March 2013 www.solarpowerworldonline.com
Technology • Development • Installation
INSIDE: >> Business Issues: Higher Standards Reduce Risk Page 26
>> Engineering Developments: Peel and Stick Solar Panels Page 34
>> Inverter Insider: Designing Backup Systems Page 42
Wasted Land No Longer Moving ground requires adaptive racking Page 16
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Electrifying ideas. We develop new ground-breaking products from brilliant ideas. With knowledge, proven technology, and engineering creativity we make today, what will lead the way tomorrow.
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2/20/13 8:51 AM
Editorial Advisory Board Natalie Holtgrefe Solectria Renewables Jose Gomez Ingeteam Steve Hogan Spire Devon Cichoski SolarWorld Marcelo Gomez Unirac Justin Barnes North Carolina (State University) Solar Center Scott Wiater Standard Solar
What do you think? Discuss this, and other solar issues at www.engineering exchange.com
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The State Of The Solar Industry Is Strong After my conversation with the Solar Energy Industries Association (SEIA) President Rhone Resch and the Solar Electric Power Association (SEPA) President Julia Hamm at PV America last month, I’m as bullish about the solar industry as I have ever been. Gone is the backlog of utility-scale projects rushed into production to take advantage of the 1603 Treasury Grant Program. Stepping into the breach are the commercial and residential sectors, which many analysts predict will make up for the lack utility-scale approvals. During a tumultuous 2012, with the trade case against China and the elections placing a drag on the industry’s progress, both issues are now settled, and my Cassandra-like predictions about the effect they would have on the industry did decidedly not come true (for once in my life, I’m thrilled to be wrong). We’re even seeing a slight rise in module prices as the price of silicon inches slightly upward, which means module manufacturers will be able to recoup some of the investments they’ve made in their factories and workers, and allow the most progressive to return from a defensive position to an offensive one. Research-and-development, which had been put on hold for much of last year because of the uncertainty, should flourish in 2013 and beyond. As our featured contractor Dan Weinman of PPC Solar says (see Contractors Corner, pg. 80), technology has expanded this industry in the past — and will do so in the future. That’s not to imply all is perfect. The recent decision of the Arizona Corporation Commission to slash solar subsidies below what even their utilities asked for should give everyone pause. And, like it or not, we now find ourselves playing the role of China in a trade dispute with India. (I predicted this back in December 2011, by the way. Once you open the door on trade wars, it doesn’t take much prodding for others to walk through it.) On the state level, there are potential hiccups in solar bastions like California, New Jersey, Colorado and Arizona (but there are also potential new bright spots like New York, Tennessee and Texas). So the industry will still have to be vigilant to solidify and expand its gains. But I’ve come to recognize this industry is full of passionate people for whom their vocation is also their avocation, and they refuse to allow this solar dream to die. I stand with you. Solar Power World stands with you. And together, we will watch 2013 be the solar industry’s best year yet.
Frank Andorka
Editorial Director fandorka@solarpowerworldonline.com
www.solarpowerworldonline.com
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The Open PV Project The Open PV Project The real-time status of the solar photovoltaic market in the U.S. Total # of Installs
Cost S/W (2012)
173, 480 policy Share
$5.83
Capacity (MW)
3959.23
of Global Sola r Capacity (43 GW)
87%
7%
Tax incentive
Sources: Vote Solar, The Institute for Local Self-Reliance and The Open PV Project of the National Renewable Energy Laboratories contributed to this page.
6%
“Solar Snapshot” provide a glimpse of the solar industry in pictures. If you have an infographic you’d like to see on this page, email it to Editorial Director Frank Andorka at fandorka@ solarpowerworldonline.com.
www.solarpowerworldonline.com
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March 2013 • vol 3 no 1 EDITORIAL
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w w w. s o l a r p o w e r w o r l d o n l i n e . c o m
Mar ch
contents
70
D e pa r t m e n t s
06 State of the State 08 Q&A 10 Future of Finance 12 Training 14 Solar Marketing 16 Racking and Mounting 70 Developments 74 Products 80
Contractors Corner
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Ad Index
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20 5 Ways To Use The Supply Chain
Smoothly introduce products to market and scale to volume production at the lowest cost.
Leadership 51 - 68
03 Solar Snapshots
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01 The First Word
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26 How Higher Standards Reduce Risk And lower costs, too.
34 Peel-and-Stick Solar Panels Stanford University research leads to decal-like application.
38 6 Ways To Avoid Damaging Roofs
Rooftops are choice locations for solar, but sometimes they come with complications.
42 Designing Backup Systems
Options for homeowners with and without pre-existing systems.
About the Cover: Solar FlexRack provided
46 Factory Farm
this photo of a landfill
Strata Solar borrowed from manufacturing’s assembly-line production
installation in Kearny, N.J.
system to construct the Belwood Solar Farm in record time.
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[ S TAT E O F T H E S T A T E ]
Solar State-By-State Report: California Vote Solar authors solar industry updates, which we publish here, state by state. This installment focuses on California.
Rooftop solar is a tremendous
Susannah Churchill Vote Solar’s Policy Advocate in California
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California success story. Homes, schools and businesses are going solar in record numbers. The growing industry now employs 43,000 Californians and has infused $10 billion in private investment into the state’s anemic economy. Yet in the midst of all this solar success, we believe California’s investor-owned utilities are using misleading cost claims to attack the very policy that has formed the backbone of our state’s rooftop solar growth: net metering. In 2006, the California Public Utilities Commission (CPUC) and the Legislature devised a plan to transform the California solar market. The California Solar Initiative was designed as a one-shot rebate program to build a self-sustaining rooftop solar market with incentives that decline as the industry grows and brings down costs. Coupled with the market-transforming rebate was net metering, a simple billing arrangement that allows customers investing in solar to get fair credit for clean power they’re generating for others to use. And it worked. California now has more than 1,400 MW of customersited solar energy systems all over the state. State rebates have come down 95% and are on the cusp of going away entirely. The market is thriving. We have California policy makers to thank for an effective program that is creating a real energy revolution. But just as California’s grid starts to truly transform, the backlash from utilities begins. Why would California utilities oppose having their 3 • 2013
Information graphic provided by Vote Solar
customers go solar? Utilities make money by getting a guaranteed rate of return on the infrastructure they build, such as transmission lines or power plants, using ratepayers’ money. Building more infrastructure is better for their bottom-lines. Rooftop solar reduces the need to add power plants. It’s good for our electricity grid, but it upsets the status quo that has boosted utilities’ revenues for so long. Utilities are claiming that net-metered rooftop solar customers aren’t paying for their share of running the grid because they have reduced utility bills, but they use some pretty fuzzy math to make their case. The ratepayer benefits from net metering are many: savings on expensive and polluting conventional power; reduced investments on expensive infrastructure (paid for by ratepayers); reduced electricity lost during long-distance transportation over power lines (rooftop solar’s surplus energy is sent directly to neighboring homes and buildings); and savings on the cost of meeting
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S T A T E
carbon reduction and renewable energy requirements. A close look at the California IOUs’ net-metering math shows that it leaves out most or all of these benefits. Furthermore, the utility calculation inflates the amount of revenue lost through net metering bill credits, making the costs appear higher than they are. What’s needed is an accurate and comprehensive look at the economic effects of net metering, considering all the costs and benefits. To that end, Vote Solar commissioned Crossborder Energy, a consulting firm, to conduct a new costbenefit analysis for ratepayers of the three big California utilities, using a CPUCapproved economic model. The results show net metering actually provides a system-wide net financial benefit to California IOU ratepayers, not a cost as the utilities assert. In total, the ratepayers of all three IOUs will save more
O F
as more net-metered systems are installed, up to about $92 million per year once we reach the state’s current 5% net-metering cap and have installed about 5,200 MW of net metered solar. So with careful accounting, we see that net metering’s benefits to the California grid outweigh the lost revenue from net-metering bill credits. It’s actually solar customers as a group that are subsidizing non-solar customers as a group. And that’s before you account for the additional benefits of a thriving solar market: job growth, investment in the local economy, climate progress and public-health improvements. Investor-owned utilities are given a monopoly in return for serving the public, and they rake in $25 billion in annual revenues for doing so. Now they are attacking a program that delivers proven benefits to Californians by
T H E
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misrepresenting it as a net cost. The interests of a few monopoly utilities should not outshine the Californians they serve. SPW Susannah Churchill is Vote Solar’s Policy Advocate in California. She can be reached at Susannah@votesolar.org.
Discuss This and other Solar issues at www.engineeringexchange.com
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Q&A [Q&A]
Colored Solar
Solar Power World spoke with Paul Wise, COO at Colored Solar, about how colored panels could spread interest in solar by offering customers choices. Here are excerpts from the conversation.
SPW Can you start by telling us about your company? PW
Mike Mrozek CEO of Colored Solar
Colored Solar is based in Ventura, Calif. The idea started when our CEO Mike Mrozek wanted to install solar on his home, but experienced some pushback from the homeowners association, which didn’t like the look of black solar panels on homes’ roofs. So Mike looked around to see if he could find some type of solar PV that would match the aesthetics of his roof. This led him to develop more stylish solar panels and to found Gold Coast Solar, which evolved into today’s business known as Colored Solar. I came on board to help Mike develop his idea for the colored solar panels. We wanted to design a product that could easily integrate into homes without having to build into the house itself, as traditional BIPV requires. We wanted to make it so installers wouldn’t have to change equipment or do anything special to install our panels. Our product is really a cross between BIPV and standard solar modules. We took our module to the Department of Energy’s (DOE) National Renewable Energy Lab and the National Center for Photovoltaics. They tested and validated that it worked as stated. SPW Who are the majority of your customers? PW
Paul Wise COO of Colored Solar
Our customers are mainly solar integrators (though we are solar installers as well) with highend customers who care about the aesthetic looks of their homes. We’re now also dealing with some commercial and governmental agencies. Our customers really enjoy the look of the product they’re getting, as well as its quality. That’s what we strive to do — create high-quality products that customers will love and want to have on their homes. SPW
Does choosing a colored solar panel mean sacrificing efficiency? PW No. There is no significant loss in efficiency with our solar panels. We are basically running ETL to
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UL 1703 certified monocrystalline and polycrystalline modules with 15% to 16% efficiency, which is comparable with the efficiency of many standard solar modules today. We’ve actually raised the bar on the product itself by designing it to last longer and in more adverse environments. Our glass, for example, is thicker than the glass on average solar modules. We’ve also had our product missile-tested using larger missiles than the projectiles regularly used with testing standards. And through additional testing, the California Electric Commission has verified our modules, as well. SPW
How are colored solar panels encouraging homeowners associations, historic preservation committees and other groups that emphasize aesthetics to go solar? PW
Many feel that black solar panels degrade the architectural and historical value of buildings. Colored solar modules reduce barriers to adoption by offering colored and stylized options that blend with aesthetic, architectural and historical features. For example, our tile red-colored modules blend in beautifully with terracotta Spanish-style roofs. We can also blend our panels in with the green grass of hillsides. The National Trust for Historical Preservation Society and the DOE have also launched the Solar America Communities program to increase the adoption of solar on historic buildings. Together, they’ve developed specific guidelines for the aesthetic of solar on historic places. I’m on boards for many homeowners associations in California and the feedback we’ve gotten from most of them is that they like what we’re doing — and people like that they have a choice. SPW This Q&A includes excerpts from one of our most downloaded podcasts. Listen to this and other Solar Speaks podcasts at www. solarpowerworldonline.com and find out more about Colored Solar at www.coloredsolar.com.
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[FUTURE OF FINANCE]
9 Points Of Confusion On Small-Scale Solar Development
Every month, there are numerous solar
Robert Sternthal president of Reznick Capital Markets Securities
conferences and seminars in the United States. At each of these events nearly every solar developer or potential investor complains about the lack of good U.S solar projects, which I find odd. After all, we are barraged on a daily basis by email updates regarding new solar developments connecting to the grid. What is going on here? What is the truth about small-scale solar projects? Who is right? Are there good projects out there? Where are they? Are there certain places where solar provides better economics? My team and I think about this daily as we work with our own clients on financing, buying and selling solar projects. I believe the truth remains that there are still few developers demonstrating continued success in this market, but since there are so many developers in the United States, what we are seeing every day are glimpses of success by a select few developers from among the masses. Let me share with you a few thoughts that may help you understand what seems to be standing in the way of progress — or which may explain what you are seeing in the market when you do see it: 1. No solar project is easy. All solar projects take time to develop and build. Even my own residential rooftop system took more than six months from start to finish — and I’m still awaiting connection. For commercial deals, there are dozens of additional issues a developer must overcome depending upon the buyer of the electricity, the type of system, location, environmental concerns and rooftop conditions, among others.
2. There is no such thing as a standard PPA/ lease. Despite the desire of solar developers to create and use standard PPAs or leases, all of them find that each of their customers has specific needs and/or desires when it comes to acquiring a solar system. Ultimately, despite the efforts of many securitization and assetbased lending experts, the differences in each deal, whether in the PPA or lease or otherwise, will prevent a one-stop shop for financing large portfolios of solar projects, with the exception of a very few.
3. Few solar developers have a portfolio that exceeds 25 MW in the distributedgeneration market. Maybe we can count a handful of developers that have built and financed more than 25 MW of projects. Many of these developers have a solid process in place to develop projects internally, while others are purchasing portfolios from the same.
4. Many solar developers of projects or portfolios of projects still lack capital. Few solar developers realize just how much equity is necessary to build a portfolio of solar projects, especially without a 1603 Grant in place. Now that solar projects require a buyer for the solar investment tax credit (ITC) (unless you have tax capacity), a developer must have the wherewithal to indemnify the buyer for the full amount of such ITC in the case of a recapture event. As a result, even many of the most successful solar developers in today’s market are starting to look for more significant sources of capital.
Robert Sternthal is president of Reznick Capital Markets Securities and has extensive experience in financing renewable energy transactions, whether they are in the wind, solar or biomass sectors. Working alongside CohnReznick LLP and CohnReznick Think Energy, Reznick Capital Markets Securities offers one of the most comprehensive financial advisory platforms in the industry.
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5. The equity capital provided for solar development still does not seem to meet the returns of the market. To date, only sale-leaseback buyers are willing to accept 7%-8% aftertax, unlevered returns. These buyers are purchasing deals at the date of delivery and still require developers to retain a decent amount of project risk. At the same time, developers that want to own their own projects require a 10% unlevered return to develop a project. Despite the reduction in panels and development costs, few projects seem to meet these 10% return hurdles at the end of the day. Accordingly, many of the projects getting done must produce lower returns. This phenomenon leads many of us to question where the low-cost capital is coming from for these projects or a desire to understand how the developer is otherwise justifying such returns.
6. The market continues to be clouded by panel manufacturers, inverter manufacturers, engineering, procurement and construction (EPCs), etc., that want to offer financing terms, as well as their products or services, in return for development of projects. Some of these parties are responsible for the lower return projects, but not all of them.
still reluctant to provide longterm loans (e.g., 15 years), and generally do not understand solar well enough yet to get through the due-diligence process or tax-equity financing easily.
9. The tax equity market for small-scale solar deals still remains limited. There are many players/brokers coming into the market trying to fill this void in the market, but tax-equity deals for small-scale solar deals are just as hard, if not harder, to complete than large-scale deals. Each project must go through a separate due diligence, even when included in a diverse portfolio of projects. As I would urge our own clients, when looking at the small-scale solar market, each deal needs to be examined and analyzed on its own merits and economics. There is no panacea to the distributed-generation sector or competition for transactions would not be so segmented and the market would consolidate to only a few major developers. That may occur eventually, but for now, all developers can continue to succeed so long as they focus on the economics of each deal and proceed to build their own track record of completed systems. SPW
7. Some solar developers – especially in renewable energy credit (REC) markets – are taking a risk/reward approach by taking large amounts of risk on the viability of selling RECs over the long-term and at sufficient pricing to provide private equity-like returns (more than 20% levered).
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8. Finding debt for solar distributed-generation (DG) projects is not easy. More and
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more regional banks are starting to jump in the game, but they are
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2/21/13 8:21 AM
[TRAINING]
May the (Solar) Force Be With You
Sylvia Minton Senior vice president for MAGE Solar Member of Board of Directors for MAGE Solar Academy Member of the Renewable Energy and Energy Efficiency Advisory Committee (RE&EEAC) at the U.S. Department of Commerce.
PV field inspectors (PVFI) are a bit like the Knights of the Jedi Order for the solar industry. The ones I know are deeply committed individuals, interested in upholding the highest standards and best practices for PV installations. Therefore, they feel they are protecting the industry’s reputation. Of course no PV system will ever go live, harness the sun and earn its owner the highly anticipated return on investment without the blessing from any of these Jedis (so much for the power of the Force). But just as all Jedis have to learn how to use their powers effectively to become guardians of peace and justice for the Galactic Republic, so must PVFIs become the most effectual protectors of the “Republic of PV.” Integrators from around the nation have told us at MAGE Solar Academy over and over how much they value a productive, professional relationship with the PVFI on their installs. They also share with us how much training and education is still necessary, especially in markets that are just now developing. Our folks listened and developed an information-packed PVFI class. The good news is that they are in good company, as many members of the Solar High Council have also started to offer educational sessions to our PVFI-Jedi knights. NABCEP, IREC and the Department of Energy, for example, have all introduced training opportunities for PVFIs, either in a classroom format, online or at least in some downloadable information. Partly, of course, this attention was spurred (and in many ways still is) by the changes in the 2011 NEC and the massive attention that solar PV received for the first time. Having an entire section (Section 690) devoted exclusively to PV brings to light several issues: • A compliant install is a must. • Understanding the requirements of Section 690 and how it relates to the existing NEC code is tantamount. • From installers to inspectors, understanding
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the fusing, grounding, bonding and signage requirements are just a few of the skills that must be perfected to “master the force.” • It tells the great success story solar is today. From a meager 50 MW in 2002 to a cumulatively installed 6.4 GW in 2012 is a phenomenal 12,800% increase in just 10 years (based on IREC and SEIA data). Lastly, it also points to a huge paradigm shift that is gradually taking place for a relatively conservative group like the code-developing National Fire Protection Association (NFPA). To designate an entire section to solar means that solar is an unstoppable energy source that is only going to grow — and grow exponentially. Call it the due diligence factor of the NFPA, but no other energy source besides solar can claim its own section. The PVFI classes serve multiple purposes and personnel. As an education provider with critical ties to a spectrum of industry workers, our contacts with MAGE Solar allow us access to the latest information for best practices, as well as the not-so-pleasant “gotchas” that installers and inspectors may encounter during inspection. Without a doubt, these classes are tremendous gestures of understanding between two sides that have all too often been divided by a war trench. To guide and lead PVFI along as they venture into solar is as important and helpful to them as it is of consequence to the PV installer. With both sides trying to keep up with the evolving code requirements, these classes are bridging the gap of understanding related to items such as what needs signage, what details to include on the signage and the preferred signage material. Then there is wiring — insulation color, conductor size, insulation material, routing of conductors — and the list goes on. Ending the seemingly relentless confusion and occasional fight over these and other critical points saves all parties (including the end-user client) invaluable time and money. SPW
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2/20/13 5:31 PM
Big solar is circling. They don’t smell blood...they smell money. It’s yours.
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[MARKETING]
5 Free Ways To Market Your Message We all understand how tight margins are in the intensely competitive solar installation market, and reaching consumers is not easy. But just because you don’t have the budget for a canvassing team, ad campaign or big sponsorship doesn’t mean you can’t launch effective and affordable marketing campaigns. Here are five ways to market effectively to your community — and they won’t cost you a dime.
Carter Lavin
Lavin is The Solar Marketing Group’s Business Development Manager and helps renewable energy companies analyze the market, articulate their messages and connect with their targeted audiences to achieve their marketing and communications goals.
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1. Social Media Your customers and local media members are on Twitter and Facebook, so you should be, too. Use these channels to show off past and current projects, update your audience on company developments and engage with your elected officials. By maintaining an active presence on social media, you can engage in broader community discussions and present your message conversationally. But always remember this cardinal rule: Social media is supposed to be social. If you just talk about yourself or post infrequently, you are wasting your time. 2. Letters To The Editors As a professional solar installer, you have the ability to comment on a host of stories that appear in your local papers/websites — energy, utilities, government involvement in the private sector, local businesses, new industries in the area or even extreme weather. You should have someone in your office who dedicates an hour or so a day to scanning local newspapers and websites. When you see stories on any of those issues, it’s time to spring into action. Write a few sentences about what you and your company have to offer on the subject (we provided you with a template for such a letter in our December column and is also available online). Then send it in to your local paper as a letter to the editor. Be sure to include your name, company and, most importantly, your phone number. Most reputable news outlets won’t print a letter to the
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editor without confirming who wrote it, so the phone number may be the most important part of what you send in. This kind of involvement will raise your company’s visibility in the local press and also help your rankings in search results if it’s posted online. 3. Volunteering “Local Installer Explains Solar Science At School” is a pretty good headline for your community paper. Figure out an easy but visible way you and your team can volunteer for a day during your slow season. This will take more time, but it could have a much bigger impact. Getting a group together to help your local food pantry or clean up a popular park is a great way to give back, while getting a great photo opportunity and write up in your weekly paper or community blog. 4. Open Houses Just as going out into the community can help raise your company’s profile, inviting the community to a project site or to the home of a satisfied customer is an excellent way to educate potential customers in a low-pressure environment. What’s more, politicians love this kind of publicity, so have them tag along. When your local congressman or Senator comes around, they will — by the nature of who they are — bring local media in tow. BINGO — free publicity all around. 5. Turn Referrals Into A Competition People love competing and rewards. Many solar installers already have a referral program set up, which is a good way to speed up word-of-mouth buzz about your company. Kick it into high gear by allowing people to opt in to a gamified referral program. Come up with non-monetary prizes to offer referrers and rank the top ones publicly. The more fun you make your referral program, the more likely people are to use it — and the more business it will bring your way. SPW
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Mounted on Moving Ground Racking system provides flexibility at landfill installation
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St e ve n B u s h o n g/ As s i s tan t E di to r
NJMC Landfill 1A in Kearny, N.J., has been little more than a garbage-filled mound dotted with shrubs for more than 30 years. Officials have long thought 1A and similar landfills could serve a greater purpose. With a view of the New York City skyline, the land would be prime real estate if it weren’t a dump. Finally, in 2011, municipalities received direction. New Jersey Governor Chris Christie released the Energy Master Plan, which recommends solar projects be constructed on landfills or brownfields instead of open space or farmlands. It also simplified the permitting process for such sites. The New Jersey Meadowlands Commission, which previously installed a 33-kW solar array on its science education building and operates the 35-acre landfill, took heed. It contracted with the local utility and a construction firm to build a 3-MW solar array, the first on a state-owned landfill. Officials dedicated the project on May 8, 2012. “What’s the point of having a closed landfill just sitting there, when you could have so much good coming from it?” says Brian Aberback, public information officer at the commission. “This project does a great deal to help the environment and boost the green economy, especially during tough economic times.” But landfills don’t make for simple installations. Unlike roofs and solid ground, landfills present the
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problem of settling. As trash decomposes, the ground could shrink under the array. Piling heavy ballast blocks and racking on top of the trash can exacerbate the issue and also endangers the landfill cap, a 1- to 3-inch thick membrane that seals trash into the ground. While a quick glance at topographic drawings from the Kearny landfill shows settling of more than 20 feet in some areas since its capping decades ago, engineers who surveyed the site for solar found good signs. Methane gas, a by-product of trash decomposition, correlates with settlement. The less gas in the methane monitoring wells, the less settlement is likely to occur. For 1A, the gas had significantly decreased over previous years. Still, engineers had questions to answer: What if settling occurred, and how could they prevent it? “Our goal in designing the solar array was to minimize the pounds per square feet, including ballast and panels,” says Matthew Skidmore, director of operations at SunDurance Energy, the construction firm that built the array. “We wanted to minimize settling as much as possible, and we used Solar FlexRack to help accomplish that.”
In recent years, governments have warmed to the idea of solar on landfills and brownfields, recognizing them as underutilized space. New Jersey Governor Chris Christie has directed municipalities to look at these spaces, instead of farmland, as potential solar sites. The Solar FlexRack Ground Mount is durable, can adapt to any terrain, and is certified to withstand heavy wind, rain and snow loads, according to the manufacturer. The racking unfolds as it’s lifted into place on the tilt bracket.
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Panels on the 1A Landfill in Kearny, N.J., were mounted at two angles: 15 and 20 degrees. To maintain consistency, installers used the 15-degree tilt on a portion of the installation on a southern-facing hill, which has a 5-degree slope.
SunDurance chose Youngstown, Ohio-based Solar FlexRack’s Ground Mount for several reasons. First, a three-person crew can build the preassembled system in less than five minutes – a claim confirmed by users — which reduces labor costs. It also uses a slide-in rail system that allows for fast panel installation. Crews worked north to south installing the system. A three-person crew set the rack, which unfolds as it’s hoisted to position on a tilt bracket, and then one person fell back to tighten nuts and bolts. A crew of laborers then installed the panels. SunDurance also chose FlexRack because the company provided a custom 2x13 rack (two rows of panels, 13 in each row), which SunDurance prefers for 18
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string sizing. The rack was 50 feet long and required special shipping, but the oversized load was worth the potential electric savings down the road, Skidmore says. The standard FlexRack is 2x12. The racking was also noncontinuous, a selling point on an irregular landscape. SunDurance hauled more than 200,000 tons of clean fill to the site to make the undulating hills of 1A look like solar panel plateaus. Subarrays allowed the flattened areas to be smaller, requiring less fill. “Everybody thinks the landfill was covered in stone originally and that it was really flat, but that wasn’t the case,” Skidmore says. “Trash has different compositions so some areas settled 10 feet while others settled 20 feet.” Construction lasted seven months. The initial months required the removal of vegetation from the site, importing fill and grading it. Then the company allowed a short period of settlement. A survey using GPS confirmed that the site settled no more than a quarter of an inch — within the margins of error for the survey — so construction continued. Concrete ballast blocks, sized 2 feet by 8 feet, were brought in and workers installed the racking on top of them. Engineers tried to keep the total system under 200 lbs./ sq. feet, but it needed to counteract a 105 lbs./sq. feet wind load, a number higher than average because the installation is on a hill not far from the ocean. Lastly, FlexRack was chosen because, as the name suggests, it’s flexible. Liberal East-West and North-South tolerances are built-in to each Solar FlexRack subarray though slotted connections on the horizontal rail and also the tilt bracket. The tolerances allow for straight lines, providing a nice look for visitors, and some wiggle room when laying down clunky ballast blocks. “On capped landfills, there’s a limited amount of space,” says Greg Lewis, a regional sales manager for Solar FlexRack. “When SunDurance laid out the site, the row was as tight as you can get without shading. It came down to inches.” In all, the Solar FlexRack provides several inches of flexibility, but SunDurance — this being their first landfill project — was still concerned.
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Landfill Solar: PROJECT: New Jersey Meadowlands Commission LOCATION: Kearny, N.J. POWER: 3 MW PV PANELS: 12,506 Kyocera solar panels SOLAR FLEXRACKS: 481 2x13 ground-mounts, custom-designed to two tilt angles CONTRACTOR: SunDurance Energy Aurora-Where_the_Action_Is:Aurora 11/5/10 1:10 PM Page 1
To be sure that if settling did occur a part of the 13-acre project wouldn’t need rebuilding, the construction company used very conservative approximations in its engineering plans for the site and built additional flexibility into a proprietary post that connects the rack to ballast blocks. Solar FlexRack and SunDurance engineers worked together to develop a sleeved pole system that has up to 24 inches of vertical adjustment. “There wasn’t a lot of previous research, so we were moving along making relatively safe assumptions,” says Skidmore. “If we did it again, the adjustment in the racking would be enough.” In other words, the company prepared for the worst. The New Jersey Meadowlands Commission, an organization charged with planning and zoning in an area that was ravaged for decades by indiscriminate dumping, on the other hand, is prepared for the best. “Part of our mandate is to both protect the environment and provide for orderly development,” says Aberback, the commission’s public information officer. “People might think that’s a conflicting mandate, but here you have a project that accomplishes both.” SPW
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Josh Chien
Design engineers are charged with creating the most innovative designs, at the cheapest prices, as fast as possible. But solar and other clean technologies, being relatively young industries, lack the deep worldwide manufacturing ecosystems that surround more mature industries. Despite the debate about whether to manufacture in-house vs. outsourcing, outsourcing remains on the rise. Fueled by intense competition, coupled with complex regulations and the increasing costs of transportation and raw materials, immature supply chains can often lead to unintended consequences. For original equipment manufacturers (OEMs) to stay competitive, they must look at alternative manufacturing solutions or face delayed market entries and product launches — not to mention higher-cost products. Here are five ways solar design engineers leverage supply chains to produce projects through new product introductions and smoothly scaling to volume production at the lowest possible costs:
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Josh Chien is responsible for leading the New Product Introduction (NPI) Advanced Manufacturing solutions on behalf of Sanmina.
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1. Create an IP Solution Map Any design project typically has five critical components. These are the design components that create 80% of the problems in getting to market because they are usually expensive, complex and require long lead times to acquire. Engineers don’t choose a part because it has all of the bells and whistles or latest technologies. They balance those attributes with being able to deliver a viable, high-quality product that quickly meets all the design specifications within or below targeted costs. Engineers work with other manufacturing and supply-chain engineers to create an intellectual property (IP) map of all the design’s components and parts. The solutions’ maps identify who owns what IP. The solar engineers then collaborate with other supply-chain and manufacturing engineers to source multiple suppliers. These partners can usually recommend alternative highquality parts with shorter lead times, or that are closer to the manufacturing or assembly lines at lower total landed costs. If a part has a sole source (a frequent case in the
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solar industry), the supply-chain engineers work with the sole source to license that IP so it can be replicated at other suppliers. For instance, an OEM may require a wireless display for its solar product. Let’s say there is only one supplier (based on the design specs), but it can’t meet the OEM’s schedule. In such cases, the manufacturing and supply-chain engineers team together to figure out a licensing arrangement that satisfies both the OEM’s needs and the IP owner’s requirements.
2. Do a Full Review of the Suppliers A full supplier review is especially important for the five most critical components. Before the material requirements plan (MRP) and bill of materials (BOM) are finalized, solar engineers work with supply-chain engineers, who conduct comprehensive reviews of various suppliers for the different components in the IP-solution map. These reviews include the suppliers’ ability to meet the design specifications for a part or component, as well as whether they:
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• have the capacity to maintain quality while simultaneously scaling to the OEM’s required volume; and • can deliver to the manufacturing plants on time globally (if needed) at the total lowest landed cost. The analyses also take into account: • the supplier’s in-house engineering (manufacturing and design) expertise and hands-on experience with similar technologies; • its equipment capabilities; • the precision and completeness of its engineering documentation; • its access to raw-material availability; and • its financial viability. Doing this before the MRP and BOM are finalized gives the solar OEM an advantage in negotiating price points and lead times. On the other hand, if these specifications are locked before the analyses are complete, the OEM runs the risk of being at the mercy of the weakest link in its supply chain. If that happens to be the one of the critical components suppliers, the OEM is faced with potentially losing revenue and market share, not to mention incurring significant increases in costs. One example often seen in the solar industry is design specifications for extruded parts that have curved, instead of straight, surfaces. Such irregularly shaped parts often require specific tooling and equipment that few solar suppliers have. Acquiring such equipment, designing the tooling and having the expertise to competently use it can add significant lead times and costs. Design engineers may be unaware that the equipment, tools and expertise is standard for other suppliers that specialize in manufacturing for other industries such as telecommunications. A supply-chain engineer at a Tier 1 manufacturer already has a source, or could more quickly find and qualify one. 3. Run DFX Analyses at Prototype and Production Phases For an OEM to be successful, a concept has to scale to volumes, meet schedules and
costs required, and at the quality its customers expect. The last thing an OEM wants is a product that fails. The best way to ensure success is to run design for excellence (DFX) analyses at prototype and production phases. DFX analyses ensure the finished product is reliable when it comes off the line, and out in the field for years to come. Both DFM (design for manufacturability) and DFA (design for assembly) analyses bring potential problems to the surface well in advance of finalizing the BOM and building tooling for material manufacturing and the assembly line. The earlier these problems surface, the sooner they can be resolved, resulting in significant savings. These analyses often highlight ways to simplify the design and provide other options for materials, manufacturing and assembly. This smoothes manufacturing and assembly, helping the OEM’s product reach the market faster and at lower costs. Given the competitive nature and speed of change in the solar industry, being able to fill an order on time is the difference between getting or losing business. This is especially true with the pressing nature of many expiring local, regional and national government incentives, tax breaks and rebates. 4. Review Country and Market Constraints Awareness of different government constraints is crucial for solar OEMs expanding their market presence into different countries. Top solar engineers work with manufacturing, supply chain and logistics experts to understand regulations and government incentives that can affect a product’s deliverability and total cost. Knowing, for instance, that a product manufactured in one country can import into another without violating any trade agreements, or import and export regulations is crucial. Sometimes there are financial www.solarpowerworldonline.com
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advantages to be gained that can help reduce total landed costs. A country could require a higher import duty if X% of the BOM was assembled outside of it. Conversely, if X% of the BOM was made within the country (or a trade partner’s), a significantly lower export duty might be charged. Bottom line: The most successful solar OEMs factor constraints and advantages into the overall product’s manufacturing strategy.
5. Build Long-Term Relationships with the Supply Chain Staying ahead of the competition is the mantra of every design engineer. But many solar engineers lack access to the depth and breadth of manufacturing and supply-chain expertise found in more mature industries. The most effective solar engineers have learned to leverage their supply-chain partners’ expertise. Successful solar engineers develop long-term, trusted relationships with these manufacturers to gain access to new technologies and processes that can be licensed or transferred from other industries to make products for use in harsh and extreme environments. Such opportunities come from developing mutually trusting relationships with OEMs, manufacturers and suppliers who adhere to strict, ethical practices in safeguarding each other’s intellectual property. These relationships foster opportunities for co-development and licensing arrangements that can help leapfrog respective competitors. DFX analyses, supplier reviews and IP solutions maps bring to light many opportunities for collaboration and partnerships for solar OEMs. Each situation, whether using existing technologies or developing new ones, leads to a case-by-case agreement regarding the intellectual property’s development and its ownership. There are many approaches to developing solutions — there is no single answer. That’s why the most well-informed solar OEMs stay focused on meeting their end goals and remain open to a range of solutions concerning how to get there. SPW
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5 Reasons to check out Solar World Today! Solar World is a full service residential and commercial installation of photovoltaic solar panels, water heating and solar pool heating. 1. Unparalleled Solar Knowledge 2. Expert Installers 3. Superb Customer Service 4. Financing Options and Incentives 5. Sustainabile and Affordable Energy
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Communicating the Customer Benefits of Information Standards How standards reduce
Tom Tansy
cost and eliminate risk in solar installations
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hen you look at the most ubiquitous technologies around us today, the success of each is most often tied directly to standardization. From networking, to video formats, to cellular communications, the establishment and implementation of information standards has significantly reduced the cost and complexity of these systems, enabling global adoption. Just as using proprietary networking gear would limit the interconnectivity and usefulness of an organization’s network, using proprietary components and solutions limits the operational effectiveness of solar installations. In spite of this obvious truth, most solar deployments still use proprietary information formats, communication protocols and monitoring and control technologies.
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As a result, today’s solar installations provide little flexibility regarding how solar plants are managed, monitored or controlled. This lack of flexibility limits the ability of solar component manufacturers and integrators to: • design low-cost, long-lasting installations; • impedes plant operators managing plants effectively; and • makes it difficult for renewable energy consumers, utilities and authorized third parties (such as equipment providers, service providers, financiers, and regulators) to access plant information without resorting to expensive, complex, custom-built systems that often result in “vendor lock in” and higher-thananticipated long-term operating expense
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One of the primary factors impeding the broad deployment of solar PV systems is the lack of interoperable, standards-based renewable energy products on the market. By establishing information standards for solar inverters, meters, modules, string combiners, environmental monitors, data-acquisition systems and management applications, the SunSpec Alliance is significantly reducing the cost of solar installations while minimizing risk and increasing operational flexibility. The reduction in cost, mitigation of risk and increase in efficiency provides a significantly higher return on investment (ROI) for solar installations, resulting in better margins for solar manufacturers, plant operators and renewable-energy consumers alike. Many customers, however, do not understand the benefits of standards. In this paper, the SunSpec Alliance outlines the
benefits of standards for solar installations and provides guidance regarding how to communicate these benefits to customers or interested third parties. In doing so, SunSpec’s goal is to educate the market on the role and benefits of standards and illustrate the significant value-add of standards-compliant solar PV systems.
Lower Costs from Top to Bottom SunSpec’s hybrid approach to standards development — deriving de facto standards from the PV industry while collaborating with traditional standards-making organizations to establish formal international standards — creates a network effect that reduces costs and encourages adoption as more systems are deployed in the field. For manufacturers and solar integrators, information standards enable delivery of
solar-plant solutions that leverage off-theshelf components and communications infrastructure, dramatically reducing cost and enabling massive economies of scale. By eliminating the need to design every product from the ground up, standards enable manufacturers and integrators to innovate on top of existing, standardized designs while ensuring that all products interoperate with existing equipment and infrastructure. The feedback loop enabled by information standards drives up plant uptime and drives down long-term costs such as warranty expense. The table below highlights the significant benefits of information standards to manufacturers and integrators during the PV plant design and construction phases. From the solar operator’s perspective, information standards:
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• Enable access to solar-plant information for all interested parties without time-consuming customization and expensive one-off administration; • Reduce component repair and replacement cost by providing the freedom to choose amongst competing suppliers; and • Simplify long-term operations for all involved. These benefits result in significant reductions in operational expenses, less complex operational procedures, reduced time to deploy new technologies, less time required to train staff and the elimination of rip-and-replace expense when new components or management systems need to be deployed. This last point — rip-andreplace expense — is something that few operators consider at project inception and yet looms as a strong likelihood when the vendors of proprietary systems go out of business, are consolidated or rolled up into other companies, or otherwise fade from the scene. For renewable energy consumers and utilities, information standards provide visibility into the performance of solar installations without imposing administrative hassles, significant customization expenses or management overhead. Standards also allow solar installations to more readily implement control functions — such as variable power factor and low-voltage ridethrough, enabling new revenue streams for consumers and grid optimization opportunities for utilities. To summarize, the impact of information standards in the solar PV market is the dramatic reduction of installation costs, significantly increased plant uptime, lower long-term operational costs, greater visibility for all affected industry participants, a radical advancement of the state of the art of PV plant monitoring and control, and the enablement of ancillary grid services. Given these factors, information standards play a key role in making solar PV technology
Projected Cost-Per-Watt Cost Reduction of SunSpec Standards Cost Area Baseline Savings Reduction Method Modules $2.10 $0.00 Racking $0.70 $0.00 Electrical BoS $0.70 ($0.04) Enable multiple types/vendors for all ($0.02) components ($0.03) Reduce component installation time Eliminate sensor installation/ commissioning Design, Overhead, $4.20 ($0.04) Simplify design by reducing variables Profit ($0.04) Enables standardization of design templates System ($0.13) ($0.01) ($0.04) Total Reduction ($0.35)
Who Benefits from the Cost Reduction of Solar Standards?
Party Benefits of Standards Manufacturers Rather than developing every new component from the ground up, manufacturers can innovate on top of standardized form factors and communications protocols. Solar Operators Standards enable solar operators to easily provide access to solar data to all customers without the need for expensive, time- consuming customizations for each third party. In addition, components can be swapped out at any time without the fear of having to rip and replace an entire system. Renewable Energy Customers receive Consumers more visibility into the performance of solar installations without being charged for significant customizations and ongoing management costs. Utilities Adoption of reference designs will result in increasing plant uptime and total energy output by enabling better oversight.
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Increase de-rating factor accuracy Reduce risk (insurance cost) Reduce construction and start up time (financing cost)
Resulting Cost Reduction Building from standard form factors, etc. results in faster time to market and greater economies of scale for new products.
There are significant cost reductions in terms of the initial cost of equipment, the time to deploy new technology, the time required to train staff, and the elimination of rip-and-replace costs when new components or management systems need to be deployed. Because the solar operator no longer needs to engage in costly customizations for each customer, customers do not have to pay significant markups for these services. The backward and forward compatibility of components will reduce lifetime costs.
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BUS INE S S IS S UE S Standard Device Models Inverter
Applications / Analytic Engines
Common Transport Protocols: Modbus, Zigbee, TCP
Storage
Local SCADA
Cloud
Meter SunSpec Gateway (On-Premise)
String Combiner
SunSpec Platform (Big Data)
Module
SunSpec Web service - 61850
Tracker
IEC 61850 Monitoring and Control End to End Security
Weather Sensors
SunSpec Alliance Architecture
competitive with all other forms of energy generation and in helping to establish PV systems as a safe and bankable asset class.
Lower Risk By incorporating de facto industry standards — instead of starting from scratch —SunSpec information standards reduce risk by ensuring maximum interoperability. SunSpec Alliance standards leverage widely deployed technologies such as Modbus, Ethernet, DNP3, XML, Zigbee and web-services interfaces. These technologies are embedded in many state-of-the-art PV monitoring and control systems, can be deployed over standard IP network infrastructures (i.e. the same infrastructures supporting most corporate networks and the Internet itself) and are well-understood by hundreds of thousands of IT professionals around the globe. By ensuring interoperability, SunSpec standards reduce the risk involved with upgrading or trading out old technology and replacing it with the latest, state-ofthe-art components. At any time in a solar installation’s life cycle, the operator can swap out components or management solutions, knowing that all are certified to work together. In addition to reducing interoperability 30
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risks, SunSpec information standards help reduce performance and efficiency risks by enabling performance metrics that invite apples-to-apples comparisons. Customers can be confident that certified products are both plug-and-play and deliver the required level of performance every time. Finally, SunSpec information standards pave a path towards emerging smart-grid standards such as IEC 61850-7-420 and Zigbee Smart Energy 2.0. These standards have been under development by utility and consumer-product companies for years, and are currently being updated to reflect recent advances in inverter-control methods. SunSpec Alliance members have been key participants in defining and promoting the adoption of smart-grid standards for inverters and PV balance-of-system solutions from the beginning. Accordingly, SunSpec-compliant products are well positioned to integrate seamlessly into utility smart grids of all types.
Increased Flexibility and Scalability Information standards ensure that the equipment and solutions you buy are going to work together, and that they are going to operate according to objective, wellunderstood specifications. Accordingly,
mixed-vendor plant installations — combining best-of-breed components — can be constructed, and ROI calculations can be made based on objective criteria and not simply upon manufacturer claims. Standards help companies simplify the procurement process and ensure that everything will not only work together, but will work optimally based on pre-defined specifications. When things are no longer under warranty and it comes time to upgrade or replace components, standards enable organizations to repair or replace elements without having to do a full rip/replace of proprietary systems. Standards also enable certain components and technologies to be used on any sized plant. This means that manufacturers, integrators, and operators can exercise tremendous buying power when building up portfolios of plants of varying sizes and leverage a common management infrastructure. For a multi-megawatt plant portfolio, the flexibility and scalability advantages of standards can result in savings of hundreds of thousands (or even millions) of euros/dollars over the portfolio lifetime.
How SunSpec is Standardizing Solar The SunSpec Alliance’s primary objective is to reduce the cost of building PV plants by developing open information standards — information models, communications protocols and system interfaces — that can be used by component vendors and integrators to create interoperable solutions. The diagram Standard Device Models depicts the areas of standardization that SunSpec standards address. SunSpec has worked with the Electric Power Research Institute (EPRI) and the Zigbee Alliance to define a specification (called WS-61850) that harmonizes SunSpec inverter standards, IEC 61850 and Zigbee Smart Energy 2.0. This specification specifically addresses the needs of Distributed Energy Resources (DER) such as solar PV plants. The Smart Energy 2.0 model integrates generation, storage, and advanced controls as defined in the EPRI “Advanced Inverter Control for DER” and is derived from the IEC 61850 standard. SunSpec members
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BUS INE S S IS S UE S BDEW grid codes mandated by Germany5. In the United States, grid-support services provided by inverters (fault ride-through, active and reactive power control, frequency and other regulation services) will be required in the near future. By applying the reference designs to access latent inverter functions, SunSpec aims to evolve U.S. and global grid standards in record time. Work in this important area commenced in 2011. SunSpec Alliance members can expect that ratified specifications will be available during 2012.
participated directly in its creation and are striving to support the advanced inverter functions. This work is being further standardized through the ASHRAE SPC201 Facility Smart Grid Information Model sponsored through the U.S. National Institute of Standards and Technology (NIST) and Smart Grid Interoperability (SGIP) process.
Tom Tansy is the chairman of SunSpec Alliance, a trade alliance of solar PV industry participants, together pursuing information standards for the renewable energy industry.
Developing Software Reference Designs While open SunSpec information standards are a good first step, documents alone are insufficient. In addition to defining open standards for all relevant subsystems —modules, inverters, interconnection systems and management systems — the SunSpec Alliance is also chartered with creating software reference implementations for each type of component. While the PV industry wishes for high uptime, the reality is different1. A review of more than 4,000 power plants monitored by Power-One2 showed that average uptime was below 80% in 2009. Sun Edison estimated that typical commercial plant uptime ranged from 50% to 80%3. Considering that 1% of downtime for a 1-MW plant results in $3,750 in production losses4, and that contractual penalties add further pain, the present situation is untenable. Adoption of reference designs will result in increasing plant uptime and total energy output by enabling faster vendor deployment and better customer oversight. The backward and forward compatibility of components will reduce lifetime costs. The opportunities for savings are substantial and are in addition to the savings listed above. Enabling Software to Activate Inverter Capabilities Inverter makers in the SunSpec Alliance are active in European markets and many have implemented the
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Establishing a Test, Certification and Branding Program to Drive Adoption A key requirement for standardization is a testing and certification program to ensure interoperability of vendor-supplied devices. Products incorporating SunSpec specifications must pass a certification test to be deemed “SunSpec certified.” SunSpec administers this program and hosts regular “SunSpec Plug-Fest” events to facilitate interoperability testing. Similar to the interoperability exercises that enabled the Internet to become rapidly and widely usable, the principle objective of SunSpec Plug Fests is to establish plug-and-play communications among renewable energy devices, thus driving down total industry integration costs and creating a vibrant market for compatible devices and services. Engineering practitioners benefit by establishing best practices and by helping to define standards that will shape the smart grid. Customers benefit from reduced costs from the economies of scale delivered by manufacturers. Each SunSpec Plug Fest leverages the SunSpec Specifications (“SunSpecs”) available at that time and enables participating vendors easily to create compatible solutions that can plug into the information technology services comprising the Smart Grid. Current SunSpecs define data formats for inverters, meters, modules, string combiners, data-acquisition systems and environmentalmonitoring systems. Test events are conducted in partnership with accredited labs to analyze and verify results. Third-party testing labs are used to ensure availability of testing resources globally and to ease the path to commercialization. The SunSpec testing and certification program is lead by TÜV Rheinland, which is a leading test house for solar PV technology, Wi-Fi, Zigbee and other smart grid technologies. Past test events have been well attended by SunSpec Alliance members, all of whom have signaled their support for standardization through their participation and contributions to SunSpec. SunSpec compliance has been specified by integrators and EPC’s around the world. SunSpec-compliant products are coming to market and are delivering value today.
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BUS I NE S S I S S U E S Summary The information standards being driven by the SunSpec Alliance enable significant cost reductions for solar component manufacturers, integrators, plant operators, utilities and renewable energy consumers alike. Even more, SunSpec standards are the basis for rapidly integrating PV power plants into the smart grid, providing ancillary grid services that deliver value beyond the initial installation cost savings. Acceleration of the growth of solar industry is dependent upon all interested parties being educated on and aware of the benefits of standardization. With SunSpec information standards in place, the PV industry can build upon the competitiveness it has already attained, sustain the profitability and economies of scale needed for widespread deployment and adoption, and compete on even footing
in the market with other forms of energy generation. SPW Bibliography 1. Itron, Inc., and Kema, Inc. CPUC California Solar Initiative 2009 Impact Evaluation Final Report. Rep. Davis, CA: Itron, June 2010. Print. 2. Tansy, Thomas. “Performance Breakout.” SolarTech 2010 Solar Leadership Summit. PG&E Events Center, San Ramon, CA. 21 Apr. 2010. Speech. 3. Culpepper, Mark. “SunEdison - Rethinking Solar: LCOE and Solar as Service.” Solar Power International. Orange County Convention Center, Anaheim, CA. Oct. 2009. Lecture. 4. Stierstorfer, Johannes. “Phoenix Solar: Operation & Maintenance as a Success Factor for Your PV Investment.” PV Power Plants 2009. Caesar’s Palace, Las Vegas, NV. Dec. 2009. Lecture. 5. Troester, Eckehard. “New German Grid
Codes for Connecting PV Systems to the Medium Voltage Power Grid.” Second International Workshop on Concentrating Photovoltaic Power Plants: Optical Design and Grid Connection. Proc. of 2nd International Workshop on Concentrating Photovoltaic Power Plants, Darmstadtium Wissenschaft Kongresse Center, Darmstadt, Germany. Concentrator Optics, 10 Mar. 2009. Web. <http://www.concentrating-pv.org/ darmstadt2009/papers.html>.
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& l e Pe
k c i t S
s l e n a P Solar
F
or all their promise, solar cells have frustrated scientists in one crucial regard: Most are rigid. They must be deployed in stiff — and often heavy — fixed panels, limiting their applications. So researchers have been trying to get photovoltaics to loosen up. The ideal would be flexible, decal-like solar panels that can be peeled off like band-aids and stuck to virtually any surface, from papers to window panes. Stanford University researchers may have turned this vision into a reality. They have developed the world’s first peel-and-stick thin-film solar cells, an advancement described in a paper in the Dec. 20 issue of Scientific Reports (www.nature.com). Unlike standard thin-film solar cells, peel-andstick solar does not require any direct fabrication on the final carrier substrate. This is a far more dramatic development than it may initially seem. All the challenges associated with putting solar cells on unconventional materials are avoided with the new process, vastly expanding the potential applications of solar technology.
Decal-like application allows thin, flexible solar panels to be mounted on almost any surface — from business cards to window panes By Glen Martin
Editor’s note: This piece was originally published on engineering.stanford.edu in December 2012 and is reproduced here with permission.
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Thin-film photovoltaic cells are traditionally fixed on rigid silicon and glass substrates, which severely limits their usefulness, says Chi Hwan Lee, lead author of the paper and a Ph.D. candidate in mechanical engineering at Stanford University. Xiaolin Zheng, a Stanford assistant professor of mechanical engineering and senior author of the paper, also explains that while developing thin-film solar cells promised to inject some flexibility into the technology, scientists found that using alternative substrates was extremely problematic. “Nonconventional or ‘universal’ substrates are difficult to use for photovoltaics because they typically have irregular surfaces and don’t do well with the thermal and chemical processing necessary to produce today’s solar cells,” Zheng says. “We got around these problems by developing this peel-and-stick process, which gives thin-film solar cells flexibility and attachment potential we’ve never seen before. It also reduces their general cost and weight.” Using the process, researchers attached thin-film solar cells to paper, plastic and window glass, among other materials. “It’s significant that we didn’t lose any of the original cell efficiency,” Zheng says. The new process involves a unique silicon, silicondioxide and metal “sandwich.” First, a 300-nm film of
nickel (Ni) is deposited on a silicon/silicon dioxide (Si/ SiO2) wafer. Thin-film solar cells are then deposited on the nickel layer using standard fabrication techniques and covered with a layer of protective polymer. A thermal release tape is then attached to the top of the thin-film solar cells to augment their transfer off of the production wafer and onto a new substrate. The solar cell is now ready to peel from the wafer. To remove it, the wafer is submerged in water at room temperature and the edge of the thermal release tape is peeled back slightly, allowing water to seep into and penetrate between the nickel and silicon dioxide interface. The solar cell is thus freed from the hard substrate but still attached to the thermal release tape. Zheng and her team heat the tape and solar cell to 90°C (194°F) for several seconds. The cell can then be applied to virtually any surface using double-sided tape or other adhesive. The thermal release tape is finally removed, leaving just the solar cell attached to the chosen substrate. Tests have demonstrated that the peel-and-stick process reliably leaves the thin-film solar cells wholly intact and functional. “There’s also no waste,” Zheng says. “The (Si) wafer is typically undamaged and clean after removal of the solar cells and can be reused.”
Xiaolin Zheng, assistant professor of mechanical engineering at Stanford University (Photo courtesy of John Todd)
Chi Hwan Lee, doctoral candidate at Stanford University
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ENGINEERING DEVELOPMENTS
Thin-film photovoltaic cells are traditionally fixed on rigid silicon and glass substrates, which severely limits their usefulness, says Chi Hwan Lee, lead author of the paper and a Ph.D. candidate in mechanical engineering at Stanford University. Xiaolin Zheng, a Stanford assistant professor of mechanical engineering and senior author of the paper, also explains that while developing thin-film solar cells promised to inject some flexibility into the technology, scientists found that using alternative substrates was extremely problematic. “Nonconventional or ‘universal’ substrates are difficult to use for photovoltaics because they typically have irregular surfaces and don’t do well with the thermal and chemical processing necessary to produce today’s solar cells,” Zheng says. “We got around these problems by developing this peel-and-stick process, which gives thin-film solar cells flexibility and attachment potential we’ve never seen before. It also reduces their general cost and weight.” Using the process, researchers attached thin-film solar cells to paper, plastic and window glass, among other materials. “It’s significant that we didn’t lose any of the original cell efficiency,” Zheng says. The new process involves a unique silicon, silicondioxide and metal “sandwich.” First, a 300-nm film of
nickel (Ni) is deposited on a silicon/silicon dioxide (Si/ SiO2) wafer. Thin-film solar cells are then deposited on the nickel layer using standard fabrication techniques and covered with a layer of protective polymer. A thermal release tape is then attached to the top of the thin-film solar cells to augment their transfer off of the production wafer and onto a new substrate. The solar cell is now ready to peel from the wafer. To remove it, the wafer is submerged in water at room temperature and the edge of the thermal release tape is peeled back slightly, allowing water to seep into and penetrate between the nickel and silicon dioxide interface. The solar cell is thus freed from the hard substrate but still attached to the thermal release tape. Zheng and her team heat the tape and solar cell to 90°C (194°F) for several seconds. The cell can then be applied to virtually any surface using double-sided tape or other adhesive. The thermal release tape is finally removed, leaving just the solar cell attached to the chosen substrate. Tests have demonstrated that the peel-and-stick process reliably leaves the thin-film solar cells wholly intact and functional. “There’s also no waste,” Zheng says. “The (Si) wafer is typically undamaged and clean after removal of the solar cells and can be reused.”
Xiaolin Zheng, assistant professor of mechanical engineering at Stanford University (Photo courtesy of John Todd)
Chi Hwan Lee, doctoral candidate at Stanford University
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Photo Courtesy of Chi Hwan Lee
While others have been successful in fabricating thin-film solar cells on flexible substrates, those efforts have required modifications of existing processes or materials, Lee says. “The main contribution of our work is that we have done so without modifying any existing processes, facilities or materials, which makes them viable commercially,” Lee says. “We have demonstrated our process on a more diverse array of substrates than ever before.” “Now you can put them on helmets, cell phones, convex windows, portable electronic devices, curved roofs, clothing — virtually anything,” says Zheng. Moreover, peel-and-stick technology isn’t necessarily restricted to thin-film solar cells. The researchers believe the process can also be applied to thin-film electronics, including printed circuits, ultra-thin transistors and LCDs. “Obviously, a lot of new products – from ‘smart’ clothing to new aerospace systems, might be possible by combining both thin-film electronics and thin-film solar cells,” Zheng says. “For that matter, we may be just at the beginning of this technology. The peel-and-stick qualities we’re researching probably aren’t restricted to Ni/SiO2. It’s likely many other material interfaces demonstrate similar qualities, and they may have certain advantages for specific applications. We have a lot left to investigate.” SPW
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The authors of the Scientific Reports paper “Peel-and-Stick: Fabricating Thin-Film Solar Cell on Universal Substrates” include Chi Hwan Lee, In Sun Cho and Xiaolin Zheng from Stanford’s Department of Mechanical Engineering, Dong Rip Kim from Hanyang University in Seoul, Korea, and Nemeth William and Qi Wang from the National Renewable Energy Laboratory in Denver. Glen Martin is a freelance writer working for the Stanford University School of Engineering.
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6 6
Ways To Avoid
Damaging Roofs
Rooftops are great for
solar, but only when
important considerations are addressed
B y To n y R u f f i n e
A
s North America’s largest roofing manufacturer, we know that rooftops are a great location for solar. Roofs are out of the way, tend to have the least shade on a property, are close to utility hookups and usually do not need additional infrastructure. As a result, approximately 80% of solar installations take place on roofs. We have worked closely with the solar industry for several years and are big advocates of rooftop solar. Working with the best players in the industry, we have seen some great solar projects on top of our roof systems. Unfortunately, many solar buyers and installers do not understand the interplay between the roofing system and solar. Most of us have heard a job sold with some variation of the line: “There are no penetrations so it does not affect your roof warranty.” When we at GAF hear that, we can be almost certain there will be a problem. Common Installation Problems A successful solar installation is not just one that generates the required amount of electricity. It also has to leave the building in serviceable condition. There is no such thing as a good solar installation on a leaky or damaged roof. Even today, in states where there is a long history of solar installations, we see problems when the solar installer did not understand or take into account conditions on the roof. A few of these problems seem to come up repeatedly:
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6
Proper Planning
If a property owner is considering solar, the roof system should be
designed with the future installation in mind. Design considerations like slope or placement of drains and
scuppers should be done to allow
maximum solar coverage. The roof system should also be chosen to support solar. High-density cover
boards, for example, should be used when solar will be installed. Membrane systems should not be loosely laid or mechanically attached, but should be fully adhered. Higher performance membranes provide cheap insurance up front. Walkway pads should be used around the solar (and slip sheets are usually recommended underneath). Most importantly, the roof installation needs to be staged to facilitate the solar installation, considering both schedules.
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ctio
n
I N S TA L L AT I O N P R A C T I C E S
1.
Not matching the roof life to the solar installationâ&#x20AC;&#x2122;s life. This one should be obvious. A solar installation may generate power for 20 years or more and have financing or PPA lengths just as long. Putting a solar installation that may last 20 years on a roof that, like many new construction roofs, is only designed to last 10 years is asking for problems. A variety of roof systems, however, can last 20 years. Also, membranes are designed for conditions on solar rooftops and so can be warranted for 35 years. Membranes are the protective, waterproofing top layer of a roofing system.
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ctio
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Choosing the Right Installer
2.
Not matching the roof design to solar. Because solar has specific performance criteria, there are points to consider when choosing a roof system to ensure the best solar performance. Solar panels, for example, tend to work best in cooler environments, so a cool membrane can provide better electrical output. Roof systems are also not usually designed for the weight of solar projects or for the foot traffic that installation and maintenance can bring. Understanding the roofing membrane is even more important when considering the potential for directly attached panels in the future. Many membranes will have compatibility issues with these designs. Ensuring the roof is solar-ready up front will avoid a lot of unnecessary work in the future.
3.
Not understanding the flow of ater. A good roof system should drain water away from the rooftop and shed it away from the building. But racking and wire harnesses can inhibit water flow, preventing water from draining in a timely manner. Even worse, water may be forced in the wrong direction, causing a leak. We have also seen drains clogged when cheap ballast disintegrated and ran out of the ballast tray. Repairs can be more difficult when solar is installed, so it’s important to take account of these concerns up front.
4.
Not considering thermal movement or wind/seismic events. We recently visited a rooftop solar installation with 250-ft long racks and no slip-sheets. The rate of thermal expansion on these racking systems was about 0.25%, which means the racks could be moving a little over a foot with each thermal cycle. We have also seen systems damaged from wind because the ballast was not properly installed and the system moved. Taking precautions during installation will avoid many problems.
5.
Not understanding rooftop conditions during installations. A good roof system is durable, but it’s not designed to be used as a construction site. Dragging panels
or racking across the membrane will damage even the heartiest roof. Dropping tools can penetrate roof membranes. Debris will clog drains or cause other problems. We have seen staging areas on new roofs look like they were 15 years old by the time the solar installation is complete. While this problem was more common a few years ago, seeing roofs torn up from solar installation is still too common.
6.
Not having a maintenance plan. Basic maintenance and inspections are necessary on commercial roofs without solar, and the need for maintenance is heightened when solar is installed. We have seen some solar installations with plants growing around panels, and others that end up in the water when a drain clogs. Crews that are used to finding problems with roofing and solar help avoid problems up front and catch other small problems before they become big issues. Many other rooftop issues can arise with solar. As new installation methods are developed, their effect on the roof system must be seriously considered. Roofing and solar make a lot of sense together. In the future, we expect the roof and solar integration to become much easier. Forward thinking property owners and solar buyers will wisely choose the right solar installer, select the right roofing materials and design a robust roof system to guarantee the best performance from any solar installation. SPW Tony Ruffine is vice esident of GAF, a North Americian manufacturer of commercial and residential roofin . The company was founded in 1886 and is currently headquartered in Wayne, N.J.
The property owner should insist on a solar installer with genuine roofing experience. Here are some tips for choosing a qualified solar installer: the installer about other • Ask rooftop installations they
have completed.
sure the installer is • Make respected by roofing-system providers.
the company has • Ensure installed solar on multiple
roofing systems using a variety of technologies.
installer should be able • The to discuss rooftop conditions,
know how the roof drains, have a strong familiarity with wire management plans, provide roof replacement and repairs, take down and re-install a system during roof replacement and repair and can provide follow up maintenance services.
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A lot of solar installers take the roofing piece for granted or do not have the experience with roof top installations to understand the challenges of each roof. That is why choosing an EPC that is familiar with the roof is crucial.
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IN VER TER INS IDE R
Get
Storm-Proof
SOLAR
By Greg Smith
Battery Backup Keeps the Lights On
L
ast year, 19 major storms struck the United States during the Atlantic hurricane season, testing our utility-grid infrastructures and disrupting the continuous (but delicate) supply of power to homes and businesses. To the dismay of most grid-tied solarpower system owners, their PV systems do not work when the grid goes down because it is required by law that owners shut down solar systems under such circumstances. So what options are available for homeowners with existing PV systems and for those without solar who want protection against grid outages?
AC Coupling One answer lies in AC coupling. Instead of backing up an entire house, critical load breakers are migrated from the main service entrance to a special subpanel. The solar-inverter breaker and the load breakers are placed into this subpanel, which is called a 42
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Public Grid
Main Service Panel
Ext. Transfer Switch
SUNNY ISLAND
Protected AC Loads
Generator
Battery
critical-loads panel. The battery inverter also feeds this critical loads panel when the grid is lost. AC-coupled battery backup systems use energy from inverters to power essential loads directly when the grid goes down. Any excess power is sent to the battery inverter to charge the battery bank.
Benefits of AC Coupling One of the benefits of an AC-coupled system is the efficient use of solar to power the loads because it is a one-step conversion from the array’s DC to utility-compliant AC. This takes the load off the battery inverter and allows the batteries to stay in a higher state-ofcharge since they might not have to discharge right away to power the loads in the house.
Planning an AC-coupled system does not require specialized knowledge of electronics, and commercially available components can be used because they are readily available. AC coupling is extremely flexible. Even years after the initial installation, a larger battery bank can be installed, and a generator or more PV can be added without additional training or components.
of system sizing were not followed. The foundation of a proper battery-bank size is the load calculation worksheet. This worksheet lists all the loads that will be connected to the protected-loads panel and will continue to operate when the grid goes down. Every load that will be connected to the critical-loads panel must be logged, along with how much power it uses and how long it will run per day. The next step in the sizing process can take place once the total watt-hours have been calculated. Another consideration is the allowable state-of-charge the battery bank can suffer. All battery manufacturers have specifications that describe the number
Sizing the Backup System System sizing is the most important part of any backup application and is usually the most neglected step. Service calls are often made because the basic concepts
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IN VE RTE R INS IDE R
of charge cycles vs. depth of discharge. The deeper a battery bank is discharged, the shorter its life expectancy. There is no universal guideline for the allowable depth of discharge — it depends on how aggressive a designer wants to be. For example, if the grid is stable with few outages, then perhaps a deep discharge (around 20%) is acceptable. If a customer experiences several long outages a year then a discharge to 50 or 60% (or higher) is prudent. A good place to start with battery inverter sizing is 1W of inverter per 1W of backup load. While most battery backup inverters have a higher 30-minute output, the nominal output rating should be used as a general guideline. This is an important step, especially if there is a requirement for sustained power output. If the average power consumption is 8 kW, a 6-kW battery inverter will not be able to keep up, and other sources of power will be necessary. The proper sizing of the inverter is also crucial because it will be the only source of power available to charge the batteries after loads have been supplied, assuming a generator is not used. Since the load profile rarely coincides with the power produced by a PV system during the day, the system should be sized to charge the batteries to an acceptable state-of-charge to account for nighttime needs. A good guideline is to have 1000W of PV per 100 Ah of battery capacity. However, the amount of sunlight available on the worst day of the year must be evaluated for PV sizing, since it is more likely that the power would go out at this time. The generator should be sized to handle the worst case scenario: all loads on, no PV. A practical guideline for generator sizing is 80% to 120% of the battery inverter at nominal capacity, but it’s wise to follow the PV rough sizing rule at twice the battery inverter nominal power. It’s extremely important to gather all the specifications for the generator and match them to the recommended guidelines set by the battery inverter manufacturer. Some generators may not be compatible. The last step is determining how much autonomy — or time off the grid — will be required. In an area with stable grids, half a day will likely suffice. In an area
Greg Smith, is a technical training specialist for SMA America. He trains a wide spectrum of professionals on the use, installation and proper design of SMA solar inverters and communication products.
plagued with power outages, perhaps two or three days should be used in the calculations. This load profile worksheet shows system sizing using the examples described (values rounded up): Battery Inverter Watts
Add all loads = 3,450W
Loads
Watts
Hours
Watt Hours
Fan
200
4
800
Freezer
800
Daily
2,190
TV
350
4
1,400
1,200
.5
600
700/30 A
2
1,400
200
6
1,200
Microwave Sump pump Lights 5x40 W
Battery Sizing
Add all watt-hours = 7,590 W/H Determine how big battery bank must be for autonomy desired:
Autonomy = 7,590 W/H per day X 2 days = 15.2 kW/HR. Next, take the autonomy value and multiply it by the system efficiency. For this scenario, the system efficiency is 80%. This is the storage required for the application. 15.2 kW/HR X 0 .8 = 19 kW/HR of required storage.
Since battery capacities are expressed in amp hours (Ah), a quick conversion must be calculated for the kW/HR value using a simple formula. In this example, the battery-bank voltage is 48V DC. 19KW/HR X 1,000 / Battery Voltage (48V)
Total Amp Hour Capacity = 395 Ah (typically rounded to 400 Ah). This is the size of the battery bank, which could be achieved through two strings of four 12-V DC batteries rated at 200 Ah each. Typically, this type of system would
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inverter. Is this enough to recharge the batteries? In an extended blackout, this will determine how much a homeowner can live on each day. Battery backup systems are ideal for homeowners who need reliable power when the grid goes down. A greater understanding of system design helps installers reassure customers that their power will stay on — even when the unexpected happens. SPW
use flooded lead acid batteries, which include Gel and AGM, but that’s just a guideline. Some FLA batteries could also work well. Talk to the battery manufacturer to find out which battery type suits the application. The last item to consider in this application is the PV size. The 400 Ah battery bank will need to be charged enough during
the day to supply nighttime and early morning loads. PV Watts estimates that New Jersey in December has approximately 2.1 kWH/kW of production. This means a solar system will produce an average of (5 sun hours) X 2.1 kWH/kW = 10.5 kWH per day, which would roughly be the equivalent of a 3000-W solar
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y F Farm actor y F Farm
The author and assistant head to a turbine inspection at a wind farm in the U.K.
actor
Strata Solar borrowed from manufacturing’s assembly-line production system to construct Belwood Solar Farm in record time
Frank Andorka, Editorial Director
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awndale, N.C., is the kind of town that a visitor might miss if he blinked. Located an hour west of Charlotte along the East Stage Coach Trail, Lawndale nestles comfortably into the Appalachian foothills. Only 611 people live there in 270 houses, all of which need electricity. So when Chapel Hill, N.C.-based Strata Solar and Charlotte, N.C.-based Duke Energy decided to build a 5-MW solar project just across the street in Belwood (population: 962), the people of Lawndale were thrilled. There was only one small problem: For the project to make financial sense, Strata Solar needed to build the project before the year ended — and it was October before it was even part of the company’s plans. “The owner came down and asked if we could get this project done by
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December so we could take advantage of the tax credits,” says John Morrison, COO for Strata Solar. “I said yes. Then I ran down to Steve Kludy [commercial solar and electrical onsite construction manager] and said, ‘How are we going to do this?’” But do it they did, thanks in large part to strong supply-chain partnerships and a dedicated workforce employing a streamlined construction process.
It’s Definitely Who You Know At any given time, Strata Solar has four to five projects going on at once. Its specialty is constructing small-scale utility projects like Belwood Farm in under four months. Company executives meet regularly to decide which projects are shovel-ready so they can move on them with speed, as they did in September 2012 to put five projects on the docket for completion by Dec. 31.
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At A Glance: Belwood Farm Project Lawndale, N.C. Total Size: 5 MW Output: 7,400 MWh (powers approximately 616 North Carolina homes) Construction Began: October 2012 Project Completion: December 2012 Power Purchaser: Duke Energy (Charlotte, N.C.) Racking: Schletter Panels: Shueco, Canadian Solar, Astronergy Inverters: SMA Crew Size: 120
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“We’re in the business of building modestly sized solar farms, somewhere in the neighborhood of 6 MW per project,” Morrison says. “We build them one after the other in a cookie-cutter fashion.” In October, the owner asked Morrison and Kludy if they could fit one more project on the schedule so Strata could take advantage of tax breaks. Part of what made the schedule feasible was the great relationships Strata has with its suppliers. When they first approached companies like Schletter (racking), SMA (inverters) and Canadian Solar and others (panels), most companies were taken aback at the tight timeframe. (For a full list of partners, see sidebar.) “We’ve made our suppliers aware of how we do business, so they know we often purchase in bulk and in a hurry,” Morrison says. “But we didn’t give them much material lead time on Belwood, and most of them said they didn’t think they’d be able to help us. “But you know what? All of them managed to work it out,” Morrison says. “It’s those partnerships between manufacturers and installers that make projects like Belwood possible.” Kyle Petty, technical sales representative for Schletter, concurred. “Working with Strata Solar was a great opportunity,” Petty said. “I’m pleased to have had the privilege of helping to bring our two companies together in a collaborative effort to provide the best possible solutions to our — and their — customers.” Racking systems were one thing. Inverters were a whole other matter. Both the size and the complexity of the machinery require more time to put into place. Morrisson breathed a sigh of relief when SMA told him Strata would get the equipment in mid-December — but he was in for a big surprise. “When SMA told us about the delivery date, we were thrilled,” Morrison says. “So imagine my shock and delight when the inverters showed up on Thanksgiving, three weeks ahead of schedule. I couldn’t have been more pleased.” Henry Dziuba, president and general manager of SMA America, said his company was proud to embrace the challenge. “SMA always appreciates the opportunity to work with Strata Solar,” Dziuba says. “We have a strong, long-standing relationship with the company, and our similar world-class processes ensure seamless execution and industry-best solutions for every project and partner.”
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P RO J E CT RE V I E W
Rock Around The Clock Once Strata secured the hardware, it turned its attention to how its workers would construct the project quickly and efficiently. Inspiration from the process came from two unexpected sources: lean manufacturing and Kludy’s unusual staffing strategy. Morrison came to Strata Solar from the world of maintaining automotive supply-chains, so he understood the twin concepts of just-in-time delivery and lean production. Morrison says Strata Solar treats the construction of solar farms like it’s a factory assembly line. “Henry Ford lives in our projects,” Morrison says. “By thinking of it in manufacturing terms, we move through the build sequence like a wave. “Each crew has a narrow set of tasks to do, just like the small production cells in a factory,” he continues. “Once they’re done with their narrow set of tasks, there’s a crew right behind them to do the next set of tasks. It’s efficient and quick.” Kludy, who has worked in construction for 41 years and spent many of them managing fasttracked electrical projects, knew that managing a crew of nearly 120 (up from a normal crew of between 60 and 70) would be a challenge.
But Morrison’s specialized-crew strategy fit in perfectly with Kludy’s long-standing project management plan, which he says has never let him down. Take inverter pads — installing one pad usually takes a week. For Belwood, eight had to be installed. Instead of having one crew do all eight, Kludy had eight crews, each focused on installing one. That meant that at the end of a week, all eight pads were constructed and were ready to have the inverters installed on them. “If you have multiple tasks to complete a project, put a crew on each one,” Kludy says. “Then when they’re done, they’re done.” With construction running as smoothly as any Toyota assembly line and with workers putting in 7-day weeks (the crews had two days off for Thanksgiving), the project shattered all company records for construction speed, making the plant ready for business in only 41 days. They made the deadline of Dec. 31, making the company’s owner happy. “I have to brag on our guys for a minute: Our entire team, from our own employees to our valued partners, worked like crazy to get this project done on an insane deadline,” Morrison says. “They came through with flying colors and showed a commitment to the customers that rivals any in the industry.” SPW
North Carolina Solar Policy North Carolina requires utilities to generate from renewable sources a certain percent of the electricity they sell. The state’s renewable portfolio standard requires investor-owned utilities to generate 12.5% of retail electricity sales from renewables by 2021, while municipal utilities and cooperatives must meet a target of 10% of renewable by 2018. The overall target for renewable energy includes technology-specific targets of 0.2% solar by 2018, 0.2% energy recovery from swine waste by 2018, and 900,000 MW-hours of electricity derived from poultry waste by 2014.
Source: Institute for Energy Research
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Finally, someone beat Advanced Energy’s 97.5% CEC efficient solar inverter.
It’s the 98% efficient AE 500 NX-HE. Advanced Energy’s AE 500 NX-HE (formerly the Solaron 500 HE) inverter just achieved the industry’s highest efficiency rating on the CEC list for the third year in a row. Now we’re up to 98% weighted CEC efficiency – improving on last year’s industry record of 97.5%, and staying one to three percentage points ahead of the competition. That 98% average includes all auxiliary power so every percentage point increase in efficiency delivers an exponential return on your investment. Oh, and lastly, its peak efficiency is 98.7%, all in.
See how much you have to gain by choosing the 98% efficient AE 500 NX-HE inverter from Advanced Energy. www.advanced-energy.com/98percent sales.support@aei.com | 877.312.3832
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The solar industry continues to have a significant impact on the U.S. economy. The Solar Foundation’s Solar Job Census 2012 reported more than 119,000 solar workers in the United States, a 13.2% increase over 2011. There are 5,600 businesses operating at over 6,500 locations in all 50 states. Solar installations also continue to grow, which also adds life to the economy. In 2011, solar installations were valued at $8.4 billion, compared to $6 billion in 2010. This growth isn’t a matter of chance — it’s a result of the innovation, ingenuity and hard work of the people who drive it: leaders. From policy to products, these individuals and companies are working for the success of the entire solar industry. The future of the industry will build on the foundation of today’s efforts. Solar Power World would like to acknowledge such achievements on the following pages. These accomplishments in racking-and-mounting, motors, software, modules and more are what drive those gigawatts and create jobs. We think they deserve recognition from you, too. Vote online for one or more of the companies listed through October. Winners will be recognized in our 2014 Renewable Energy Handbook.
Voting for this company will identify it as a leader in the solar power industry.
Vote online at: www.solarpowerworldonline.com/leadership Nominate the company you think has provided leadership in the solar industry.
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DPW Solar, located in Albuquerque, New Mexico, is a wholly owned subsidiary of Preformed Line Products (PLP). We are a major manufacturer of innovative and reliable PV mounting hardware solutions since 1993.
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PV Mounting Solutions for any Application DPW Solar, The POWER-FAB® brand of racking systems offer improved strength, longer life and lower installation costs. We design and manufacture field proven solutions for securing most PV solar modules in a variety of applications for utility scale, commercial, residential, government and industrial markets. Installers from coast to coast rely on the strength and easy to install assembly of our PV mounting structures, plus the added value our customers receive through engineering expertise and unparalleled customer support. Our 20 years of PV solar industry experience coupled with lean manufacturing capabilities allow for a quick, precise response to customer needs.
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HatiCon Solar develops and produces highquality, environmentally responsible mounting systems for the North American photovoltaic solar energy market. We provide systems for pitched roof, flat/low-slope roof and ground mount installations by combining a market-proven technology with world-class manufacturing and a strong, dedicated team. HatiCon Solar PV mounting solutions are engineered from the ground up for quick on-site installation. Universal PV module clamps slide or click onto structural rails reducing the need for specialized tools and minimizing installation times. All systems are engineered for onsite flexibility without any fabrication. With multiple production facilities, HatiCon Solar can supply projects throughout North America.
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HatiCon Solar develops and produces high-quality, environmentally responsible, IBC compliant mounting systems for the North American photovoltaic solar energy market. We provide systems for pitched roof, flat/low-slope roof and ground mount installations by combining market-proven technology with world-class manufacturing and a strong, dedicated team. Our proven system, with over 6 GW installed globally and 100MW in North America, features pre-assembled components, low part count and minimal on-site fabrication. Universal PV module clamps simply slide or click onto structural rails without any specialized tools. Our patented clamp technology provides faster installation times and reduced labor costs for a better ROI. HatiCon Solar PV mounting solutions are engineered from the ground up for fast on-site installation. Since rooftops and soil substrate vary from jobsite to jobsite, all HatiCon Solar mounting systems are designed to be flexible without any cutting or welding. Our multiple production facilities across North America decrease shipping costs, transit times, and logistical headaches. HatiCon Solar can meet ARRA and Ontario FIT program requirements. HatiCon Solar’s team works closely with our customers. Even before a project gets off the drawing board, our sales team communicates closely with solar PV plant designers, installers and geological technicians to find the most cost effective and efficient solution for specific site. Our engineering team optimizes both site layout and physical array design for power production capacity and cost. We work closely with our customer’s project managers and our production plants to ensure timely deliveries and streamlined logistics.
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In 2009 LUFFT’s innovative “WS Family” of weather sensors entered the Global Solar Industry. The introduction of the new WS501 and WS301 with integrated Kipp and Zonen CMP3 pyranometer created a high level of interest being the only integrated weather station with high end pyranometer available on the market. The new LUFFT solar instruments along with seven other WS Family members created an overwhelmingly positive industry response. Currently There are hundreds installed in the field with thousands on the order books for 2012/13. The WS Family of sensors have no moving parts and are maintenance free. LUFFT offers a standard two year warranty and in-house calibration lab with DKD certified temperature/humidity chamber and two fully automated wind tunnels. These benefits and superior customer service make LUFFT an industry stand out. Customers talk and LUFFT listens. Features like integrated external temperature sensors with adhesive for measuring panel temperature, RS-485 MODBUS-RTU communication (along with 4 other available protocols) and an optional external rain gauge add to the appeal of LUFFT WS Family weather stations. Additional features such as plane of array measurement will be available Q2 2012. New sensors such as the WS100 stand-alone pyranometer with MODBUS-RTU will also enhance the offering later this year. LUFFT WS Family weather stations fill critical requirements for large and small scale solar projects. This is important to project owners and operators as well as installers, electrical contractors and systems integrators. No matter where you are in the world, electrical utilities require accurate weather data reporting for solar projects. Weather data is necessary in order to monitor project performance and protect a solar farm investment. In order to defend their investment, project owners also require weather data alongside electrical production data in order to assure panel efficiency and project performance. Integration of weather measurement used to be a bothersome requirement to complete a solar project. Now with LUFFT all in one Weather Stations, weather data is easy to install and integrate. Expensive solar installations deserve the most reliable protection from extreme weather. Automatic tracking of solar panels is an efficient way to maximize the efficiency of a solar farm. LUFFT ultrasonic wind sensing technology can be installed as part of a dual axis tracking system to help protect solar panels from damaging high winds. LUFFT maintenance free ultrasonic wind sensors are installed with each tracked array to measure and signal the project controls to move the panels to flat or “safe mode”. To keep in pace with the market and the modern technologies, electronic devices have been developed parallel to the mechanical products according to the basic principle “Tradition and Innovation”. Meaningful contributions to the Solar Industry are very important to LUFFT as a company. Listening to customers, executing new ideas and having the technical ability to meet the demand of a growing industry help LUFFT keep up with customer wants. This is the goal of LUFFT and what makes LUFFT a leader in the Solar Industry.
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Moxa manufactures industrial-grade communication hardware that connects to inverters, power meters, smart string combiners, weather stations, and other devices for easier and smarter management over the network and Internet. A wide range of products are available, including: data-loggers; industrial Ethernet switches; wireless access points; IP cameras; and more. Moxa hardware complies with open communication standards, and is known for being durable, reliable, and easy to deploy. Learn more at www.moxa.com.
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Our History Since 1970, Nordic Fiberglass has been committed in providing quality fiberglass products for the Electrical Industry. We are the leading manufacturer of high quality fiberglass products for the underground electrical industry. Our complete line of products include; box pads for single and three phase transformers, oil-filled switchgear, and ground sleeves for single and three
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PanelClaw is a leading international supplier of photovoltaic mounting systems for both flat roof and ground mount applications. Every PanelClaw system is backed by a stateof-the-art testing and certification program and engineered to deliver superior design flexibility and ease of installation. With over 300 megawatts successfully deployed, and a flawless track record for safety and reliability, PanelClaw delivers mounting and balance-ofsystem solutions to accelerate the adoption of photovoltaics worldwide. With over 300 MW deployed worldwide, PanelClaw is a global leader in the design and manufacturing of flat roof and ground mount PV racking systems. Since its inception, PanelClaw has focused on accelerating the adoption of photovoltaics worldwide. With its emphasis on safety and reliability, PanelClaw was instrumental in the creation and adoption of the UL 2703 standard for grounding and bonding of solar racking systems, becoming the first in the industry to have its entire product line third-party certified for listing to the standard. As the first solar racking company to earn ETL certification for its in-house testing laboratory, PanelClaw has been able to significantly reduce costs and project lead times.
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RBI Solar, Inc. designs, engineers, manufactures and installs solar mounting systems for large commercial and utility scale projects. As a specialist in ground mount, roof mount, and custom designed specialty solar structures, RBI focuses on providing best-in-class racking systems and project management capabilities to serve owners and integrators. RBI Solar offers a broad range of solar racking systems to support every PV module manufacturer. RBI provides complete solar mounting solutions to solve virtually any structural mounting challenge in the solar world. Services include complete design, signed and sealed drawings for all 50 states, high tech manufacturing, nationwide installation and end to end technical
Leveraging more than 70 years of experience in the commercial
support to help you solve the toughest challenges
design-build specialty structures market, RBI Solar, works with its clients to
in the industry. All of RBI Solar mounting systems
identify the most economical, durable and robust solution. In partnering
come with a 20 years limited warranty.
with RBI Solar you will benefit from working with the leading manufacturer of specialty steel and aluminum structures in North America. When working on a project we focus on single point responsibility for the entire solar mounting system from complete design and engineering to product manufacturing and on-site racking installation. Nothing falls through the cracks between different companies as we will take responsibility for all aspects of the solar mounting systems. No other company in the solar market has both capabilities and infrastructure that RBI Solar has developed over the years to handle your project
RBI Solar, Inc.
5513 Vine Street Cincinnati OH 45217 Telephone: 513 242-2051 E-mail: info@rbisolar.com www.rbisolar.com
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solarpowerworldonline. com/leadership Voting for this company will identify it as a leader in the solar power industry. 3 â&#x20AC;˘ 2013
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2/21/13 10:41 AM
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[lea dershi p With over 45 years of experience in
i n
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REFUsol, Inc.
power electronics, REFUsol is one of the top three providers of solar inverters globally and one of the fastest growing companies in this field. REFUsol‘s efficient and award-winning solar inverters help customers maximize the yield of their photovoltaic plants, whether for small roof-top installations or large-scale solar plants. REFUsol is headquartered in Metzingen, Germany and has further international offices in Europe, Korea, China, India and the U.S. as well as sales and service partners in key strategic photovoltaic markets around the world.
A pioneer in photovoltaics As a specialist in power electronics, REFUsol, Inc. has been producing high-quality inverters in Germany for more than 47 years. As early as 1997, REFUsol developed the first linecommutated photovoltaic inverter, based on the many years of experience. Today, our products can be found in solar power systems and solar parks all over the world. Our quality standards are stringent. That’s why we’re IS O 9001: 2000 certified. REFUsol focuses on developing, manufacturing and distributing efficient photovoltaic inverters. With a peak efficiency of 98.7% REFUsol inverters are among the most efficient on the market. The product range comprises string and central inverters with power outputs ranging from 3.6 kW to 1.3 MW. The variety of applications for our systems is correspondingly extensive, from single-family houses to megawatt solar parks. Our commitment to photovoltaics extends beyond the development and manufacture of cutting-edge technology. We have developed a web-based tool for documenting the performance of a PV system daily: the REFUlog Internet portal. This enables customers to view or display in graphical form and evaluate all important operating parameters of their solar plants.
25 countries, 4 continents, 1 goal Strong presence
REFUsol Inc.
REFUsol operates around the globe: with staff in Germany and Europe, subsidiaries in the U.S., India, China and South Korea and many national sales and service partners. Our goal is to support our customers with our expertise and our products in all major PV markets around the world. In December of 2011 we opened our new manufacturing facility in Greenville, South Carolina. We are committed to supporting the local solar advocacy programs and renewable energy industry in the United States.
48025 Fremont Boulevard Fremont, CA 94538 Tel.: (408) 775 - 7744 info-usa(at)refusol.com www.refusol.com
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solarpowerworldonline.com/leadership Voting for this company will identify it as a leader in the solar power industry. www.solarpowerworldonline.com
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Your Solar System should last as long as your roof. SolarDock makes that happen. Throughout North America and around
When we invented SolarDock in 2003, our goal was to create a racking system that met the needs of commercial property owners and tenants. We knew they wanted a system that would protect their building while providing a strong ROI.
the world, SolarDock is recognized among leading integrators, distributors and site owners as the premier choice in custom tilt solar mounting system. Made in USA
This is why SolarDock is made from durable mill-grade aluminum and stainless steel, why we’ve invested in rigorous wind-tunnel and CFD analysis, and why we’ve earned TUV Rheinland’s certification.
and Canada, SolarDock has been used on more than 40 MW of flat-roof and ground mounted projects worldwide. Learn more about SolarDock online at
Our drive to innovate continues. Our quest for quality endures. SolarDock is leading the way in:
SolarDock.com as well as on Twitter, YouTube, Facebook, and Google+.
Protecting the roof SolarDock makes no penetrations, even at high angles, and has no metal parts that touch the roof, eliminating the chance of roof leaks & damage. In addition, our patented design distributes the system’s weight evenly across the rooftop, avoiding high point loads that can damage the building’s roof structure.
Protecting the solar panels SolarDock’s full-frame support protects the panel from micro-fractures created by wind uplift forces. Enclosed sides & back protect the wiring from damage caused by weather, animals, and birds. And to top it off, SolarDock uses no positive points of attachment, letting the frame do what it is designed to do, support and protect the module.
SolarDock 201 W 14th St, Suite 101
Protecting the bottom line
Wilmington, DE 19899
SolarDock saves money throughout the life of the system, with reduced installation costs, little or no operations costs, and increased power generation.
info@solardock.com 1.302.504.0124 www.solardock.com
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Outperforming expectations with the vision to consider every detail. That's the SolarDock way. solarpowerworldonline.com/leadership
SolarDock is precision engineered to: • Protect the roof, with a fully non-penetrating, non-abrasive design • Generate more power, with higher tilt angles, up to 35 degrees • Speed up installation, with modular installation, built in wire management, and integrated panel & equipment grounding • Last as long as your roof and solar panels, covered by a 25 year warranty UL Listed and TUV certified, SolarDock’s patented design has been rigorously wind tunnel and CFD tested, up to 150 mph wind zones, per ASCE 7-05.
Voting for this company will identify it as a leader in the solar power industry.
SOLAR POWER WORLD
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www.solarpowerworldonline.com
2/21/13 1:02 PM
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Solar FlexRack is a solar industry innovator providing advanced engineered integrated products and services to EPCs and energy companies in North America that are looking to optimize their efforts and lower balance of system costs. Solar FlexRack offers several innovative PV mounting systems that drastically reduce installation time. In addition to ground mounts, Solar Flexrack has roof and carport models, as well as single-axis tracker units. Additional products and services are available to assist on any commercial solar project. Contact Solar FlexRack by phone 888-3808138 for a QuikQuote, or visit their website at www.SolarFlexRack.com.
Why Solar FlexRack Is a Leader in Solar Since its inception in 2009, Solar FlexRack has had one goal — a lower costper-watt for solar energy. Every new product we introduce, every refinement we make, continues to work toward that goal. When solar energy is costeffective, it will become mainstream. Solar energy is truly the one sustainable green energy alternative technology that has the most potential for freeing us from the environmental damage caused by carbon emissions, which even so-called clean gases create when burned.
Products That Make a Difference Solar FlexRack
888-380-8138 www.SolarFlexRack.com
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We entered the solar industry with a product that drastically reduced balance of system costs. While most PV mounting systems arrays required almost 30 minutes and a crew of five to install, our pre-assembled ground mount racks were installed in less than five minutes with a crew of just three. The labor savings made the difference for some substantial solar projects that were close to being shelved due to high installation costs. After Solar FlexRack was chosen, the projects were more cost-effective and moved forward. Soon after introducing our first model, we added roof and carport models — both of which featured labor savings via at least partial pre-assembly while still maintaining the robust characteristics needed to withstand wind and snow loads.
solarpowerworldonline. com/leadership Voting for this company will identify it as a leader in the solar power industry.
Solar FlexRack now offers the cost-effective FlexRack Utility Ground Mount, which is engineered for savings with optimal use of materials — and the amazing FlexRack Tracker that pumps up energy production.
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And the Winner is?
Solar Universe is a national organization built specifically to launch and grow
The solar industry is growing like never before and with growth comes consolidation. Big companies are getting bigger while independent installers compete for a smaller piece of the pie. The top 10 solar companies are increasingly dominant year after year.
local solar businesses. In an industry growing at remarkable rates every year it
The winners are finding ways to scale their business with more efficient sales and marketing techniques that allow them to get in front of customers faster and get them off the market. Being on the right side of this equation is crucial to being able to keep up in the solar industry. Solar Universe continues to be a leader in the solar space and among the top 10 solar installers by insuring itsâ&#x20AC;&#x2122; network has the right tools to thrive.
is imperative to have the right tools and the right people to succeed. To do this we provide our network lead volume through our national call center, battle-proven software systems to increase efficiencies, top-notch financing products (SunRun), and customized sales technology to improve close rates that give our network an edge in a growing and competitive solar marketplace. From our start in 2008,
The Winners Have Speed, Scale, and Purchasing Power
our tools have helped our installers delight
Over the last year the industry has become less about creating demand for solar and more about capturing the demand for solar. Customers are becoming more educated and are starting to seek out solar companies directly. To be a leader in that type of environment you will have to have tools and systems that allow you to get to the customers first and get them off the market.
thousands of customers. Currently, our network is in 11 states and we are actively selecting new professional solar businesses to join the network across the US.
Solar Universe has established itself as a leader in the solar space by providing its network with the tools, leads, financing, and sales support to thrive in their local marketplace. Just a few of the benefits available to our network include: Industry-Leading Financing Our network gets access to SunRun financing as well as other strong and competitive financing options that accept a FICO as low as 620. More Leads. Less Legwork. Leads driven by targeted ad buys, our national call center (open 7 days a week) qualifies customers and sets up close ready appointments with the decision makers.
Corporate Headquarters 1152 Stealth Street Livermore, CA 94552
Strength in Numbers
Phone: +1 925 455 4700
Shared best practices from our national network and one-on-one guidance from a dedicated Solar Universe Advocate Team help our network stay ahead of the curve.
Email: sales@solaruniverse.com
Solar Universe is currently seeking solar companies across the US to join the network. If you are interested in finding out more about Solar Universe visit us at www.SolarUniverse.com/grow or give us a call at (925) 455-4700
www.SolarUniverse.com
*Installation data from California Solar Initiative as of December 2012
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solarpowerworldonline.com/leadership Voting for this company will identify it as a leader in the solar power industry.
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www.solarpowerworldonline.com
2/21/13 2:36 PM
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Solar World NC-Corp is an Eastern North Carolina Solar provider of residential and commercial solar solutions. Incorporating value, respect, integrity, pride and professionalism into every project. Established in 2008 as a solar installation company. Solar World NC-Corp’s operates in Wilmington, North Carolina in the United States. For more information, please visit our website at www.solarworldnc.com.
Solar World; a Solar Panel Installer Serving Eastern North Carolina Solar World NC-Corp offers full service residential and commercial installation of photovoltaic solar panels, water heating and solar pool heating. Mission: to help millions of homeowners and businesses adopt solar power, protect themselves from rising electricity costs and protect their environment from polluting power sources. Solar World NC also educate solar customers about the market and the huge potential for natural resource and climate protection. Solar World NC-Corp
11 N. 23rd St. Wilmington, NC 28405 910-200-2623 stacy@solarworldnc.com
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Solar World NC-Corp has extensive experience with designing and installing unique solar systems for both residential and commercial projects. Our team of installers understand your requirement for consistency high returns, and they understand and work with customers to provide requisite knowledge through all stages of a project. We were also ranked #71 in the nation as solar p.v. installers by www.solarpowerworldmagazine.com. Like the sun, a properly installed solar panel is a constant source of power. Finding a team of experts to which you can entrust your investment is vital. By listening to the issues and concerns of our customers, Solar World understands that efficiency and a future-oriented energy supply are drivers of your financial and sustainable success.
Voting for this company will identify it as a leader in the solar power industry. www.solarpowerworldonline.com
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2013
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Spire is a leading global manufacturer of photovoltaic (PV) cell and module production, testing and metrology equipment. The Company’s technologically advanced products provide customers with exceptional performance and the lowest total cost of ownership. Embedded in Spire’s equipment and turn-key lines are process recipes that allow customers to achieve the highest levels of factory efficiency, yield, and output. Spire’s flagship product, the Spi-Sun Simulator, has become the industry standard in module performance testing. It is now used by more than 30 standards testing laboratories worldwide and is a staple in mass production lines around the globe. Spire’s turn-key module lines are offered in manual, semi-automated, and fully automated configurations, and can be used to make both silicon and thin film modules in high volume production. The quality and consistency of Spire’s products and services have resulted in awards and widespread brand recognition for the company throughout the international PV community.
Spire One Patriots Park Bedford, MA 01730-2396 (USA) Phone Toll Free:877-91-SPIRE Phone: 781-275-600 info@spirecorp.com www.spirecorp.com
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e n e r g y ] Spire Corporation is a leading global manufacturer of
photovoltaic (PV) cell and module production, testing and metrology equipment. The Company’s technologically advanced products provide customers with exceptional performance and the lowest total manufacturing equipment cost of ownership. Embedded in Spire’s equipment and turn-key lines are process recipes and design features based on decades of experience that allow customers to achieve the highest levels of factory efficiency, yield, and output. Spire’s flagship product, the Spi-Sun Simulator, has become the industry standard in module performance testing. It is now used by more than 30 standards testing laboratories worldwide and is a staple in mass production lines around the globe. The Company recently introduced the new Spi-Sun Simulator 5600SLP “Blue”, the most advanced module simulator available today offering a Class A+ spectrum from 300nm -1100nm, including an option to 1300nm delivering best in class module power measurement accuracy and repeatability (</= 0.15%) . Additionally the system offers Class A + (twice as good as Class A) spatial uniformity and temporal stability. It is easily integrated into certification, calibration, R&D lab environments or fully-automated module production lines. Spire’s turn-key module lines are offered in manual, semi-automated, and fully automated configurations, and can be used to make both silicon and thin film modules in high volume production. The quality and consistency of Spire’s products and services have resulted in awards and widespread brand recognition for the company throughout the international PV community. The Company’s equipment is used by over 300 companies in 50 countries worldwide. Spire was a pioneer in the PV industry. Since 1969, The Company has developed, manufactured and marketed highly engineered products and services for a wide range of commercial markets including PV manufacturing equipment and optoelectronic components. Spire’s involvement in the solar industry began with development of spacebased solar cells. Focus shifted to terrestrial photovoltaic applications soon afterward, and the Company quickly built a leading position as a worldwide supplier of solar cell and module manufacturing equipment with embedded, advanced processes. After nearly 40 years in the industry, Spire has developed very strong worldwide brand recognition and now offers a comprehensive portfolio of PV manufacturing equipment. Spire continues to focus on value through technology innovation, leveraging the industry’s best technical expertise, lowest cost of ownership, and worldwide support services. Spire Solar Systems, a division of Spire Corporation, designs, installs, and maintains large-scale PV systems for situations as diverse as big-box retail chains, manufacturing plants, farms, universities—even a 19th century mill. Spire’s mission is simple: to ensure clients achieve optimal results from their investment in both cost savings and energy production. Their in-house team of engineers, project managers, and financial experts has worked in the solar industry for decades, and has garnered a level of expertise only made possible by this experience. Spire Solar Systems continues to build its reputation on effectively delivering optimallydesigned solar energy systems for clients that often involve navigating a myriad of challenges. The team works closely with all stakeholders through every aspect of projects to overcome technical, financial, regulatory, and other hurdles. www.solarpowerworldonline.com
2/21/13 2:54 PM
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Trim-Lok Inc. is well recognized and respected
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Trim-Lok, Inc. manufactures custom
as a leader in the manufacture of top quality
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trims and seals, Trim-Lok provides high quality,
20 different industries (RV, automotive
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Nitrile PVC, dense Neoprene, rigid and flexible PVC, ABS, PP, PE, TPO, TPE, TPV and TPR. Our extrusion lines provide the flexibility to run single material extrusion as well as multi-material extrusion (co-extrusion). Trim-Lok was founded in the late 1960’s starting with an innovative coextruded trim piece used on motorcycle helmets. Using a proprietary process to slit, stamp and coin steel and/or aluminum, these strips get coextruded with flexible PVC and roll
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in the RV industry. Our mission states, “To be the leader and trusted supplier of choice for innovative Trim and Seal solutions”. Trim-Lok goes above and beyond the normal supplier service requests. We like to deliver a full service “solution” to our customers. That means performing the following: onsite customer reviews of the problem, engineering design & development using the latest in 3D CAD software and FEA, reverse engineering as required, utilizing state of the art rapid prototyping techniques,
Trim-Lok 1-888-Trim-Lok (874-6565) www.trimlok.com
internal lab testing of the desired specifications, specific selection of materials to match the customers’ requirements, onsite fit trials of first articles, and more! Trim-Lok provides a personal hands-on approach to every customer. That is why our custom business growth has been in the double digits over the last few years.
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Shine a Light on Solar Efficiency: Innovative engineering has enabled WAGO to strengthen every link of the Solar Chain.
WAGO Corporation provides North
Protect it: The 811 Series Lever-Actuated Fuse Holders provide PV combiner boxes with a new approach to supplemental protection up to 1000 V DC. Lever actuation replaces traditional screw-based terminations with an industry-first application of CAGE CLAMP® Spring Pressure. Maintenance-free and vibration-proof, these liftand-lock terminations reduce wiring time up to 50% — no torque specs or specialty tools.
America with innovative Interconnect, Electronic Interface, Terminal Block and Automation solutions. Headquartered in Germantown, WI, WAGO features stateof-the-art manufacturing and 75,000
Touch-safe, the DIN-rail mount Midget-Style Fuse Holder achieves 100 kA SCCR (30 A, 750 V AC/1,000V DC) for supplemental protection.
sq. ft. of storage capacity for 36,000 product locations. Extensive engineering
Connect it: The 2716 Series high-current PCB terminal block provides tool-free, lever-actuated termination of conductors 16–6 AWG. Ideal for field-wired devices such as solar inverters, simply: Lift the lever; insert stripped conductor; and lower lever. Elegantly efficient, the lever minimizes operator strain and eliminates screws and requisite specialty tools/ torque specs.
resources, a 25,000+ product portfolio, custom-manufacturing and 150 dedicated professionals ensure WAGO has the resources and expertise to help you get
Available in 2- to 8-pole configurations, several clamping units can remain open simul-taneously for connecting multi-conductor cables. Maintenance-free CAGE CLAMP® Spring Pressure terminations resist vibrations. Ratings: up to 600V/65A (UL) and 1000V/76A (IEC).
the job done.
Track it: WAGO-I/O-SYSTEM’s Solar Positioning Function and Tracking Function Blocks costeffectively optimize PV efficiency and reliability. • Solar Positioning Function Block — Boosts concentrated solar arrangement efficacy by enabling dynamic solar mirrors to follow the sun’s arc within +0.02o via WAGO-I/O-SYSTEM. The Function Block pairs solar variables with a WAGO Controller’s internal clock to optimize mirror position via motion components. • Solar Tracking Function Block — Can increase PV energy production by up to 30% vs.fixed panels. Via WAGO-I/O-SYSTEM, it aligns PV panels with the sun, while providing Atomic Clock accuracy, servo motor control and Bluetooth® wireless data exchange. • Aboard the World’s Largest Solar Boat — 758 Series I/O-IPCs are managing solar energy for the Tûranor PlanetSolar catamaran. The I/O-IPC controls charging for three batteries and 10 Drivetek Maximum Power Pick Trackers (MPPT) via 13 CAN buscouplers. These high-end DC/DC converters improve solar absorption for the fixed deck-mounted PV panels and are safety-critical. Tûranor has no gasoline backups for steering/propulsion.
WAGO Corporation N120 W19129 Freistadt Road Germantown, WI 53022 1-800-DIN-Rail www.wago.us
Measure it: The DIN-rail 789 Series Feedthrough Current Sensors optimize PV energy production by continuously measuring DC currents. Networked via MODBUS serial connection, the 789-620 (0–80A DC) and 789-621 (0–140A DC) Sensors transmit data with an accuracy of 0.5% (full scale value). This helps operators quickly identify defective/damaged PV modules, bolstering performance and reliability.
info.us@wago.com
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The feedthrough configuration simplifies commissioning by eliminating conductor termination. Up to 32 Sensors can reside on one MODBUS segment for connection to the WAGO-I/OSYSTEM, or virtually any PLC-/PC-based system, as a MODBUS Slave. The Current Sensors are addressable via on-unit DIP switch and have an operating temperature of -20°C to +70°C.
solarpowerworldonline.com/leadership Voting for this company will identify it as a leader in the solar power industry.
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[D EV ELOPMENTS ]
Solar Powers EVs at the San Diego Zoo
Photos Courtesy of SDG&E and Ken Bohn, San Diego Zoo Global
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K at h ie Z ip p /A s s oc iat e E d it or
Photovoltaic (PV) solar panels are now powering 10 solar canopies to charge electric vehicles (EVs) at the San Diego Zoo. The solar-to-EV project is among the first of its kind. Kyocera (www. kyocerasolar.com) solar panels charge EVs in the zoo’s parking lot and provide power to the electrical grid. Contractor Independent Energy Solutions designed and installed the solar canopies, which produce a total of 90 kW. The solar panels provide power to five EV charging stations, including one in a nearby ADA-accessible parking space. The solar canopies also provide shade to approximately 50 cars in the zoo’s southeast parking area. Also, a 100-kW battery system uses lithium-polymer technology to store solar power, offsetting demand on the electrical grid and recharging EVs even when the sun is not out. When the battery is full, excess energy is fed into the grid to improve power reliability for the surrounding community.
The solar-to-EV project is run by San Diego Gas & Electric (SDG&E) and is a part of the zoo’s commitment to environmental sustainability. SDG&E also partnered with Smart City San Diego, collaboration between the utility and local companies, government and universities to drive projects that improve the region’s energy independence, reduce greenhouse gas emissions and showcase San Diego as a clean energy leader. “This collaborative project combines two major sustainability initiatives – solar energy and electric vehicles – showcasing to millions of visitors that the future of energy is in San Diego today,” says Jim Waring, executive chair of CleanTECH San Diego and Smart City San Diego partner. “Kyocera’s commitment to quality and local manufacturing is important to Smart City San Diego’s mission, as well.” All Kyocera solar panels used in this project were manufactured at the company’s San Diego facility. SPW
www.solarpowerworldonline.com
2/20/13 11:20 PM
Largest Solar Array in Northeastern Wisconsin KI, a furniture manufacturer in Green Bay, Wis., now possesses the largest solar array in that part of the state. The 115-kW system, comprised of 480 PV solar panels and spanning about 22,820 square feet, is expected to produce about 152,640 kWh of clean energy annually while displacing 108 metric tons carbon dioxide emissions. “This PV system will help KI reduce its energy use and carbon footprint, while educating visitors, employees and our customers about the benefits and importance of renewable energy,” says Dick Resch, chief executive officer at KI. The system, installed by electrical contractor Electric Corp., is the largest solar project in the Wisconsin Public Service territory. The local utility serves 24 Wisconsin counties and adjacent upper Michigan peninsula, about 441,000 electric customers in all. The system uses SolarDock (www. solardock.com) mounting systems. The mounts are high-performance, lightweight and install without penetrating the roof, which eliminates leaks. The flexible, modular structure also facilitates expansion and transfer of solar installations, while a UL and TUV Rheinland-approved integrated grounding method saves time and material. The system was funded in part by a Focus on Energy grant. Additional funding was made available for the project from a WPS Bonus Bid Program grant awarded to Eland Electric to promote renewable energy. SPW
Discuss This and other Solar issues at www.engineeringexchange.com
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[D EV ELOPMENTS ]
Solar Modules Matter To Low-Income Families
The year began bright for five lucky San Diego County families. As a result of the 2012 Solar Holiday Drive, led by Sullivan Solar Power, (www. sullivansolarpower.com) a handful of lowincome families received free solar panels for their homes. Just before Thanksgiving, Sullivan Solar Power announced a partnership with a California nonprofit organization, GRID Alternatives, to bring solar power to lowincome homes. Through its Solar Affordable Housing Program, GRID Alternatives installs solar in communities that may not otherwise have access. The organization mobilizes job trainees and other volunteers, providing
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hands-on experience installing solar panel systems. As part of the partnership, Sullivan Solar Power team members will be
46 locally manufactured Kyocera solar panels will go to low-income residences at no cost to San Diego homeowners as
volunteering their time to assist the GRID Alternatives team with the donated projects. “GRID Alternatives is thrilled to have partnered with Sullivan Solar this holiday season to bring the gift of clean green power to families who really need the savings,” says Paul Cleary, regional director of GRID Alternatives. For every San Diego county resident that signed up to go solar with Sullivan Solar Power between Nov. 21 and Dec. 31, the company donated one solar panel to GRID Alternatives. Collectively,
a result of Sullivan Solar Power’s solar holiday drive and its donations to GRID Alternatives. “The initiative ended more successfully than we had envisioned,” says Daniel Sullivan, the founder and president of Sullivan Solar Power. “We are blessed and grateful to be in a position to provide the gift of solar energy to families who need financial relief from high electricity costs most.” SPW
www.solarpowerworldonline.com
2/20/13 11:23 PM
[D EV ELOPMENTS ]
Solar Modules Matter To Low-Income Families
The year began bright for five lucky San Diego County families. As a result of the 2012 Solar Holiday Drive, led by Sullivan Solar Power, (www. sullivansolarpower.com) a handful of lowincome families received free solar panels for their homes. Just before Thanksgiving, Sullivan Solar Power announced a partnership with a California nonprofit organization, GRID Alternatives, to bring solar power to lowincome homes. Through its Solar Affordable Housing Program, GRID Alternatives installs solar in communities that may not otherwise have access. The organization mobilizes job trainees and other volunteers, providing
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hands-on experience installing solar panel systems. As part of the partnership, Sullivan Solar Power team members will be
46 locally manufactured Kyocera solar panels will go to low-income residences at no cost to San Diego homeowners as
volunteering their time to assist the GRID Alternatives team with the donated projects. “GRID Alternatives is thrilled to have partnered with Sullivan Solar this holiday season to bring the gift of clean green power to families who really need the savings,” says Paul Cleary, regional director of GRID Alternatives. For every San Diego county resident that signed up to go solar with Sullivan Solar Power between Nov. 21 and Dec. 31, the company donated one solar panel to GRID Alternatives. Collectively,
a result of Sullivan Solar Power’s solar holiday drive and its donations to GRID Alternatives. “The initiative ended more successfully than we had envisioned,” says Daniel Sullivan, the founder and president of Sullivan Solar Power. “We are blessed and grateful to be in a position to provide the gift of solar energy to families who need financial relief from high electricity costs most.” SPW
www.solarpowerworldonline.com
2/20/13 11:23 PM
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[PRODUCTS ]
A 30-Year Guarantee MAGE Solar has released a 72-cell, 285-W polycrystalline module. The company says the module mirrors the performance of other panels in the Powertec Plus family, but its larger footprint reduces labor time and installation costs. The module also has a zero to 5+ watts tolerance for maximum power generation, meaning it performs at least at nameplate value. MAGE guarantees the product for 10 years, then 90% for 12 years and 80% for 30 years.
MAGE Solar www.magesolar.com
Design Software For Mobile Devices SMA has launched a free Web version of its Sunny Design software. Sunny Design Web offers the same features as the desktop version as well as enhancements. The program is for Mac, iPad and tablet users, as well as PC users. Desktop users of Sunny Design 2.0 can import projects into the mobile software, and the workflow will be similar. Sunny Design Web can estimate the potential rate of consumption, investment costs and effect of parameters on energy consumption.
SMA SunnyDesignWeb.com
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[ PR O D U C T S ]
Fittings Make For Fast Installation The Kindorf hold-down clamps and grounding washer from Thomas & Betts enable fast and easy panel installation. The clamps, available in “T” and “L” configurations, feature hardware pre-assembled on the clamp, and a selforiented channel nut that is staked to the bolt. The clamp body and channel nut are made from high-strength, extruded aluminum alloy 6061-T6 with a clear, anodized finish. The grounding washer features slotting that eliminates the need to disassemble the clamp assembly for installation. The bolt, lock washer and flat washer are made from Type 304 stainless steel.
Thomas & Betts www.tnb.com
Monitoring App For iPhone Ingeteam’s iPhone app provides access to all the production information of a PV plant. The app has been developed with a new version of the monitoring software Ingecon Web Monitor, a web portal for PV plant access. This software also contains all the Ingecon data sheets on Ingeteam’s inverters and solutions. The app is available on the App Store in five different languages (English, Spanish, German, French and Italian). All the energy generation data is available in list and graphic format, as well as by e-mail.
Ingeteam www.ingeteam.com
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[PRODUCTS ]
A Lighter System The Rayport-G offers high adjustability, providing installation forgiveness and tolerance adherence at a light weight. Integrated grounding, pre-cut and pre-drilled beams, and pre-assembled components expedite the installation. Galvanized throughout for corrosion resistance and constructed of customengineered profiles, the new system has passed analytical and physical testing.
AET aetenergy.com
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innovation, technical developments and resources however you choose to engage with us. It’s up to you! Technology • Development • Installation
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[PRODUCTS ]
Solar-Powered Lighting Firestone SunWave SMRT (Solar Motion Response Technology) Daylighting uses solar-powered GPS technology and mirrors to track the sunâ&#x20AC;&#x2122;s movement and bring high levels of diffused natural light into buildings. The system allows businesses and schools to reduce their energy use for lighting by up to 80%. Air conditioning costs are also reduced, due to the lower demand needed to offset the heat generated by electric light fixtures. The system blocks harmful UV rays while providing light equivalent to an 800-watt metal-halide bulb.
Firestone www.firestonebpco.com
Ballasted System In Fewer Pieces Available in 5- and 10-degree tilt angles, the PowerFab CRS-G2 mounting system features 50% fewer components than the previous generation. A fully ballasted, non-penetrating system that is wind-tunnel tested, the CRS-G2 accepts standard concrete blocks. Additionally, the new CRS-G2 system features a modular design that simplifies roof layouts and allows for on-site modifications. The racking assembles with one tool and permits field adjustments for roof contour changes. The integrated grounding solution meets the UL 467 standard.
DPW Solar dpwsolar.com
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[ AD ABB ................................................. 24
PV America ................................... 69
Advanced Energy ........................ 50
RBI Solar ........................................ 33
Aurora Bearing Company .......... 19
REFUsol ......................................... IFC
CreoTecc ....................................... 4
SolarDock ..................................... 31
CS Hyde ......................................... 11
Solar FlexRack .............................. 15
DPW Solar ..................................... 22
Solar Universe, Inc....................... 13
EDF ................................................. 40
Solar World NC Corp. ................. 25
FESTO ............................................ 9
Spire ............................................... 2
Haticon Solar ................................ 45
TEAL Electonics Corporation ... 73
Ilsco Solar ..................................... 37
Trim-Lok Inc. ................................ 7
Lufft USA ....................................... 45
Wago ............................................. IBC
Moxa, Inc. .................................... BC
Zilla ................................................. 37
I N D E X ]
Nordic Fiberglass, Inc. ................ 28
[ 2 0 1 3
L eade r s h i p ]
Aurora Bearing Company .......... 52
December 2012 www.solarpowerworldonline.com
DPW Solar ..................................... 53 Technology • Development • Installation
FESTO ............................................ 54
INSIDE:
Haticon Solar ................................ 55
>> DEVELOPMENTS: A Burst Of Color PAGE 6
Lufft USA ....................................... 56
>> BUSINESS ISSUES: Solar Should Get FIT PAGE 44
Top
100
Moxa, Inc. .................................... 57 Solar Contractors
March 2013 www.solarpowerw
orldonline.com
Panel Claw .................................... 59
Technology • Deve lopment • Insta llation
RBI Solar ........................................ 60
PAGE 25
INSIDE: >> Business Issues : Higher Standards Reduce Risk PagE 26
REFUsol ......................................... 61 SolarDock ..................................... 62
>> Engineering Developments: Peel and Stick Solar Panels PagE 34 >> Inverter Insider: Designing Backup Systems PagE 42
Nordic Fiberglass, Inc. ................ 58
Solar FlexRack .............................. 63
Wasted Land No Longer
Moving ground requ
ires adaptive rack
ing
PagE 16
Solar Universe, Inc....................... 64 Solar World NC Corp. ................. 65 Spire ............................................... 66 Trim-Lok Inc. ................................ 67 Wago .............................................. 68
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[CONTRACTORS C O R N E R ]
PPC Solar, Taos, N.M. For more than 30 years, Dan Weinman,
Dan Weinman
President of PPC Solar
president of PPC Solar (one of Solar Power World’s Top 100 Solar Contractors), of Taos, N.M., has watched the solar industry grow and prosper. Weinman started at age seven by helping his father ,who founded the company. The company’s goal was to provide electricity to those who lived far away from easy access to traditional power lines. “When we got our first system, we were still burning kerosene lamps,” Weinman says. “It brought a lot of convenience to our lives. So I grew up with solar and living off the grid.” New Mexico is not a densely populated state (at the time of the 2010 census, New Mexico had 17 people per square mile; the entire United States, in contrast, has 87 people per square mile), so it’s not hard to find people living far away from electrical transmission lines. Weinman says the company’s philosophy is based around three central principles: • Protect the environment not only through solar installations but also through other sustainable business practices; • Being a part of and providing help for the community; and • Being solutions oriented.
PPC Solar Vital Statistics:
“There’s definitely a sustainable community out here in New Mexico,” Weinman says. “We have a lot of artists and others in our area who don’t want to be in the middle of society. We help them live comfortably off the grid.” PPC Solar serves northern New Mexico and southern Colorado (approximately five hours away) and has 10 employees. The company focused almost entirely on residential until 13 years ago, when Weinman saw a shift in the market. Weinman says his company has installed nearly three-quarters of all solar installations in Taos County (population: 33,000). “When grid-tie inverters became available, we saw a significant shift in the business and opened up the market for us to move into other segments,” Weinman says. “We used to be 100% residential, but now we’re 75% commercial and 25% residential.” What Weinman enjoys most about the industry is how it continuously feeds his love of technology. “I’ve watched this industry grow exponentially since my father started the business, and that growth has been driven in large part by technology,” Weinman says. “I love technology, so this has been a great industry for me.” SPW For the full interview with Dan Weinman of PPC Solar, go to www.solarpowerworldonline.come and search Contractors Corner to hear the podcast.
Employees:.....................10 MW Installed (2011).....2.37 MW Installed Overall....4.6 Founded:..........................1979 Website: www.ppcsolar.com
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Industrial Wireless
Industrial Ethernet
Serial Connectivity and Networking
Embedded Computing
Smart Solar Ideas from Moxa
The IA3341 Series RISC-based Industrial Embedded Computer Moxa ART 32-bit ARM 9 Industrial Processor 4 DIs and 4 DOs with 3 KV digital isolation protection 2 AIs and 2 thermocouple inputs; sensor types J, K, T, E, R, S, B, N 2 software selectable RS-232/422/485 serial ports 50 bps to 921.6 Kbps serial speed, supporting non-standard baudrates Dual 10/100 Mbps Ethernet ports for network redundancy SD socket for storage expansion
Rcore Software Platform Moxaâ&#x20AC;&#x2122;s Rcore ready-to-run platform makes it easy for programmers to develop embedded software. Rcore includes easy-to-use application libraries, tested bug-free sample code, and requires less time for the concept validation and development cycle enabling a faster time-to-market that meets or exceeds customer requirements. The Rcore Community also offers our partners easy access to software and technical knowledge about embedded systems, along with an interactive forum to share knowledge with embedded computing professionals. Visit http://rcorecommunity.moxa.com/ for details.
Supports Modbus TCP library to retrieve AI and thermocouple data
Use your Smart Phone to scan for more information.
Moxa, Inc.
Tel: 1-888-669-2872 Fax: 1-714-528-6778 usa@moxa.com www.moxa.com
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