Solar Power World - FEBRUARY 2012

February 2012 www.solarpowerworldonline.com

Technology • Development • Installation

INSIDE: >> DEVELOPMENTS PAGE 6

>> MANUFACTURING PROCESSES PAGE 22

>> TECHNOLOGY DEVELOPERS PAGE 42

A Guide to Successful

CSP PAGE 34

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Big wave surfer.

SolarWorld Authorized Installer.

Work-life balance achieved.

Kohl Christensen, Oahu, Hawaii “I have been traveling to remote locations on surf trips for years and now, after becoming a solar contractor and teaming up with SolarWorld, it feels really good to be able to travel back to these spots and share some of my knowledge... I am glad I can help.”

Partnering with America’s largest solar panel manufacturer allows Kohl to chase big waves and spread his passion for solar. Find out how becoming a SolarWorld Authorized Installer can help you achieve a work-life balance at

SolarWorld.com.

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Editorial Advisory Board

THE

FI RS T

WO RD

Let’s Not Fight Amongst Ourselves

Natalie Wiener Solectria Renewables Jose Gomez Ingeteam Raheleh Folkerts Renewable Energy Systems Americas Steve Hogan Spire Gary Mull Westinghouse Solar 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

(Editor’s note: In the interests of full disclosure, SolarWorld Americas sits on Solar Power World’s editorial advisory board.)

F

or those of you who follow my blog (and if you don’t, shame on you), you already know that the debate over the Coalition for American Solar Manufacturing’s (CASM) trade complaint against Chinese panel manufacturers fascinates me .

Not a day went by during the past five months where I didn’t receive a press release from people weighing in on the conflict. It was usually from one of the two heavyweights in the fight — the Coalition for Affordable Solar Energy (CASE), which opposes the action, and CASM, led by SolarWorld Americas, which filed the complaint last October. The volleys often arrived on successive days, as one organization responded to a press release put out by the other the day before.

I worry that public spats like these weaken the industry overall. I wish we could handle this internal industry dispute behind closed doors instead of taking potshots at each other through the media. No matter how this turns out, I worry that the trust between these the U.S. manufacturers and installers might be irreparably harmed.

I heard Shayle Kann from GTM Research say he expects tariffs to be imposed on Chinese imports, possibly by the end of March, that will range anywhere from 10% to more than 100% as a result of the CASM trade complaint.

He added that the Chinese producers would not stand by and let that happen without consequences. China could impose tariffs on silicon imports from the United States or move their production plants to other Southeast Asian countries to avoid the tariffs (in some cases, this is already happening). So Kann doesn’t see any huge spike in PV module prices as a result of the tariffs — and therein lies the crux of the matter for me.

CASE’s main argument against the trade complaint is that the loss of inexpensive Chinese solar panels will slow the growth of U.S. installations, thereby hurting the downstream members of the supply chain: installers. They argue that it’s OK if U.S manufacturers who can’t compete with the Chinese module makers go out of business.

But I don’t agree, especially if Kann’s supposition is true that the tariffs will have no significant impact on module prices. I believe that the United States can’t cede the actual manufacturing jobs — real, tangible, good-paying jobs — to everyone else in the world.

China joined the World Trade Organization in 2000 (with U.S. support, I might add), under which they agreed to play by the rules. That’s why I support U.S. government’s efforts to require the Chinese to adhere to the World Trade Organization’s rules and regulations when it comes to fair competition.

(For a deeper examination of the pros and cons of the trade complaint so that you can make up your own mind, please see pages 26-33.)

Frank Andorka Editorial Director fandorka@wtwhmedia.com

www.solarpowerworldonline.com

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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

contents

18 D e pa r t m e n t s 01 The First Word 05 Policy 06 Developments 11 Breakthroughs 14 Inverter Insider 16 Project Review

The trade case brought against Chinese solar manufacturers could undermine the solar industry’s significant progress at the moment it is poised for success.

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Ad Index

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30 Let’s Hold China Accountable 34 A Guide To Successful CSP

About the Cover:

38 Keep Your PV System Well Grounded

provided by eSolar

This month’s cover photo was

Here are the basics you must know to keep yourself and others safe while putting in a solar installation.

of Burbank, Calif.

The photo shows its Sierra SunTower concentrating solar

42 Solar Goes To College

California school produces a 1 MW CPV plant — and uses it to launch a solar training program for its students.

power (CSP) plant

Table of Contents 2-12 Solar_Vs4.indd 3

2

Renusol came to the United States to sell product. It stayed because of the skills and work ethic of U.S. workers.

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22 Made in the USA

26 The Solar Industry Benefits from the U.S. & China Competition

63 Products Contractors Corner

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F e at u r e s

Racking and Mounting

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18 Training 19

Febr uar y

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in Lancaster, Calif.

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[POLICY]

Solar for Everyone?

Not yet — but we just might be headed in the right direction.

Discussions of state solar policy frequently revolve around the costs and benefits associated with particular approaches and few would dispute that an analysis of these broad considerations is an essential step in the formulation of any public policy.

However, gross costs and benefits are not the entire picture. The distribution of costs and benefits is an equally important consideration, and finding the proper balance is intensely challenging for policymakers.

“Solar for everyone” has a nice sound, but it is easier said than done.

To illustrate how the equity dilemma can play out in practice, let’s consider a hypothetical cash incentive program where funds are raised from electricity ratepayers.

The ratepayers pay a surcharge of some type (e.g., a societal benefits charge, an RPS rider, etc.) on their bills, which is then used to pay the incentive.

The presumption behind a blanket surcharge on all customers is that these same customers all stand to benefit from the resultant program in some way. However, the most tangible benefits accrue only to those who are able to participate in the program; for a variety of reasons, most customers are not able to do so.

Renters or lessees, for instance, are frequently not able to participate in solar incentive programs. Other customers who do own a residence or a building may not have an appropriate site for solar as a result of extensive shading, unfavorable roof orientation or restrictions on how structures may be modified (e.g., zoning rules, private covenants, and historic structure status). Still others may not be able to afford the cost of

a solar installation even with an incentive. Similar criticisms exist for other support mechanisms, including tax incentives and net metering, ultimately giving rise to the accusation that solar benefits only a select few at the expense of the larger populace.

There are, of course, counterarguments to this assertion, as well as policy solutions that can help rectify inequities where they do exist. For instance, one can argue that the environmental benefits of solar accrue to society as a whole rather than any individual, and that economic development and job creation benefit a diverse group of individuals and businesses. On the policy side, solar access laws, low-income programs, community solar programs, and laws that allow third-party ownership structures can make solar a viable option for those that would not have otherwise had the opportunity.

Unfortunately, though, in reality there is no such thing as a perfect distribution of benefits and costs, and the scenario described earlier barely scratches the surface of important policy questions.

For instance, should development be aligned with the location of ratepayer collections or focused on locations where benefits are the greatest (e.g., areas of grid congestion)? What is the proper balance of customer-sited vs. utility-scale generation? Should utilities be able to own solar assets on customer rooftops? If so, does this reduce customer-owned opportunities, and should non-utility solar service providers be extended this same opportunity?

The solar policy landscape is rife with such issues, and stakeholder consensus is hard to come by. On the other hand, the increasing diversity of the U.S. solar market suggests that a combination of policy evolution and private sector innovation is moving the industry towards more opportunities for more stakeholders. So solar for everyone? Not yet — but we just might be headed in the right direction. SPW

www.solarpowerworldonline.com

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Justin Barnes is a Senior Policy Analyst at the North Carolina Solar Center (NCSC), where he has worked on the Database of State Incentives for Renewables and Efficiency (DSIRE) since 2007. In addition to performing general updating and maintenance of DSIRE, Justin also manages D S I R E ’s q u a n t i t a t i v e RPS research and the N C S C ’s a c t i v i t i e s under the Solar America Communities Outreach (SACO) partnership.

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[DE VELOP MENT S

RESI D ENT I A L ] K at h ie Z ip p / As s i s tan t E di to r

A Convenient Way to Install Solar MyGen Kits from Kyocera Solar

Another Option for Small Solar

are comprehensive, convenient ways to install solar on a home or business. The preengineered systems include the modules, inverter, racking, monitoring, grounding, manual, drawings and minor components needed to complete a grid-tied solar energy installation.

Recently, the company has added the MyGenflex, which offers versatile installation, expansion and monitoring. The kit also includes Kyocera’s KD240-W modules and M215 microinverters from Enphase Energy.

The high-efficiency microinverters convert direct current produced by solar modules into alternating current from each individual module in an array. This allows adding to a solar energy system as needed. Furthermore, Enlighten software from Enphase monitors each microinverter and solar module in the system.

Performance information is available via the web, allowing owners and installers to track system performance.

MyGen Made in America kits qualify for participation in the ARRA Buy America Program, offering the benefits of U.S.-based manufacturing. SPW

Solar design company, PHAT Energy, based in Los Angeles, offers a line of American-made carports with highefficiency SunPower panels. The PHATport is a portable and expandable awning array option for homeowners and business interested in integrated solar.

The company says it begins by focusing on design and then making aesthetics equal to function and performance. The PHATport arrives on site as a complete kit and installs quickly.

The structure can also be outfitted with lights, electrical outlets, vehicle chargers, security cameras and audio speakers.

However, with concealed chases in the beams, there is not a wire to be seen. SPW Sunpower us.sunpowercorp.com/homes PHAT Energy www.phatenergy.com/phatport

Enphase Energy enphase.com Kyocera Solar www.kyocerasolar.com 6

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[D EVEL O PM ENT S

A Microinverter for AC Modules Solar modules that produce grid-compatible AC power have been a long-sought goal of the PV industry. Limitations of traditional systems with series-wired DC modules and failure-prone central inverters have held back performance and made rooftop solar impractical or unsuitable for up to 50% of sites.

However, SolarBridge says its AC module Pantheon microinverter makes sites with varied layouts or partial shading viable for solar. Sites with limited space or budget become practical as well with the flexibility of AC systems and a 25-year warranty. The device uses film capacitors instead of failure-prone components such as electrolytic capacitors, tantalum capacitors and optoisolators. By eliminating energy losses from variable shading, module mismatch, uneven soiling and costly DC wiring, AC modules with Pantheon microinverters produce up to 25%

Developments 2-12_Vs3.indd 7

more energy per site than alternative systems.

The system includes the SolarBridge PV-Dock, Power Manager and Power Portal. Yielding one of the lowest levelized cost of energy of any solar system, SolarBridge Pantheon microinverters enable manufacturers to overcome limitations of traditional DC modules.

Insight into module-level operating information is a powerful tool for maintaining high PVsystem performance. If shortfalls in output from equipment faults, installation errors or environmental factors go unnoticed, the energy production and resulting financial hit can be significant—especially with performance-based incentives.

The SolarBridge Management System closely tracks the operating performance of every SolarBridge Pantheon-enabled AC module. A Power Manager and Power Portal work together to provide installers and technicians information to quickly identify and resolve site issues.

The Power Manager is an onsite gateway that communicates with Pantheon-enabled AC modules over the site’s electrical wiring.

Its durable NEMA4X enclosure can mount outdoors next to modules load center, ensuring reliable

CO M M E R C IA L ]

data exchange with the modules and access to the Power Manager during installation and service.

The Power Manager can also communicate with the modules before connection to the grid.

This enables a site crew to identify and resolve potential installation issues before leaving a newly built system.

Connectivity options and user interface allow flexibility. The RJ45 jack provides builtin networking to a local broadband router.

Alternatively, an optional wireless kit uses the ZigBee protocol to connect the Power Manager to the router when running Ethernet cable is impractical. In addition, the Power Manager’s two-button hardware and LCD provide immediate access to diagnostics. A single-site version of the Power Portal is also available from the Power Manager’s embedded web server, providing graphical software for system commissioning and troubleshooting – even at sites with no internet access.

The Power Portal is a hosted software application that aggregates the operating data from the modules across all sites. System owners can view current and historical performance charts for their PV arrays.

Module manufacturers gain direct visibility into their installed base, allowing monitoring field performance of AC modules. Installers can effectively manage all of their customer systems through the Power Portal. Commissioning a new site is also easy with the application’s graphical interface for site layout and design. SPW SolarBridge Technologies solarbridgetech.com 2 • 2012

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[DE VELOP MENT S

UT I LI T Y]

Composite Enclosures Protect Components Enclosures for utility-power PV applications must withstand their environment. Such enclosures protect essential systems such as power management and power distribution, sensitive instrumentation such as combiner and battery boxes, and protect inverters and other components from corrosion and UV damage. Though material options for enclosures include

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metals and plastics, composites offer a few advantages over traditional options.

Thermoset materials, such as a polyester resin combined with glass, create a composite FRP (Fiberglass Reinforced Polyester) that is durable and weather resistant. FRP provides greater corrosion protection than painted carbon steel, yet performs better than metal and

www.solarpowerworldonline.com

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SOLAR ENERGY: These type of collectors utilize solar energy by heating a fluid flow that is then used to generate electricity. Heat is transferred by surface-to-surface radiation from the outside shell to the pipe walls. Shown is the heat flux vector and temperature on both surfaces.

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With COMSOL Multiphysics® you are empowered to build simulations that accurately replicate the important characteristics of your designs.

The key is the ability to include all physical effects that exist in the real world. This multiphysics approach delivers results—tangible results that save precious development time and spark innovation.

comsol.comcomsol.com /booklet /reactor

© 2012 COMSOL. COMSOL and COMSOL Multiphysics are registered trademarks of COMSOL AB. Capture the Concept is a trademark of COMSOL AB. Other product or brand names are trademarks or registered trademarks of their respective holders.

COMSOL 2-12 Solar.indd 9

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[DE VELOP MENT S

plastics in harsh environments.

Strength is a measure of a material’s ability to withstand stretching or compressing under load. Toughness indicates how much energy a material can absorb before rupture. Increasing strength, tensile or compression usually decreases toughness and vice versa.

Whereas steels often have high strength, they exhibit low toughness so they dent easily and are difficult to drill or penetrate.

Thermosets and thermoplastics, or composites, exhibit average strength but high toughness and so can withstand sudden impacts and maintain their shape.

Composites can now be designed for both high strength and toughness due to

UT I LI T Y]

additives and fiber reinforcements.

In spite of a higher initial cost than steel or aluminum, composites have negligible maintenance and minimal recurring cost requiring no replacement (due to deterioration in service).

Therefore, composites have a lower overall cost over the product’s life.

Composites are also not conductive, less likely to be affected by temperature because of material stability, lighter and easy to modify.

Furthermore, Stahlin non-metallic enclosures use a non-halogenated fiberglass known as SolarGuard. The company says this provides chemical and flame resistance, outperforming other

available SMC formulations by as much as 60%. SolarGuard also retains glass and color after exposure to concentrated UV light, and so helps reduce the effects of UV degradation such as surface roughening and fiber blooming.

Stahlin developed the original composite enclosures 50 years ago. The company offers a warranty on all their non-metallic enclosures, guaranteeing the product will be free of failure due to manufacturer defects for 10 years. SPW Stahlin www.stahlin.com

Protect & Monitor Solar PV Panels Series 789 current sensors continuously measure DC currents to optimize PV energy production. Networked via the MODBUS serial protocol, the sensors transmit data with an accuracy of 0.5% helping system operators quickly identify defective or damaged PV modules. t Up to 32 current sensors per MODBUS segment t Max. MODBUS cable length = 3,937 ft. t Network with virtually any PC or PLC based system t 2 modules measure up to 80A or 140A DC For more information on monitoring solar string or sub-array efficiency, visit us at www.wago.us/pv.htm or at Solar Power International – Booth #1316

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[ B REAKT HROU G H S ]

Putting the Spotlight on

Selenium Measurement Fr a n k A n d or ka /E d it or ia l D ire c t or

T

Colnatec’s Helios quartz crystal microbalance (QCM) measurement system addresses these selenium issues and also solves the “drift” problem of emission spectography.

he Copper-Indium-GalliumSelenium (CIGS) process is arguably the best recipe currently available for thin-film solar cells. Promising efficiencies on par with crystalline silicon and a cost to manufacture that is significantly less (notwithstanding the current commodity price of silicon wafers from China), CIGS research and production is continuing at an accelerated pace.

The production effort is split between the co-deposition process, where the four CIGS components are simultaneously vaporized onto the substrate in a vacuum system, and the CIG + Se “furnace process,” where a sputtered CIG layer is exposed to selenium vapor which is then driven into the film in a rapid thermal process step. Both methods have yielded cells with efficiencies of more than 20% in laboratory tests, and both have yielded cells of less than half that in production operations.

The discrepancy between the “Lab to Fab” numbers can be traced, in part, to the process control systems used in the cell manufacture. It’s one thing to carefully control a research level chamber using state of the art film thickness measurement tools, where Angstrom level accuracy and controlled conditions prevail. It’s quite another to monitor a continuous production line where the movement of substrates www.solarpowerworldonline.com

Breakthroughs 2-12 Vs3.indd 11

and materials wreaks havoc on even the most robust measurement scheme. And therein lies one of the barriers to success in the thin-film solar cell world: how to best process-control the production line.

A critical metric for CIGS films is the absolute thickness of the individual component or compound layers. The ratio of each material in the final product determines in large part the efficiency of the finished cell. Using vacuum or atmospheric pressure deposition, the mixing ratios of the elements can be determined by measuring the rate, in Angstroms or nanometers, per second. There are few instruments that can do this real time, however. One is an optical method called emission spectroscopy, while the other is mass based. The latter is referred to as a quartz crystal microbalance, or QCM for short.

Emission systems work well when calibrated properly but have the tendency to “drift’ or fall out of calibration over time.

The QCM, on the other hand, is extremely accurate but suffers from a limited life of the quartz crystal used in continuous production. Further, one of the components in CIGS, selenium, is a high vapor pressure material that can infiltrate the housing holding the crystal sensor, leading to shortcircuiting and ultimately failure. As a result, QCM’s have severe limitations in CIGS lines that must be addressed by work arounds.

Fortunately, a new generation QCM has been developed that addresses these selenium issues and also solves the “drift” 2 • 2012

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[ B R E A KT H RO U G H S ]

“A second generation Helios, capable of operation at 600°C is in early stages of development.

This will allow the first real-time problem of emission spectroscopy.

Called the Colnatec Helios, this advanced QCM features two ground breaking innovations:

Scott Grimshaw

measurement of the rapid thermal anneal used in the CIG+Se furnace process This is the most critical step in controlling the cell

Grimshaw, CTO at ColnaTec, has been involved in the development and manufacture of film thickness measurement systems since 1987, Grimshaw is currently developing a new class of quartz crystal microbalance (QCM) His mission at Colnatec is to build thickness sensors that will directly lead to increasing the efficiency of thin film solar cells.

Check out their website at colnatec.com.

1) a self-cleaning mechanism efficiency.” that allows the quartz sensor to be heated past the selenium evaporation temperature, causing the film to “re- evaporate” off the surface (effectively bringing the crystal to like-new” condition after it has reached its Helios offers the same Angstrom useful life); and level accuracy as traditional QCMs but without the limitations. Further, using an 2) a high temperature (300° C) advanced-regulation system employed in sealing mechanism that prevents the electronics which mates to the Helios, the selenium vapor from penetrating there is no variation in absolute calibration the housing used to hold the crystal. of the sensor.

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This surpasses the emission spectroscopic method in ultimate measurement accuracy and does so at a significantly reduced cost. The Helios system can also be calibrated to match thickness standards, meaning the “Lab to Fab” errors are significantly reduced. Helios can operate in vacuum, atmosphere or even overpressure systems.

A second generation Helios, capable of operation at 600°C is in early stages of development. This will allow the first real-time measurement of the rapid thermal anneal used in the CIG+Se furnace process. This is the most critical step in controlling the cell efficiency. A surplus or deficit of selenium driven into the CIG sputtered layer adversely affects the composition and correspondingly the phase of the CIGS film.

An additional application of this “Helios 2” unit will be the monitoring of the selenium source and effluent lines employed in a number of commercial systems. The current lack of an in-situ monitor in these chambers has lead to widespread waste of selenium as well as overly complex selenium removal or scrubbing systems to prevent release of Se into the environment. By reducing the selenium usage, benefits in reducing material cost and pollution containment will be instantly realized.

Currently in beta site testing, the Colnatec Helios is slated for sale in the third quarter of 2012. SPW

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2 • 2012

Breakthroughs 2-12 Vs3.indd 13

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[I N VE RTE R

INS I D ER]

RPS TL from Bonfiglioli

B

onfiglioli is one of the world’s leading suppliers of power conversion systems solutions within the renewable energy market. With over 1200MWac of solar PV installations currently in place, including Europe’s largest power plant at Rovigo, Italy (70 MWp) and the 51MWp plant in Puertollano, Spain, Bonfiglioli has proven it has the innovative know-how and technical capability to bring utility and large-scale PV power plants to life, including utility grid power management.

One product in Bonfiglioli’s renewable energy portfolio is the RPS TL, a uniquely-designed high-powered photovoltaic inverter system that provides maximum energy harvest. The scalable, modular design, already in extensive use in Europe, provides one of the widest ranges of inverter ratings in the market, which ensures an optimal matching with any size array.

Compared to other single, high power inverters, Bonfiglioli’s unique design, with multiple inverter modules, ensures maximum system reliability: a single fault will affect only one inverter module while the balance of the system continues to operate, which minimizes loss of energy production. Bonfiglioli RPS TL series inverters are available in either master-slave or multi-MPPT configurations.

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Technical Overview: • A wide range of inverter power ratings from 300 KWac to 1283 KWac • Modular inverter system with up to 7 MPPT inputs • Designed to UL and CSA standards (certification is pending) • Maximum efficiency of up to 98.4% • DC Load Break disconnect for each inverter module to provide isolation from the solar array • Includes main AC breaker to provide overall protection for inverter lineup • Floating, positive-grounded and negative-grounded arrays are possible Bonfiglioli’s solar inverter system is designed to reduce or eliminate the incidence of failures. Top-quality electro-mechanical components and faster, more secure, fault-free connections ensure maximum uptime, lower maintenance costs and overall higher performance and return on investment. SPW More information at BonfiglioliUSA.com/PVinsider

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Not to scale. Image is suggested serving only. Do not try this at home.

* kWh/kWP

Solar Frontier Americas Inc., 3945 Freedom Circle, Santa Clara, CA 95054Â USA Tel: +1 408 916 4150 www.solar-frontier.com

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[PROJ ECT

REVI EW ] K at h ie Z ip p /A s s is t a n t E d it or

Stimulating Schools With Solar in California

Solar installations are helping California schools fight budget cuts and rising energy rates.

U

tilities are often school districts’ second greatest expense after staff.

Between budget cuts and rising energy prices, many U.S. schools have found themselves struggling. California’s San Ramon Valley Unified School District (SRVUSD) near Oakland, Calif., found itself in such a situation and knew something had to be done.

After several months of studies and public meetings, the SRVUSD board of education opted to take advantage of a government bond program.

In May 2010, the district approved a solar project to generate ongoing savings that would enable paying back the loan as well as continued savings.

Installation of 3.3-MW of solar carports at five schools began about a year later. The system’s been in operation since last fall, generating more than 80% of the schools’ energy demand. The project is expected to save the district about $24.4 million over the next 25 years.

Challenges Construction, however, wasn’t so easy. School campuses with tight space, trees and among neighborhoods can be challenging sites for solar.

“Most of the district’s schools’ roofs were not oriented well for solar panels,” says Terry Koehne SRVUSD Community Relations Director. “The age of the roofs was also an issue because of concerns about penetrating to anchor the panels.”

The final five schools were selected because of their open parking lots, which allowed space for solar carports. Still, such limited space called

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JMC Steel Group’s Atlas Tube division was able to work through PDM Steel to provide 1,200 tons of large-size HSS squares and rectangles to for use in the steel columns of the solar carports. By leveraging its resources and relationships, JMC Steel delivered the order on time, despite a tight schedule.

–photo courtesy of SRVUSD

for high-capacity modules on a small area. With a module efficiency of 20%, SunPower Corp.’s E-Series solar panels seemed like the right choice. More than 10,000 panels in the system allow generating up to 50% more power than with conventional panels of only 12% to 15% efficiencies.

Parking lot structures also allow using automated panels, which rotate with the sun to maximize exposure. Hence, Bill Kelly, managing director at Sunpower, says the company used both fixed and tracking shade options.

“Four of the five schools have single-axis, elevated Sunpower T0 trackers, which track from east to west and generate about 25% more energy than fixed panels,” he says. “One school’s architecture was

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Five schools in the San Ramon School District have received solar carports, and one also has rooftop solar panels. These schools include: California High School, Dougherty Valley High School, Monte Vista High School, San Ramon Valley High School and Diablo Vista Middle School. –photo courtesy of Sunpower

especially constrained, so we added fixed rooftop panels as well.”

Kelly says another challenge was working within a tight time frame.

“Because things are usually so busy during the school year, we’re often confined to working during summer break,” he says.

Work began on the project in April 2011 and completed in September.

Kelly admits it was tough to get the work done, but the company has experience installing on schools and so has developed a process.

“We do preconstruction planning to make sure materials and labor are in place so we can stay on schedule,” he says. “Also, the schools in this district were particularly modernized, so updated electrical systems and other technology infrastructure made things easier.”

JMC Steel Group’s Atlas Tube division provided 1,200 tons of steel used in the solar carport supports. It also had to meet a tight deadline.

“We were asked to begin delivery within four weeks of receipt of the order,” says Jelani Rucker, director of marketing and business development at JMC Steel. “As one of the few sources for this sized product in North America, it was critical that we delivered, or the project completion date would have been in jeopardy.”

Rucker says the company was able to deliver on time because of its strong relationships with steel coil manufacturers and rail companies.

Funding The total project cost $23 million, but low-interest bonds enabled the district

to afford it. Such Qualified School Construction Bonds have been made available for a limited time as part of the federal 2009 American Recovery and Reinvetment Act. SRVUSD was approved to receive $25 million through the program and will pay the money back to a bank through the energy the systems generate — the government will pay back the interest to the bank.

“Also, the current Pacific Gas & Electric (PG&E) rebates for solar energy are generous, and the price of solar panels is relatively low because of the economy,” Koehne says.

“Installation costs have also been falling because of the economy, so we felt this was an opportune time to take advantage of the program.”

Benefits After about 16 years, the bonds will be paid off and the district will begin realizing an estimated $3 to $5 million per year in energy savings to its General Fund Budget. But the project benefits aren’t all financial. The board also realized the importance of the district modeling environmental stewardship and energy conservation, so it chose a project that will offset 76.3 million lbs of CO2 emissions over 25 years. The project also helped create local jobs, not to mention that the teachers and students are enjoying

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the shaded parking and better lighting at night.

“SunPower has also started an internship and renewable energy education program, and our students, in turn, have become ambassadors for the solar initiative,” Koehne says.

SunPower uses the systems as educational tools to help students understand solar power. Also, its Solar Academy internship provides opportunities for 16 high school students in the district.

“So far, community response to our solar initiative has been positive,” Koehne says. “People are supportive of the district saving millions in energy costs, particularly in these tough economic times. The district is looking into the possibility of combining the remaining unused funds to provide solar at one additional school.

Many districts in California are turning to solar energy.

“Sunpower plans to installed solar at 90 schools in California,” Kelly says.

“Its really rewarding that technology we’ve developed here in California is being used by schools here to save money and get students excited about renewable career opportunities.” SPW

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[TRAINING]

Solar training important as ever for

a renewable energy-fueled future

April Clark is a writer and marketing communications coordinator for nonprofit renewable energy educator Solar Energy International, based in Carbondale, Colo.

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In any profession, training is as necessary as a formal business plan or a good coffeemaker in the employee lounge. All three improve productivity and help the business focus on getting the job done right.

They can also give employees a boost.

Training for a career in the renewable energy industry should take top priority as the industry grows. There are safety issues for the installers working in the field on solar projects, as well as local and regional licensing requirements for renewable projects involving industry standards and legalities.

Solar industry expert Jeff Spies, president of SolarSpies, a solar training and consulting firm specializing in training program development and events, knows the importance of education in an industry experiencing exponential grow.

“Successful solar companies take training seriously,” said Spies, secretary of the North American Board of Certified Energy Practitioners (NABCEP), a photovoltaic (PV) and solar thermal installation certification organization. “The top solar installation companies have placed a priority on quality training to ensure their employees are current on the latest code considerations, product innovations, design intricacies and installation procedures.”

Spies notes that the solar industry is a technical field that requires strong knowledge of the electrical and mechanical aspects of PV design and installation.

“Capable instructors can impart their wisdom to solar professionals helping them understand not only the theory of how it should be done, but the practicality of how it gets done profitably,” he said.

For those who want to invest in a future in the renewable energy field, hands-on workshops or online trainings are available through a variety of outlets. A quick Internet search for “solar training” highlights multiple training providers who educate in solar technologies. Non-profit training organizations and community colleges can provide programs geared to train solar professionals. In-person trainings can range from one and two days to 2 • 2012

week-long workshops with a hands-on component.

“Quality PV training pays for itself within the first few jobs that you tackle,” Spies said. “While many designers and installers learn by doing, they will pay more in this DIY learning process than if they were to take a quality training class and learn the best practices that increase system and installation efficiency.” Training not only ensures quality in the field, but it keeps staff safe and the customer safe.

Injuries can lead to lawsuits or — worse yet — fatalities.

“The industry moves at a blistering pace necessitating a continuing education mentality,” Spies says. “New products, code revisions, and incentive changes influence the continuous evolution of training on these topics. Designers/ installers must keep abreast of these developments if they hope to compete in increasingly competitive environment.”

“Since PV employs the skill sets of two of the top 10 most deadly professions in the United States (roofing and electrical work) training on proper PV and OSHA safety protocols is imperative,” he continued. “The exemption for fall protection that the roofing industry once enjoyed is now history, and OSHA is aggressively targeting PV installation companies for violation of these mandates. It is incredibly important that your design and installation staff all receive training from instructors that have the experience of working in this dangerous trade to learn the practical tactics key to creating a safe work environment.” SPW

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[ R ACKI N G

an d

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Fr a n k A n d or ka /Edi to ri al D i rec to r

Managing Municipal Budgets Unirac’s ease of assembly made it the perfect choice for this budget-conscious project.

More municipalities than ever are looking to lower costs in the wake of poor economic times and slashed budgets. One of the most obvious places to start is to provide your town with selfgenerated, more efficient energy.

When the Lower Township (N.J.) Municipal Utilities Authority (LTMUA) decided to move in that direction, they explored adding a solar farm to their water treatment plant. The location had good sun exposure, and the plant had the land (four acres of drying ponds no longer in use). They signed a 15year power-purchase agreement (PPA) with Calvi Electric of Atlantic City to provide the electricity.

Now all they needed to do was find a contractor who could do the job. Enter Mike Adkins and Cambria Solar, an installer in Pleasantville, N.J. “They wanted to save money on their electric bills and cut down the high rates they felt they were being charged by Atlantic City Electric,” says Adkins, who heads up Cambria’s Construction and Installation division. “They put out a request-forproposal (RFP), and we came back with the lowest price.”

What started as a 50-KW project quickly morphed into a 1.3-MW project when Cambria pointed out that a bigger system could power the entire plant. State grants and solar incentives made the larger project affordable, and LTMUA decided to move ahead.

The problem Cambria faced was finding a racking-and-mounting system that would allow easy installation to ensure the project was finished quickly. Adkins looked at several different options, but finally settled on Unirac’s ISYS GroundMount System.

The Solution Adkins says Cambria was looking for a solution they knew they could count on. The company had experience with Unirac and knew they could effectively handle a project from

Type: Ground-Mount PV Size: 1.3 MW

Company: Unirac

Project Location: Villas, N.J. Partners: Cambria (project manager); Lower Township Municipal Utilities Authority (client); Calvi Electric of Atlantic City (N.J.) (utility) Projected Annual Savings: $150,000 annually

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beginning to end.

“We wanted someone that could provide us with field and engineering support to help us through the project,” Adkins says. “We knew Unirac’s system is robust.”

Marcelo Gomez, director of marketing for Unirac, says that once a contract is signed, the company turns it over to an internal project team that the client can call any time.

“In the solar industry, it’s all about how ready you are to deal with whatever challenges come up,” Gomez says.

“Once we sign an agreement — once the deal is done — the project is immediately handed off to a dedicated management team.

“We can answer any questions the client might have, and we’ll even go to the site to help them out if necessary,” he continues. “We make sure the client

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has access to the best means and methodologies to use our products.”

Adkins says Unirac’s support for the Lower Township project began six months before the first panel was installed. Once the project began, Cambria had questions about how tight the racking system’s collars were supposed to be — they felt Unirac’s specifications wouldn’t work on this particular job.

The company flew its engineers out from New Mexico, examined the project and agreed with Cambria. The tightening specifications were adjusted, and Cambria was able to proceed with little interruption.

“We worked closely with the company — its engineers in particular — and we were really able to get a good read on the project before we started work,” Adkins says. “We knew exactly

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what it would cost, which allowed us to give the municipal officials a clearer idea of what they were purchasing.”

The project itself required work around the clock, and Adkins says the racking system allowed them to pre-assemble the racking. During the day, this flexibility allowed Cambria to place double the crews in the field, which meant installing the panels in half the time.

“We set out tents on the property and built the frames at night,” Adkins says. “It saved us a lot of time during the actual installation.”

Gomez is convinced such flexibility won them the contract from Cambria.

“We were chosen because of our pre-assembly capabilities,” Gomez says.

“That provides the installer with a certain amount of flexibility and helps them do their jobs more effectively.”

The LTMUA spent no capital dollars for the construction of the project. The 50-KW unit produces electric at a cost to the LTMUA of zero per KW for electrical power generated by the unit for the next 15 years. The 750-KW unit produces electricity for the LTMUA at a cost of $0.0375 per KW for electrical power generated for the first five years, with an escalation rate to $0.05 per kW during the 15-year term of the contract. The LTMUA had paid Atlantic City Electric Co. an average of $0.14 per KW of energy used.

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Adkins says the project was completed successfully, and the Lower Township was just waiting for final state approval before they flipped the switch.

Local inspections went smoothly.

“They were really tickled by how smoothly the project went, and we couldn’t have done it without using a racking system that allowed them to move forward quickly,” Adkins said.

“They’ve estimated that they will save around $150,000 per year in electricity costs. It really worked out well for everyone.” SPW

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Made in the Renusol came to the United States to sell product. It stayed because of the work ethic of U.S. workers.

Fr a n k A n d o r k a / Ed ito r ia l D ir e c to r

The hottest debate in the United States solar industry revolves around

whether or not the country can keep manufacturing jobs here instead of shipping them overseas. An examination of recent history does not provide much positive news. Over the past 20 years, more companies are shipping jobs overseas in search of cheaper materials and labor. That trend shows little sign of slowing.

But Renusol, a racking-and-mounting manufacturing company based in Atlanta, has bucked this historical trend. Under the theory that the manufacturing should be closer to the market, Refusol CEO Bart Leusink says the company decided to build its products here in North America.

The company produced the first version of the system in the late 1970s. About 10 years ago, CentroSolar Group, a solar-glass firm, purchased Renusol. Since then, the company has installed 1 million systems. The product has become one of the most dominant in Europe.

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MANUFACTURING PROCESSES

“Those were European products developed for a European market,” Leusink says. “But the company decided to expand beyond Europe into the United States. Moving our production facilities closer to the new market was the logical next step.”

Renusol doesn’t own the factories that produce its racking systems — it doesn’t need to take on the extra expense. After all, the necessary infrastructure already exists in the network of auto manufacturing plants scattered throughout the United States.

Workers at these plants have the skills and experience to manufacture large plastic parts, which make up Renusol’s product line.

The 15 companies Renusol looked at to build its products already work for the automotive industry and are used to working with these types of materials.

“The skills are really tied to the production process and not the product itself,” Leusink says. “To my knowledge, they have always done related parts and components like the ones we need to produce.”

What makes the United States such an attractive place to do business, Leusink says, is that so many of the materials used in

Workers at Renusol’s Wisconsin plant already have the skills to work with the materials that go into the company’s plastic racking and-mounting systems.

producing their racking systems are made here, particularly by companies within the petrochemical industry. Renusol’s products are made of 100% recycled materials (production scrap) from those industries.

“The raw material has been used since the 1950s in the oil industry for above-ground piping,” Leusink says. “It’s also used in truck liners

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2/21/12 2:43 PM

Renusol is proud that its products are made in the United States — a fact it promotes heavily in its ads (though it plans to be even more aggressive in the coming year).

and shelters for cows, demonstrating proven durability.”

“All of the materials come from the United States,” he adds. “They are made by Americans — through all the steps in the process.”

Leusink explains how its products are made, starting with the engineering to the production process, until they come out as finished racking systems.

“We decided to find ways to reduce ballast since it is a ballasted system and interconnect each individual panel,” Leusink says. “We came up with various shapes and did wind-tunnel tests on scale models of arrays. They have to withstand weather and use for long periods of time, so we want to do our due diligence to make sure they can do what our customers expect.”

When the raw materials first come into the factory, the different blends of plastic pellets are no larger than rice grains. Then they are heated and run through rollers and a weight to flatten them out.

The newly rolled sheets are then fed into a die-cutting machine that cuts out the shapes.

Once that’s done, the Renusol mounting system

is ready to go.

“What makes Renusol unusual is that it’s one product per panel instead of having different lengths of galvanized steel that you have to cut on site,” Leusink says. “It’s much easier to budget and scale — once you know how many panels you’re going to fit on the roof, you know how much your mounting system is going to cost you.”

Leusink says he’s proud Renusol’s products are built in the United States — a fact that the company promotes in its ads, though he admits it hasn’t pushed it as aggressively as he should.

He says he doesn’t agree with the recent trade petition against China, arguing instead that it’s up to U.S. manufacturers to fight back by buying American.

“If the goal is to protect U.S. manufacturing, people should look more closely at working with companies in the United States,” Leusink says. “Companies that have sold our product for several years may not know that it was engineered and built in the United States. More companies need to promote their commitment to this country.” SPW

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The Solar Industry Benefits From

U.S. & China

Competition

The trade case brought against Chinese solar manufacturers could undermine the solar industry’s significant progress at the moment it is poised for success.

Ro be rt D. Han s e n a n d S te p h a n ie A . Bu r n s

With a largely jobless recovery here at home and a Chinese

image: istockphoto.com

economy that is “cooling down,” a trade war over solar module production threatens both nations’ economies and the global viability of the solar industry.

Currently, the U.S. Department of Commerce is investigating whether or not it should impose preliminary tariffs in the case, which is occurring against the backdrop of a growing chorus of political rhetoric. Meanwhile, China’s Commerce Ministry is not standing idle — they are gearing up for action. It appears they are serious about initiating their own measures in anticipation of the United States advocating for trade remedies.

At a time of economic dislocation and discontent, it is tempting to politicize trade disputes. But no nation or industry “wins” when these disputes escalate — and the unintended consequences of such an escalation will most likely outweigh the larger, negative impact on this important relationship with our largest trading partner.

The pending case raises concerns, but resolving this issue through an adversarial confrontation will impede both countries’ abilities to benefit from a growing solar market in the United States and abroad. Such benefits are only possible through lower prices catalyzed by healthy competition between global manufacturers. Countries around the world realize the economic contributions the solar industry can provide and are supporting new technologies and markets. This is not news. But to be clear:

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T R A D E

D I S P U T E

Competition and incentives need to be fair for all industry players.

Our companies, Dow Corning Corp. and Hemlock Semiconductor Group, are among the world’s leading suppliers of polysilicon and other key solar materials that power solar innovation. Together, our common goal is to contribute to and support a thriving solar industry.

Our recent U.S. investments of more than $5 billion back up that statement. We are expanding research,

And, as the solar industry continues to grow and achieve economies of scale, it will further drive job creation in communities around the country, up and down the value chain from manufacturing to installation.

The world wants and needs growing, sustainable and environmentally beneficial sources of energy. To that end, a growing U.S. solar market is good business for everyone — for our companies and dozens of other domestic manufacturers; for distributors, developers, and installers; and for households, small businesses and

Burns is Dow Corning Corp.’s chairman.

As the solar industry continues to mature, the steep decline in solar panel prices have made solar energy affordable, delivering significant benefits for consumers while encouraging the development of large-scale photovoltaic projects.

Hansen is president and CEO of Dow Corning Corp.

development and manufacturing capacity for materials such as polysilicon to help meet growing global demand.

Our investments have made positive contributions toward getting the economy back on track — creating thousands of high paying jobs in economically hard-hit states like Michigan and Tennessee.

Further, our business analyses indicate that now is the time for America’s solar industry to take off. The amount of new solar wattage installed in the United States has grown more than 70% each year since 2008.

Last year alone, the solar industry created approximately 100,000 jobs, an increase of nearly 7 percent.

As the solar industry continues to mature, the steep decline in solar panel prices have made solar energy affordable, delivering significant benefits for consumers while encouraging the development of large-scale photovoltaic projects. These installations, from residential rooftops to utility-scale solar farms, are helping the economy and the environment.

Continued investments made by domestic and foreign solar companies will allow solar to play an increasingly pivotal role in our country’s energy mix.

other enterprises.

In a down economy, the numbers help tell the tale: A recent Forbes story notes that the U.S. was a $5.6 billion gross exporter in solar-related products in 2010 – exporting $1.9 billion more than it imported – including net exports of approximately $400 million to China.

The solar industry is ready for its moment in the sun: Here at home, we hope fairness prevails so that the investigatory process proceeds without acrimony, political overzealousness or protectionism.

At stake are U.S. jobs, U.S. exports, and U.S. consumer benefits for a strategically important U.S industry. SPW

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Let’s Hold

China Accountable

By Gordo n B ri n se r

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image: dreamstime.com

T

he Coalition for American Solar Manufacturing, which SolarWorld leads, is striving to remove unfairly traded imports from the U.S. market as a first step toward rekindling robust international competition, growth in U.S. renewable-energy manufacturing jobs and steady and sustainable gains in efficiency and affordability.

Unless markets operate on principles of robust and fair trade and competition, without the negative effects of illegal overseas subsidies, there is no free trade. Moreover, the promises of solar energy manufacturing – energy security in a clean-energy world, growth in domestic manufacturing jobs and their rich economic payoff, and solar made entirely according to high environmental standards – will shift beyond the United States’ reach.

SolarWorld and CASM believe in investing, producing and employing in the United States, which are both environmentally friendly and costeffective. Why shouldn’t we? The National Renewable Energy Laboratories recently published a presentation concluding that Chinese producers face a 5% cost disadvantage, compared with U.S. producers, in manufacturing and delivering solar products to the U.S. market, when transoceanic shipping costs are included.

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T R A D E

D I S P U T E

We believe in a future where technology and industry that American scientists and entrepreneurs invented and developed can thrive again on U.S. soil, employing Americans under decent and safe working conditions, producing solar according to high environmental and labor standards, and providing U.S. consumers with a reliable, accountable and secure source of energy. Our ability to do so should not depend on the actions of a foreign government’s five-year industrial plan.

Many longtime solarindustry participants – our coalition represents 150 employers of more than 14,500 U.S. employees Brinser is president of – fully grasp the serious SolarWorld Industries concerns posed by China’s America Inc., based in centrally planned industrial Hillsboro, Ore. In 2008, strategy, launched just Brinser joined Solaras solar is poised to go World as vice president mainstream. Others, of operations for U.S. especially recent entrants, manufacturing facilities. have misstated why Gordon serves on the SolarWorld Industries board of the Oregon Built Environment and SustainAmerica filed trade petitions able Technologies Center, Oct. 19 to hold the Chinese or BEST. solar industry accountable to the laws of international trade.

They have fixated on short-term pricing – as if China, having invested billions of dollars in mounting an export campaign to sell product at artificially low prices to wipe out competition, will hold prices low after it has succeeded. This fixation persists even as manufacturers around the world – including China – struggle under the weight of excessive manufacturing capacity that the Chinese government sponsored in its drive

to flood foreign markets. Only companies that can count on long-term, strategic government sponsorship can hold out at such artificially low pricing.

It shouldn’t be this way. Government has no business intervening in foreign marketplaces. In fact, international and U.S. trade laws prohibit it, and we have asked the federal government to investigate China’s trade practices and subsidies and, if necessary, remove this distortive interference.

Sustainable competition, not a government-underwritten monopoly, optimizes efficiency, innovation and cost and price reduction long term.

The trade cases are founded on a core consensus within the world trade arena: While subsidies are not inherently improper, it is illegal for a nation to use them to ramp up production to grow well beyond the needs of domestic consumption, and then dump exports at prices below production costs into a foreign economy and thereby harming that foreign economy’s market and industry.

This is precisely what China is doing.

Their strategy has unfolded at least since 2009, when the chief executive of a Chinese solar producer, now the world’s largest, acknowledged it in The New York Times in 2009.

China now has enough solar manufacturing to produce roughly 16 times more product than its domestic market demand. Virtually all of its production goes overseas. China’s subsidies – too numerous for even its own government to count – are fueling its export drive. Further, China is subsidizing its anticompetitive campaign using a variety of export subsidies, including guarantees, credit and insurance – all explicitly illegal.

Of course, short-lived profits from unfair trade can handsomely benefit a small number of people in a targeted country – but almost never the end-user. With solar, unfortunately, end users have not seen anything like the 40 to 50 percent declines in wholesale prices that have come since 2010. Moreover, neither the environment nor the American consumer will be long-term winners if China is allowed to continue violating international trade law.

Those who have built their fortunes on dumped and subsidized Chinese solar imports argue that the future growth of the U.S. solar industry depends on these illegally traded products. They are wrong from economic, environmental and rule-oflaw perspectives.

The U.S. solar market and solar installations will continue to grow, with or without China’s unfairly traded goods.

Solar is here to stay. The only question is whether U.S. solar manufacturing will be allowed to play a role, as its invention in the 1950s, in refining crystalline silicon solar manufacturing, innovating its products and leading the industry forward. In the alternative, China will dominate a new generation of technology that will reduce America’s dependence on fossil fuels. We will see our increasing dependence on our Far East energy source eclipse our future potential for greater energy security.

Chinese domination of this market would pose both short and long-term trouble. With little, if any, transparency China has exhibited a cynical approach to international trade in concrete ways, including its intractable currency manipulation, monopolistic tactics on rare earths, woeful environmental legacy, and

SolarWorld has deep U.S. roots and many long-tenured U.S. solarindustry employees, together boasting industry relationships built over more than 35 years.

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T R A D E

horrendous safety record on consumer products, from pet foods to baby formula to drywall.

Until SolarWorld filed its trade cases last October, China’s strategic plans for solar unfolded precisely to plan, a testament to the Chinese government’s ability to execute its carefully controlled central planning. Indeed, even as champions of Chinese imports tout equipment and raw material exports that, until recently, headed East in impressive volumes, China’s government has made strides to corner these markets as well.

China’s plan to dominate the solar industry is straightforward enough to outline. First, provide billions of dollars of domestic subsidies to build massive excess manufacturing capacity. Then reap capital from U.S. stock exchanges without meeting U.S. securities requirements for transparency or accountability. Export as much product as possible while neglecting to develop a desperately needed domestic solar market. Overproduce solar by employing dirty energy and abusive environmental practices. Ship these so-called green products to the U.S. market in a manner that maximizes their carbon footprint. Sell them at prices so low that they undercut U.S. producers poised to sustainably and responsibly meet all domestic demand. Tap U.S. taxpayer subsidies while barring non-Chinese companies from access to the Chinese market or its subsidies. Drive U.S. producers to go out of business or stage hundreds of layoffs (at a dozen plants in the past two years). Purchase the production equipment of the failed manufacturers for pennies on the dollar. Finally, cement control over the formerly robust U.S. supply chain, including production of equipment and raw material.

These policies are as economically unsound as they are environmentally regrettable.

But in challenging China’s illegal trade practices, SolarWorld and its U.S. allies are on the right side of the law – and history.

Solar manufacturing can and should take place in the major markets where it is sold. Domestic factories can and should grow thousands of jobs for decades to come. Legal and fair international competition can and should produce sustainable price declines. Solar manufacturing, of all things, can and should embrace sustainable environmental practices.

Most industry participants believe these outcomes warrant the struggle. SolarWorld has deep U.S. roots and many longtenured U.S. solar-industry employees, together boasting industry relationships built over more than 35 years. For our leadership on this issue, we are proud to say we have broad support from hundreds of companies and thousands of U.S. workers, including many spread throughout the very segments – distributors and installers – that the Chinese importers claim to represent.

They, like us, are unwilling for the U.S. solar industry to raise the white flag. We are confident our trade petitions will

benefit the entire U.S. solar industry when they restore a place for fair and legal trade, high production standards and robust world competition.

We are willing to fight for this all-American vision. SPW Â

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A Guide To Successful

CSP

Most power plants use fossil fuels as a heat source to boil water. The

steam from the boiling water spins a large turbine, which drives a generator to produce electricity. However, a new generation of power plants with concentrating solar power (CSP) systems use the sun as a heat source.

The three main types of concentrating solar power systems are: linear concentrator, dish/ engine, and power-tower systems.

People have used solar power for centuries, and it’s been prevalent in the news for 150 years or so. But concentrated solar power is a fairly recent development, involving various techniques for selectively focusing the suns rays on collectors to increase output. It does work, and various large CSP generating plants around the world are now producing significant power.

CSP systems use mirrors or lenses to concentrate a large area of sunlight, or solar thermal energy, onto a small area. Electrical power is produced when the concentrated light is converted to heat, which drives an

<<

engine (usually a steam turbine) connected to an electrical power generator.

CSP is being widely commercialized, with about 740 MW of generating capacity added between 2007 and end of 2010. More than half (about 478 MW) was installed during 2010, bringing the global total to 1,095 MW. Spain added 400 MW in 2010, while the U.S. added 78 MW, including two fossil-CSP hybrid plants. Concentrating technologies exist in four common forms: parabolic trough, dish Stirling, concentrating linear Fresnel reflector, and solar-power tower.

Parabolic trough CSP consists of a linear parabolic reflector that concentrates light onto a receiver positioned along the reflector’s focal line. The receiver is a tube positioned directly above the middle of the parabolic mirror and filled with a working fluid. The reflector follows the sun during the daylight hours by tracking along a single axis. A working fluid (such as molten salt) is heated to 150–350°C as it flows through the

receiver and is then used as a heat source for a power-generation system. Trough systems are the most developed CSP technology.

Fresnel reflectors are made of many thin, flat mirror strips to concentrate sunlight onto tubes through which working fluid is pumped. Flat mirrors allow more reflective surface in the same amount of space as a parabolic reflector, thus capturing more of the available sunlight, and running much cheaper than parabolic reflectors.

Fresnel reflectors can be used in various size CSPs. Dish Stirling or dish engine system consists of a stand-alone parabolic reflector that concentrates light onto a receiver positioned at the reflector’s focal point. The reflector tracks the Sun along two axes. The working fluid in the receiver is heated to 250–700°C and used by a Stirling engine to generate power.

A solar tower rises in the desert. Power-tower systems are one of the most effective concentrated solar power systmes on the market.

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Examples of CSP Applications Solar Reserve has a large plant at Tonopah, Crescent Dunes, Nev. The facility will supply about 480,000 MWh of clean, renewable electricity annually, enough for 75,000 homes. The project is based on a field of mirrors, called heliostats, and power towers roughly 600-ft tall. Electric utilities favor SolarReserve’s solution because the molten salt storage provides electricity whenever the utility demands it. SolarReserve’s power plants can generate electricity 24 hours per day, or only when electricity demand is at its highest.

Other renewable technologies, such as wind and traditional solar power, offer no or limited thermal storage, and therefore can only generate electricity when the wind blows or the sun shines. eSolar has developed a cost-effective utility-scale CSP power plant based on massmanufactured components and designed for rapid construction, uniform modularity and unlimited scalability. The system is based on a field of sun-tracking heliostats that reflect solar heat to a thermal receiver mounted atop a central power tower. The focused heat boils water within the thermal receiver and produces steam. The plant pipes the steam from each thermal receiver and aggregates it at the turbine, powering a generator.

The steam then reverts back to water through cooling, and the process repeats.

A small and mass-manufactured heliostat is the building block of the eSolar plant. eSolar designed the heliostats for deployment in pre-fabricated “heliostat sticks” that can install easily with minimal training. A 46-MW eSolar power unit consists of 12 towers (each with its own northsouth heliostat sub-field), a turbine generator set and a steam condenser. The 250-acre project host 46-MW units.

E NG I NE E RI NG T E CHNO L O G Y D E V E L O P M E N T S

Solar power tower consists of an array of dual-axis tracking reflectors (heliostats) that concentrate light on a central receiver atop a tower; the receiver contains a fluid such as sea water. The working fluid in the receiver is heated to 500–1,000°C and used as a heat source for power generation or energy storage. Power-tower development is less advanced than trough systems, but it offers higher efficiency and better energy storage capability.

Several factors play into CSP generation. Let’s take a moment for a quick summary:

Location: Large CSP installations tend to be sited where the sun shines. Right now, the southwestern U.S. is a favored location, as is Spain and the sunnier parts of Europe.

Spain is a leader in concentrated solar power technology, with more than 50 government-approved projects in the works.

Also, it exports its technology, further increasing the technology’s stake in energy worldwide. Because the technology works best with areas of high solar radiation,

experts predict the biggest growth in places like Africa, Mexico, and southwestern U.S.

Government subsidies: Europe leads the United States, at least in part, because European governmental subsidies were more generous and became available earlier.

The United States experiences risks of politicization from subsidies, probably due repercussions of Solyndra’s bankruptcy.

Cost of power generated: As of September 2009, the cost of building a CSP station was typically about $2.50 to $4 per watt, while the fuel (the sun’s radiation) is free. Thus a 250-MW CSP station would have cost about $600 million to $1 billion to build. That works out to $0.12 to $0.18/ kwh. To put this in perspective, Arizona Public Service (APS), Arizona‘s largest utility company, purchases power from the Palo Verde Nuclear Generating Station at a cost of $0.0165/kwh. Nonetheless, new CSP stations may be economically competitive with fossil fuels. Nathaniel Bullard, a solar analyst at Bloomberg New Energy Finance, has calculated that the cost of electricity at a

Novatec’s modular solar steam generator uses Fresnel collectors. It is an evolution of parabolic trough technology, using flat glass mirrors in place of parabolically curved mirrors. Sixteen parallel lines of mirrors reflect solar energy onto a receiver in which water is vaporized. The resulting steam can be directed to a steam turbine for power generation or used for seawater desalination, solar cooling and other industrial heat applications.

Flat mirrors permit a simpler solar field array, particularly compared with conventional parabolic trough technology. Novatec Solar’s linear Fresnel design offers advantages over parabolic troughs: • Lower construction cost and easier, more rapid assembly • Scalable production capacity (continued next page)

The electroceramic coating eleminates pretreatments and typically eliminates the need for as many as two paint layers, all in one step.

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• Lower susceptibility to wind damage • More efficient land use • Reduced reflector shading by receiver • Automated construction of key components • Lighter construction enabling use of smaller motors • No need for receiver tracking • Low water use, a feature further enhanced by Novatec Solar’s patented automated cleaning technology

BrightSource’s solar-field optimization software is used during system design to determine the optimal position of each heliostat to maximize output and meet a power production profile. The technology also provides considerable design flexibility, allowing building projects on sites with irregular topographies and shape.

Using actual site conditions and custom-built meteorological datasets, the software produces precise GPS-ready mappings ready for download to solar field installation crews.

Their proprietary heliostat control software system, the Solar Field Integrated Control System (SFINCS), controls the heliostats arrayed in the solar field to track the sun and aim the sunlight onto the receiver.

SFINCS performs functions including:

• Solar-energy management, to focus the ideal amount of solar energy on the receiver at various times of the day to maximize electricity production while ensuring that the solar receiver’s flux and temperature limits are not exceeded • Solar field control, to provide aiming points on the solar receiver surface for each individual heliostat as well as facilitating start-up and shutdown • Heliostat tracking maintenance, to calibrate the heliostats based on three-dimensional laser scanning and other photogrammetric methods

Concentrated solar works best in places where the solar irradiation is high — places like the southewest United States.

project under construction in Southern California will be lower than that from photovoltaic power, and about the same as that from natural gas.

System storage: Users demand power at hours when the sun isn’t shining. This is being addressed through several alternative approaches, including hybrid plants that generate electricity through other means such as burning fossil fuels when sunlight is unavailable, and plants that employ molten salts or other working fluids that can store or retain heat when sunlight is unavailable.

When the sun isn’t shining, several steps can help continue generating power. For example, burning natural gas or coal during off hours provides supplementary energy, or supplying from the grid to.

Such alternatives have been discussed or tested. SPW

At the core of the SFINCS are proprietary algorithms that perform real-time optimization of the distribution of energy across solar receivers using real-time, heliostat-aiming and closed-loop feedback systems. In addition, SFINCS can automatically configure the heliostats to protect them from inclement weather.

Abengoa Solar’s hybrid technology integrates a combined cycle plant and a solar field, which combines the benefits of solar energy with the combined cycle. With this technology, solar energy is used as an auxiliary energy supply, increasing the cycle efficiency and reducing associated CO2 emissions. Hybrid plants can refer to new construction as well as the addition of a solar field to an already existing combined cycle plant. The solar field may use a parabolic trough or tower.

One example is a solar-coal hybrid, which combines the benefits of solar energy and coal plants. This approach can replace a significant portion of coal consumption by the energy contribution from the solar field.

During daylight operation, solar replaces coal for much of the energy supply. As the radiation decreases during the late afternoon, the coal contribution replaces the solar contribution, allowing the boiler to operate at full load at all times. In the early morning hours, the process is done in reverse, gradually replacing the coal energy contribution to solar, while maintaining the technical minimum to optimize the operation of the coal boiler. SPW

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Keep Your PV System Here are the basics for

staying safe during a solar installation.

Well Grounded Of all the elements of a U.S. solar installation, the

grounding portion of the system may well be the most important.

First, it is required to ground all PV systems. Second, a properly grounded system will help protect you and your employees from unintentional shocks and possible deaths. Third, it can help prevent fires in the system post-installation, avoiding potential lawsuits from angry homeowners. In other words, properly grounding your PV installation protects you.

Frank Andor k a / E di t o ri a l Di re ct o r Photos C our t e sy o f S t a n da rd S o l a r

Here are the basics you need to know to properly install a grounding system on your next PV array.

Two Types of Grounding C.J. Colavito, commercial engineering manager and North American Board of Certified Energy Practitioners (NABCEP) certified solar PV installer for Rockville, Md.-based Standard Solar, says most installers are familiar with equipment grounding (EG), which is the more traditional and visable form of grounding. He says grounding is designed to keep installers â&#x20AC;&#x201D; and anyone else who has to service 38

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Grounding: Electrical systems that are grounded shall be connected to earth in a manner that will limit the voltage imposed by lightning, line surges, or unintentional contact with higher-voltage lines and that will stabilize the voltage to earth during normal operation.

Source: Article 250.4(A)(1), National Electric Code (NEC)

Ground Fault: A ground fault in photovoltaic (PV) arrays is an accidental electrical short circuit involving ground and one or more normally designated current-carrying conductors. Ground-faults in PV arrays often draw people’s safety concerns because it may generate DC arcs at the fault point on the ground fault path. If the fault is not cleared properly, the DC arcs could sustain and cause a fire hazard.

m

Source: Tech Topics: Photovoltaic Protection, Note 1, Issue 1 from Meresen, a global electrical component producer. Written by Ye Zha, Electrical Engineer and Robert Lyons Jr. Product Manager

System Ground vs. Equipment Ground: The National Electrical Code (NEC) requires that all PV Systems over 50 V have one current-carrying conductor connected to ground (690.41). The connection between that conductor (either the positive or negative DC conductor as well as the neutral conductor if the system has an AC component) and the earth is the system ground.

The NEC requires that all exposed metal parts (e.g. racking, conduit, enclosures) of PV systems (regardless of voltage) must also be grounded (690.43). This equipment ground is accomplished through the electrical interconnection (or bonding) of all those metal parts with the earth.

Source: Andrew Truitt, principal of Truitt Renewable Energy Consulting in Denver

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INSTALLATION

PRACTICES Proper grounding in combiner boxes must use bond bushings and ground terminals.

the system in the future — from coming into contact with electrical current. Any metal or potentially conductive materials that are likely to be energized (having electrical current run through it) in the system must be grounded.

“If it’s metal, it needs to be grounded,” Colavito says. “That means the racking-and-mounting, junctions, frames — everything. If the steel bonding to your conduit is a metal pole, connect a copper conductor to it and conduct it to the ground. On PV systems, you always have to do equipment grounding — no one wants to be electrocuted.”

The second type of grounding is called system grounding, Colavito says. One of the two conductors coming out of the PV system will be grounded — normally it’s the negative wire. All system-grounded conductor wires must be white and are usually inside the inverter. It also includes a ground fault fuse to prevent fires within the system from excessive current flowing into the ground.

WS Family

The Essentials Of A Grounding System Andrew Truitt, principal of Truitt Renewable Energy Consulting in Denver, says a grounding system is only as strong as its weakest link, so all components are important. There are, however, a few components that are found in almost all PV grounding systems (as defined in the Article 100 of the National Electric Code (NEC)): Grounding Electrode: “A conducting object through which a direct connection to earth is established.” The grounding electrode is usually a ground rod but can also be a UFER, underground metal water pipe, ground ring or any other means compliant with Article 250.52.

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Grounding Electrode Conductor (GEC): “A conductor used to connect the system-grounded conductor or the equipment to a grounding electrode or to a point on the grounding electrode system. ” This is typically a wire that is sized based on the potential fault current that could flow through it if something went wrong in the electrical system. PV systems have separate requirements for both the DC and AC components, but both sets of requirements can often be met with one conductor (690.47).

Equipment Grounding Conductor (EGC): “The conductive path(s) installed to connect normally non–currentcarrying metal parts of equipment together and to the system grounded conductor or to the grounding electrode conductor, or both.”

Truitt adds that both the GEC and the EGC must be sized according to the NEC guidelines and must be either a bare copper conductor or an insulated conductor with green insulation (with or without yellow striping).

The connection between the various components of the grounding system are equally as important as the items mentioned above, which is why it is crucial that all equipment used in a ground system (and throughout the entirety of the PV system, for that matter) be listed by a nationally recognized testing laboratory and installed according to the manufacturers’ specifications, Truitt says.

Grounding System Installation As installers begin the installation of a grounding system, Truitt offers a few key elements to keep in mind:

Module Grounding: Like every other exposed metal component of a PV system, aluminum module frames must be grounded. There are many products available for grounding modules and just as many opinions about the optimal method. Truitt is partial to the most costly and time-consuming method: the tin-plated copper lay-in lug. He likes this method because it is the easiest method to install based on the “first to make, last to break” mantra of grounding (i.e. the grounding system should be installed before any current flows out of the PV modules and should remain in place until the modules are disconnected and all current flow has ceased).

Array Grounding Conductor Installation: The grounding conductor that runs within the array typically serves as both an EGC and the DC GEC and must be installed accordingly (690.47(C)). In most cases this can be accomplished with a solid barecopper #8 wire. As the system size increases, it may become necessary to increase the conductor size as circuits are combined, and this must be done by irreversible means (250.64(C)) such as a copper crimp splice.

Enclosure and Conduit Grounding: All metal enclosures (boxes) and conduits that contain energized conductors must be properly grounded per the manufacturer’s instructions.

This is typically done by routing the EGC/GEC through some type of “lay-in” connection that allows the grounding conductor to maintain its continuity. Different situations require different equipment grounding methods, so it is important to consult NEC Article 250 if any questions arise. SPW

Here is an example of module and rail grounding with lugs.

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California school produces a 1 MW CPV plant — and uses it to launch a solar training program for its students.

Fr a n k A n d o r k a / Ed ito r ia l D ir e c to r

In 2006, a group of college and university presidents came together and created the

American College and University Presidents’ Climate Commitment. A small community college in Victorville, Calif., signed the agreement and immediately investigated renewable energy alternatives to produce at least 1 MW of its energy needs.

Victor Valley College originally examined the possibility of constructing a 1 MW wind turbine, but the administrators worried about the noise it would create for the college community. That’s when they hired gkk works, an Irvine, Calif.-based planning, design and construction firm, to help them figure out other options.

“They had a piece of land on the college campus that we determined would be perfect for a solar array,” says Al McQuilkin, a principal with gkk. “We helped them hone in on building a 1 MW solar field.”

The college then put together the funding, which included block funds that had been approved by voters and money it had left over from the aborted wind project, McQuilkin says.

It started out trying to negotiate a power purchase agreement (PPA) with a utility, but it had concerns over the way the agreement was going to work. It quickly discovered that if they developed their own solar array, the payback to the college would be shorter. At that point,

Valley College in Victorville, Calif., turned to SolFocus to build its << Victor 1 MW solar farm because they were intrigued by the company’s CPV technology. One year into the project, it is outperforming expectations.

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SolFocus approached the college with its concentrated photovoltaic (CPV) technology.

“We told them we were already working on finding the right vendor, but we’d be happy to include them on the request-for-proposal (RFP),” McQuilkin says. “We were looking for a solution that would cost us X and pay us back in Y years. We received five proposals from five different companies.”

The more that officials at the college looked at the different proposals, they kept coming back to SolFocus.

“We were intrigued by the CPV technology it offered,” McQuilkin says. “It turned out to have significant advantages over its competitors.”

The Technology Nancy Hartsoch, vice president of marketing for SolFocus, says the college had two objectives in choosing to build this solar farm: • It wanted to provide as much of their daytime power as possible from solar power; and • It wanted to be able to expand its educational offerings by teaching students how to service solar arrays.

What Hartsoch says differentiates SolFocus from other CPV providers is the type of cells it uses. The cells in the system are multijunction, III-IV cells, which are tiny (less than 1 square centimeter) and are 40% efficient. Instead of using an optical system to concentrate the sunlight, it uses a series of three mirrors (a primary mirror, a secondary mirror and an optical rod). This system, according to the company, allows the system to concentrate the sun 650 times more on to the cells.

“The cells we use are much more expensive than traditional PV — they were originally designed for space travel,” Hartsoch says. “We were the only CPV company to put in a bid on this project, and we won it because of price and our

environmental footprint. Our system is 97% recyclable, which gives us an environmental advantage as well.”

In all, the project cost $4.6 million, along with a separate operations-and-maintenance contract for 10 years that cost $460,000, according to McQuilkin [For a full breakdown of where the money came from, see sidebar on page 45].

The Results According to school estimates, the cost savings to the college will be nearly $20 million over the 25-year life of the plant, and the payback period is around five years.

“We were impressed with the technology, which was different from what everyone else was offering,” McQuilkin says. “On top of that, after its first year in operation, it is actually performing at a higher level than we expected.”

More importantly, McQuilkin says, is the commitment SolFocus demonstrated in helping the college start its solar energy associate’s degree program.

“The educational and training aspects of this agreement are critical to the college, which wants to be in the forefront of emerging technologies,” McQuilkin says.

“There has to be a place to train the next generation of solar industry workers, and

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Victor Valley Community College, in conjunction with SolFocus, is turing its project into a teaching facility, with a two-year associate’s degree in solar technology to be launced this fall.

this farm provides Victor Valley with an advantage.”

McQuilkin says he has personally conducted several tours of the facility with students, and there’s great interest in seeing how the system works.

“It becomes a learning experience for them,” McQuilkin says. “This project has really spurred the development of the program at the school.”

Hartsoch says SolFocus is committed to helping the college develop its solar curriculum. So far, the company has provided guest speakers and recently engaged them in the testing of new technologies.

“We’re here to support them as they get the program started,” Hartsoch says. “By the start of the fall semester this year, they will have a two-year associate’s degree program, and we will be involved in that in a serious way.” SPW

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introduction

[lea dershi p

i n

so l ar

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The U.S. solar energy market grew 140% in third quarter 2011, according to the Solar Energy Industries Association (SEIA), making it one of the fastest-growing sectors of the economy. Our nation’s solar power now exceeds 3,600 MW.

However, this growth isn’t a matter of chance — it’s a result of the innovation, ingenuity, and just plain hard work of the people who help drive it: leaders. From policy to products, these individuals and companies are working for the success of solar.

The future of the industry will build from 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 megawatts 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 2013 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.

www.solarpowerworldonline.com

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20 MW solar field with AE Solaron inverters

[lea dershi p

Advanced Energy (Nasdaq: AEIS) is a global leader in reliable power conversion solutions used in thin-film plasma manufacturing and solar energy generation.

The company’s solar energy business delivers highly reliable inverters, complimentary Balance of System (BoS) products, and robust Operations and Maintenance (O&M) services that allow our customers to secure more solar projects and increase their earnings. AE Solar Energy enables utility scale, commercial, and residential solar project stakeholders to offer system owners a lower Levelized Cost of Energy (LCOE) and improved peace of mind their PV system will deliver on long-term production goals.

With more than 30 years of leadership in innovation and in delivering energy solutions, combined with a legendary reputation for customer service, AE has become a trusted partner to solar project developers, financiers and beneficiaries around the globe.

i n

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Customer Experience AE Solar Energy enables utility scale, commercial, and residential solar project stakeholders to offer system owners a lower Levelized Cost of Energy (LCOE) and improved peace of mind their PV system will deliver on longterm production goals. With more than 30 years of leadership in innovation and in delivering energy solutions, combined with a legendary reputation for customer service, AE has become a trusted partner to solar project developers, financiers and beneficiaries around the globe.

Innovation AE is never satisfied; from our roots in reliability and LCOE, to continually improving our quality, systems and people to ensure energy delivered, period. We pioneer improvements in distributed generation, grid interactivity performance, utility interactive functionality, and energy management solutions.

Energy DeliveredTM AE delivers highly reliable and efficient inverters designed with an architecture optimized to deliver the lowest possible levelized cost of electricity (LCOE).

Our simplified BoS solutions reduce system design support, project management time and increase savings on installation. Simply put, AE delivers life-cycle performance.

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Solar Site Solutions AE delivers whole-site operations and maintenance service plans that increase the reliability of customers’ PV systems. AE global services is dedicated to responding quickly to issues, whether that means rolling a truck, providing phone support or anything in between. We provide application engineering support and warranties for up to 20 years, partnering with customers for the entire project life-cycle.

solarpowerworldonline. com/leadership

AE Solar Energy’s inverter manufacturing

Voting for this company will identify it as a leader in the solar power industry.

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team

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Process and Batch Control Strategies PAC, Process Controllers, Analog I/O, HMI, Fieldbuses and Networks Discrete/Machine Control Strategies PLC, Motion Control, Logic and Programming Software, Discrete I/O, HMI, Networks Asset Management Fieldbuses Information Management Networking, Ethernet, Databases, Connectivity Beckhoff Automation provides advanced, open automation products based upon proven industrial technologies. Solar cell manufacturers, machine builders and solar power plants can implement high performance Beckhoff control systems more efficiently and at a lower overall cost than traditional PLC and motion control systems. Beckhoff has been a long-time proponent of open controls architectures, full system interoperability, advanced remote connectivity and lean automation solutions. As more businesses in the solar industries are calling for these types of cost-effective solutions, Beckhoff is well positioned today to support them. Beckhoff sales and service are handled directly, with no intermediaries involved for exceptional customer service and consultation.

Safety Strategies Machine, Emergency Shutdown Energy Management Sustainability, Variable Frequency Drives, Motors, Motion Control

Beckhoff’s product range includes PC-based control, Industrial PCs, Embedded PCs, programmable automation controllers (PACs), PLCs, operator interfaces, EtherCAT® (next generation Ethernet fieldbus technology), I/O compatible with over 15 different fieldbuses, servo drives and motors.

Beckhoff Automation 12150 Nicollet Ave, • Burnsville, MN, 55337 • USA Phone: 1.877.TwinCAT Fax: 952.890.2888 Email: beckhoff.usa@beckhoff.com www.beckhoffautomation.com

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solarpowerworldonline. com/leadership Voting for this company will identify it as a leader in the solar power industry.

Beckhoff is also advancing leading edge automation solutions that deliver high performance at a low cost. This includes Scientific Automation, which merges automation, PLC and motion control with advanced condition monitoring and high precision measurement technologies.

Today this can be handled all on one powerful, PC-based automation controller and cost-effective EtherCAT Terminals, eliminating the need for many expensive “black boxes.”

Another advanced solution from Beckhoff is eXtreme Fast Control Technology (XFC), which efficiently brings automation performance to new heights, with greatly increased system precision and I/O response times < 100 μs.

www.solarpowerworldonline.com

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Boker’s, Inc. is a Woman Owned, ISO 9001:2008 registered manufacturer of high quality stampings and non-standard washers and spacers. To request Boker’s, now celebrating 93 years of experience, offers a wide selection of non-standard washers and spacers, as well as a broad range of stamping capabilities. Washers are available in 26,000 non-standard sizes, with outside diameters ranging from 0.080” to 5.140”.

a complimentary copy of the company’s 2012 Washer Catalog, 2012 Scheduling Calendar and Metric Conversion Chart, or Stamping Brochure, contact Boker’s at: 612-729-9365

With numerous inside diameters, thicknesses and over 2,000 commonly specified and hard-to-find material options—including various types of steel, aluminum, brass, copper, nickel silver, plus non-metallic materials such as PTFE, Polyester, Fiber and Nylon—Boker’s provides millions of washer possibilities.

TOLL-FREE 800-927-4377 (in the US)

Boker’s also delivers precision manufacturing of stampings in a complete range of sizes: flat blanking and piercings up to 12” x 12”, metal forming in thicknesses from .005” to .134”, and draws of up to 3” deep and 8” in diameter.

Boker’s additionally offers complete Statistical Process Control (S.P. C.) capability, in-house tooling, “Dock-To-Stock” and “Just-In- Time” programs, and ISO 9001:2008 registered status. Washers, spacers, shims and stampings are available in short, medium or long runs with short turnaround times.

Boker’s, Inc. 3104 Snelling Avenue Minneapolis, MN 55406-1937 612-729-9365 TOLL-FREE 800-927-4377 (in the US) www.bokers.com.

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COMSOL provides software solutions for multiphysics modeling and simulation.

The company’s flagship product, COMSOL Multiphysics, is a software used for the modeling and simulation of any physics-based system. Its customers are researchers and engineers working for leading technical enterprises, research labs, and universities.

Full details about COMSOL Multiphysics and related products are available at www.comsol.com.

In today’s fast-paced research and development culture, simulation power gives you the competitive edge. COMSOL Multiphysics delivers the ideal tool to build simulations that accurately replicate the important characteristics of your designs. Its unparalleled ability to include all relevant physical effects that exist in the real world is known as multiphysics.

This approach delivers results—tangible results that save precious development time and spark innovation. COMSOL Multiphysics brings you this remarkable technology in an easy-to-use, intuitive interface, making it accessible to all engineers including designers, analysts, and researchers.

COMSOL, Inc. 1 New England Executive Park Suite 350 Burlington, MA 01803

From its inception, COMSOL was designed to address multiphysics problems to help you predict what will happen to desired level of accuracy. The software starts with first principles like transport phenomena, electromagnetic field theory, and solid mechanics as basic fibers. Then, in a practical and flexible user interface, you can weave these fibers together in a self-consistent way to solve your particular simulation needs. The end result is a model that you can trust, because you control every aspect of the underlying physics.

Ph: 781-273-3322 Fax: 781-273-6603 www.comsol.com

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The adoption of COMSOL Multiphysics as a core technology has driven leading businesses forward and improved their bottom line. Request a free copy of COMSOL’s Product Booklet! www.comsol.com/campaigns/booklet/

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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CS HYDE COMPANY supplies high performance materials used in most major industries. We are a custom-converter of pressure sensitive adhesive tapes, films, silicone, fabrics, belting, rubber and threads.

Some of our uniquic cababilities include laminating adhesives, die cutting, slitting, sheeting, and print & bar-code. Our major products include materials made with Teflon® Fluoropolymer, Kapton®, UHMW, Silicone Products, FEP, Mylar®, Kynar®, Solef®, Kevlar®, PEEK, Nitrile, Tefzel®, Ultem®, etc.

We are the perfect source for both the small and large customer. Minimums are low and our prices are competitive. Samples & Technical assistance available!

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CS Hyde Company is always changing and adapting to suit you, the customer. We take the inititive to work on your project along with you, offering suggestions and our product knowledge wherever it may be useful. We enjoy learning new things and our team is always looking for a new challenge. We believe it is a necessity to take the time to give you our support.

With the benefit of an automated control system, our precision slitting machine can cut rolls of material to standard and custom sizes. We support 1 and a half, 3, and 6 inch cores, and can cut material as large as 60 inches WIDE while maintaining tight tolerances throughout.

We also have the capability to die-cut pieces of material using a variety of different methods. Whatever your company needs, we have something to suit your specific application. CS Hyde Company is proud to offer the capability to cut custom shapes to a very tight tolerance.

In addition, we can cold laminate an adhesive of your choice to a variety of materials, and utilize the superior product line that 3M has to offer to ensure the best performance out of your CS Hyde order.

Whether it’s Teflon Tape, Silicone Foam, Kevlar thread, or Mylar film, we have what your company needs to keep running smoothly. Call one of our representatives today to help find the product your specific application requires.

CS Hyde Company 1351 North Milwaukee Avenue Lake Villa, IL 60046 USA

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Phone: 800-461-4161

We are open from 8am to 5pm on week

Email: sales@cshyde.com

days, call us today for a quote or email

www.cshyde.com

sales@cshyde.com. You can also order

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on-line at our website, www.cshyde.com.

solarpowerworldonline. com/leadership Voting for this company will identify it as a leader in the solar power industry.

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About Dunkermotor: Headquartered in Elgin, Illinois, Dunkermotor is the North American sales, technical support and logistics subsidiary of Dunkermotoren GmbH, for 60 years the world market leader in customized, configurable sole-source fractional horsepower motion control solutions composed of BLDC, PMDC and AC electric motors, gearmotors, controls, encoders and brakes, as well as innovative Thrust Tube linear motion solutions.

With headquarters in Bonndorf, Germany in the Black Forest and production and/or logistics facilities in Europe, Asia and the U.S., Dunkermotoren employs 1000 globally and produced over 3.2 million motors in 2011 for the solar, semiconductor, medical, factory and commercial automation, packaging and mass transportation industries.

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The new Dunkermotor STM line is designed to enable the control of up to 127 motors over a 5000 meter (16,400 feet) bus length utilizing the motors’ integral CANopen interface with a single economic, off-the-shelf PLC having a solar tracking function block. The STM integral control brushless motors can also be used with industrial PCs as well as Profibus and Modbus networks. The embedded intelligence of the STM motors’ integral controls, which are designed with up to 650,000 hour MTTF, dramatically reduces bus traffic by running complex routines on board, such as homing and closing the position loop with an attached absolute encoder or inclinometer. In addition, the motors’ embedded intelligence can also take over mission critical functions, like returning to a safe position, when the network is down.

The low voltage brushless dc STM motors are available in three millimeter frame sizes (45, 65, 75) with powers up to 530W (0.7 hp) and can be easily integrated with existing design slew drives, pan and tilt mechanisms and linear actuators used in the solar industry. Where additional gear reduction is required, the STM motors can be mated to Dunkermotor’s own modular planetary or worm reducers offering up to 678 Nm (6000 in-lb) peak torques.

For further information contact: Dunkermotor

The standard STM motors are designed to be maintenance free for life. They are rated for IP65 environmental protection; employ special venting devices to prevent condensation, as well as proprietary lubrication techniques for the low speed, high torque and wide temperature ranges found in solar applications.

The STM’s integral control also features speed and torque regulation capability to prevent mechanical damage.

2511 Technology Drive, Suite 105 Elgin, IL 60124 Phone (224) 293-1300 Fax (224) 293-1301 Email info@dunkermotor.com http://www.dunkermotor.com http://www.facebook.com/ dunkermotor

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Dunkermotor’s leadership in the solar power industry is based on 20 years experience in solar industry motion control with over 150,000 units in the field. Dunkermotor’s new line of brushless dc Solar Tracker Motors (STM) with integral fieldbus-enabled motion controllers are optimized to reduce development time, lower installation costs and provide lowest total cost of ownership (TCO) in a variety of solar tracking applications.

Electric energy production can be increased by 30-35% more with solar tracking compared to fixed photovoltaic panel systems.

To learn more visit: www.dunkermotor.com Or call 224-293-1300

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“Dunkermotor customers have found that we add significant value to their solar tracker projects not only because of our extensive global experience in photovoltaic applications, but also in every element of concentrating solar power: from parabolic trough and power tower to Fresnel and Stirling dish,” said Wilfrid Vinson, president of Dunkermotor. “This new generation of STM products with fieldbus connectivity, scalability and diagnostic capability is an excellent example of how Dunkermotor employs its experience in the solar field to bring forth new innovations that will help customers deploy their projects quickly with proven solutions that offer lowest total cost of ownership. Much of this expertise and many of these advantages are easily employed in factory automation and special machinery applications as well.”

Dunkermotor’s complete Solar Tracker Motor line extends from simple low voltage brushed DC motors all the way up to ruggedized brushless servo gearmotors with integral control intelligence and fieldbus interfaces.

www.solarpowerworldonline.com

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For a quarter of a century, one company stands as a leader in making renewable energy practical and profitable. That company is enXco. enXco is dedicated to creating real value from the power of the sun, earning our partner’s respect and confidence, and delivering the best possible services and results. We take a life-cycle approach to project development; which includes site selection, procurement of equipment, financing, permitting, project planning and construction, long-term operations and maintenance, and project decommissioning and repowering.

With our experience and meticulous attention to detail, we ensure that green electricity stays in the black. By striking the optimal balance between the health of the planet, and the well-being and prosperity of the businesses and communities who partner with us, we generate clean energy for a sustainable future. enXco’s strength is grounded in the extensive experience the Company has gained across the spectrum of services required for the development and long-term operation of successful renewable energy projects.

enXco Corporate Headquarters 15445 Innovation Dr. San Diego, CA 92128 Toll Free: 888.90.enXco www.enxco.com

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Our core expertise lies in Project Development and Operations & Maintenance.

Project Development: enXco’s Project Development team is dedicated to creating value by managing projects from origination through commercial operation. Initial efforts involve identifying potential project sites, establishing business relationships with landowners, and securing permits and transmission rights. As the project progresses, our team executes all contracts, secures financing, procures equipment, and assures timely construction for full operation.

Operations & Maintenance: enXco Service Corp has a breadth of experience, servicing seven different types of panels. With more than 700,000 panels under contract, representing over 70 megawatts of power, enXco Service Corporation is the North American leader in providing third-party Operations & Maintenance Services. enXco Service Corporation is fully equipped to manage the balanceof-plant and to perform all required services for your solar project. We ensure installation conforms to owner’s direction, manufacturer’s instruction, equipment requirements, and industry best practices to optimize project availability.

Our full range of services include precommissioning support and balance-of plant services during the warranty period including scheduled and unscheduled maintenance options. Our team has extensive experience and provides the highest quality maintenance services performed by trained enXco technicians under stringent safety standards. enXco Service Corporation provides 24/7 remote monitoring and troubleshooting from our state-of-the-art Operations Control Center (OCC). The OCC uses advanced technology to optimize plant availability and profitability. The NERC compliant facility is staffed 365 days a year with trained and experienced operation technicians increasing your revenues around the clock.

Engineering Expertise: The Center of Technical Excellence is enXco Service Corporation’s latest expansion in service offerings. The CTE is staffed by seasoned engineers whose expertise ensures your solar plant’s performance is optimized. The CTE engineers perform root-cause analysis and implement engineering solutions to your renewable energy operating problems. Our skilled CTE engineers and rapid response translates into optimized performance and savings for our customers.

www.solarpowerworldonline.com

2/22/12 1:05 PM

[lea dershi p G. LUFFT Mess- und Regeltechnik has been dealing with the production of climatological measuring equipment since its foundation by Gotthilf Lufft in 1881.

The precision workmanship of highly

skilled specialists has enabled the LUFFT label to be known and the products to be purchased worldwide. The LUFFT products and equipment are to be found wherever atmospheric pressure, temperature, relative humidity and other environmental factors require to be measured or recorded.

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”.

USA Lufft USA Inc. 420 Boardwalk Dr Youngsville, North Carolina 27596 www.lufft.com 919.556.0818

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LUFFT as a Leader in the Solar Industry 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.

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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Engineering Next Generation Energy® is often engaged in assignments that expand the boundaries of traditional methods and employs innovative technologies to achieve desired results. Years of industry related knowledge and experience allows us to understand the impact architectural, structural, electrical and mechanical specifications have on the outcome of a site specific system. Our team of P.E., LEED, and NABCEP certified engineers, and dedicated staff of experienced professionals, ensures the solution you receive delivers performance and value for years to come.

Procurement Next Generation Energy® solutions incorporate the industries most innovative and efficient products available. Our purchasing department partners with best-in-class manufacturers to simplify product selection and ensure pricing and availability while our national and international distribution partners ensure timely delivery of systems to customers.

Manufacturing Next Generation Energy® is constantly evaluating product improvements while developing and validating innovative new products. The NGE-TU Series Solar Thermal collector is just one example of a Next Generation Energy® product innovation that is one of the industries most efficient solar energy products today while our NGE-PV modules are setting new standards for design and performance. Our engineers work closely with global manufacturing partners to ensure Next Generation Energy solutions stay ahead of the curve in meeting the needs of the marketplace.

Next Generation Energy 75 Waneka Pkwy, Lafayette, CO 80026 USA 303.665.2000

Solutions Next Generation Energy® partners with specifiers, engineers, contractors, and end-users to deliver performance based energy solutions to meet a variety of needs. It is not unusual for Next Generation Energy® to be called upon to expand the boundaries of conventional thinking and deliver in areas where others have yet to venture. Our industry knowledge and experience allows us to integrate renewable energy systems such as solar thermal, solar photovoltaic, wind, grid tied and off-grid hybrid solutions, network design, and monitoring as integral components to reduce costs and maximize investments in new energy solutions such as geothermal, hydro, cogeneration, and more.

Toll-free 877 NGE4SUN ngeus.com

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Experience Next Generation Energy® provides more than just renewable energy solutions.

With over 70 years of accumulated industry related knowledge and technological know how, Next Generation Energy® is your partner in all matters concerning renewable energy application and implementation. In our decades of experience, we’ve designed and integrated performance-based energy management solutions into new and existing structures, developed innovative new products, and introduced processes that have changed the way our customers do business.

Visit www.ngeus.com for more information.

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Next Generation Energy® Next Generation Energy® is a leader in the engineering of renewable energy products and solutions. Our team of dedicated professionals serve the needs of architects, engineers, contractors, and end-users by providing single source accountability for full-service design consulting, engineering, procurement, manufacturing, and distribution of complete energy management systems for new and retrofit projects.

Next Generation Energy® Next Generation Energy® is a leader in the engineering of renewable energy products and solutions. Our team of dedicated professionals serve the needs of architects, engineers, contractors, and endusers by providing single source accountability for full-service design consulting, engineering, procurement, manufacturing, and distribution of complete energy management systems.

With over 70 years of accumulated industry related knowledge and technological know how, it is not unusual for Next Generation Energy® to be called upon to expand the boundaries of conventional thinking and deliver in areas where others have yet to venture. Our industry knowledge and experience allows us to effectively integrate renewable energy systems such as solar thermal, solar photovoltaic, wind, grid tied and off-grid hybrid solutions, network design, and monitoring as integral components to reduce costs and maximize investments in new energy solutions such as geothermal, hydro, cogeneration, and more.

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2/22/12 1:10 PM

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DRIVING INNOVATION IN MOTION. Nook Industries, Inc. (Cleveland, OH) recently completed its fortieth (40th) year as an industry leading manufacturer of linear actuators, ball screws, roller screws and acme screws.

Nook continues to develop new products while adopting a growth model of “vertically” integrated manufacturing. This business model has allowed the company to identify and react quickly to markets and applications that will benefit from Nook’s integration.

Targeted growth in new product applications for Nook’s Precision Screw Group (PSG) and Precision Actuator Group (PAG) include metric products to service World markets.

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PRECISE EFFICIENCIES: Nook has been recognized as a leader in the precision ball screw industry for over 40 years. Nook manufactures the widest breadth of precision rolled ball screws ranging from 4mm diameters to up to 50mm diameters. Nook’s state-of-the-art manufacturing facility incorporates precision CNC thread rolling, CNC in-line induction heat treating, laser lead-accuracy measurement equipment, a fully comprehensive metallurgical laboratory, and torque testing equipment. These machines, 40 years of experience, and the most advanced engineering and manufacturing teams in the linear motion world produce the greatest ball screws available today.

Nook is also the only manufacturer in the world to design and manufacture its own thread-rolling dies. This capability enables Nook to produce custom ball screws, acme screws, and roller screws. Nook’s engineering teams often design custom ball screws for customers needing ball screws that meet exact load carrying specifications and product life requirements. No other ball screw manufacturer in the United States can deliver the flexibility and product breadth that Nook offers its customers.

DEVELOPMENTS IN MOTION: Nook’s Precision Actuator Group recently introduced the ∞ 1™ Roller Screw Actuator that was tested to over 1,000,000+ cycles of continuous duty (49 million inches of travel) at 2500 lbs of thrust and at a travel rate of 10 in/second.

Nook’s new ∞ 1™ Roller Screw Actuator offers a cost-effective alternative to hydraulics.

This high-performance, heavy-duty electromechanical actuator offers long life with high dynamic and static load capacity.

Nook’s Precision Screw Group also recently launched its miniature ball screw product line designed for smaller envelopes and lighter loads. Nook’s miniature ball screws are currently being manufactured in high volumes for robotic, medical, military, and aerospace applications. Nook developed the small diameter ball screw line as an extension to its Power Trac™ ball screw offering to provide design engineers a globally accepted metric product for compact, portable, and lightweight applications requiring high accuracy, repeatability, and durability.

NOOK INDUSTRIES, INC. 4950 EAST 49th Street Cleveland, Ohio 44125-1016 (216) 271-7900 | (800) 321-7800 www.nookindustries.com

Additionally, Nook manufactures ActionJacTM, Worm Gear Screw Jacks, and Electric Cylinders. Nook’s complete line of standard and custom engineered ball screw and machine screw actuators fit applications requiring 1/4 ton up to 100 tons of force. Standard configurations include upright or inverted units with translating or rotating lifting screws. Nook’s Screw Jacks can be configured with standard AC motors as well as servo motors and can be used individually or in multiple jack arrangements for a larger mechanical system.

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Nook has established an advanced configurable and downloadable 2D & 3D CAD library to reduce engineer’s development time and is available at www.nookindustries.com.

For more detailed information call: 1-800-321-7800

solarpowerworldonline. com/leadership Voting for this company will identify it as a leader in the solar power industry.

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About Solar Frontier Solar Frontier K.K., a 100% subsidiary of Showa Shell Sekiyu K.K. (TYO:5002) (“Solar Frontier”), has a mission to create the most economical, ecological solar energy solutions on Earth. Building on a legacy of work in solar energy since the 1970s, Solar Frontier today develops and manufactures CIS (denoting copper, indium, selenium) thin-film solar modules for customers in all sectors around the world. Solar Frontier’s gigawatt-scale production facilities in Miyazaki, Japan, integrate compelling economical and ecological advantages into every module: from lower energy requirements in manufacturing to the higher overall output (kWh) of CIS in real operating conditions. Solar Frontier is headquartered in Tokyo, with offices in Europe, the U.S.A., and the Middle East.

Visit www.solar-frontier.com for more information.

Americas Solar Frontier Americas Inc. 3945 Freedom Circle Santa Clara, CA 95054 USA Tel: +1 408 916 4150 www.solar-frontier.com

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Solar Frontier K.K. is the world’s largest and fastest-growing manufacturer of CIS thin-film photovoltaic (PV) modules.

We are leading the commercialization of revolutionary CIS PV to help the world achieve a sustainable energy portfolio. In 2011, we brought on line the largest CIS manufacturing plant in the world, raising Solar Frontier’s annual production capacity to gigawatt-scale across three factories in Miyazaki, Southern Japan. We are headquartered in Tokyo, have over 1500 employees and staff, and operate regional offices in Germany, Saudi Arabia and the United States.

Combining world-record efficiencies, uncompromising engineering standards, and excellent bankability, we offer our customers more kilowatthours, reliability, and ecological peace of mind. To date, we have supplied over 500 MW of our CIS modules across a wide range of sectors and geographies, ranging from residential rooftop installations in Japan to utility power plants in countries such as France, Germany, India, Thailand, Saudi Arabia and the USA. Solar Frontier is a wholly-owned subsidiary of Showa Shell Sekiyu K.K. (TYO: 5002), which is listed on the Tokyo Stock Exchange. Showa Shell Sekiyu has over 100 years of experience operating in the energy business and is based in Tokyo. Solar energy is the company’s second core business, along with petroleum products, as part of its medium-term strategy.

Solar Frontier leverages over 30 years of leadership in solar R&D and over 100 years of energy expertise derived from our parent company, Showa Shell Sekiyu. Spurred by the oil crises of the 1970s, we began developing solar technologies in collaboration with the Japanese government and academia, and early industry leaders such as Arco Solar. In 1993, we identified CIS as having the greatest potential of any PV technology. We ramped up our first plant in 2007, followed two years later by our second plant. By July 2011, we achieved full commercial operation of the world’s first gigawatt-scale CIS production facility – also Japan’s largest PV production plant – just 21 months after breaking ground.

Designed for durability, proven for reliability, and advanced in capability, Solar Frontier’s CIS technology has gained the trust and confidence of major customers worldwide. Black & Veatch, an independent and global engineering, consulting, and construction company, has issued a report after assessment of Solar Frontier and its technology, while the quality of our panels is verified through the Atlas 25+ comprehensive PV durability testing.

But equally important is proving to new customers our status as industry leaders. Solar Frontier leverages over 30 years of technological leadership and the over 100 years of energy experience of its parent company, Showa Shell Sekiyu. Solar Frontier is the first Japanese PV module manufacturer to receive warranty insurance from Munich Re, as well as optional coverage for project finances. www.solarpowerworldonline.com

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About SolarWorld AG: The SolarWorld AG Group (ISIN: DE0005108401) is a worldwide leader in offering brand-name, high quality, crystalline solar-power technology. Its strength is its fully integrated solar production. From silicon as the raw material through wafers, cells and modules all the way to turn-key solar systems of all sizes, the group combines all stages of the solar value chain. The central business activity is selling quality modules into the installation and distribution trades and crystalline wafers to the international solar cell industry. Group headquarters are located in Bonn, Germany, with sales sites in Singapore, South Africa, Spain, France as well as in the U.S. state of California. The group´s largest production facilities operate in Freiberg, Germany and Hillsboro in the U.S. state of Oregon. Sustainability is the basis of the group strategy. Under the name Solar2World, the group supports care projects using off-grid solarpower solutions in developing countries, exemplifying sustainable economic development. Worldwide, SolarWorld employs about 3,300 people. SolarWorld AG has been quoted on the stock exchange since 1999 and today is listed on, among others, the TecDAX and ÖkoDAX as well as in the sustainability index NAI.

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SOLARWORLD IN THE USA With a record of more than 35 years of domestic manufacturing on U.S. soil, SolarWorld is the most experienced American producer of photovoltaic silicon crystals, wafers, cells and panels. At 500 megawatts of annual capacity to produce photovoltaic cells, the company also is the largest U.S. manufacturer of solar technology, though its corporate and market presence reaches into all of the major solar-technology markets.

U.S. headquarters: SolarWorld’s U.S. operations are headquartered in Hillsboro, Oregon, where its 690,000 square feet of building space sits on a 97-acre site set among the campuses of Intel’s biggest operational hub in the world.

Hillsboro: In Hillsboro, Oregon, the company’s vertically integrated U.S. manufacturing facility grows silicon crystals, squares and shapes crystal into ingots, slices ingots into wafers, transforms both monocrystalline and polycrystalline wafers into photovoltaic cells and assembles cells into solar panels. SolarWorld not only manufactures its products in the USA but also purchases the bulk of its raw materials in more than 40 U.S. states.

Camarillo: Camarillo, California, is the robust U.S. hub of SolarWorld’s sales and marketing activities in the Americas.

History: Camarillo has been a crucible of world solar-technology pioneering and leadership since the 1970s, beginning with the startup Solar Technologies International in 1975. The enterprise was further developed, in turn, by ARCO Solar, Siemens Solar and Shell Solar. SolarWorld bought the legacy operations in 2006. Combined, SolarWorld’s work force of industry experts has hundreds of years of industry experience. Some in Camarillo date back to the era around 1980.

4650 Adohr Lane Camarillo, CA, 93012 Phone: : +1 805 388 6590

Expansion: In 2007, SolarWorld purchased a 480,000-square-foot factory in Hillsboro that Komatsu had built and equipped – but barely used – for chip fabrication. SolarWorld added a second, 210,000-squarefoot building there in 2009. The main plant, retrofitted and re-equipped, is driving production toward its 500 MW cell capacity. Combined, the buildings reached 1,000 employees in late 2010. Camarillo employs more than 100 others.

Fax: +1 805 388 6395 Email: customerservice(at) solarworld-usa.com www.solarworld.com

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solarpowerworldonline. com/leadership Voting for this company will identify it as a leader in the solar power industry.

AROUND THE WORLD The company’s corporate parent is SolarWorld AG, headquartered in Bonn, Germany, and traded on the Frankfurt Stock Exchange. Freiberg is the company’s German manufacturing hub. In wafer production alone, capacity has reached expansion to 1 gigawatt of annual capacity. SolarWorld dedicates itself exclusively to advancing solar PV technology as a safe, secure and clean energy source.

SolarWorld has annual sales of more than $1.8 billion, employs about 3,300 people worldwide and operates in Europe, Asia, Africa and the Americas.

www.solarpowerworldonline.com

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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 America with innovative

Connect it: The 2716 Series high-current PCB terminal block provides toolfree, 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.

Interconnect, Electronic Interface, Terminal Block and Automation solutions.

Headquartered in Germantown,

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).

WI, WAGO features stateof-the-art manufacturing and 75,000 sq. ft. of storage capacity for 36,000

Track it: WAGO-I/O-SYSTEM’s Solar Positioning Function and Tracking Function Blocks cost-effectively optimize PV efficiency and reliability.

product locations. Extensive engineering resources, a 25,000+ product portfolio,

• 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.

custom-manufacturing and 150 dedicated professionals ensure WAGO has the resources and expertise to help you get

• 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.

the job done.

Charge it: The 758 Series I/O-IPC combines PC flexibility with PLC capabilities into a robust control and networking system for solar array charging. Utilizing CoDeSys V2 software, Linux OS, IEC programming languages and multiple onboard fieldbus protocols, I/O-IPC provides cost-effective, real-time control. Via WAGO-I/O-SYSTEM, the I/O-IPC supports custom solar applications, including PV articulation and remote monitoring.

• 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

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.

www.wago.us 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/O-SYSTEM, 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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[lea dershi p Westinghouse Solar is an industry leader in the design and manufacturing of integrated plugand-play solar power systems.

In 2007, Westinghouse Solar pioneered the concept of integrating the racking, grounding directly into the solar panel. This revolutionary solar panel, originally branded “Andalay”, quickly won industry acclaim. In 2009, the company again broke new ground with the first integrated AC solar panel, reducing the number of components for a rooftop solar installation by 80 percent and lowering labor costs by 50 percent.

This first AC panel, which won the 2009 Popular Mechanics Breakthrough Award, has become the industry’s most widely installed AC solar panel.

Award-winning Westinghouse Solar Power Systems provide the best combination of safety, performance and reliability, while backed by the proven quality of the Westinghouse name.

For more information on Westinghouse Solar, visit www.westinghousesolar.com.

Tel: 888.395.2248 www.WestinghouseSolar.com

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The Leader in Integrated Plug-and-Play Solar Power Systems

Westinghouse Solar is an industry leader in the design and manufacturing of integrated plug-and-play solar power systems. In 2007, Westinghouse Solar pioneered the concept of integrating the racking, grounding directly into the solar panel. This revolutionary solar panel, originally branded “Andalay”, quickly won industry acclaim. In 2009, the company again broke new ground with the first integrated AC solar panel, reducing the number of components for a rooftop solar installation by 80 percent and lowering labor costs by 50 percent. This first AC panel, which won the 2009 Popular Mechanics Breakthrough Award, has become the industry’s most widely installed AC solar panel.

Award-winning Westinghouse Solar Power Systems provide the best combination of safety, performance and reliability, while backed by the proven quality of the Westinghouse name.

Innovation Born in the Field Founded as an installation company in 2001, the organization grew rapidly resulting in thousands of PV sales and installations across the United States.

Resulting from this vast experience, they recognized that PV industry innovation at the component level had flourished, however the industry had yet to offer an innovative way of integrating those components into an easy to install solution that reduced cost, while providing a more reliable and better looking system.

Product Evolution This whole system approach was the genesis for the Andalay product that was introduced to the solar industry in 2007. This revolutionary design was self contained, with all racking, grounding, and wiring built in creating the industry’s first integrated rack-less solar panel.

Building on this innovation, in 2009, the company integrated a micro-inverter directly into the panel and introduced the first plug-and-play AC solar panel, further reducing the time and costs it took to install a solar power system. That same year, the simple elegance of this integrated design led Lowe’s Home Improvement stores to adopt the solution, selling Westinghouse Solar Power Systems direct to contractors and homeowners.

In 2011, the company pioneered a flat roof solution leveraging the same simplistic design and integration resulting in the perfect solution for commercial flat roof projects. By reducing the component count to three primary parts, this lightweight, non-penetrating solution, assembles rapidly and delivers an unmatched savings in total system costs, while enabling installation on a wider variety of roofs than any other system on the market.

Today, Westinghouse Solar sells its solutions through its network of Authorized Dealers. By becoming an Authorized Dealer, installers can benefit from a variety of support including advertising and promotion, the right to use the Westinghouse Solar brand, and the opportunity to sell a product that has considerable consumer appeal, backed by a brand that has been known and trusted for over 100 years.

Doing Business with Westinghouse Solar If you are interested in learning how your company can leverage this industry leading technology, contact us today to learn more.

www.solarpowerworldonline.com

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Zilla® Corporation Zilla® Corporation, manufacturer of Zilla® racking and mounting solutions, has developed the simplest, most adaptive, and comprehensive system in the marketplace today. Providing a variety of mounting options for solar products, Zilla®’s many proprietary and patented products provide all-inclusive solutions.

From individual products to complete system design, Zilla® Corporation delivers environmentally friendly, practical and affordable innovations to installation professionals worldwide.

Zilla® Corporation Zilla® Corporation is the manufacturer and distributor of Zilla® racking products for flush mount, ground mount, and ballast mount solar photovoltaic and solar thermal installations. From individual products to complete system design, Zilla® Corporation delivers practical and affordable innovations to solar installation professionals worldwide. Zilla® systems and components are completely interchangeable and are extremely easy to install. Requiring less material and less labor, Zilla® solutions provide safer, stronger, and lighter installations that exhibit the highest standard of quality and craftsmanship while reducing cost to the customer. Let Zilla® Corporation’s dedicated and experienced team of professionals partner with you to deliver beautiful solutions that integrates into a new building design or enhance the most contemporary restoration.

Less is More Our patented rails are geometrically superior to all other profiles requiring up to 18% less material while producing superior strength. Quite simply, our strength to weight ratio and low profile are attributes that separate Zilla® from all other products. From residential, commercial, municipal to utility scale projects, Zilla® is engineered with performance, versatility and simplicity in mind. Zilla® components are interchangeable system wide and extremely easy to install. Zilla® installations require less material and less labor allowing for safer, stronger, and lighter installations exhibiting the highest standard of craftsmanship, strength and aesthetics -- while reducing cost to the customer.

Standard Hardware Zilla® rails connect with simple, standard 3/8” bolts which makes Zilla® the installers’ choice for practical and affordable solar projects. Once you start using Zilla®, there is no turning back. Zilla® will change the way you do business.

Visit zillarac.com for more information.

Environmentally friendly Zilla® engineers create racking systems that not only fit the project, but also fit the budget.

Zilla® products have minimal components, making them simple to install allowing customers to save money. Zilla® steel products use over 75% recycled car components, while the aluminum product line uses up to 50% of recycled material and are completely recyclable at the end of their life cycle.

Adaptability Zilla® racking is compatible with any roofing types including asphalt shingles, tile, metal roofs, bituminous, and flat roofing membranes. The Zilla® non-penetrating ballasted system is a perfect solution for flat roofs. Zilla® Flashings provide installers with safer and stronger mechanical attachments to structure with easy electrical or plumbing penetrations and carry 25-year paint warranties and come in over 30 custom colors. Sleep easy at night with Zilla® Flashings knowing your system is leak free. Whether the project requires attachment to an existing rafter or the design of a structural support frame, Zilla® allows for a versatile and simple solutions. Custom applications are no problem for Zilla®.

Zilla Corporation 77 Waneka Pkwy Lafayette, CO 80026 720-880-6700 www.zillarac.com

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Site specific design Zilla®’s team of engineers provide full design support including site optimized layout, engineering, permit documentation, and installation assistance or training. Zilla®’s products can be found on all continents, from mountaintop to sea level, they securely hold the systems you need 24/7/365 in the harshest environments on the planet.

Sexy Aesthetics play a prominent role in successful project completion. From the multiple color options to a low profile flush mount system, Zilla® delivers beautiful solutions that integrate into new building design and any retrofit project.

solarpowerworldonline.com/leadership Voting for this company will identify it as a leader in the solar power industry.

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Visit zillarac.com for more information.

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[ PR O D U C T S ]

Switched Combiner for Solar A switched combiner from Eaton Corp. combines the company’s 600-vDC solar disconnect and source-combiner box in one enclosure. The device is UL 1741 listed and provides a single point to combine incoming photovoltaic strings and disconnect direct current power close to the PV modules. It also saves installation time and costs through a side-operated UL 98 design with a heavy duty safety switch main disconnect.

This fusible versions has one set of fuse clips mounted on the center pole for complete isolation of the fuse when the switch is in the “off” position. Other options include surge protection, current monitoring and wireless communication.

Eaton www.eaton.com

Monitoring Modules The ACM300 communications gateway from Azuray lets PV array owners monitor system performance at a module level.

In addition to monitoring, the device can be used for remote diagnostics. It serves a web page via the Ethernet connector directly to a computer or network. Also, it collects data from the solar modules and controls the function of the power optimizers. Collected data is used to calculate the most

Central Inverters reach 98.7% efficiency

effective system operating point where system components are producing maximum energy output. The device can enable or disable the output of the AP300 power optimizers via power line communications over the existing DC wiring.

Conext Core XC central inverters from Schneider Electric

Safety features include safe installation mode and manual

feature peak efficiencies of up to 98.7%. Configurable

shut-off.

DC voltage ranges and power outputs also allow for flexibility for all panel types and installations, while the inverter is capable of interacting with the grid interactive

Azuray www.azuraytech.com

capability with low voltage ride through and VAR control.

Other features include standard 1000-Vdc input for long string lengths, load break rated DC switch disconnector and RS485 or Modbus communications. Options include insulation monitoring systems and positive or negative grounding kits, warranty extensions and more.

Schneider Electric www.schneider-electric.com

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[PRODUCTS ]

Non-Metallic Tubing Saves Time and Money Carlon Flex-Plus Electrical Non-Metallic Tubing and accessories from Thomas & Betts require less installation time than traditional conduit systems.

Available in Carlon Blue, the non-metallic flexible raceway is designed for use in walls, floor and nonplenum ceilings. The tubing is lightweight, flexible and free of sharp edges. It also allows installers use one continuous length from box to box, which eliminates the need for couplings. Also, it can be bent by hand so there is no need for benders and separate elbows, making it easier to pull wire through. The tubing and accessories are suitable for routing power and communications cabling.

Rotational Measurement Sensors for Solar PMI360DV Rotational Measurement Sensors from Pepperl+Fuchs are available with analog output and in several models. The inductive-based sensors that offer measurement settings from a minimum range of zero to 90 degrees, and a maximum

range of zero to 360 degrees. One may also set

Thomas & Betts Corp. www.tnb.com

position, with simple buttons for each configurable

rotation direction, PNP output signal width and zero function. Voltage or current output is available with repeatable accuracy to 0.5 degrees and resolution to 0.2 degrees. LED indicators provide visual status for power, lost target and configuration lock variables.

Models with up to three independent PNP outputs are available, enabling a single sensor to replace non-configurable multiple-sensor mounting arrangements.

Pepperl+Fuchs www.pepperl-fuchs.us

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[ PR O D U C T S ]

Detecting Arc Faults SolarBOS says it’s offering the industry’s first working arc-fault and ground-fault detection and interruption0combiner box, as well as a ground fault interruption for PV systems. The AFDI combiner allows system integrators to meet the letter of the 2011 National Electric Code in a cost-effective and reliable manner. The combiner box has a module that detects series arcs and automatically disconnects the ungrounded conductor from the rest of the system, breaking the circuit and stopping the arc, which prevents fires from starting. It can also be configured to work with a Ground Fault Interruption (GFI) device or system to open the ungrounded output of the combiner box when a ground fault is detected. The company says without AFDI or GFI capability at the combiner box, there is no way to automatically shut off the output from a PV array in the case of an arc fault or ground fault in the array wiring.

The AFDI combiner not only solves this problem and meets the new NEC requirements in a cost-effective way.

SolarBOS www.solarbos.com

A More Predictable Module The SF260 Poly X-tra UL polycrystalline module from Hanwah Solar features a predictable output — a positive power sorting of 0 to + 5 W. It also has an anti-reflective coating for a high rate of sunlight absorption and can with stand high snow loads. The module carries a 12-year warranty and 25-year performance warranty.

Hanwah Solar www.hanwha-solarone.com

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Inverters For Commercial And Utility Solar REFUsol offers its 012K-UL, 016K-UL, 020K-UL and 024K-UL three-phase transformerless string inverters for the U.S. solar market. Recent UL certification assures safe operation of the inverters for rooftop or ground-mount projects throughout the country. The light, compact inverters feature a precise MPP tracker, which enables the inverters to adjust their settings accordingly and achieve high efficiency, even with different temperatures and varying sun exposure. Due to the extreme low-power losses around the complete input voltage area of the inverters, it was possible to build an inverter with pure convection-cooling only. This low-power loss results also in a significant reduction of heat dissipation, which prevents overheating on indoor installation.

REFUsol www.refusol.com

Inclinometer Measures Accurately In All Environments Sherborne Sensors offers the LSW series of rugged, high-precision inclinometers, designed for demanding, all-weather applications. Available in angular ranges ±3° to ±90°, the series can operate in temperatures from -18 to 70 degrees Celsius and survive shock levels up to 1500g. The sensor system is protected in a durable stainless steel case, weatherproof to IP67 and resistant to immersion in water. Also featured is a field replaceable weatherproof moulded IP68 connector/cable system, which enables the LSW to connect to a DC power source and a readout for a complete operating system.

Sherborne Sensors www.sherbornesensors.com

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[ AD

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Leadership page

Advanced Energy .......................................BC ......................48 Beckhoff .......................................................IBC .....................49 BOKER’S, Inc. ..............................................33........................50 Citel ................................................................. 6 COMSOL ....................................................... 9 .......................51 CS Hyde .......................................................... 2 .......................52 Dunkermotor ................................................4 .......................53 enXco ............................................................13 .......................54 Imada, Inc. ...................................................12 Lufft USA ......................................................40 ......................55 Next Generation Energy ...........................12 .......................56 Nook Industries, Inc. ..................................29 .......................57 Solar Frontier Americas Inc. .....................15 .......................58 SolarWorld ...................................................IFC .....................59 Upsolar .........................................................46 WAGO ...........................................................10 .......................60 Westinghouse Solar ...................................24 .......................61 Zilla ................................................................41 .......................62

» A global educational engineering network, Connect, share and learn today. www.engineeringexchange.com www.solarpowerworldonline.com

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[CONTRACTORS CORNER]

New England Breeze Solar, Hudson, Mass.

Mark Durrenberger

Owner New England Breeze Solar

Mark Durrenberger, owner of Hudson, Mass.-based New England Breeze Solar, first became aware of the solar industry while in college. It was 1979, and President Jimmy Carter installed 32 solar panels on the White House.

He wanted to get a degree in energy engineering to help push the solar industry forward, but his college program, in his words, didn’t go anywhere. So he drifted into nuclear energy instead, receiving a Ph.D. in nuclear engineering. He never lost his love of solar energy, however.

“Then Al Gore selected me to be one of his climate change advisors,” Durrenberger says.

“It took me back to my roots, and that’s why I founded New England Breeze Solar in 2006.”

The company, which employs 13 people, is primarily an installer of grid-tie domestic hot water systems. Nearly 95% of the company’s installations are residential, with a smattering of

New England Breeze Solar:

small commercial. It has installed more than 500 KW and did more than $3 million in 2011. It focuses on the residential market in eastern Massachusetts.

“Most of our competitors do both residential and commercial,” Durrenberger says. “The biggest payoffs are in commercial arena — there’s more profit per job.”

Durrenberger says the reason New England Breeze Solar focuses on the residential market because he — and his employees — love working with homeonwers.

“We’re not a company that can sell to everyone,” Durrenberger says. “We’ve turned down clients in the past because we couldn’t do the right thing for them.

We’re not just going to install solar panels for the sake of installing solar panels.”

In his view, the solar industry is on the upswing and will continue to grow.

“As energy prices continue to rise, people are going to do what they need to do to lock in energy prices,” Durrenberger says. “Solar is going to give them an opportunity to do that.” SPW

3-year growth:................635% 2011 Sales: ....................$3.18 million 2008 Sales: ....................$432,000 Employees:.....................13 Founded: .......................2006 Website: www.newenglandbreeze.com

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| EC11-09USA |

Reduce Cabinet Size with the Rugged and Powerful CX5000 Controller.

The flexible CX5000 Embedded PC with Intel Atom thrives in temps from -25 to 60 °C ®

™

www.beckhoff.com/CX5000 The Beckhoff CX5000 Embedded PC series with convenient DIN rail mounting: for flexible application as a compact Industrial PC or as a PC-based controller for all-in-one PLC, Motion Control and visualization: Intel® Atom™ Z530 CPU, 1.1 GHz (CX5010) or 1.6 GHz (CX5020) Durable and compact magnesium housing High operating temperature range between -25 and 60 °C (-13 and 140 °F) Fanless, without rotating components (Compact Flash as storage medium) Direct I/O interface for EtherCAT Terminals and Bus Terminals for all major fieldbuses Optional space for serial or fieldbus interface Integrated 1-second UPS CX1020/CX1030 Embedded PC with Intel® Pentium® M CPU, 1.8 GHz or Intel® Celeron® M ULV CPU, 1 GHz

CX1010 Embedded PC with Pentium® MMX-compatible CPU, 500 MHz

CX9000/CX9010 Ethernet controller with Intel® IXP420 XScale® technology, 266 MHz or 533 MHz

CX8000 Fieldbus controller with ARM9 CPU, 400 MHz, e.g. for PROFIBUS, PROFINET, EtherCAT and Ethernet

IPC I/O Motion Automation

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Finally, someone beat Advanced Energy’s 97.5% CEC efficient solar inverter.

It’s the new 98% efficient Solaron 500 HE. Advanced Energy’s new 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 Solaron 500 HE inverter from Advanced Energy. www.advanced-energy.com/98percent sales.support@aei.com | 877.312.3832

Advanced Energy, Solaron, and PV Powered are U.S. registered trademarks or service marks of Advanced Energy Industries, Inc.

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