PES: Europe

CORPORATE FOCUS

98

First of all: the result of the quality process

Due to the integrated production in Thalheim – from growing crystals to the finished module – Sovello knows precisely what material is used in the production process, where and why it is used, and has all the tools for measuring the end result. Quality checks throughout the production process of each product provide a consistently high level of workmanship.

In this way the company can offer a high-quality product that underlines its claim to sell premium quality products that are “made in Germany”. Since 2011 this also

comes with an extended warranty of 10 years for products produced in Thalheim, enabling Sovello to guarantee even longer term and more sustainable product security for its customers. Thanks to their excellent specific output/weight ratio (W/kg), the company’s photovoltaic modules are easy to handle and are suitable for any kind of installation. In addition, Sovello also offers solutions both for small systems and large areas with high voltage and low voltage variants. Intelligent connections of the cell strings also ensure that our modules provide the highest possible output even in weak light situations and still perform above-average, even in partial shade.

More stable production procedure

The innovative production process of STRING RIBBON wafers at Sovello significantly reduces silicon waste and is by far more effective than most conventional processes. A 190µm thin ribbon of silicon is continuously created by pulling two filaments vertically through molten silicon. This ribbon solidifies during cooling, becomes stable and is then cut into 150mm wafers with a laser. The reduced number of production steps also ensures a more stable production procedure than most conventional processes

In comparison to STRING RIBBON the conventional production process used by other producers of solar wafers is more error-prone and consists of many production steps: large blocks of silicon are cast or drawn; next, the blocks are cut in silicon cubes, so-called ‘ingots’ which are then sliced into wafers. This process produces a significant amount of waste which cannot be recycled.

In the eyes of the company, quality is the benchmark used to determine the extent to which Sovello modules fulfil the

Introducing the quality processOne of the largest fully-integrated solar module producers in the world, Sovello ensures that all the elements of the production process correspond to the highest quality standards and constantly aim for improved sustainability and energy efficiency. Indeed, it is Sovello’s aim to become the world’s ‘most sustainable solar company’. PES takes a look behind the scenes of the company’s quality process.

SOVELLO ED_v2.indd 98 15/08/2011 15:41

www.pessolar.com 99

CORPORATE FOCUS

requirements of its customers. Aspects such as functionality, performance and price play a key role here. By the same token, the company is able to use raw materials resource – sparingly, thanks to the innovative production process – putting the company in the position to achieve its vision of sustainability. The customers of Sovello AG set the standards for the quality strategy of Sovello AG.

The three pillars of quality management

The quality of the company’s products is founded on three pillars: process, personnel and product. The first pillar represents efficient processes. Sovello achieves such process efficiency by focusing clearly on the value-added process. The second strategic pillar is the training and qualification of company employees. The extremely high level of complexity of company processes, from both a commercial and technical standpoint, can be successfully handled by employees who are highly qualified, experienced and motivated every day. The third pillar is product quality: Sovello modules meet current guidelines, laws, technical regulations and norms.

Quality checks – that is to say, standardised processes and preventative measures – are made at every stage of the value stream process: from checking the raw material, through the production process itself to the final inspection and dispatch of modules. Implementing these checks designed to ensure the highest quality standards, Sovello fulfils its quality promise.

Supplier quality standards

The quality success of Sovello AG starts with its suppliers. They provide the company with information about how they guarantee the quality of their supply products. In addition to this, Sovello assesses the performance of its suppliers on a quarterly basis. The company audits the supplier’s QM system at the production sites. Adherence to quality standards when goods are received, they undergo incoming inspection to see if they meet the specification criteria.

Quality standards during wafer production

Sovello is able to ensure the quality standards during the wafer production, from silicon to STRING RIBBON wafer. For example, when pulling the wafer from the silicon melt, the melting temperature and thickness of the pulled ribbon is checked. Similarly, the graphite parts which come into contact with the silicon melt are monitored. The entire process of the wafer production takes places under clean room conditions. So any contamination occasions are excluded, from the raw material, for example silicon of semiconductor quality, through the high-purity graphite to the resulting wafer.

SOVELLO ED_v2.indd 99 15/08/2011 15:42

PES: Europe

CORPORATE FOCUS

100

When slicing the wafer from the silicon ribbons using a laser, care is taken to ensure a smooth process. Sovello AG employees regularly inspect the laser process: they closely examine the wafer’s cross-section and quality. Quality control inspectors take regular samples. The exposure to air at high temperatures creates an oxide coating on the wafer’s surface which must be removed to maximise the electricity gain of the cell. The wafers are drawn through an acid solution bath where their surfaces undergo a cleaning process.

Afterwards, the wafers are rinsed and dried to prepare them for the next step in the process. Before it moves on to the cell production stage, the wafer is subjected to a comprehensive inspection. In order to be able to properly check the quality of the wafer, the measuring system is regularly checked and calibrated.

Quality standards during cell production

Sovello also ensures product quality during cell production phase, from wafer to the cell. The aim is to convert the wafer into a cell. The sheet resistance, anti-reflexion coating, contact placing, optical as well as electrical properties of the resulting cells are monitored. The cells represent the starting product to manufacture modules.

Quality standards during module production

The ready to use Sovello product is created in the module area of the production site. Sovello ensures that the quality of the module is right as well. The desired soldering process is ensured by a pull test, a method which is common throughout the electronics industry. It is important for the solar cells to be properly soldered in the Sovello module to ensure that the module can perform at its best. Furthermore, company employees monitor the lamination process, whereby the module components are permanently fixed to each other. Due to this permanent monitoring of the gel content the enduring stability of the company’s modules can be guaranteed. Furthermore, the high pot and grounding is checked.

Another step is to measure comprehensively the output of the module. All of the company’s products are measured using a calibrated flasher. Consistently positive output tolerances increase both the yield and profitability of solar installations using Sovello modules. Regular comparisons with accredited test agencies such as TÜV Rheinland, Fraunhofer ISE and PI Berlin help to ensure the quality of performance tests carried out on Sovello flashers. Carrying out internal and external comparative cross checks is a key component of our quality assurance concept.

During the final inspection, a comprehensive visual check of the modules is performed as well, in which the workmanship and

components are examined. The end result is a finished product with a guaranteed mechanical load of 5.4 kN/m2 and a maximum system voltage of 1,000 volts.

Reliability programme

The threshold values laid down for the mechanical load and voltage are not conjured out of thin air, but are the results of reliability tests. Besides external tests through accredited laboratories, Sovello modules successfully passed the intern reliability tests. The company’s reliability programme comprises a range of mechanical, electrical and endurance tests. It is based heavily on the strict IEC

61215 and IEC 61730 guidelines, rigorously inspecting every part of the product, from the junction box to the cell.

The mechanical tests determine the load, the stability of the connections and the ability of the module to withstand hail. Sovello ascertained the extent of the resilience of its modules by having its employees expose modules to a variety of different weather conditions over several hours. In the hail test, robots fire ice balls in rapid succession at the resilient modules.

The electrical tests measure the performance under outdoor conditions. In the outdoor test, photovoltaic systems

comprising company modules were installed, since which time a variety of influencing facts have been recorded.

In the endurance tests, the way in which the modules react to humidity under both hot and cold conditions is investigated. To do so, the modules are subjected to permanent stress in climatic chambers.

Module certification

Solar modules manufactured by Sovello AG have been certified in accordance with the standards of the Low Voltage Directive (LVD) 2006/95/EG considering the IEC 61730-1:2004 and IEC 61730-2:2004 security regulations. As well the accredited certification body TÜV Rheinland checks regularly if the Sovello modules fulfil the IEC 61215:2005 guidelines.

With regard to North America, Sovello modules have a certification according to UL 1703 standards.

On the basis of this initial certification, country specific listings are carried out in order to fulfil the conditions of national promotion programmes designed for electricians and end users. In order to sell Sovello modules on the British market, the Department of Energy and Climate Change has listed the T and X series Sovello modules. To acquire the listing, Sovello carried out an inspection of its production facilities in line with the MCS norm, the so-called factory production control.

In Australia, the modules of the X and T series has been listed by the industry association Clear Energy Council. Both were finalised on the basis of the IEC 61215 standards. The task of listing Sovello modules in Florida and California has been assumed by Florida’s Energy Research Institute and the California Energy Commission on the basis of the certification according to UL 1703 standards.

In France, Sovello modules are certified according to the CSTB standards.

The Sovello AG is certified according to DIN EN ISO 9001:2008 and DIN EN ISO 14001:2004. Certification according to BS OHSAS 18001:2007 and ISO 16001:2008 is planned for this year.

Quality assurance is a dynamic process which is subject to continual change and customer requirements: In order to be able to react and make decisions in a timely fashion, the respective quality status is called up on a regular basis.

For more information, please visit: www.sovello.com

About the companySovello is an integrated manufacturer of solar wafers, solar cells and solar modules. One of the key differentiators of Sovello’s high-performance quality products vs. traditional multi crystalline modules is the resource-friendly production process and short energy pay-back time.

The Sovello Group operates three production plants in Bitterfeld-Wolfen, Sachsen-Anhalt, Germany. The first plant, SV1, started production in June 2006. In June 2007, the second production facility, SV2, came online. With SV3, the third finished plant, Sovello’s production plants have reached a nominal production capacity of about 180 Megawatt peak (MWp) per year in Germany and 40 MWp per year in Canada. The capacity is permanently expanding. Sovello AG employs about 1.250 people in Bitterfeld-Wolfen. With the launch of Soventix GmbH and Soventix Canada in 2010, Sovello has expanded its scope to the international turn-key solutions business.

STR

ING

RIB

BO

N IS

A R

EG

ISTE

RE

D T

RA

DE

MA

RK

SOVELLO ED_v2.indd 100 15/08/2011 15:42

Quality, Made in GermanyEvery Sovello Pure Power solar module passesthrough 130 quality checks.

StabilityOur solar modules withstand highest windand snow loads of up to 5.4 kN/m2 (minimumrequirement pursuant to IEC 61215: 2.4 kN/m2).

Simple handlingSovello Pure Power solar modules are robust and lightweight modules.

SustainabilitySovello builds the world‘s most sustainable modules with the shortest energy amortisation time.

WarrantyWe offer a 10-year warranty on the workmanshipand also guarrantee more than 90 % (80 %) of the nominal power after 10 (25) years.

High earnings100% positive output tolerance and best specific energy yield.

Let‘s talk about facts.Sovello Pure Power series

You can find out more about our products at www.sovello.com

IMG / Sovello

26. EU PVSEC

Hamburghall B6

stand A37

Q.BIG Communication GmbH, Kunde: Sovello, Anzeige: PESEuropeEdition, 210 mm x 297 mm (zzgl. 5 mm Beschnitt), ISO Coated v2 300, 09.08.2011Sovello SPFC.indd 1 15/08/2011 14:24