Production Factory Setup Service in World Wide


View of Main Equipments for Solar Module Production


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card_diamond.gifSYSTEM BASIC COSTcard_diamond.gif




Amount (usd)



M1000 PV Module Production Facility




Total Equipment Cost




Total Technology Transfer Cost




Estimated Pack and Ship FCA




TOTAL M1000 Line costs




M2000 PV Module Production Facility




Total Equipment Cost




Total Technology Transfer Cost




Estimated Pack and Ship FCA




TOTAL M1000 Line costs


Note: Factory reserves the right to change specifications without notification in the interest of improving the capabilities of the products described in this document. Estimated shipping dates are subject to change based on production capacity at the time of order.


card_diamond.gifTERMS OF SALEcard_diamond.gif


square06_blue.gif VALIDITY OF QUOTE

60 days from received proforma invoice.

All Prices In USD FCA Ottawa, Ontario, Canada, unless otherwise noted. 

Prices subject to change, but valid on date of proposal.

Normal terms are irrevocable letter of credit.

Other options are available subject to agreement of Procon Group or NewSun’s financiers.

square06_blue.gif STANDARD PAYMENT

Down Payment of 40% with contract effectiveness

Progress Payment of 50% with delivery to Canadian port

Final Payment of 10% on completion of commissioning of line and training of Buyer's personnel and signing of acceptance certificate, or 3 months from installation of equipment whichever comes first.

square06_blue.gif DELIVERY SCHEDULE

The delivery schedule is expressed in terms of weeks after the contract becomes effective.  Contract effectiveness is normally the date on which we receive a down payment and an ILC acceptable in form and substance.  Delivery depends on the complexity of the line ordered and the factory loading.  At the time of acceptance of an order, the actual delivery schedule is agreed to.  Approximate delivery for the M1000 or M2000 is 28-30 weeks for full line

square06_blue.gif PACKAGING

Cost of crating suitable for ocean transport is included for all shipments on FCA terms. 

Customer is responsible for insurance of all items during transport. Procon Group Factory NewSun is not liable for any damages that may occur during shipment or transport. In the event of shipment damages, Factory will dispatch technical personnel to repair said damages.  All costs and expenses, including parts will be billed to customer’s account.


square06_blue.gif TESTING

Prior to authorizing shipment of equipment, Factory will conduct electrical, mechanical and throughput  testing on all equipment.  Customer is welcome to send representatives.


square06_blue.gif ACCEPTANCE

Facroty reserves the right to require its agent to be present at the time of unpacking of all equipment at the Buyer’s premises.  Upon delivery of Equipment at the Buyer's premises, Factory NewSun will dispatch personnel for supervision of Installation, Commissioning and Training, within 3 weeks of receiving notice in writing that the equipment has arrived, and has been delivered without damage. To protect its proprietary technology, Factory requires its customers to agree that the technology supplied is for the exclusive use by the customer only in the line supplied.    We require a commitment that the customer will respect the investment Factory NewSun has made in its people, and will not attempt to entice them away during time spent in the customer’s facility integrating and commissioning the line.

Customers for turn-key lines are not entitled to install equipment without a Factory representative being present.  If customer installs the equipment without Factory presence, Factory is not liable for any problems that arise due to improper installation by customer.  Factory NewSun will dispatch technical personnel to repair installation damages.  All costs and expenses, including parts are customer’s responsibility

square06_blue.gif SERVICE and REPAIR

For major equipment, service and repair will normally be carried out at customer’s facility.  In such cases, the customer will be responsible for all travel and living expenses of Factory personnel. 

All requests for service and repairs must be accompanied by a service  purchase order, detailing the problem before Factory personnel are dispatched to customer’s facility. 

The final cost of the service purchase order will be determined by the daily service rate, travel, accommodation, parts and additional expenses as billed by Procon or Factory NewSun technical personnel.

In case of returns for warranty repair to be carried out at factory NewSun , customer is responsible for all shipping expenses to and from site.

square06_blue.gif SPARE PARTS

Spare parts for 1 years operation  included with the equipment.

square06_blue.gif WARRANTY

The warranty period for all Goods and Services will be for 1 year from receipt by customer.

All equipment manufactured by sub-contractors to Factory NewSun will bear the warranty of the manufacturers, which will be passed on to the customer.

Warranty does not apply to wear items and consumables.  Contact Procon or Factory NewSun for further details.

Procon Group or Factory NewSun does not warranty used/refurbished equipment – supplier warranties will be passed on to customer.

square06_blue.gif ORDER CANCELLATION

If the customer chooses to opt out of the purchase order/contract, Procon Group Export center or any department are not obligated to refund the initial down payment sum.  The contract for the turnkey line will be the governing document.

If the customer fails to take delivery of the equipment within 30 days of written notice, Procon Group Factory NewSun reserves the right to cancel the order.  Contact Factory NewSun for further details.

square06_blue.gif OTHER

Costs do not include any taxes or duty outside Canada.  Additional terms may be applicable as per purchase contract.

Procon Group of Factory NewSun is not liable for any loss in profit, operating costs or other consequential damages resulting from failure or defect of purchased equipment.

We also can give the orther production system from Procon Group Partner Spire Inc in USA for Automation system based Turnkey supply.



As described herein, Procon Group Photovoltaic produce machinery NewSun offers to coordinate the supply and installation of a photovoltaic module assembly line in a facility of your choice. NewSun is well positioned to provide the line and on-going production support, including a supply of silicon solar cells (from sources for which we have supplied the technology and have marketing exclusivity) and other materials for production.


The module assembly lines described in this proposal are the M 2000 and M 1000 lines. 


The M 2000 line enables a production capacity of at least 10 MW per annum on a three-shift basis, using 125 mm x 125 mm solar cells.  (One working shift is equivalent to 2000 hours per annum.)


The M 1000 line offers a production capacity of over 5 MW per annum with the same size cells.


Included in the supply of either production line, Procon Group Solar Energy Machinery NewSun will:


§      square06_red.gif  Provide all necessary state of the art equipment and technology for manufacturing and testing photovoltaic modules. 

The line will test incoming cells, process them into modules, and test the final modules.  The line is designed to be easily operated by an unskilled labor force following training by NewSun.  Equipment supplied includes that necessary for handling incoming materials.


§      square06_red.gif Provide training for the work force in both Canada and Customer’s Country. 

The training includes training in equipment operation, maintenance, production procedures, and materials preparation and flow.  Detailed documentation will be provided to guide the on-going factory operations.


§      square06_red.gif Supervise installation and commissioning of the production line in Customer’s Factory 

This will include supervision of the first full-scale production of a minimum of 100 modules once the line is commissioned. 


§      square06_red.gif Provide the necessary solar cells and other materials to make PV modules.

Materials will be provided for training purposes as well as for initial product manufacture to an agreed level.  All materials will be made available for the initial production run in Taiwan.


§      square06_red.gif Provide an on-going source of solar cells and other materials at competitive prices.


§      square06_red.gif Assist in product marketing and systems design.

NewSun also offers to assist in design and sourcing of the utilities to be included in the production facility, including any back-up power source.



For photovoltaic module manufacture, we provide the necessary equipment and technology to assemble multi-crystalline or mono-crystalline silicon solar cells into state-of-the-art photovoltaic modules. Key equipment items provided in the line are designed and made by NewSun, designed by NewSun and fabricated under contract, or are purchased as standard items from reliable equipment manufacturers. In all cases, NewSun adds all the necessary technology to the equipment. Once production starts, we offer to continue to source and supply suitable solar cells and other materials to you to be used in the production of modules, until such time as you may implement solar cell production as the next stage of development.  Procon Group Hight Technology Development Devision NewSun can also provide a complete solar cell manufacturing line.




circle06_skyblue.gif Typically in standard module production lines, 36 solar cells are connected in series (redundant interconnects for reliability) to be able to charge a 12 Volt battery.  When the cells are interconnected and encapsulated against the environment, they form a rugged building block called a solar photovoltaic module that may used in various combinations for providing electricity. A superstrate of high tempered low iron solar glass is normally used (an alternative is Tefzeltm)to protect the cells from the environment and from impact damage.  The cells are laminated between layers of ethylene vinyl acetate (EVA) and backed by a layer of impact and moisture resistant Tedlartm/polyester/Tedlartm or Tedlartm/polyester/EVA laminated film.  Glass may also be used as the backing material. 


circle06_skyblue.gif The special laminating process assures a strong bond between the superstrate, cells and backing substrate. The laminated module is edge sealed and framed by a lightweight custom aluminum extrusion, which interlocks at all four corners to give outstanding mechanical strength, allowing for rough handling and ease of installation.  To complete the weatherproof module, junction boxes designed for easy wiring access, are securely attached to the backs of the modules.


circle06_skyblue.gif Module power ratings depend on the solar cells used.   Cells of 100 mm x 100 mm size, which have efficiencies in the 13 to 15% range, will yield modules rated between 45 and 53 Watts.  Mono-crystalline silicon cells of 125 mm x 125 mm pseudo-square size have typical power ratings (Standard Test Conditions) of 1.9 to 2.2 Watts, yielding 70-78 Watt modules when encapsulated. Multi-crystalline silicon cells 125 mm x 125 mm size, made by technology supplied by NewSun have an average rating of 2.1 Watts, to give 75 Watt modules.  Modules with 150 mm x 150 mm cells will have typical ratings in the 110-120 Wp range.


circle06_skyblue.gif All cells may be cut into smaller segments to yield low power modules.



    Model M1000 is a semi-automatic line designed to produce over 5 MWp of modules per annum on a a three shift basis using 125 mm x 125 mm cells.


      Model M2000 is a semi-automatic line designed to produce approximately 10 MWp of modules per annum on a three shift basis using 125 mm x 125 mm cells.


All lines are supplied with tooling for two sizes of cells (typicallly 125 mm and 150 mm size).  Extra tooling can be supplied to use a third size (typically 103 mm cells). 


All lines can be tailored to meet our customer's requirements.



Model M8000 is designed to have a throughput of over 8.5 MWp per shift year with 125 mm x

125 mm cells and up to 14 MWp per shift year with 150 mm x 150 mm cells



circle06_skyblue.gif Solar cells are the incoming material to this line. A solar cell tester is provided to allow testing and sorting of the cells into matched categories. Alternatively cells can be provided pre-sorted into categories.  The cell tester quoted with the line is a manually loaded one for the M 1000 line and with auto sorting for the M 2000 line.  The tester is intended to check incoming cells on a sampling basis.

circle06_skyblue.gif Tested and sorted silicon solar cells are tabbed and interconnected in strings.  We provide automated tabbing and stringing/arraying equipment (ST 500 and MA 500S) to first tab the cells, and then connect them into strings or arrays. A string inspection and test station is supplied to ensure strings operate properly. Three ST 500 units are supplied in the M2000 line, each capable of tabbing 300 cells per hour. The ST 500 takes a coinstack of cells placed on the loader, and moves them automatically through alignment, pre-heat and tabbing stations. Solder coated interconnect material is automatically cut to length, fluxed, placed on the cells and solder reflowed (pulsed light raise the cell above the solder reflow temperature). 

circle06_skyblue.gif The tabbed cells are placed at the output in coinstacks which are then inverted and transferred to two loaders on the input of a separate semi-automatic stringer (Model MA-500S).  An option is to include a flip-over mechanism at the output of the ST-500. Strings are prepared alternating from the two coinstacks so that after solder reflow (heated platen and light based) the stings are already oriented for interconnection in a module.  Strings are placed by a vacuum pick-up on a string inspection and test station is supplied to ensure they operate properly, then once tested placed by the vacuum pick-up on arraying jigs in the arraying station which is integrated with the test station.

circle06_skyblue.gif At the arraying station, arraying jigs are used to position bus bars to contact the ends of the strings.  Individual strings are picked up and transported using a String Vacuum Transfer Unit (VT-100S or VT-125S or VT150S).  Interconnected arrays are picked up and transported using a multi-string Vacuum Transfer Unit (VT-36100 or VT-36125 or VT-36150)

circle06_skyblue.gif A module sandwich (layers of low iron tempered glass, EVA, solar cell array, EVA and backing material) is laid up on a specially designed lay-up table. 

circle06_skyblue.gif The sandwich is then laminated at an elevated temperature, under pressure and vacuum using a double vacuum laminator. In the lines as quoted, the laminator is equipped with auto loading and unloading to laminate multiple modules at a time.  Throughput with fast cure EVA is a minimum of 4 lamination cycles per hour when curing is done in the laminator.  (5-6 lamination cycles per hour are possible depending on the mode used)

circle06_skyblue.gif Either two PL 410 laminators or one PL 500 laminator with auto load and unload model is used in the M2000 line.


circle06_skyblue.gif Each module is moved in turn to a framing station where it is positioned centrally to allow the frames to be inserted by pneumatics firmly onto the edges of the module.  (The frames will previously have a pre-measured amount of silicone dispensed into the slot designed to hold the laminate – a semi-automatic dispense unit will be provided for this purpose). The framing station includes equipment for securing the four corners of the frame. 

circle06_skyblue.gif The module is then moved to a termination station where the junction boxes are secured to the back of the modules using manual dispensing of epoxy or silicone.  Leads from the module are secured to terminals in the junction box, then the modules are transferred to a curing rack until dry enough to be tested. 

 circle06_skyblue.gif Upon removal of the laminate and after complete cooling, the excess EVA is trimmed, and the module tested in the simulator/tester (XE 1190 Series)

 circle06_skyblue.gif A high voltage tester (to 3000 volts) is provided to guarantee voltage isolation between the cell circuit and the module frame.

 With suitable jigs and materials sizes, all our lines can handle 100, 125 and 150mm diameter mono-crystalline silicon cells; and 100-103 mm x 100-103 mm, 125 mm x 125 mm, or 150 mm x 150mm square or pseudo-square multi-crystalline or mono-crystalline silicon solar cells.


Module Production Line Core Process Summary







XC 1000P or PA Solar Cell Tester/Sorter

Tests pre-sorted cells on sampling basis.



ST 500 Automatic Tabber

Automatic tabbing.  


Stringing and Arraying

MA 500S Automatic Stringer accompanied by arraying station

Automatic stringing/arraying.  Array finished in arraying jigs. Vacuum transfer to string test

Quality Check


Module Sandwich Assembly

Lay-up Station – automated in M2000 line

Sandwich consisting of glass, EVA, cell array, EVA, backing material.

Quality Check



PL 410 or PL 500 Laminator w/auto load

Laminates sandwiches into modules

Quality Check



XE 1190 Module Tester/Solar Simulator

Tests performance under simulated sunlight.


Frame Assembly

Manually operated framing equipment

Framing, addition of junction boxes



High Voltage Tester

Tests isolation of cell array from frame.  Safety test.










Solar Cell tester:  Model XC1000P/PA**





PL410 with auto load/unload

2 PL 410 or 1 PL 500 w/ auto load/unload


Manual tabbers/stringers for rework and incase of down time

1 MT-200

1 MS-200

2 MT-200

2 MS-200


Semi-autoTabbing Equipment

2 ST-500

3 ST-500


Semi-auto Stringing Equipment Accompanied by Arraying station with jigs for 3 sizes of modules.

2 MA-500S

2 MA-500S


String Tester

1 LTS-90

2 LTS-90


Module Lay-Up Station with rollers to transfer to input conveyor of laminator, and overhead transfer of sandwich materials

1 Manual

Automated 1 or 2 depending on laminator choice


EVA Trimming Station




Applicator for auto dispensing of silicone on frames




J-Box application station




Vacuum Transfer Units: String. Associated with stringing and string test equipment-move on overhead track




Vacuum Transfer Units: Array- associated with arraying and lay-up stations-move on over head track.




Glass Cleaner:  PJ60-6 series 200




Module Tester     XE 1190

1 XE1190

1 XE1190 w Auto load


Dicing Saw*  


CD100 SA


Trolleys for glass transport, cell transport, curing of epoxy, materials holding, finished product.




Overhead tracks to link equipment and allow ease of transport of work in progress*




Sheeting equipment for cutting EVA to size -Rosenthal




Equipment Service Kit




High Voltage Tester




Assembly/Framing Station



* Spare Parts included. *

 * The dicing saw is used to cut full size solar cells into smaller cells for low power custom modules*.

 * Cell Tester is not needed if combined cell and module line ordered.  Automatic unit is included in the cell lines.*



  For convenience, throughput and yield are specified based on using 125 mm x 125 mm silicon solar, cells which very conservatively give > 2.0  Wp +/- 0.15 Wp at AM1.5 spectrum and 25oC.  (Ratings are also given below for 103 mm x 103 mm cells with power rating between 1.4 and 1.5 Wp per cell)


  All lines with suitable fixtures can handle 100, 125 and 150 mm diameter mono-crystalline silicon cells; and 100-103 mm x 100-103 mm, 125 mm x 125 mm, or 150 mm x 150mm square or pseudo-square multi-crystalline or mono-crystalline silicon cells.


  Our standard throughput rating is for a 2000 hour (50 week) shift per annum, with 20% de-rating of actual capacity to allow for inefficient use of personnel and down-time servicing of equipment.




Line Model


103 mm x 103 mm cells


125mm x 125mm cells


150 mm x 150 mm cells


>1.6 Wp/annum/shift

>1.8 MWp/annum/shift

>2  MWp/annum/shift


>3.0 Wp/annum/shift

>3.3 MWp/annum/shift

>3.5 MWp/annum/shift

Yield:   All module lines are designed for greater than 95% yield. 

Breakage is normally less than 0.5%, but less than 2% breakage is guaranteed.



Once a contract is signed, recommendations will be made in the technical documentation for the Facility to be set up by the Buyer.  This includes recommendations on Building, Utilities and Services.  If the Buyer wishes, NewSun will also contract to provide the necessary utilities and services (e.g. De-Ionized water supply for Cell Line) on a turnkey basis.  A detailed layout to fit the Buyer's facility will be provided once a contact is signed.



Cost of sufficient spare parts is negotiated at contract signing.

Detailed spare parts list defined when contract is signed, and becomes part of the contract.

Procon Group NewSun offers to source and supply the customer's on-going spare parts needs for 5 years.



Procon Group NewSun offers to contract with our customers to supply materials sufficient for at least three month's operation of the line once commissioned.  Materials provided can be shipped with the line, and are not readily available in the Customer's country.


Procon Group NewSun will also quote the supply of sufficient materials for one full year's production at the line's design level at the time of contract signing.  Since materials prices are subject to fluctuation, prices for these quantities are not given in the original line proposal.



As an integral part of each production line package, we offer a range of technical services including Training, Installation/Commissioning support, and ongoing service backup.  Complete and detailed Documentation is provided to enable the customer to understand and readily operate the processes and equipment, and to service and maintain the equipment.




At the customer's option, initial training can be provided in Canada. Training will always be carried out in the customer's facility upon installation of the equipment.


Training covers the operation and maintenance of all equipment and processes included in the production line

The number of people trained is at the customer's option, but should include at least 2 for smaller lines and 3 for larger automated lines.


The training period in the customer's country is from 1-4 weeks depending on the complexity of the line. 


As part of contract signed between Factory NewSun and customer, a document entitled "TRAINING PROTOCOL" will be included so that the trainees may be fully prepared in advance.



Line Documentation is provided in advance to allow the Buyer to properly prepare the site, equipping it with the correct utilities so the equipment may be readily connected up upon arrival.  This documentation may be tailored to the specific facility available at the Buyer's site.

Upon advice from the Buyer, our Representative(s) will visit the factory and supervise the installation and commissioning of the production line.  This includes supervision of trial production runs.

The number of persons dispatched to the Buyer's factory depends on the complexity of the line, but normally will not exceed 3 people.  The period typically ranges from one to four weeks.

Well in advance of the visit, the Buyer is provided with a detailed document entitled "INSTALLATION, TEST AND COMMISSIONING PROTOCOL"




 - General Description of the Line

 - Equipment Description and Specifications

 - Utilities Requirement and Site Preparation

 - Materials Specification, Usage and Sources

 - Process Flow, Tasks and Manpower

 - Test and Acceptance Protocol

 - Training Protocol

 - Installation, Test and Commissioning Protocol



 - Detailed Step-by-Step Instructions for each process

 - Process Design Parameters

 - Quality Control, Process Troubleshooting Procedures, Equipment Set Points



 - Detailed Manuals including instructions for Installation, Operation, Maintenance and Servicing.    


Appendix A – Labour Breakdown


Step No. 

Process Step Description


No. of Operators


Cell Test/Sort




Tabbing of Cells/Arraying of Cells

B, C, D



Complete/Test Circuit




Lay-up and Laminate

F, G



Final Assembly




Test and Inspect




Materials preparation/glass wash




Total Number of operators


 Number of operators is approximate, but will not vary by more than 1-2 persons from list shown.

The number may be reduced if pre-tested solar cells are the input to the line.

Personnel are semi-skilled labour trained on the line, and with experience, it may be possible to reduce the number required.


 For M-2000 line add 5 more operators per shift 



Appendix B.  Briff Description of Equipment

PV Production Equipment (See Full Automatic Standard production System) anipink06_next.gif


PL 210

Platen size 930 mm x 1500 mm.

Maximum laminate size 830 mm x 1400 mm.

Manual Load, clamshell lid lifting, PLC control.


PL 310

Platen size 1160 mm x 1750 mm.

Maximum laminate size 1060 mm x 1650 mm.

Optional auto load (L/U 300), PLC control.


 PL 410

Platen size 1400 mm x 1960 mm.

Maximum laminate size 1300 mm x 1860 mm.

Optional auto load (L/U 400), PLC control.




Belt and conveyor loader and unloader  for  the PL 310 and PL 410.

(specify if auto load/unload included at time of order or added at a later date)

Module Lay-Up Station

(normally supplied with module line only)


Supports rack holding rolls of EVA, Tedlar and Craneglass.

Used with an array VTU, which transfers cell arrays to position for module assembly.

Frame Assembly Station

(normally supplied with module line only)


Two stages and two module trolleys.

Framing, termination and addition of the junction box complete the PV module.

Glass Washer


PJ 60-6

PJ 84-6

Three cycles clean glass 1520 mm to 2130 mm in width.

Electro-coated knives are height adjustable.

Maximum operating speed is 4.9m per minute.

High Voltage Tester

TOS 5051 Hi-Pot tester for testing insulation between module frame and module terminal to 3000V.
Solar Cell Tabber MT-200 Tabletop tabbing stations. Manual load of cells. Able to handle cell sizes to 200 mm x 200 mm.  MT-200 includes cutting of tabs to length, fluxing and solder reflow.  MT-200 will tab >180 cells per hour.
Solar Cell Tabber


Semi-automatic tabber. Loads from coinstack, unload to coinstack.  Auto lead cutting and flux application.  Approximate throughput of >300 cells per hour. 

Able to handle cell sizes to 150 mm x 150 mm.

Solar Cell Stringer MS-200

Approximate throughput of >15 9-cell strings per hour.

Loads tabbed cells from stack and places in string.  Solder re-flow via IR light source. Able to handle cell sizes to 200 mm x 200 mm by changing jigs.

Solar Cell Stringer/Arrayer MA-500S

Interconnects cells in strings. and places in an arraying jig ready for final end buss bar connect.  Automatic.

Throughput equivalent to 8 of 36 cell modules per hour.

Able to handle cell sizes to 200 mm x 200 mm.

String Arraying Jigs

(normally supplied with module line only)

SAJ-100/9 &100/12

SAJ-200/9 &200/12

SAJ-300/9 &300/12

Temperature resistant material with guides to accurately position cells in a string.

Able to handle cell sizes from 100 mm to 150 mm in 9-cell and 12-cell strings.

Module Arraying Jigs

(normally supplied with module line only)

MAJ-100/9 or 12

MAJ-200/9 or 12

MAJ-300/9 or 12


Temperature resistant material with guides to accurately position cells in the array.

Able to handle cell sizes from 100 mm to 150 mm in 4x9 and 3x12 configurations. 200 mm cells in 4x9 configuration

String Vacuum Transfer Unit

(normally supplied with module line only)

VT-100S/9 or 12

VT-125S/9 or 12

VT-150S/9 or 12


Vacuum transfer units with soft pads for pick-up and transfer of interconnected strings of cells.

Uses compressed air and vacuum chip.

Able to handle cell sizes from 100 mm to 200 mm in 9-cell and

Inquiry: procon@procongroup.ogr or