EcoSunPV’s Photovoltaic Panels are made with the latest generation POLYcrystalline cell technology and are manufactured under the strictest international standards.
Making of our Solar PV Panel:
– Solder up the Cells into Strings
The cells come onto the assembly line in graded Boxes. We only put grade “A” cells into our Panel(Module). We do not cut the cells when making High Wattage Panels(120 Watt and up). Before stringing up, the cells are re-sorted for color consistency. Then they are soldered into a string (in an “electrical” series). There are 6 strings of 10 cells each in our 230 Watt Panel.
– Lay-up & Busing
A low-iron, high transparency (93%+) 3.2mm tempered glass is the substrate of our panel. A layer of EVA is placed onto the glass. The 6×10 cell strings are then placed onto the EVA. Then another EVA layer is placed onto the BACK of the cell strings. Afterwards, a back-sheet (standard white, optional black or, aluminium) is then placed on the EVA. Bus bars are then soldered perpendicular to the string ribbons, to complete the panel circuitry.
– Pre-Lamination Test
The un-laminated panel is placed on an EL-tester. Electricity current is pushed through the cell string circuit causing them to “Glow”. A high-resolution digital picture is taken when the cells are “Glowing”. This picture reviews/shows micro cracks, thin/missing ARC coats, non-continuous silver-lines and, etc. The defective components reviewed in this test are then replaced and the panels re-tested before lamination.
A final visual check was done to ensure proper alignment and spacing of the cells to the glass substrate. Then the panel is put into a vacuum oven (called the laminator in the trade). The vacuum oven first sucks ALL the air out, leaving no air bubbles between the layers of material. Heat and external pressure is applied to squeeze the glass panels, and the oven’s heat melts the EVA and back sheet to the glass and cells making the panel into one durable integrated glass unit.
The glass panel coming hot out of the oven is trimmed with a razor blade when it is still soft from the heat. The trimmed panel is cooled, then placed on a pneumatic device (known as the framer in the trade). A Permanent UV resistent silicone rubber bead is applied onto the aluminium frame. The frame is then squeezed together simultaneously on all sides on to the glass assembly.
This process creates a bubble free permanent bond between the tempered glass to the aluminum frame. This structural bond eliminates the corner stress of the whole unit. This structure is far superior to frames that are held together by 8 screws.
– Sun Simulator Testing
Every one of EcoSunPV’s panel has gone through a complete performance test. The result is disclosed to the end-user linking to each panel’s Bar-code.
The Sun Simulator puts out an industrial standard flash. The simulator sensors picks up the electricity profile of the panel and records same into its memory bank. Each data set links to the bar-code of each panel (which is unique).
The panels are then sorted into Wattage categories based on test results.
– High-Pod Testing
All panels goes through this inspection test prior to shipment. In this test, A 2600 Volt flash current is pushed through the aluminium frame of the panel simulating lightning. The Cell circuit is hooked up to the tester to measure “how much of the 2600 Volt leaked into the circuitry”. Leakage of over 1/2 of a Watt will trigger a reject.