Sourcing Domestic Inverter Issues and Challenges

ISA Workshop on Solar Inverters 23rd July, 2010 Dr. J. N. Roy Vice President (R&D/Engineering) Solar Semiconductor Pvt Ltd

Presentation Layout
1. Solar PV Value Chain 2. Company Overview 3. Cost Structure of PV Installation Solar Power Electronics 4. Classification of Inverter 5. Desired Features of Inverter 6. Comparison between Inverter and PCU

Solar PV Value Chain

Solar Semiconductor in the value chain

PV Systems MG Silicon Poly Silicon Silicon Wafers PV Cells PV Modules

Thin Film

Company Overview
A Vertically Integrated System Integrator providing end to end SI services
Our Product & Services
Family of mono and multi crystalline modules

Overview
Global Company founded in 2006 Subsidiaries in India & Dubai

Incorporation

Financials

Revenue growth from $15M in FY2008 to $95M in FY2009.

Solar cells

Blue Chip Customers & Suppliers

System Integration & Design Manufacturing

Strong customer base in the key markets of USA, Europe and India Strategic tie-ups with top tier suppliers

Sizable Manufacturing 200 MW Manufacturing Capacity in Fab City SEZ 200MW North America /Canada Manufacturing by 2011

Power Systems

Team

Experienced Silicon Valley Team, with strong background in high quality, hitech mass manufacturing of Semiconductors and Systems Over 900 full-time employees as of April30, 2010

Company Proprietary and Confidential

SSI High Quality process

Long term Power Sustainability Thermal Cycling, Wet Leakage and other tests ensure quality Electro Luminescence (EL) Imaging to detect Cell micro cracks prior to shipment Guaranteed high output and quality Sample as well as in line detection

Normal Visible Image

EL Process: Good Quality

EL Process: Bad Quality

Key Milestones for Solar Semiconductor

2007 1st 3MW Order 2008 Backlog over 500MW 2009 Growth in SI business & capacity expansion
Commencement of commercial production at Fab City Possession of Fab City Land First major purchase order with SunPower Contract signed with Ibersolar
Incorporation of SSPL Pilot test run of Module Line

Apr 06

Jan 07

July 07

Sept 07

Dec 07

Jan 08

Feb 08

Mar 08

Apr 08

Jun 08

Feb 09

Jun 09

Obtained EOU license for Kompally Unit

First sales contract: Fotosolar Commencement of commercial production

Announced IBC Solar as a strategic partner; contract for over 100MW over next three years

UL Certification

Customer contract with prestigious US company ISO 9001:2000 certification

Expansion of module manufacturing facility in Hyderabad Signed AS Solar contract for 224MW over 7 years Signed DS Wafer Supply Contract

Solar Semi Product Quality Focus

Lean manufacturing Automated lines

Date
Nov 2007

Certification
CE Mark ISO 9001:2000 certification IEC 61215 certification IEC 61730 certification CSA listing VDE certification UL certification

Jan 2008

Feb 2008

SPC

Feb 2008

Six Sigma

March 2008

April 2008

Quality Circles

June 2009

Recognized by TV Rheinland, a quality certifying body

Solar Semiconductor has demonstrated the emphasis and focus on the quality of their Solar Photovoltaic modules, and unequivocally gives Solar Semiconductor a leadership status in the Photovoltaic manufacturing marketthey have consistency in their production process and their product quality is exceptionally high - Enrico Ruhle (MD), TV Rheinland, June 2008
Company Proprietary and Confidential

Solar Semi Manufacturing at FabCity

160, 2 & 3BB Tabbing and Stringing capability Quality process at every step

200,000 sq.ft. facility

Flash testing

Scalable Projects with Solar Semi Technology

Ground Mount with Tracker Commercial Roof Top Hotel Roof Top

Car Port Top System

Small Residential System

Residential Roof

Cost Structure of Solar PV Installation

. BOS cost, including inverter is significant portion of the total cost.

Cost Structure
Cost of Poly- Wafer Cell- Module Cost of Inverter. Costly DC connections. Inverter life issue. Maintenance Issue

Solar PV Long Life

Increase operating life Inverters today have mean time between failure (MTBF) of less than 10 years Computed MTBF above 100 years has been achieved in recent modular solar inverters. Solar PV panels easily meet 25yrs life requirement Certification Must match panel capability
Eliminate electrolytic capacitors Avoid delicate power devices

Classifications of Solar PV System

Off-Grid DC Couple System- Indian

Off Grid AC Couple System- e.g. SMA

Off-Grid : Pump System

No batteries/grid as buffer! Match power consumption with power generation by controlling speed of the pump. Make power generation as close as possible to maximum power

On Grid

Classification based on Installations

Multi String Inverter

Classification based on Installations(Cont.d)

Central Inverter

Classification Based On Topology

Solar Inverter With Transformer

Classification Based On Topology

Solar Inverter Without Transformer

Block Diagram of PCU

Control Board

Boost (w/MPPT), Buck Converter

Input
Solar Panel

Input Protection Charge Controller

Half-Bridge Inverter

Transformer

Classical Rectifier

H-Bridge Inverter

Battery

Output
Output Protection

Challenges :PCU
Parallel operation of PCU Units Parallel operation needs synchronism of PCUs Should have communication between PCUs Controlling should be done based on input from each PCUs Control should be there based on inputs from each Battery bank units of PCUs Load Management control is needed Master-Slave mechanism should be available Control should take care of optimal operation of PCUs Control should take care of safe operation of PCUs Failure of one or more of PCUs should not affect Parallel Operation of others

Intelligent Control Required

PCU (Cont.d)

Desire Features of Solar Inverter

1. Flexibility Inverters required to install indoor as well as outdoor. 2. Reliability Live span should be more than 25 years 3. Durability Warranty for period of 5 years and AMC for a period of 20 years 4. Control Inverters required to be compatible with a broad palette of the most diverse components . 5. Support Design/Simulation support

Comparison
Comparison INDIAN INVERTERS FORGIEN INVERTERS 5 Year Warranty with AMC. It can be extended to 10 Years Indoor and Outdoor 20 Years has been proved Wireless is available Standardized & Simulation support Greater than 97% 24 V and 48 V are fixed compact size light weight more IEC,TUV,UL

Reliability Flexibility Durability Control Design & Support Efficiency Battery Voltage Size Weight Cost Certification

2 Years Warranty Indoor 20 Years Expected Wireless is not available Custom made less than 94% 24,48,96,120,240 V Large size Heavy weight Less compared to Forgien IEC,TUV

Limitations
1. Indian manufacturer mainly manufactures PCU . 2. PCU combines Inverter and battery charging unit. 3. Indian PCU unit are custom made not standardized to feed customer requirement 3. Engineering support is minimal.

Thank You!