Making high-quality,
high-power solar cells
and modules using U.S.-based technology at
affordable costs to address the world’s energy needs
Today’s Host
Dr. Ajeet Rohatgi, Suniva co-founder and CTO
Dr. Ajeet Rohatgi, Regents Professor in the school of
Electrical Engineering at Georgia Tech; co-founder and
Chief Technology Officer of Suniva
• World-renowned PV scientist
• Over 30 years in PV research & high-efficiency
solar cell development
• More than 400 publications and 16 patents
2
Today’s Speakers
Jim Morgenson, Director, Market
Development, SMA America
3
Today’s Speakers
Anthony Coker, Suniva’s Sr. Director, Business
Development
Sol Haroon, Senior Systems Engineer
4
Grid Integrated 1,000 VDC Systems:
The New Standard for Commercial PV
Presentation from Jim Morgenson,
Director, Market Development,
SMA America
5
Grid Integrated 1,000 VDC Systems:
The New Standard for Commercial PV
SMA is a true growth story
Commercial 1000 VDC UL
Solutions
>
Founded in 1981
>
Sales 2012: $1.6 billion (EUR 1.2B)
>
Over 30 GW of SMA installed WW
>
Well-positioned in 21 countries
>
Award-winning corporate culture
>
Innovation, pillar of success
Sunny Tripower
TL-US
Sunny Central
CP-US
Inverter Capacity Shipped
10
8
6
4
2
0
2005
2006
2007
2008
2009
2010
2011
2012
GW
> SMA was again customers´ first choice in 2012
> 98% CEC efficiency
> 98.5% CEC efficiency
> 1000 VDC, UL Listed
> 1000 VDC, UL Listed
> 2 Independent MPPTs
> 10% Overload
> Full Grid Mgmt
Features
> Full Grid Mgmt
Features
> Commercial/Industrial
> Commercial / Utility
1,000VDC for Commercial Systems
US PV Market - History
- Started with residential
@600 VDC
- Migration to commercial
@600 VDC
(de facto standard)
- Utility “behind-the-fence”
@1,000 VDC
1,000 VDC for Commercial Systems…The New Standard
What’s new ?
All equipment now available UL listed @ 1,000 VDC:
MODULES:
PV CABLE :
DC COMBINERS:
•
SUNIVA 60 Cell
•
ALLIED WIRE & CABLE
•
AMTEC SOLAR
•
SUNIVA 72 Cell
•
GENERAL CABLE
•
SOLARBOS
•
SOUTHWIRE
•
TEALSOLAR
•
SHOALS
•
SUNLINK
•
SHOALS
DC RE-COMBINERS:
DC DISCONNECTS:
STP xxxxx TL-US – 10
12 / 15 / 20 / 24kW
UL listed 1,000 VDC
INVERTERS:
•
BENTEK
•
SMA
•
SMA - Sunny Tripower
•
SOLARBOS
•
BENTEK
•
SMA - CP-US
•
SHOALS
•
EATON
•
SHOALS
SC xxx CP-US-10
500 / 630 / 720 / 750 /
800kW
UL listed 1,000 VDC
Code Compliance
Provisions exists in current NEC codes for 1,000 VDC Commercial Applications:
•
690.7 (C) Describes Maximum Voltage:
Over 600 volts, see Article 690, Part IX
•
Article 690, Part IX:
Over 600 volts, see Article 490
•
Article 490 addresses equipment operating over 600V:
Not written with PV systems in mind,
Some AHJ interpretation required
• SolarPro article “1,000Vdc Utilization in Nonresidential
PV Applications” an excellent reference
Code Compliance
Bottom Line, AHJ (Authority Having Jurisdiction):
• Non-residences and residences greater than two family
dwellings
• Inaccessible to unqualified personnel (includes commercial
rooftops)
• Provided all equipment is listed and approved for such use by
your local AHJ
Contact your AHJ early… enjoy the benefits
Note: NEC 2014 redefines non-residential low voltage as 1000V and below
1,000 VDC Benefits
•
Lower Installed Cost
•
Higher System Performance
•
Economic Value
1,000 VDC – Lower Installed Cost
•
750kWac rooftop example
• Ex. module 270W
• UL listed for 1,000 VDC
• 4,140 Modules
• 1,117,800 Watts DC
1,000 VDC – Lower Installed Cost
•
750kWac rooftop example
• 600 VDC
• 4,140 modules
• 12 modules per string
• 345 strings
• 15 combiners / home
runs
1,000 VDC – Lower Installed Cost
•
750kWac rooftop example
• 1,000 VDC
• 4,140 modules
• 20 Modules per string
• 207 Strings
• 9 Combiners / Home
Runs
…X 31
STP 24000 TL-US – 10
1,000 VDC – Lower Installed Cost
•
750kWac example
BOS Wiring – Qty’s
600 VDC
1,000 VDC
Difference
12 * 345
20 * 207
Same Qty (4,140)
Modules
15
9
(6)
#10 AWG (ft) Module to Combiner
46,618
27,340
(19,278)
350MCM (ft) Combiner to Inverter
4,703
2,500
(2,203)
1,466
523
Modules - (#/String) * (# of Strings)
String Combiner Boxes, Home Runs (qty)
300MCM (ft)
"
943
4/O AWG (ft)
"
665
~40% of the DC BOS wiring costs
Approximately $20K – $30K of savings at installation
(665)
1,000 VDC – Higher Performance
750kWac example - lower line losses
Higher Voltage
Lower Losses
~ 0.5% Greater efficiency due to lower line losses @ 1,000
VDC
1,000 VDC – Higher Performance
Higher Inverter Performance
Higher Voltage
Lower Losses
• 1,000 VDC inverter class is typically:
VDC
~ 0.5% - 1.0% greater efficiency Vs. 600
Sunny Central 800CP-US - 98.5% CEC (record!)
97.5% with MV transformer
Sunny Tripower
98.0% CEC - 480VAC
1,000 VDC – Higher Performance
Value of 1% efficiency utilizing
750kWac rooftop example
1% could be worth
$40,000 or more… per
750kW inverter
over 20 years
1,000 VDC Benefits
•
Lower installed cost ~ 40% DC BOS
wiring / material savings
• Qty (1) 750kW Inverter & pad
•
Higher system performance ~ 1.52%
• Lower line losses
• Higher inverter efficiency
• Economic value
~ $100,000 per MWdc or ~ $0.10/Watt
Industry Momentum
1,000 VDC for
Commercial Systems
Thank You!
Thank You!
Thank you!
SMA Solar Technology
21
QUALITY & RELIABILITY TESTING
MODULES ARE FIELD TESTED, CERTIFIED & PASSED THE HIGHEST LEVELS OF QA TESTING
Certification
Reliability
•
•
•
•
•
1000V Listed with all leading international agencies
In-house and third party validation
UCL Extended Stress Test – Passed at Fraunhofer ISE
Bankability Audit by Beck/SAIC – Passed
IEC Salt Spray Extended Severity Level 6 – Passed
PID free as tested at PV Evolution Labs
PAN File verification at PV Evolution Labs
Energy Yield
Verified by independent labs & field sites
• Long Term Field Performance Analysis at TUV – 100%
• Hundreds of installs, documented field performance and yields – out perform
22
SUNIVA OVERVIEW
Manufacturer of high-efficiency, crystalline silicon
PV cells & modules
– High-Efficiency Cells: 19.2+% in production;
over 20% in laboratory; roadmap to 22+% by 2014
– High-Power Modules: Up to 16+% in production;
60-cell modules up to 270W, 72-cell modules up to
315W
– Buy America Compliant Modules: Global products
and one of the highest U.S.-content modules on the
market
– Manufacturing Capacity: 170 MW in the U.S. and
expanding in 2013; 500 MW in Asia
23
SUNIVA & GEORGIA TECH DEEP ROOTS
2007: Suniva
Founded
1992: GA Tech
University
Center of
Excellence
(UCEP)
Established
1992: Dept.
of Energy
provided
funding
1985: PV
Program
Established at
Georgia Tech
24
Deep Roots with GA Tech,
Continued Collaboration
 Suniva has access to over
$50M worth of advanced
research equipment at
UCEP/Georgia Tech
 Suniva benefits from a
budget of over $43M of
PV-related research
programs funded partly
by the U.S. DOE
SUNIVA & GEORGIA TECH DEEP ROOTS
Rooftop, Parking Canopy installation on
Georgia Tech’s Carbon Neutral Lab
90 kW rooftop installation on Georgia Tech’s
Clough Center
25
SUNIVA INNOVATION IN THE VALUE CHAIN
The solar
cell is the “DNA” of
any PV system, and hence the
key driver of value
Silicon
Ingot
Wafer
Cells
Modules
Balance
of System
Solutions
Unique
Partnerships
26
Systems
Integrators
CELL TECHNOLOGY ROADMAP
Execution
Optimization Innovation
 < 6months Startup
 Proprietary recipes
 Industry leading
 Process optimization
performance
 2-bus bar cell design
 Material and
equipment
improvements
Simplification
 Front side emitter
improvement
 Process
Simplification
Efficiency
 3-bus bar design
ARTisun
Select
19.0%
ARTisun
18.0%
ARTisun
17%
2008
2008
27
Collaboration
ARTisun
Select +
19.5%
 Advanced
Metallization
 Finer Gridlines
ARTisun
Star
20%
 Proprietary >20%
cell structure
 Back side
improvements
 Proprietary Cell and
 Higher efficiency at  NREL certified over
 World’s First
 Full Al BSF
Process
adopter of Implant
Lower Cost
20%
ARTisun
IBC
> 22%
 N-type substrate
 Back contact
eliminates all
shading
 Integrated front &
back side
enhancements
 Simplified 12-step
process
 N-type Select Plus
We
Weare
arehere
here
2014
2014
SUNIVA MODULE RELIABILITY:
IN-HOUSE MODULE LAB CAPABILITIES
Performance
Reliability &
Safety Testing
Applications Lab
Quality
Assurance
28
• Spectral Response
• Cell and Module IV Characterization
• Infrared Imaging- Shunts/Hotspots
• Outdoor array performance monitoring (4 onsite
PV arrays, full weather station)
• Environmental Test Chamber for Cells and
Modules including thermal cycling, high humidity
freeze, damp heat
• TC200, HF10, DH1000 per IEC61215
• In-house static load testing
• High-potential testing
• Ground continuity testing
• Solar Simulator; Spire-SPI 4600 Single Light Pulse
Flash Tester
• Stringer; 3 Bus Capable Komax Xcell 3400
• Laminator, full-size
• Final assembly and test
• Resonance Ultrasonic Vibration Crack detector
• GP Solar Tester for Cell Strength and Solder Peel
Tester
• Electroluminescence (EL imaging)
WHY WE DO TESTING! EXAMPLES OF PRODUCT
FAILURES SEEN ON COMPETITOR’S MODULES
Failure: This junction box sample failed after
only 300 hours in the damp heat chamber.
Solution: Suniva’s in-house QA tests go
beyond standard certification
requirements; testing to 2000 hours of
damp heat tests (1000 hours is standard
testing).
Failure: Module/partial shading results in cell
hot spots that can cause elevated
temperatures and module failure.
Solution: Suniva modules are designed
and tested to advanced ASTM standards
(beyond IEC) ensuring safe operating
temperature.
29
Failure: hidden cracks and bad EVA led to
discoloration, AKA “Snail Trail”.
Solution: Suniva’s in-house QA team tests
all materials
Failure: PV module with burnt diode causing
module voltage drop and overall power loss.
Solution: Suniva’s in-house QA tests go
beyond standard certification
requirements; diodes to series fuse rating
of systems.
Failure: Cell current mismatch leads to power
loss.
Solution: Suniva sub bins by current to
ensure all cells match.
Failure: Severe weather damage can
result in mechanical load failure.
Solution: Suniva modules are
tested to 5400 Pa.
SUNIVA’S ENHANCED TEST PROTOCOLS
Enhanced Test Protocols
Ensure Module Reliability
• Suniva tests the safety and reliability of our modules beyond standard UL
and IEC certification requirements. (The power performance of Suniva’s
modules must not degrade by more than 5% while exposed to double the IEC
61215 test protocols.)
• Suniva tests beyond standard UL and IEC requirements to better simulate
performance over the rated service lifetime.
• Suniva tests all new PV materials that enter our value chain, exceeding
standard UL and IEC certification requirements.
Results:
30
Ensure safety and reliability of products
Ensure we incorporate new materials
Demonstrate long-term module performance
without a higher risk of reliability failures
 Validate new cell designs & materials
Validate changes in process specifications
OUR ENHANCED TEST STANDARDS
Stress Sequences
UL1703 safety standard:
•
Thermal Cycling (TC)
- 200 cycles of 85° C to -40° C
•
Humidity Freeze Cycling (HF)
- 10 cycles of 85% RH/ 85° C to -40° C
IEC 61215 performance standard (in addition to UL1703):
•
Damp Heat Test (DH)
- 1000 hours at 85% RH and 85° C
•
Thermal Cycling with bias
- Current Injection above 25° C
•
Combined UV-TC-HF sequence
- 15 kWh UV preconditioning followed by 50 cycles of TC
(85° C to -40° C) and 10 HF cycles (85° C to -40° C with
humidity)
•
Bypass diode test to 1.25 times short circuit ISC (11 amps
approx.)
Fraunhoffer extended reliability tests (in addition to IEC and UL):
•
Infrared/Hotspot inspection
•
Enhanced UV Tests
•
Enhanced Thermal Cycling
•
Enhanced Damp Heat Tests
Suniva Material Qualification (in addition to above):

Bypass diode test to rated series fuse level for system current
up to 15 amps (1.25 x Isc is the IEC standard).

Hotspot test per ASTM standard tests up to 50 hours of testing
for long term reliability ( vs. 5 hours which is the IEC standard)

Extended chamber testing to ensure long term (similar to
Fraunhoffer Reliability Tests)
31
How Stressful Are the Extended
Fraunhoffer Reliability Tests?
Thermal Cycling (85° C to -40° C)
•
This is hotter than anywhere on earth ever by 15 degrees
to a freezing low temperature rarely seen.
•
A biased thermal cycling test involves injecting max power
circuit current into the module. Module voltage is close to
operating voltage and power is dissipated in module.
•
Evaluates materials ability to withstand daily night/day
cycles. Stresses solder bonds, mechanical connections,
materials with differing thermal expansion coefficients and
the solar cells.
•
Thermal cycling to 400 cycles (vs. 200)
Damp Heat: (85 % RH @ 85° C)
•
Humidity soak at elevated temperatures. Average
humidity in Florida in the summer is around 75%.
•
Drives corrosion mechanisms, probes material quality as
well as lamination adhesion of all materials.
•
Damp heat test to 2000 hours (vs. 1000)
UV Test: (60° C ±5°C)
•
Increased dose: 90kWh (vs. 15 kWh)
Hotspot:
•
Tests for worst case shading to evaluate cells and
potential power loss due to low current (the worst case
shading is the full- or partial shading situation with the
highest hot-spot temperature.)
RH: Relative Humidity, C, Degrees Celsius
CERTIFICATIONS – BANKABILITY
Certification Logo
Certification Type
Description
UL 1703/UL ORD-C1703-01
All OPT and MV Series Suniva modules are certified to US and Canadian
safety standards
IEC 61215/IEC61730-1/-2
All OPT and MV Series Suniva modules are certified to IEC standard for
product safety and performance Fraunhofer Extended Reliability
FSEC
Florida Solar Energy Center: Suniva modules comply with Section 377.705
of the Florida Statutes for solar energy equipment sold in Florida.
Micro Certification Scheme (UK)
Independent evaluation of factory quality management system and
product certification.
CEC US
California Energy Commission: Suniva modules are compliant with SB1 in
California for state incentive programs.
PV Evolutions PID Free Certified
PAN File Validation
32
OPT Series Suniva modules certified for durability testing that goes beyond
traditional IEC performance and reliability testing protocols to
demonstrate PV module bankability.
All OPT and MV Series modules have third party validation demonstrating
reliable performance, ensuring modules are not susceptible to Potential
Induced Degradation (PID) due to expected system voltage biases.
Third party evaluated solar module performance modeling file for PV Syst
software based on independent panel measurement, allowing for accurate
and bankable PV system performance estimates.
SAIC: IE Report
Independent engineering evaluation of Suniva’s technology, PV module
and manufacturing facilities.
EU Commercial Bankability
Listed with large European bank for bankability of projects up to
5 MWp in size.
CERTIFICATIONS – BANKABILITY CONT’D
Puerto Rico
CE, Conformité Européene
All OPT and MV Series modules comply with essential requirements of
European health, safety and environmental directives IEC 61701 Salt Spray
All OPT Series and MVT modules passed severity salt corrosion test
IEC 61701 Severity (6).
UL 790 Fire Resistance
Clean Energy Council, AU
IEC 61215 10.16 Storm Resistance
IEC 61215 10.17 Hail Impact Test
33
All OPT Series and MVP modules are qualified by the Government of
Puerto Rico.
All OPT and MV Series modules are rated to have a Class C Fire Rating.
All OPT and MV Series PV modules are accredited by Australia's Clean
Energy Council, demonstrating Suniva’s solar modules meet Australian
standards and ensures eligibility for PV Rebates when installed on a
qualifying system in Australia.
All OPT and MV Series PV modules are tested to withstand severe static
loads due to heavy winds , snow and IEC.
All OPT and MV Series PV modules are tested and qualified to withstand a
25 mm diameter ice ball travelling at 23 m/s per the IEC 61216 10.17 Hail
impact test standard.
BSI: ISO 9001:2008
Suniva’s factories have ISO certified Quality Management System:
Internationally recognized standard for quality management.
BSI: ISO 14001:2004
Suniva’s factories have ISO certified Quality Management System:
Internationally recognized standard for quality management.
Long Term Field Performance Analysis 3rd party verification of long term field performance testing.
SUNIVA’S HIGH PERFORMANCE MEANS
HIGHER VALUE
Cost-effective, high-efficiency monocrystalline panels also provide
superior energy performance.
Key contributing factors:
 Suniva Optimus series panels have less than a 1% mismatch from nameplate. Many
panels typically have a 2% or even a 3% mismatch.
 The monocrystalline cells have excellent low and ambient light performance.
 Higher efficiency generally also means better high temperature performance (more
energy converted to electrical power means less energy left to generate heat). A lower
temperature coefficient mean less sensitivity to temperature changes and a less variable
energy yield.
 Suniva uses the highest quality materials in its modules to ensure a long service life and
high energy output over time. Suniva conducts on-going component and materials testing
in their module labs to incorporate the latest advances after proving reliability.
Producing more power year after year translates into a lower cost of energy per unit
produced over the life of the system investment which is the true measurement of system
cost and value (LCOE).
Higher performance means lower levelized cost of energy (LCOE)
34
NEC COMPLIANCE / ADDRESSING NEEDS NOW AND IN THE FUTURE
Suniva panels help ensure full NEC 2011 compliance through cells, materials,
junction box, and connectors. As NEC 2014 solidifies, Suniva remains at the
forefront to help ensure your system compliance.
– Ready for the potential NEC 2014 changes of Article 690 Section IX and
Article 490 from 600V to 1000V
– PID-free means that all system grounding means such as negative
grounding, positive grounding, and floating are permissible for 1000V
designs
– Future considerations for arc-flash potential detection through
integration of panel-level electronics
– Offering full modeling/simulation through PVSYST, Helioscope, and other
tools to further quantify 1000V system design and energy yields specific
to your system parameters and needs
SUNIVA MODULES WITH SMA INVERTERS:
BANKABLE ENERGY YOU CAN COUNT ON
35
FEEDBACK – CONTACT US
Via our Websites
www.suniva.com/contact.php
36
www.sma-america.com/en_US/contact.html