THE OPTIMAL PV MODULE SIZE

Nicholas Strevel

THIN FILM SCALES FORM FACTOR IMPACTS

• Unit of process for CdTe is the glass; scaling benefit • ~2.47m2 module reduces variable BOS costs
• Unit of process for c-Si is the wafer; no scaling benefit • More Watts per install operation
• Same manufacturing process as the previous technology • Site construction is faster; less modules to install
• Highest power utility-scale modules in the market • Structural and labor components are reduced for $/W
• Module installs trials independently verified by 3rd party EPC
Thin film cost scales non-linearly...
FS Series 6 Larger module size equals lower variable BOS
440 Wp
FS Series 4
120 Wp

E R C O S T
L E = L O W
0.6m

ER M O D U
BIGG
2.47m 2
2.0m

Time to Comissioning

Time to Comissioning
1.2m

Module Connections

Module Connections
Number of Modules

Number of Modules
Mounting Hardware

Mounting Hardware
Homerun Wiring

Homerun Wiring
Module Labor

Module Labor
1.2m

...similar to LCD screens.

2m2 2.4m2

C O S T
R E E N = LOWER
E R S C
BIGG Field Install Trials
Normalized Normalized
Rate Cost
Exosun
First Solar Series 6 1.00 1.00

No cost benefit from scaling c-Si Canadian Solar Modules

Delta
1.10
-10%
1.39
-39%
Crystalline Silicon Batch Technology: Unit of process is the Wafer
ATI
C O S T First Solar Series 6 1.00 1.00

L E ≠ L O WER Canadian Solar Modules 0.98 1.24

E R M O D U
BIG G *$60/hr, 430W, 340W
Delta 2% -24%
Polysilicon Ingot Wafer Solar Cell Solar Module

WHY WE CHOSE 1.23M X 2M STRINGS & HARNESSES

• ~2m module height is common, proven to work on any structure • Series 6 has a shorter string length (6 modules for 1500VDC)
• Module is optimized for a comfortable two person lift • Harness lowers cost by:
• The larger the module, the lower the variable BOS cost –– Creating a sub-collection point
• Structure design constraint is wind load, not module weight –– Effective increase of string length
• 1.23m width is independent of the loading profile • Structural / Site Flexibility
Wind Pressure –– Harnesses can be designed optimally for site specific
PNL , PND conditions. For example, a 7 string (in parallel) harness
Too small; Right size; Too large; or a 5 string harness.
BOS costs high 2 person lift, BOS 3+ person lift or lift assist • Smaller electrical ‘pixel’ allows optimized structures
lower • Independently validated by Sgurr and Burns & McDonnell
M F lateral
F uplift Typical 7 string harness (positive)
Fequivalent OVER 168’ EFFECTIVE STRING LENGTH!

2.47m 2 Module Size

Module Installation Efficiency Variable BOS value

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