solar power world - january 2015
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Technology • Development • Installation
January 2015www.solarpowerworldonline.com
ONLINE NOWGALA OVERVIEW:
2014 Top SolarContractors Gala
Overview Video
PODCAST:
SunLink VP discussesground mount
products, the market
and supply chains
TOP PRODUCTS:
The solar industry hascontinued to see strong
growth in 2014
top100+
PRODUCTS OF 2014
Solar Power World executive
editor Lee Teschler discusses
the durability of SolarWorldpanels with Sebastian Hopfe,
quality engineer at the
company. Hopfe discusses
the construction of the panels
and other technical details.
“Normally you shouldn’t ride a
bike on them,” Hopfe said.
Yury Reznikov, vice president
of product management at
SunLink, a solar mountingsystems provider, discusses
trends in the solar ground-
mount market, including key
product differentiators and
supply chain best practices.
http://dwo.me/1DoMjMY
Much of this expansion is
fueled by innovative products
that show increasingly
improved reliability and
performance. Better
products are the basis for
more efficient and profitable
projects, which contribute to
solar becoming a grater part
of the U.S. energy mix.
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Technology • Development • Installation
January 2015
www.solarpowerworldonline.com
pages 55 - 117L E A D E R S H I P I N S O L A R I S S U E
Developments
IN SOLAR
MODULES
ALSO INSIDE Removing snow
Blogging for businessExperiencing a fire test
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T H E F I R S T W O R D
We’re focused on you
Natalie HoltgrefeSolectria Renewables
Jose GomezIngeteam
Steve HoganSpire
Devon CichoskiSolarWorld
Marcelo GomezUnirac
Justin Barnes
North Carolina (S tateUniversity) Solar
Center
Scott WiaterStandard Solar
EditorialAdvisoryBoard
1 • 2015 SOLAR POWER WORLD 1
Happy new year! Have you made resolutions for 2015? Maybe you’ll anchor
yourself every time you work on a roof. Maybe you’ll commit to more frequent
Facebook updates (pictures, please). At Solar Power World, we have steeredour ship toward one goal. Simply, we want to help you do your job better,
starting today. With that mission in mind, we will continue to deliver the most
useful information about solar technology, development and installation, while
expanding our regular coverage to include software and solar services.
But to begin, our first issue of the year includes a special focus on modules.
Leading companies share the latest on frameless modules, cell efficiencies,
solar shingles and integrated modules. Future special sections will focus on
racking and mounting (March), inverters and storage (August) and financing and
insurance (November).
While modules, inverters and mounting comprise a bulk of the solar
industry, as well as our coverage, there is much more to the business.
Software, for instance, is increasingly a game-changer. Financing software
helps businesses obtain funding. Design software assists with complex layout
decisions. Sales software helps sell solar faster. Our first article discusses how
manufacturers use software to help customers—and themselves.
While software deals with intangibles, sometimes a successful business just
needs help mowing the grass. Our new section on solar services helps you find
the help you need to improve your business, from O&M to engineering services.
Our first section is a duo of articles featuring snow-removal service Solar Maid andseveral metal forming companies that manufacture custom solutions.
Finally, with our revised “Projects Spotlight” section, we
aim to share stories from the field and what technology
is used to make projects successful. All of this is in
addition to our insightful marketing, finance and
installation columns, features and other unique, high-
value content. Enjoy 2015, and good luck making the
most of your solar business. We’ll be here to help you
along the way! SPW
A s s o c i a t e E d i t o r S t e v e n B u s h o n g
s b u s h o n g @ w t w h m e d i a . c o m
WHAT DOYOU THINK?
Connect and discuss this and
other solar issues with thousands
of professionals online
@ S o l a r 2 S t e v e n
@ S o l a r P o w e r W o r l d
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EDITORIAL
Managing Editor
Kathie Zipp
@SolarKathieZ
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Steven Bushong
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Michelle DiFrangia
@wtwh_michelle
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Mary Heideloff
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John Hansel
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Joshua Jones
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Patrick Curran
@wtwhseopatrick
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Jennifer Calhoon
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Bruce Sprague
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Crain’s Cleveland Business Fast 50 2014
2 SOLAR POWER WORLD www.solarpowerworldonline.com
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J a n u a r y 2 0 1 5 • v o l 5 n o 1
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
10 32 34 40 118ON THE COVER
CONTENTS
Developments In Solar ModulesSPECIAL SECTION:
Find out about frameless designs,the benefits of integrated modules,
what’s new with solar shingles
and the importance of miniscule
differences in panel efficiencies.
FIRST WORD
MARKETING
INSTALLATION PRACTICES
FINANCING
INVERTER INSIDERHybrids in the U.S.
RACKING & MOUNTINGEarth screws, tracking and elevated systems
BATTERIES, STORAGE & OFF-GRID
Microgrid charter school retrofit
SERVICESSnow removal and custom manufacturing
SOFTWAREWeb-based tools
PROJECTS
CONTRACTORS CORNER
SOLAR SNAPSHOT
PRODUCTS SPOTLIGHT
ARRAY AFLAME:
Viewing a PV system fire test at
Underwriters Laboratories
Associate editor Steven Bushong
witnessed a panel fire test at UL
headquarters and brings us a detailed
behind-the-scenes look.
TRANSFORMER TRANSFORMATION:
Your next solar inverter could be a
distribution transformer
Distribution transformers that feed
power from utility lines to homes and
businesses could soon change into
devices that double as inverters.
01
04
06
08
22
28
32
34
38
118
122
124
126
40
50
SOLAR LEADERSHIP page 55-117
1 • 2015 SOLAR POWER WORLD 3
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4 SOLAR POWER WORLD 1 • 2015 www.solarpowerworldonline.com
[ M A R K E T I N G ]
Content marketing has become animportant tool in business marketing efforts,and solar companies are embracing it with blog
initiatives. REC Solar, Run on Sun and SolarCity
each have popularized their blogs. And perhaps
you’ve encountered The Energy Miser from MarkDurrenberger, president of Massachusetts-based solar
installation company New England Clean Energy.
We asked the company’s marketing director, Susan
Boucher, to share some thoughts on the aim and
production of The Energy Miser.
Solar Power World: Why do you think it’simportant to blog?New England Clean Energy: It’s important to blog
simply for SEO. Relevant content brings people inand introduces them to our business. In the past 30
days, The Energy Miser has had nearly 1,000 hits. For a
small, local installer, we see that as a huge success.
In addition, we’ve always been a company that
focuses on education. An educated consumer is our
best customer. The blog is a perfect forum for digging
into solar issues and developments in more detail than
Facebook, Twitter and our e-newsletter allow.
Site stats suggest people are reading full articles.
They spend much more time on our blog pages than
our website pages (or maybe they’re just going to get
a cup of coffee while the blog is up on their monitor).
SPW: What are some of the key blog-writing guidelines you follow?NECE: We try to stick to 300 to 500 words andinclude at least one visual to spice it up. We love data
and charts. Content-wise, we shoot for conversational
and educational with a touch of humor.
SPW: How frequently do you blog?NECE: The goal is to blog at least monthly. It usuallyends up being slightly less due to lack of time.
Because our blog has in-depth articles rather than a
daily diary approach, this frequency seems to work.
Heather Centorbi
Heather Centorbi is a Marketing
Coordinator at WTWH Media, the
publisher of Solar Power World.
For more marketing advice, go tomarketing.wtwhmedia.com.
SPW: Do you talk generically aboutthe industry or specifically about yourbusiness?NECE: The Energy Miser is not a stream ofconsciousness blog where Mark says what he
had for breakfast or reports a funny comment
he heard at the bank. We use Twitter and
Facebook for brief observations or quips.
While his personality comes through on The
Energy Miser, it’s not about him. It’s about
solar. We focus on in-depth analysis of solarindustry issues seen through the lens of
our own experience. Mark interprets issues,
technologies or trends, and brings them to
life with his own analysis or anecdotes.
SPW: How do you make sure peoplefind your blog?NECE: We use our social media outlets—Facebook, Twitter and LinkedIn—to drive
people to The Energy Miser, and we often linkto the blog in our e-newsletter. Recently, we
added the blog URL to our business cards.
SPW: What’s been your most popularblog so far?NECE: Our most popular post is, “Tree Math:Solar Panels vs. Trees, What’s the Carbon
Trade-off?” It was published two years ago
and is still, consistently, our most popular
post, even though some of the links have
long since disappeared. Our readers find the
content still relevant though. Plus, we actively
refer people to that post who are debating
taking down trees to make solar work.
SPW: Have you ever encounteredchallenges or complaints about yourblog and how did you deal with it?NECE: One time a customer thoughtthey were portrayed negatively in an
example, though no name was given. Wedidn’t agree—we would never try to cast
a customer in a negative light. We were
happy to respond by simply removing that
reference from the post. SPW
New England Clean Energyshares tips on blogging for new business
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6 SOLAR POWER WORLD 1 • 2015 www.solarpowerworldonline.com
[ I N S T A L L A T I O N P R A C T I C E S ]
Removing nailsNail removal is necessary on most flashings to
position the upper edge of the flashing up into the
third course of shingles. To remove a nail, use a
roofing bar or flat bar and follow these steps:
1. Break the shingle seal in the proper location.
Be careful not to damage the shingles. A key
consideration is making sure you are at the seal
strip area and not separating laminated layers of
the shingles.2. Using a roofing bar, separate the lower shingle
from the upper shingle while feeling for the nail
locations.
3. Use the wedge tip of the tool to pry the nail up
and remove the nail from between the shingles
on the course above. You will need to break the
seal in the next course upward to remove the nail.
A hole will remain where the nail once was. While
flashing will cover the hole, it’s good practice toapply a small amount of sealant to the puncture,
completely filling it, but not too much or you could
blister the shingle.
Installing wood blocksSometimes it’s not possible to mount directly
to a rafter. When the mount
falls between two rafters, it is
required that you install wood
blocks between rafters. Wood
blocking allows installers to
place the mount anywhere,
without concern for rafter
locations.
Wood blocking can be done
with two-by-fours, two-by-sixes
or four-by-fours. Quick Mount
PV recommends a four-by-four
as it offers the largest mounting
surface and full lag screw
engagement with the rafter.Follow these steps:
1. Drill a hole where the mount
will be positioned.
Jeff Spies
Solar Power World Contributor
Jeff Spies is senior director of
policy for Quick Mount PV andSecretary of NABCEP.
2. Inside the attic, measure the distance
between rafters where the hole is drilled.
3. Measure and cut the wood block to that
length.
4. Insert the block between rafters centered
under the holes for each mount.
5. Use screws or nails to secure the wood
block to the rafters.
Cutting tile for hooks
Often, installers choose to use tile hooksto save time because they don’t require
a top flashing. To begin, remove the tiles
under which you will work.
For curved tiles, make sure your hook
is positioned at the side of the valley of
the tile. That minimizes the amount of tile
lug—the thicker part of the tile near the
edge—that you will have to cut, but make
sure you have sufficient clearance under
the hook so it will not strike the top of thetile under compression loading. With your
tile hook securely installed, position the
tile over the tile hook and mark the tile
lug on both sides of the tile hook. A tuck-
pointing blade is best for cutting off this
section of the tile lugs. A conventional
Three quick tips for solar mounting
Wood blocking allows installers to place the mount
anywhere, without concern for rafter locations.
See these and other tips
performed on video at the Quick
Mount PV website,
www.quickmountpv.com.
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[ I N S T A L L A T I O N P R A C T I C E S ]
1 • 2015 SOLAR POWER WORLD 7
diamond blade is best
for cutting holes. Safety
glasses and a dusk mask
are musts for cutting tile.
Rest the tile on
a sturdy surface and
hold the saw firmly to
avoid injury. Use the
tuck pointing blade to
remove just enough
lug to allow the tile
to sit back in place
comfortably over the
hook. If the tile does not
sit back down properly,
you need to remove
more of the lug, or
sometimes a bit of the
tile further up that might
interfere with the upper
part of the hook. SPW
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The "fuel" of a solar project is the most critical factor driving itscommercial success or failure. Where is irradiance strongest. How
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8 SOLAR POWER WORLD 1 • 2015 www.solarpowerworldonline.com
[ F I N A N C I N G ]
Building strong relationships with energyinvestors is crucial for solar developers whowant to receive financing for projects. Onepowerful way to speed up project finance, whilealso building strong partnerships, is to focus onpresenting projects in a way that is appealing toinvestors.
If investors do not provide specificguidelines on how they want to receiveinformation about a project, developers
should focus on building a great data room, aplace online where companies share businessdocuments. These are my top three rules for agreat data room:
• Transparency• Transparency• Transparency
Here are my best practices to effectively
achieve transparency:
Include an executive summaryAn up-to-date executive summary savesinvestors’ time. This will be the first documentreviewed before logging into your data room. Agreat executive summary should be three pagesat most and communicate the following:
• What is your ask?• Project size (DC and AC)• Estimated total project cost• Annual production (kWhr or MWhr)• Project location• Project merits• Developer’s history and experience• Third parties involved. Mention if a third party
can be substituted. Investors value flexibilityand may prefer their own EPC and O&Mpartners.
• Timeline of target dates for key milestones
(site control, key permits, powerpurchase agreements, interconnection,commencement of construction, commercialoperation date, etc.)
Haresh Patel
Special To Solar Power World
Haresh Patel is the CEO and co-
founder of Mercatus, a providerof cloud-based software
solutions that simplify renewable
energy investment.
• Key document summaries—a briefparagraph summarizing the status of keydocuments. For example, you may write,“Interconnection Agreement is expected inDecember 2015. Facilities Study receivedin July 2015. Estimated interconnectionupgrade cost of $350,000, in which$100,000 due at execution of theInterconnection Agreement and thebalance, $250,000, due at commercial
operation.”• Financial summary—as an initial litmus
test investors typically look at unleveredpre-tax and after-tax IRRs. Developers canprevent unnecessary back and forth withinvestors by having a simple, but accurateunlevered pro-forma available.
Note: This is also applicable for aportfolio of projects.
Present an up-to-date and relevantdata roomSpending hours or days reviewing a dataroom in detail and then receiving anemail with 30 additional documents thatshould have been there in the first place isextremely frustrating. At the same time, don’tdump every project document you have intothe data room. Be comprehensive, but noinvestor needs to review version 2 of 8 of a
Site Lease Agreement.
Create a folder nomenclatureInvestors greatly appreciate being able toeasily navigate a data room. A simple folderhierarchy for a renewable energy projectshould include the following categories: SiteControl, Environmental, Permits, Production,Interconnection, Off-take, EPC, ProjectCompany, O&M, Financials.
Have a document nomenclatureSimilarly, a simple document namingmethodology simplifies the experience for an
Appealing to investors: Tips for a great data room
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[ F I N A N C I N G ]
WHAT DOYOU THINK?
Connect and discuss this and
other solar issues with thousands
of professionals online
investor. Answer the following questions:
1) What is this document? 2) What version
is it? 3) What is the date? 4) Is it executed?
An example of an executed Power
Purchase Agreement would look like this:
PPA_Final_081413_FullyExecuted.
Don’t hide skeletons
Developers are often reluctant to share
any potentially detrimental information
about a project. Nevertheless, hiding
information that will eventually be
uncovered during the due diligence
process destroys credibility and
jeopardizes the entire project. Be
upfront with potential project risks
and communicate the actions in
place to resolve them.
Much of this may seem
like common sense, yet we see
insufficient organization andtransparency every day. At Mercatus,
we have appraised over 22 GW of
renewable energy assets. Ideally,
developers could solicit projects with
a score recognized industry-wide, but
until that is established transparency
is required by developers to unlock
capital and get lots of projects across
the finish line. SPW
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1 0 SOLAR POWER WORLD 1 • 2015 www.solarpowerworldonline.com
SPECIAL SECTIONSGENERATION TECHNOLOGIES
MICHELLE DIFRANGIAASSISTANT EDITOR
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1 • 2015 SOLAR POWER WORLD 1 1
BIPV is a quickly growing sector
of the global solar market.
Transparency Market Research
expects this area to grow by
18.7% by 2019, reaching 1.15 GW.
One BIPV product picking up
popularity is the solar shingle.By nature of their design, solar
shingles are primarily geared for the
residential market, said Josh Wimble,
communications manager at Dow
Solar, manufacturer of the Powerhouse
Solar Shingle. This is because sloped
shingle and tile rooftops are most often
found on single-family homes.
Solar shingles not only look
aesthetically pleasing, they also serve
a function outside powering the house.
Apollo, a solar shingle developed by building
products manufacturer CertainTeed, is
designed with waterproofing capabilities.
“The Apollo panels generate electricity from the
PV cells and also function as the roof itself by shedding
water just like the surrounding shingles or tiles, so you
don’t have to install a roof underneath it,” said Mark
Stancroff, director at CertainTeed.
Solar shingles increase the integrity
of the roof over conventional panels byhaving 10 times fewer roof penetrations
and greatly reducing wind uplift concerns.
Apollo solar shingles
and tiles are made up of
crystalline silicon solarcells and can withstand
winds up to 110 mph.
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1 2 SOLAR POWER WORLD 1 • 2015 www.solarpowerworldonline.com
“Solar shingles increase the
integrity of the roof over conventional
panels by having 10 times fewer roof
penetrations and greatly reducing wind
uplift concerns,” added Wimble.
Perhaps the biggest news in solar
shingle technology is the ability to
integrate with a wider variety of roofing
materials. Initially, solar shingles couldonly integrate with standard asphalt
shingles. But now, Dow has developed
its shingles to integrate with cedar
shake, concrete and clay tile, polymer
and traditional slate.
Another added benefit is that solar
shingles don’t use traditional rack
mounts, thus are free from configuring
balance-of-system technologiesinto the installation. CertainTeed’s
SPECIAL SECTIONSGENERATION TECHNOLOGIES
RBI Solar Inc.| 513.242.2051 | [email protected] | www.rbisolar.com
SINGLE SOURCE RACKING SOLUTIONS
“LET US TALK ABOUT YOUR NEXT PROJECT”
DESIGN ENGINEERING MANUFACTURING INSTALLATION
. . . .
Optimize performance
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@ Heli-Cal.com
For more information on Custom Couplings,
go to Heli-Cal.com or call (877) 435-4225
© 2014 Helical Products Company, Inc. | www.heli-cal.com
Optimize performance
for your application with
Simplify assembly
Accommodate shaft misalignmentsMaterials for harsh environments
Reliable and accurate performance
Outstanding quality/Made in the USA
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1 4 SOLAR POWER WORLD 1 • 2015 www.solarpowerworldonline.com
polymeric frame allows the shingle to
seamlessly integrate with the roof and
provides hassle-free roof replacement.
“With standard rack and panel,
the entire system needs to be pulled
off and reinstalled when replacing
the roof. But with solar shingles, the
system can stay in place and the new
roof can be installed around it,” saidStancroff.
Although solar shingles are a viable
option when retrofitting existing roofs,
Chris Jones, commercial director at
Dow Solar, said homeowners receive
the greatest financial return when
shingles are installed when building
new or re-roofing existing homes.
“It allows a homeowner or
homebuilder to install a solar array
with the same roofing labor, whilesaving money by off-setting re-
roofing material costs,” said Wimble.
“With increasing simplicity, a roofing
crew can be trained to install
the solar shingles and do the
installation in only a little more
time than it takes to re-roof with
ordinary shingles.”
An array of 350 shingles could
reduce one's electric bill by 40
to 60%, but it costs upward of
$20,000. However, in addition tofederal, state and local incentives,
companies like Dow Solar and
CertainTeed are finding their
own ways to drive costs down
and make solar shingles price-
competitive with rooftop solar. For
Dow, customer savings start by
working closely with builders and
roofers, selling kitted systems with
all the necessary parts rather than
pricing individual components, andgiving region-based quotes that
include local labor costs. SPW
With standard
rack and panel,
the entire system
needs to be pulled
off and reinstalled
when replacing the
roof. But with solar
shingles, the system
can stay in place andthe new roof can be
installed around it.
Powerhouse
shingles, made of CIGSthin-filmsolar cells,are certifiedto resist upto 150-mphwinds, hail up
to 1.25 in. indiameter andheavy rain.
SPECIAL SECTIONSGENERATION TECHNOLOGIES
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Global solutions for renewable energy often require a globalapproach to products and supply. When an international Sapacustomer expanded their solar business into North America, theyfound Sapa Extrusions was already here and ready to support them.
With 23 locations across North and South America, the Sapateam was able to coordinate with global colleagues to quicklytransfer the tools, data, and knowledge required to rapidly begin
producing material. Thanks to Sapa, our customer soon had locallyproduced material in hand across multiple regions, faster thandealing with multiple extrusion companies.
From cost-effective regional production of materials, to global
transfer of information between facilities, working with SapaExtrusions offers customers the very best in aluminum extrusiondesign and production.
For more about Sapa and renewable energy: [email protected] • (877) 710-7272
A wide array of aluminum extrusion solutions for solar and wind
Sapa Extrusions North America
GREENER FUTURE
SHAPING A
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SPECIAL SECTION
S
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1 6 SOLAR POWER WORLD 1 • 2015 www.solarpowerworldonline.com
SPECIAL SECTIONSGENERATION TECHNOLOGIES
Integratedsolar modules
COME WITH
KATHIE ZIPPMANAGING EDITOR
Power optimizer and microinvertercompanies are joining with module
manufacturers to offer more integrated
solutions to the solar market. But what is the
difference between these systems and what
advantages do they offer solar contractors?
“The microinverter is converting DC
into AC, while a power optimizer performs
DC to DC conversion, and therefore an
inverter (to convert DC to AC) is needed
in a grid-connected system,” said JuanCarlos Gonzalez, senior technical manager
at Jinko Solar. “Also, optimizers tend to be
more efficient, while microinverters tend to
have more flexibility.”
Gonzalez added that buying
a solar module with an integrated
electronic offers
some advantages
for installers rather
than buying them
separately.
“From a logistics
point of view, there
are no extra boxes,
shipping, warehousing
or extra part numbers
needed,” he said.Brian Cox of Axitec Solar added that
from a construction standpoint, there
is no additional hardware required, no
pre-configurations and no additional
communication connections required
during the installation with integrated
modules.
“Less wiring and avoiding having to
install the electronics separately makesinstallation easier,” he said.
Don Hammond, vice president of
sales and marketing at Mage Solar, also
sees the advantages integrated modules
offer solar installers.
“Installers love that integrated panels
just plug in to each other without any
high voltage DC. This makes installation
much safer and panels can be shut down
individually if needed,” he said. “Becauseof their plug-and-play technology,
integrated systems can be expanded
without problems. This usually eliminates
any initial consumer hesitationsbecause the systems can be scaled to
accommodate any budget.
Usually, integrated modules
offer the same warranty conditions
as a traditional PV module, about 25
years, said ET Solar product manager
Zhaoyang Zhang. However, the price
can run a bit higher.
Still, while the initial hard costsmight be higher in some cases,
Hammond says they can be quickly
recouped after considering the saved
installation labor and time.
“It’s really hard to think of an
actual disadvantage these modules
might present,” Hammond said. “It’s
a relatively young technology and so
maybe one of the challenges for the
industry is to create more awarenessand provide better information about
the ease of use and installation for
integrated modules.” SPW
Some integrated solar modulepartnerships:
Andalay and Enphase
Axitec and Tigo Energy
Canadian Solar
ET Solar and SolarBridge
JA Solar and Tigo Energy or SolarEdge
Jinko Solar and Tigo Energy
Mage Solar and SolarBridge
Trina Solar and Tigo EnergyUpsolar and Tigo Energy
Yingli and Tigo Energy
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SPECIAL SECTION
S
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1 8 SOLAR POWER WORLD 1 • 2015 www.solarpowerworldonline.com
SPECIAL SECTIONSGENERATION TECHNOLOGIES
STEVEN BUSHONGASSOCIATE EDITOR
efficiency are important
Why news OFIN
Solar panel manufacturers produce
a steady stream of news about
advancements made in labs. Often, news
heralds a higher efficiency solar cell—
usually a few tenths of a percent at a time.
“Any corporation out there, from
Apple to Ford, wants to show they’re
continuing to innovate and answering
the needs of their customers,” said
Daniel Chang, product manager atTrina Solar. “They’re saying, ‘We’re
walking the walk.’”
Sounds good. But, from a technical
standpoint, is a few tenths of a percent
really that important?
“People seem to think of this like
test scores—a 100% versus a 99.5%,”
said Tom Thompson, key account
manager at JA Solar. “They think,
what’s the big deal? But it is a big deal.”
These small improvements have
at least two important consequences,
according to experts. First, even asmall efficiency increase can make a
remarkable reduction in installed cost.
And second, they contribute to the
long-term success of solar technology.
“A one-point rise in module
efficiency (e.g. 16% to 17%) is worth
about 1.5 to 3 cents per watt in
installation cost savings,” said Lyle
Rawlings, president and CEO of
Advanced Solar Products. “In any space-
constrained project, it can make the
difference between a sale and no sale.”
In the 1980s, solar modulessold for $100/watt. Improvements in
manufacturing, such as the way a cell is
doped or cut from raw material, have cut
manufacturing costs to about $.50/watt.
“Every time our industry doubles
production, costs drop by about 20%,”
Thompson said.
For solar installers to benefit from
increased solar cell efficiencies, R&D
needs to make it into a company’s
manufacturing line, and at a price
consumers are willing to pay.
A typical module can take threemonths to two years to complete the
whole process, experts said.
“The go-to-market process includes
data sheets, installation manuals, collateral,
sample modules and certifications,” Chang
said. “All of those little parts need to be
taken care of before we can sell.”
Chang said most reported
efficiency improvements eventually
make it into manufacturing, especially
as the go-to-market process in the
solar industry matures. But companies
must also consider their manufacturingcapacity and the stomach of customers.
“If we were to ask our production
team to make something that’s not going
to sell, it’s cannibalizing on what we can
currently produce,” Chang said. “We’re
constantly listening to our customers.”
As the industry matures, it appears
customers continue to demand higher
efficiencies at lower cost, and module
companies are happy to report on their
progress, which comes with one more
benefit: Higher efficiency modules mean
fewer are needed for a target output,and solar can reduce the ecological
footprint of energy production even
more. SPW
A one-point rise in module eff iciency (e.g. 16% to 17%) is worth
about 1.5 to 3 cents per watt in installation cost savings.
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SPECIAL SECTIONSGENERATION TECHNOLOGIES
2 0 SOLAR POWER WORLD 1 • 2015 www.solarpowerworldonline.com
The frameless crystalline solar
module is gaining traction in the
industry. Some customers prefer theway they look and how they perform.
But even with their benefits over their
framed cousins, frameless modules
haven't picked up much steam in
the installation department. Here's a
quick summary of what's out there
and what's holding them back.
Types
A frameless module has a pretty
obvious definition—there’s no frame.
A dual glass (AKA glass-on-glass or
glass-glass, among other names) is
also pretty self-explanatory—solar
cells are sandwiched between
two pieces of glass. Keep in mind
that frameless is not a synonym
for glass-on-glass. SolarWorld’s
glass-glass module (the SunmoduleProtect) has an aluminum frame.
On the other end, Solaria’s range
of frameless crystalline solar panels
have a backsheet instead of two glass
pieces. So make sure you're dealing
with a true frameless module.
Benefits
The most notable benefit is no need
for grounding. Without a metal
frame, frameless modules are less
likely to shock workers. Frameless
modules are also great for those
framelessmodules
THE ON
KELLY PICKERELASSOCIATE EDITOR
worried about potential induced
degradation (PID). Electrical current
can’t leak out of a frame that isn’tthere, so modules are more efficient.
If it’s a dual-glass module, it has a
stronger fire safety rating because
there’s no backsheet. Frameless
modules also provide a unique
aesthetic value for customers who
want to blend their solar systems into
roofs.
Detriments
Why aren’t more frameless modules
installed in the field? The main hold-
up is the lack of compatible mounting
systems. A number of mounting
companies cater to specific types of
frameless modules—including Array
Technologies trackers and Schletter’s
Eco Series laminate clamps—but
they’re almost entirely for thin-filmframeless modules. A few companies,
such as Lumos Solar, manufacture
both the modules and the racking
systems and have carved out a nice
niche for themselves. Lumos’s LSX
frameless modules mount with their
own racking solution, providing
customers a one-stop shop.
Outlook
Most companies seem to be dabbling
in the frameless pool but are not
diving head-first. Trina Solar’s PDG5/
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1 • 2015 SOLAR POWER WORLD 2 1
Duo Max dual glass module has been on the North
America market for more than a year. Canadian Solar
will release its double-glass Diamond Module sometime
in 2015. But as more and more module manufacturers
announce their own frameless models, the need for
mounting is necessary for market growth.
Lumos Solar has been in a class of its own for awhile—offering both the module and the racking. “It's
interesting to us to see big guys now offering frameless
modules,” says Scott Franklin, president and CEO of
Lumos Solar. “I think they've all realized a few things—
there's no PID, there's no corrosion of the frames, there
are a lot of durability benefits. I think they're just trying to
find other niches and areas to push into.
"I suspect you'll see a lot more frameless modules
being used in utility-scale installations and larger
installations, because they're looking for a lower cost
wherever they can. If they can find a smart mounting
solution, then they can eliminate the cost of frames.
There's definitely an opportunity." SPW
WHAT DO
YOU THINK?
Connect and discuss this and other solar
issues with thousands of professionals online
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I N V E R T E R I N S I D E R
How are
inverters used in solar projects?
KATHIE ZIPPMANAGING EDITOR
Hybrid inverters are commonly used
in the developing world, but they are
starting to make their way into daily use
in certain areas of the U.S due to their
ability to stabilize energy availability.
A solar inverter’s main job is to
convert DC power generated from thearray into usable AC power. Hybrid
inverters go a step further and work
with batteries to store excess power
as well. This type of system solves
issues renewable energy variability and
unreliable grid structures.
“Inverters for grid-tied applications
can only provide power based on what
the array can immediately generate from
the sun,” explained Bryan Whitton, product
manager at Darfon. “Hybrid inverters can
store power in batteries and then drawnupon it as needed for energy stabilization.”
Hybrid inverters can vary in size,
performance and features. But Mara
White, product manager for OutBack
Power, said most models usually
operate bi-directionally, meaning they
can convert DC power from modules
to usable AC power and then convert
stored AC from the batteries to power
loads when needed. “Hybrids can also
remain grid-connected and use a mix of
renewable and non-renewable energy to
charge batteries and offset loads,” White
added.
Some contractors have used
hybrid inverters in the residential,
remote home applications for the past
decade or two. But Allan Gregg, VP of
applications engineering at GreatWall—
which manufactures Satcon inverters—
said the range of applications has
expanded over the past few years to
include large capacity microgrids aswell as grid-connected systems.
Historically, hybrid inverters
have been used more frequently in
developing countries that do not have
access to a reliable power grid.
“In North America and Europe,
hybrid inverter-based systems are
usually elective,” White explained. “Users
choose to use them for storing energy
for self-consumption or provide back-up power during emergencies. But in
the developing world, hybrids are more
of a necessity to compensate for weak
or intermittent grids or a lack of grid
A hybrid inverter system in a residential in-stallation. Hybrid inverters work with batteriesto store power.-OutBack Power.
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I N V E R T E R I N S I D E R
2 4 SOLAR POWER WORLD 1 • 2015 www.solarpowerworldonline.com
electricity all together. Microgrids in
places such as India, Asia and Africa are
also driving hybrid inverter adaptation.”
Still, Whitton said hybrid models are
beginning to be used on a more daily
basis in areas of the U.S. where the grid
is unpredictable, such as Hawaii, or in
states where net-metering has been
widely supported. “Applications with less
than ideal solar characteristic are also
good for hybrid-based systems because
they can store power and redistribute it
during peak times, improving payback,”
he added. “Basically, if the site has the
potential for losing the grid frequently,
you should consider a hybrid for off-
grid operation.”
Having the flexibility of a hybrid
system can add initial cost to a project,
though experts say this can be offset bythe ability to self-consume all of one’s
available PV electricity.
There are also important design
considerations when using hybrid
inverters. For example, Gregg warned
that the battery bank voltage should
be compatible with the DC input
requirements of the inverter, and there
should be enough solar capacity to
supply the load as well as charge thebatteries.
Wiring can also be more complex
when using hybrid inverters, especially
when panels are dedicated for critical
An example of power flow in a hybrid inverter system.The inverter can direct power to a load or the grid ifneeded, or store it in batteries if not. It can also usepower from the grid if needed. -GreatWall
backed-up loads. “And as with any
device that does several jobs at once,
a hybrid inverter is usually slightly less
efficient,” White added, “although,
improvements in other balance-of-
system components can compensate for
that slight loss easily.”
There are also specific electrical
safety issues with any type of energy
storage, so White recommended getting
specialized training in energy storage
techniques and design. “Most available
Another breed of hybrids
Another segment of hybrid inverters
includes inverters that can use two
energy sources. For example, Ginlong
offers a PV / wind hybrid inverter that
has inputs for both sources, instead
of having to use two inve