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Solyndra Confidential

Solyndra Product Training

• Product details

• Installation

• Connectors

• String Design

• Fuse Calculation


Product Details

Solyndra Confidential3

Solyndra ProductCylindrical Modules in Panel, with Mounts Included

Panel: 40 cylindrical modules in frame

Product: Panel + mounts

Cylindrical thin film cells

in glass modules


What’s Inside the Tubes?

• CIGS Thin Film: Copper, Indium, Gallium and Selenium (Diselenide)

• Film divided into ~150 cells using cutting lasers

• Cells are connected in series by internal conduction layers

• High Voltage/Low Current (more kWh/Roof Area) relative to c-Si solar panels


Optical Coupling Gives Concentrating Effect

• Tube within a tube design means less PV material required; reduces manufacturing cost

• Optical Coupling Agent (OCA) is safe, colorless fluid between tubes that acts as lens to concentrate light (1.5x) onto the CIGS material

• Dealing with Spills In Crate/Container

Small spills absorb into wood pallet of crate

Larger spills are unlikely

On a Roof

OCA is slippery so should be cleaned immediately

Cleanup kit available to perform safe removal

Disposal Classification: Not Hazardous Waste

• Material Safety Data Sheet (MSDS)

– Available in multiple languages

– Proves to authorities OCA is NOT toxic or hazardous


Hermetically Sealed for Reliability

Conventional CIGS Panels

–Watertight package isolates

CIGS thin film materials from

moisture

–Eliminates major issue for CIGS

and ensures long-term stability

• Moisture can penetrate, forming

oxides which degrade CIGS cells


Conventional PV = Inefficient Light Collection

Mechanical tracking required to capture more direct light

Poor collection of diffuse light

No collection of reflected light


Cylindrical Module = Optimized Light Collection

Horizontal mounting is optimum for solar energy

production; no need to tilt Solyndra panels

• Direct Sunlight:

Same collection at all

angles = “Self-Tracking”

• Diffuse Sunlight:

Enhanced collection

from all angles

• Reflected Sunlight:

Collection of light that

first missed tube


Conventional Photovoltaic System

Higher Solar Electricity Output Per Rooftop at Lower Cost of Electricity


Rooftop Example: >80% More Power and Electricity

1657.9 kWp Solyndra 907.3 kWp c-Si

c-Si panels oriented South, off building axis

to maximize efficiency

Solyndra panels can be oriented with building

axis to maximize roof coverage without

sacrificing efficiency


Self Tracking = More Energy Collected• Solyndra panels capture more energy early and late in the day

versus conventional panels

• Specific Yield (kWh/kWp) a better performance metric than Wp

Solyndra vs c-Si

Fremont, CA

Timestamp: June 15, 2008


Minimal Building Orientation Impact on Yield

85%

90%

95%

100%

105%

-90 -75 -60 -45 -30 -15 0 15 30 45 60 75 90

Solyndra

Angled Flat PV

West South East

Panel Azimuth

Example: Sacramento, CA.. Flat panel tilt = 20°

Relative

Annual

Power

Generation

• Solyndra loss ~1% @ 45°

from South.

• Tilted PV systems at 0° on a 45° building add system complexity

and sacrifice nameplate power

http://images.google.com/imgres?imgurl=http://upload.wikimedia.org/wikipedia/commons/thumb/f/f8/Compass_Rose_English_North.svg/300px-Compass_Rose_English_North.svg.png&imgrefurl=http://en.wikipedia.org/wiki/Boxing_the_compass&h=300&w=300&sz=63&hl=en&start=3&sig2=-NygrVNf9RKVo7hrUULWEQ&usg=__J40LIXtyT84lclWZSrNa3bu6EZ0=&tbnid=SrlbzooOoCE6WM:&tbnh=116&tbnw=116&ei=5pIUSai7A5CksQO-pPmICw&prev=/images?q=Compass+image&hl=en&rls=GZEZ,GZEZ:2008-30,GZEZ:en&sa=N


Self-Cleaning (Lower Soiling Loss)

Conventional Flat Plate Module

Solyndra soiling loss is ~1/2 that of titled PV panels

Dirt pools on flat surface Dirt rolls off cylinders


Test Results Validate Soiling Advantage

-10%

-5%

0%

0 9 16 21 28 35 42 49

Solyndra 3 Panel Avg.

C-Si 30° Tilt

C-Si 0° Tilt

Days

Test Location: Fremont, CA. < 200 yards from I-880

Soiling

Related

Efficiency

Reduction

Solyndra soiling loss is ~1/2

that of titled PV panels.

• Cylinders prevent pooling

• Dirt falls off the steep faces

• Wind blowing through the panels

removes dry dirt.

• Morning dew beads up, runs

around, and drips off the modules.

Rain

Rain


Lower Temperature Operation

Flat Plate Module With

Insulating Mounting

Conventional Flat Plate

Module & Mounting

Lower temperatures provide higher energy output and improved reliability

Air flow

Cylindrical Modules

in Panel


Solyndra Cells Cooler Than Flat Plate PV

Measurements by Pt100 RTD

• on back side center of Sharp panel

• in the center of the center module of the Solyndra panel


– Wind blows through Solyndra panels: no attachment to roof

or ballast required

Certified for applications up to 208 km/h

Lift force on Solyndra panel far less than panel weight

Imparts negligible structural loads

– A conventional panel will blow off roof if not attached or

ballasted; lift force can damage roof and structural integrity

Superior Rooftop Wind Performance

Conventional PVSolyndra


Performance Benefit in Light Snow

• Snow falls through Solyndra

panels & enhances albedo

(~95%+ Reflectivity)

• Snow sticks to c-Si panels

and causes loss of output

Solyndra array

c-Si array


2 Weeks

After Snow

Some

Bridging

Fully Bridged

Overnight

Mechanical Snow Loads

Snow Condition

ft m

Light, unpacked snow 7.3 2.2

Heavy, unpacked snow 3.2 1.0

Packed snow 1.9 0.6

Solid Ice 1.0 0.3

2800Pa

• Light snow will fall through

• Bridging in Heavy, Wet Snow

• Not an issue for panel strength in

moderate snow locations

• Solyndra max 2800 Pascal

(58.5lbs/ft2 or 285.5kg/m2)


Packaged System: Panel & Simple Mounting Hardware

• Non-penetrating and self-ballasted

• Up to 3x faster installation

• Up to 2x lower installation cost

vs.

Solyndra Conventional PV

Penetrating Non/Minimally-Penetrating

or


Solyndra’s Panel Mount Technology

Standard

Panel Mount(hard insulation, non-Rockwool)

Load Distributed Foot

Panel Mount (soft insulation, Rockwool)

22


Solyndra Roof Loading

Panel Mount ViewsIsometric From below

Contact Area = 17.6 in2

0.12 ft2

0.01 m2

Panel

Inner Panel Mount

Outer Panel Mounts

Component Mass

Panel Weight lbs 68.3 kgs 31.0

Panel Mount Weight lbs 1.1 kgs 0.5

Mass Distribution Per Mount

Inner Panel Mount lbs 35.2 kgs 16.0

Outer Panel Mount lbs 18.1 kgs 8.2

Contact Area Forces

Inner Panel Mount lbs / ft² 287.8 kg / m² 1405

Outer Panel Mount lbs / ft² 148.2 kg / m² 724

Rooftop Distributed Load

100% Coverage lbs / ft² 3.3 kg / m² 16.3


Fast, Easy, Economic Installation: Savings up to 50%

Connect Mounting Hardware Easy Panel Transport

Install ClipPlace, Plug In DC Connectors

and Ground Strap

Video

../../../../../../Video/Rooftop Assembly/Rooftop_Instructional_v.1.mov


50kW Customer Installation: Utah, USA


Concave

Convex

Flat with obstructions

Easily Installed Over Different Roof Areas

Curved


Data Sheet: Panel Electrical Data

• Range of available panels with increasing Wp

• Higher voltage, lower current (more kWh/Roof Area) vs c-Si panels

• Low temperature coefficients: As temperature increases, power

decreases less than other panels (c-Si -0.48%/˚C, CdTe -0.25%/˚C)


Data Sheet: System Information


Solyndra Panel Installation Training


PV Panel

Modules

End Covers

Frame

Lateral Clip

Hole

Ground Strap

Panel

Mounts

Blue SOLARLOK®

Connector (negative)

Red SOLARLOK®

Connector

(positive)

Ground Lug

Hole

Product Definitions and Identification

SOLARLOK® un-keyed

connector (negative)

SOLARLOK® un-keyed

connector (positive)


Safety and Handling PrecautionsTo avoid injury from electric shock or

laceration, care should be observed when

handling and working around panels.

•Don’t

• Carry a panel alone

• Handle by tubes

• Drop/place objects on panel

• Sit/Stand/Lean on panels

• Carry objects that obstruct your

view when working around panels

• Place panels where persons may

walk or trip over them

Do

• Lift with two persons

• Handle only by metal frame

• Carry one panel at a time

• Stack only in original packaging


Panel Mount Description

•Panel Mount–Panel mounts are made of white powder coated aluminum and are screwed into

the long-rail side of the panel. Panels are held in place by placing panel frame

under ridge of mount.

–Panels are self-ballasting with no roof penetration required to mount.

–Mount height is standardized to clear low roof obstructions.

Panel Installation

GuideFrame Installation

Screw Hole

Foot

Ridge


Provided PartsItem Picture Part # Description

Panel Mount 0040-30175

Panel mount for Solyndra photovoltaic panel. Attached using

1/4-20 screw. Because panels share panel mounts, the number

of panel mounts required will vary with each installation.

General Purpose

Screw0520-30658

M5 Phillips head with star washer, stainless steel. Used for

panel mounts, ground strap (2), lateral clip (2), and ground lug

(1). Total number required will vary with installation.

Ground Strap 0011-30029Insulated copper wire with lugs at each end. Used between the

long side of adjacent panels for array grounding.

Lateral Clip 0020-30213

Used to connect frames together with 10-32 screws. Has teeth

on one side; these go against aluminum frame to insure a good

connection.

Panel Prep Block 0205-30029Used to support the panel while installing Panel Mount. Four

are provided with each shipment.

OCA Clean-up Kit 0240-30833Clean up kit in case of panel breakage. One kit needed per

building or installation site.


Optional PartsItem Picture Part # Description

Cable Tray - Long 0020-30198 Used for routing the home-run cables around the array.

Cable Tray – Short 0020-30199 Used for routing the home-run cables around the array.

Cable Tray Clip 0020-30205

The cable tray clips are installed on the short side of the panel.

They are used to support the cable tray that contains the

home-run power connections.

SolarLok female

connector (+ red ring)0710-00075

Used to connect the home-run cables to the output connection

of the strings of the array (1394462-3).

SolarLok female

connector (- blue ring)0710-00077


of the strings of the array Tyco part number 1394462-4).

SolarLok male connector

used for ground, neutral. 0710-00379


of the strings of the array (6-1394461-2).

SolarLok male plug 0048-30100 Used to seal unused male Tyco SolarLok connectors

SolarLok female cap 0048-30094 Used to seal unused female Tyco SolarLok connectors

Ground Lug 0700-30198

Attaches to panel with a small screw. The wire-clamping

portion is open-jawed; permits the use of a continuous length

of grounding wire. Also available as Ilsco GBL-4DBT.

Pad, Panel Mount, TPO 0020-30225Pad for panel mount - TPO type roof membrane junction, at the

option of end user.

Pad, Panel Mount, PVC 0020-30226Pad for panel mount - PVC type roof membrane junction, at the

option of end user.

Pad, Panel Mount, EPDM 0020-30227Pad for panel mount - EPDM type roof membrane junction, at

the option of end user.


Recommended Installation Tools

Tyco tools for making electrical connections (jumpers & homerun leads)

Cable Stripping Tool

Tyco #1-1579002-2Crimping Tool

Tyco #1-1579004-2

Extraction Tool

Tyco #1102855-3

Small Electric Screwdriver Belt & Hardware Pouch


Panel Preparation – Staging & RolesStage parts to speed installation and avoid bottlenecks

Roles People Work Description

Panel Assembly 2 Remove panels from crate and stage installation materials

Install mounts, ground straps, lateral clips and ground lugs

Manage crate materials including recyclable plastic corner pieces

Carrier/Installer 2 Move panels from assembly area to array location

Place panel with previous panels, holding while electrical connections are made

Deliver messages about panel orientation and hardware requirements

Electrical 1 Install earth ground wire to first panel in column

Attach ground straps between panels in the same column

Install lateral clips between panels in adjacent column

Connect Tyco connectors for series and parallel connections

Decide who will perform each installation function


Lift panel from crate, handling only by the frame, and place on foam panel block

Panel Preparation - Handling

One person holds the panel (tube side), while the other person gets the mounts


Latch 4 mounts one at a time on the panel frame with the small tab facing up.

Panel Preparation – First Panel in Column

Align the mount hole with the large hole on the panel frame. Screw in place.


Loosely connect ground strap to frame. Connect ground lug to first panel in column.

Panel Preparation – Hardware Attachment

Loosely thread lateral clip screw on inner short rail. Carry panel horizontally.


Connect a 10AWG (6mm2) ground wire to the first panel in a column.

Panel Installation – System/Frame Ground


Remove the plastic pieces and set aside for recycling

Panel Preparation – Second Panel in Column

Latch only 2 mounts on the panel and install the ground strap (no lug required)


Carry second panel to first panel and latch into shared mounts

Panel Preparation – Connect Second Panel

Use tab to guide panel into position. Frame ridge must be under mount ridge.


Connect ground strap from short rail of one panel to short rail of adjacent panel.

Panel Installation – Electrical Connections

Connect Tyco connectors to form a series string.


Repeat steps to complete a column, checking alignment per the roof plan.

Array Origin

Panel Installation - Complete the String

Frame mis-aligned Frame aligned


Loosely install lateral clip at panel prep and place panel next to first column

Panel Installation – Second Column

After attaching frame ground, secure columns together with the lateral clip


Install cable tray clips on short rail. Route homerun leads in cable trays.

Panel Installation – Cable Trays

Rotate cable trays into mounts and clips, and then snap in place


Connect: Array > Combiner Box > Inverter > AC Grid

Connect Leads and Inverter


Tyco SolarLok Connectors

Name

Date


Tyco SOLARLOK® Connector Types• Male/Female determined by internal pin/socket, not outer housing

• Outer housings compatible between different wire sizes; pin/socket difference

Male has Pins Female has Sockets

Colored

O-rings

Indicate

Polarity/

Keying

Stamp

Shows

Polarity/

Keying

Wire Size Tyco Part Numbers

(mm2) (AWG) Male Plus Male Minus Male Neutral Female Minus Female Plus

4.0 12 1394461-3 1394461-4 6-1394461-2 1394462-4 1394462-3

6.0 10 6-1394461-5 6-1394461-6 6-1394461-4 5-1394462-6 5-1394462-5

Used on Solyndra Panels

For distributor inventory and contact information, check Tyco website:

http://www.tycoelectronics.com/commerce/sck/show_distributor_inventory_form.do

http://www.tycoelectronics.com/commerce/sck/show_distributor_inventory_form.do


Visual Connector Compatibility Chart

Male Neutral (Not Keyed)

Male Negative (Keyed)

• Same connectors found on

Solyndra panels.

• Use these connectors for

Homerun leads also

• Male Negative not found on

Solyndra panels

• Not compatible with female

positive (red o-ring)

connector

Male Positive (Keyed)

• Male Positive not found on

Solyndra panels

• Not compatible with female

negative (blue o-ring)

connector

Female Negative (Keyed)

Female Positive (Keyed)


Optional Connector Covers

• An array of Solyndra panels will contain some open panel connectors

• Open panel connectors within the array do not pose a safety or

reliability issue, but caps/covers are available if desired.

SolarLok female cap

Solyndra part no.: 0048-30094

SolarLok male dust cover

Tyco part no.: 1394739-1

Solyndra part no.: 0048-30100


Recommended Installation Tools

Tyco tools for making electrical connections (jumpers & homerun leads)


Tyco #1-1579002-2

Crimping Tool

Tyco #1-1579004-2

Extraction Tool

Tyco #1102855-3


Tyco SOLARLOK® Connector Assembly Steps

Step 3: Assemble Housing Notes

1. Use 4.0mm setting for Steps 1,2

2. Listen for noticeable “snap” sound

upon successful pin/socket

insertion in Step 3

Step 1: Strip Wire


Tyco #1-1579002-2

Step 2: Crimp Connector

Crimping Tool

Tyco #1-1579004-2

• Homerun and string jumper cables should be constructed with Tyco SOLARLOK®

connectors for easy connection to Solyndra panel connectors.


String Design


Panel Connector Orientation4 Connectors (Enables Series and Parallel Connections)

• Each panel has a positive and a negative side

• Modules (tubes) are connected in parallel within a harness along the panel frame

(red/blue shading)

• Each side of the panel has two connectors, one at each corner. One connector is keyed

either positive or negative, and the other is universal male. All are labeled or color coded.

Male Positive

Female Negative

Female Positive

Male Negative

+ Positive Side

- Negative Side


String Building Blocks: Vertical Rectangle


String Building Blocks: Horizontal Rectangle


String Building Blocks: Combination


String Building Blocks: Triangle


Panel and Vertical Series String Connections

• A series string is constructed

by connecting positive and

negative panel sides

• Connections should be made

on both sides of the panel

(both sets of blue-red arrows)

for redundancy and a clean

looking installation.

• We recommend orienting

panels and strings

consistently within an array

when possible to simplify

assembly.

Positive (+) Side

Negative Side (-)

Panel Series String

Positive (+) Side

Negative Side (-)

1

2

3

4

5

N


Vertical String-Block Connections

Parallel

Connections

Parallel

Connections

Series

Connections

+ +

- -

Positive

“Home Run”

Negative

“Home Run”

Negative

“Home Run”

Positive

“Home Run”

String-Block (3 Parallel Strings)

• Sub-Arrays are constructed

by connecting 3 series strings

in parallel with each other

• “Home Runs” are wired to

combiner box fused inputs or

directly to an inverter.

• Only one set of “Home Run”

points (the closest) need be

connected

• Dust caps are available to

protect unused “Home Run”

connectors.


Horizontal Series String Connections

• Horizontal String Connections

+ -

Positive (+)

Side

Negative (-)

Side”Series

Connection

Series

Connection

Series

Connection

No

Connection

No

Connection

No

Connection

No

ConnectionNo

Connection

1 2 3 4

• In some cases, it may be more convenient to construct horizontal strings

which can be achieved by alternating the panel orientation

• It is important to make connections only where indicated, otherwise

shorting may occur

N


Horizontal String-Block Connections

• Horizontal “String-Block” Connections

N

+

-

Positive (+)

Side

Negative (-)

Side”

1 2 3 4 5

1 2 3 4 5

1 2 3 4 5

Parallel

Connection

P1

Parallel

Connection

P2

Parallel

Connection

N2

Parallel

Connection

N1

• Two sets of jumpers are required between positive and

negative ends of the strings

1m Positive Jumpers

P1

P2

1m Negative Jumpers

N1

N2


Alternate String Connections

• “Wrapping” String Connections

+ -

Positive (+)

SideNegative (-)

Side

Series

Connections

No

Connection

1

2 3

4

• In some cases it may

be necessary to

continue a string

around a corner

(wrapping)

N


Alternate String Connections

• Hybrid String Connection (Skylight Example)

N

+

-

Positive (+)

Side

Negative (-)

Side

Skylight

Skylight Setback

Series

Connection

1

2

3 4

Series Connections Series

Connection

5


Connectorized HomeRun Jumpers

66


Real World Example: Movie Theatre•130kWp, 805 Panels, 4 Different Levels, 6 Layout Shapes


Costco, Hazlet, NJ; 3060panels, 530kW

68


Importance of Array-to-Inverter Matching

• “With too few modules in series an inverter cannot maintain an array’s

MPP under high temperature conditions for the site, sacrificing energy

harvest

• Too many modules in series results in voltages above 600/1000 Vdc,

which can damage equipment, violate [local electrical] codes and void

the [inverter] manufacturer’s warranty”1

Note 1 – John Berdner, Array to Inverter Matching, SOLARPRO, December/January 2009

Maximum Series String

Length Limited By

Minimum Series String

Length Limited By

•Inverter maximum input voltage

•Wiring voltage rating

•Inverter minimum operating voltage

•Panel’s Vmp and temp coefficient of Voc

•Site temperature range


Inverter Operating Range vs MPP Range

Inverter Operating Range

Inverter MPP Range


Inverter Selection and String Sizing Worksheet


DC Wp to AC Derate Percent

•Real world performance typically lower than projected

–Voltage drops, panel mismatch, soiling losses reduce array output

–Inverter not always operating at peak efficiency

–Array output power lost in inversion process from DC to AC

•To make best use of inverter capacity, adjust

“DC Wp to AC Derate Percent” to match installation

conditions


Fuse Calculation and SFR


Calculating Total Fault Current

• If a ground-fault occurs, current can back-flow through a string to ground from two sources:

–Back-feed from other parts of the array

–Other strings protected by the same fuse

• Total Fault Current that can back-flow is calculated as follows:

– IBack-feed = IFuse

– IOther strings = n-1 Strings * String Isc * 1.25

– IFault = IFuse + IOther strings

* 1.25 is a safety factor for Δ STC

fuse fuse

array

back-feed:

Gnd

Fault

Ifault

n-1 strings


Calculating Fuse Sizes

•Per the U.S. National Electrical Code (NEC), fuse size is

calculated as follows:

– IFuse = 1.56 safety factor * Number of strings per fuse * Panel Isc

– Select the next largest available fuse size

•Example (3 strings of 165Wp Panels)

– IFuse = 1.56 * 3 * 2.74 = 12.82

– Next largest available fuse size is 15A


Three Strings in Parallel Maximum

•Maximum Fuse Size

–IFuse = 1.56 safety factor * 3 strings * 2.77A Isc = ~13A

–Next largest available fuse size is 15A

•Maximum Fault Current < 23A Series Fuse Rating

–IFaultMax = IFuse + (n-1 Strings * String Isc * 1.25)

–Plug in known values: 23 = 15 + (n-1 * 2.77 * 1.25)

–Solve for n: ((23-15)/(2.77*1.25)) +1 = 3 Strings

–Check: 15A + (2 strings * 2.77A * 1.25 safety factor) = 21.9


Sub-Array:3 Parallel Strings

5 Panels/String (600V)

(8/String in EU @ 1000V)

Array: 3 x 15-Panel Sub-Arrays

9 Parallel Strings

45 Panels

+

-

+

-

+

-

Parallel String-Block Connection

Every system string is in parallelHome-Run Cables

Inverter

Junction

Box


Questions?

solyndra product training - ostrovní off-grid ... · light, unpacked snow 7.3 2.2 heavy, ... outer...

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