This is the report of Summer Internship done by me in India's No.1 solar manufacturing company ''WAAREE Energy Ltd.''. Just explore it and do give feedback, everyone.

1. 1
A SUMMER INTERNSHIP REPORT
Submitted by
SASHIKANT TIWARI
SAP ID.:500041217
Roll No.:R630214066
At
WAAREE Energies Ltd.
Plot No. 231-236 Surat Special Economic Zone
Diamond Park Sachin, Surat-394230, Gujrat
Submitted to
Department of Electrical and Power Engineering
University of Petroleum and Energy Studies
Energy Acres Dehradun, Uttrakhand

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BONAFIDE CERTIFICATE
Certified that this SUMMER INTERNSHIP Report is a work of
SASHIKANT TIWARI (RollNo.R630214066) who carried out the work from 22
May - 14 July, 2017 at WAAREE Energies Ltd., Plot No. 231-236 Surat Special
Economic zone, Diamond Park Sachin, Surat-394230, Gujrat
Mr. Varun Singh Panchal Mr. Vishal Upadhyay
Manager- Operations HR and Admins.

3. 3

4. 4
Acknowledgement
It is always a pleasure to remind the fine people in the Engineering
program for their sincere guidance I received to uphold my practical as
well as theoretical skills in engineering.
Firstly I would like to thank Mr Narendra Balkishan Soni (Head of
Department, Department of Electrical and Power Engineering,
UPES) for meticulously planning academic curriculum in such a way
that students are not only academically sound but also industry ready by
including such industrial training patterns.
I would specially like to thanks Dr. Santosh Dubey (Associate
Professor, Department of Physics, UPES) for the positive attitude he
showed for my work and recommended me to the WAAREE.
Finally, I would also like to thanks Mr. Jignesh Rathod (Deputy
General Manager), Mr. Vishal Upadhyay (HR and Admins. WAAREE
Energies Ltd.) and Mr. Varun Singh Panchal (Manager- Operations,
WAAREE Energies Ltd.) for giving me this opportunity and their
guidance during the course of the internship.

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CONTENTS
Chapter No Topic Page No.
1. Company Introduction 6-8
2. Quality Department
2.1 Quality Standards 9
2.2 Quality Lab 10-12
2.3 Quality Lab Tests 13-22
3. Shop FloorDepartment
3.1 Standard Solar cell 23-24
3.2 Shop Floor 25-33
4. Merlin Department
4.1 Merlin Solar 34-37
4.2 Merlin Flexible Modules 37-40
5. Conclusions 41

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CHAPTER 1
Company Introduction
The WAAREE Group consortium was founded in 1989 with a focus on
Instrumentation; they have since established themselves as India’s premier multi-
diverse technology group having forte in multifarious verticals such as Solar
Energy, Industrial Valves, Petroleum Equipment’s & Process control
Instrumentation. They have a presence in over 68 countries, serviced through their
sales offices in India and 8 offices globally in UAE, Europe, USA and Australia.
In 2007 WAAREE began its foray in renewable energy with the establishment of
WAAREE Energies Pvt Ltd (WEPL). WEPL has a modern state-of-the-art &
automatic production line for PV modules at the Surat Special Economic Zone
(SEZ), located 250 km. north of Mumbai. A full range of PV modules from 1Wp
to 300Wp are manufactured for various on-grid and off-grid applications, and are
exported to a number of countries globally, and in India. WEPL offers
comprehensive dollar solutions all under one banner.
SolarPhotovoltaic Modules, Solarsystems and EPC Solutions:
 With an annual productioncapacity of 100 MW, WAAREE manufactures a
complete range (3Wp to 300Wp) of off-grid as well as on-grid PV Modules
 State of the art manufacturing facility is located in Special Economic Zone
(SurSEZ) in Surat, Gujrat WAAREE PV modules are certified by all major
global accreditation bodies around the world
 They provide complete EPC services to developers and promoters of Solar
Power Generations Systems, Solar Power Plants & Solar Off Grid Power
Plants

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FACTSHEET
NATURE OF BUISNESS MANUFACTURER
ADDITIONAL BUISNESS  EXPORTER
 SERVICE PROVIDER
 ASSOCIATION
 DISTRIBUTOR
TOTAL NUMBER OF
ENPLOYEES
501 – 1000 PEOPLE
YEAR OF ESTABLISHMENT 2007
LEGAL STATUS OF FIRM PRIVATE LIMITED COMPANY
ANNUAL TURNOVER RS. 100- RS. 500 CRORE

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VISION
Our Vision is to provide high quality and costeffective sustainable energy
solutions across all the markets, reducing carbonfootprint- paving way for
sustainable energy thereby improving quality of present and future human life.
MISSION
By virtue of our commitment to our stakeholders, we strive for continuous
improvement in the quality of our productand services.
VALUES
The core values of our organization are those values that underline our work &
strategies we employ to fulfil our Vision & Mission.
Fig. 1 (a)

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CHAPTER 2
Quality Department
A quality engineer is a professional who understands the principals of productand
service quality evaluation and control, according to the Energy Facility Contractors
group. Quality engineers work in manufacturing plants, taking responsibility for
the quality of a company’s products. By working with departmental managers,
production staff and suppliers to ensure quality, they aim to minimize the costof
reworking or waste and maximize customer satisfaction with the products.
Quality Standards
Quality engineer establish, implement and maintain quality management systems
to measure and controlquality in the productionprocess. Theywork with designers
to establish quality standards for individual products and set out the standards in
documents and process forthe productionteam. They may also base their systems
on independent standards, such as ISO 9000, which sets out the criteria for a
quality management system and enables companies to work towards
internationally recognized quality accreditation.
Customer Focus
Quality standards provide guidance and tools for companies that want to ensure
their products and services consistently meet customer’s requirements, according
to the International Organization for Standardization. Quality engineers monitors
feedback from customers to identify any quality concerns and liaise with customers
to resolve any issues.

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Quality Lab
Most of the products are imported from different companies and made to use
in the manufacturing of Modules. To insure the quality of WAAREE
manufactured products, some quality tests are performed on these. Material
required for module manufacturing are;-
 Solar Cells
Fig. 2 (a)
 EVA (Ethylene Vinyl Acetate)
Fig. 2 (b)

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 Bus bars/ Ribbon
Fig. 2 (c)
 Glass
Fig. 2 (d)
 Back Sheet
Fig. 2 (e)

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 Junction Box
Fig. 2 (f)
 Aluminium Frame
Fig. 2 (e)
All the above mention Raw materials are required for manufacturing a
module and before doing that each component has to pass its own set of
tests which are performed on their specific instruments in the Quality
lab performed by the quality engineers.

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Various Lab Tests Performed by Quality Department
 Solar Cell Tester
Cells are always bought form other companies like Indo Solar, Jupiter
etc. Before putting those cells in manufacturing module some random
lot from the entire shipment is tested. According to the reference cell or
golden cell parameter which is given by the company at STC is
checked here with the help of Cell Tester. So, it is a machine in which
cells anode and cathode is connected through its bus bars and a light of
irradiance 1000 w/m2 is flashed. The output of all the electrical
parameters along with the graph is recorded in the connected PC.
Before checking the electrical parameters visual is also done to ensure
that there will not be any kind of chip, oxidation and poor printing on
cell. Otherwise the lot is rejected and entire shipment will be asked to
send back.
Fig. 2(f)

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 Gel Content Test
This test is performed to set the Recipe of laminator for lamination of
module. It will vary according to the manufactures live First EVA (Ethyl
Vinyl Acetate), STR EVA, etc. Five samples of EVA is cut and placed over
glass which is laminated according to the recipe given by the manufacturer.
After lamination five samples taken to the lab for gel content test. From each
samples 12 g EVA is taken and test is performed and gel content need to
come in b/w 91-94 %.
Purposeof performing the gel content test is to;-
1. To check the bonding of EVA (EVA to back sheet and EVA to glass)
2. To check that the optical phenomenon will take efficiently
3. To check the durability of EVA
 Sox let Setup;-
After weighing 12g of the gel of EVA from the samples which are taken
from the laminator. These are wrapped in the filter paper and placed in the
Sox let Setup having solution of either Xylene (Boiling point- 138 deg. C) or
Toluene (Boiling point- 107 deg. C). Generally Toluene solution is preferred
because of its low boiling point over Xylene. So, once these are placed in the
set up. These left for 6 hours continuous heating at 100 deg. C in the Set up.
Now, after the completion of 6 hours cycle take out all the filter papers
consisting of EVA gel and put these in Oven for 4 hours at 105 deg. C for
Toluene and 135 deg. C for Xylene. After 4 hours take out the samples and
weigh again. You will find some difference and the gel is more pure and
clear now. Just take the percentage of new weight to the older one and make
sure that it will come in between 91%-95%, anything above or below is not
accepted.

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 Heating Oven;-
There is this other way of doing it than Sox let setup and it is in Heating
Oven. Everything is same except time, Oven need 24 hours of heating and 4
hours for drying. In Oven heating is done at 60 Deg. C and drying
temperatures are just same as mentioned above in the Sox let setup.
Calculation;-
Weight of Sample EVA= W2 g
Weight of Filter Paper= W1 g
Weight of Residual= W3 g
Weight of dried EVA= (W3 – W1) g
%age of gel content = (W3 – W1) g * 100/ W2
Fig. 2 (g)
 Pressure CookerTest
The purposeof Back Sheet in a module is to trap the sun Radiation for
efficient output.
Back Sheet can be of any materials mentioned below;-
TPT = Tedler Polyester Tedler
EPE = EVA Polyester EVA
TPE = Tedler Polyester EVA

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This test is performed at 2 bar pressure and 121 deg. C temperature for 3
days i.e., 72 hours. After every 24 hours sample is checked to find out any
changes if observed. Generally after 48 hours Back Sheet began to loosen up
its layering off and after 72 hours it will became very hard. If those two
mentioned things happened with the Back Sheet then it will be considered
good as rejected.
Fig. 2 (h)
 Ingress ProtectionTest(IP 67)
The junction Box which is used to put the output of module and diodes in it
needs to be protected from moisture and any leakages that will lead to short
the outputs. RTV (RoomTemperature Vulcanized is used to seal the
Junction Box with the module. To check that system is leak proofIP 67 test
is performed on it.
A sample JB attached with a piece Back Sheet sealed with RTV is put in 1 m
tube which is filled with water is place completely immersed for 30 minutes.
After completion of 30 minutes it is taken out and JB is opened to check that
whether there is any leakage or not.

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Fig. 2(i)
 PeelTest
This test is performed to check the strength or bonding of EVA with the
Back Sheet and Glass. The bonding of EVA very important in order to
provide stability to the cells which are placed between layers of EVA and
also as per the optics point of view. To perform this test a sample is taken
with EVA to glass and other one is with EVA to Back Sheet. Sample is
attached with a tape which is fixed to the contacts. Oncesample is fixed,
now tensile force is begun to apply on it till the required force limit or
above. If sample is able to survive required force than it is passed and ready
to manufacture.
The required force need to be around;
1. EVA to Glass = 70 Newton
2. EVA to Back Sheet = 80 Newton

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Fig. 2 (j)
 Salt Mist Test
This test is performed to check the durability of the aluminium frame of the
module against rusting by creating an artificial environmental condition.
This test is performed for 28 days continuously.
Cycles per day = 22 cycles (22 hours) and 2 hours of NaCl spray
Humidity set up of the machine = 85
Temperature = 35 deg. C
Frame is made up of Aluminium with anodizing coating over it.

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 Fragmentation Test of Glass
Glass which is used in modules is having Trans- piracy of greater than 93%.
Glass is having to sides one is Air side and the back side for EVA
placement. Glass Air side is coated with Antireflection coating. The glass is
especially designed in order to make sure that one is breaks by any accident
of any means; it should be divided into small pieces to ensure the safety of
working personnel.
In this test a brand new glass is taken and manually cracked under controlled
condition and many samples pieces in a duct tape are taken to the lab to
check the breaking pattern of it. While collecting the pieces for testing
makes sure that you should not take samples within 100 mm range of the
point from which you’ve cracked the glass. Now place you samples over 25
cm2 paper zing. Count the number of pieces within that area, if the number
of pieces in the sample is less than 40 than you can go with that glass from
the particular manufacturer. If the number of pieces is more than 40 you
need to reject those glasses from the manufacturer.
Fig. 2 (l)

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 Bypass Diode Thermal Test
Rating of diodes is 25 Amp (for 320 W) and 15 Amp (for 220 W). Module is
placed over thermal sheet for 1 hour. Temperature = 75 deg. C
Time = 1 hour
Length of cable from JB is either 1000 mm or 1200 mm.
 PID (PotentialInduced Degradation)Test
PID is potential induced performance degradation in crystalline photovoltaic
modules, caused by so-called stray currents. This effect may cause power
loss of up to 30 per cent. The cause of harmful leakage currents, besides the
structure of the solar cell, is the voltage of the individual photovoltaic
modules to the ground. In most undergrounded PV systems, the PV modules
with a positive or negative voltage to the ground are exposed to PID. PID
occurs mostly at negative voltage with respectto the ground potential and is
accelerated by high system voltages, high temperatures, and high humidity.
The latest trend in PID evaluation testing is to focus on the effect that
moisture has in promoting deterioration, so PID evaluation testing chamber
method in a high temperature/humidity environment is receiving widespread
attention.
1. Mini-module size
Three sample panels can be tested simultaneously.
2. Full module size
Ten sample panels can be tested simultaneously.

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 Artificial Climatic Chamber Test
In order to make assessments with regards to quality and reliability PV
modules are exposed to artificial aging in laboratory. The aim of this
exposure is the reproduction of field loads and typical defects. Indoor testing
is carried out in different climate chambers, which expose modules to certain
environmental conditions such as humidity, temperature or irradiation. For
type approval testing the quantitative test conditions and exposure times are
defined in testing standards IEC 61215 (crystalline silicon) or IEC 61646
(thin film).
Item
Testconditions (IEC 62804, 1stedition, issuedAugust 6,
2015)
Chamber
temperature
60°C±2°Cor85°C±2°C
Chamber
humidity
85%±5%
Applied
voltage
condition
-600DCVor -1000DCV
Leak current
measurement
range
±200nA to ±1mA
Number of
basic channels
3ch

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However, these standards do not test for lifetime but infant mortality, which
approves the functionality of PV modules and that they can be operated for a
longer period in temperate climates. Forextreme environmental conditions
(desert or tropical regions) different conditions and exposure times have to
be defined – as well as individual testing procedures for lifetime testing.
Fig. 2 (m)

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Chapter 3
Shop Floor Department
Photovoltaic module from its Solar cell to string to module is prepared in
this department. WAAREE aims to produce1000-1200 modules daily on the
basis of demand. Productionis the functional area responsible for turning
inputs into finished output through a series of production processes.The
production manager is responsible for making sure that raw materials are
provided and made into finished goods effectively. Before working in this
department there are following general things one should know about solar.
Information about Standard SolarCell;-
 Standard size of solar cell worldwide is 156.75X156.75 mm
 A standard solar cell consists of 105 fingers which is updated from 95
fingers.
 4 BB (Bus Bar) solar cells are in use but very soon5BB solar cells are
expected to arrive in the market.
 Temperature = 24+-2 degree Celsius
 Voc = 0.6 volt
 Isc = 8 amp
 P = 4.8 Watt
 Irradiance = 1000 w/m2
 Width of front Bus Bar is 1.3 mm
 Width of Bach Bus Bur is 2.21 mm
 Thickness of cell is 0.200+-20 microns

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 Important Points regarding the Designing of modules;-
 P (Wattage of a Module) = (Efficiency of Cell (in %) * No. of Cells *Cell
Area *irradiance)
 Cell Area in m2
 Irradiance in 1000 W/m2
 Module Efficiency = (P max)/ (Module Area)
 Fill Factor= (P max)/(Voc*Isc)
 Bus Bar width = 5 mm
 Bus Bar thickness = 0.300+-20 microns
 Solar Cells are imported from companies like Indo Solar, Jupiter, etc.

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Shop Floor;-
1. T&S (Tabbing & Stringing);-
In Tabbing & Stringing machine strings of the solar module is prepared
automatically. Tabbing & Stringing machines series-connect cells by
welding wirings onto cells to form “strings”. Operator need to feed cells,
Bus Bar ribbons, flux and perform visual inspection of the prepared string. If
a string is good to go after visual, it will be put on pallets from where it will
sent to next section.
Assume if any cell is having crack, chip and visual defect than that string is
put on different pallet which will be sent to Re-work.
Fig. 3(a)

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 Acceptance criteria of Strings at T & S
S.No. Defect Acceptance
Criteria
Measurement
Method
1. Cell crack No Visible cell
crack is accepted
Visual Inspection
2. Cell chipping/ Edge chipping 1. V chip not
allowed.
2. Silicon
chip up to
0.5X0.5
mm
allowed
3. U chip:
L<=2 mm
& H<=0.5
mm
Steel Gauge
3. Cell to cell gap 2+-0.5 mm (1.5
to 2.5 mm)
Visual Inspection
4. Yellowish spoton ribbon No yellow spot
on ribbon
accepted
Visual Inspection
5. Ribbon cross <= 0.5mm ribbon
cross onmax 3
cells per module
Steel Gauge
6. Grid line cut <=1mm , Qty.
<=6 per module
Scale
7. Colour variation in cells Reddish or dark
blue and rest of
the part light blue
not acceptable
Visual Inspection
8. Colour variation in string Reddish or dark
blue mixing with
light blue
Visual Inspection

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2. Layup Section;-
In this section a set of workers manual put string from the pallet on to the
glass with a layer of EVA. This equipment alternately supplies strings on
stacked tempered glass and EVA. In the following process, strings are wired
to form matrices. Now after putting cells strings upside down, this is passed
to other set of workers. In the second step of layup next set of workers do the
soldering and connect Bus Bars to it. After that cells are covered with other
layer of EVA and then a Back Sheet. Once it is examine by the Junior
Engineer, it will be sent to the next section.
Fig. 3 (b)
3. Inline EL (Electro Luminance) Section;-
In this section module after layup is given voltage and current to check
whether it having any crack or not. When voltage and current is given to the
module all the cells began to illuminate which is capture by a camera placed
beneath the table. The camera output is shown to the screen of computer and
if there is any fault in a cell that particular cells will be shown dark in the
image. If a module is passed this EL test and marked OK by the operator
then it will be sent to the other section but if it failed to do so, then module is
sent for Re-work.

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Analysis and detection of structural defects during production cycle.
Spatially resolved detection of defects and feedback loops for corrective
measures in the productionprocesses. High reproducibility of measurement
results.
Fig. 3 (c)
4. Laminator;-
After the verification from the EL section module is sent to Laminator
section where it is put in those big lamination machine. There are several
machines available for lamination ant at a time one machine can have 4
module of as much as 320 W for lamination. Lamination takes place for
15minutes according to the Recipe sent by the quality department. All the
vacuum pressure and time set according to the Recipe. Once modules come
out of the Laminator, it will be allowed to coolfor say 15-20 minutes. Then
these sent to next section for further process.

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 Recipe of Module Lamination:
PROCESS TIME UPPER
VACUUM
LOWER
VACUUM
Vacuum 230 Sec -100 kp -100 kp
Pressing 90 Sec 60,75,0 -100kp
Lamination 480 Sec 0 -100 kp
Cover Open 50 Sec -100 kp 0
Table Temperature; - 146-152 degree Celsius
This recipe changes were according EVA manufactures and on the basis of
quality lab testing.

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5. Trimming Section;-
During lamination pressing is done and because of that heat melting some of
the EVA came out of the module which need to be removed before doing
anything further on the module. This process ofcutting extra material is
known as trimming. In this section some workers manually trim these extra
materials by using industrial blades which are meant for this purposeonly.
After trimming it sent to the next section.
Fig. 3 (d)
6. Visual Examination;-
Now once again visual inspection is done by some quality engineers to
ensure the great quality of module offered by the company. During visuals
they look for the correctarrangement of cells with proper gaps, there
shouldn’t be any foreign material during lamination inside the module and
any kind of visual crack. Quality is the prime concern of the company
which will check at each and every step.

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Fig. 3 (e)
7. JB(JunctionBox) placing Section;-
Once modules are visually OK then, JB is put on the outputs of the modules
for proving connection. The JB is attached to the module by using a RTV
(Room Temperature Vulcanized) sealant gun.
Fig. 3(f)

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8. Frame Placementsection;-
Once JB is placed on the module, it is sent for its second last step i.e., frame
placement. Aluminium frame is put on the module again with the help of a
RTV (Room Temperature Vulcanized) sealant gun.
9. Offline EL tester Section;-
Here in this final step of Shop floor modules after framing are again proceed
for EL (Electro Luminance) test. If found any kind of fault, the module is
strait away rejected.
 NOTE;- All the above process in the plant Shop floor is taken place
with extreme caution. All the working personnelneed to wearcaps,
gloves and shoe caps while working. The inside temperature of sopfloor
need to be around 24+-2 Deg. C as per the quality standards.
Fig. 3 (g)

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 Rework ofRejectedStrings;-
String pallets which are rejected by from the T&S (Tabbing & Stringing)
section are received by Rework section. In Rework section workers
manually remove all the damaged cells from the string using solder iron and
flux which are replaced by some good cells in position of them. Once a
string is fixed with OK cells than it will be sent again to the Layup section
for further process. Supposea complete module after Framing is rejected by
the Offline EL testing section, than it will be considered as a B-Type module
and will be sold to those customers who are willing to buy it with some
reasonably lower rates. These defected modules will definitely generate
power but at reduced ratings.
Fig. 3 (h)
 DispatchArea;-
Before stacking the modules for dispatch, these are tested for one last time in
sun simulator.
SUN Simulator;-In sun simulator artificial sun lights with the help of strong
halogen light made to fall in a very dark chamber where modules one by one
hang against light source. In this all the readings of module is checked like
Voc, Isc, Power output and efficiency at 1000 W/m2. If found OK then it is
allowed to go for dispatch after good amount of packing in order to prevent
it from getting damaged during transportation.

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Chapter 4
Merlin Department
 MERLIN SOLAR
Conventional forms of solar deployment which rely on aluminium-framed-
tempered-glass constructs are the industry work horse. However, their
weight and rigidity prevent their use in applications that demand rugged,
lightweight, flex tolerant, and aesthetic appeal. This has limited their use
primarily to large grid connected solar farm applications. Merlin™ delivers
innovative crystalline silicon based solar solutions which address demanding
deployments such as on metal roofs, auxiliary power for transportation, flush
mounted residential solar, and military applications. Merlin with world class
manufacturing company Waaree Energies (Surat, India) provide the scale
and quality manufacturing required to seamlessly meet demand.
 Why Merlin?
 The Merlin module offers improved light capture and reduced sheet
resistance
 Overall power output is 14% higher than the conventional modules
 Merlin performs significantly better than conventional modules in
low-angle incidence conditions (6:30 AM – 9:00 AM and 2:00 PM –
6:00 PM), as well as low light conditions
Amp hours (a unit of charge) in particular are an important metric for
electric battery charged applications. On this criterion, Merlin clearly shines
against the competition. By the end of one day, the merlin modules provides
60% more Ah to a battery.
Not only do Merlin modules producemore power than the competitor
design, they are also extremely rugged and have been tested to withstand
significant environmental stress.

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 Merlin cellmodules VS ConventionalModules
Fig. 4 (a)
 10% reduction in total installed system costcompared to conventional
systems
 Up to 80% less silver than traditional three bus bar cells and modules
 Up to 50% lighter in weight, making it easier to install, transport and
allows placement of panels in areas where traditional panels could not
be installed

36. 36
 3-5% power increase per module compared to standard modules
 Increased durability and flexibility improves dynamic loading
performance and reduces breakage during transportation and
installation
 Flexible grid eliminates three bus bar cell metallization, increasing fill
factor and reducing shading losses, resulting in higher current and
increased efficiency
 Wide, flexible grid connecting tabs allow for durable cell-to-cell
connections, improving reliability at the same time as their high
conductivity increases module efficiency
 EasyIntegration
A flexible, coated-coppergrid is attached to the segmented fingers
eliminating the three bus bars. The combination of segmented fingers and
GT’s patented flexible grid design makes it easier to move current off the
cell which reduces resistive losses and improves efficiency. The flexible grid
provides 20 high-conductivity paths for the current to travel along rather
than the three bus bars found on traditional cells. And… because there is less
shading, cell efficiency is further boosted. Merlin technology improves the
way cells connectby eliminating the need for stringing and tabbing. The thin
connecting strip running along the width of the grid provides a highly
flexible and durable way to connect cells. Cells can now be connected more
closely together making the module smaller than a conventional module. A
common sourceof module failure occurs when ribbons break due to metal
fatigue caused by dynamic loading conditions during shipping or in the field.
The flexible connecting strip at the end of each grid solves this problem.

37. 37
Fig. 4 (b)
 Materials required to make a flexible module of Merlin cells;-1. 1.
ETFE (Ethylene Tri Floro- Ethylene) - 1
STR 0.2mm EVA (Ethylene Vinyl Acetate) - 1
Transparent Back Sheet - 1
EVA (Ethylene Vinyl Acetate) - 2
Cells
EVA (Ethylene Vinyl Acetate) - 2
Back Sheet - 1
The above mentioned points are the steps to make layup for Flexible
Merlin Modules. To make these types of modules full merlin cells are
used. These cells are made to attach by worker manually with an iron
solder and flux. Before giving cells to form strings, Cells are visually
checked and EL test is performed individually on each cell
respectively. Once a cell is declared OK after Visual and EL test, it is
sent for making strings of merlin modules. The workers of Merlin
department are somewhat more precise as they have to do almost
everything on their own unlike the standard module manufacturing
department, which is mostly automated. As soonas the strings are
ready, pallets are sent for layup. In Layup firstly a glass is used as the
level surface on which module Layup is done.

38. 38
On the glass one layer of ETFE is placed with its air side facing the
glass. On ETFE one layer of STR EVA which is of 0.2 mm thickness
is placed. After one layer of EVA, Transparent Back Sheet is placed;
on this regular thickness EVA with 2 layers is placed. Now cell
strings are arranged on the below layer with propermeasurements and
soldering is done. Cells are layered again with two layers of EVA.
After EVA layers finally a Back Sheet is placed which completes the
module Layup. Before sending the module to a laminator on which all
the lamination cycles is calibrated according to the flexible module,
EL (Electro Luminance) Test is performed to check any kind of
internal cracks which are not visible from naked eyes.
Once lamination is done than module is trimmed and EL is done to
find any cracks, if there after lamination. As soonas the module is
declared visually OK bye the quality engineer, it was sent to the
dispatch department. From the dispatch center modules are sent to
their respective customers.
Lamination; - Recipe for Flexible Module (Merlin)
PROCESS TIME UPPER
VACUUM
LOWER
VACUUM
Vacuum 230 Sec -100 kp -100 kp
Pressing 90 Sec 60,75,0 -100kp
Lamination 480 Sec 0 -100 kp
Cover Open 50 Sec -100 kp 0
Table Temperature; - 146-152 degree Celsius

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 Types of Merlin Modules
 GX Series
Merlin Solar (MST) GX series PV module line is a glass front,
flexible module designed for a wide range of photovoltaic
applications, including commercial and residential rooftops, car
ports, metal roofs, and other weight sensitive environments.
Fig. 4 (c)
 FX Series
Merlin Solar (MST) FX series PV module is a polymer flexible
module designed for a wide range of photovoltaic applications,
including commercial and residential rooftops, carports, metal
roofs, and other weight sensitive environments. Available in
three different configurations: 6 x 6 cells, 2 x 18 cells, and 2 x
12 cells.

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Fig. 4 (d)
Fig. 4 (e)
 BR Series
Merlin Solar (MST) BR series PV module line is a glass front,
back rail module designed for a wide range of photovoltaic
applications, including commercial rooftops, ground mount and
residential.

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Conclusion
The 2 month spent in WAAREE Energies Ltd. has been a unique experience
to me. It was an eye opener to how a Photovoltaic Module is manufactured
in real. This internship gives the exposer to both Quality and Manufacturing
operations.
Through practical training, I have gain a great learning to systematic work
coordination in an environment that is conducive coupled with friendly staff
that is always there to help.