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GreenSolar Equipment Manuacturing Ltd.

About GreenSolar

GreenSolar is a high tech photovoltaic R&D company. Its target is to become one of the leaders

on the thin lm PV market. GreenSolar has the background of the well expert technical team from

EnergoSolar who already successfully installed over 100 MWp a-Si producon line worldwide.

GreenSolar manufactures, installs and services turn-key producon lines of thin lm solar modules.

It has a manufacturing capacity of 100 MWp producon lines/year on its 10.000 m2 producon

facility in Budapest. GreenSolar develops and sells its own technologies m aking it an ideal partner

for companies entering or expanding into the fast growing thin lm PV market.

Solar energy is becom-

ing a primary soluon of

choice for energy policy

decision-makers in many

countries around the

world. Large scale so-

lar energy producon is

about costs, return on in-

vestment and reliability,

factors that low cost thin

lm technologies can best

serve. The worldwide PVmodule producon ca-

pacity is expected to grow

dramacally in the next

decade and low cost thin

lm producon capacies

will lead that growth.

GreenSolar is involved in tan-

dem a-Si thin lm technolo-

gies making it a go-to tech-

nology source and equipment

manufacturer. GreenSolar

pursues research of a-Si/ c-

Si technology. GreenSolar

operates a state of the artpilot line having a oor space

of 1200 square meters. Ten

years of experse in thin lm,

the scale of R&D acvity, the

range of technologies and

the oer of a cost eecve

and exible turn-key produc-

on line makes GreenSolar

your real thin lm specialist.

Turn-key production lines or

tandem thin flm silicon solar modules

Product Catalog

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Turn-key tandem thin lm solar

module manufacturing systems

7 MWp/Year Tandem Thin Film Solar Module

Manufacturing System with Manual Loading

Edge grinder

laser scriber for TCO

Preheat chambers

1st glass washer

2nd glass washer

Box loading station

Box cleaning station

Active layer deposition chambers

Cool down chamber

Conductive layer deposition line

Panel light IV tester

Sand blaster

Ultrasonic bonding

EVA lay-up station

Module laminator

Assembly stations

Final IV tester

FORKLIFT WAY

Gas abatement systemDust filter

Glass driller

ISO7classcleanroom

ISO7classcleanroom

52000

Glass cutter

26000

31000

47000

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Why thin ilm solar modules are competitive

Within the past decade, the market of the solar photovoltaic modules grows at a very fast

pace. Aer some lile slow down in 2005-2006 due to the silicon shortage, the rate of growth

of the pv market recovered very fast, together with the commissioning of the new high purity

silicon producon facilies. The global nancial crisis of 2008-2009 had its eect over the pv

industry and market. The good of the bad is for consumers, hence the solar module prices havebeen halved within a very short me. GreenSolar gives a very viable soluon to the quest of

the compeveness by making possible the producon of solar modules at the lowest cost of

ownership on the market, and also the lowest cost of investment.

Cost of ownership example

Descripon Cost [USD] Cost [EUR] Cost [%]

Direct Materials 0.471 $/W 0.344 /W 68.16%

Depr. Producon Line (7 years) 0.125 $/W 0.091 /W 18.09%

Other Direct Costs 0.054 $/W 0.039 /W 7.81%

Personnel 0.020 $/W 0.015 /W 2.89%

Maintenance 0.010 $/W 0.007 /W 1.45%

Depr. Ulies (7 years) 0.008 $/W 0.006 /W 1.16%

ld ( ) $/ /

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Turn-key production lines

For a smooth start in thin lm module producon GreenSolar will provide you a real turn-key

soluon including the equipment, technology, know-how and a package of services including

assistance in business planning, factory design, installaon and setup, personal training, support

for material resourcing, performance and equipment warranty, aer warranty services and

technology upgrades.

With the delivery me of less

than one year GreenSolar

oers you a quick appearance

and a dynamic expansion in

the market. With GreenSolar

you have the opportunity to

start with a producon plant

with low level investment and

go for cercaons and for

big scale step by step in line

with your market penetraon.

With a producon line from

GreenSolar modules are

made in a simple process of

glass in module out, which

signicantly reduces materials, labor and energy inputs. The straight forward economic and well

designed technology and machinery keep quality high at a very compeve cost level. The special

easy-to-manage factory concept allows you low expense for building , skilled sta and maintenance.

Your likely producon cost with GreenSolars producon lines and technology will be one of the

lowest on the market accompanied with good quality allowing you protable producon under all

circumstances. On the top of that GreenSolar oers technology upgrades ensuring you long term

compeveness on the market.

Environment

We all know that solar energy is a good soluon to reduce the carbon emissions that contribute to

the greenhouse eect, and to the gl obal climate change. Thus solar modules are green, but have

you ever thought about how green their manufacturing is?

It is a very odd thing to reduce the carbon emissions by gaining energy by photovoltaic devices,

while the manufacturing of some solar modules contributes to the emission of gases, which are

much more harmful greenhouse gases than carbon dioxide.

Sulphur Hexauoride (SF6) is the most potent

greenhouse gas that it has evaluated, with a

global warming potenal of 22,800 mes that

of CO2 when compared over a 100 year period.

Nitrogen Triuoride (NF3) is a greenhouse gas,

with a global warming potenal 17,200 mes

greater than that of CO2 when compared over a

100 year period.

Fluorine gas that is claimed to be

environmentally friendly alternave to SF6

and NF3 is nevertheless a potenally hazardous

and very agressive substance, which in contactwith water forms hydrouoric acid that is

so agressive, that it corrodes even glass and

stainless steel.

Would you like to handle such substances in

your factory?

Can anybody guarantee that no leaks will ever

occur?

GreenSolars technologies do not require any kind of uorine gases, neither SF6, N F3, nor F2, thus

using GreenSolar manufacturing equipment means saving the atmosphere.

Many technologies use such agressive gaseous chemicals because of the need to remove from the

electrodes of the CVD equipment the unwillingly deposited (doped or undoped) silicon. How is

possible that such unwanted deposion doesnt occur in GreenSolars CVD reactors?

The soluon is gi ven by design, hence in GreenSolars reactors the space where plasma is generated

is surrounded by the glass of the solar plates. Therefore 99.95% of the silicon deposion occurs

where it is intended, exactly on the surface of the future sol ar modules under process.

The lile deposion, which is in excess, all occurs on removable parts, that are taken out of the

reactors and cleaned mechanically, without the use of any chemicals, whenever it is needed.

If you are environmentally-conscious, before choosing one or another of the available producon

lines and technologies, ask for the uorine and uoride consumpons.

For a sustainable life, GreenSolar provides you only completely green, environmentally friendly

FLUORINE-LESS THIN FILM TECHNOLOGIES.

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ProcessTechnology

The manufacturing process applied by GreenSolar is based on what is known as amorphous

silicon technology. A key feature of this technology is the use of Plasma Enhanced Chemical

Vapor Deposion (PECVD) to form the amorphous silicon semiconductor lm layers. Although the

energy conversion eciency of amorphous modules is lower than that of single-crystal units (an

average of 6-7% compared to an average of 12-16%), they are cheaper to produce and convertmore electrical energy than crystalline modules with the same nominal power used under high

temperature environment or in diuse light condions.

The amorphous silicon thin lm solar

cell technology oered by GreenSolar

Hungary Equipment Manufacturing Ltd.

involves the deposion of two extremely

thin solar cell structures on top of each

other onto a TCO-coated glass sheet with

a total layer thickness of less than one

micron.

This structure is called tandem or double

juncon solar cell.

Regarding the operaon of this solar cell

structure, the rst cell converts mainly the

shorter wavelength part of the spectrum

of incident light while the second cell

converts the longer wavelength part.

Comparing this structure to the so-called

single juncon structure, where only one solar cell structure is deposited on the TCO-coated

glass sheet, it is possible to achieve the same absorpon while the individual cells are thinner.

The thinner the amorphous silicon layers are the

less the degradaon and the higher the stabilized

eciency of the solar cells.

As amorphous silicon thin lm solar cells have more

favorable temperature dependence compared to

their mono- or polycrystalline counterparts and

they work beer in diuse or low intensity lightcondions their yearly generated energy yield

under real life condions relave to their nominal

power is higher, as well.

Another advantage is that since thin lm solar cells

contain much less acve material than the mono-

and polycrystalline solar cells and their technology

involves only low temperature processes, their

producon is more cost eecve.

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GLASSWASHER

EDGEGRINDING

FORKLIFT WAY

FORKLIFT WAY

FORKLIFT WAY

FORKLIFT

WAY

FORKLIFT

WAY

step1

step2

D

ispensing

machine

46000

67400

Panel light IV tester

Class A IV tester

ISO

7class

cleanroom

Box loading station

Box cleaning station

Box storage

Dust filter

ISO 7 class cleanroom




Semi-Automated Manufacturing System

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Recommended Equipment QuantitiesDescripon 7 MWp/year 15 MWp/year 30 MWp/year

GLASS PREPARATION [p cs or se ts ] [p cs or se ts ] [p cs or se ts ]

Glass Cuer 1 1 1

Glass Driller 1 1 1

Edge Grinder 1 1 1

Glass Washer (Aer Grinding) 1 1 2SPUTTER DEPOSITION OF T HE TCO LAYER (OPTIONAL)

Heang Tunnel (OPTIONAL) - - (1)

Vercal TCO Spuering System (OPTIONAL) - - (1)

Cooling Tunnel (OPTIONAL) - - (1)

Wet etching staon (OPTIONAL) - - (1)

PATTERNING OF THE TIN OXIDE LAYER

Laser Scribing System for Tin Oxide 1 1 2

Glass Washer (Before a-Si Deposion) 1 1 1

DEPOSITION OF THE TANDEM a-Si MATERIAL

Roboc Loading-Unloading Staon - - 2

Box Carrier for a-Si 8 16 32

Box Carrier Carts 8 16 -

Box Carrier Transport System - - 1

Preheat Oven 2 4 8

PECVD Deposion System for a-Si Layer 2 4 8

Cool-Down Chamber 2 4 8

EXHAUST MANAGEMENT SYSTEM

Gas Abatement System 1 2 2

Filter System 1 2 2

PATTERNING OF THE a-Si LAYER

Laser Scribing System for a-Si Layer 1 1 2

SPUTTER DEPOSITION OF THE BACK CONDUCTIVE LAYER

6 Chambers Spuer System for Al & ZnO 1 2 4

PATTERNING OF THE BACK CONDUCTIVE LAYER

Laser Scribing System for Al & ZnO 1 1 2

ENCAPSULATION

Laser Edge Deleon System 1 1 1

Ultrasonic Bonding System 1 2 2

EVA Applicator 1 2 1

EVA Laminator 1 3 6

Electrical Assembly Staon 1 4 2

Mechanical Assembly Staon 1 4 2

Juncon Box Filling Staon - - 1

MODULE TESTING

Quick Panel Light I-V Tester 1 1 2A Class Panel Light I-V Tester 1 1 2

Insulaon Tester 1 1 1

Climate Chamber - 1 1

Measurement Device Set 1 1 1

Light Soaker - 1 1

In-line Resisvity Meter (OPTIONAL) - - (2)

In-line Haze Tester (OPTIONAL) - - (1)

In-line Visual Purity Meter (OPTIONAL) - - (1)

OTHER INSTRUMENTS

Laser Marking System - 1 1

Maintenance Instruments 1 1 1

Transport Carts 21 12 12

Roller Table 4 - -

Conveyor System - 1 1

Utilities needed

Descripon 7 MWp/year 15 MWp/year 30 MWp/year

Factory oor space [m2]

(without warehouse, oces etc.)

1500 3000 6000

Installed electric power [kW] peak

average

440

290

970

600

1800

1200

Compressed air [liters/min] peak

average

1350

900

1850

1230

2000

1400

Cooling water* [m3/hour] peak

average

11

5.8

22

11.5

38

22

* It is strongly recommended to have a closed loop cooling water circuit.

City water City water is used by the laminators for cooling down

and also for service operaons.

It is up to the user to consider a closed loop system

also here.

Process water The main process water is used in the glass prepara-

on and the washing systems.

The washing system pically needs de-ionized (DI)water for the rinsing, and normal water for the pre-

washing.

Glass preparaon and washing machines work par-

ally with water recycling system.

Air condioning The temperature in the building shall stay within

23 2C.

The humidity level shall be in the 50-70% range

(non condensing).

Cle an room condions It i s re commended that a -S i pae rn ing to be done in

Clean Room Class 7 (as per ISO 146441-1 standard)

Technology gases The supplier of the process-gases shall buid the GasSupply System and shall supply the gases during the

operaon.

The process requires the following gases:

Ar, N2, H2, He, SiH4, CH4, 3% B(CH3)3 in SiH4, and 3%

PH3 in Ar.

Nitrogen is needed both as nitrogen gas and l iquid

nitrogen.

The quality of the gases shall be guaranteed at the

consumpon point by the supplier of the gas system.

The gas system supplier suppliess the gas detector

system as well.

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Module Dimensions [mm] 12456357

Module Area [m2] 0.79

Cell Aperture Area [m2] 0.71

Inial Power [W] 55

Degradaon rate [%] 18

Stabilized [Wa/Module] 45

Total hours per year [hours] 8 760

Upme [%] 80.5

Real Producon [hours] 7 056

Nominal Producon [MW] 7 15 30

Tact me [pcs/hour] 24 48 96

Produced Modules [pcs] 169 334 338 668 677 376

Yield [%] 94.0 98.0 98.5

Good Modules eecve [pcs] 159 183 331 914 667 215

Producon eecve [MW] 7.16 14.93 30.02

Tipical annual capacity of the production lines

Manpower needed


Operang personnel that must work in every shi

Glass preparaon (+OPTIONAL TCO) 5 4 4 (+3)

Lasers 3 4 4

PE-CVD 4 6 8

PVD (+ sandblaster for 7MWp only) 2 + 4 1 2

Encapsulaon, assembly and test 8 14 14

Quality control 2 3 4

Maintenance and repair 2 3 4

Total personnel per shi 30 35 40 (43)

Technical management and support personnel (dayme only)

CTO and deputy CTO, Workshop Manager 2 2 2

Speciality engineers 6 6 6

Quality manager 1 1 1

Chief of maintenance - 1 1Warehouse personnel 2 4 6

Total dayme personnel 11 14 16

Examples for the Performance of the Produced PV Solar Modules

Descripon Customer 1 Customer 2

Electrical SpecicaonsStabilized Rated Parameters at STC*

Rated maximum power Pmax 45 W 52 W

Rated voltage at Pmax Umpp 47.4 V 71.2 V

Rated current at Pmax Impp 0.95 A 0.74 A

Open circuit voltage Voc 65 V 93.5 V

Short circuit current Isc 1.3 A 0.88 A

Temperature coecients Uoc

Isc

Pmax

0.28 %/C

+ 0.09%/C

0.19%/C

0.30 % /C

+ 0.08 %/C

0.15 % / C

Maximum system voltage V 1000 V 600 V

Mechanical Specicaons

Dimensions [mm] 1 245 635 7 1 245 635 7

Total surface [m2] 0.79 0.79

Acve surface [m2] 0.71 0.71

Lateral structuring laser paern laser paernOverall weight [kg] 13.5 13.5

* STC (Standard Test Condions): 1,000 was/m2 irradiance,

AM 1.5 solar spectral distribuon, 25 C cell temperature.

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Beyond eficiency

Conclusions of a real-life module performance tesng in Bulgaria. Standard thin lm solar

modules model SP44 have been installed on a test PV eld and have been monitored for ve

months, together with polycrystalline modules of one of the well-known brands. The modules

were installed under an

opmal x lt angle. Thetotal installed capacity

was about 1.7 kWp for

both types of modules

connected to the same type

of inverters under similar

dc condions.

During the enre test, an

average daily irradiance

of 5.8 kWh/m2 with peak

days of 7.9 kWh/m2 have

been recorded. Ambient

temperature ranged from

+1C to +40C with an average of +22C. The output P AC values of the integrated daily energy

d bt i d f th i t

50

40

30

20

10

0

Weekly

SpecifcYields[kWh/kWp]

16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

Weeks of the year 2010

50

40

30

20

10

0

Weeklyirradiance[kW

h/m2

]

30

25

20

15

10

Averagetemperature[

OC]

SP44 modulespolySi modules

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Fully Automated Manufacturing System

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www.greensolar.hu

Intellectual PropertySince 2010 February GreenSolar Equipment Manufacturing Ltd is the legal owner of the IP, know-how, logo

and brand name of EnergoSolar Hungary Ltd. GreenSolar hired most of the expert technical and adminis-

trave sta of the former EnergoSolar, and connues to work on the projects started once by EnergoSolar

Hungary Ltd in China.

RealizationsGreenSolar is a young company, but it has a well assembled team of managers, designers, engineers, techni-

cians etc. This team has already produced and installed a total manufacturing capacity of 120 MWp/year

in several locaons*:

2005-2007 Bangkok Solar Co., Ltd., Thailand2006-2008 Tianjin Jinneng Solar Cell Co., Ltd., China

2007-2008 HelioGrid Hungary Ltd., Hungary

2008-2009 SolarPro AD, Bulgaria

2009-2010 Parity Solar Technology Zhenjiang Co., Ltd., China

*as of the end of year 2010.

R&D ProjectsRecently GreenSolar has built up its new pilot line for R&D acvies, as the development of increased

eciency thin lm silicon solar modules, manufacturing of double size solar modules, creaon of micro-

morph solar modules and further reducon of manufacturing costs.

GreenSolars policy is to deliver to its customers products of the best performance and compeveness.

Contact Details

GreenSolar Equipment Manufacturing Ltd.

Gymri t 128., H-1103 Budapest, Hungary

European Community

Tel.: +36-1-445-0777, Fax: +36-1-434-0101,

e-mail: [email protected], hp://greensolar.hu

VAT No.: HU11706906

DisclaimerThe contents of the present brochure are for general informaon and promoon purpose

and by any means do not represent any commercial oer.

In order to get a quotaon, please contact the sales personnel of GreenSolar by e-mail to

[email protected] or by fax to the number +36-1-434-0101.

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