The First Solar Series 5 module from the front and back
Thin-film master First Solar plans to release a new set of solar modules next year much larger—in output and area—than both its standard CdTe model and traditional 60- and 72-cell c-Si panels. What does this mean for installers? We try to answer the basics on First Solar’s new Series 5 modules.
What’s different about the new module?
First, let’s backtrack and explore what First Solar already offers. The company’s popular Series 4 module has a frameless, glass-on-glass structure and is small in stature at 600 mm x 1,200 mm (a traditional 60-cell c-Si module from Trina Solar is about 990 mm x 1,650 mm, while a 72-cell Trina module is 990 mm x 1,950 mm). The Series 4 module is rated at about 105 W (Trina’s 60-cell is rated at 265 W and the 72-cell is 320 W). First Solar thin-film modules are commonly used on large utility-scale solar projects, and the Series 4 module is often positioned horizontally and stacked three- or four-high on ground-mounts.
The new Series 5 module can first be imagined as three Series 4 modules connected together in the arrangement frequently seen out in the field, but it’s not that simple.
“[Series 4] is actually a separate and discrete device,” said Steve Krum, director of corporate communications for First Solar. “Three modules are adhered to twin metal rails, eliminating the need for mounting clips, and connected with a simplified wiring harness that combines the output from each module into a single feeder.”
First Solar’s Series 4 and new Series 5 module compared to traditional 60- and 72-cell c-Si panels from Trina Solar. Design credit: Allison Washko, WTWH Media
The Series 5 module (now at 1,200 mm x 1,860 mm and rated at 365 W) is not too different on the surface to what utility-scale contractors are already out in the field installing, except it comes “pre-assembled” in a more standardized format.
How will installation change?
For those working on projects with high labor and BOS costs, Krum said the Series 5 module will save time and money. No mounting clips are needed; neither is additional wiring harnessing.
“Series 5 features an integrated twin rail structure that allows for installation to a mounting table or tracker with four bolts, which improves installation velocity,” Krum said. “Series 5 can be installed by two-person crews manually or a single installer and crane/lift operator.”
This larger module design, which is more akin to traditional c-Si panels, allows the Series 5 to be mounted on third-party mounting structures, thus producing more opportunities for developers to find the cheapest and best vendors to reduce BOS costs. And for installers interested in using thin-film on projects but deterred by the non-traditional size and attachment of the Series 4 modules, the Series 5 module opens up a new customer base more aligned to c-Si.
A typical First Solar installation using Series 4 modules stacked four-high at Agua Caliente Solar Project in Arizona.
For installers already familiar with stacking Series 4 modules three-high, Series 5 module installation should be much easier with condensed wiring and mounting.
When will we see the module?
First Solar first introduced the module to the European market at Intersolar Europe in Munich this June to a warm response. Series 5 modules will be on display at Solar Power International, mounted to a number of third-party racks.
Manufacturing plants in Ohio and Malaysia will be converted to add the rail assembly to some production lines with additional lines added based on market demand. The company expects to begin shipping the new modules in late 2017 after fine-tuning more reduction of BOS costs.
What else is First Solar working on?
Already planning past Series 5, First Solar is developing a Series 6 line. Essentially a Series 5 module without the three separate panels, the Series 6 module will be one continuous laminate, about the same size as Series 5 but rated at more than 400 W. Because of the larger, one-sheet size, these panels may need custom mounts, but all of this is still under development. Look for a potential 2019 launch.