GreenSolar Equipment Manufacturing Ltd.

About GreenSolar

GreenSolar is a high tech photovoltaic R&D company. Its target is to become one of the leaders on the thin film PV market. GreenSolar has the background of the well expert technical team from EnergoSolar who already successfully installed over 100 MWp a-Si production line worldwide. GreenSolar manufactures, installs and services turn-key production lines of thin film solar modules. It has a manufacturing capacity of 100 MWp production lines/year on its 10.000 m2 production facility in Budapest. GreenSolar develops and sells its own technologies making it an ideal partner for companies entering or expanding into the fast growing thin film PV market. Solar energy is becoming a primary solution of choice for energy policy decision-makers in many countries around the world. Large scale solar energy production is about costs, return on investment and reliability, factors that low cost thin film technologies can best serve. The worldwide PV module production capacity is expected to grow dramatically in the next decade and low cost thin film production capacities will lead that growth. GreenSolar is involved in tandem a-Si thin film technologies making it a go-to technology source and equipment manufacturer. GreenSolar pursues research of a-Si/ cSi technology. GreenSolar operates a state of the art pilot line having a floor space of 1200 square meters. Ten years of expertise in thin film, the scale of R&D activity, the range of technologies and the offer of a cost effective and flexible turn-key production line makes GreenSolar your real thin film specialist.

Turn-key production lines for tandem thin film silicon solar modules Product Catalog

Turn-key tandem thin film solar module manufacturing systems

7 MWp/Year Tandem Thin Film Solar Module Manufacturing System with Manual Loading
47000

Final IV tester

Sand blaster

Conductive layer deposition line ISO 7 class cleanroom

Assembly stations

Ultrasonic bonding Module laminator

Cool down chamber Active layer deposition chambers

31000

26000

EVA lay-up station Panel light IV tester Preheat chambers ISO 7 class cleanroom

Glass cutter laser scriber for TCO 1st glass washer

Gas abatement system Box cleaning station

Dust filter

2nd glass washer

Glass driller

Edge grinder

Box loading station

FORKLIFT WAY

52000

Turn-key tandem thin film solar module manufacturing systems

Why thin film solar modules are competitive
Within the past decade, the market of the solar photovoltaic modules grows at a very fast pace. After some little slow down in 2005-2006 due to the silicon shortage, the rate of growth of the pv market recovered very fast, together with the commissioning of the new high purity silicon production facilities. The global financial crisis of 2008-2009 had its effect over the pv industry and market. The good of the bad is for consumers, hence the solar module prices have been halved within a very short time. GreenSolar gives a very viable solution to the quest of the competitiveness by making possible the production of solar modules at the lowest cost of ownership on the market, and also the lowest cost of investment.

Cost of ownership example

Description
Direct Materials Depr. Production Line (7 years) Other Direct Costs Personnel Maintenance Depr. Utilities (7 years) Depr. Building (25 years) Total Cost of Ownership Exchange rate = 0.73 /$
1.16% 1.45%

Cost [USD] 0.471 $/W 0.125 $/W 0.054 $/W 0.020 $/W 0.010 $/W 0.008 $/W 0.003 $/W 0.691 $/W

Cost [EUR] 0.344 /W 0.091 /W 0.039 /W 0.015 /W 0.007 /W 0.006 /W 0.002 /W 0.504 /W

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L ow

Cost of Ownership
0.43%

Cost [%] 68.16% 18.09% 7.81% 2.89% 1.45% 1.16% 0.43% 100% o st of o w n e tc

2.89%

7.81%

Direct Materials

st

c ost

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Depr. Production Line (7 years) Other Direct Costs 18.09% Personnel Maintenance 68.16% Depr. Utilities (7 years) Depr. Building (25 years)

The cost of ownership for the thin film solar modules produced with GreenSolars equipment and technologies, can be as low as 0.70 $/W or 0.50 /W in certain locations.

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Turn-key production lines

For a smooth start in thin film module production GreenSolar will provide you a real turn-key solution including the equipment, technology, know-how and a package of services including assistance in business planning, factory design, installation and setup, personal training, support for material resourcing, performance and equipment warranty, after warranty services and technology upgrades. With the delivery time of less than one year GreenSolar offers you a quick appearance and a dynamic expansion in the market. With GreenSolar you have the opportunity to start with a production plant with low level investment and go for certifications and for big scale step by step in line with your market penetration. With a production line from GreenSolar modules are made in a simple process of glass in module out, which significantly reduces materials, labor and energy inputs. The straight forward economic and well designed technology and machinery keep quality high at a very competitive cost level. The special easy-to-manage factory concept allows you low expense for building, skilled staff and maintenance. Your likely production cost with GreenSolars production lines and technology will be one of the lowest on the market accompanied with good quality allowing you profitable production under all circumstances. On the top of that GreenSolar offers technology upgrades ensuring you long term competitiveness on the market.

Environment

Turn-key tandem thin film solar module manufacturing systems

We all know that solar energy is a good solution to reduce the carbon emissions that contribute to the greenhouse effect, and to the global climate change. Thus solar modules are green, but have you ever thought about how green their manufacturing is? It is a very odd thing to reduce the carbon emissions by gaining energy by photovoltaic devices, while the manufacturing of some solar modules contributes to the emission of gases, which are much more harmful greenhouse gases than carbon dioxide. Sulphur Hexafluoride (SF6) is the most potent greenhouse gas that it has evaluated, with a global warming potential of 22,800 times that of CO2 when compared over a 100 year period. Nitrogen Trifluoride (NF3) is a greenhouse gas, with a global warming potential 17,200 times greater than that of CO2 when compared over a 100 year period. Fluorine gas that is claimed to be environmentally friendly alternative to SF6 and NF3 is nevertheless a potentially hazardous and very agressive substance, which in contact with water forms hydrofluoric acid that is so agressive, that it corrodes even glass and stainless steel. Would you like to handle such substances in your factory? Can anybody guarantee that no leaks will ever occur? GreenSolars technologies do not require any kind of fluorine gases, neither SF6, NF3, nor F2, thus using GreenSolar manufacturing equipment means saving the atmosphere. Many technologies use such agressive gaseous chemicals because of the need to remove from the electrodes of the CVD equipment the unwillingly deposited (doped or undoped) silicon. How is possible that such unwanted deposition doesnt occur in GreenSolars CVD reactors? The solution is given by design, hence in GreenSolars reactors the space where plasma is generated is surrounded by the glass of the solar plates. Therefore 99.95% of the silicon deposition occurs where it is intended, exactly on the surface of the future solar modules under process. The little deposition, which is in excess, all occurs on removable parts, that are taken out of the reactors and cleaned mechanically, without the use of any chemicals, whenever it is needed. If you are environmentally-conscious, before choosing one or another of the available production lines and technologies, ask for the fluorine and fluoride consumptions. For a sustainable life, GreenSolar provides you only completely green, environmentally friendly FLUORINE-LESS THIN FILM TECHNOLOGIES.

The manufacturing process applied by GreenSolar is based on what is known as amorphous silicon technology. A key feature of this technology is the use of Plasma Enhanced Chemical Vapor Deposition (PECVD) to form the amorphous silicon semiconductor film layers. Although the energy conversion efficiency of amorphous modules is lower than that of single-crystal units (an average of 6-7% compared to an average of 12-16%), they are cheaper to produce and convert more electrical energy than crystalline modules with the same nominal power used under high temperature environment or in diffuse light conditions. The amorphous silicon thin film solar cell technology offered by GreenSolar Hungary Equipment Manufacturing Ltd. involves the deposition of two extremely thin solar cell structures on top of each other onto a TCO-coated glass sheet with a total layer thickness of less than one micron. This structure is called tandem or double junction solar cell. Regarding the operation of this solar cell structure, the first cell converts mainly the shorter wavelength part of the spectrum of incident light while the second cell converts the longer wavelength part. Comparing this structure to the so-called single junction structure, where only one solar cell structure is deposited on the TCO-coated glass sheet, it is possible to achieve the same absorption while the individual cells are thinner. The thinner the amorphous silicon layers are the less the degradation and the higher the stabilized efficiency of the solar cells. As amorphous silicon thin film solar cells have more favorable temperature dependence compared to their mono- or polycrystalline counterparts and they work better in diffuse or low intensity light conditions their yearly generated energy yield under real life conditions relative to their nominal power is higher, as well. Another advantage is that since thin film solar cells contain much less active material than the monoand polycrystalline solar cells and their technology involves only low temperature processes, their production is more cost effective.

Technology

Process

Turn-key tandem thin film solar module manufacturing systems

Turn-key tandem thin film solar module manufacturing systems

15 MWp/Year Tandem Thin Film Solar Module Semi-Automated Manufacturing System

FORKLIFT WAY

ISO 7 class cleanroom

Panel light IV tester

Dust filter

FORKLIFT WAY FORKLIFT WAY

46000

EDGE GRINDING

GLASS WASHER ISO 7 class cleanroom

Box storage

FORKLIFT WAY

Box cleaning station

Dispensing machine

Class A IV tester Box loading station

step 2

step 1

FORKLIFT WAY

67400

Turn-key tandem thin film solar module manufacturing systems

Recommended Equipment Quantities
Description GLASS PREPARATION Glass Cutter Glass Driller Edge Grinder Glass Washer (After Grinding) SPUTTER DEPOSITION OF THE TCO LAYER (OPTIONAL) Heating Tunnel (OPTIONAL) Vertical TCO Sputtering System (OPTIONAL) Cooling Tunnel (OPTIONAL) Wet etching station (OPTIONAL) PATTERNING OF THE TIN OXIDE LAYER Laser Scribing System for Tin Oxide Glass Washer (Before a-Si Deposition) DEPOSITION OF THE TANDEM a-Si MATERIAL Robotic Loading-Unloading Station Box Carrier for a-Si Box Carrier Carts Box Carrier Transport System Preheat Oven PECVD Deposition System for a-Si Layer Cool-Down Chamber EXHAUST MANAGEMENT SYSTEM Gas Abatement System Filter System PATTERNING OF THE a-Si LAYER Laser Scribing System for a-Si Layer SPUTTER DEPOSITION OF THE BACK CONDUCTIVE LAYER 6 Chambers Sputter System for Al & ZnO PATTERNING OF THE BACK CONDUCTIVE LAYER Laser Scribing System for Al & ZnO ENCAPSULATION Laser Edge Deletion System Ultrasonic Bonding System EVA Applicator EVA Laminator Electrical Assembly Station Mechanical Assembly Station Junction Box Filling Station MODULE TESTING Quick Panel Light I-V Tester A Class Panel Light I-V Tester Insulation Tester Climate Chamber Measurement Device Set Light Soaker In-line Resistivity Meter (OPTIONAL) In-line Haze Tester (OPTIONAL) In-line Visual Purity Meter (OPTIONAL) OTHER INSTRUMENTS Laser Marking System Maintenance Instruments Transport Carts Roller Table Conveyor System 7 MWp/year [pcs or sets] 1 1 1 1 1 1 8 8 2 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 21 4 15 MWp/year [pcs or sets] 1 1 1 1 1 1 16 16 4 4 4 2 2 1 2 1 1 2 2 3 4 4 1 1 1 1 1 1 1 1 12 1 30 MWp/year [pcs or sets] 1 1 1 2 (1) (1) (1) (1) 2 1 2 32 1 8 8 8 2 2 2 4 2 1 2 1 6 2 2 1 2 2 1 1 1 1 (2) (1) (1) 1 1 12 1

Utilities needed
Description 7 MWp/year 15 MWp/year 30 MWp/year
6000 1800 1200 2000 1400 38 22 Factory floor space [m2] 1500 3000 (without warehouse, offices etc.) 440 970 Installed electric power [kW] peak average 290 600 Compressed air [liters/min] peak 1350 1850 average 900 1230 11 22 Cooling water* [m3/hour] peak average 5.8 11.5 * It is strongly recommended to have a closed loop cooling water circuit. City water

City water is used by the laminators for cooling down and also for service operations. It is up to the user to consider a closed loop system also here. The main process water is used in the glass preparation and the washing systems. The washing system tipically needs de-ionized (DI) water for the rinsing, and normal water for the prewashing. Glass preparation and washing machines work partially with water recycling system. The temperature in the building shall stay within 23 2C. The humidity level shall be in the 50-70% range (non condensing). It is recommended that a-Si patterning to be done in Clean Room Class 7 (as per ISO 146441-1 standard) The supplier of the process-gases shall buid the Gas Supply System and shall supply the gases during the operation. The process requires the following gases: Ar, N2, H2, He, SiH4, CH4, 3% B(CH3)3 in SiH4, and 3% PH3 in Ar. Nitrogen is needed both as nitrogen gas and liquid nitrogen. The quality of the gases shall be guaranteed at the consumption point by the supplier of the gas system. The gas system supplier suppliess the gas detector system as well.

Process water

Air conditioning

Clean room conditions

Technology gases

Turn-key tandem thin film solar module manufacturing systems

Manpower needed
Description
Glass preparation (+OPTIONAL TCO) Lasers PE-CVD PVD (+ sandblaster for 7MWp only) Encapsulation, assembly and test Quality control Maintenance and repair Total personnel per shift CTO and deputy CTO, Workshop Manager Speciality engineers Quality manager Chief of maintenance Warehouse personnel Total daytime personnel

Examples for the Performance of the Produced PV Solar Modules

7 MWp/year 15 MWp/year 30 MWp/year
5 3 4 2+4 8 2 2 30 2 6 1 2 11 4 4 6 1 14 3 3 35 2 6 1 1 4 14 4 (+3) 4 8 2 14 4 4 40 (43) 2 6 1 1 6 16 Maximum system voltage

Operating personnel that must work in every shift

Description Customer 1 Electrical Specifications Stabilized Rated Parameters at STC*

Rated maximum power Rated voltage at Pmax Rated current at Pmax Open circuit voltage Short circuit current Temperature coefficients Pmax Umpp Impp Voc Isc Uoc Isc Pmax V 45 W 47.4 V 0.95 A 65 V 1.3 A 0.28 %/C + 0.09%/C 0.19%/C 1000 V

Customer 2
52 W 71.2 V 0.74 A 93.5 V 0.88 A 0.30 % /C + 0.08 %/C 0.15 % / C 600 V 1 245 635 7 0.79 0.71 laser pattern 13.5

Technical management and support personnel (daytime only)

Mechanical Specifications
Dimensions [mm] 1 245 635 7 Total surface [m2] 0.79 Active surface [m2] 0.71 Lateral structuring laser pattern Overall weight [kg] 13.5 * STC (Standard Test Conditions): 1,000 watts/m2 irradiance, AM 1.5 solar spectral distribution, 25 C cell temperature.

Tipical annual capacity of the production lines

Description
Module Dimensions [mm] Module Area [m2] Cell Aperture Area [m2] Initial Power [W] Degradation rate [%] Stabilized [Watt/Module] Total hours per year [hours] Uptime [%] Real Production [hours] Nominal Production [MW] Tact time [pcs/hour] Produced Modules [pcs] Yield [%] Good Modules effective [pcs] Production effective [MW] 7 24 169 334 94.0 159 183 7.16

7 MWp/year 15 MWp/year 30 MWp/year

12456357 0.79 0.71 55 18 45 8 760 80.5 7 056 15 48 338 668 98.0 331 914 14.93 30 96 677 376 98.5 667 215 30.02

Beyond efficiency
Conclusions of a real-life module performance testing in Bulgaria. Standard thin film solar modules model SP44 have been installed on a test PV field and have been monitored for five months, together with polycrystalline modules of one of the well-known brands. The modules were installed under an 30 SP44 modules optimal fix tilt angle. The 50 50 polySi modules total installed capacity 25 was about 1.7 kWp for 40 40 both types of modules connected to the same type 30 30 20 of inverters under similar dc conditions.
Weekly Specific Yields [kWh/kWp] Weekly irradiance [kWh/m ] Average temperature [ C]

During the entire test, an 15 average daily irradiance 10 10 of 5.8 kWh/m2 with peak days of 7.9 kWh/m2 have 0 0 10 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 been recorded. Ambient Weeks of the year 2010 temperature ranged from +1C to +40C with an average of +22C. The output PAC values of the integrated daily energy production obtained from the inverters.
O

20

20

From the collected data specific yields, as well as module performance ratios were calculated and compared. Specific yields and performance ratios were compared on weekly bases, as well as daily data were analyzed as the functions of irradiance and average ambient temperature. On the average about 6% higher specific yields were obtained for the SP44 dual-junction thin-film modules than that of the polycrystalline ones, as represented in the above diagram. The second diagram represents the daily performance ratios of the SP44 modules, compared to that of the reference polycrystalline installation. For the amorphous modules an increasing tendency is seen with the increasing daily average temperature, while in the case of the polycrystalline modules this tendency is quite the opposite. From the irradiance and temperature analysis it is seen that the thin-film silicon modules SP44 may perform about 10-15% better under high irradiance (> 5 kWh/m2*day) and high average temperature (> 23C) conditions than the polycrystalline ones. Generally thin film cells tend to perform better under harsh working conditions, such as long hours of extremely strong sunshine and its generated heat, as well as extreme and diffuse light conditions (e.g. sunrise, sunset and cloudy weather).

Turn-key tandem thin film solar module manufacturing systems

30 MWp/Year Tandem Thin Film Solar Module Fully Automated Manufacturing System

www.greensolar.hu

Intellectual Property

Since 2010 February GreenSolar Equipment Manufacturing Ltd is the legal owner of the IP, know-how, logo and brand name of EnergoSolar Hungary Ltd. GreenSolar hired most of the expert technical and administrative staff of the former EnergoSolar, and continues to work on the projects started once by EnergoSolar Hungary Ltd in China.

Realizations

R&D Projects

GreenSolar is a young company, but it has a well assembled team of managers, designers, engineers, technicians etc. This team has already produced and installed a total manufacturing capacity of 120 MWp/year in several locations*: 2005-2007 Bangkok Solar Co., Ltd., Thailand 2006-2008 Tianjin Jinneng Solar Cell Co., Ltd., China 2007-2008 HelioGrid Hungary Ltd., Hungary 2008-2009 SolarPro AD, Bulgaria 2009-2010 Parity Solar Technology Zhenjiang Co., Ltd., China *as of the end of year 2010.

Contact Details

GreenSolar Equipment Manufacturing Ltd. Gymri t 128., H-1103 Budapest, Hungary European Community Tel.: +36-1-445-0777, Fax: +36-1-434-0101, e-mail: sales@greensolar.hu, http://greensolar.hu VAT No.: HU11706906

Recently GreenSolar has built up its new pilot line for R&D activities, as the development of increased efficiency thin film silicon solar modules, manufacturing of double size solar modules, creation of micromorph solar modules and further reduction of manufacturing costs. GreenSolars policy is to deliver to its customers products of the best performance and competitiveness.

Disclaimer

The contents of the present brochure are for general information and promotion purpose and by any means do not represent any commercial offer. In order to get a quotation, please contact the sales personnel of GreenSolar by e-mail to sales@greensolar.hu or by fax to the number +36-1-434-0101.
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