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Winners 2009

PV Material Award

• Solar Business, Dow Corning Corporation
Dow Corning® PV-6100 Cell Encapsulant Series

Consumables

•
Pasan SA
CT 801 Cell Tester

Energy Usage Award

• Advanced Energy Industries, Inc
Solaron grid-tie inverters

PV Application Award

•
Mecasolar
MS Tracker 10
Meca Solar Logo

PV Process Equipment Award

•
DEK Solar
PVP1200 screen printing platform
DEK Logo

PV Process Subsystem/Monitoring Award

• Newport Corporation
PV IsoStation

Silicon Innovation Award

•
Mallinckrodt Baker
J.T.Baker PV-160
JT.Baker

Device Integration Award

• Siemens AG
SINVERT 1700 MS

Thin Film Innovation Award

•
Oerlikon Solar Ltd
TCO 1200 System

Industry Development Award

• Fraunhofer ISE

Turnkey Company of the Year Award

• Spire Corporation

Factory Solution Provider of the Year

• IB Vogt

Solar Inspiration Company Award

• First Solar

Solar Inspiration Individual Awards

• Nick Sarno Head of Manufacturing LDK

Pasan SA
CT 801 Cell Tester


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Pasan::CT801The CT 801 Cell Tester includes in the same compact architecture a single-flash xenon light source, an automatic sliding contact frame, a test chuck with interchangeable plates to fit any cell configuration, even cells with back-contacts like the Sun-Power A-300, a calibrated reference cell, and a Panel-PC type computer.

To become a fully featured cell testing unit, it needs to be connected to an external electronic load and flash generator, itself included in a 19“ 6U rack. Its single-flash technology gives a negligible heating on cell junction level, in the tenths of a degree range, much lower than continuous-light testers, so the most accurate I/V curve determination can be achieved. Its active light control ensures an accurate light level within 1 % during all flash duration of 4 ms, so there is no need for irradiance correction of measured values.

A simple ambient temperature probe allows for thermal correction of results, ensuring accurate values even in the case of temperature variations during the day or from day to day. The lamp assembly includes our patented light-uniformization device to allow less than 1 % ununiformity over the tested cell. This is particularly important with multicrystalline cells in which some zones may be more efficient than others giving unconsistent results on cell testers with bad light uniformity. The lamp also includes proper filtering to ensure true Class A spectral distribution. The innovative contacts design uses single-wires made of special nickel- copper alloy.

This stainless alloy is delivered in hard, springquality type and combines very low resistance as well as good elasticity to apply pressure on cell to be measured. Contacts disposition allows slight mechanical wiping to self-clean the contact region. The single-wire contact design is much more efficient than the usual pump-type contacts in which contact resistances may vary from a few milliohms to hundred of milliohms and necessitating ten or more contacts to statistically lower this effect. In standard, the tester is delivered with six contacts pairs; four for current and two for voltage.

This can be extended up to nine contacts pairs to match large cells with three metallization bands. In manual operation, the unit is delivered with a pedal switch to allow hand-free working. When the cell is roughly positioned on the chuck, the operator actions the pedal switch. An air blowing system will accurately position the cell on the chuck, then the contacts move down, the flash is fired, the measurement is taken during flash and the contacts move up automatically.

The result is then displayed on the screen. Cells can be sorted according to predetermined classes and results are also available in up to 16 classes on a potential-free interface for signalization or to drive an external cell sorter. On special demand, programs including statistics and lot management can be provided. On option, but at the expense of a longer measurement cycle, shunt resistance can be measured on dark mode. Otherwise, series and shunt resistances values will be approximated from slopes of the I/V curve near Voc and Isc.

DEK Solar
PVP1200 screen printing platform


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The PVP1200 is a breakthrough modular screen printing platform designed to deliver the high yields and throughput rates required by the solar processing sector for high-accuracy metallization of crystalline silicon (c-Si) solar cells.

All the key features of the PVP1200 that provide its clear competitive edge come from its innovative design which allows DEK to deploy its acclaimed lean manufacturing strategy during production. This permits lead times of weeks, rather than months, allowing manufacturers to ramp up productivity fast.


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The product is exceptionally compact - an increasingly critical consideration in factory floor real estate utilization for maximum ROI. This means the printing process operates at approximately waist height, offering clear visibility and fast print area access for easy maintenance. With its tiny footprint, manufacturers can have two or more PVP1200 printers occupying no more space than a single competitive system.

Fast and modular, the PVP1200 delivers throughput of 1200 solar cells per hour and maintains a six-sigma process capability at an accuracy of ±12.5 microns for maximum repeatability. Dedicated handling for thin wafers minimizes breakages during metallization to maximize yield and cost-of-ownership, while high-speed machine vision ensures perfect alignment.

The driving force of DEK's PV1200 line; the PVP1200 is part of a complete metallization solution along with purpose-designed loader/unloader, buffering, in-line inspection and wafer flipping systems. The PV1200 is a turnkey solar cell metallization solution perfectly balanced to operate at optimal throughput and incorporating advanced process technologies to ensure maximum yield and minimum waste. Enhancing the offering even further, DEK's proven manufacturing model positions it perfectly to work in partnership with equipment suppliers and system integrators to support further additions to the line such as drying and firing technologies.

Why this product stands out from the crowd:
  • 1200 solar cells per hour throughput
  • Six-sigma process capability at a resolution of ±12.5 microns
  • Compact footprint increases factory floor real estate utilization and ROI
  • Fast and easy scalability for changing market demands
  • Innovative design offers rapid print area access for easy maintenance
  • High-speed machine vision for perfect alignment accuracy
  • Advanced handling technologies minimize breakages and optimize yield
  • Short lead-times enable manufacturers to ramp up productivity quickly
  • Modularity future-proofs production flexibility

Advanced Energy Industries, Inc.
Solaron grid-tie inverters
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Benefits
  • Increase Decrease levelized cost of energy (LCOE)
  • Achieve higher energy harvests
  • Reduce balance-of-system (BoS) costs
  • Reduce operating and maintenance (O&M) costs
  • Increase project system ROI
  • Monitor and control with flexible, integrated communications
  • Rely on worldwide service and support
Features
  • 500 kW , high-power, transformerless, bipolar design
  • Largest core engine in its class—with the industry's smallest footprint and lightest weight per kW
  • 98.5 peak, 98.1 weighted97.7% European efficiency (pending)
  • IDS™ data monitoring and communications
  • Remote PV Tie (RPT™) array accessory
  • Nearly three decades of experience in solar PV industry
  • 24 x 7 x 365 global service and support

Achieve the best LCOE, Levelized Cost of Energy, possible with Advanced Energy's Solaron® 500E inverter. Solaron inverters directly deliver improved great LCOE with higher energy harvests, lower BoS costs, and lower O&M costs. This robust, 500 kW inverter offers a stable, higher voltage, transformerless engine which allows many units to be wired in parallel into a single medium voltage transformers—making it ideal for utility-scale PV installations. In addition, each unit includes Integrated Data System (IDS™) monitoring and control capabilities to provide remote control, real-time site performance updates. An optional Remote PV Tie (RPT™) array accessory can cut your BoS costs even further. All are backed by AE warranties and customizable training, service, and support programs such aslike AE Safeguard® service.

Increase Energy Harvests with High Efficiency and Better BoS Optimization

The AE Solaron 500E inverter expands improves upon our field-proven, North American, bipolar, transformerless product family.architecture. Higher power and 98.197.7% European-weighted efficiency translate to immediate system cost savings and greater returns on your PV investment. For example, you can install fewer panels in your PV system to achieve equivalent a similar AC energy harvest. Or, use similar panel counts to get years of higher kWh production.

A combination of advanced controls, smooth MPP tracking, separable bipolar architecture, and proprietary IGBT switching efficiently and reliably converts raw, solar DC power to high-quality AC grid electricity. The Solaron inverter combines the largest core engine in its class with the smallest footprint and lightest weight to deliver ½ MW in a compact outdoor rated IP-45 package. Solaron inverters require no additional buildings or enclosures for exterior operation.

Monitor & Control Your System
A secure, integrated LCD and keypad provide fundamental unit data on the exterior inverter cabinet. In addition, the on-board Integrated Data System (IDS™) communications system—included at no additional charge—collects a wide range of data for remote monitoring and greater performance insight. Features include:

  • Detailed unit configuration monitoring and control
  • Access to comprehensive performance data
  • Valuable product and maintenance documentation

Connect to any web browser for a number of built-in graphical representations of real-time temperature, current, and voltage data—or download a CSV file and configure your own custom data and analysis reports.

Cut PV System Wiring Costs with the Remote PV Tie (RPT™) Accessory
With the addition of an AE Solaron Remote PV Tie (RPT™) accessory, you can further reduce BoS installation costs and achieve even higher system efficiency. The RPT accessory reduces large-diameter copper home-run cables as well as (I2)R losses for up to 4% more power output during operation. The RPT also offers flexibility in system design and inverter installation for large, utility-scale solar farms.

Comprehensive, Customizable Service and Support Reduce Operating and Maintenance Costs

The Solaron inverter is durable, robust, and reliable for ongoing, low-maintenance operation. However, if needed, AE's worldwide service organization is available 24 x 7 x 365 for support. We also offer proactive services, including extended warranties (up to 20 years) and SafeGuard® service programs to help you maximize uptime and power generation. Our highly trained specialists can perform routine system queries, remote testing and diagnostics, and annual on-site inspections, all at a nominal cost.

Oerlikon Solar Ltd
TCO 1200 System
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Oerlikon Solar Ltd

The Oerlikon Solar TCO 1200 is a fully automated high volume system for the deposition of a novel and adjustable Transparent Conductive Oxide (TCO) film. The TCO 1200 process technology allows adjustment of film morphology and conductivity to match ideal parameters for the PV absorber stack while utilizing an innovative ZnOx film composition with superior light trapping versus standard SnOx films. As Oerlikon Solar is the number one supplier of end-to-end production lines according to VLSI Research with over 350 MWp of installed production capacity, the TCO 1200 systems have become the de facto industry standard for the production of thin film silicon solar modules.

TCO films have been used within thin film PV panels since the beginning of the technology. The TCO film needs to: allow full spectrum light onto the panel for generation of energy by the PV absorber, act as a current collector and act as a light scattering and trapping layer which forces key wavelengths to traverse the PV absorber stack for multiple reflections, increasing the chance for the light to create electricity. The standard technology for deposition of TCO films has been sputtering. Unfortunately the sputtering process allows only a small window of process adjustment and no optimization of material composition or light scattering. Another popular approach to TCO fabrication, especially by glass manufacturers, is Atmospheric Pressure CVD (APCVD). APCVD techniques typically require very high deposition temperatures, >500° C, and so forces the films to be applied to the glass directly without any PV absorber films present. This is possible only for the first film on glass at the beginning of module manufacture, however, the back contact TCO film cannot be deposited by APCVD. The TCO 1200 LPCVD (Low Pressure Chemical Vapor Deposition) reactor has several new hardware and chemistry innovations, allowing a fast and highly uniform IR camera controlled heating, a low temperature process (›200° C) and controllable conductivity and crystal morphology through adjustable doping gas delivery. These features allow the film to be adjusted to optimize panel power output.

In order to develop the next generation thin film silicon PV cells, light trapping by advanced TCO is essential. The new LPCVD process from Oerlikon Solar has demonstrated higher light trapping abilities. This is especially important for micromorph solar cells where the absorber layers are engineered to be as thin as possible while keeping the efficiency high. In addition, amorphous silicon single junction cells have an enhanced susceptibility to Staebler-Wronski degradation, so efficient light management allows a reduction in layer thickness, fundamental for high performance in these material systems. The output current of an Oerlikon Solar TCO film is significantly higher than a high quality commercial APCVD film, accounting for an additional 0.5% improvement in stabilized efficiency. The TCO 1200 LPCVD manufacturing system allows in a single layer to optimize a tandem absorber stack with very high haze light scattering, very low sheet resistance and excellent transmission characteristics. Also, the low temperature nature of the deposition allows this same TCO layer to be used successfully for the TCO back contact, again increasing light trapping within the cell.

Until today over 900'000 panels have been produced using the TCO 1200 systems from Oerlikon Solar for front and back contacts. The additional 0.5% efficiency gained translates into higher power per module and also in a significant economic benefit: e.g. 100 Wp modules are becoming 105 Wp modules which means to the solar farm developer a direct module savings of 5%. In a 30 MWp solar farm with 300'000 modules this accounts to saving 15'000 installed panels or about $3 million

First Solar
FS Series 2 PV Module


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First Solar FS Series 2 PV Modules are designed for use in grid-connected, commercial power plants and are sold to leading system integrators, independent power project developers and utility companies worldwide. The modules are CdTe thin film in construction that will generally produce more electricity under real-world conditions than conventional solar modules with similar power ratings and the lowest cost per watt overall.

Solar cells become less efficient at converting solar energy into electricity as their cell temperatures increase. However, the efficiency of Cadmium Telluride is less susceptible to cell temperature increases than traditional semiconductors, enabling First Solar thin film modules to generate relatively more electricity under high ambient ( high cell) temperatures. The semiconductor material also converts low and diffuse light to electricity more efficiently than conventional cells under cloudy weather conditions. CdTe permits simple device structures and manufacturing processes, leading to low cost production.

Front (substrate) and back (cover) laminated glass sheets are heat-strengthened to withstand handling and thermally induced stresses, while avoiding breakage over the 25+ year module life. Manufactured in highly automated state-of-the-art facilities certified to ISO9001:2000 quality and ISO14001:2004 environmental management standards. Tested by leading US and European institutes and certified for reliability and safety: Safety Class II; IEC 61646; CE Mark & UL 1703.

Modules are life cycle managed with a collection and recycling program, providing module owners with no cost , pre -funded , end of life take back and recycling of modules.

Mallinckrodt Baker, Inc
J.T.Baker PV-160
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The J.T.Baker PV-160 Solar Cell Surface Modifier is a wet chemical surface modifier applicable to in-line manufacturing processes of crystalline silicon (c-Si) solar cells.

Following emitter formation, J.T.Baker PV-160 surface modifier's modification of cell surface properties delivers higher value solar cells by improving cell conversion efficiency.

Developed in cooperation with Energy research Centre of the Netherlands (ECN), J.T.Baker PV-160 surface modifier improves cell conversion efficiency by enabling an enhanced cell response to blue light. Modifying surface properties of c-Si solar cells after emitter formation, J.T.Baker PV-160 surface modifier provides photovoltaic cell manufacturers with a powerful surface modification chemistry proven to increase the value of their solar cells by improving absolute cell efficiency by up to 0.3%.

In addition to removing residual phospho silicate glass (PSG) left behind following a standard hydrofluoric acid (HF) bath, J.T.Baker PV-160 surface modifier is the only commercially available cleaning chemistry able to deliver the high-value, competitive advantage of improved cell efficiency. Solar cells made using J.T.Baker PV-160 surface modifier produce more electricity and are more valuable than cells made without the product.

  • Produces more efficient solar cells that provide higher electrical output and are more valuable than cells made without J.T.Baker PV-160 surface modifier.
  • A 100% water soluble formulation eliminates the need for an intermediate solvent rinse, decreasing total processing time and cost
  • Long bath life, typically greater than 80 hours; process optimization resulted in bath lives of more than 100 hours in high volume manufacturing
  • A self-limiting surface modification process designed to slow down with treatment time, thereby diminishing the chance of destructive processing.

Newport Corporation
PV IsoStation


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Newport's PV IsoStation Workstation is a, 36”x 60” ergonomic workstation specifically designed for PV test and development applications. It features integrated storage and shelving for instruments, solar simulators and other devices and a specially treated work surface that reduces light reflectivity by a factor of six compared to typical optical table surfaces. The PV IsoStation workstation is ideal for a wide range of photovoltaic applications and provides a 6x less reflective work surface than standard workstations to minimise the effects of reflected and scattered light.

The RG series 3' x 5' breadboard is a lightweight honeycomb structure that superior to granite or steel plate platforms and much easier to assemble and move. The breadboard surface has a durable black matte finish on the surface and has a ¼-20 hole pattern on 1” centres. The instrument rack is a standard 19" rack mount integrated into the workstation fame. The rack is constructed of welded heavy gauge steel for stability and ruggedness. Far more rigid than sheet stock rolled C-channel frames, the PV tubular construction is easier to clean and does not have crevices to collect contaminates. The PV frame comes standard in powder coat black. The workstation frame is enclosed on all sides, except the rear, with two doors opening toward the front of the workstation.

Solar Business, Dow Corning Corporation
Dow Corning® PV-6100 Cell Encapsulant Series


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Dow Corning® PV-6100 Encapsulant Series relies on the UV stability of the silicone molecule to deliver improved durability and increased efficiency for crystalline modules compared to incumbent organics. PV-6100 Encapsulant Series provide an ultra-transparent layer of protection for the solar cell in a panel and can replace incumbent technologies. The silicon-based material provides higher efficiency, longer module life, and optimum UV resistance. The new processing platform can achieve higher production rates for crystalline and amorphous silicon thin film modules, reducing the cost per kilowatt-hour of solar power.The process increases manufacturing efficiency and reduces total cost of ownership through lower processing temperatures, faster throughput, as well as lower capital and less factory space needed for the equipment.

The Dow Corning® PV-7010 and PV-7020 Potting Agents were developed to eliminate the guesswork . There are hundreds of available coatings, encapsulants, potting agents, sealants, adhesives etc…available. The challenge is to evaluate correctly which of these actually work best for solar energy applications, while providing target life-time parameters and overall performance levels required. Dow Corning's PV-7010 and PV-7020 Potting Agents are designed to insulate PV cells' electrical junction boxes, providing cost-effective electrical insulation and long-lasting protection from moisture, heat and other environmental conditions, the company claims. These materials remain flexible and stable over wide temperature variations (-40 degrees to 150 degrees °C) and offer easy reparability and global availability. The PV-7010 offers a faster cure rate, while the PV 7020 has greater viscosity and thermal conductivity.

Mecasolar
MS Tracker 10


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Mecasolar design, manufacture and distribute dual axis, azimuth and vertical solar trackers, such as MS Tracker 10 in its two versions MS Tracker 10 and MS Tracker 10 +. The trackers come with a 10-year guarantee on parts,workmanship and displacement.

The MS TRACKER 10 and 10 PLUS trackers perform solar tracking through astronomical programming. The PLC incorporated into the system controls actuation of the two gear motors, which position the photovoltaic surface perpendicular to the sun's rays, thus maximising electrical energy generation; the tracker may also be placed in a night position and may assume the evening position in order to being the daily work cycle.

With the Mecasolar tracking system, increased performance is offered for photovoltaic installations as compared to installations on fixed structures. Claimed increases are greater than 35% and vary depending upon the geographic location at which the plant is located, it can reach as high as 45% for some regions in Spain, according to the company.

The MS TRACKER sits on a foundation or concrete footing reinforced with corrugated wire mesh. It is anchored to the footing by securing nuts and locknuts on steel stud bolts. The solar tracker is comprised of two metal profile substructures made of hot dipped galvanised steel, which give the structure a robust resistance. The tracker's central body is comprised of a ‘V-shaped' structure on which the frame rests in which the photovoltaic modules are mounted. Mecasolar has the ISO 9001:2000 certificate, CE Certification for conformity with European Directives 98/37/CE, 73/23/CEE and 2004/108/CE. The tracker has been designed according the following standards: DIN 1055-4 (8.86), DIN 1056 (10.84) and MV-103 Building Standard.

Siemens AG
SINVERT 1700 MS


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SINVERT PV inverters, are a family of three phase grid-connected inverters in the range of 60kVA up to 1700kVA. They already serve as central inverters in a large number of PV power plants.

With Siemens' SINVERT 1700 MS, four units of 420kVA act as a single 1.7MVA PV inverter. The combination of up to four single inverters working together maximises performance, yield and availability.

Less service labour and down-times mean less cost in the return on investment equation in a PV power plant that requires a minimum of maintenance care. The most reliable and field-proven components, such as modules and their mounting structures, cabling and combiner boxes as well as the inverters with their containers and the whole medium voltage equipment are critical. To control these complex power plants, an industrial-grade supervision system is necessary.

Equipped with features like master slave operation, symmetry monitoring and VAr control, Siemens SINVERT covers the current and future recommendations of a reliable and almost maintenance-free operation.

Fraunhofer ISE


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Spire Corporation


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Spire Corporation is a leading global solar company providing turnkey solar factories, capital equipment, systems and integration to manufacture PV modules and cells worldwide. With over 40 years and $100 million in R+D and PV, our unique experience and technical depth put us in a unique position to ensure the success of our customers. Applying expertise in materials technologies across all product lines, Spire has a rich heritage of utilizing science and research to develop leading edge products that generate renewable energy and deliver advanced solutions to businesses worldwide.

Spire's comprehensive approach gets you in the PV market including: state of the art equipment, embedded process knowledge, critical supply guarantees, workforce training, facility planning and layout, factory automation, module design services, and module certification assistance. Spire's factories and equipment address crystalline cells and modules, back end thin film and CPV solar cell foundry services.

Spire Corporation also assists companies take advantage of large tax credits and stimulus money provided by the US government for setting up solar factories and creating jobs in the USA with their “Succeed in America” program. The USA is the next high growth PV market and Spire is well-prepared and uniquely positioned as a board member of SEIA, a DoE funding recipient, and having equipment in test labs worldwide.

We invite you to discover why over 90% of solar manufacturing companies include Spire equipment and expertise in their turnkey solar production lines.

IB Vogt GmbH


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ib vogt, Berlin/ Germany, is a leading service provider for consulting, planning, construction and optimization of factories for the photovoltaic industry. Whether wafer, cell or module, crystalline or thin-film technology – with proven professional expertise and more than ten years experience in the PV sector, ib vogt covers the entire range of technologies available on the market. The company’s roots go back to the year 1991. After complete specialization on the solar industry in 1998 a dynamic growth process began. Since than ib vogt has realized more then 1,2 GWp production capacity.

As a service provider offering comprehensive consultation and services, ib vogt advises customers in the pre-phase of a project on markets, technologies, plants, sites, investment and operating costs. The company’s in-depth PV know-how helps the client to set up a bankable business plan, to establish a customized project strategy, to reduce total cost of ownership and to achieve optimum costs per watt. During the realization of the factory ib vogt takes on overall project management as well as factory design and plant planning. From the development of a piece of land, to monitoring construction progress, to installation and commissioning of equipment ib vogt is always onsite as responsible project manager. The project management is the central interface for customers and project partners by integrating all parties into a well functioning network. Customers can concentrate on their core business from the very beginning, while a finely tuned interdisciplinary team of experienced engineers takes care of the construction and equipment of the factory. In the long term, customers profit from lower operating costs, smooth production processes, and flexible options for expansion.

ib vogt stands for outstanding cost efficiency, time-to-market and high quality projects. References of the company include international projects for Q-Cells, Sovello, T-Solar and Sunfilm

Nick Sarno Head of Manufacturing LDK


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Nick Sarno has been instrumental in guiding one of the fastest set ups of a brown field site to product ever. Leveraging his vast experience at MEMC, Sarno took on the role at LDK at a time when much of the world presumed that the Chinese entry into the polysilicon market would be beset with difficulty and poor quality product. This was based on China's difficult entry into semiconductor manufacturing. However, with no technical restraints placed upon the region, as with manufacturing, China has proven they are not only capable of competing with the global community when the playing field is level, but have proven they can be world leaders. LDK has been one of the success stories in the polysilicon market and Nick Sarno has been a key driver within the impressive team from LDK.

 
The Awards Team

 

David Ridsdale
Editor In Chief
dr@angelbcl.co.uk

Jackie Cannon
Publisher
jc@angelbcl.co.uk
     
 
Stephen Whitehurst
Commercial Director
stephen@angelbc.co.uk
Tommy Beazley
Account Manager
tb@angelbcl.co.uk
     
 
Shehzad Munshi
Account Manager
sm@angelbcl.co.uk
     
     
 
Tom Brun
USA Account Manager
tbrun@brunmedia.com
 
Janice Jenkins
USA Account Manager
jjenkins@brunmedia.com
 


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