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8/4/2019 GScatalog en 20110209
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GreenSolar Equipment Manuacturing Ltd.
About GreenSolar
GreenSolar is a high tech photovoltaic R&D company. Its target is to become one of the leaders
on the thin lm PV market. GreenSolar has the background of the well expert technical team from
EnergoSolar who already successfully installed over 100 MWp a-Si producon line worldwide.
GreenSolar manufactures, installs and services turn-key producon lines of thin lm solar modules.
It has a manufacturing capacity of 100 MWp producon lines/year on its 10.000 m2 producon
facility in Budapest. GreenSolar develops and sells its own technologies m aking it an ideal partner
for companies entering or expanding into the fast growing thin lm PV market.
Solar energy is becom-
ing a primary soluon of
choice for energy policy
decision-makers in many
countries around the
world. Large scale so-
lar energy producon is
about costs, return on in-
vestment and reliability,
factors that low cost thin
lm technologies can best
serve. The worldwide PVmodule producon ca-
pacity is expected to grow
dramacally in the next
decade and low cost thin
lm producon capacies
will lead that growth.
GreenSolar is involved in tan-
dem a-Si thin lm technolo-
gies making it a go-to tech-
nology source and equipment
manufacturer. GreenSolar
pursues research of a-Si/ c-
Si technology. GreenSolar
operates a state of the artpilot line having a oor space
of 1200 square meters. Ten
years of experse in thin lm,
the scale of R&D acvity, the
range of technologies and
the oer of a cost eecve
and exible turn-key produc-
on line makes GreenSolar
your real thin lm specialist.
Turn-key production lines or
tandem thin flm silicon solar modules
Product Catalog
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Turn-key tandem thin lm solar
module manufacturing systems
7 MWp/Year Tandem Thin Film Solar Module
Manufacturing System with Manual Loading
Edge grinder
laser scriber for TCO
Preheat chambers
1st glass washer
2nd glass washer
Box loading station
Box cleaning station
Active layer deposition chambers
Cool down chamber
Conductive layer deposition line
Panel light IV tester
Sand blaster
Ultrasonic bonding
EVA lay-up station
Module laminator
Assembly stations
Final IV tester
FORKLIFT WAY
Gas abatement systemDust filter
Glass driller
ISO7classcleanroom
ISO7classcleanroom
52000
Glass cutter
26000
31000
47000
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Turn-key tandem thin lm solar
module manufacturing systems
Why thin ilm solar modules are competitive
Within the past decade, the market of the solar photovoltaic modules grows at a very fast
pace. Aer some lile slow down in 2005-2006 due to the silicon shortage, the rate of growth
of the pv market recovered very fast, together with the commissioning of the new high purity
silicon producon facilies. The global nancial crisis of 2008-2009 had its eect over the pv
industry and market. The good of the bad is for consumers, hence the solar module prices havebeen halved within a very short me. GreenSolar gives a very viable soluon to the quest of
the compeveness by making possible the producon of solar modules at the lowest cost of
ownership on the market, and also the lowest cost of investment.
Cost of ownership example
Descripon Cost [USD] Cost [EUR] Cost [%]
Direct Materials 0.471 $/W 0.344 /W 68.16%
Depr. Producon Line (7 years) 0.125 $/W 0.091 /W 18.09%
Other Direct Costs 0.054 $/W 0.039 /W 7.81%
Personnel 0.020 $/W 0.015 /W 2.89%
Maintenance 0.010 $/W 0.007 /W 1.45%
Depr. Ulies (7 years) 0.008 $/W 0.006 /W 1.16%
ld ( ) $/ /
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Turn-key tandem thin lm solar
module manufacturing systems
Turn-key production lines
For a smooth start in thin lm module producon GreenSolar will provide you a real turn-key
soluon including the equipment, technology, know-how and a package of services including
assistance in business planning, factory design, installaon and setup, personal training, support
for material resourcing, performance and equipment warranty, aer warranty services and
technology upgrades.
With the delivery me of less
than one year GreenSolar
oers you a quick appearance
and a dynamic expansion in
the market. With GreenSolar
you have the opportunity to
start with a producon plant
with low level investment and
go for cercaons and for
big scale step by step in line
with your market penetraon.
With a producon line from
GreenSolar modules are
made in a simple process of
glass in module out, which
signicantly reduces materials, labor and energy inputs. The straight forward economic and well
designed technology and machinery keep quality high at a very compeve cost level. The special
easy-to-manage factory concept allows you low expense for building , skilled sta and maintenance.
Your likely producon cost with GreenSolars producon lines and technology will be one of the
lowest on the market accompanied with good quality allowing you protable producon under all
circumstances. On the top of that GreenSolar oers technology upgrades ensuring you long term
compeveness on the market.
Environment
We all know that solar energy is a good soluon to reduce the carbon emissions that contribute to
the greenhouse eect, and to the gl obal climate change. Thus solar modules are green, but have
you ever thought about how green their manufacturing is?
It is a very odd thing to reduce the carbon emissions by gaining energy by photovoltaic devices,
while the manufacturing of some solar modules contributes to the emission of gases, which are
much more harmful greenhouse gases than carbon dioxide.
Sulphur Hexauoride (SF6) is the most potent
greenhouse gas that it has evaluated, with a
global warming potenal of 22,800 mes that
of CO2 when compared over a 100 year period.
Nitrogen Triuoride (NF3) is a greenhouse gas,
with a global warming potenal 17,200 mes
greater than that of CO2 when compared over a
100 year period.
Fluorine gas that is claimed to be
environmentally friendly alternave to SF6
and NF3 is nevertheless a potenally hazardous
and very agressive substance, which in contactwith water forms hydrouoric acid that is
so agressive, that it corrodes even glass and
stainless steel.
Would you like to handle such substances in
your factory?
Can anybody guarantee that no leaks will ever
occur?
GreenSolars technologies do not require any kind of uorine gases, neither SF6, N F3, nor F2, thus
using GreenSolar manufacturing equipment means saving the atmosphere.
Many technologies use such agressive gaseous chemicals because of the need to remove from the
electrodes of the CVD equipment the unwillingly deposited (doped or undoped) silicon. How is
possible that such unwanted deposion doesnt occur in GreenSolars CVD reactors?
The soluon is gi ven by design, hence in GreenSolars reactors the space where plasma is generated
is surrounded by the glass of the solar plates. Therefore 99.95% of the silicon deposion occurs
where it is intended, exactly on the surface of the future sol ar modules under process.
The lile deposion, which is in excess, all occurs on removable parts, that are taken out of the
reactors and cleaned mechanically, without the use of any chemicals, whenever it is needed.
If you are environmentally-conscious, before choosing one or another of the available producon
lines and technologies, ask for the uorine and uoride consumpons.
For a sustainable life, GreenSolar provides you only completely green, environmentally friendly
FLUORINE-LESS THIN FILM TECHNOLOGIES.
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Turn-key tandem thin lm solar
module manufacturing systems
ProcessTechnology
The manufacturing process applied by GreenSolar is based on what is known as amorphous
silicon technology. A key feature of this technology is the use of Plasma Enhanced Chemical
Vapor Deposion (PECVD) to form the amorphous silicon semiconductor lm layers. Although the
energy conversion eciency of amorphous modules is lower than that of single-crystal units (an
average of 6-7% compared to an average of 12-16%), they are cheaper to produce and convertmore electrical energy than crystalline modules with the same nominal power used under high
temperature environment or in diuse light condions.
The amorphous silicon thin lm solar
cell technology oered by GreenSolar
Hungary Equipment Manufacturing Ltd.
involves the deposion of two extremely
thin solar cell structures on top of each
other onto a TCO-coated glass sheet with
a total layer thickness of less than one
micron.
This structure is called tandem or double
juncon solar cell.
Regarding the operaon of this solar cell
structure, the rst cell converts mainly the
shorter wavelength part of the spectrum
of incident light while the second cell
converts the longer wavelength part.
Comparing this structure to the so-called
single juncon structure, where only one solar cell structure is deposited on the TCO-coated
glass sheet, it is possible to achieve the same absorpon while the individual cells are thinner.
The thinner the amorphous silicon layers are the
less the degradaon and the higher the stabilized
eciency of the solar cells.
As amorphous silicon thin lm solar cells have more
favorable temperature dependence compared to
their mono- or polycrystalline counterparts and
they work beer in diuse or low intensity lightcondions their yearly generated energy yield
under real life condions relave to their nominal
power is higher, as well.
Another advantage is that since thin lm solar cells
contain much less acve material than the mono-
and polycrystalline solar cells and their technology
involves only low temperature processes, their
producon is more cost eecve.
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GLASSWASHER
EDGEGRINDING
FORKLIFT WAY
FORKLIFT WAY
FORKLIFT WAY
FORKLIFT
WAY
FORKLIFT
WAY
step1
step2
D
ispensing
machine
46000
67400
Panel light IV tester
Class A IV tester
ISO
7class
cleanroom
Box loading station
Box cleaning station
Box storage
Dust filter
ISO 7 class cleanroom
Turn-key tandem thin lm solar
module manufacturing systems
15 MWp/Year Tandem Thin Film Solar Module
Semi-Automated Manufacturing System
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Turn-key tandem thin lm solar
module manufacturing systems
Recommended Equipment QuantitiesDescripon 7 MWp/year 15 MWp/year 30 MWp/year
GLASS PREPARATION [p cs or se ts ] [p cs or se ts ] [p cs or se ts ]
Glass Cuer 1 1 1
Glass Driller 1 1 1
Edge Grinder 1 1 1
Glass Washer (Aer Grinding) 1 1 2SPUTTER DEPOSITION OF T HE TCO LAYER (OPTIONAL)
Heang Tunnel (OPTIONAL) - - (1)
Vercal TCO Spuering System (OPTIONAL) - - (1)
Cooling Tunnel (OPTIONAL) - - (1)
Wet etching staon (OPTIONAL) - - (1)
PATTERNING OF THE TIN OXIDE LAYER
Laser Scribing System for Tin Oxide 1 1 2
Glass Washer (Before a-Si Deposion) 1 1 1
DEPOSITION OF THE TANDEM a-Si MATERIAL
Roboc Loading-Unloading Staon - - 2
Box Carrier for a-Si 8 16 32
Box Carrier Carts 8 16 -
Box Carrier Transport System - - 1
Preheat Oven 2 4 8
PECVD Deposion System for a-Si Layer 2 4 8
Cool-Down Chamber 2 4 8
EXHAUST MANAGEMENT SYSTEM
Gas Abatement System 1 2 2
Filter System 1 2 2
PATTERNING OF THE a-Si LAYER
Laser Scribing System for a-Si Layer 1 1 2
SPUTTER DEPOSITION OF THE BACK CONDUCTIVE LAYER
6 Chambers Spuer System for Al & ZnO 1 2 4
PATTERNING OF THE BACK CONDUCTIVE LAYER
Laser Scribing System for Al & ZnO 1 1 2
ENCAPSULATION
Laser Edge Deleon System 1 1 1
Ultrasonic Bonding System 1 2 2
EVA Applicator 1 2 1
EVA Laminator 1 3 6
Electrical Assembly Staon 1 4 2
Mechanical Assembly Staon 1 4 2
Juncon Box Filling Staon - - 1
MODULE TESTING
Quick Panel Light I-V Tester 1 1 2A Class Panel Light I-V Tester 1 1 2
Insulaon Tester 1 1 1
Climate Chamber - 1 1
Measurement Device Set 1 1 1
Light Soaker - 1 1
In-line Resisvity Meter (OPTIONAL) - - (2)
In-line Haze Tester (OPTIONAL) - - (1)
In-line Visual Purity Meter (OPTIONAL) - - (1)
OTHER INSTRUMENTS
Laser Marking System - 1 1
Maintenance Instruments 1 1 1
Transport Carts 21 12 12
Roller Table 4 - -
Conveyor System - 1 1
Utilities needed
Descripon 7 MWp/year 15 MWp/year 30 MWp/year
Factory oor space [m2]
(without warehouse, oces etc.)
1500 3000 6000
Installed electric power [kW] peak
average
440
290
970
600
1800
1200
Compressed air [liters/min] peak
average
1350
900
1850
1230
2000
1400
Cooling water* [m3/hour] peak
average
11
5.8
22
11.5
38
22
* It is strongly recommended to have a closed loop cooling water circuit.
City water City water is used by the laminators for cooling down
and also for service operaons.
It is up to the user to consider a closed loop system
also here.
Process water The main process water is used in the glass prepara-
on and the washing systems.
The washing system pically needs de-ionized (DI)water for the rinsing, and normal water for the pre-
washing.
Glass preparaon and washing machines work par-
ally with water recycling system.
Air condioning The temperature in the building shall stay within
23 2C.
The humidity level shall be in the 50-70% range
(non condensing).
Cle an room condions It i s re commended that a -S i pae rn ing to be done in
Clean Room Class 7 (as per ISO 146441-1 standard)
Technology gases The supplier of the process-gases shall buid the GasSupply System and shall supply the gases during the
operaon.
The process requires the following gases:
Ar, N2, H2, He, SiH4, CH4, 3% B(CH3)3 in SiH4, and 3%
PH3 in Ar.
Nitrogen is needed both as nitrogen gas and l iquid
nitrogen.
The quality of the gases shall be guaranteed at the
consumpon point by the supplier of the gas system.
The gas system supplier suppliess the gas detector
system as well.
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Turn-key tandem thin lm solar
module manufacturing systems
Descripon 7 MWp/year 15 MWp/year 30 MWp/year
Module Dimensions [mm] 12456357
Module Area [m2] 0.79
Cell Aperture Area [m2] 0.71
Inial Power [W] 55
Degradaon rate [%] 18
Stabilized [Wa/Module] 45
Total hours per year [hours] 8 760
Upme [%] 80.5
Real Producon [hours] 7 056
Nominal Producon [MW] 7 15 30
Tact me [pcs/hour] 24 48 96
Produced Modules [pcs] 169 334 338 668 677 376
Yield [%] 94.0 98.0 98.5
Good Modules eecve [pcs] 159 183 331 914 667 215
Producon eecve [MW] 7.16 14.93 30.02
Tipical annual capacity of the production lines
Manpower needed
Descripon 7 MWp/year 15 MWp/year 30 MWp/year
Operang personnel that must work in every shi
Glass preparaon (+OPTIONAL TCO) 5 4 4 (+3)
Lasers 3 4 4
PE-CVD 4 6 8
PVD (+ sandblaster for 7MWp only) 2 + 4 1 2
Encapsulaon, assembly and test 8 14 14
Quality control 2 3 4
Maintenance and repair 2 3 4
Total personnel per shi 30 35 40 (43)
Technical management and support personnel (dayme only)
CTO and deputy CTO, Workshop Manager 2 2 2
Speciality engineers 6 6 6
Quality manager 1 1 1
Chief of maintenance - 1 1Warehouse personnel 2 4 6
Total dayme personnel 11 14 16
Examples for the Performance of the Produced PV Solar Modules
Descripon Customer 1 Customer 2
Electrical SpecicaonsStabilized Rated Parameters at STC*
Rated maximum power Pmax 45 W 52 W
Rated voltage at Pmax Umpp 47.4 V 71.2 V
Rated current at Pmax Impp 0.95 A 0.74 A
Open circuit voltage Voc 65 V 93.5 V
Short circuit current Isc 1.3 A 0.88 A
Temperature coecients Uoc
Isc
Pmax
0.28 %/C
+ 0.09%/C
0.19%/C
0.30 % /C
+ 0.08 %/C
0.15 % / C
Maximum system voltage V 1000 V 600 V
Mechanical Specicaons
Dimensions [mm] 1 245 635 7 1 245 635 7
Total surface [m2] 0.79 0.79
Acve surface [m2] 0.71 0.71
Lateral structuring laser paern laser paernOverall weight [kg] 13.5 13.5
* STC (Standard Test Condions): 1,000 was/m2 irradiance,
AM 1.5 solar spectral distribuon, 25 C cell temperature.
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Beyond eficiency
Conclusions of a real-life module performance tesng in Bulgaria. Standard thin lm solar
modules model SP44 have been installed on a test PV eld and have been monitored for ve
months, together with polycrystalline modules of one of the well-known brands. The modules
were installed under an
opmal x lt angle. Thetotal installed capacity
was about 1.7 kWp for
both types of modules
connected to the same type
of inverters under similar
dc condions.
During the enre test, an
average daily irradiance
of 5.8 kWh/m2 with peak
days of 7.9 kWh/m2 have
been recorded. Ambient
temperature ranged from
+1C to +40C with an average of +22C. The output P AC values of the integrated daily energy
d bt i d f th i t
50
40
30
20
10
0
Weekly
SpecifcYields[kWh/kWp]
16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34
Weeks of the year 2010
50
40
30
20
10
0
Weeklyirradiance[kW
h/m2
]
30
25
20
15
10
Averagetemperature[
OC]
SP44 modulespolySi modules
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Turn-key tandem thin lm solar
module manufacturing systems
30 MWp/Year Tandem Thin Film Solar Module
Fully Automated Manufacturing System
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www.greensolar.hu
Intellectual PropertySince 2010 February GreenSolar Equipment Manufacturing Ltd is the legal owner of the IP, know-how, logo
and brand name of EnergoSolar Hungary Ltd. GreenSolar hired most of the expert technical and adminis-
trave sta of the former EnergoSolar, and connues to work on the projects started once by EnergoSolar
Hungary Ltd in China.
RealizationsGreenSolar is a young company, but it has a well assembled team of managers, designers, engineers, techni-
cians etc. This team has already produced and installed a total manufacturing capacity of 120 MWp/year
in several locaons*:
2005-2007 Bangkok Solar Co., Ltd., Thailand2006-2008 Tianjin Jinneng Solar Cell Co., Ltd., China
2007-2008 HelioGrid Hungary Ltd., Hungary
2008-2009 SolarPro AD, Bulgaria
2009-2010 Parity Solar Technology Zhenjiang Co., Ltd., China
*as of the end of year 2010.
R&D ProjectsRecently GreenSolar has built up its new pilot line for R&D acvies, as the development of increased
eciency thin lm silicon solar modules, manufacturing of double size solar modules, creaon of micro-
morph solar modules and further reducon of manufacturing costs.
GreenSolars policy is to deliver to its customers products of the best performance and compeveness.
Contact Details
GreenSolar Equipment Manufacturing Ltd.
Gymri t 128., H-1103 Budapest, Hungary
European Community
Tel.: +36-1-445-0777, Fax: +36-1-434-0101,
e-mail: [email protected], hp://greensolar.hu
VAT No.: HU11706906
DisclaimerThe contents of the present brochure are for general informaon and promoon purpose
and by any means do not represent any commercial oer.
In order to get a quotaon, please contact the sales personnel of GreenSolar by e-mail to
[email protected] or by fax to the number +36-1-434-0101.
GScatalog20110209_v3