SOLAR MODULE MANUFACTURING UNIT

[EIRI/EDPR/3990] J.C.: 2119XL

INTRODUCTION

Photovoltaic cells are connected electrically in series and/or parallel circuits to

produce higher voltages, currents and power levels. Photovoltaic modules consist
of PV cell circuits sealed in an environmentally protective laminate, and are the
fundamental building blocks of PV systems.

PV Module or Solar PV Module is an assembly of photovoltaic (PV) cells, also known

as solar cells. To achieve a required voltage and current, a group of PV modules (also
called PV panels) are wired into large array that called PV array. A PV module is the
essential component of any PV system that converts sunlight directly into direct
current (DC) electricity. PV modules can be wired together in series and/or parallel to
deliver voltage and current in a particular system requires.

PV is emerging as a major power resource, steadily becoming more affordable and

proving to be more reliable than utilities. Photovoltaic power promises a brighter,
cleaner future for our children.

Using the technology we have today we could equal the entire electric production of
the United States with photovoltaic power plants using only about 12,000 square
miles.

In 1839, Edmund Becquerel discovered the process of using sunlight to produce an

electric current in a solid material, but it wasn't until a century later that scientists
eventually learned that the photovoltaic effect caused certain materials to convert
light energy into electrical energy.

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The photovoltaic effect is the basic principal process by which a PV cell converts
sunlight into electricity. When light shines on a PV cell, it may be reflected, absorbed,
or pass right through. The absorbed light generates electricity.

In the early 1950s, photovoltaic (PV) cells were developed as a spin-off of transistor
technology. Very thin layers of pure silicon are impregnated with tiny amounts of
other elements. When exposed to sunlight, small amounts of electricity are produced.
Originally this technology was a costly source of power for satellites but it has
steadily come down in price making it affordable to power homes and businesses.

CELLS MODULES AND ARRAYS

Photovoltaic cells are connected electrically in series and/or parallel circuits to

produce higher voltages, currents and power levels. Photovoltaic modules consist of
PV cell circuits sealed in an environmentally protective laminate, and are the
fundamental building blocks of PV systems. Photovoltaic panels include one or more
PV modules assembled as a pre-wired, field-installable unit. A photovoltaic array is
the complete power-generating unit, consisting of any number of PV modules and
panels.

Photovoltaic cells, modules, panels and arrays

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The performance of PV modules and arrays are generally rated according to their
maximum DC power output (watts) under Standard Test Conditions (STC). Standard
Test Conditions are defined by a module (cell) operating temperature of 25o C (77o F),
and incident solar irradiance level of 1000 W/m2 and under Air Mass 1.5 spectral
distribution. Since these conditions are not always typical of how PV modules and
arrays operate in the field, actual performance is usually 85 to 90 percent of the STC
rating.

Today’s photovoltaic modules are extremely safe and reliable products, with minimal
failure rates and projected service lifetimes of 20 to 30 years. Most major
manufacturers offer warranties of 20 or more years for maintaining a high percentage
of initial rated power output. When selecting PV modules, look for the product listing
(UL), qualification testing and warranty information in the module manufacturer’s
specifications.

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 CONTENTS
INTRODUCTION
CELLS MODULES AND ARRAYS
PHOTOVOLTAIC CELL
PHOTOVOLTAIC MODULES
SINGLE CRYSTALLINE
STRING RIBBON
PHOTOVOLTAIC PANELS
PHOTOVOLTAIC ARRAY
PROJECT LOCATION-AHMEDABAD (GUJRAT)
WEATHER
CITY MAP OF AHMEDABAD
TRANSPORTATION
BY AIR:-
BY ROAD:
BY TRAIN:
HISTORY OF PHOTOVOLTIC CELLS
TYPES OF PV MODULE
CRYSTALLINE SILICON PV MODULE
(I) SINGLE CRYSTALINE (MONO-CRYSTALLINE)
CONSTRUCTION
TECHNICAL SPECIFICATION
ADVANTAGES OF MONOCRYSTALLINE PV MODULE
LONGEVITY
DISADVANTAGES
APPLICATIONS OF MONOCRYSTALLINE SOLAR PANELS
(II) POLY-CRYSTALLINE (MULTI CRYSTALLINE)
CONSTRUCTION
ADVANTAGES OF POLYCRYSTALLINE PV MODULE
DISADVANTAGES OF POLYCRYSTALLINE SOLAR PANELS
CONSTRUCTION OF PV MODULE
THE 6 MAIN COMPONENTS OF A SOLAR PANEL
PV CELLS
A MONOCRYSTALLINE SOLAR CELL
GLASS
FRAME
EVA FILM
BACK SHEET
JUNCTION BOX
BYPASS DIODES
NUMBER OF CELLS IN MODULE

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PROS & CONS OF PV
COMPLETE PHOTOVOLTAIC-BASED ELECTRICAL SYSTEMS:
CONFIGURED SOLAR ELECTRIC SYSTEMS
PHOTOVOLTAIC MODULE PERFORMANCE
PHOTOVOLTAIC APPLICATIONS
PHOTOVOLTAIC BENEFITS
SOLAR CELL I-V CHARACTERISTIC
SOLAR CELL I-V CHARACTERISTIC AND THE SOLAR CELL I-V CURVE
SOLAR CELL I-V CHARACTERISTIC CURVE
THE ELECTRICAL CHARACTERISTICS OF A PHOTOVOLTAIC ARRAY
SOLAR ARRAY PARAMETERS
EXAMPLE OF I-V CURVE AND RATINGS OF A 12 V SOLAR (PV) PANEL
IDEAL SOLAR CELL
IDEAL SOLAR CELL (SIMPLIFIED)
EFFECT OF TEMPERATURE
THE AFFECTS OF IRRADIANCE
FIGURE :- PV CELL POWER OUTPUT AS A FUNCTION OF VOLTAGE.
EFFECT OF LIGHT INTENSITY
CONCENTRATORS
LOW LIGHT INTENSITY
LINE CAPACITY
TABBER AND STRINGERS: 2
LAY-UP: 2
INTERCONNECTION 1
LAMINATORS: 2
SOLAR PV MODULE SPECIFICATION
(B) ELECTRICAL SPECIFICATION
DIFFERENCE BETWEEN STC AND NOCT:
STC (STANDARD TEST CONDITIONS):
APPLICATIONS OF POLYCRYSTALLINE SOLAR PANELS
ADVANTAGES OF PV PANNEL
DISADVANTAGES OF PV PANNEL
USES AND APPLICATION OF PV POWER PLANT
APPLICATIONS OF MONOCRYSTALLINE SOLAR PANELS
APPLICATIONS OF POLYCRYSTALLINE SOLAR PANELS
EXAMPLES OF SOME APPLICATIONS OF PHOTOVOLTAICS ARE THE FOLLOWING:

INDUSTRY, TELECOMMUNICATIONS & PUBLIC SERVICES

HEALTH
RESIDENTIAL
B.I.S. SPECIFICATION
PROCESS FLOW CHART FOR SOLAR PANEL
FABRICATION PROCESS OF MONOCRYSTALLINE SOLAR PV MODULE
A. SOLAR CELL

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B. EVA (ETHYLENE VINYL ACETATE)
ENCAPSULANT’S (EVA) REQUIREMENTS:
C. BACKSHEET
REQUIREMENTS OF REAR SURFACE:
D. GLASS
REQUIREMENTS:-
E. JUNCTION BOX WITH BYPASS DIODES AND CONNECTING CABLES JUNCTION
CABLES JUNCTION BOX CONSISTS OF THE FOLLOWING:-
F. CONNECTING RIBBON TWO TYPES OF CONNECTING RIBBON ARE
G. SILICONE SEALANT
SEALANT
H. SHORT AND LONG FRAMES (BACKBONE OF THE MODULE STRUCTURE)
MARKET POSITION
PV MODULES MARKET – INDIA
RISING IMPORTS:
DOMESTIC INDUSTRY WOES
WAY FORWARD
RISEN ENERGY
WAAREE
ZNSHINE
VIKRAM SOLAR
ADANI
TRINA SOLAR
RENESOLA
JINKOSOLAR
LONGI SOLAR
CANADIAN SOLAR
GLOBAL MARKET
TECHNOLOGY INSIGHTS
APPLICATION INSIGHTS
GRID TYPE INSIGHTS
REGIONAL INSIGHTS
KEY COMPANIES & MARKET SHARE INSIGHTS
PV PRODUCTION LINE
M-01 AUTOMATIC GLASS LOADING
M-02 AUTOMATIC ENCAPSULANT CUTTING AND LOADING
M-03 AUTOMATIC TEMPLATE LOADING
M-04 INSPECTION TABLE
M-05 TABBER AND STRINGER MTS-3000
M-06 LAY-UP SYSTEM
M-07 MIRROR INSPECTION TABLE
M-08 AUTOMATIC BUSSING IC100 (3 HEADS
M-09 INTERCONNECTION CHECKING + LABEL PLACING
M-10 EL INSPECTION

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M-11 AUTOMATIC FOIL CUTTING AND LOADING
M-12 BUFFER
M-13 LAMINATOR
M-14 AUTOMATIC EDGE TRIMMING
M-15 AUTOMATIC OPTICAL INSPECTION
M-16 AUTOMATIC FRAMING UNIT
M-17 JBOX WORKING TABLES
M-18 AUTOMATIC JBOX POTTING MACHINE
M-19 JBOX POTTING DISPENSING MACHINE
M-20 JBOX SILICONE DISPENSING MACHINE
M-21 CURING LINE
M-22 MODULE TESTING STATION
M-23 AUTOMATIC MODULE SORTING
M-24 AUTOMATIC GLASS LOADING
M-25 SECOND GLASS LOADING
M-26 AUTOMATIC MODULE SORTING FOR GG (INSTEAD OF M-23)
M-27 AUTO CELL LASER CUTTING MACHINE (OPTIONAL)
ACCESSORIES
A-01 CELL TESTER
FUNCTION:
CHARACTERISTICS:
ADVANTAGES:
ASSEMBLY LAYOUT
LINE LAYOUT (PROPOSED)
PLANT LAYOUT
MANUFACTURERS/SUPPLIERS OF SOLAR PV MODULE
RAW MATERIAL
SUPPLIERS OF SOLAR CELL
SUPPLIERS OF EVA ENCAPSULATE
SUPPLIERS OF TEMPERED GLASS
SUPPLIERS OF ALUMINIUM FRAMER
SUPPLIERS OF JUNCTION BOX
SUPPLIERS OF SILICON GEL
SUPPLIERS OF THERMO PLASTIC BACK SHEET
MACHINERY SUPPLIERS
COMPELETE PRODUCTION PLANT
SUPPLIERS OF POWER TRANSFORMERS
SUPPLIERS OF ELECTRICAL MEASURING INSTRUMENTS
MACHINERY PHOTOGRAPHS
AUTOMATIC GLASS LOADING
AUTOMATIC ENCAPSULANT CUTTING AND LOADING
AUTOMATIC TEMPLATE LOADING
INSPECTION TABLE
TABBER AND STRINGER MTS-3000

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MIRROR INSPECTION TABLE
AUTOMATIC BUSSING IC100 (3 HEADS)
INTERCONNECTION CHECKING + LABEL PLACING
AUTOMATIC FOIL CUTTING AND LOADING
BUFFER
LAMINATOR
AUTOMATIC EDGE TRIMMING
AUTOMATIC OPTICAL INSPECTION
AUTOMATIC FRAMING UNIT
J BOX WORKING TABLES
J BOX POTTING DISPENSING MACHINE
J BOX SILICONE DISPENSING MACHINE
CURING LINE
MODULE TESTING STATION
AUTOMATIC MODULE SORTING
AUTOMATIC GLASS LOADING
AUTOMATIC MODULE SORTING FOR GG (INSTEAD OF M-23)
AUTO CELL LASER CUTTING MACHINE (OPTIONAL)
CELL TESTER
PRODUCT PHOTOGRAPHS

APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)

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 COST ESTIMATION

Plant Capacity 0.75 MW/Day

Land & Building (12000 sq.mt.) Rs. 14.47 Cr
Plant & Machinery Rs. 3.45 Cr
Working Capital for 1 Month Rs. 35.07 Cr
Total Capital Investment Rs. 80.70 Cr
Rate of Return 57%
Break Even Point 31%

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