide a starting point for improving the accuracy of quantita-tive PV lifetime predictions.”5 The constant evolution of requirements showcases the importance of tests like performance and reliability to keep pace with the market. By going beyond simply meeting standards, performance testing helps manufacturers substantiate claims and differentiate their market offerings.

Performance and reliability testing: going the extra milePerformance and reliability are key differ-entiators for manufacturers wanting to stand apart from the competition and predict the long term reliability and performance of their modules. These tests are also important for investors who will look at the results, forecasts and warranty coverage before investing in any given project. Below is a brief description of each test:

• Reliability testing: This type of test measures the probability of compo-nents to fail over time. This test allows manufacturers to better evaluate which component failed, and also answers the “why” and “where” of the failure. The manufacturer’s product must pass the qualification and reliability tests in parallel. Corrective measures can then be implemented, thus saving on product development time and increasing overall quality prior to the product being distributed.

• Performance testing: This test not only shows the performance of the

Performance and Reliability Testing of Photovoltaic modules - Insurance for Your Investment

Figure 1. Module pricing trends 1985-2011

32 – Global Solar Technology – October 2011 www.globalsolartechnology.com


• product over time, it also analyses the power degradation and lifetime of the modules. It is part of the qualification test as well and provides the basis for profitability and security of investment as it helps manufacturers substantiate product claims and market differentia-tors.

These two types of tests promote photovol-taic performance and reliability in different environments. Manufacturers can take a few extra steps to perform these market differentiating tests, which can also be customized, making the process simpler and more efficient.

A specific example of reliability testing includes the Accelerated Life Testing (ALT), in which the thermal and humidity chambers go through a number of cycles to determine how the product survives over and above the qualification certifica-tion testing. They may go through 2 to 15 additional cycles to establish how long the product can last and how well the product does under extreme conditions. These tests might include higher temperature levels than the standard requirements in the certification (normally tests conducted at 85°C or 90°C would be tested at 100°C or 120°C) and would determine the prod-uct’s durability. Based on measurable key parameters, the lab can then determine the

relative lifetime of the PV module.

The “Thresher Test” is also part of the qualification sequence which helps deter-mine the degradation patterns of different c-Si solar modules. In this case, a standard test is performed and then voltage bias is added which in turn precipitates the silicon cell failure.

Additionally, normal certification quali-fication tests must be improved and must meet certain parameters such as more cycles, higher temperature and, longer exposure to UV light to determine how well a product survives and in parallel will highlight what the failure modes are. Also testing is needed to determine if the product can withstand regional differ-ences so testing needs to include salt mist and ammonia corrosive testing. Extended outdoor testing is also necessary in different environments of hot and humid, hot and dry, snow, sea shore, farm field, and industrial areas to determine if the quality of the product can withstand these environmental conditions. These tests are meant to push the limits of the PV module and ultimately improve the product as it strives to survive or outlast its stated warranties.

why intertek is your partner

of choice for solar testingAccording to the Clean Energy Group, a nonprofit advocacy organization, working in the U.S. and internationally on inno-vative technology, finance and policy programs in the areas of clean energy and climate change, there are a few barriers to entry with solar power including one on

“reliability” which they describe as:• “Reliability: The absence of solar

technologies in the public eye and confusion about its performance and capabilities create concerns about the reliability of solar technology. As a result, it is not perceived as up to the task of powering our energy needs.”6

For this particular road block, a third party test lab is an unbiased partner delivering independent verifications and therefore allowing investors and the marketplace, as a whole, to trust these reliability, perfor-mance and durability reports and the conclusions that are drawn from them. A certification laboratory can be a key partner helping manufacturer’s build up their customers’ confidence.Indeed, with additional reliability and performance tests, more checks and balances are put in place enabling the products to not only comply with the minimum standards but to go above and beyond these types of inspections so that the product is truly built to last.

Figure 2. US PV installations 2005-Q1 2011 (Source: GTM Research / SEIA)



Unlike many other certification bodies, Intertek is a true solution-provider for auditing, inspection, testing, quality assur-ance, and certification services for the solar industry. Our unique in-depth expertise has brought confidence and assurance to leading companies whose solar panels bear the ETL mark.

By partnering with Intertek, manufac-turers can claim the following advantages:• Third-party assurance: Your PV

module is certified by a renowned NRTL—Intertek—a member of IECEE and a CBTL for IEC.

• Increased revenue: Getting your products to market faster maximizes your revenue potential and results in cost savings (up to 40%) and increase mind and market shares.

• Competitive differentiation: With both the performance and reliability tests, it can get your product to provide critical performance data to support competitive differentiation.

• Fast turnaround: The timeframe in which products are tested and ETL-certified is one of the fastest on the market. Intertek can start testing your PV module, PV system, BIPV, Solar Thermal and CPV products to the UL and IEC standards within 2 weeks.

• History of innovation: The ETL (Electrical Testing Labs) mark carries a long history of innovation, influence, and independence. It is over 100 years old and is on a vast array of products in the industry since its original foun-dation by Thomas Alva Edison in 1896.

Intertek’s Solar Energy Centers of Excellence are located in Lake Forest, California Shanghai, China and are two of the industry’s most advanced Solar Energy laboratories. Both laboratories operate state-of-the-art equipment and can test and certify to North American and International standards for safety, performance and reliability. Intertek also operates Photovoltaic and Solar Thermal laboratories in Plano, Texas, San Francisco, California and Guangzhou, China to support our clients globally.

To test your PV modules today or get more information, visit www.intertek.com/solar or call +1 949-448-4100.

Bibliography1. http://www.greentechmedia.com/articles/read/u.s.-solar-energy-industry-continues-fast-growth-with-

strong-q1-2011/2. h t t p : / / t h i n k p r o g r e s s . o r g /romm/2011/06/09/241120/solar-is-ready-now-%E2%80%9Cferocious-c o s t - re du c t i ons - m a ke - s o l ar- pv -competitive/3. http://www.greentechmedia.com/articles/read/2-billion-in-doe-conditional-loan-guarantees-for-two-california-csp-plants/

4. h t t p : / / w w w . f r o s t . c o m /prod/ser vlet/market-insight-top.pag?docid=2329216525. http://www.nrel.gov/ce/ipvmqa_forum/index.cfm

6. http://www.cleanegroup.org/assets/Uploads/2011-Fi les/Press-Releases/CreatingDemand-HowtoMarketSolarRenewableEnergyFocus-SinclairOctober2009.pdf

Mr. Rai has been in the product safety and certification business for 24 years. He has chaired several equipment and product safety standard development committees. He is a leading expert in the field of solar module testing and certification worldwide, with presentations at industry events and several published articles to his credit. Mr. Rai has a degree in physics and electronic engineering technology.

Mr. Robusto has a quality and reliability background in concentrated photovol-taics and other high technology optical products. As the engineering manager for the Intertek PV laboratory in Lake Forest, California, Paul was instrumental in doubling the testing and certifica-tion capacity of the PV Lab. Paul has exten-sive experience in developing state of the art new products along with establishing their respective production lines. He holds a Ph.D. in physics from UCLA, with emphasis in optical properties of materials.

34 – Global Solar Technology – October 2011 www.globalsolartechnology.com

applications, minimizing the amount of space needed while lowering installation costs. www.andersonpower.com

Solaredge launches a new line of North american inverters with up to 98% weighted efficiency, and extended temperature rangeSolarEdge Technologies, provider of end-to-end solar power optimization systems and monitoring solutions, has introduced a new line of top efficiency, single phase solar inverters for the North American market.

SolarEdge inverters once again top the CEC list with an industry leading 98 percent weighted average efficiency. The new range of inverters is designed for North American

aPP Solar SPec Pak—First multi-pin connector to meet the PV industry requirements in ul 6703aAnderson Power Products has informed that Solar SPEC Pak is the first multi-pin connector to meet the photovoltaic industry requirements specified in UL 6703A, passing the same harsh environ-mental tests used to qualify solar panels.

Solar SPEC Pak has power handling capa-bilities up to 1000 volts and features a locking latch that complies with NEC 2008 section 690.33(C) requirements. Designed for wire to wire applications, Solar SPEC Pak is capable of handling up to 4 indi-vidual lines which reduces the number of traditional connectors needed in solar

installations, and can be ordered with an extended operating temperature range of -40°F - 140°F (-40°C - 60°C).

The SolarEdge inverters are specifically designed to work with SolarEdge power optimizers, for maximum flexibility in system design for residential and commer-cial installations, enabling full roof utiliza-tion for more modules and larger capacity per PV system. www.solaredge.com

Sofics PowerQubic technology used to protect solar panel ic from electrical overstressSofics announces that its PowerQubic® EOS technology has been chosen by eSilicon Corporation for a high-voltage solar power application.

New products forNew products

integrators andinstallers

integrators andinstallers

TitleNew products

PowerQubic technology will protect the 15V interfaces on a new IC that eSilicon is creating for a customer who will use it in solar-panel power converters. The converters transform DC voltage from the solar panels into standard AC voltage for residential and commercial use.

PowerQubic technology is designed to enhance reliability in high-voltage systems such as automotive and motor controls, power management and conversion circuits. Sofics offers TSMC-approved PowerQubic solutions in 0.25um BCD and is currently developing others. All versions can be ported to other processes. www.sofics.com

eiQ energy partners with Boots on the roof to train solar system installers in parallel solar technologyeIQ Energy and Boots on the Roof have entered into a partnership to introduce eIQ Energy’s vBoost module technology to Boots on the Roof ’s solar photovoltaic (PV) training programs.

To start that process, eIQ Energy has contributed a dozen vBoost converter modules to the Boots on the Roof solar training program. This new equipment will be featured in the school’s commercial PV construction training program and added to the design exercises in its commercial PV design course. By incorporating vBoost modules into the curriculum, Boots on the Roof students will gain valuable experience building systems with eIQ Energy’s inno-vative Parallel Solar technology.

In traditional series architectures, under-performing solar panels can affect the electricity output of an entire system, like a bad bulb in a string of Christmas lights. With eIQ Energy’s patent-pending Parallel Solar technology, panels are connected in parallel, allowing each panel to operate at its own peak performance while a vBoost module steps up the voltage to create a constant output that enables the system’s inverter to run at optimal efficiency. eiqen-ergy.com

SFS intec launches solar offeringSFS intec has recently launched a new range of solar specific bracket and post solutions to meet contractors’ growing demand for a fast and simple fix of photovoltaic (PV) panels.

Whilst the reduction to the Feed-In Tariff (FIT) rates appear to be leaving some sectors within the industry in dismay, SFS intec has seen a continued demand for solar technology and has developed three bespoke, easy to install fastening systems.

Colin Yeates, sales and marketing director at SFS intec, said, “The changes due to be implemented by the government in April will inevitably cause many to re-evaluate the use of solar technology. But on closer inspection, the changes to the tariffs are not a linear 50% reduction across the board, indeed rates for larger installations were reduced far less.” www.sfsintecusa.com

Soitec to donate a Plug&Sun™ mini-tracker to three development aid organizations to support their electrification projects

Soitec (Euronext), intends to provide remote locations in very sunny regions with a solution facilitating access to clean and reliable electricity thanks to its concentrator photovoltaic (CPV) tech-nology. Today, Soitec is launching the first edition of its Sunidarity program for development aid organizations in order to support their efforts to promote economic and human development in these remote regions. Soitec will donate its innovative Plug&Sun™ product, which can be used to generate electricity completely autono-mously where it is needed most, to the selected projects.

At present, 20 percent of the world’s population does not have access to elec-tricity, but the vast majority of the affected regions boast tremendous potential for solar energy. According to Soitec, greater

use of solar energy can help to combat both climate change over the long term and energy poverty. This drive is reliant on technological innovation and on collective development aid initiatives. www.soitec.com

Ge energy unveils new

everGold solar duty disconnectsRenewable energy distributors and installers now have a streamlined product design for the installation of commercial photovoltaic (PV) disconnects that reduces the components and labor required for the installation process.

The new solar duty disconnects in GE’s line of EverGold™ Solar balance of system (BOS) electrical components provide minimum complexity and maximum savings with a simple and dependable alternative to stocking and installing splice boxes and oversized disconnects.

The 100-amp, four-pole disconnect (UL-listed, 600Vdc) accepts up to four combiner box inputs, making it ideally suited for medium to large commercial PV installations. The fourth pole reduces the total number of disconnects required. www.geindustrial.com/solar



reduced energy consumption. The tech-nology leaders are inverter applications in the solar market, but also uninterrupt-ible power supplies have new targets for improved efficiency.

Vincotech’s latest article compares and contrasts two types of modules, one with silicon switches and the other with SiC (silicon carbide) switches. This compar-ison indicates that modules with SiC JFETs achieve higher maximum efficiency, whereby the gains increase at higher switching frequencies. This means the user is able to increase both efficiency and switching frequency. Raising the switching frequency allows smaller passive filter components such as inductors and capaci-tors to be used, which reduces overall system costs.

SiC switches constitute a new class of 1200V switches. They enable engineers to signifi-cantly increase efficiency and switching frequency for demanding applications such as solar inverters. www.vincotech.com

BTU to highlight advanced thermal processing equipment at PV Korea 2012BTU International will highlight its next-generation thermal processing equipment in Booth K-41 at the upcoming Solar Energy Expo 2012 (Expo Solar/PV Korea). BTU experts will be on hand to discuss advanced thermal processing solutions for photovoltaics including metallization, diffusion and annealing.

BTU’s new TRITAN™ HV90 dual-lane metallization firing system will be intro-duced to the Korean market. This state-of-the-art system features increased throughput at 3600 wafers per hour, an edge support transport system, and a tempera-ture spike faster than three seconds. www.btu.com

New power semiconductor module from Vincotech combines MNPC topology with SiC switchesEfficiency is becoming increasingly impor-tant in power electronics. Many appli-cations are driven by the initiatives for

Innovative laser technology convinces PV manufacturersIn December, InnoLas Systems GmbH received orders from two international manufacturers for production systems with a capacity of more than a gigawatt. These systems support the innovative laser doped selective emitter (LDSE) technology. This additional process step uses the laser to diffuse dopants into the silicon underneath the later added metal contacts. Using this process, the efficiency of mono-silicon and poly-silicon cells can be increased by up to 0.5 percentage points.

The InnoLas systems achieve an outstanding throughput for this process step, so that one line can produce up to 100 MW cell power. www.innolas-systems.com

Vishay releases 45 V TMBS Trench MOS Barrier Schottky rectifiersVishay Intertechnology, Inc. has expanded its offering of TMBS® Trench MOS Barrier Schottky rectifiers with 12 new 45 V devices

New products for manufacturersNew products


New products

in three power package options that feature a wide range of current ratings from 10 A to 40 A. With extremely low forward voltage drops down to 0.51 V typical at 20 A, the rectifiers are optimized for use in solar cell junction boxes as bypass diodes for protection.

The devices released include the single-chip V(B,F)T1045BP, V(B,F)T2045BP, V(B,F)T3045BP, and V(B,F)T4045BP. Each device is offered in the power TO-220AC, ITO-220AC, and TO-263AB packages.

All rectifiers feature a 200 °C maximum junction temperature in DC forward current without reverse bias (t ≤ 1 hour). The devices are compliant to RoHS Directive 2002/95/EC and WEEE 2002/96/EC. www.vishay.com

New process for PV module productionThe TPedge module, jointly developed by Bystronic glass and the Fraunhofer Institute for Solar Energy Systems ISE, has successfully completed the mechanical load test and hail impact test. The char-acteristic features of the TPedge module technology are the local fixing of the cell —without lamination—and a glass edge sealing. The TPedge modules in the full-format measuring 1636 mm x 985 mm were subjected to the mechanical load test up to a force measuring 2400 N/m2 and the hail impact test with ball speeds of 23 m/s.

The tests that were performed on two TPedge modules were based upon the requirements as set out by the IEC 61215 Standard. No loss in performance could be detected on the modules following testing in the accredited “TestLab PV Modules” at Fraunhofer ISE. Losses in performance of up to five percent are permitted in the complete test sequence in accordance with the standard. According to a “TestLab PV Modules” statistics, approximately ten percent of module failures that occur during the certification tests are as a result of the mechanical load and hail impact test. www.bystronic-glass.com and www.ise.fraunhofer.de

Solar3D sets world record for silicon solar cellSolar3D, Inc., the developer of a 3-dimen-sional solar cell technology to maximize the conversion of sunlight into electricity, has performed a series of tests of its new silicon solar cell design that projects the

efficiency to be 25.47 percent, dramatically higher than current technology.“Our recent tests involve a larger design that contains multiple micro 3D photovol-taic structures that will make up a complete Solar3D cell. The results have exceeded our expectations,” said Jim Nelson, president and CEO of Solar3D. “If the results of the simulations hold up in fabrication, as we expect, our cell’s performance will be the highest conversion efficiency achieved in silicon solar cells.”

The company’s innovative solar cell tech-nology utilizes a 3-dimensional design, with increased cell surface area, to permit each solar cell to extract the maximum energy possible out of incident sunlight. Solar3D’s management believes that this breakthrough solar cell design will dramatically change the economics of solar energy. www.solar3d.com

Imec, Polyera and Solvay set 8.3% efficiency record for organic solar cell with inverted device architectureImec, Polyera and international chemical group, Solvay, have achieved a new world-record efficiency of 8.3% for polymer-based single junction organic solar cells in an inverted device stack. These excellent performance results represent a crucial step towards successful commercialization of organic photovoltaic cells.

Solar power is gradually becoming cost-competitive with traditional mainstream energy sources such as coal, oil, and nuclear. Continued reduction of manu-facturing and installation costs of solar panels will further drive this cost-compet-itiveness. Organic solar cells are holding the promise of addressing these issues, due to their potential to be manufactured on large-areas at high-throughput, and on lightweight, flexible substrates (like plastic or textiles), significantly reducing trans-portation and installation costs. This, along with optical translucency, gives organic solar cells the potential to be cheaply inte-grated into everything from clothing to building facades and windows.

Imec has developed a proprietary inverted bulk heterojunction architecture for polymer-based solar cells that simultane-ously optimizes cell light management and increases device stability. With this architecture, and a proprietary Polyera semiconductor in the photoactive layer, a team of imec and Solvay researchers now announces a certified conversion efficiency of 8.3%. This is the highest certified effi-ciency reported to date in the world for inverted polymer cell architectures. www.imec.be and www.solliance.eu

BTU International’s TRITAN™ HV90 metallization firing system exceeds industry specification for yieldBTU International, Inc., a leading supplier of advanced thermal processing equipment to the alternative energy and electronics manufacturing markets, announces that its TRITAN™ HV90 dual-lane metallization firing system exceeds industry standards for wafer breakage. The three-belt, three-speed system boasts a yield better than 99.99%, exceeding the industry standard for metallization firing.

“The HV90’s three-belt, TriSpeed™ system optimizes the thermal profile providing our customers a unique advantage to improve fill factor and cell efficiency,” said Bob Bouchard, product marketing manager for metallization products at BTU. “In an extensive field test comprised of over one year of full production, the TRITAN HV90 had a breakage rate of less than 0.01%, less than half of the industry standard of 0.02%.” www.btu.com


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