PV System

Permitting and Inspection

Presented by

Bill Brooks, PE
Brooks Engineering
PV Codes and
Standards 101
 What are the applicable codes and
standards for PV systems?
• Electrical codes - NEC Article 690 - Solar
Photovoltaic Systems – NFPA 70
• Building Codes – ICC, ASCE 7
• 2009 Uniform Solar Energy Code—IAPMO
• UL Standard 1703, Flat-plate Photovoltaic
Modules and Panels
• IEEE 1547, Standard for Interconnecting
Distributed Resources with Electric Power
Systems
• UL Standard 1741, Standard for Inverters,
Converters, Controllers and Interconnection
System Equipment for Use With Distributed
Energy Resources
Photovoltaic System
Basics
Current varies with irradiance

Siemens Solar Module SP75

Performance at Different Irradiances

6
5
Current (amps)

1000 W/m2, 25 oC
4
800 W/m2, 25 oC
3 600 W/m2, 25 oC
2 400 W/m2, 25 oC
200 W/m2, 25 oC
1
0
0 5 10 15 20 25
Voltage (volts)
Voltage varies with temperature

Siemens Solar Module SP75

Performance at Different Cell Temperatures

6
5
Current (amps)

4 1000 W/m2, 0 oC
1000 W/m2, 25 oC
3
1000 W/m2, 45 oC
2 1000 W/m2, 60 oC
1
0
0 5 10 15 20 25
Voltage (volts)
Differences Between PV and
Conventional Electrical Systems
• PV systems have dc circuits that require special design
and equipment.
• PV systems can have multiple energy sources, and
special disconnects are required to isolate components.
• Energy flows in PV systems may be bi-directional.
• Utility-Interactive PV systems require an interface with
the ac utility-grid and special considerations must be
adopted. (utility must be involved-hence utility training)
Ain’t that purdy….
…and this is so much better…
NEC Article 690
overview
PV Systems and the NEC
• Article 690 addresses safety standards
for the installation of PV systems.
• Many other articles of the NEC may also
apply to most PV installations.
NEC Sections Applicable to PV
Systems
• Article 110: Requirements for Electrical
Installations
• Chapter 2: Wiring and Protection
− Most of the chapter--especially
− Article 250: Grounding
• Chapter 3: Wiring Methods and Materials
− Most of the chapter—especially
− Article 300: Wiring Methods
− Article 310: Conductors for General Wiring
• Article 480: Storage Batteries
• Article 690: Solar Photovoltaic Systems
NEC Article 690:
Solar Photovoltaic Systems
• I. General (definitions, installation)
• II. Circuit Requirements (sizing, protection)
• III. Disconnect Means (switches, breakers)
• IV. Wiring methods (connectors)
• V. Grounding (array, equipment)
• VI. Markings (ratings, polarity, identification)
• VII. Connection to Other Sources
• VIII. Storage batteries
• IX. Systems over 600 Volts
NEC Article 690:
Solar Photovoltaic Systems
• I. General (definitions, installation)
− 690.1 Scope—PV Systems (only)
− 690.2 Definitions—PV Output Circuit, Inverter Input
Circuit—1 ½ pages of PV-specific jargon
− 690.3—“Wherever the requirements of other articles
of this Code and Article 690 differ, the requirements
of Article 690 shall apply”
− 690.4—Installation “Equipment: …shall be identified
and listed for the application”
− 690.5—Ground-Fault Protection—to reduce fire
hazards
− 690.6—AC Module—dc wiring is considered internal
Electrical Equipment Listing
• AHJs generally require listing for
components and electrical hardware.
• Some components available for PV
systems may not have applicable or any
listing.
• Recognized testing laboratories include:
• UL
• ETL Semko (Intertek)
• CSA
• TÜV
NEC Article 690:
Solar Photovoltaic Systems
• II. Circuit Requirements (sizing, protection)
− 690.7 Maximum Voltage—Table 690.7 and
manufacturers data. Max. 600Vdc for residential.
− 690.8 Circuit Sizing and Current
• 690.8(A) Max current = rated Isc x 1.25 = Imax
• 690.8(B) Min ampacity and overcurrent = Imax x 1.25
− 690.9 Overcurrent Protection
• 690.9(A) Generally required on all source circuits—
exception: a.)no backfeed; and, b.) total Imax less than
conductor ampacity.
− 690.10 Stand-Alone Systems
• Inverter output need only meet demand.
• No multi-wire circuits on 120V inverters.
NEC Article 690:
Solar Photovoltaic Systems
• III. Disconnect Means (switches, breakers)
− 690.13—Need to disconnect all conductors
connected to building. No disconnect in grounded
conductor
− 690.14—Location—details and options (more to
come)
− 690.17—Switch or Circuit Breaker—Warning sign
when line and load energized in open position.
NEC Article 690:
Solar Photovoltaic Systems
• IV. Wiring methods
− 690.31(A) FPN—PV modules get HOT
− 690.31—single conductors outside conduit allowed
in array.
− Table 690.31—temp. correction must be applied to
conductors.
− 690.33—requirements for connectors.
− 690.35—Ungrounded PV Power Systems
NEC Article 690:
Solar Photovoltaic Systems
• V. Grounding (system, equipment)
− 690.41 System Grounding
• Over 50Vdc must be grounded or comply with 690.35
− 690.42 Point of System Grounding Connection—one
point, at GFP device if provided.
− 690.43 Equipment Grounding—metal likely to
become energized must be grounded—listed
equipment can be used to bond modules to support
structure..
− 690.45 Size of EGC—Table 250.122 with GFP
− 690.47 Size of GEC—ac use Table 250.66; dc use
Table 250.166
Electrical System Grounding
• The NEC defines grounding as a connection to
the earth with sufficiently low impedance and
having sufficient current-carrying capacity to
prevent the buildup of voltages.
• Grounding of electrical systems offers
personnel safety and minimizes the effects of
lightning and surges on equipment.
Electrical Grounding Types
(Huge Confusion Over These Terms)
• System Ground (grounding): Connecting the
circuit to ground (i.e. the negative of a dc array,
the neutral of a split single-phase system, or the
neutral of a bi-polar dc system)
• Equipment Ground (bonding): Connecting all non-
current carrying metal parts to ground (metal
enclosure, module frame, etc…)
Nice Lugs! (poor fasteners)
690.43 Equipment Grounding
[2008 NEC]

• “Devices listed and identified for grounding

the metallic frames of PV modules shall be
permitted to bond the exposed metallic
frames of PV modules to grounded
mounting structures. Devices identified and
listed for bonding the metallic frames of PV
modules shall be permitted to bond the
exposed metallic frames of PV modules to
the metallic frames of adjacent PV
modules.”
NEC Article 690:
Solar Photovoltaic Systems
• VI. Markings (ratings, polarity, identification)
− 690.53—DC PV Power Source—4 items; rated
current, rated voltage, max voltage, max current
− 690.54—Interactive System Point of
Interconnection—rated ac current and voltage
− 690.56—Sign at service entrance when PV
disconnect not located at the service disconnect.
NEC Article 690:
Solar Photovoltaic Systems
• VII. Connection to Other Sources
− 690.60 Listed inverters for grid-connected systems
− 690.61 inverter deenergize when utility is out (part of
listing process)
− 690.64 Point of Connection
• 690.64(A) Supply Side—230.82
• 690.64(B) Load Side—dedicated breaker; 120% of busbar
or conductor; 2008 NEC requires sign and breaker location
to obtain 120% allowance for all PV systems.
• VIII. Storage Batteries
• IX. Systems over 600 Volts
 Summary of Key PV-Related
Changes for the 2005 and
2008 National Electrical Code
II. Circuit Requirements [2008 NEC]
690.7 Maximum Voltage.
• New table and calculation option.
• Table 690.7 is now graduated in 4ºC increments.
• “When open-circuit voltage temperature
coefficients are supplied in the instructions for
listed PV modules, they shall be used to
calculate the maximum photovoltaic system
voltage as required by 110.3(B) instead of using
Table 690.7.”
II. Circuit Requirements [2008 NEC]
690.7 Maximum Voltage.
• Example Calculation
• Shell SQ-175PC has a Voc Temperature Coefficient
in their literature of:
− αVoc = -129 mV/ºC; Voc =44.6V
− Coldest expected Temp=-25ºC; Rating @ 25ºC (STC)
• Vmax (per module) = 44.6V + [-129 mV/ºC x
(1V/1000mV) x (-25ºC–25ºC)] = 51.05 Volts.
• Table 690.7 [2008]: Vmax = 44.6V x 1.20 = 53.52V
• Table 690.7 [2005]: Vmax = 44.6V x 1.25 = 55.75V
III. Disconnecting Means [2005 NEC]
Article 690.14 (Additional Provisions)
• Clarification on location of PV Disconnecting Means and
Location of Inverters in Not-Readily-Accessible
Locations
• New Section (D) Utility-Interactive Inverters Mounted in
Not-Readily Accessible Locations. Utility-interactive
inverters shall be permitted to be mounted on roofs or
other exterior areas that are not readily accessible.
These installations shall comply with (1) through (4):
− (1) A direct-current photovoltaic disconnecting means shall be
mounted within sight of or in the inverter.
− (2) An alternating-current disconnecting means shall be
mounted within sight of or in the inverter.
− (3) The alternating-current output conductors from the inverter
and an additional alternating-current disconnecting means for
the inverter shall comply with 690.14(C)(1).
− (4) A plaque shall be installed in accordance with 705.10.
 Article 690.31 [2005 NEC]
Wiring Methods Permitted
• New 690.31(E) related to PV Output Circuits in
metallic raceways.
• “(E) Direct-Current Photovoltaic Source and Output
Circuits Inside a Building. Where direct current
photovoltaic source or output circuits of a utility-
interactive inverter from a building-integrated or
other photovoltaic system are run inside a building or
structure, they shall be contained in metallic
raceways or metal enclosures from the point of
penetration of the surface of the building or structure
to the first readily accessible disconnecting means.
The disconnecting means shall comply with 690.14(A)
through 690.14(D).”
Article 690.31 [2008 NEC]
Wiring Methods Permitted
• New language in 690.31(B)
• “(B) Single-Conductor Cable. Single-
conductor cable type USE-2, and single-
conductor cable listed and labeled as
photovoltaic (PV) wire shall be permitted in
exposed outdoor locations in photovoltaic
source circuits for photovoltaic module
interconnections within the photovoltaic
array. Exception: Raceways shall be used
when required by 690.31(A).”
 Side Note on Temperature
310.15(B)(2)[2008 NEC]
• Table 310.15(B)(2)(c) Ambient Temperature
Adjustment for Conduits Exposed to Sunlight On
or Above Rooftops Temperature Adder
Distance Above Roof to Bottom of Conduit °C °F
0 – 13 mm (1⁄2 in.) 33 60
Above 13 mm (1⁄2 in.) – 90 mm (31⁄2 in.) 22 40
Above 90 mm (31⁄2 in.) – 300 mm (12 in.) 17 30
Above 300 mm (12 in.) – 900 mm (36 in.) 14 25
Article 690.33 [2008 NEC]
Connectors
• New language in 690.33(F)
• “(E) Interruption of Circuit. Connectors shall
be either (1) or (2):
• (1) Be rated for interrupting current without
hazard to the operator.
• (2) Be a type that requires the use of a tool to
open and marked “Do Not Disconnect Under
Load” or “Not for Current Interrupting.” ”
Article 690.35 Ungrounded
Photovoltaic Power Systems

• Ungrounded systems have not been prohibited,

but the 2005 NEC was the first code cycle
where the requirements are specifically called
out.
• Included is an exception in 690.41 for
consistency.
Article 690.35 Ungrounded
Photovoltaic Power Systems [2005, 2008]
• “Photovoltaic power systems shall be permitted to
operate with ungrounded photovoltaic source and
output circuits where the system complies with
690.35(A) through 690.35(G).
− (A) Disconnects. All photovoltaic source and output circuit
conductors shall have disconnects complying with 690, Part III.
− (B) Overcurrent Protection. All photovoltaic source and output
circuit conductors shall have overcurrent protectioncomplying
with 690.9.
− (C) Ground-Fault Protection. All photovoltaic source and
output circuits shall be provided with a ground-fault protection
device or system that complies with (1) through (3):
• (1) Detects a ground fault.
• (2) Indicates that a ground fault has occurred
• (3) Automatically disconnects all conductors or causes the inverter
or charge controller connected to the faulted circuit to
automatically cease supplying power to output circuits.
Article 690.35 Ungrounded
Photovoltaic Power Systems (cont.)
− (D) The photovoltaic source and output conductors shall consist of the following:
− (1) Nonmetallic jacketed multiconductor cables
− (2) Conductors installed in raceways, or
− (3) Conductors listed and identified as Photovoltaic (PV) Wire installed as
exposed, single conductors.
− (E) The photovoltaic power system direct-current circuits shall be permitted to
be used with ungrounded battery systems complying with 690.71(G).
− (F) The photovoltaic power source shall be labeled with the following warning at
each junction box, combiner box, disconnect, and device where the ungrounded
circuits may be exposed during service:
WARNING
ELECTRIC SHOCK HAZARD
THE DC CIRCUIT CONDUCTORS OF THIS
PHOTOVOLTAIC POWER SYSTEM ARE
UNGROUNDED AND MAY BE ENERGIZED
WITH RESPECT TO GROUND DUE TO
LEAKAGE PATHS AND/OR GROUND FAULTS.
− (G) The inverters or charge controllers used in systems with ungrounded
photovoltaic source and output circuits shall be listed for the purpose.
690.45 Size of Equipment
Grounding Conductors [2008 NEC]
• “(A) General. Equipment grounding conductors in
photovoltaic source and photovoltaic output
circuits shall be sized in accordance with Table
250.122. Where no overcurrent protective device
is used in the circuit, an assumed overcurrent
device rated at the photovoltaic rated shortcircuit
current shall be used in Table 250.122. Increases
in equipment grounding conductor size to address
voltage drop considerations shall not be required.
The equipment grounding conductors shall be no
smaller than 14 AWG.”
690.47(C) Systems with Alternating-Current
and Direct-Current Grounding Requirements
[2005 NEC]
• “Photovoltaic power systems with both alternating-
current and direct-current (dc) grounding requirements
shall be permitted to be grounded as described in (1) or
(2):
− (1) A grounding-electrode conductor shall be connected between
the identified dc grounding point to a separate dc grounding
electrode. The dc grounding-electrode conductor shall be sized
according to 250.166. The dc grounding electrode shall be
bonded to the ac grounding electrode to make a grounding
electrode system according to 250.52 and 250.53. The bonding
conductor shall be no smaller than the largest grounding
electrode conductor, either ac or dc.
− (2) The dc grounding electrode conductor and ac grounding
electrode conductor shall be connected to a single grounding
electrode. The separate grounding electrode conductors shall be
sized as required by 250.66 (ac) and 250.166 (dc).”
690.47(C) Systems with Alternating-Current
and Direct-Current Grounding Requirements
[2008 NEC]
• 2008 NEC has 8 qualifying provisions to “assist” in specifying
the grounding requirements.
• Attempt is to combine the ac equipment grounding
conductor on the output of the inverter with the grounding
electrode conductor for utility-interactive inverters with
GFP.
• The requirements are difficult to follow and do not
encourage straightforward enforcement of provisions.
• The 2011 NEC provides and understanding of the intent of
2008 NEC.
 690.47(D) Additional Electrodes for Array
Grounding [2008 NEC]
• “Grounding electrodes shall be installed in
accordance with 250.52 at the location of all ground-
and pole-mounted photovoltaic arrays and as close as
practicable to the location of roof-mounted
photovoltaic arrays. The electrodes shall be
connected directly to the array frame(s) or
structure.”
− GEC from array frames to electrode sized to 250.166
− No substitute for equipment grounding conductor
− Ground-mount structure meeting 250.52 complies
− Roof-mounted may use building steel meeting 250.52(A)(2)
• Exception 1—Arrays with integral loads (area lights)
• Exception 2—If closer than 6’ from existing electrode
690.53 Marking: DC PV Power Source[2008 NEC]

• (1) Rated maximum power-point current

− Imp x number of series strings
• (2) Rated maximum power-point voltage
− Vmp x number of modules in series
• (3) Maximum system voltage
− FPN to (3): See 690.7(A) for maximum photovoltaic
system voltage.
• (4) Short-circuit current
− FPN to (4): See 690.8(A) for calculation of maximum
circuit current.
• (5) Maximum rated output current of the
charge controller (if installed)
2008 NEC Complete Rewrites
Article 690.64 Point of
Connection (B) Load Side
• “Where distribution equipment, including
switchboards and panelboards, is fed
simultaneously by a primary source(s) of
electricity and one or more utility-interactive
inverters, and where this distribution
equipment is capable of supplying multiple
branch circuits or feeders, or both, the
interconnecting provisions for the utility-
interactive inverter(s) shall comply with (B)(1)
through (B)(7).”
Article 690.64(B) (cont.)
• “(1) Dedicated Overcurrent and Disconnect.
Each source interconnection shall be made at a
dedicated circuit breaker or fusible disconnecting
means.
• (2) Bus or Conductor Rating. The sum of the
ampere ratings of overcurrent devices in circuits
supplying power to a busbar or conductor shall
not exceed 120 percent of the rating of the
busbar or conductor. In systems with panelboards
connected in series, the rating of the first
overcurrent device directly connected to the
output of a utility-interactive inverter(s) shall be
used in the calculations for all busbars and
conductors.”
Article 690.64(B) (cont.)
• “(3) Ground-Fault Protection. The
interconnection point shall be on the line side of
all ground-fault protection equipment.
Exception: Connection shall be permitted to be made to
the load side of ground-fault protection, provided that
there is ground-fault protection for equipment from all
ground-fault current sources. Ground-fault protection
devices used with supplies connected to the load-side
terminals shall be identified and listed as suitable for
backfeeding.
• (4) Marking. Equipment containing overcurrent
devices in circuits supplying power to a busbar or
conductor supplied from multiple sources shall be
marked to indicate the presence of all sources.”
Article 690.64(B) (cont.)
• (5) Suitable for Backfeed. Circuit breakers, if
backfed, shall be suitable for such operation.
FPN: Circuit breakers that are marked “Line” and “Load”
have been evaluated only in the direction marked. Circuit
breakers without “Line” and “Load” have been evaluated
in both directions.
• (6) Fastening. Listed plug-in-type circuit
breakers backfed from utility-interactive
inverters complying with 690.60 shall be
permitted to omit the additional fastener
normally required by 408.36(D) for such
applications.”
Article 690.64(B) (cont.)
• “(7) Inverter Output Connection. Unless the
panelboard is rated not less than the sum of the
ampere ratings of all overcurrent devices
supplying it, a connection in a panelboard shall
be positioned at the opposite (load) end from the
input feeder location or main circuit location.
The bus or conductor rating shall be sized for the
loads connected in accordance with Article 220.
A permanent warning label shall be applied to
the distribution equipment with the following or
equivalent marking:
WARNING
INVERTER OUTPUT CONNECTION, DO NOT
RELOCATE, THIS OVERCURRENT DEVICE”
 Expedit
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 Why do we need
Permit Guidelines?
• Variations in compliance requirements—some are
insufficient to protect the public, others may not
be consistent with established standards.
• Need a predictable process with uniform
enforcement of code requirements for
jurisdictional authorities and installing
contractors.
Required Information for Permit
• Site plan showing location of major components on the property.
This drawing need not be exactly to scale, but it should represent
relative location of components at site (see supplied example site
plan). PV arrays on dwellings with a 3’ perimeter space at ridge
and sides do not need fire service approval.
• Electrical diagram showing PV array configuration, wiring system,
overcurrent protection, inverter, disconnects, required signs, and
ac connection to building (see supplied standard electrical
diagram).
• Specification sheets and installation manuals (if available) for all
manufactured components including, but not limited to, PV
modules, inverter(s), combiner box, disconnects, and mounting
system.
 Step 1: Structural Review of
PV Array Mounting System
• Is the array to be mounted on a defined,
permitted roof structure? Yes/No
(structure meets modern codes)
• If No due to non-compliant roof or
ground mount, submit completed
worksheet for roof structure WKS1.
Roof Information:
• Is the roofing type lightweight (Yes = composition,
lightweight masonry, metal, etc…)_____________
− If No, submit completed worksheet for roof structure
WKS1 (No = heavy masonry, slate, etc…).
• Does the roof have a single roof covering? Yes/No
− If No, submit completed worksheet for roof structure
WKS1.
• Provide method and type of weatherproofing roof
penetrations (e.g. flashing, caulk).____________
Mounting System Information:

• The mounting structure is an engineered

product designed to mount PV modules?
Yes/No
− If No, provide details of structural attachment
certified by a design professional.
• For manufactured mounting systems, fill out
information on the mounting system below:
 Mounting System Information:
a) Mounting System Manufacturer ___________Product Name and
Model#_____________
b) Total Weight of PV Modules and Rails ___________lbs
c) Total Number of Attachment Points____________
d) Weight per Attachment Point (b÷c)_________________lbs (if greater
than 45 lbs, see WKS1)
e) Maximum Spacing Between Attachment Points on a Rail
______________inches (see product manual for maximum spacing
allowed based on maximum design wind speed)
f) Total Surface Area of PV Modules (square feet)_________________ ft2
g) Distributed Weight of PV Module on Roof (b÷f)_______________ lbs/ft2
− If distributed weight of the PV system is greater than 5 lbs/ft2, see
WKS1.
Step 2: Electrical Review of PV System
(Calculations for Electrical Diagram)
• In order for a PV system to be considered for an
expedited permit process, the following must apply:
1. PV modules, utility-interactive inverters, and combiner boxes are
identified for use in PV systems.
2. The PV array is composed of 4 series strings or less
3. The Inverter has a continuous power output 13,440 Watts or less
4. The ac interconnection point is on the load side of service
disconnecting means (690.64(B)).
5. The electrical diagram (E1.1) can be used to accurately represent the
PV system.
Site Diagram
• Drawing does not need to be to scale,
but it should basically show were the
major components are located.
• If array is ground mounted, it should
show that it conforms with allowable
setbacks.
One-line Diagram
• Should have sufficient detail to call out the
electrical components, the wire types and
sizes, number of conductors, and conduit type
and size where needed.
• Should include information about PV modules
and inverter(s).
• Should include information about utility
disconnecting means (required by many
utilities).
 Major Component and
Array Electrical Information

• Inverter information
• Module information
• Combiner Box
• Disconnects
 Inverter information
• Model number and manufacturer’s “cut sheets”
for the specific model.
• Listing—is the inverter listed to UL1741 and
labeled “Utility-Interactive”? For a current list of
compliant inverters, visit the California Solar
Program website. www.gosolarcalifornia.com
• Maximum continuous output power at 40oC
Module information
• Manufacturer’s “cut sheets” for the specific
model.
• Listing. The module should be listed to UL 1703.
For a current list of modules that are listed to UL
1703, visit the California website.
www.gosolarcalifornia.com

• Listing label information

Typical PV Module Label
Array electrical information
• Number of modules in series
• Array operating voltage
• Array operating current
• Maximum system voltage
• Array short circuit current
Field Inspection
Section 1. Field Inspection
Checklist for Array:
• a) Array matches plans
• b) Wire Management
• c) Module and Array Grounding
• d) Electrical enclosures on Roof Accessible
and Connections Suitable for the Environment
e) Array Fastened and Sealed According To
Attachment Detail
• f) Conductor Ratings and Sizes
 Inspection Checklist for Array:
a) Array Matches Plans
•PV module model number matches plans and spec sheets
•Get a digital photo of module label, if possible
Typical PV Module Label
Common Installation Mistakes with
Array Modules and Configurations
• 1. Changing the array wiring layout without changing
the submitted electrical diagram.
• 2. Changing the module type or manufacturer as a
result of supply issues.
• 3. Exceeding the inverter or module voltage due to
improper array design.
• 4. Putting too few modules in series for proper
operation of the inverter during high summer array
temperatures.
Inspection Checklist for Array:
b) Wire Management

• The most important safety issue is

proper support and protection of
conductors.
Wire Management
Proper Installation of Exterior
Cables
• NEC 338.10(B)(4)(b) states how USE-2 is
to be installed in exterior locations.
• PV Wire/Cable should follow the same
installation methods as USE-2.
• Section 338.10 refers the installer on to
Article 334.30 (NM Cable) for support
methods
 Proper Installation of Exterior
Cables—Article 334.30
• 1. Secured by staples, cable ties, straps, hangers, or similar
fittings at intervals that do not exceed 4.5 feet
• 2. Secured within 12 inches of each box, cabinet, conduit body,
or other termination
• 3. Sections protected from physical damage by raceway shall not
be required to be secured within the raceway
• 4. Cable shall closely follow the surface of the building finish or
of running boards ((NEC 334.15)—the analogous installation for USE­
2 in PV arrays is for the conductors to follow support rails or module
extrusions)
• 5. Protected from physical damage by raceway when necessary
Wire Management—Proper
Wire Management—Room for
Improvement
Wire Management—Support?
Common Installation Mistakes with
Wire Management
• 1. Not enough supports to properly control cable.
• 2. Conductors touching roof or other abrasive
surfaces exposing them to physical damage.
• 3. Conductors not supported within 12 inches of
boxes or fittings.
• 4. Not supporting raceways at proper intervals.
• 5. Multiple cables entering a single conductor cable
gland (aka cord grip)
• 6. Not following support members with conductors.
Proper cable glands into
Combiner Box
Common Installation Mistakes with
Wire Management—cont.
• 7. Pulling cable ties too tight or leaving them too
loose.
• 8. Not fully engaging plug connectors.
• 9. Bending conductors too close to connectors.
• 10. Bending USE-2 cable tighter than allowable
bending radius.
• 11. Plug connectors on non-locking connectors not
fully engaged
Wire Management—Physical Damage
Wire Management
count the bad ideas
Wire Management
—wire bending radius
Wire Management—plug engagement
Wire Management—Follow
structural members & What the…?
What you can’t see won’t hurt
you??
Inspection Checklist for Array:
c) Module and Array Grounding
• Most common concern of field
Wrong
inspectors. connectors
• Ungrounded module frames
are a potential safety hazard.
• All array metal “likely to
become energized” must be
properly bonded together and
grounded with lugs on each
module and mounting rails or
some equivalent equipment
grounding method.
 Module bonding and grounding
methods
• 1. Some modules are designed to be grounded using a stainless-
steel thread-forming screw threaded into the module frame
holding the EGC at a grounding symbol. An isolating washer, such
as a stainless cup washer is often used to isolate the copper
conductor from the aluminum frame to prevent galvanic
corrosion.
• 2. Some modules can be grounded to their mounting structures
with stainless steel star washers placed between the module and
the support structure. This creates an electrical bond while
isolating the aluminum frame from dissimilar materials such as
galvanized steel. The EGC is attached to an electrically
continuous support member with a properly installed grounding
lug.
 Module bonding and grounding
methods—cont.
• 3. Some modules can be grounded by properly installing a properly
rated lay-in lug to the either the grounding point on the module, or
any unused mounting hole. The EGC is run through this lay-in lug to
bond the modules together.
• 4. For specific module mounting products (e.g. UniRac, ProSolar,
DPW, etc…), there exists listed grounding clips to bond typical
aluminum framed modules to the mounting structure. Only the
proper clip can be used with each mounting structure. This allows the
EGC to be connected to the electrically continuous rail. This method
is consistent the NEC 690.43 and NEC 250.136.
• 5. Some modules can be grounded together using serrated clips
that hold the module to the support structure and electrically bond
with the module. One lug on any module can ground a whole row.
Early module and structure
grounding improvements
Identifying Grounding Clips

Notice slight
gap caused
by properly
installed clip.
Common Installation Mistakes
with Module and Array Grounding
• 1. Not installing a grounding conductor on the array at all.
• 2. Using cad-plated Tek screws to fasten ground wires or lugs
to modules.
• 3. Using indoor-rated grounding lugs on PV modules and
support structures.
• 4. Not protecting EGCs smaller than 6 AWG from physical
damage.
• 5. Allowing copper EGC to come in contact with the aluminum
rails and module frames.
• 6. Assuming that simply bolting aluminum frames to support
structures provides effective grounding.
Nice Lugs! (poor fasteners)

Improper Cad
Tek screw
used to hold
lug
 Aluminum bolted to
Indoor lugs and Tek steel without isolation
screws washers and no
effective bond
Grounding Hardware and
Components
Indoor lug and
Tek screw

Stainless
hardware looks
like new

Galvanized washer
showing galvanic
corrosion with
aluminum contact
Inspection Checklist for Array:
d) Electrical enclosures on Roof Accessible and
Connections Suitable for the Environment

• NEC 690.34 Access to Boxes. Junction, pull, and

outlet boxes located behind modules or panels shall
be so installed that the wiring contained in them can
be rendered accessible directly or by displacement of
a module(s) or panel(s) secured by removable
fasteners and connected by a flexible wiring system.
Rooftop j-boxes in compliance
with 690.34
 Junction Boxes Waterproof
wirenuts must be
• Connection between in j-boxes
conductors in an outdoor
location generally must be
done within a rainproof
junction box, NEMA 3R, or 4
(unless with approved
connector)

• Junction boxes are

commonly used to
transition conductors from
exterior to conduit
conductors and for
combining array source
circuits.
 Improper Connections

Wire twisted together,

wrapped in tape, and
in the sun

Dry wirenut and

not in a j-box
Ratings and locations of
Disconnects
NEMA 3R
disconnect on
sloped roof
designed for
vertical mounting
only

Black cover to
shield improperly
installed switch
only served to
make switch
invisible
Ratings and locations of Combiner
Boxes
NEMA 4
Combiner Box
with disconnect
built-in. Designed
for horizontal or
vertical mounting
Common Installation Mistakes
with Electrical Boxes, Conduit
Bodies, and Disconnecting Means
• 1. Installing disconnects rated for vertical installation in a non-
vertical application.
• 2. Installing improperly rated fuses in source combiners and
fused disconnects.
• 3. Covering boxes or conduit bodies making them nearly
inaccessible for service.
• 4. Not following manufacturer’s directions for wiring
disconnect for 600 Vdc ratings.
• 5. Installing dry wire nuts in wet locations and inside boxes
that get wet routinely.
• 6. Using improper fittings to bring conductors into exterior
boxes.
Many disconnects like these require the
ungrounded conductor to be broken twice
in series to get the 600Vdc rating

Incorrect Correct
Breaking of
grounded
conductor
Correct Fuses
Correct Fuses
Correct Fuses ??
Correct Fuses ??
Correct Fuses
and Terminals ?
Proper Current Rating?
Proper Current Rating?
Properly Rated Disconnects
and Inverters
Inspection Checklist for Array:
e) Array Fastened and Sealed
According To Attachment Detail
• Roof penetrations must be properly
sealed to preclude leakage.
• Do a hand pull test on a sample of lag
screw attachments to make sure they
are secured to rafters.
• Look in attic to see if lags are visible.
Proper and Improper Flashing
 Common Installation Mistakes
with Mounting Systems:
• 1. Not using supplied or specified hardware with the mounting
systems.
• 2. Substituting Unistrut for special manufactured aluminum
extrusions.
• 3. Not installing flashings properly.
• 4. Not using the correct roof adhesives for the specific type of roof.
• 5. Not attaching proper lag screws to roofing members.
• 6. Not drilling proper pilot holes for lag screws and missing or
splitting roofing members.
Inspection Checklist for Array:
f) Conductor Ratings and Sizes
• Exposed Array Conductors—The only single-
conductor cables allowed in 690.31(B) are USE-2
and PV Wire (Cable).
• Conductors in raceways on rooftops—Table
310.15(B)(2)(a) adds an additional 14°C-30°C to
the ambient temperature. These high
temperatures nearly always limit ampacity
below the terminal temperature ampacity.
Conduit Exposed to Sunlight Above
Rooftops —Table 310.15(B)(2)(a)
Common Installation Mistakes
with Conductors:
• 1. Not accounting for high operating temperatures in
rooftop conduit.
• 2. Specifying THHN conductors rather than wet rated
conductors in drawings where raceways are clearly
located outdoors.
• 3. Specifying or installing THWN conductors in
raceways that may exceed 60°C without properly
correcting the THWN conductors for this temperature.
Incorrect conductors and roof
plumbing into combiner box
Improperly Rated Conductors
THWN conductors
outside conduit
Section 2. Specifics For
Ground-Mounted Arrays
• a) Foundation and mounting structure review
• b) Electrical bonding of structural elements
• c) Additional array electrode [690.47(D)]
• d) Attachment method according to plans
• e) Wiring not readily accessible
Support Structure and Attachment
Support Structure and Attachment
Support Structure and Attachment
Wiring not readily accessible?
Readily accessible or not?
 Common Installation Mistakes
with Ground Mounting Systems:
• 1. Not using supplied or specified hardware with the mounting systems.
• 2. Substituting Unistrut for special manufactured aluminum extrusions.
• 3. No bonding of support structure or discontinuous grounding of
support structure.
• 4. Dissimilar metals in contact with one another (e.g. aluminum and
galvanized steel).
• 5. No bonding of aluminum structural elements to steel structural
elements.
• 6. Array wiring readily accessible to other than authorized personnel.
Section 3. Appropriate signs
installed

•Sign construction
•Photovoltaic Power Source
•AC point of connection
•alternative power system
 Sign Construction
• The NEC is not extremely specific about what signs
should be made of.
• NEC 110.21 states, “The marking shall be of
sufficient durability to withstand the environment
involved.”
• Electrical industry standards for outdoor signs is
that signs should be metal or plastic with engraved
or machine printed letters, or electro-photo
plating, in a contrasting color to the sign
background.
Indoor signs may allow more
variety of construction
Photovoltaic Power Source Sign
Signs and Labels
AC Point of
Interconnection
Signs and Labels
it is possible to
have too many.
Section 4. Check that equipment
ratings are consistent with
application and signs
Inverter Labels
Disconnects consistent with
requirements
Guts—show and tell
Guts—show and tell
Guts—show and tell
Guts—show
and tell
Good Installation Practices
Good Installation Practices
Good Installation Practices
Good Installation Practices
Nice Work
Nice Work
Nice Work
Nice Work
Nice Work
Nice Work
Nice Work