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The A-Z of PV Module specs – explained

jdanzi@atensolar.com (Aten Solar) — Fri, 02 Mar 2012 17:04:11 +0000

In this article we will thoroughly investigate PV module Spec Sheets or known also as “cut sheets”. Since there are literally thousands of modules available on the market it is necessary to know how to use that information most efficiently. Let’s start with most obvious features of the cut sheet, the mechanical aspects of the module.

Dimensions

Will be given in millimeters and inches, which also determines the surface area – it gives installers an idea how the modules should be fit on the roof, ground - or pole – mount installations. After layout is determined, the space between modules has to accommodate for mid clamps and end clamps, usually one inch apart for each clamp. The area of the module is crucial to determine weight load or to calculate wind forces acting on the modules and structure they are attached to. Thickness of the module will determine type of clamps installer is going to use. Quite often mid clamps differ only with the bolt length, whereas end clamp are shorter or longer depending on module thickness. Weight is also listed on most specification, since there is always a limit it can be added to the roof structure. Point to remember: many permitting authorities will accept PV modules to be mounted on pitched roofs without professionally engineered design, so long as there is only one layer of existing roofing material present.

There are different types of solar cells: mono-crystalline, poly-crystalline or thin film. There are variable numbers of cells per module from 36 to 108 but most common are 60 and 72 cell modules. Most PV modules cells operate near 0.5V and quite often they are connected in one string in series, yielding 36V per module so called V_mpp at max imum power output. However, other connections like 2 stirings of 36 cells will yield around V_mpp = 18V per module. Surface area of the cell will determine current output, I_mpp.

Most if not all solar modules have a plastic back sheet that seals the cells against environment. Its material is usually white but some modules come with black back sheet to match customer esthetic needs. It has to be handled with care since it is fragile underbelly of the module. To protect crystalline cells and simultaneously provide transparent surface modules use low-iron, high-transparency

tempered glass with an antireflection surface treatment. Low iron glass has high clarity, and tempered glass shatters into small fragments, instead of sharp shards, if broken. Modules are strenuously tested for weight loading and impact resistance, and the front glazing of a module is extremely durable. Thin-film modules may use a polymer film (plastic) as the front sheet, which is designed for arrays in high-impact environments.

The module lead’s connector type is important. Often called “quick-connects,” many new products are on the market. The old standard—Multi-Contact (MC) 4—has been joined by Tyco, Radox, Amphenol, and others. The 2011 NEC mandates that these connectors be touch-safe and, for circuits greater than 30 volts, require a tool for opening. Most of these connectors are not cross-compatible, so mixing modules will require properly mating connectors. Factory-installed module leads will be listed in the spec sheet with wire size, insulation type, and length of the leads (positive and negative leads are not always the same length). Wire diameter generally ranges from 14 AWG to 10 AWG; or they may be listed in square millimeters (mm2).

Bypass Diodes

Shading a small part of a PV module can have a disproportionally large effect on its output. Additionally, when a module is partially or completely shaded, the current flowing through the module can reverse direction and create hot spots, which can lead to deterioration of the cell, the internal connections, and the module back sheet. A bypass diode stops the reverse flow of current and also directs electrical flow around the shaded section of the module. Nearly all modules come with factory-installed bypass diodes, with the exception of some thin-film modules. A typical 72-cell module with all the cells in series will have three bypass diodes, each bridging a series of 24 cells that can be bypassed if any or all of those cells are shaded.

I-V Curve

Standard test conditions (STC) are the conditions under which a manufacturer tests modules: 1,000 W per m2 irradiance, 25°C (77°F) cell temperature, and 1.5 air mass index. Real-world operating cell temperature is often 20 to 40ºC above the ambient temperature. STC (bright sun and a relatively low cell temperature) are not typical for field operation of modules, but they do provide a

consistent standardized reference to compare modules. An I-V curve (current-voltage) curve is generated at STC for every cell and module manufactured. The I-V curve contains five significant data points (Pmax, Vmp, Voc, Imp, and Isc; discussed below), which are used for system design, troubleshooting, and module comparisons. I-V curves can also be diagrammed for any operating temperature and irradiance level, but the points listed on a module specification sheet and those printed on the back of the module are at STC unless otherwise stated. Peak Power (Pmax or Pmp)

The specified maximum wattage of a module, the maximum power point (Pmax), sits at the “knee” of the I-V curve, and represents the product of the maximum power voltage (Vmp) and the maximum

power current (Imp). This wattage is produced only under a very specific set of operating conditions, and real environmental conditions (changing irradiance and cell temperature)

will alter a module’s Pmax.

Vmp

At STC and tested under load, voltage at max power (Vmp) is the highest operating voltage a module will produce. Vmp, adjusted for highest operating cell temperature, is used to calculate the

minimum number of modules in series.

Voc

Open-circuit voltage (Voc) occurs when the module is not

connected to a load. No current can flow in an open circuit and, as a result, Voc occurs at the point on the I-V curve where current is zero, and voltage is at its highest (Note: the module produces no

power under open-circuit conditions.) Voc is used to calculate the maximum number of modules in a

series string. Because voltage rises as the temperature drops, calculations are performed for the coldest expected operating conditions. This ensures that NEC parameters and equipment

voltage limitations are not exceeded.

Imp

At STC, and tested under load, the maximum power current (Imp) is the highest amperage a module can produce. Imp is used in voltage drop calculations when determining wire gauge for PV circuits. This is a design consideration rather than an NEC ampacity calculation, for minimizing voltage drop and maximizing array output.

Isc

Short-circuit current (Isc) is the maximum amperage that the module can produce. There is no voltage when a module is shortcircuited, and thus no power. Isc is the measurement used to size conductors and overcurrent protection, with safety factors as required by the NEC.

NOCT

Frequently, nominal operating cell temperature (NOCT) specifications are also listed on a manufacturer’s sheet. These are measurements calculated at different conditions than STC, using

a lower sunlight intensity (800 W per m2); an ambient (not cell) temperature of 20ºC; and a wind speed of 1 meter per second; with the module tilted at 45°. The NOCT value itself is the cell

temperature—given in degrees Celsius—reached under these conditions, Compared to the STC 25ºC cell temperature, the NOCT value will always be higher, usually by about 20ºC. NOCT values are used to mathematically calculate other test condition data points without resorting to further laboratory tests. NOCT conditions tend to more closely resemble the field conditions PV arrays generally operate in, and so give a perspective on “realworld” module operation.

Power Tolerance

Power tolerance is the range within which a module manufacturer is stating the module can deviate from its STC-rated Pmax, and thus what the manufacturer warranty covers. Common values are +/-

5%, -0%/+5, and up to +/-10%. A 200-watt module with a +/-5% power tolerance could produce a measured output of 190 to 210W. Finding modules with a -0% power tolerance can ensure the

best value per dollar spent, and keep arrays operating at closer to predicted output. Module Efficiency & Cell Efficiency Efficiency is the measure of electrical power output divided by solar input. At STC, power in is equal to 1,000 W per m2 and power out is the rated Pmax point. Assuming a module sized at exactly 1 square meter, and rated at 150 W Pmax, module efficiency would be 150 W per m2 ÷ 1,000 W per m2, which equals 15%. The typical crystalline efficiency range spans 12% to 15%, but there are high-efficiency modules over 19%, and amorphous silicon modules on the low end with efficiencies around 6% or 7%. Cell efficiencies will be slightly higher than module efficiencies because there is usually a small amount of empty space between cells. When deciding what module to purchase, if W per square

meter (known as power density) is the driving factor, then a module with high efficiency should be chosen. But in many instances, there is plenty of room for an array and price per watt will be given higher priority than module efficiency. Temperature Coefficients Modules are directly affected by both irradiance and temperature, and because of environmental fluctuations, also experience power output fluctuations. When exposed to full sun, the cells will reach temperatures above the STC temperature of 25°C. And sometimes cell temperatures are lower than 25°C, such as on cold winter days.

Temperature coefficients are used to mathematically determine the power, current, or voltage a module will produce at various temperatures deviating from the STC values. The temperature coefficient of open-circuit voltage is used to figure out the PV array’s maximum system voltage at a site’s lowest expected temperatures. The temperature coefficient of power can be used along with pyranometer-measured irradiance to calculate the power an array should be producing, which can be compared to actual output to verify proper performance.

Warranty

A limited warranty for module power output based on the minimum peak power rating (STC rating minus power tolerance percentage) means that the manufacturer guarantees the module will provide

at least a certain level of power for the specified period of time. Many warranties are stepped—covering a percentage of minimum peak power output within two different time frames. For example,

a common warranty guarantees that the module will produce 90% of its rated power for the first 10 years and 80% for the next 10 years. A 200 W module with a power tolerance of +/-5% means that

the module should produce at least 171 W (200 W × 0.95 power tolerance × 0.9) under STC for the first 10 years. For the next 10 years, the module should produce at least 152 W (100 W × 0.95

power tolerance × 0.8). Module replacements are frequently done at a prorated value according to how long the module has been in the field. More manufacturers are now offering linear power warranties,

which are represented by a maximum percentage power decrease per year for a set number of years, for example, that module power output shall not decrease by more than approximately 0.7% per year

after the initial year of service, for the first 25 years.

At the end module specs are designed to help customers choose the appropriate product for their installations. The most important factors when choosing solar modules should not only the price per watt but the craftsmanship, efficiency and warranties. However, no matter how appealing a module is, it’s crucial how many years the producer was has been on the market and if the company is in good economic and financial standing. Some questions to ask: what are the warranties good for (what does it cover)? Is there an insurance company to backstop the company in case they go under? Do they have a linear warranty? How many years workmanship?

While quality of solar cells is crucial, the quality of connectors (quick connects) and wiring for instance cannot be underestimated since they also have influence on safety and efficiency of the whole system.

Unnecessary repairs due to poor quality of these components might cause unexpected and frustrating delays in power production. From an installers point of view, specs provide crucial information on how to connect modules to the inverter and how to design electrical layouts. Moreover, test conditions under which solar cells were tested are quite often misunderstood. STC testing conditions, while idealistic and rarely fulfilled in the real life conditions provide common ground for testing all solar modules, so different manufacturers can be compared to the same point of reference. To conclude, understanding and getting as much useful information from the specifications will result in better design and overall success of the whole installation. The next article we will discuss the "ins and outs" of micro inverters and power optimizers.

Developments in Lowering the "Real" Costs of PV Modules

yabdou@atensolar.com (Yousri Abdou) — Wed, 16 Nov 2011 11:38:42 +0000

New innovations and technologies will be necessary for solar PV-based energy to flourish and attract even more diverse implementations. Based on print and internet research, solar manufacturing is indeed entering a very important transition in its way to lower real overall costs of solar celsl and in turn the solar modules. True, module pricing has been declining rapidly but this has been based on declining revenues and over capacity in the global solar crystalline space rather than cost reducing innovations.

One of the keys to increasing competitiveness is to draw down the costs of production. The U.S. Energy Information Administration recently concluded that the ‘cost of generation’ (in US$/MWh) of solar PV will make it 2 times as expensive as wind, more than 3 times as expensive as nuclear, and slightly less than 4 times as expensive as conventional coal by 2016.

Taking into account only the solar cell itself, there are two main ways to lower the cost of energy generation: 1) make more efficient solar cells, or 2) lower the costs to produce them. As silicon is the largest cost in conventional solar cell production, (making up 50%-60% of the overall cost), it is pivotal that costs associated with its use be lowered. Currently, solar cell wafers must be thick enough to survive the direct contact metallization processes. Industry standard solar cell manufacturing processes use screen printing equipment which directly contacts the wafer and can exert enough force to cause breakage for thin wafers. If metallization could be done without touching the wafer, it would allow for silicon solar cell wafers to be much thinner than they are today, which could reduce the overall costs of the device.

Applied Nanotech is pioneer in so called non-contact print techniques, where processes like inkjet, aerosol jet, and spray coating offers several important advantages over traditional manufacturing approaches. These techniques provide a route to realize thin-sillicon wafer, which directly transforms to lower module costs. Implementation of this technology is a good 2 to 3 years away. Let’s see if it makes it into a solar cell near you….

“86’ing” Silver from Crystalline Modules

yabdou@atensolar.com (Yousri Abdou) — Tue, 01 Nov 2011 15:46:00 +0000

All contemporary modules utilize silver as a conductor in manufacturing solar cells. It is less resistive than copper, which directly translates to better efficiency but unfortunately, it increases module prices significantly. In order to decrease the price of the module, researchers in Germany began investigating where copper can be an alternative to silver. If the project is successful, the affiliated companies expect to be able to cut the costs of solar cell manufacturing by around 10%.

Another improvement in increasing efficiency of solar cells comes by way of Las Vegas. No, not sin city but what is dubbed “LasVeGas”. It is a German acronym standing for:”long-term stable front – side metallization on the basis of environment-friendly galvanic layers”. Both projects are still in theoretical phase, thus it will be a few more years before practical implementation will see the day light. In first phase, researchers will study the depositing of copper on existing cell structures and secondly, interconnection of the new cells into modules. This will entail transferring the results into actual production. A grant of 1.8 million Euros was set up by German Federal Research Ministry, which will be used by joint venture of the companies Schott Solar, Rena GmbH and CiS Research Institute.

PV installation costs decrease over past decade

yabdou@atensolar.com (Yousri Abdou) — Tue, 12 Jul 2011 14:58:39 +0000

The average installed cost of a photovoltaic (PV) system has declined substantially since 1998 — by almost 30 percent. Early indications show that the rate of decline accelerated in 2010. This historical trend suggests that PV policies have achieved some success in fostering competition within the solar industry and have satisfied a key goal: encouraging cost reductions over time.

An annual report identifying trends in the installed cost of grid-connected PV systems in the United States - “Tracking the Sun III” confirms that the installed cost of PV systems declined substantially since 1998. Roughly 75 percent of this cost reduction was associated with a decline in non-module costs; these may include inverters and mounting hardware, and also labor, permitting and fees, shipping, overhead, taxes and installer profit. Starting in 2005, cost reductions began to stall, as the supply-chain and delivery infrastructure struggled to keep pace with rapidly expanding global demand.

Installed Cost Trends over Time for Customer-Sited PV

Over the past year, consumers in the United States finally started to reap the benefits of declines in module prices. Based on preliminary data, average installed costs fell dramatically in 2010. “Tracking the Sun III” presents partial-year cost data for systems installed during 2010 in California and New Jersey, the two largest markets in the United States (figure 2). For systems installed through the California Solar Initiative program during the first 10 months of 2010, average installed costs were $1 per watt below the 2009 average. Similarly, in New Jersey, average costs through June 2010 were down $1.20 per watt from 2009 levels.

The report also finds that PV systems demonstrate economies of scale. Systems smaller than 2 kilowatts (kW) that were installed in 2009 averaged $9.90 per watt, while systems larger than 1,000 kW averaged $7 per watt, or about 29 percent less. Additionally it shows that installed costs for residential systems declined significantly when the PV systems were installed on new structures. Among residential systems in the 1–kW to 3–kW range funded through two California incentive programs (the New Solar Home Partnership Program and the California Solar Initiative) and installed in 2009, PV systems installed on new residential structures cost $1.60 watt less than comparably sized residential retrofit systems (or $1.90 per watt less for rack-mounted systems).

The report also describes trends in PV incentive levels and the net installed cost paid by system owners after receipt of such incentives. The combined post-tax value of all levels of incentive — state/utility cash incentives plus state/federal income tax credits — averaged $3.90 per watt for both residential and commercial PV systems installed in 2009. This translates into an average net installed cost of $4.10 per watt for residential PV and $4.00 per watt for commercial PV. For commercial PV, this represents virtually no change from 2008, as the average incentive and pre-incentive cost remained relatively flat. However, for residential PV, the average net installed cost in 2009 represented a historic low, having declined $1.30 per watt, or 24 percent, in only one year. This trend is largely a consequence of lifting the $2,000 cap on the federal investment tax credit for residential PV systems beginning in 2009.

Trend toward declining installed costs, along with the narrowing of cost distributions, suggests that PV deployment policies have achieved some success in fostering competition within the industry. In other words, overall prices declined and improved PV delivery considerably. The fact that states with the largest PV markets have somewhat lower average costs than states with smaller markets lends credence to the premise that state and utility PV deployment policies can affect local costs. However, installed costs in Japan and Germany are significantly lower than in the United States, suggesting that deeper near-term cost reductions may be possible here. Indeed, further cost reductions will be necessary if the PV industry is to continue expanding in the customer-sited market, given some policymakers’ desire to further ratchet down the financial support offered to PV installations.

By Konrad Gornicki

China Conquers Renewable Energy Market

yabdou@atensolar.com (Yousri Abdou) — Wed, 15 Jun 2011 18:05:15 +0000

Roughly two and a half ago, photovoltaic panels cost about US$3.50 a watt. Today they hover around US$2 a watt, and by sometime in 2012 they're predicted to be less than US$1 a watt.

Last July, the Chinese government stated it would subsidize 50% of investments for solar power projects. Between now and 2015, the administration plans to more than double its “environmental protection” spending to as much as $454 billion. This will result in mandates for using renewable energy generation sources, including solar. They're so low that European and Japanese suppliers can't compete with the low cost of Chinese products. Only the best equipment is used in China. The Chinese solar panel quality is as good as or better than the top brands in Europe or Japan. One of the most labor intensive elements of solar panel manufacturing is the final assembly. Despite China's greatest advantage being its low cost of labor and output, Chinese companies are beginning to do final assembly in the United States in order to sell into municipal and government projects through the ARRA (American Recovery and Reinvestment Act) requirements.

A good example of Chinese solar entrepreneurship is Yingli Green Energy. With global demand up, Yingli doubled production capacity and ran its factories 365 days a year, 24/7. The company claims that they sold everything, and Europe seems to be the largest market since they provide generous subsidies for solar-energy producers, for instance 60 percent of Yingli's revenues last year came from Germany. Yingli plans to expand production another 70 percent this year, and it isn't alone: Other Chinese solar companies, including Suntech Power Holdings and LDK Solar, plan double-digit production boosts in 2011. Suntech is expanding U.S. market; the company opened an 117,000-square-foot panel plant in Arizona last year and is doubling its U.S. head count to 150 people. "All of the major Chinese producers are engaged in massive, very aggressive capacity-expansion programs," says Paul Leming, an analyst with Soleil Securities in New York. Tellingly, Chinese-based Suntech Power Holdings will become the second-largest supplier of photovoltaic (PV) cells in the world this year behind Arizona-based First Solar, Inc. Our purchasing department has seen an increased amount of newer Chinese manufacturers looking to stock and list their modules on our website. Our decision to list modules on our website includes reviewing the Fraunhofer Institute in Germany to determine if they have experience evaluating these lesser known brands. Second, we speak to our European customer base and have them give us testimonials on certain name brands new to the North American scene. The selections are daunting, however having Aten Solar as a source for information and reviews allows installers or “do it your selfers” a level of comfort and assurance when deploying their next solar array.

Welcome to Decision Paralysis

yabdou@atensolar.com (Yousri Abdou) — Tue, 17 May 2011 17:03:14 +0000

The global market this year will be dramatically different than 2010. Rapid production expansion in 2010 and sluggish demand in Germany and Italy in 2011 has led to a build-up of module inventory globally. We estimate there are more than 500 companies manufacturing modules at the moment. In the global market place, Aten alone has designed and sold products from 22 different brands last year. 2011 will see many new module brands appearing on the US market as manufacturers who had focused on the European market shift towards the US. Some manufacturers will go to market based on containerized orders (over 500 modules per order) while others will sell pallet quantities of 20. Aten Solar plans on being the go-to source for sorting through this increasingly complex and volatile market.

A Preview of Enphase M215

yabdou@atensolar.com (Yousri Abdou) — Tue, 10 May 2011 18:48:28 +0000

Dear friends and dealers,

I got a first-hand look at the M215 with some hands-on demonstrations in NJ. Here's a quick rundown of M215 info that I've got:

* recommended DC input is up to 260W - while module right-sizing for the M190 continues to be 125% of inverter rating, on the M215 it's 120% because...
* the M215 is more efficient than the M190 - CEC weighted efficiency at 96.5%, and beta tests are looking even higher
* the M215 is both smaller and lighter than the M190, has a single mounting point, and has improved communications software
* it is made for 60-cell panels only
* S22 for MC4 (rather than S12) and S23 for Tyco (rather than S13)
* string configurations are 26 panels for 208V, or 17 panels for 240V
* like the D380, the inverter is phase-agnostic; the cable determines the phase
* using the 20A breaker

There is no longer an AC interconnect or an Enphase extension cable in the M215 world. Instead, cable will be sold in spools or rolls that can be cut to length to fit your installation, with drops spaced evenly apart. Cables are available for both portrait and landscape installations (where the drops in landscape are further apart). This cable will be run through a strain relief and into a J-box (acting as the AC interconnect). It can also have drops capped off to act as an extension cable between rows. This will cut down on the number of parts that need to be ordered. Cable will be available in several lengths, including a 240 drop "bulk roll," and smaller 30 and 40 drop rolls.

I've attached a cut sheet for the M215 here, and if you are looking for an Enphase Road Show to get to, check this link: http://enphase.com/next-gen/

Product Details

New kid in town? (A brief review of the new Enecsys micro-inverter)

yabdou@atensolar.com (Yousri Abdou) — Fri, 29 Apr 2011 17:18:36 +0000

The Enecsys micro-inverter represents a breakthrough in inverter design for residential and commercial solar photovoltaic (PV) installations. Its patented technology has, for the first time, eliminated components that limit inverter life, namely electrolytic capacitors and opto-couplers. Originally developed at Cambridge University, UK, the Enecsys micro-inverter enables solar PV systems to harvest between 5% and 20% more energy over their lifetime. The electrical components of Enecsys design are also worth mentioning since electrolytic capacitors were replaced by their much more reliable ceramic counterparts, significantly prolonging the life of the micro-inverter. Shading caused by clouds or obstructions have minimal impact on overall system performance because power is harvested from each module individually, rather than from groups of modules strung together. This also means that installations can mix and match different modules and do not need to be on the same roof plane, multiple planes can be used to harvest more energy and systems are scalable. A potential single point of failure – the central inverter – is eliminated and dangerous high-voltage DC is not produced.The Enecsys micro-inverter is the only product of its kind, available in both Europe and North America that matches the operating life of solar modules (more than 25 years), operates from -40 to +85 degrees C and and has a warranty for 20 years. Enecsys micro-inverters are installed on the rack behind solar modules, either one inverter per solar module, or one for every two modules.

The following is sample systems applying two competitive micro-inverter technology and regular string size inverter.

1) Enphase system: 20 x REC 230W , 20 micro-inverters M190-72 with Envoy; total $15,350 plus mounting and other BOS.

2) Enecsys system: 20 x REC 230W – $9154.00, 20 micro-inverters Enecsys SMI-S240W -72 plus; total $16,343 plus mounting and other BOS

3) Kaco with Watchdog : 20 x REC 230W – $9154.00, Kaco 5002i inverter; total $14,161 plus

Mounting and other BOS.

At first regular string inverter seems to be the most economical. It will harvest the least amount of power though, since shading and other factors will have effect on the whole system, so the price per kilo watt/hr is actually higher than other two systems. The micro-inverter technology allows Enphase and Enecsys work more independent from mentioned factors since power is harvested at each and every module. It seems that Enphase has Enecsys beat in terms of pricing, but during days when maximum power output can be expected i.e. 230W per module, the Enecsys has upper hand because it can gather all energy from modules, while Enphase will cut of at 190W. It is worth mentioning that Enphase is not easily available and potential clients have to wait several weeks before they can implement the system. Enecsys on the other hand is available with no delays. So therefore buyers finally have options when it comes to their micro inverters pv projects. We predict this is just the start of an explosive sub market.

Written by

Konrad Gornicki

Enphazed? (Comparison of MPPT-per-module Options)

jdanzi@atensolar.com (Aten Solar) — Fri, 01 Apr 2011 15:51:56 +0000

Over the past year, there has been an explosion in the popularity of solar inverter solutions with MPPT tracking for each module. This technology has significant benefits in output, reliability, and flexibility over standard centralized inverter options, especially in partially shaded environments. Of course, there is a cost drawback to every new and complex entry into the market, but cost-benefit analysis will show that in some cases the extra investment will pay for itself handily.

There are three types of MPPT-per-module systems on the market: standalone MPPT controllers such as Tigo products, per-module microinverters like Enphase, and the SolarEdge system, which has a central inverter connected to MPPT trackers per module. The most popular of these by far is Enphase, and for good reason: the flexibility is unparalleled. Enphase sells microinverters in single-phase and three-phase configurations with power levels at 190W and 210W and with MC4 or Tyco connectors. Modules can be mixed and matched, and the inverters are inexpensive to replace if they fail out of warranty. Unfortunately, availability is still extremely tight, so if you are an installer or a homeowner who is looking for Enphase, you better get in line.

Let’s see what happens when we implement Enphase and Tigo solutions on a typical 4 kWp system located in central NJ with a 30˚ pitched roof and partial (50%) shading on two modules on one string and one module on another for 3 hours during the peak of the day:

1) Enphase system parts: 18x Gloria Solar 230W, 18x Enphase M190 with Envoy and cabling: approx. $13,500 plus mounting and other BOS.

2) Tigo system parts: 18x Gloria 230W, 18x Tigo ES050V, Tigo monitor, Kaco 3502xi: approx. $13,100 plus mounting and other BOS.

3) Control system parts: 18x Gloria 230W, Kaco 3502xi: approx. $11,700 plus mounting and other BOS.

The Enphase output will only decrease by the lack of energy going out from the three shaded modules, or approximately 1.08 kWh per day at 3.9h insolation and an 80% derating factor. The Tigo system will operate slightly differently—because the output is stil DC, it will regulate the voltage and current on the affected modules until the string is uniform. Tigo calls the technology “impedance matching” since it observes and matches impedance seen at each energy maximizer connection, but the current in the string does not need to stay uniform since the maximizer will bypass current around modules as suited. As a result, the system will lose 1.08 kWh plus impedance matching losses. Unfortunately, the exact losses are rather difficult to calculate, especially since Tigo’s algorithm is proprietary. The control system, without any MPPT per module device, will lose approximately 6.5 kWh per day, or about 50% of the maximum without shading.

In this sense, both Enphase and Tigo systems are both winners because they give significantly lower costs per kWh even if costs per peak kW are slightly higher. In fact, with SREC prices at $500 per 1000 kWh, the Enphase system will pay for itself over the control system in about two years. If you or your clients have significant shading, please consider investing in one of these solutions—your mileage may vary, but in the end, you will benefit.

Are transformerless inverters worth it?

jdanzi@atensolar.com (Aten Solar) — Sat, 22 Jan 2011 17:24:34 +0000

Transformerless PV inverters have been available in ROW markets for several years now, but a change to the NEC guidelines for PV has allowed these units to be produced for use with the 60 Hz grid in the US and Canada. They are significantly lighter than their galvanically isolated counterparts and can offer a wider range of operating voltages than traditional inverters because of their advanced switching circuitry. However, there has been reluctance among installers to implement these units, mostly due to lack of necessity and perceived safety concerns. This article will explain the differences between galvanically isolated and transformerless inverters to better inform the installer.

The idea behind transformerless switching has existed long before the PV market was even developed. Device engineers have known that a pair of field-effect transistors operates most efficiently in a complete ON or OFF state, when no current flows through them, and they dissipate no power. Thus, amplifying an ideal square wave would theoretically be 100% efficient. If a signal is modulated by a much higher-frequency square wave, the result is pulse width modulation (PWM), and the corresponding circuit is called Class D. In this manner, it is possible to convert DC to DC, or efficiently switch DC to AC. For solar inverters, the technology was not available in the past because of the high cost of the switching MOSFETs and IGBTs. These, however, are getting cheaper and faster every year, so the technology has become more cost-effective than analog switching into large masses of copper and iron. The same technology is making electric cars feasible.

The downside of not having galvanic isolation is the possibility of a ground fault destroying the inverter and causing an electrical fire. With a transformer, if the secondary is shorted, then all of the current will flow through the primary and will (hopefully) be stopped by a thermal disconnect once the transformer overheats. Without one, if no protection exists or if the protection fails to detect the ground fault and trip, the large MOSFETs or IGBTs will immediately fail in a rather catastrophic manner. Fortunately, the likelihood of such an event occurring is extremely remote, and all such inverters are required to have ground fault protection as per UL 1741 requirements. The burden, however, remains on the installer to insure that backfeed current in the case of an undetected ground fault is taken into account when sizing combiner and disconnect fuses.

Thus, provided that the correct simple calculations are performed, there are few downsides and numerous benefits to transformerless inverters. Crews will certainly notice the reduced weight and size of these new inverters, and home and business owners will see increased yields over traditional designs due to increased efficiencies and wider operating voltage ranges. In short, there are always early adopters of new technologies, as well as holdouts who refuse to let go of their horse buggies when the rest of the world is already driving cars. Here, the cars are well proven.

Our New Years Solar Wish List

jdanzi@atensolar.com (Aten Solar) — Sun, 23 Jan 2011 14:25:14 +0000

On December 7, the solar industry was granted our first wish: the extension of the tax package that includes a one-year extension of the Department of Treasury's Section 1603 program. As of November 22, the Treasury had shelled out a grand total of $416,184,641 in grants for solar energy projects in the U.S., according to data from the Solar Energy Industries Association (SEIA). The corresponding minimum total investment (the basis upon which the grants were claimed) reached $1,387,282,137. The government’s investment has launched, and with the latest extension, will be sure to continue, the successful creation of jobs and opportunity in all 50 states for construction workers, electricians, plumbers and contractors that have struggled during the difficult economic climate.

Our second wish is for the Department of Energy to practically and efficiently divest funds for its loan guarantee program so that the average tax payer can reap the advantages of his initiatives. Just last month, three White House advisers expressed concern about the DOE loan guarantee program in three areas. First, there is the potential for some funds to be lost if such funds are not obligated to projects by the deadline. Second, the officials noted a risk that the program would be criticized for slow implementation. And third, they highlighted the potential for funds to be committed to projects that would have happened anyway, without government assistance.

Our third wish is for PV module prices to decrease starting from Q2 2011, setting the stage for grid parity and a broader acceptance of grid tie PV. Beginning in 2008 and continuing into 2010, wholesale module prices began a steep downwards trajectory, in response to expanded manufacturing capacity and the global financial crisis. Due to strong investments from the Chinese to boost total capacity of cells, ingots and module assembly operations, more capacity than ever before will be available for export to familiar markets. At present, the majority of production is dependent on exports, accounting for up to 40-50%. With photovoltaic cells, for example, China’s total output of 2008 2300MW (megawatts) comprised 97% of the Chinese products exported is relatively small. Moreover, with exports totaling more than 10 billion US dollars, the Chinese domestic market for its production is underdeveloped. Moreover, the halting or deep reductions to the Feed in Tariffs (FITS) in France, Spain, Italy and the 900 lb gorilla, Germany, will surely alter the pricing landscape next year. Therefore, all the excess capacity should yield lower prices for the 2011 solar season.

In connection with our third wish, we would like to see a continued downward push towards lower installation costs. Unfortunately, the reductions in module prices from 2008 did not translate into a noticeable reduction in average installed costs for PV systems in 2009, perhaps reflecting a natural lag between the time that PV system installation contracts are signed and the time that PV systems are installed. Currently, a California PV installation costs USD$6.5/watt and a New Jersey PV installation costs USD$6.3/watt. Preliminary evidence does suggest, however, that the average costs for PV systems installed in 2010 will be substantially lower than in 2009.

My last wish places the onus on the elected officials to continue their important work of ratifying aggressive RPS, and fair grid tie standards in their respective operating areas. Getting all the foundation work completed on the more than 3,273 traditional electric utilities in the United States will set the stage for a larger market for PV and not regional markets confined to 10 solar consuming states.

One wish has been granted; if the other wishes come true this will undoubtedly ensure another 30% annual growth rate for our industry.

Nice Rack! A Review of Various Residential Solar Roof Mounting Types

jdanzi@atensolar.com (Aten Solar) — Tue, 04 Jan 2011 13:24:22 +0000

Installers and system integrators alike can easily be confused by the myriad of solar roof mounting styles and types available on the market. There are several reputable manufacturers, and they have become favorites in the industry due to availability and performance. Others, such as no-name brands or new, proprietary solutions should be used with caution or not at all. This article will act as a short review to aid the selection of a mounting configuration with an ideal mix of cost, reliability, and aesthetics.

The bread and butter of residential roof-mounting is, of course, Unirac SolarMount. There is no other product on the market available so broadly and with so many potential configurations. The mounting rails themselves come in regular and heavy-duty versions (with a thick support added to the rail) in polished aluminum, mill finish, and anodized black. Additionally, installers can choose between top mount and bottom mount module clamps, although most go for the top-mount versions for ease of installation. In dry climates and well-insulated shingle roofs, it is sufficient to simply screw down the SolarMount L-feet directly to the roof rafters for a solid hold. However, for homeowners that are more concerned about water leakage or aesthetics, or for tile roofs, Unirac provides standoffs of varying heights, to be used together with flashings for waterproofing. For systems where roof pitch is insufficient or nonexistent, there are also tilt legs available to increase module insolation. The downside to Unirac’s SolarMount is the expense—systems such as Pro Solar may not be as versatile but are an excellent now-cost alternative.

Professional Solar is a direct competitor to Unirac, and offers high value roof mount and ground mount products. Three heights of rails are available: regular (1.5”), deep (2.5”) and extra deep (3”), each with the appropriate accessories. The rails are of a somewhat simpler construction and offer less aesthetic appeal than the SolarMount counterparts, but as long as extreme winds are not involved, they work just as well mechanically. Unlike Unirac, Pro Solar’s method of attaching to tile roofs does not require the removal or breaking of any tiles. A sliding member is concealed under a set of tiles, and the rails are screwed down to it from above. The usual kind of standoffs, flashings, and tilt legs are available, although the tilt legs’ length is not adjustable, as Unirac’s is.

Iron Ridge also offers high-quality roof mounting in regular (XRL) and heavy-duty (XRS) styles, and they are worth exploring as well. While the product construction quality is a notch or two above offerings from Pro Solar, Iron Ridge’s system is not as versatile as Unirac’s. Additionally, it is more difficult to supply customers with these products due to availability and the lead times from major suppliers. Other module-specific or proprietary products such as Sharp’s SRS and Lumos’s PowerMount are also on the market, but do not garner the same level of respect as long-time favorites Unirac and Pro Solar. Conceivably, the tried-and-true is that for a reason.

My Grownup (Solar) Christmas List

jdanzi@atensolar.com (Aten Solar) — Thu, 23 Dec 2010 16:07:02 +0000

Q3 and Q4 of 2010 has been fairly tumultuous as far as product offerings and availability. Though the US market has seen the arrival of new products such as SMA’s TL line of grid-tie inverters and an expansion in availability of Sanyo HIT high-efficiency modules, pending installations have been hampered by constant shortages of American-made modules (Sharp and SolarWorld) as well as near non-availability of Enphase microinverters and accessories. Furthermore, the US market has seen a rise in pricing from most Tier 1 Chinese module manufacturers, which has led tenser relations with installers and suppliers buying direct. Many (if not most) of these issues were the result of market fluctuations and were not the result in human error in supply chains. However, some issues, especially the microinverter shortage, were caused by miscalculations of demand. No market is perfect, but the following list is what Aten Solar (and other distributors, no doubt) would like to see from the industry in Q1 2011 forward:

An increase in inventory of American-made modules. Although Chinese goods are almost always lower-priced, many publically-funded projects require ARRA-compliant components
More availability on Enphase inverters. The backlog of 4-6 weeks on Enphase products has become difficult to handle, especially when customers already have modules and other BOS components on the ground
Debut of Sanyo HIT 225/230W modules and Yingli Panda Series modules for the US. Sanyo already has small form-factor modules up to 235W available in Europe, but offerings in the US only rise up to 220W. The high-efficiency Panda Series were announced early Q2 2010 and still have not arrived stateside
Debut of Kaco large residential inverters in the US. Kaco is currently losing the opportunity to compete with its larger counterpart SMA by not releasing any residential inverters larger than 5kW. The larger inverters were promised by late Q4 2010 or early Q1 2011, and are not arriving yet.

Despite the above shortcomings, the steadily rising demand for solar products is keeping the industry very successful as a whole. As a result, established module and inverter manufacturers have all had to increase production volumes and allocations significantly. Aten Solar’s business flow has grown fivefold since the early part of 2010, and we are confident that such growth will continue onward into next year.

So with all that being said Happy Holidays and Season's Greetings to All!

High Efficiency Solar Panel Considerations.

jdanzi@atensolar.com (Aten Solar) — Thu, 18 Nov 2010 14:28:11 +0000

New, high-efficiency solar modules such as the Sanyo HIT line or Sunpower are becoming more common in the PV marketplace and are considerably more expensive than the average solar module. The question is, are they worth it to the average homeowner? This depends on the goal the property owner is trying to achieve with a PV system. If there is a glut of unshaded roof space and only a certain yearly energy output is required, then high-efficiency modules can be a waste and the owner’s investment will take longer to pay off, if ever. Alternatively, if there is a deficiency of roof space or the owner wants to generate as much power as possible, then such modules may be beneficial. Let’s explore the issue on two different roofs:

Roof A: 37° pitch, 50ft wide, 12ft deep, unshaded

Roof B: 37° pitch, 30ft wide, 12ft deep, unshaded

Let’s assume that our power requirement on Roof A is 6 kW AC (assuming 95% inverter efficiency). If we use CentroSolar modules on Roof A, we can mount two rows of 14 modules and get 6.118 kW AC, close to our target. The CentroSolar modules are relatively inexpensive at $2.19/W for this quantity, so the panels would end up costing $14,082. If we mount Sanyo 220W modules on the same roof in two rows of 14, we get 5.852 kW AC. Here, the improved temperature performance of the Sanyo system would make up for the difference in nominal power. However, the Sanyos cost $3.54/W, meaning that the buyer will spend almost $22,000 on modules without much benefit over the CentroSolar option.

Now, let’s assume that the owner of Roof B wants to maximize his output. He can use two rows of 9 Centrosolar modules to get 3.496 kW AC and spend $9053, or he can go with two rows of 11 Sanyo modules and produce 4.598 kW AC, costing him $17,130. The extra 1.2 kW AC may sound welcome, but the homeowner must realize that the margin will actually cost him close to $7 per watt. Naturally, there is no “correct” choice here, but any homeowner should be well-aware of the additional burden on his or her pocketbook as well as the return (or lack thereof) on investment.

For more information on which system is right for you please contact Aten Solar at 800-310-7271 or feel free to use our contact form and a representitive will get back to you right away.

One Size Fits All

jdanzi@atensolar.com (Aten Solar) — Thu, 11 Nov 2010 12:54:18 +0000

Yes, the renewable energy industry has literally exploded since project financing for larger commercial and utility scale was made available here in the U.S. Also in 2009 solar module prices fell between 30% and 50% compared to an average 5% to 10% drop in previous years. In just 10 years something called a feed in tariff, or what’s better known as a FIT allowed for investments in both private and commercial owned electricity generated to be fed into the public power grid. This allowed for investors to receive reimbursement in a form of a fixed price for a Kwh of electricity. As you probably heard numerous times, Germany has demonstrated to the rest of the world how to make solar energy feasible and from inverters manufacturers to EPC’s, German companies continue to pave the way in all aspects of this industry. All told, Germany has installed about 10 GW since FIT inception and has created at least 15,000 jobs.

In 2009 Gainesville, Florida Regional Utilities (GRU) announced they were going to lead the nation and announce the first fit in the USA which allowed rate payers who sign up within the 1st two years of the program a guaranteed fixed rate of $.32 per kilowatt for 20 years. GRU estimates that investors will see a 5-percent return on investment for large-scale projects.

Kudos to Gainesville for truly setting the stage for an incentive program that is easily understood, bankable, mandated by a state authority and most importantly replicated. As solar professionals, Aten Solar understands that it is difficult or downright impossible to get the more than 3,273 traditional utility companies to agree to any incentive program. In the US solar industry, we are riddled with an alphabet soup of acronyms and catch phrases such as SREC, PBI, MassCEC, Sunsense, Sunshine to the point it is madding. Understanding and financially modeling the myriad of incentive programs and relevant state and federal tax incentives and rebates will cause the U.S. to adopt solar at a slower pace than many European markets and the 47 other countries that have adopted FITS.

Industry lobbying from SEPA, SEIA and regional trade associations need to put the pressure on the law makers to adopt a national incentive schema for solar to be more mainstream. If a FIT is accepted in the U.S, adjusted on state by state basis, more installs would occur therefore pushing the module, components and install prices down further in order for most U.S. states to reach the coveted grid parity market. Undoubtedly, if this is truly “our prize”, then it only makes sense to have one or two incentive programs nationwide.

Solar Cells Printed on Paper

jdanzi@atensolar.com (Aten Solar) — Thu, 11 Nov 2010 12:25:16 +0000

The three big challenges are that solar cells are expensive to produce, they’re not very efficient, and you need some means to store the energy collected. What if you could simply staple solar panels to your house rather than hiring a professional installation team? That’s not as far-fetched as it sounds — MIT researchers have figured out a way to print thin film solar cells on paper using a process that resembles a standard inkjet printer. If they’re able to gear efficiencies up to scale, the development could revolutionize the production and installation of solar panels.

MIT’s new semiconductor-coated paper features carbon-based dyes that give the cells an efficiency of 1.5 to 2 percent. That’s not incredibly efficient (typical solar panels are 20-40% efficient), but the convenience factor makes up for it. In the future, researchers hope that the same process used in the paper solar cells could be used to print cells on metal foil or even plastic.

Of course, paper solar cells are a long way from commercialization. MIT researchers say that the technology is still in the research phase and it could take years before being commercialized. And once it is? There’s no telling how it could revolutionize the home solar industry, which currently relies on pricey professional installers to set up panels.

Unfortunately we haven’t heard any word on new battery technologies to go with these new solar cells. But we are sure there’s some group of really smart people working to tackle that aspect of solar energy.

Affordable Solar Power from a weed?

jdanzi@atensolar.com (Aten Solar) — Thu, 11 Nov 2010 12:24:01 +0000

Believe it or not weeds can provide a very positive effect on global warming. Thepokeberry weed – native to North America, South America, East Asia and New Zealand and whose red dye was once used by American Civil War soldiers to write letters home – may now hold the secret for revolutionizing the next generation of low-cost photovoltaic cells, making widespread, affordable homegrown solar power a real possibility. Especially for countries who find themselves in unfortunate economic circumstances.

Researchers at Wake Forest University’s Center for Nanotechnology and Molecular Materials were able to create a more efficient fiber-based solar cell by coating the solar cell’s fibers with the pokeberry dye, which helps the fibers absorb more sunlight. This, together with the humble pokeberry’s red dye, the fiber-based solar cells generate twice as much power than current thin-film technology. And what’s even better is that the pokeberry can grow anywhere, including dry and inhospitable places.

“They’re weeds,” says the center’s director Dr. David Carroll. “They grow on every continent but Antarctica.”

With their spin-off company FiberCell Inc., Wake Forest is now developing these fiber-based solar cells for the commercial market.

So how does a fiber-based solar cell work? Made of millions of tiny, plastic cylinders or fibers that trap sunlight until it is absorbed, this configuration means that a fiber-based cell can collect light at any angle, from sunrise to sunset because there is much more surface area available.

To manufacture these highly-efficient ‘hybrid’ cells, the plastic fibers are stamped onto plastic sheets and the absorber dye (this is where cheap and locally-grown pokeberries come in) is sprayed on. The sheets are flexible, which means that manufacturers can make them and ship them at a low cost to developing countries. Once there, local factories can spray the absorbent pokeberry dye on the cells.

Dr Carroll points out that compared to a plant making flat-cell solar panels, which would cost about $15 million, a fiber-based solar cell finishing plant would only cost $5 million, which would make this kind of solar power much more accessible. “We could provide the substrate,” says Carroll. “If Africa grows the pokeberries, they could take it home. “It’s a low-cost solar cell that can be made to work with local, low-cost agricultural crops like pokeberries and with a means of production that emerging economies can afford.”

Weeds may have been given a bum rap with everything they do to grow in the cracks of our sidewalks and driveways, but perhaps one day we will all be fortunate enough to also have them on our roofs.

KACO NEW ENERGY USA partners with distributor Aten Solar

jdanzi@atensolar.com (Aten Solar) — Thu, 11 Nov 2010 12:31:27 +0000

KACO new energy the world’s second largest inverter manufacturer; with over 2GW of PV inverters in the field to date is thrilled to announce the most recent partnership with distribution specialist Aten Solar.

Aten Solar has been a presence in the solar market for the past 20 years with a heavy focus in distribution for the past ten. Their commitment to superior customer service and supplying the most reliable products on the market make them an ideal distribution partner for KACO. They have a reputation in the solar industry for providing their clients with personalized support similarly to how KACO prides itself on interacting with partners. “It’s a perfect marriage of ideals” says sales rep Clinton Porter.

As of April 2010 the blueplanet brand KACO 02xi inverters will be readily available off the shelf at the Aten Solar warehouse in Bradley Beach, NJ.

ABOUT KACO:

A powerful partner for PV system solutions, KACO new energy has built a tradition of excellence in the photovoltaic inverter and power electronics industries. Our German-based factory engineers have been developing, designing and manufacturing current inverters and power electronics for more than 60 years.

The KACO blueplanet product family has set new standards in photovoltaic applications – particularly in reliability, efficiency, power density, and patented technology to meet NEC requirements. As the heart of your photovoltaic installation, your KACO inverter pumps electricity into the public grid continuously and efficiently. The efficiency of the KACO blueplanet inverters will earn you money and a solid return on your solar investment. Additional information about KACO is available at www.kaco-newenergy.com.

ABOUT Aten Solar:

Aten Solar is a leading value added distributor of complete environmental and sustainable products. Engineers from the solar thermal heating, conventional heating, ventilation and air conditioning industries created Aten Solar to meet the demand for solar energy solutions globally. The company’s purpose is to provide a unique product mix that is compelling for buyers amidst a plethora of products and technologies.

Thin Film vs. C-si Modules

jdanzi@atensolar.com (Aten Solar) — Thu, 11 Nov 2010 12:35:35 +0000

As you probably well know, we have been in front in promoting thin film modules for 3 years now when most online sellers were selling pricey c-si modules. Based on our modeling software, our testing and user testimonials, we are convinced that a-si modules will produce at least 9% more Kwh/yr than 12-14% more efficient (due to better temperature coefficients) c-si models in sunnier places; and suffice to say isn’t the name of the game Kwh produced and not DC STC watts?

So as long as you have the surface area, we have advocated and endorsed these modules. The concern about increased a-si framed module degradation compared to their c-si brethren has no substance. So based on my premise, how do you feel about thin film modules today? Would you use thin film modules in your current or future projects?