affordable costs to address the world s energy needs

Transcription

1 Making high-quality, high-power solar cells and modules using U.S.-based technology at affordable costs to address the world s energy needs

2 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

3 Today s Speakers Jim Morgenson, Director, Market Development, SMA America 3

4 Today s Speakers Anthony Coker, Suniva s Sr. Director, Business Development Sol Haroon, Senior Systems Engineer 4

5 Grid Integrated 1,000 VDC Systems: The New Standard for Commercial PV Presentation from Jim Morgenson, Director, Market Development, SMA America 5

6 Grid Integrated 1,000 VDC Systems: The New Standard for Commercial PV

7 SMA is a true growth story > 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 Commercial 1000 VDC UL Solutions Sunny Tripower TL-US Sunny Central CP-US Inverter Capacity Shipped GW > 98% CEC efficiency > 1000 VDC, UL Listed > 2 Independent MPPTs > Full Grid Mgmt Features > Commercial/Industrial > 98.5% CEC efficiency > 1000 VDC, UL Listed > 10% Overload > Full Grid Mgmt Features > Commercial / Utility > SMA was again customers first choice in 2012

8 1,000VDC for Commercial Systems US PV Market - History - Started with VDC - Migration to VDC (de facto standard) - Utility VDC 1,000 VDC for Commercial Systems The New Standard

9 What s new? All equipment now available UL 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 STP xxxxx TL-US / 15 / 20 / 24kW UL listed 1,000 VDC DC RE-COMBINERS: DC DISCONNECTS: INVERTERS: BENTEK SMA SMA - Sunny Tripower SOLARBOS BENTEK SMA - CP-US SHOALS EATON SHOALS SC xxx CP-US / 630 / 720 / 750 / 800kW UL listed 1,000 VDC

10 Code Compliance Provisions exists in current NEC codes for 1,000 VDC Commercial Applications: (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

11 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

12 1,000 VDC Benefits Lower Installed Cost Higher System Performance Economic Value

13 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

14 1,000 VDC Lower Installed Cost 750kWac rooftop example 600 VDC 4,140 modules 12 modules per string 345 strings 15 combiners / home runs

15 1,000 VDC Lower Installed Cost 750kWac rooftop example 1,000 VDC X 31 STP TL-US 10 4,140 modules 20 Modules per string 207 Strings 9 Combiners / Home Runs

16 1,000 VDC Lower Installed Cost 750kWac example BOS Wiring Qty s 600 VDC 1,000 VDC Difference Modules - (#/String) * (# of Strings) 12 * * 207 Same Qty (4,140) Modules String Combiner Boxes, Home Runs (qty) 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) 300MCM (ft) " 943 1, /O AWG (ft) " 665 (665) ~40% of the DC BOS wiring costs Approximately $20K $30K of savings at installation

17 1,000 VDC Higher Performance 750kWac example - lower line losses Higher Voltage Lower Losses ~ 0.5% Greater efficiency due to lower line 1,000 VDC

18 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 % CEC (record!) 97.5% with MV transformer Sunny Tripower 98.0% CEC - 480VAC

19 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

20 1,000 VDC Benefits Lower installed cost ~ 40% DC BOS wiring / material savings Qty (1) 750kW Inverter & pad Higher system performance ~ 1.5-2% Lower line losses Higher inverter efficiency Economic value ~ $100,000 per MWdc or ~ $0.10/Watt Industry Momentum 1,000 VDC for Commercial Systems

21 Thank You! Thank You! Thank you! SMA Solar Technology 21

22 QUALITY & RELIABILITY TESTING MODULES ARE FIELD TESTED, CERTIFIED & PASSED THE HIGHEST LEVELS OF QA TESTING Certification 1000V Listed with all leading international agencies Reliability 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 22 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

23 SUNIVA OVERVIEW Manufacturer of high-efficiency, crystalline silicon PV cells & modules 23 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

24 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 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 24

25 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

26 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 Systems Integrators Unique Partnerships 26

27 CELL TECHNOLOGY ROADMAP Execution Optimization Innovation Simplification Collaboration Efficiency < 6months Startup Industry leading performance 2-bus bar cell design ARTisun 17% Proprietary recipes Process optimization Material and equipment improvements 3-bus bar design ARTisun 18.0% Front side emitter improvement Process Simplification ARTisun Select 19.0% Proprietary Cell and Process World s First adopter of Implant ARTisun Select % Advanced Metallization Finer Gridlines Higher efficiency at Lower Cost Full Al BSF N-type Select Plus ARTisun Star 20% Proprietary >20% cell structure Back side improvements NREL certified over 20% ARTisun IBC > 22% N-type substrate Back contact eliminates all shading Integrated front & back side enhancements Simplified 12-step process 2008 We are here

28 SUNIVA MODULE RELIABILITY: IN-HOUSE MODULE LAB CAPABILITIES Performance Spectral Response Cell and Module IV Characterization Infrared Imaging- Shunts/Hotspots Outdoor array performance monitoring (4 onsite PV arrays, full weather station) Reliability & Safety Testing Applications Lab 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 Quality Assurance Resonance Ultrasonic Vibration Crack detector GP Solar Tester for Cell Strength and Solder Peel Tester Electroluminescence (EL imaging) 28

29 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: hidden cracks and bad EVA led to discoloration, AKA Snail Trail. Solution: Suniva s in-house QA team tests all materials Failure: Cell current mismatch leads to power loss. Solution: Suniva sub bins by current to ensure all cells match. 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: 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: Severe weather damage can result in mechanical load failure. Solution: Suniva modules are tested to 5400 Pa.

30 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 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: Ensure safety and reliability of products Demonstrate long-term module performance Validate new cell designs & materials Ensure we incorporate new materials without a higher risk of reliability failures Validate changes in process specifications 30

31 OUR ENHANCED TEST STANDARDS Stress Sequences UL1703 safety standard: Thermal Cycling (TC) cycles of 85 C to -40 C Humidity Freeze Cycling (HF) - 10 cycles of 85% RH/ 85 C to -40 C IEC performance standard (in addition to UL1703): Damp Heat Test (DH) 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) 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 % 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 31

32 CERTIFICATIONS BANKABILITY Certification Logo Certification Type Description UL 1703/UL ORD-C All OPT and MV Series Suniva modules are certified to US and Canadian safety standards IEC 61215/IEC /-2 All OPT and MV Series Suniva modules are certified to IEC standard for product safety and performance Fraunhofer Extended Reliability FSEC OPT Series Suniva modules certified for durability testing that goes beyond traditional IEC performance and reliability testing protocols to demonstrate PV module bankability. Florida Solar Energy Center: Suniva modules comply with Section 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 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. 32 EU Commercial Bankability Listed with large European bank for bankability of projects up to 5 MWp in size.

33 CERTIFICATIONS BANKABILITY CONT D Puerto Rico CE, Conformité Européene IEC Salt Spray All OPT Series and MVP modules are qualified by the Government of Puerto Rico. All OPT and MV Series modules comply with essential requirements of European health, safety and environmental directives All OPT Series and MVT modules passed severity salt corrosion test IEC Severity (6). UL 790 Fire Resistance All OPT and MV Series modules are rated to have a Class C Fire Rating. Clean Energy Council, AU IEC Storm Resistance IEC Hail Impact Test BSI: ISO 9001:2008 BSI: ISO 14001:2004 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 Hail impact test standard. Suniva s factories have ISO certified Quality Management System: Internationally recognized standard for quality management. 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. 33

34 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

35 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

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