SIMPLE TESTING TO EVALUATE TABBING RIBBON COATING … · 2018-07-12 · US solar PV trade war! – Usha Prasad TECHNOLOGY FOCUS 18. Simple Testing to Evaluate Tabbing Ribbon Coating

Mike GrenowInterview Inside

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SIMPLE TESTING TO EVALUATE TABBING RIBBON COATING ALLOYS, FLUXES, AND CELL METTALIZATIONSMANUFACTURING SOLAR PHOTOVOLTAIC PRODUCTS IN THE UNITED STATES • TENNESSEE: AN EMERGING SOLAR INDUSTRY LEADER

Covering India, Thailand, Malaysia, Singapore, The Philippines and Hong Kong

ForÊSolarÊandÊPVÊManufacturingÊProfessionalsSoutheast Asia

Volume 3 Number 4 June/July 2012

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ContentsEDITORIAL2. There seems to be no let-up in the Sino-

US solar PV trade war!– Usha Prasad

TECHNOLOGY FOCUS18. Simple Testing to Evaluate Tabbing

Ribbon Coating Alloys, Fluxes, and Cell Mettalizations Jim Hisert, Indium Corporation Jon Major, Indium Corporation Johannes Wendt, Q-Cells SE

SPECIAL FEATURES11. The Indian Solar Market – a new Solar

champion is growing up16. Success story Morgan Solar – challenging

the sun23. Tennessee – An emerging Solar industry

leader

INTERVIEW14. TRINA – Mike Grenow

REGULAR FEATURES4. Industry news6. New products for integration, installers &

manufacturers9. New products for Manufacturers30. International diary

Volume 3, No. 4June/July 2012

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Global Solar Technology – June/July 2012 – 1www.globalsolartechnology.com

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There seems to be no let-up in the Sino-US solar PV trade war!

Usha PrasadTechnical Editor

Yes, there seems to be no let-up in the Sino-US solar PV trade war. Firstly, last month, China reportedly

launched an investigation as to whether exporters from the US and South Korea illegally dumped solar-grade polysilicon. Four companies, GCL-Poly Energy Holdings Ltd, LDK Solar Co., Daqo New Energy Corp. and China Silicon Corp. are said to have filed complaints with China’s Ministry of Commerce (MOC).

Later, the Coalition for Affordable Solar Energy (CASE) responded to some anti-dumping complaint filed by Germany's SolarWorld at the European Commission.

According to CASE, solar installation costs are said to have fallen by 75 percent over the last four years. This has led to creation of jobs in the solar industry. This trade ruling apparently threatens to turn a win-win situation into lose-lose one, all in the name of punishing China.

Instead of escalating the US-China solar trade conflict, wouldn't it be better to start a broader collaborative process right away?

Closer to home, the SOLARCON India 2012 event is less than a month away. We are sure that the China-US solar trade war will be up for discussion very soon. As for the event itself, there are some very interesting sessions lined up such as:• CEO panel discussion on “Key

Requirements of Short-Term and Long-Term Solar Manufacturing Sustainability in India.”

• CEO Forum on “Can India Touch 100 GW Installed Solar Power Capacity by 2030?”.

• CFO Forum on “Solar Power Project Financing & Price/KWH of Solar Power — Setting Realistic Expectations”.

• “Manufacturing Cost Reduction” session.

• “The Indian PV Landscape by 2022” session.

• “Manufacturing Innovations in PV: Technology Outlook & Trends” session.

• Off-grid sessions: “Policy & Regulatory Enablers for Off-Grid Solar PV Growth in India”.

• “Rooftops, Micro Grids and other Off-Grid PV Applications.”

As an industry expert puts it, the solar market in India is at an inflection point. Solar capacity additions in the country is on the rise, which would help in realising the target set by the Jawaharlal Nehru National Solar Mission. Solar polices by respective states is sure to boost the sector. The solar capacity in the country which stood at about 20 MW in 2010 has crossed the 1 GW milestone in June 2012.

One sincerely hopes that there remains a strong focusing on the promise of affordable solar power in India.

— Usha Prasad

www.globalsolartechnology.com

Editorial

Bonfiglioli Transmissions (Pvt) Ltd,Business unit-RePV, Survey No. 528/1, Perambakkam High Road,Mannur Village, Sriperambudur Taluk, Chennai - 602 105, IndiaPh: +91 44 67103800 • Fax: +91 44 67103999 • [email protected]

Investing in solar energy for a brighter future.

As one of the world’s leading players in clean energy today, Bonfiglioli has the innovative know-how and technical capacity to bring utility and largescale PV power plants to life.

Bonfiglioli designs and manufactures a wide range of high-efficiency products for energy conversion from 30 KW to 1.6 MW inside the Bonfiglioli Vectron Center in Germany, a centre of excellence for photovoltaic energy, ensuring an optimal return of investment.

With over 12 years experience in the Indian market,15 branches spread across the country for sales and after-sales service, Bonfiglioli is one of the leaders driving the green revolution in India.

The future is bright with Bonfiglioli.

Siliken expands to the Asian market with two new offices in Japan and Singapore

Siliken, the international company dedicated to developing applications for the PV solar energy sector, continues its positioning and expansion in the Asian market. Recently, the company opened two new offices in Tokyo and Singapore which, in addition to its business presence in Australia, will cover demand in the Asian-Pacific region.

The decision to strengthen its presence in this market is based on the need to respond to a growing demand for PV quality solutions, a sector which pits Siliken against low-cost competitors.

The company’s main business efforts are geared towards residential and commercial applications, accounting for more than 70 percent of all installations carried out and in which both the performance and quality of the modules are key factors. However, the company also covers ground installations, which is a very steadily growing segment.

Yingli Green Energy obtains the first JIS Q 8901 Certification from TUV Rheinland Japan

Yingli Green Energy Holding Company Limited, a leading solar energy company and one of the world’s largest vertically integrated photovoltaic manufacturers, which markets its products under the brand “Yingli Solar,” informed that its wholly-owned subsidiary, Yingli Green Energy Japan Corporation, Ltd. obtained the first JIS Q 8901 Certification from TUV Rheinland Japan Ltd.

The JIS Q 8901 Certification was established on February 29, 2012 in the aim to encourage wider adoption of PV power generating systems, as well as to promote product reliability and user protection in Japan solar market. The certification specifies requirements for reliability assurance system concerning design, production and product warranty for PV modules.

“Yingli Green Energy becomes the first PV module manufacturer to obtain the JIS Q 8901 Certification from TUV Rheinland Japan, which demonstrates

that Yingli’s products fully meet the strict requirements of Japanese consumers, and will significantly help us develop the industrial and residential market in Japan,” said Masaki Mizuta, managing director of Yingli Japan. “We expect that the new FiT program started from July 1, 2012 will accelerate the Japan solar market. This certification will be a key factor for us to establish long-term cooperative relations with Japanese consumers and to provide high-quality and competitive products for them.”

“After establishment of the JIS Q 8901, TUV Rheinland Japan has started the certification scheme in July 2012. With our PV operation in Japan we again demonstrated that our aim is to provide excellent services to the industry and support in the creation of confidence in long-term product reliability. Yingli Green Energy has demonstrated its commitment towards market needs and expectations by successfully implementing all requirements of the JIS Q 8901. We are happy to hand over the certificate today,” said Stefan Kiehn, manager, Photovoltaic Laboratories of TUV Rheinland Japan. www.yinglisolar.com

Global Solar Energy brings powerful building integrated solar to Japan’s growing renewable energy market

Global Solar Energy, Inc., a leading manufacturer of flexible solar technology, has expanded into Japan’s growing solar market, establishing local partnerships and offering a new design of its PowerFLEX BIPV system that has been adapted specifically for use on rooftops in Japan.

Together with partners CBC Co. Ltd, Eco Holdings and OG Corporation, Global Solar is making it easy for Japanese businesses to adopt the most powerful flexible solar roofing module on the market and take advantage of the country’s new feed-in tariff (FIT).

On July 1st the Japanese government’s progressive new FIT program went into effect, requiring utilities to pay 42 yen per kilowatt-hour (about $0.52 per kilowatt-hour) for 20 years from solar plants generating 10 kW of energy or more. As the country reduces its dependence on nuclear energy and opens the door for

more renewable energy adoption through the new FIT, researchers estimate this could foster a solar market of $9.6 billion and 3.2 gigawatts (GW) of capacity.

With 12.6 percent aperture efficiency, the Global Solar PowerFLEX BIPV module delivers the highest efficiency in the flexible module sector. Its large format and a high power density (300 W) bring down installation and balance of system (BOS) costs. With a lightweight and flexible design, the PowerFLEX BIPV system is the perfect solution for commercial roofs where traditional glass solar modules are too heavy.

Typical Japanese buildings have compact roofs, making the PowerFLEX BIPV a perfect fit as the module allows more power generation per square foot than any other BIPV solution. Additionally, by being applied directly to a roofing surface and requiring no mounting hardware or roof penetrations, Global Solar’s system maintains the integrity and aesthetics of a building structure.

Largest solar power plant on the Maldives goes online

The Maldives is accelerating the energy turnaround in its own country with the commissioning of the largest solar power plant so far. A new 294 kilowatt photovoltaic plant has been supplying power to hospitals and schools on six islands since last week.

WIRSOL SOLAR AG is the first German company which has installed solar systems in the sunny paradise with an output of 652 kW. The global project developer from Baden-Württemberg wants to build at least 20 MW more over the next few years.

Power is almost exclusively produced by diesel generators on the Maldives. Noise and air pollution are the consequences for the island state in the Indian Ocean. The roughly 1,200 islands in the Maldives predominately lie no more than one metre above the rising sea level.

This type of power production is also extremely expensive. The costs for one kilowatt hour of diesel are currently about 29 US cents. The Maldives spend roughly 17 percent of its gross national product on the import of diesel, while the price for fuel is constantly rising. The island state has therefore decided to be the first country to produce its entire power

Industry news

4 – Global Solar Technology – June/July 2012 www.globalsolartechnology.com

Industry news

requirements by using regenerative energy sources. It wants to achieve this ambitious goal by 2020.

IBC SOLAR AG surpasses the 2GW mark

IBC SOLAR AG, a global leader in photovoltaic systems, celebrates its 30th anniversary this year. At the end of June 2012, IBC SOLAR AG implemented more than 2GW of solar modules group-wide.

In March the company also reached another milestone with the delivery of its ten millionth solar module.

On average, the company has supplied around 475.000 households with environmentally friendly solar energy each year.

From early beginnings in 1982 as an engineering firm, IBC SOLAR has become one of the world’s leading providers of complete photovoltaic systems. The company, located in Germany’s Upper Franconian region, has received numerous awards, including Bavaria’s ‘Best 50 Award’, ‘Employer of the Year’, ‘SIEgER 2012’ and Ernst & Young’s ‘Entrepreneur of the Year 2009’.

In addition, the company recently acquired a number of accreditations including, DIN ISO 9001, DIN ISO 14001 and BS OHSAS 18001.

IBC SOLAR has a distribution system that has proven successful since the company was founded. The company regards its distribution network as the most important sales channel which it focussed on back in 1985 and has since developed into a comprehensive network of local partners.

AT4 wireless obtains the CPV accreditation for CPV

T4 wireless has obtained CPV accreditation which enables it to perform testing according to the Standard IEC 62108 for concentrated photovoltaic (CPV) modules. As the photovoltaic industry is growing at a rapid rate, module manufacturers are constantly starting up new strategies and looking for innovative materials that reduce costs and increase effectiveness.

After a long time of research, the Concentrating Photovoltaic (CPV) technology has experienced a remarkable development, as it uses lens able to focus the light onto small high-efficiency cells in order to maximize the performance and reduce the cost per watt.

These Concentration modules offer high energy yield (kWh/installed kW); higher efficiency, allowing smaller module

area; lower product costs, because of the reduction of semiconductor material; lower installation costs, and excellent performance in late afternoon.

AT4 wireless has recently been accredited by ENAC (Entidad Nacional de Acreditación in Spain) so as to perform testing according to the IEC 62108 Standard for Concentration Photovoltaic Modules.

WAAREE launches easy finance facility for the EPC as well as the solar modules

WAAREE Energies Pvt. Ltd. premium end to end solution provider in Solar Energy has launched easy finance scheme as a bridge finance as well as long term finance for the Solar PV projects. WAAREE will be offering finance to the companies who have already signed the PPA’s or planning to set the power project under various schemes. WAAREE financial product covers the bridge finance till project developers close long term finance.

The launch of WAAREE’s new scheme – Bridge/long term finance has laid the foundation for a bright future. Our effort to provide EPC projects with this commercial instrument has given a big impetus to developers under National Solar Mission (JNNSM). This exceptional way of financing emerged at appropriate hours for assisting the stakeholders of JNNSM. This has initiated assured growth in the nascent Solar market across India. WAAREE’s role is now to strategically give a new life to solar activities Pan India and provide required financial support for the entire solar market and fulfil JNNSM goal.

India’s largest and most efficient solar HVAC system with storage developed by Clique Solar inaugurated

India’s largest solar HVAC system with storage installed at NETRA (NTPC Energy Technology Research Alliance), Greater Noida was recently inaugurated by Union Minister of Power Sushil Kumar Shinde.

While leading the nation’s power generation capacity, NTPC’s focus has been on developing cutting edge technologies which will help in cost reduction and environment protection. To this end, NETRA has set up a Solar Energy Research Facility at Greater Noida. As part of this facility, Clique Solar, a Mumbai based Solar Thermal company,

has installed India’s first, and probably, world’s largest solar HVAC system with storage.

The Solar HVAC System consists of two large paraboloid solar concentrator dishes (ARUN® concentrator) providing dry saturated steam at about 200kg per hour to a 50 TR (i.e. about 175 kW of cooling) Vapour Absorption Machine (VAM). In turn, the VAM supplies chilled water at 7°C to the local cooling units installed in various rooms. The distinguishing feature of the system is the storage tank that can store up to 2 days of chilling. Offices are generally closed on weekends. To avoid wasting the solar energy, this 2-day storage facility has been included. The stored energy can be utilized to deliver cooling in late evenings or to cool a larger area.

Hanwha Group completes solar power generation project at Baijitan Nature Reserve in Lingwu, Ningxia, China

Hanwha Group, Korea’s top-10 business group, has completed the donation of a solar photovoltaic (PV) plant dedicated to assist rehabilitating land degradation, combating desertification and mitigating drought effects in the Baijitan National Nature Reserve of Lingwu City, Ningxia, China. The installation was completed with support of the United Nations Convention to Combat Desertification (UNCCD) and the State Forestry Administration and Forestry Department of Ningxia Hui autonomous Region. This project marks the first time the UNCCD’s has worked in cooperation with a private company to combat desertification.

Located near the Southwest edge of the Mu Us Desert, Lingwu City has a fragile, arid ecosystem which faces severe land degradation and desertification. The problem has intensified under the pressure of unsustainable development in past decades. With the partnership and support of the UNCCD, the Hanwha Group donated and installed an 80kWh solar PV generation facility, manufactured by Hanwha SolarOne, Co. Ltd., and provided technical training needed to manage and operate the facility. The solar plant will power a 3,200-square-meter greenhouse in the Baijitan Nature Reserve. Hanwha’s cooperation with Ningxia and the UNCCD is a unique public-private partnership which offers a framework for sustainable and long-term solutions to fighting desertification.


Industry news

New test meter for PV power analysis

A highly versatile new AC/DC clamp meter has been introduced for effective power measurement and diagnostic testing of solar PV systems.

The high performance Seaward Solar Power Clamp is capable of measuring DC and AC circuit power, in addition to true RMS voltage and current, harmonic distortion, power factor, resistance & continuity, diode check and capacitance.

The advanced new power meter has been specially designed for use by solar PV installers and technicians interested in power measurement and analysis on AC and DC systems and carrying out diagnostic checks on inverters.

With the 25 year lifetime of PV systems, periodic inspection and testing is necessary to ensure that they are operating efficiently and that maximum power yields continue to be provided. As the PV industry matures there is expected to be a significant increase in the volume of periodic inspection and maintenance work, making the Solar Power Clamp an ideal tool for this job.

The rugged and reliable Power Clamp can be used for maintenance and troubleshooting on the PV system after commissioning and to ensure that the inverter and other system components are working properly.

The new instrument forms part of the Seaward Solar range of specialist test instrumentation and accessories for the solar PV sector. These include the new PV150 dedicated electrical test kit, Solar Survey 100 and 200R multi-function irradiance and surveying tools, the and the SolarCert Elements PV system test record keeping program.

TMEIC’s SOLAR WARE® Main Site Controller provides centralized management of utility-scale PV installations

Built on decades of engineering experience with power electronics, the Solar Ware® Main Site Controller (MSC) offers the industry’s most advanced grid management. The MSC provides overall coordination and control of the PV plant by

providing access to complete information regarding the plant’s power production. The MSC also operates multiple Solar Ware® inverters.

The Solar Ware® Main Site Controller’s unique features include:• Single point access to the status of all

inverters.• Power Limit Reference Control – can

enable or disable the site-wide power limit function.

• Slew Rate Control – smoothes spikes in power output caused by events related to start-up and shut-down, power limit changes, etc.

• Power Factor Compensation – using power generation feedback from the Power Optimization network, the MSC calculates a reactive current reference for each inverter so that the total power factor does not change with load.

• Reactive Power Reference –MSC provides a fixed amount of VARs to the grid.

• Screen displays show status of the entire site, and allow configuration of the site rated power. Trend displays show details of the MSC operation, VAR output, average inverter voltage and site power limit.

• Integration as a possible factor for cost reduction by photovoltaic producers

Solar Maid introduces new O&M cost reduction tool

Solar Maid, North America’s leading janitorial solar O&M company has released a new solar O&M cost reduction tool called “Soil Boundary Analysis”™ which is helping solar system owners and managers better determine optimal O&M scheduling which provides direct cost savings.

In recent years, the solar industry has been blindsided by the escalating costs associated with solar O&M. The solar industry has become victim to its own sales hype believing that the systems they are installing will continue to produce at peak levels for 25 years with little to no maintenance required.

Reality tells us a much different story and the numbers do not lie. Consider the fact that all invertor manufacturers advise cleaning and replacement of the cooling fans and filters annually, that does not seem like “maintenance free” to me. A report released by NREL found that a minimal annual washing of solar panels increases production by an aggregate average of 16 percent and you don’t need to be a math prodigy to figure out that over a short period of time, dirty solar panels will lead to substantial production losses.

While the industry grapples with the issue of solar O&M and the bite it is taking from production revenue, help is coming from an unlikely place, the one company that stands to benefit the most from increased O&M expenditures. The leading janitorial solar O&M Company in North America, Solar Maid is the first company to develop a new tool to help solar asset managers lower their overall O&M costs and they are giving it away for free.

Geostellar unveils instant solar analysis for everyone

Geostellar, providers of advanced geomatic technology, launched today the first-ever online platform for property owners to instantly analyze the potential value of solar energy on their rooftops. West Virginia serves as the first region in the company’s nationwide rollout, with plans to launch in additional key markets over the remainder of 2012.

Through 3D simulations and proprietary algorithms, Geostellar instantly assesses the energy generation potential, environmental benefits and financial savings of “going solar.” Interested homeowners and commercial facilities managers can enter their address on Geostellar.com, where the property’s rooftop is analyzed on factors including shading, slope, orientation, incentives and utility rates. Property owners are invited to submit the resulting data to receive a free, independent system design with recommendations on equipment configuration, financing and installation options that provide the best financial return and achieve the maximum benefits from state and federal incentives.

New products for Integrators & Installers



Through the U.S. Department of Energy’s SunShot program, the “Rooftop Solar Challenge” awarded $12 million in funding to 22 regional teams to improve financing options, reduce barriers and lower costs for commercial and residential solar energy systems. Geostellar received $500,000 to assist with mapping the Mountain State, where a net metering program and a unique incentive for alternative fuels infrastructure have laid the groundwork for a strong solar market. Geostellar’s West Virginia Full-Scale Solar Team includes West Virginia University Natural Resources Analysis Center, Mountain View Solar, the JOBS Project, and Jack Fuller, Ph. D., a professor of management and industrial relations at WVU.

SolarEdge and Zep Solar launch the Zep Compatible™ Power Optimizer

SolarEdge Technologies and Zep Solar launched the joint solution of the Zep Compatible™ power optimizer at the Intersolar North America in San Francisco. The new power optimizer is seamlessly integrated with the frame of any Zep Compatible solar module. Unlike other module-level electronics on the market, the SolarEdgeZep Compatible™ power optimizer can be installed, without the need to run grounding wire, and combines its superior energy harvesting with the labor saving and aesthetic advantages of the Zep Solar mounting system.

Zep Compatible solar modules are available today from leading module makers such as Trina Solar, Yingli Solar, Canadian Solar, Sharp Solar, Upsolar, and ET Solar among others. The addition of SolarEdge’s power optimizer to the Zep Compatible platform will offer additional benefits and options to users of the technology, including some of the largest residential integrators in North America.

SolarEdge power optimizers present a 99.5percent peak efficiency and 98.9 percent weighted efficiency. The power optimizer maximizes energy production for each individual module offering

greater energy yields in both shaded and un-shaded scenarios and eliminating any form of module mismatch. Furthermore, module–level monitoring provides full visibility of system performance and remote troubleshooting. SolarEdge’sZep Compatible power optimizer can be connected to PV modules on the ground, allowing the mounting hardware, power optimizer and module to be installed on the roof at the same time. Wires are managed by snap-in wire clips offered by Zep Solar, which further streamline the installation process.

GE’s latest central inverter technology clears path for utilities to boost solar energy production worldwide

Marking a new technology milestone in the global effort to increase renewable energy production by driving down overall system costs, GE has deployed the first 1,500-VDC (volts, DC current) open circuit (OC) central inverter for utility scale solar power plants. The inverter will help reduce overall system costs, which is vital to making solar power a more economical alternative to fossil fuel technologies.

Central inverters are key components of photovoltaic (PV) plants. The technology converts DC power produced by solar panels to AC power, which is then fed into the main grid.

GE Energy’s Power Conversion business developed, built and delivered its 1,500-VDC ProSolar central inverter technology to solar power plant system integrator

BELECTRIC, the global market leader in terms of installed power. BELECTRIC installed GE’s advanced central inverter at its new solar power plant in southern Germany, utilizing PADCON’s 1500 VDC System Technology.

Balqon Corporation introduces HIQAP Lithium Battery for solar energy storage applications

Balqon Corporation, a developer of electric vehicles, drive systems and lithium battery storage devices, introduces low cost high capacity lithium batteries as an alternative to the current industrial deep cycle lead acid batteries. The new HIQAP(TM) batteries are available in 12, 24 and 48 Volt configurations with an amp hour capacity ranging between 700 Ah to 1000 Ah. HIQAP(TM) battery packs include Balqon proprietary Battery Management System (BMS) and related power electronics components for direct replacement of current lead acid battery packs. HIQAP(TM) lithium battery packs are designed to support large daily loads requiring deep depth of discharge and high energy transfer efficiency for solar, micro-grids, off-grid storage and telecom applications.

With estimated life of over 10 years and high energy transfer efficiency of lithium batteries, users can now capture 15 percent more energy from the solar panels. Growing worldwide concern over lead contamination resulting from lead acid batteries can hamper sustainable growth of the solar industry. HIQAP(TM) low cost, high efficiency, long life and zero maintenance can help long term growth of the industry.

HIQAP(TM) batteries include large format 1000 Ah and 700 Ah, 3.25 VDC folded prismatic cells connected in a series, available in 12V, 24V and 48V configurations. Life cycles of HIQAP(TM) batteries vary from 2500 cycles to 5000 cycles based on depth of discharge. Low internal resistance allows for over 95 percent efficiency during energy transfer compared to 80 percent efficiency of equivalent deep cycle lead acid batteries.




TUV Rheinland introduces new testing services to PV module manufacturers

TUV Rheinland PTL, North America’s largest solar and photovoltaic (PV) testing company, has introduced new services to test the quality and safety of components, modules and solar energy systems. These include testing of PV modules depending on their specific application; testing criteria stricter than the criteria mandated by the official standard; and continuous testing of the manufacturer’s production process and products.

The company offers new tests to evaluate performance of PV modules depending on where they are used. These requirements include salt spray tests for modules installed in coastal regions, ammonia tests for modules installed in agricultural areas, various snow load tests, and the initial criteria of a testing program for modules in deserts.

TUV Rheinland has also developed new services that go beyond the basic design certifications according to IEC 61215 or IEC 61646. The company is now performing regular, often unannounced, production inspections when certifying the designs of new manufacturers. TUV Rheinland specialists also select modules for laboratory tests directly from production rather than accepting items provided by the manufacturer, as set out in the standards.

AT4 wireless obtains the CPV accreditation for concentrated photovoltaic

AT4 wireless has obtained CPV accreditation which enables it to perform testing according to the Standard IEC 62108 for concentrated photovoltaic (CPV) modules. As the photovoltaic industry is growing at a rapid rate, module manufacturers are constantly starting up new strategies and looking for innovative materials that reduce costs and increase effectiveness.

After a long time of research, the Concentrating Photovoltaic (CPV) technology has experienced a remarkable

New products for

Manufacturers


development, as it uses lens able to focus the light onto small high-efficiency cells in order to maximize the performance and reduce the cost per watt.

These Concentration modules offer high energy yield (kWh/installed kW); higher efficiency, allowing smaller module area; lower product costs, because of the reduction of semiconductor material; lower installation costs, and excellent performance in late afternoon.

From now on, CPV module manufacturers can rely on the support of AT4 wireless, laboratory with more than 20 years of experience in testing and certification, in order to carry out the IEC 62108 testing that will let their modules to obtain TÜV Nord Certification, ETL for USA, and CEC (California Energy Commission in United States of America) Certification.

SGS joins forces with Atlas Material Testing Technology

SGS, the world’s leading inspection, verification, testing and certification company, entered into a contractual agreement with Atlas Material Testing Technology, a global leader in accelerated weathering instruments and weathering testing services, allowing for the expansion of the Atlas 25+ photovoltaic (PV) module durability test program.

SGS to Enhance Atlas 25+The Atlas 25+ test program has

been helping manufacturers determine the long-term durability of photovoltaic modules since 2009. Combining state-of-the-art accelerated instrument and outdoor exposure testing, Atlas 25+ complements short-term IEC qualification tests with long-term durability and reliability assessment to support warranty and performance claims. A comprehensive battery of tests, the original Atlas 25+ program integrates laboratory and outdoor environmental exposures to focus on the long-term product “wear-out” period that can result in declining module performance or complete module failure.

With the Atlas/SGS collaboration, the standard Atlas 25+ exposure and testing procedure will be enhanced with a six-month streamlined “basic” program

offering faster results and a twelve-month wider-ranged “premium” program to include additional climate factors and performance measurements. SGS clients will be able to access Atlas 25+ singularly or as an optional addition to the larger SGS PV performance tested certification which includes options for corrosive gas (e.g. NH3), salt mist, fire and potential-induced-degradation (PID) resistance to name a few. Modules passing these tests along with Atlas 25+ will receive SGS-PV performance tested ratings.

MAGE SOLAR introduces first plug and play AC-module on market with 30/30-Warranty

MAGE SOLAR, part of the globally operating MAGE GROUP, is introducing the first AC-module on the market backed with a 30-year assurance for module and microinverter.

The top-performing, premium quality MAGE POWERTEC PLUS PV-Modules are leading the industry with their positive 5 watt tolerance, 10-year product warranty, and 12-year 90 percent power guarantee, and the company’s distinctive 30-year 80 percent power guarantee. Now MAGE SOLAR is extending the same exceptional features to the newest member of its powerful product family, the MAGE POWERTEC PLUS AC-Module which will make its first appearance at Intersolar in San Francisco this month.

MAGE SOLAR’s complete AC-PV solution provides an extremely secure and time-saving option compared to other stand-alone microinverter systems. As the DC-to-AC microinverter is integrated into the module frame, the need for one central inverter or multiple string inverters is eliminated: the pre-installed, fully insulated AC-cable can simply be plugged into the AC-cable connector of the adjacent MAGE POWERTEC PLUS module, making this one of the easiest to install modules in the rapidly growing PV-market.

The microinverter technology is provided through a partnership with SolarBridge Technologies, the Texas-based leader in innovative module-integrated inverter design. SolarBridge

Pantheon II microinverters preassembled in the new MAGE SOLAR AC-module feature an unrivaled 30 year warranty to match the module’s industry-leading 30 year 80 percent power guarantee.

CAMiNI firing furnace successfully qualified for mass production processes

Roth & Rau AG, a member of the Meyer Burger Technology Group, has developed new technology for its “CAMiNI” firing furnace which sets new standards in terms of temperature stability and repeatability. The CAMiNI has also successfully qualified for use in mass production processes.

A major Taiwanese cell manufacturer deployed the CAMiNI furnace for the first time in its production lines. By the end of the qualification stage, involving a 1,000,000 wafer endurance trial, the manufacturer reported better process results than those achieved with competitor products. This success is due above all to the technologies newly developed for CAMiNI, which enable processes to be adapted flexibly to different cell types and which set new standards in terms of temperature stability and repeatability.

Alongside its maintenance-free ceramic roller transport system, the integrated drier system within CAMiNI enables users to significantly shorten the processes involved. Based on the results achieved, the conclusions drawn by the first CAMiNI customer were especially positive. On the one hand, the company achieved maximum cell efficiency rates of up to 19.14 percent during the qualification stage (average: 19.0%), while at the same time significantly reducing energy consumption (approx. 50%) and reporting extremely low breakage rates.

During the firing process, the contact lines printed on the solar cell are burnt in and thus connected with internal emitters, enabling electricity to be conducted out of the cell.

As a product which is especially suited for implementation within existing production lines, the CAMiNI firing furnace further strengthens the Meyer Burger Group’s innovative system offering in photovoltaic technology.

New products for Manufacturers


New products for Manufacturers

The Indian solar market – a new solar champion is growing up

India is one of the fastest growing solar markets worldwide. This development is driven by policies introduced by the

Indian government which over the coming years wants to turn India into one of the most important “solar states”. This is the environment in which the international solar industry is meeting for the fourth year running at India’s largest exhibition and conference for the solar industry, Intersolar India, from November 6 – 8, 2012. In hall 1 of the Bombay Exhibition Centre (BEC) in the Indian capital of Mumbai, around 350 exhibitors are expected to present their latest products and services from photovoltaics and solar thermal technologies across an exhibition space covering 20,000 square meters.

The Intersolar India Conference kicks off one day prior to the exhibition. From November 5–8, 2012, over 700 industry experts are convening at the LeelaKempinski Hotel in Mumbai and the Bombay Exhibition Centre (BEC) to discuss the latest developments across international solar markets.

The Indian solar market is undergoing sweeping developments. While, according to figures published by the Ministry for New and Renewable Energy (MNRE), India had a mere 10 megawatts (MW) of installed photovoltaic (PV) capacity in 2009, this figure had risen to over 200 MW by the end of 2011.

According to MNRE forecasts, the total photovoltaic (PV) output will exceed the two-gigawatt (GW) mark before the end of this year. The Indian government has even more ambitious goals for the future: According to the Jawaharlal Nehru Solar Mission (JNNSM), the target is for 20 GW of capacity to be installed by 2022, making India one of the most promising and fastest growing solar markets in the world. This is the environment in which the international solar industry is meeting for the fourth year running at India’s largest exhibition and conference for the solar industry, Intersolar India, from November 6 to 8, 2012. Around 350 exhibitors are expected to present their latest products and services from photovoltaics and solar thermal technologies across an exhibition space covering 20,000 square meters. Under the motto Connecting Solar Business, the exhibition helps demonstrate existing technological potential and strengthens the business network at an international and local level.

Plentiful amounts of sunshine for the growing electricity demand

According to DebashishMajumdar, chairman and director of the Indian Renewable Energy Development Agency (IREDA), India’s thirst for energy will double by 2020. The solar industry has

the ideal prerequisites to play an eminent role in meeting this demand. According the management consultancy Ernst & Young, 250 to 300 days of sunshine per year and 4 to 7 kilowatt hours of insolation per square meter make India one of the most promising locations for solar energy in the world. In addition, there is no lack of space for solar power plants. Just one percent of the country’s surface area would be enough to fully cover the forecasted electricity demand with PV by 2031.

Great potential for large PV power plants and microgrids

India’s government has long recognized the immense potential of solar technology in meeting the country’s energy demand. In addition to JNNSM, the expansion of capacities is mainly promoted locally by individual federal states. In the federal state of Gujarat, for example, a fixed feed-in tariff has been agreed and Power Purchase Agreements covering around 965 MW have been signed. Many other Indian states are expanding their capacities with the help of tenders for PV projects. In the federal state of Karnataka, for example, 60 MW were awarded recently as part of a tender and a further 25 MW in Orissa and 200 MW in Madhya Pradesh have been won. More tenders of various sizes are continually added: 250 MW are up for tender in

Intersolar India will be held from November 6 – 8, 2012 at Bombay Exhibition Centre (BEC), Mumbai.



Rajasthan while the federal state of Tamil Nadu is planning to have 3 GW installed in the coming three years.

On November 5, the Intersolar India Conference opens with a double session on current and future developments within India’s solar market, entitled India’s PV Market. On November 6, starting from 9:00 am, the Large-Scale PV Systems lecture series looks at topics ranging from the planning and financing through to the construction and maintenance of these systems.

India not only holds great potential for large-scale PV systems, but also for grid-

independent solar systems and the small local power grids known as microgrids. With 400 million potential customers, this market offers similar potential to the market for cell phones, which enabled one in two Indian households to own a cell phone within the space of just a few years. The consultancy Bridge to India estimates that the photovoltaic market for telecommunication systems alone will account for 2 GW within the next five years. In addition, there is demand for PV installations to provide electricity for basic needs, such as lighting and electrical appliances. For this reason, the Intersolar

India Conference concentrates on rural electrification in a double session entitled Off Grid PV Market India, which takes place on November 6 from 9:00am to 1:00pm. The strong insolation also offers ideal conditions for the application of solar thermal technologies, for instance in the use of solar process heat for commercial buildings and industry. Several presentations on November 5 from 10:00am to 6:00pm and on November 6 from 4:15pm to 6:00pm focus on opportunities for solar thermal technologies.

New category for the Intersolar AWARD: Solar projects in India

As part of the Solar Projects category, which was first introduced in 2012, the Intersolar AWARD presents a prize in the category of Solar Projects in India for the first time at Intersolar India. The solar industry’s innovation award in the areas of Photovoltaics, Solar Thermal Technologies and PV Production Technologies was presented at Intersolar Europe in Munich on June 13. To be valid for entry into the category of Solar Projects in India, projects must be fully completed but must not be older than two years at the time the application for the Intersolar AWARD is submitted. Exhibitors at Intersolar India 2012, Intersolar North America 2012, Intersolar China 2011 and Intersolar Europe 2012 are entitled to apply. Companies wishing to apply for the Intersolar AWARD in the category Solar Projects in India may register via the Intersolar India website under Exhibitor Services, Marketing + Promotion, Intersolar AWARD from August. The registration forms can be downloaded from here.

Intersolar India 2012 takes place at the Bombay Exhibition Centre (BEC) in Mumbai from November 6–8, 2012. www.intersolar.in

India’s government has long recognized the immense potential of solar technology in meeting the country’s energy demand. In addition to JNNSM, the expansion of capacities is mainly promoted locally by individual federal states. In the federal state of Gujarat, for example, a fixed feed-in tariff has been agreed and Power Purchase Agreements covering around 965 MW have been signed.



16 – Global Solar Technology –March/April 2012 www.globalsolartechnology.com

TRINA interview:Mike Grenow

belt tightening at the moment. As a vertically inte-grated supplier producing everything from the ingot

share the pain across each sector, or are you a lum-bering giant?

industry over recent years has been government sub-sidy driven. Every company now has to look at their business model and envision a future without the

The price of silicon has collapsed by over 50% in the past 12-18 months. Has that been a benefit or a challenge to Trina?I am not aware of the actual price we pay for silicon, but the reduction in silicon prices has helped all module manufacturers to o�er more competitively priced modules. On the other end of the supply chain, we do hear of some of the more highly priced silicon producers stopping production – we hope that remaining, lower-priced produc-ers can make up the di�erence and main-tain a stable supply chain for silicon. As we get closer to grid party, the solar pv market will transform from one that is

TRINA is one of the

world’s largest suppliers

of PV cells and mod-

ules. Trevor Galbraith

spoke to Mike Grenow,

Director of Marketing

about some of the

challenges facing the

industry today.

TRINA interview - Mike Grenow


Global Solar Technology – March/April 2012 – 17www.globalsolartechnology.com

currently policy-driven to one that is market-driven. Do you think that will make a big dif-ference to Trina?Absolutely, it will. We look at grid parity as a local phenomenon in each country and each territory within each country and it needs to be defined by application. Private home installations need to be compared against the price of electricity at the domes-tic point of supply, whereas distributed gen-

have to be compared against a di�erent set

also by the type of electricity generation, is it nuclear, or coal, or gas as there is typi-cal a ratio of 2:1 or in some cases 3:1 di�er-ence between the cost of retail electricity versus wholesale. We are already seeing grid parity at a domestic level in areas of southern California and upstate New York. Southern Italy and some parts of southern Australia have also reached grid parity.

So in these areas that have reached parity in SoCal and New York state, have you seen significant increases in demand for solar installations?

Yes we have, but grid parity is only

of an average domestic solar installa-tion is $30,000 with an ROI (Return On

still a big decision for homeowners, partic-ularly in today’s di�cult financial climate.

-vate financial programs such as Solarcity

Your new honey systems mod-ules claim an increased multi-crystalline panel efficiency of 274 Watts peak. What tech-nology improvements have you made to achieve this?It really is a combination of technology

key improvement has been in the area of

surface texturing, which allows better sur-face area for capturing more sunlight and

a world record and we need to work hard to ensure we hold onto that world record. We are building our technology innova-tions around multicrystalline silicon; how we connect the cell, the types of glass we use and we capture light at the cell surface level.

Do you utilize micro-inverters on the module, or do you use standard inverters?At the moment we try to work as closely as possible with our customers to make sure our panels work well with their favorite or preferred brand of inverter technology. We find that in each country there happens to

-tional inverter companies that sell world-wide, but there are always local companies that manufacture inverters for the local market. At some point in the future I am sure we will see a Trina system that incor-porates micro-inverters onto the panel.

Your Trinamount system offers a huge labor, and therefore cost-saving. Another benefit you claim is it offers greater protec-tion against theft. Is this is a common or significant prob-lem in the industry?Yes, I have heard of solar installations, especially during the construction phase, where panels of up to 20 – 50 Gigawatts are stolen from the construction site. When each 250 watt solar panel looks like a $250 bill there is considerable incentive to steal them. What we have developed is a system that requires a special Trina tool to assem-ble the panels and without one, you cannot take them apart.

Do you have a module tracking system in place and what kind of warranty do you offer?Our warranty is head and shoulders above

-try warranty is 90 percent warranty up to 10 years and 80 percent warranty up to 5 years and it is built as a step. Our warranty is linear in that it steps down 2% per year every year until 10 years, so we are basically guaranteeing 3-5 percent more power than other providers. With regard to module tracking, we work with the largest system integrators in the world and every panel that we ship has a flash report that com-municates to the buyer what the voltage characteristics of that panel is under vari-ous light conditions. Our customers take that information and build it into a data-base where they track the performance of

code readers and that communicate with the database and feedback information.

Where does Trina see it’s future growth coming from?Referring back to the discussion on grid parity, we feel that the solar industry is only just reaching first base. Honey has the technology to take us forward to the next level and we have the financial strength to help make that happen. And while that happens, creating world class products and solutions that maintain us in a leadership position.

TRINA interview - Mike Grenow


Success Story Morgan Solar: Challenging the sun

Solar energy, either thermal or photovoltaic, has become the fastest-growing alternative energy

technology globally. It is popular because it provides individuals and corporations with the ability to make an individual effort towards reducing the effects of climate change.

Since October 2003, Ontario has added more than 1,200 megawatts of new, renewable generation, including more than 150 solar projects of varying sizes, including residential systems and small arrays on commercial buildings, institutions and schools.

In 2010 alone, Ontario installed 168 megawatts of solar photovoltaic capacity, surpassing New Jersey as the second leading North American jurisdiction for new solar projects during that year. Ontario could soon surpass California in annual installations if recent growth rates continue. This is good news for investors who are interested in Ontario, as opportunities continually grow for renewable energy generators and for manufacturers of renewable energy products and services.

One great example of the opportunities that abound for innovation and growth in Ontario is a firm called Morgan Solar. Still a start-up, Morgan Solar has nevertheless lured one of the world’s top solar industry executives to be its CEO and received financial backing from one of the world’s largest wind and

The company’s future is built on its innovative technology, cheaper materials and smarter production techniques. Morgan is a University of Toronto engineering graduate with a specialty in optics and a life-long fascination with solar power, heightened by service in the Democratic Republic of Congo with Médecins Sans Frontières as a hospital administrator.



solar energy firms. Morgan Solar’s made-in-Ontario breakthrough technology will soon start delivering competitively priced solar power – a multi-billion-dollar enterprise.

“I’m serious,” says Morgan Solar president John Paul Morgan who started the Toronto-based company in 2007, shortly after returning from a life-changing year in Africa. “We expect to be earning billions within the decade. The market is there.”

Indeed, worldwide solar energy production has increased by nearly 4,000 per cent in this century’s first decade and is expected to top $100 billion next year. Much of that growth was spurred by incentive and subsidized pricing encouraged by environmentally sensitive governments. “But solar companies dependent on subsidies are not likely to survive the long run,” says Morgan. “We adopted an entirely different model.”

From its inception, Morgan Solar’s goal was to provide solar power at prices competitive with other energy sources, or at grid parity. “We’re already there when it comes to high-priced markets such as California, the Middle East and island nations that rely on oil for electricity,” Morgan says. “We’re almost there with natural gas and we are on our way to matching coal.”

The company’s future is built on its innovative technology, cheaper materials and smarter production techniques. Morgan is a University of Toronto engineering graduate with a specialty in optics and a life-long fascination with solar power, heightened by service in the Democratic Republic of Congo with Médecins Sans Frontières as a hospital administrator.

“In Africa, I saw how a lack of access to electricity and to affordable energy in general was a barrier to development and better lives for the people there,” says Morgan. “At the same time, I knew that a tremendous amount of energy from the sun is simply wasted on the ground. I felt that solar power’s technical problems were soluble.

“Economical solar power is more than just liberating us from fossil fuels and delivering clean energy. It’s also an opportunity to provide less expensive energy that will take millions of people out of darkness. It’s a force for positive change.”

After leaving Africa, Morgan started studying photovoltaics on his own. Within months he began securing patents for his unique way of concentrating sunlight.

Morgan had developed a special opticlens that catches incoming light and directs it in a concentrated form to a high-efficiency solar cell.

The lens and accompanying system is so powerful that the energy efficiency rate is 25 per cent, almost double the industry standard of about 14 per cent.

Morgan’s groundbreaking discovery attracted the attention of American

Asif Ansari, a legend in the solar power industry. Among Ansari’s 20 start-up successes in the cleantech and aerospace industries were four in solar energy. Once, he persuaded Google to invest US$10 million in one of his ventures, eSolar Inc., a California-based solar thermal technology powerhouse. When Ansari last year examined first hand, what Morgan Solar had achieved, he agreed readily to move to Toronto and takeon the company’s reins. “When I saw what they had achieved,” recalls Ansari, “I knew they were onto something, that this could be a real game-changer.”

Ansari brought immediate international credibility to the small start-up. About the same time, Morgan Solar landed a second major investment from Iberdrola, Spain’s major energy company and a global leader in alternative energy. And last November, North American energy-delivery powerhouse Enbridge Inc. invested $10 million in Morgan Solar, its first investment in solar technology.

But Morgan Solar has even more than scientific leadership, much of it developed in collaboration with a lab at the University of Ottawa that sets it apart from the pack. For its smaller – and

more efficient– Sun Simba solar panels, the company sought and found cheaper materials that worked as well orbetter than those used by competitors. And it rejected a customized manufacturing process for injection moulding commonly used to produce auto parts and televisions.

Explains Morgan: “We are producing solar energy cheaper through vastly lower raw material costs, and the panels can be

made through simple, automated processes at existing manufacturing facilities.”

Another Morgan Solar advantage down the road – the panels are fully recyclable after their 20-year lifespan.

Today, the company is focusing its sales efforts on large companies that have a major energy stake. It expects to announce a flurry of contracts throughout 2012, beginning in the spring and summer. Morgan says the company’s first customers will be outside Canada in jurisdictions where there are no subsidies for solar power. “We can stand on our own,” he says.

Eventually, Morgan Solar wants to capture the consumer market. Declares Morgan: “We want to be on every roof top where the sun shines.”

www.morgansolar.com

“Economical solar power is more than just liberating us from fossil fuels and delivering clean energy. It’s also an opportunity to provide less expensive energy that will take millions of people out of darkness. It’s a force for positive change.”




When it comes to PV module manufacturing, there are many critical processes that impact

production yield. The soldering process is considered one of the most critical of these processes and requires consider-able engineering to establish consistent, reliable solder joints. Alloy selection, sol-dering profile and technology, bus bar metallization, and mechanical properties of the ribbon all play a role in the soldering process. Another important variable that is often overlooked in the PV industry is flux. The purpose of flux in PV manufactur-ing is to clean and activate the surface by removing oxides from the bus bar metalli-zation and solder surface, and to keep them free of oxides during the soldering process. This ensures that there is wide spreading of the molten alloy, proper intermetallic formation, and ultimately, a strong solder joint. There are several PV fluxes in the market; many are traditional wave solder fluxes found in the electronics assembly industry. When selecting a flux for a PV application, it is critical to understand how the flux interacts with the bus bar and solder to ensure that wetting is optimized. Bus bar metallizations (typically Ag) are more difficult to wet to than traditional PCB substrates (e.g., OSP, HASL, ImAg, ImSn or ENIG) due to the high porosity of the sintered Ag, which can oxidize easily. Therefore, choosing the best no-clean flux that leaves little to no residue and provides the best wetting is critical. The best way to test a flux is in a pro-

duction line under actual working condi-tions. This can be impractical if too many materials are included in the evalua-tion process. There are, however, ways to understand the capabilities of a range of flux materials without scrapping a large amount of production parts and time. Here we describe a test procedure that can be used to initially compare fluxes with minimal time, capital expense, and equip-ment. The key data is the quality of a flux to promote wetting of various alloys on a variety of surface finishes.¹ This will be calculated as a change in solder diameter after reflow. There are also more involved methods to test wetting that can measure wetting force and time.2 Performing this test requires only 3 pieces of equipment: tweezers, calipers, and a hot plate. A series of multiple hot-plates will speed up testing because mul-tiple temperatures can be used without waiting for temperature change and equi-librium.3 In this testing, a 5-zone con-duction system* was used to reflow the samples. With a reflow system such as this, a precise nitrogen atmosphere can be maintained, if desired. The testing for this report was done in air to more accurately simulate typical tabbing/stringing pro-cesses. Solder of exact known volume was needed for this test. The solder alloys were chosen to reflect the common alloys used as solder coating on tabbing ribbon, and consisted of the following alloys: 57Bi/42Sn/1Ag (solidus 139°C), 62Sn/36Pb/2Ag (solidus 179°C), 60Sn/40Pb

Simple testing to evaluate tabbing ribbon coating alloys, fluxes, and cell metallizations

Jim Hisert, Indium Corporation

Jon Major, Indium Corporation

Johannes Wendt, Q-Cells SE




(solidus 183°C), and 96.5Sn/3.5Ag (solidus 221°C). The size of the solder preforms measured 0.76mm x 1.52mm x 0.79mm. This is a standard preform size used to simulate the volume of “0603’”electronics components (0.06” x 0.03”). The preforms for this testing were also stored in tape and reel packaging for convenience. Various cell metallizations were also used. Applicable surfaces should be chosen based on cells used for current module designs and future projects. Each flux/alloy was tested on 9 different cells from various manufacturers. Bus bars are known to be an uncontrolled variable in most module assembly processes because changes in metallization paste firing times and temperatures can affect the solder-ability of these glass/silver structures. The oxidation of these bus bars during storage can also negatively affect the wetting of the tabbing ribbon. It is best to test fluxes and alloys with one lot of cells within a few days to eliminate lot-to-lot and oxidation variations. The second leading cause of experimental variation with this method originates from lot/oxidation changes in

metallization. By using a batch of metal-lizations that were processed differently, solder spread was affected.

Figure 1. A variety of cell types were tested.

ProcedureEach cell was marked to avoid confusion throughout testing. A flux pen was used to apply flux to the cell bus bar and sufficient time was allowed for the flux to dry onto the surface of the cell. Next, the preforms were placed along the cell metallization lengthwise, spaced 1cm between each pre-form. At this point, the cell was ready to be placed onto the hotplate. (Figure 2)

The cells were placed on a pre-heated hot plate for a set amount of time. During experiment verification, it was found that differences in the time of reflow were the leading cause of variation in hot plate wetting tests (up to 74%). This parameter needs to be controlled during testing. It is true that different fluxes respond to reflow profiling in different ways, and although determining the optimal time-above-liq-uidus and peak temperature for each flux would have been more fair to each chemis-try, a rapid “ worse case” profile was used to keep this test quick and simple – and helped to drive many flux/alloy/cell com-binations to failure.

Data collection and ProcessingThe resulting spread of each flux/alloy/cell combination was determined by using the following formula:Spread Length Formula S = (Lf/Li)100-100 Where: S = Increase in preform length Lf= Final solder length Li= Initial length of preform

Figure 2. Preforms in tape and reel and on the cell.




Results and further TestingTo provide an unbiased cross-section of tabbing fluxes and cell metallizations in the industry, each flux received a code that was used throughout testing. The percent increase in solder length for each flux is shown in Figure 4. Similar data was gener-ated for each solder alloy that was tested. It is important to note that wetting tests with copper substrates (an electronics industry standard) are only valid when soldering to copper surfaces. The best flux for fired glass-frit metallizations may not even be considered if the only flux test used is based on copper or oxidized copper. After a database of wetting results for existing products is in place, it becomes easy to see the advantage of any new fluxes. This information helps to find new applications for existing fluxes and proper uses for prototype fluxes. Figure 3 shows the difference in solder spread between cell metallization types; Figure 4 demonstrates the effect of different fluxes; and Figure 5 compares different tabbing ribbon coating alloys.

All the fluxes and alloys used are cur-rently being tested for peel force4 on vari-ous cell designs. Peel force measures the stability of the metallization, whereas the size of the solder spot is better when evalu-ating spreading behavior. By combining these two tests, along with results using various tabber/stringers, recommenda-tions for most applications will be verified and optimized ahead of time.

conclusionThis test procedure was designed to incor-porate simple tools that are readily avail-able in most laboratories. The test is also designed to be conducted off-line and with minimal resources. While the test does not offer feedback of manufacturing parame-ters, it does help to sort out material sets, which can save a considerable amount of line time.Calculating change in solder diameter after reflow is easy and should be used to compare the materials that may be used in a tabbing and stringing process.*Falcon 5-Zone, Sikama International

References1. J. Hisert, A. Mackie, “The Evolution Revolution

in Flux”, Advanced Packaging, July 20072. J. Wendt, M. Köhler, M. Träger, “Quantifying

the Solderability of Lead-Free Solder Alloys on Solar Cells Using Wetting Balance Analyzer”, 26th EU PVSEC, Hamburg 2011

3. J. Hisert, S. Wathne, “Mastering Material Sets: Simple Testing to Evaluate Ball Attach Fluxes”, Advanced Packaging, October 2008

4. J. Wendt, M. Träger, R. Klengel, M. Petzold, D. Schade, R. Sykes, “Improved Quality Test Method for Solder Ribbon Interconnects on Silicon Solar Cells”, IEEE, June 2010

5. B. Lalaguna, P.Sanchez-Friera, I.J. Bennett, L.J. Caballero, J. Alonso, “Evaluation of Bismuth-Based Solder Alloys for Low-Stress Interconnection of Industrial Crystalline Silicon PV Cells, 22nd EU PVSEC, Milan, 2007

6. Sebastian Schindler, Steffen Wiese, “Investigation of Wettability and Interface Reactions of Sn-Pb, Sn-Cu, Sn-Ag and Sn-Ag-Cu Solders for Solar Cell Interconnections”

7. S.V. Sattiraju, B. Dang, R.W. Johnson, Y. Li, J.S. Smith, and M.J. Bozack, “Wetting Characteristics of Pb-Free Solder Alloys and PWB Finishes”

Figure 3. Poor wetting vs. good wetting due to cell metallization.

Figure 4. Poor wetting vs. good wetting due to flux chemistry.

Figure 5. Examples of various levels of solder spread due to the combination of flux, alloy, and cell metallization.



Large and sustainable solar PV generators on industrial roof top provide energy security

Praveen Kumar Kulkarni

Residential Roof top projects with few private EPC companies is being mooted/ realised in Gandhi Nagar,

Gujarat, which is a welcome initiative with few PILOT cases and their results.

While supporting MNCs in INDIA before, the roof top of these large manufacturing units can be put to best use for solar PV power generation, with the falling prices of PV component, the surface area of roof top of such useful industrial SHEDs (mostly at 11 deg to 16 deg inclination) can be used (subject to structural design sustainability with design verification and validation for each location).

Few of large factories like Alstom, ABB, L and T, ESSAR, Refineries, Ports, Auto giants, Steel plants etc. in Gujarat / India can even house the PV panels equivalent to 4 MW / single location or more due to such large and useful roof top surface/exposed area.

It would be a good idea to collect the data on available surface area i.e roof top area of such large factories, steel plants, port or process industries located in GUJARAT / INDIA where solar irradiation can be best utilized with an effective planning to harness solar PV energy generation.

No policy exists as of now to stop them using their own roof for their internal benefits, considering tariff escalation for commercial purpose in the decade to come... However, Government can provide necessary and modest FISCAL incentives to promote Solar PV power generation while allowing the factory for their captive consumption. Thus, promote the idea of Solar Generators!

Important: FIT (Feed In Tariff) or letting out roof surface area to third party (as is the case with residential roof top system) or such initiatives will increase or load common man, which must be avoided at all costs.

With a good technology deployment mind set to use the DC power and then judiciously convert to AC power as per the need of the factory between 7 am to 6pm be planned.

The idea is to replace the consumption of Diesel in DG or Gas or Coal during these hours by switching to Solar PV in a phased way so that Production does not get interrupted during the operation or during the erection of the PV panel above the roof (ie., no production down time or interruption or no damage to the existing structure of the factory sheds).

Indicative figures (only for reference): The COG of Rs. 4 to 5/kwh (Cost of Generation without ROE) with high equity with sample project cost of Rs. 6 Crore and 7.5 Crore/MW can be realized today. Less land usage (Electrics item location only), not much of additional structures, improved cabling through existing Cable trays route/supports, learned maintenance team available will be able to bring down the costs further.

Joint awareness is necessary to promote solar PV power generation on Factory roof top so that Industry owners can come forward in bringing down the carbon emission (not just by buying the certificates or energy like what torrent is doing, but, need to support them to invest in Solar Generators !), but, with a real participation. This will enable business creation and employment generation within the existing units with a good awareness of CLEAN TECH initiatives on Climate change with a business case (no charity please).

Excess power, if generated, with little mark up price on COG can be sold to Utility companies with good FISCAL incentives as “The business is no charity” and “Common man need not support solar PV generation through his nose”



always with high tariff being supported by Government as it will not be sustainable due to high budget deficit.

There is always a scope for improvement on business numbers with a good intent and with a positive outlook at the INDIA’s foot print on Global climate change in an economical way with long term sustainability for its socio-economic objectives with a clear business plan with increased stake holder participation with a great transparency at all levels with the necessary education.

There is a Large Scope for roof top energy generation by the industries to relieve grid pressure during production

hours. Roof top use on RESIDENTIAL ROOF in other parts of the world are not successful as the rent to be paid and the real energy generation, non-feasibility to connect the generated power to GRID due to Grid failures (in INDIA “No Power in Grid” is very frequent, hence, it may lead to manipulation or corrupt practices) and its monitoring / review are expensive and no transparency and may lead to wrong business practices...

It is better to collect the data of large and usable roof surfaces of Industry (which will run in to 100s of MW solar PV power generation opportunity through Industry roofs) in each state and publish in the MNRE web site officially to evolve a good business case, where the industry owner may like to hire good EPC company and maintain it as Solar PV may be their non-core business area.

Please note that we need to use the Land for accommodating the Solar PV wherever possible, with a distributed

Generation concept to reduce the oil import... we can use the day power of Solar PV to the maximum along with day peak requirement, thus, for night power or peaking requirement (when solar PV power is not available), then, we can use other resources.

This can be a good solution along with hybrid power mix with SMART GRID metering to reduce the power theft and to improve the load side demand management very efficiently.

Many auto industries are finding their place in Gujarat at a low cost land, which is a welcome point as the Government is a good facilitator.

In order to ensure, future energy security, let the roof of these industry shed be designed (before giving them approval for their structures) to be Solar PV panels mounting compliant, so that in future these industries can deploy solar PV Generators to promote renewable energy, reduce coal or oil import due to grid power usage, thus, contribute to Current account deficit too.

This shall apply to steel plants which are investing CAPEX for their capacity expansion etc. MECON /CET/SAIL/Dastur co. etc., may please be informed accordingly to incorporate in the structural designs in future.

Though it may increase the cost of steel a bit, in principle, but it can be cost effectively designed, however for having secured government land (public property), the industry needs to give back to the society in the form of promotion for clean tech energy generation to reduce oil usage and thereby pollution related issues.

It is also an endeavor to use the land for multi-purpose ie., set up auto/steel industry + Power generation (be it captive or surplus). Let all new Industry sheds (structures) be, as a mandatory, implement structures to house future PV panels, through an ordinance (if need be).

Let the CAPEX for Solar PV Generator be provided after the internal accruals, but, we will be reserving the space (most precious land) for future PV energy generation as a sustainable energy development plan.

* The author is a Gold Medalist from SLN College of Engineering, Gulbarga University, Karnataka, India. Industrial work experience of over 23 years with PSU, MNCs. He had worked for: Tungabhadra Steel Products Ltd., Hospet from 1988 to 1995. Executed engineering of 21 Hydro Mechanical Equipment projects. Deputed to Japan for five months as part of UNIDO program to become JICA participant-1994. He introduced CAD in TSPL with software programs for design of Gates, Hoists and Cranes. He was deputed to TSPL Hyderabad branch to assist business development of Steel Plant Equipments.

With SMS Demag India Ltd, (German MNC), he engineered Steel Melt Shop equipments of Jindal Vijay Nagar Steel Plant. Apart from being the Head of Secondary refining equipments viz VD, VOD, RH, RHOB, SMS equipments, he supported the pre-bid and business development activities thru ICB of SMS Demag Secondary refining equipments. Visited SMS Demag, Duisburg on company assignments ALSTOM Portugal/India (French MNC) hired him as a Consultant and Part of Management team to launch Hydro Mechanical Equipment in India in their Baroda factory. Prepared Business plans, Export support (1ME,Owenfalls ,Uganda), tendering support to realize and launch Omkareshwar Project.

Established KK NESAR PROJECT PRIVATE LIMITED to execute renewable energy projects on EPC basis with a collaborative business approach with Indian specific needs.

Joint awareness is necessary to promote solar PV power generation on Factory roof top so that Industry owners can come forward in bringing down the carbon emission




Tennessee Solar Institute (TSI) is a model of how collaboration between Oak Ridge National Laboratory, the State of Tennessee and the University of Tennessee has resulted in increased solar energy use and a rapidly growing solar industry. TSI has leveraged more than $40 million in private investments, produced over 174,000 job hours worked with a total cumulative benefit to the state’s economy in excess of $63.8 million and deployed over 7 MW of solar energy. Tennessee is poised to be an example to other states through its comprehensive solar energy and development program, focused on job creation, education, and renewable power production.

Tennessee, more commonly known for country music and the Great Smoky Mountains than its burgeoning solar industry, made a remarkable surge in the last few years to emerge as a leader in the solar energy industry. Thanks in part to

a welcoming environment for clean energy firms and a state-sponsored initiative in the Tennessee Solar Institute (TSI), Tennessee is home to an increasing cluster of 180 solar companies vying for a piece of a growing $137 billion global solar market. The Tennessee Solar Institute was launched in April 2010 and, as we enter the second quarter of 2012, it’s successfully achieved its goal of expanding solar energy deployment and growing the solar industry throughout the state. As part of the State of Tennessee’s Volunteer State Solar Initiative--a comprehen-sive solar energy and economic development program, TSI’s programs have deployed approximately 7 MW of solar energy. That might seem small compared to solar deploy-ment in the Sunbelt states, but consider this:• Tennesseehadlessthan0.1MWofinstalledsolarPVcapacityin2008,Inlessthan3

years, Tennessee has added 27 MW of installed solar energy.• The economic impacts fromTSI’s programare evenmoreprofound: it’s leveraged

more than $40 million in private investments, produced over174,000 total job hours with a total cumulative benefit to the state’s economy in excess of $63.8 million.

• Thisrapidlygrowingindustryemploysover6,400Tennesseansinthesolarandsolar-related industry, according to a 2011 report from Middle Tennessee State University.

Tennessee: An Emerging Solar Industry Leader


BlueCross BlueShield is an installation grantee in Chattanooga



TSI focused on three programs to grow the industry, spur innovation and deploy solar energy.

Solar Innovation Grant ProgramThe purpose of the Solar Innovation Grant Program was to facilitate the growth of companies in Tennessee’s solar value chain by providing technical assistance, work-force development opportunities, increas-ing energy efficiency in operations as well as incorporate renewable energy into the workplace. Thirty-five companies (large and small, young and old) are benefitting from TSI-supported projects. The outcome of these projects have not been fully real-ized yet, however, TSI’s investment of $12.7 million in funding is starting to bear fruit. Since 2008, Soltility has grown from one person with an idea to a thriving firm with 17 employees by offering high-paying jobs with a future in a high-tech industry that’s growing worldwide. Soltility sells, designs, installs and maintains commer-cial solar power arrays from a Spring Hill, Tennessee facility that was once part of the Saturn car manufacturing campus. Grants to Soltility from the Tennessee Solar Institute helped with marketing strategies and fabricating equipment that started paying off right away. Now, instead of putting solar instal-lations together on-site—at the mercy of wind, rain, mud, and missing parts—installations are completed as much as possible in the controlled conditions

of a manufacturing plant, resulting in increased production and quality control. As a result, Soltility has been able to reduce racking and installation costs significantly, making solar energy accessible to more people and increasing sales in the process. CaraSol Energy is a start-up company that is manufacturing solar thermal panels. With a new design in hand, TSI grants helped CaraSol establish a production facility and develop a marketing plan. In addition to start-ups, well-estab-lished solar companies in Tennessee have taken advantage of TSI grants. These

grants have allowed companies like Sharp Manufacturing Company of America, Shoals Technologies Group, and AGC Flat Glass to embark on energy efficiency upgrades and worker training that other-wise they would not have pursued. For example, Shoals Technologies Group in Portland, Tennessee formerly supplied auto parts to Bosch, Delphi and others. In 2003, looking for new oppor-tunities, Shoals started supplying First Solar with plug-and-play solutions for solar farms. Today, 100 percent of Shoals Technologies’ business is tied to solar


Eco Travel Plaza is a TSI Installation grantee in Crossville, TN

Tony Trigiani, President of DPI, at Diversified Power, an installation and innovation grantee in Piney Flats, TN



power. TSI provided support for new manufacturing equipment and associ-ated worker training, allowing Shoals to expand its manufacturing capacity and exports. The company now employs more than 300 people at its Portland factories, exports 75 to 80 percent of what it makes, and ships parts made in Tennessee all around the world— to India, Germany and even to China.

Solar Installation Grant ProgramTSI’s Solar Installation program expanded the use of solar energy and gave businesses in 41 Tennessee counties more control over their energy costs while putting con-tractors back to work. one of the hardest hit sectors by the recession, to work. In total, 156 grantees in this program deployed over 6.7 MW of solar energy to agricultural, commercial and industrial users. The program’s $11.58 million of funds leveraged $25.8 million in private-sector d o l l a r s . In addi-tion, the electricity produced

will generate over $1M in income through Tennessee Valley Authority’s Generation Power Providers Program.

Solar PV workforce trainingTSI has been offering Solar Photovoltaic training courses across the state to help the state’s workforce acquire the skills it needs to enter the renewable-energy market. Nine courses have been taught in con-junction with Pellissippi State Community College and the University of Tennessee’s Center for Industrial Services. The five-day training workshops are led by Earl Pomeroy, a manufacturing consultant for TSI and the University of Tennessee’s Center for Industrial Service. The workshop covers many different aspects of the solar PV field, including: PV history and market developments, solar concepts and terminology, onsite PV system configurations and PV safety. On the fourth day, participants were given the opportunity to practice skills

they learned on solar PV configurations and components. All students must pass a NABCEP exam and received a certificate of completion. Approximately 200 Tennesseans have taken advantage of the solar PV trainings courses. Established companies like electri-cal contractors as well as unemployed Tennesseans have taken advantage of this free program. Unemployed workers are beginning to find work in the solar field. One of our students, Matt Caldwell, said since taking the class last February, he as been able to line up installation jobs that should last throughout the summer. He tried to get jobs like these for almost a year since being laid off from factory worked, but no one would hire him before completing the class.

Solar industry needs assessmentTo benchmark the state’s progress, the Tennessee Solar Institute commissioned a report to detail the growth of the state’s solar sector, and identify specific needs that must be met if Tennessee’s solar sector is to reach its full potential.


Inset: Sustainable Future Solar Park, Knoxville, TNBottom: Workforce Development Solar PV Workshop Instructor Earl Pomeroy (left) with students at a class in Spring Hill, TN.




Tennessee’s Solar Value Chain: A Workforce Development Needs Assessment identifies more than 200 organizations in Tennessee’s solar industry, including 180 for-profit and 62 non-profit entities. Since 2008, 33 new entrants have joined Tennessee’s solar value chain, with 15 set-ting up shop in 2010 alone. TSI’s report finds the solar energy industry is fueling small business growth in Tennessee. Of the firms in Tennessee’s solar value chain, 58 percent have 25 employees or less, and 78 percent employ 100 people or less. Small businesses employ half of all American workers, and generally create 65 percent of new jobs. A case in point: Diversified Power International (DPI) in Piney Flats, Tennessee. Technical support and a Solar Innovation grant from TSI allowed the company to move manufacturing, research and development from Taiwan to Tennessee. This allowed DPI to now employ 40 people this year—up 14 from 2010. Diversified Power International designs and manufactures battery chargers, power management systems, and other power-related equipment, and solar products are a big part of its business. Moving its R&D back to Tennessee increased product and quality control. The company now has a zero defect rate in its printed circuit boards. Additionally, Tennessee’s growing solar industry is attracting entrepreneurs, who in turn foster innovation throughout the solar supply chain. TSI found that 18

entrepreneurs in Tennessee’s solar indus-try have taken steps to protect their intel-lectual property. The needs expressed by manufacturing firms center on improving their operations and competiveness in a global market. Sixty-three percent of respondents iden-tified employee training as a significant issue within the manufacturing sector. The next phase of TSI’s solar value chain research will focus on understand-ing capacity and demand for solar prod-ucts and on identifying bottlenecks and other issues that must be addressed to ensure continued growth of Tennessee’s solar value chain. This information will drive further strategic planning and orga-nizational initiatives, with an eye toward long-term industry sustainability.

Into the futureWith dozens of success stories from across the state under its belt, TSI added one more before 2011 was over. The U.S. Department of Energy awarded a $622,960 grant to a team led by the University of Tennessee, Tennessee Solar Institute, and the Howard H. Baker Center for Public Policy. The goal of UT’s project is to reduce non-hardware costs associated with customer acquisition, permitting, inspection, installation, and interconnection. These costs currently comprise approximately 30 to 40 percent of the total installation cost of a rooftop PV system.

Factor in the already rapidly dropping cost of solar PV modules-50 percent during 2011-and it’s clear that solar advances business opportunities for Tennesseans. With companies old and new in Tennessee investing and innovating in the solar industry, the Tennessee Solar Institute is playing a significant role in enabling this rapidly growing industry to gain a competitive edge in the national and international solar industry. q

John Sanseverino, PhD is the director of programs at the Tennessee Solar Institute. http://solar.tennessee.edu/

The Tennessee Solar Institute was launched in 2010 as part of the State of Tennessee’s Volunteer State Solar Initiative--a compre-hensive solar energy and economic develop-ment program that focuses on job creation, education, renewable power production, and technology commercialization efforts. TSI’s grant programs have leveraged more than $40.3 million in private investments, with a total cumulative benefit to the state’s econ-omy in excess of $63.8 million.

This material is based upon work supported by the Department of Energy under Award Number DE-EE0000160. CDFA 81.041

Sharp is an Installation and Innovation grantee in Memphis, TN


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