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Ponencia impartida por César Cerezo de Suntech sobre el control de claidad en el proceso de fabricación de células y módulos.
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Suntech products portfolio 2011 - Europe
Polycristalline
Monocristalline (S)
STP190S-24/Ad+
PLUTO200-Ade
Ade HiPerforma™
Ad+
STP230-20/Wd
PLUTO295-Vdm
Vdm HiPerforma™
Vd
Wd poly
STP280-24/Vd
Monocristalline Polycristalline
Wd mono
STP250S-20/Wd
Wdm HiPerforma™
PLUTO245-Wdm
3
Suntech Modules
Only the highest quality materials and components go into Suntech modules, so we can
offer the most Reliable, High Performance products
Durable, corrosion-resistant frame
High-transmission tempered
glass
High performance
backsheet (TPT)
Reliable Junction Box
Durable cables
Locking connectors
4
EVA
EVA
Interconnected solar cells
Example: Frame of Vd, Modules
Frame Features:
• Anodized Aluminum Profiles
• 1956x992x50 (LxWxH)
• Robust Hollow Chamber Design
• Front Surface Coverage 11 mm
• Base Depth 35 mm
• 2 Grounding Holes (Long Side Center)
• 4 Mounting Holes x side (Long Side)
• 16 Drainage Holes (Short & Long Side)
5
Product Portfolio – A Footprint
Handy Format Suitable for Residential Roof
190 Wp nominal power
Mono Crystalline 125x125 mm (5 inches) Cells
Small Format Module with 3.2 mm Glass
72 cells [6x12], nearly quadratic cell area („jumbo“)
1580 x 808 x 35 mm / 62.2 x 31.8 x 1.4 inches
Efficiency: 14.9%
15.5 kg / 34.1 lbs
STP190S - 24/Ad+
6
Product Portfolio – A Footprint
Highest Performance Suitable for Every Roof
200 Wp nominal power
Based on Mono Crystalline tech. 156x156 mm (6 inches) Cells
Small Format Module with 3.2 mm Glass
72 cells [6x12], nearly quadratic cell area („jumbo“)
1580 x 808 x 35 mm / 62.2 x 31.8 x 1.4 inches
Efficiency: up to 15.7%
15.5 kg / 34.1 lbs
Hi Performa™ Pluto200-Ade
7
Product Portfolio – „A“ Footprint
Just RoofTM - Fully Integrated PV System
187 Wp / 195 nominal power
Mono Crystalline 125x125 mm (5 inches) Cells
Small Format Module with 3.2 mm Glass
72 cells [6x12], nearly quadratic cell area („jumbo“)
1621 x 841 x 33 mm / 62.2 x 31.8 x 1.4 inches
15 kg / 34.1 lbs
approved by CSTB (A-TEC)
CEIAB approved for highest FIT (FR)
JR 187/195
8
Product Introduction – W Footprint
The Allround Solution in an Universal Format
240 – 245 Wp nominal power
Based on Poly Crystalline tech. 156x156 mm (6 inches) Cells
Medium to large format Module with 3.2 mm Glass
60 cells [6x10],
New design 1640 x 992 x 50 mm / 65.6 x 39.0 x 2.0) inches
Efficiency: up to 15.1 %
19.1 kg / 34.1 lbs
Hi Performa™ Pluto245 - Wdm
9
Product Portfolio – W Footprint
Universal and Cost Optimzed for Best ROI
225 – 230 Wp nominal power
Poly Crystalline 156x156 mm Cells
Medium to large format Module with 3.2 mm Glass
60 cells [6x10]
1665 x 991 x 50 mm / 65.6 x 39.0 x 2 inches
(as of 2012: 1640 x 992)
Efficiency: 13.6%
19.8 kg / 43.7 lbs
STP230 - 20/Wd
10
Product Portfolio – W Footprint
Excellent Efficiency and Universal Format
245 – 250 Wp nominal power
Mono Crystalline 156x156 mm (6 inches) Cells
Medium to large format Module with 3.2 mm Glass
60 cells [6x12], nearly quadratic cell area („jumbo“)
1665 x 991 x 50 mm / 65.6 x 39.0 x 2.0) inches
(as of 2012: 1640 x 992)
Efficiency: up to 14.8%
19.8 kg / 34.1 lbs
STP250S - 20/Wd
11
Product Portfolio – V Footprint
Large Scale Format to Reduce BOS
280 Wp nominal power
Poly Crystalline 156x156 mm (6 inches) Cells
Large format Module with 4 mm Glass
72 cells [6x12]
1956 x 992 x 50 mm / 77.0 x 39.1 x 2 inches
Efficiency up to 14.4 %
27.0 kg / 59.5 lbs
STP280 - 24/Vd
12
Product Portfolio - V Footprint
Highest Performance in a Large Scale Format
290 - 295 Wp nominal power
Based on Poly Crystalline 156x156 mm (6 inches) Cells
Large format Module with 4 mm Glass
72 cells [6x12]
1956 x 992 x 50 mm / 77.0 x 39.1 x 2 inches
Efficiency: 15.2 %
27.0 kg / 59.5 lbs
Hi Performa™ Pluto295-Vdm
13
Standard Design
STP 190S-24/Ad+
STP 250S-20/Wd
Just Roof 187 / 195
STP 250S-20/Wd
STP 280-24/Vd STP 230-20/Wd
Sta
te:
23.0
9.2
011 -
subje
ct
to c
hange w
ithout
notice
HiPerforma Ade-200
HiPerforma
Product Portfolio
14
STP 280-24/Vd STP 230-20/Wd
HiPerforma
STP 250S-20/Wd
STP 280-24/Vd
Large Scale
STP 230-20/Wd
HiPerforma
HiPerforma Vdm-295
Standard
Standard
Standard
Large Scale
Large Scale
HiPerforma Wdm-245
HiPerforma Wdm-245
HiPerforma Vdm-295
HiPerforma Wdm-245
HiPerforma Vdm-295
HiPerforma Wdm-245
HiPerforma
17
How do you make decisions on products today?
By Nameplate Power?
By Cost?
By Availability?
Have you ever considered other key parameters?
Power Tolerance (+/- 5%, +/- 3%, +/- 5W or only positive (0/+5%)?
Impact of Degradation Effects during first Light Exposure (LID)?
Cell and Module Matching?
Long Term Warranty?
Decision Making on PV Modules 17
Product Benefits - Quality
52 steps at the quality control:
several check points on cell level
several check points on module level
intake control div. measurements final inspection
components module measurements pre delivery check
20
21
Product Benefits - Quality
VDE Certified In-House Test Lab:
SUNTECH is one of few module manufacturers
with an own test lab
1.400 m² indoor test area
(biggest in China)
7.000 m² outdoor test area
own UV chamber for aging tests
capable of performing more than 50 different
tests according to, or even beyond the
IEC 61215 / 61730 and
UL 1703 standard
spot testing of raw materials,
new products and production modules
(5pc/line/week)
22
Product Benefits - Quality
Double IEC Testing:
to ensure that SUNTECH always delivers highest quality
e.g. 2000h damp heat test instead of IEC required 1000h
yearly audit by a certified institute
Salt Mist Corosion Test according to IEC 61701 :
modules are approved for marine climate
minimum distance to coast line > 500 m
Product Benefits - Quality
23
Ammonia Resistance according to DIN 50916 T2:1985
SUNTECH modules are resistant to ammonia
several installed case studies over 10 years
Product Benefits - Quality
24
Product Benefits - Quality
• IEC 61215 and IEC 61730 certified
• Member of PV Cycle (End of Life Module Recycling Program)
• CE compliant
• Protection Class II (acc. to DIN 40011)
• Suntech meets international ISO 9001 standard
• ISO 14001 certified (Environmental Management Standard)
25
SUNTECH Certifications / Awards / Compliances / ….
• MCS certified (required in the UK)
• Salt Mist & Ammonia Proof
=
V
I
+ + + + +
Modules with mismatched current operate at Imin, limiting string output
Outdoor testing of optimized strings with current-sorted modules shows
2% More Power generated vs. mismatched strings
Percentage gain due to additonal module current classification
-4.00%
-2.00%
0.00%
2.00%
4.00%
6.00%
8.00%
9:14
9:30
9:46
10:02
10:18
10:34
10:50
11:06
11:22
11:38
11:54
12:10
12:26
12:42
12:58
13:14
13:30
13:46
14:02
14:18
14:34
14:50
15:06
15:22
15:38
16:14
16:30
16:46
17:02
17:18
TimePercentage Gain
+ + + =
Current Sorting: Suntech sorts modules into 3 amperage categories (I1, I2 ,I3) for
Maximum string output
Product benefits- Performance /current sorting
PModule = UModule x IModule
VString = sum(VModule 1 .. VModule N)
IString = min (IModule 1 .. IModule N)
27
Product Benefits - Performance
SUNTECH´s current sorting
in a serial connection the weakest current determines the total
strength of current in the string
Example of STP250S-20/Wd, taken from a customer flash list:
Calculation without current sorting
String 1 Ø 254,06 Wp x 25
Impp Max. 8,49 A Δ = - 0,27 A = Ø 245,98 Wp x 25
Impp Min. 8,22 A Δ = - 3,2 %
String 2 Ø 253,7 Wp x 25
Impp Max. 8,47 A Δ = - 0,26 A = Ø 245,90 Wp x 25
Impp Min. 8,21 A Δ = - 3,1 %
String 3 Ø 254,18 Wp x 25
Impp Max. 8,53 A Δ = - 0,33 A = Ø 244,34 Wp x 25
Impp Min. 8,20 A Δ = - 3,9 %
String 4 Ø 253,49 Wp x 25
Impp Max. 8,47 A Δ = - 0,32 A = Ø 243,91 Wp x 25
Impp Min. 8,15 A Δ = - 3,8 %
= 24,5 kWp
28
Product Benefits - Performance
SUNTECH´s current sorting
without current sorting the installer gives away power
due to FIT cuts it gets more and more difficult to get a good ROI
29
Calculation with current sorting
String 1 Ø 253,37 Wp x 25
Impp Max. 8,26 A Δ = - 0,11 A = Ø 250,00 Wp x 25
Impp Min. 8,15 A Δ = - 1,3 %
String 2 Ø 253,72 Wp x 25
Impp Max. 8,35 A Δ = - 0,08 A = Ø 251,29 Wp x 25
Impp Min. 8,27 A Δ = - 1,0 %
String 3 Ø 254,08 Wp x 25
Impp Max. 8,41 A Δ = - 0,06 A = Ø 252,26 Wp x 25
Impp Min. 8,35 A Δ = - 0,7 %
String 4 Ø 254,62 Wp x 25
Impp Max. 8,53 A Δ = - 0,12 A = Ø 251,04 Wp x 25
Impp Min. 8,41 A Δ = - 1,4 %
= 25,1 kWp
Product Benefits - Performance
SUNTECH´s current sorting
installed capacity without current sorting: 24,5 kWp
installed capacity with current sorting: 25,1 kWp
Δ 0,6 kWp -> 2,4%
10 kWp Si-Mono
28,75 ct/kWh
30°
2,4% means in € (10 kWp):
= ~ 75* € /year
= ~ 1500* € /20 years
* Suntech takes no responsibility for errors and/or
omissions with regards to the content
Roof angle = 30°
orientation = south
location = Munich, Germany
30
31
Product Benefits - Performance
SUNTECH’s current sorting:
all SUNTECH standard products are presorted by Power first, then by current
delivery comes in 3 different classes: I1, I2 und I3
a Current sticker can be found in the frame, and out of every pallet
presorting is not charged by Suntech
better system performance guarantees customer satisfaction
For internal use only
250
Voltage (Ump)
Current
(Imp)
250
250
250
250
250
I1 I2 I3
2/3 of yearly average irradiation is
as per definition weak light
1. Chemical edge cutting process
2. High fill factor
Excellent weak light
performance
Excellent Weak Light Performance
Explanation Weak Light Conditions:
Measured irradiation is typically between
200 W/m² and 800 W/m²
Irradiation intensity for weak light conditions
is below 400 W/m²
e.g. cloudy, dusty etc. weather conditions
morning and evening hours
SUNTECH‘s edge insulation process
patented process
treatment in an acid bath
removal of unfavorable phosphor
particles along the edges
without process: leak current power
loss
increase of the shunt resistance
1. Chemical edge cutting process
2. High fill factor
Product Benefits - Performance
33
Excellent Weak Light Performance
Fill Factor:
FF = (Impp x Umpp)/(Isc x Uoc)
ideal FF would be 1 but is technically
not achievable
fill factor shall be between 0 and 1
the higher the fill factor the better
Higher Rsh and lower Rs Higher Fill Factor
Suntech Yingli Hanwha Canadian LDK Trina JA Solar Sharp Jinko Solar-
world
Pluto200-Ade Panda 260 SF220 Poly
x-tra
MaxPower
CS6 245D-20
TSM-DC01A
(comax) JAM6 Secium NU-E245(J5) JKM-245M SW 250
0,7925 0,7495 0,7686 0,7618 0,7723 0,77 0,7562 0,749 0,7636 0,7698
Excellent weak light performance
the higher the shunt resistance the more
energy goes into the electrical consumer
high shunt resistance high fill factor
valid for 1000 W/m² as also for
200 W/m²
2. High fill factor
Excellent weak light
performance
Product Benefits - Performance
35
Comparison of the Temperature coefficient:
Comparison of Ade against most efficient mono modules
Suntech Yingli Solarfun Canadian LDK Trina JA Solar Sharp Jinko Solarworld
Pluto200-Ade Panda 260 SF160 Mono MaxPower
CS6 190D-24(s)
TSM-DC01A
(comax) JAM6 Secium NU-E245(J5)
JKM-
195M(R165) SW 245
-0,38 -0,45 -0,44 -0,45 -0,47 -0,45 -0,44 -0,485 -0,43 -0,45
15,56%
13,64%
15,56%
19,15%
15,56%
13,64%
21,65%
11,63%
15,56%
0,00%
5,00%
10,00%
15,00%
20,00%
25,00%
Product Benefits - Performance
36
Comparison of NOCT (nominal operating cell temperature):
The lower the NOCT the higher the energy output
Suntech Yingli Solarfun Canadian LDK Trina JA Solar Sharp Jinko Solarworld
Pluto200-Ade Panda 260 SF160 Mono MaxPower
CS6 190D-24(s)
TSM-DC01A
(comax) JAM6 Secium NU-E245(J5)
JKM-
195M(R165) SW 245
45 46 45 45 45 46 45 47,5 45 47
2,17% 2,17%
5,26%
4,26%
0,00%
1,00%
2,00%
3,00%
4,00%
5,00%
6,00%
C° Low TC
Product Benefits - Performance
37
Positive tolerance for reliable energy yield:
nameplate can be misleading without considering tolerance
Suntech modules only have positive power tolerance of 0 /+ 5%
39
Product Benefits - Reliability
250 Wp
Other
250 Wp
STP 250S-20/Wd
Suntech Yingli Solarfun Canadian LDK Trina JA Solar Sharp Jinko REC
5 % 3 % 3 % 5 W 5 W 3 % 3 % 10 % 3 % 5 W
0 % -3 % -3 % 0 W 0 W 0 % -3 % -5 % -3 % 0 W
0 W
to 12,5W
-7,5 W
until 7,5W
-8,4 W
until 8,4 W
0 W
until 5 W
0 W
until 5 W
-7,05 W
until 7,05 W
-7,5 W
until 7,5W
-11,5 W
until 23 W
-7,35 W
until 7,35 W
0 until
5 W
Product Benefits - Reliability
Product and power output warranty:
10 years of product warranty
equated Power output warranty
based on the Nominal Power
transferable if PV inst. ownership changes
40
-6,30% -6,30%
1,30%
-6,20%
1,30%
-6,30%
-8,30%
-5,50%
-3,40%
1,30%
*Jinko offers a linear warranty on request
(@ e.g. 250 Wp
nameplate):
Extended snow & wind load
conditions:
According to internal and VDE confirmed tests
Suntech increased the wind & snow loads :
Normative requirements wind:
2400 Pa vs. Suntech = 3800 Pa
Normative requirements snow:
2400 Pa vs. Suntech = 5400 Pa
underlines that Suntech offers high
quality and high resistant modules
Extended Load Test
41
Please refer to Suntech IEC manual for more details
Product Benefits - Summary
Summary of product benefits:
Better system performance
due to Current Sorting
Excellent temperature behaviour
Excellent weak light performance
due to best in class fill factor
Reliability
52 steps at the quality
control
VDE certified test lab.
Double IEC testing
VDE
Positive power tolerance
with power warranty
above industry standard
4 steps power warranty
over 25 years + 10 year
Product Warranty
SUNTECH modules
withstand highest wind
and snow loads
42
52 steps
Test Lab
x2 Testing
Performance Quality