Field Inspection Guideline

for PV Systems

Prepared for:

Interstate Renewable Energy Council

(available at www.IRECUSA.org)

Prepared by:

Brooks Engineering
873 Kells Circle
Vacaville, CA 95688
www.brooksolar.com

Version 1.0
August 2009

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Dedication:

This document is dedicated to a person that represents the very best of those who have
worked on field inspection processes as they relate to PV systems. Chuck Whitaker, of BEW
Engineering, passed away in the months prior to the release of this field inspection process.

Chuck Whitaker:

Chuck Whitaker passed away in early May of 2009 at the age of 52 in the midst of a
distinguished career supporting the development and implementation of most of the codes and
standards that govern and support PV systems both nationally and internationally. His passing
coincided with the start of this version of the field inspection process. The author had the
privilege of knowing Chuck for two decades and working closely with him for over 8 years as his
employee and colleague. It is difficult to overstate Chuck’s contribution to the PV industry since
his influence is found in nearly every code and standard that has been developed for PV
equipment and systems over the past 25 years. It is only fitting that this document, which
includes his influence, be dedicated to his memory. A huge hole is left in the PV industry with
Chuck’s passing, and it is the hope of many of us in the codes and standards arena to be able to
carry on his tireless work with a semblance of the skill, whit, and humor that was the hallmark
of this amazing individual.

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INTRODUCTION: ............................................................................................................................. 3
Field Inspection Guidelines for PV Systems .................................................................................. 4
Section 1. Field Inspection Checklist for Array: ....................................................................... 4
a) Number of PV modules and model number matches plans and spec sheets ................ 4
b) Wire Management: Array conductors are neatly and professionally held in place ....... 5
c) Module and Array Grounding ......................................................................................... 9
d) Electrical Boxes and Conduit Bodies On Roof Reasonably Accessible and Electrical
Connections Suitable for the Environment .......................................................................... 10
e) Array Fastened and Sealed According To Attachment Detail....................................... 12
f) Conductor Ratings and Sizes ......................................................................................... 13
Section 2. Specifics For Ground-Mounted Arrays ................................................................. 15
a) Foundation review ........................................................................................................ 15
b) Mounting structure review ........................................................................................... 15
c) Electrical bonding of structural elements..................................................................... 15
d) Additional array electrode ............................................................................................ 16
e) Attachment method according to plans ....................................................................... 16
f) Wiring not readily accessible ........................................................................................ 16
Section 3. Appropriate Signs Installed ................................................................................... 17
a) Check proper sign construction .................................................................................... 17
b) Check for sign identifying PV power source system attributes at dc disconnect......... 18
c) Check for sign identifying ac point of connection [690.54]. ......................................... 18
d) Check for sign identifying switch for alternative power system. ................................. 18
Section 4. Check that equipment ratings are consistent with application and signs............ 18
a) Check that inverter has a rating as high as max voltage on PV Power Source sign. .... 18
b) Check that circuit breakers or fuses in combiner or fused disconnect are dc rated at
least as high as max voltage on sign. .................................................................................... 18
c) Check that switches and OCPDs are installed according to manufacturers
specifications (i.e. many 600Vdc switches require passing through the switch poles twice in
a specific way). ...................................................................................................................... 19
d) Check that inverter is rated for the site ac voltage supplied and shown on the ac point
of connection sign. ................................................................................................................ 19
e) Check that OCPD connected to the ac output of the inverter is rated at least 125% of
maximum current on sign, and is no larger than the maximum OCPD on the inverter listing
label....................................................................................................................................... 19
f) Check that the sum of the main OCPD and the inverter OCPD is rated for not more
than 120% of the busbar rating. ........................................................................................... 19
Section 5. Worksheet for PV System Field Inspection........................................................... 20

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INTRODUCTION:

The field inspection process is key to the development of a healthy and safe PV industry. Much
focus has been given the permitting process in the past few years for well-deserved reasons.
With all the focus that has been placed on the permitting process, the field inspection process
deserves even more attention than permitting. A permit package can be assembled that looks
quite professional, making the contractor seem knowledgeable and competent. However, the
contractor may have little concept of proper installation techniques. The field installation can
clearly indicate the competency of the contractor more tangibly than the permit package.

Some jurisdictions around the country are opting for a very simple project review stage to allow
contractors to begin construction. These jurisdictions are putting much more emphasis on the
field inspection phase. With this increased emphasis on the field inspection part of the approval
process, inspectors need to be better informed on what to look for in a system inspection.
Contractors also need to be well-versed in proper installation techniques and system design
requirements so that costly field mistakes can be avoided.

This field inspection guideline for PV systems has been developed with many years of field
inspection experience working with local jurisdictions and other individuals that routinely
perform inspections for jurisdictions, financiers, and manufacturers. The intent of this guideline
is to consolidate the most import aspects of a field inspection into a simple process that can be
performed in as short as 15 minutes. Explanation and illustrative pictures are provided to
instruct the inspector on the specific details of each step.

The ultimate goal of this guideline is to provide a basic knowledge of how to inspect a PV
system so that a field inspector can take this framework and develop the experience necessary
to perform these inspections quickly and thoroughly. Too many badly designed and installed PV
systems have been approved to date. By clarifying the issues of concern, and providing a
detailed checklist for the field inspector, fewer poorly designed and installed systems will be
approved. As local inspectors become familiar with typical products and sound installation
techniques, contractors doing marginal work will be forced to improve or find another line of
work.

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Field Inspection Guidelines for PV Systems

To perform a field inspection of a PV system properly, it should be done in a consistent and

organized fashion. The inspector should start either at the PV array or at the service entrance,
and work their way to the other extreme of the system. For the purpose of this document, we
will start the inspection at the array and work our way to the service entrance. As we work our
way through the inspection, it will be noted which items to pay particular attention to and
those items that should be photographed for future reference. If an inspector prefers starting
at the service entrance, the reverse order of the inspection can be performed. The key is
consistency and thoroughness. After many years of experience inspecting PV systems, it is still
easy to miss important points when a methodical checklist is not used. This document will
explain, step-by-step, each inspection point with a summarizing checklist to use in the field.

At a minimum, a copy of the one-line diagram and the site diagram should be available at the
site for the inspector’s use during field inspection. If any variations exist between the reviewed
plans and the site installation, those changes should be noted on those drawings along with any
necessary explanation as to why adjustments were made to the plans. If substantial changes
are found in the field installation, the as-built changes may need to be referred back to plan
review to ensure code compliance.

Section 1. Field Inspection Checklist for Array:

a) Number of PV modules and model

number matches plans and spec sheets

The very first item to inspect is the PV

array. This can be difficult at times,
particularly if multiple roof faces are
used in the array and building block
visual access to the roof. Ideally, the
inspector will get on the roof, with fall
protection supplied by the contractor, Figure 1 Verify Type and Number of Modules
so that a detailed inspection of the
array can be carried out. At times, the steepness of the roof, or the insurance provisions of
the county will not allow inspectors to get on the roof. In the case where the inspector is
unable to get on the roof, the array inspection should take place using a ladder or personnel
lift. The contractor should have one of those options prepared at the time of the inspection.

Once access to the roof has been obtained, or view of the roof is available from a ladder,
the first item is simply to count the number of modules in the system. It is critical that
number of modules agree with the provided plans since the ratings of equipment, both for
voltage and current depend on the proper configuration. It is common for suppliers to
substitute different product between when the permit is pulled and the final installation.
Although this is understandable, the new array configuration must be provided in supplied
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 as-built
built plans, and the alternative calculations made for changes in the photovoltaic power
pow
source sign (see section 3).

Once the number of PV modules is confirmed to match the drawing, the PV module model
number should be compared with the modules shown in the plans. Occasionally, module
model numbers can change between the time that the permit documents are approved and
the final inspection. For products that are substantially identical, the different module
model number can be substituted without being considered a
product difference, provided documentation shows that the
products are the
he same. Confirming the model number of a module
can be a challenge. For residential rooftop PV systems, the listing
labels supplied by the testing laboratory are on the back side and
difficult or impossible to view. One option is for a digital photo to
be taken of the PV module label, and a copy of the photo supplied
at the time of inspection. An alternative to a printed version would
be for the contractor take a picture of the back side of the module
and show the picture to the inspector. If neither of th
these methods
can be accomplished, a single representative module should be
moved to provide a visual inspection of the label. Figure 2 PV Module
Listing Label

Lastly, with the module model number and quantity of modules confirmed, the physical
layout of the array should match the supplied site plan. Small variations may be common to
avoid roofing obstacles not noted in the original design which may be acceptable. However,
wholesale location changes should be documented in the permit package with an accurate
as-built
built drawing in case the loc
location change has structural implications.

Common Installation Mistakes with Array Modules and Configurations:

1. Changing the array wiring layout without changing the submitted electrical diagram.
diagram
2. Changing the module type or manufacturer as a result of supply ly issues.
issues
3. Exceeding the inverter or module voltage due to improper array design.
design
4. Putting too few modules in series for proper operation of the inverter during high
summer array temperatures.

b) Wire Management: Array conductors are neatly and

professionally held in place

One of the most important safety issues with a PV array is

that the conductors are properly supported. It is
unacceptable for conductors to lay on roofing materials or
come in contact with sharp or abrasive surfaces. The Figure 3 USE-2
2 conductors touching
installation methods
ds for the exterior USE
USE-2 conductors, roof surface
commonly used in PV arrays, is stated in NEC 338.10(B)(4). This section refers the installer on to

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Article 334.30 for support methods. Article 334 is entitled Non-Metallic Sheathed Cable (often
referred to by the trade name Romex). The requirements for fastening NM cable are well
understood by jurisdictions. The requirements for support in NEC 334 are summarized in the
following points:

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 is one of the quickest ways to read

the competence of a contractor or installation team.

Figure 4 conductors properly protected by
Properly installed conductors should be virtually raceway with grounding bushing-should be
invisible from the ground level with no conductors secured within 12 inches of fitting (not shown)
hanging unsupported. Branches, snow, and ice, have
a tendency of pulling loose conductors away from
their supports and damaging the conductors or the
module. When conductors are run between
support rails, or on the upper edge of a PV array,
getting visual confirmation of the quality of wire
management may require the inspector getting
onto the roof or positioning a ladder at the side of
the array to view underneath the array. Many
wiring sins are covered by PV modules, but these
Figure 5 (incorrect) FNMC without support
wiring mistakes can be lethal.

In addition to observing proper support of conductors, the inspector should inspect a sample of
plug-and-receptacle connectors to ensure that they are fully engaged. Often installers are not
properly trained on how to make these connections and don’t get them fully engaged. Another
problem that relates to connectors and conductors is bending the conductor too close to the
outlet of a plug or receptacle, potentially damaging the connector. Also the bending radius of

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USE-2 cable must be observed. As with many cable, the minimum bending radius is 5 times the
diameter. If the diameter is 0.2”, the minimum RADIUS is 1” (2” bend).

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)
5. Not following support members with conductors.
6. Pulling cable ties too tight or leaving them too
loose.
Figure 6 multiple conductors in single
7. Not fully engaging plug connectors.
conductor cross-threaded cable gland
8. Bending conductors too close to connectors.
9. Bending USE-2 cable tighter than allowable bending radius.
10. Plug connectors on non-locking connectors not fully engaged

Figure 7 proper cable glands with 2-conductor inserts in combiner box

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Figure 8 Connectors loose and not supported within 12 inches of connector

Figure 9 improper cable support with exposure to physical damage

Figure 10 poor conductor handling and bending radius too tight

8
 Figure 11 improper use of chase nipple and exceeding conduit fill with no end fitting

c) Module and Array Grounding

An area of intense concern to the inspector is PV module and array grounding. Much confusion
and controversy has surrounded this issue, but it is one of the most important safety issues in a
PV installation. Many inspector focus the majority of their time and effort on this one item. This
focus is justifiable since an improperly grounded PV array can be hazardous. This section will
focus on module and array grounding and leave PV system grounding to the section that covers
the inverter inspections. The key to module grounding is creating an electrical connection
between the module frame, nearly always an aluminum extrusion, with the equipment
grounding conductor (EGC). Creating this connection can be handled in a few specific ways.

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.
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 as there are differences in how each

9
 mounting structure attaches PV
modules. These grounding clips
offer a solid electrical connection
allowing the electrically
continuous rail to be grounded
with the EGC. This method is
consistent the NEC 690.43 and
NEC 250.136.
5. Lastly, some modules can be

grounded using serrated clips that Figure 12 grounding clip and lug designed for UniRac rail
hold the module to the support
structure and electrically bond with the module. In this case, the EGC is connected to the last
module in a row of modules that each have this specially-rated clip.

Once it is confirmed that the modules are properly bonded and grounded to the EGC for the dc
portion of the system, the 2008 NEC in 690.47(D) requires all arrays to have additional array
grounding. This additional grounding is primarily for lightning and surge grounding. For ground-
mounted systems, this is typically a driven ground rod with a Grounding Electrode Conductor
(GEC) sized according to 250.166 (minimum 8 AWG). The support structure may comply as an
electrode, provided the steel is buried at least 8 feet in the earth just like a ground rod. Rooftop
systems are not exempt from this requirement. If a building has building steel available that is
properly grounded, that building steel can be used as the grounding electrode. A properly sized
GEC is connected from at least one common point on the array and the building steel. If no
building steel is available, as with most residential installations, then a separate GEC must be
run from a common point on the array directly to a ground rod at the closest practical point to
the array. If that closest point is within 6 feet of the main service grounding electrode, then the
main building ground can be used rather than driving a new ground rod.

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.

d) Electrical Boxes and Conduit Bodies On Roof Reasonably Accessible and Electrical
Connections Suitable for the Environment

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It is understandable for contractors to preserve aesthetics by placing electrical junction boxes
and combiner boxes under PV modules so that they cannot be seen from the ground. This is
acceptable only if the panel covering the box can be easily removed and held in place on the
roof while working on the box or conduit body. Generally speaking, it is always best to have
boxes or conduit bodies that need access to be adjacent to, rather than under the PV array.
Mounting these devices at or near the top of the array may provide the best access and hide
them most effectively for aesthetics purposes.

If a disconnecting means is located on the roof of a building, proper installation and clearances
are required for access to the disconnect. Most disconnects commonly on the market are rated
to be mounted only in the upright position. Mounting disconnects on their backs on sloped or
flat roofs should be avoided unless the disconnecting means specifically allows mounting in that
way in the installation manual. If the disconnecting means includes fuses, inspect the fuses for
proper ratings as with source combiners. Be aware that common class R fuses will say 600 Volts
in large letters, but the small print often shows the dc rating at 300 Volts if the fuse has any dc
rating at all. Also, be aware that most disconnecting means operating at 600 Vdc require
passing through the disconnect blades twice in series. A few import exceptions exist including
the Square D H361, H362, and H363 disconnects in their fused and unfused versions. These
special Square D disconnects have been evaluated by the listing agency to handle 600 Vdc per
pole. The Square D H361 disconnect is also listed for two conductors per terminal. Most other
disconnects have been evaluated to 600 Vdc by passing the conductor through two of the poles
in series. Regardless of the manufacturer, any application of a disconnecting means for a dc
application must be documented by the manufacturer.

While on the roof, any junction box with terminations and/or fuses should be inspected for
proper connectors and fuses. A variety of rooftop
junction boxes are used including waterproof NEMA 4
boxes and rainproof NEMA 3R boxes. In either case,
penetrations into the box must be with proper fittings
suitable for wet locations and NEMA 3R boxes may
restrict the angle at which the box is to be mounted.
Unless specifically allowed in the installation manual,
most NEMA 3R rainproof boxes must be mounted
vertically. Any exceptions must be documented in the
installation manual or other official documentation.
Outdoor boxes, mounted at roof angles, notoriously
Figure 13 incorrect NEMA 3R disconnect on
fill with water over time. It is advisable that all
sloped roof designed for vertical mounting only
connectors be waterproof in such boxes. Options
include waterproof twist-on wire splices, heat shrink butt splices, and various direct burial
options. Twist-on wire splices for indoor boxes should always be avoided in outdoor
applications as they corrode quickly. Terminal strips in junction boxes should be installed above
any water outlets in NEMA 3R boxes.

11
Any source combiners with fuse holders should be mounted in such a way that the fuses can be
accessed without having to remove modules or
disable the PV system. Fused combiners are
intended to be accessed and tested on an ongoing
basis while the system is operating. During the
field inspection, any roof-mounted combiner boxes
should be opened and the fuses examined to be
certain that properly rated fuses are used in the
source combiner. Some source combiners may
specify a specific fuse model and size to be used,
while others many simply state the fuse voltage
rating and maximum fuse size. The fuse should be
Figure 14 properly flashed roof penetration
identified on the barrel with the ac/dc voltage
ratings and fuse current setting. If this information is not found on the barrel of the fuse, then
proper documentation must accompany the fuse if the specific fuse is not listed on the source
combiner cover or documentation. A common way to make a well-engineered, well-installed PV
system dangerous is to install improper fuses.

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.

e) Array Fastened and Sealed According To Attachment Detail

The attachment detail should be supplied with the

mounting system manufacturer’s information. The
contractor should supply this detail with an explanation
of the sealing process used to preclude roof leakage,
should the array be mounted on a roof surface. Typical
sealing of roof penetrations are done with flashing at
round pipe penetrations, special lag screw flashings (see
QuickMount.com), and various caulking materials to seal
lag screw holes using caulk that is compatible with the
roofing material. Leaking roofs are of primary concern to
homeowners, and can cause significant property damage
so sloppy or improper installation of penetrations and Figure 15 properly installed flashed roof
penetration
flashings should not be tolerated.
12
While examining the roof attachments, a simple test can
be done if the inspector is on the roof. With protective
gloves to prevent cuts on sharp edges, pull up on a PV
module near one of the supports. If the support moves a
significant amount, it is likely not attached properly.
Several years ago in Southern California, a PV system
blew off a roof during high winds since it was attached to
the roof tile with plastic anchors rather than being
properly attached to the roof rafters or trusses. A simple
pull test would have quickly identified that the array was
not properly attached to the roof.
Figure 16 uninstalled flashing

Even if the proper lag screws are used for the mounting system, installers can poorly install the
lag screws. Proper lag screw mounting requires a pilot hole in the center of the roofing member
at approximately 75% of the diameter of the lag. Any shank must be piloted at the full diameter
of the lag to the full depth of the unthreaded shank. It is difficult to inspect for lag screw
mounting with other than the simple pull test mentioned earlier. Another option to inspect lag
screws is to enter the attic under the PV array and see if any lag screws are showing or there is
any evidence of improper pilot holes such as split rafters or trusses.

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.

f) Conductor Ratings and Sizes

Exposed array conductors

One of the most common errors in PV system
design and installation is the specification and
installation of the conductors based on the
conductor ratings and sizes. The correct choice
of conductor must be based on the
environmental conditions it is exposed to. The
PV array conductors at the modules to the first Figure 17 incorrect conductors exposed and
junction box must be outdoor-rated cables since touching roof and no strain relief--3strikes

13
few, if any PV modules sold allow for raceways to be installed on them. The 2008 NEC allows
specifically two types of cables for exterior use: (1) USE-2, underground service entrance
conductors with a 90C rating; and, (2) PV Wire, also labeled PV Cable, that is an identified cable
specifically for exterior use and double-insulated to comply with the requirements for NEC
690.35 (D)(3) for ungrounded PV power systems.

Conductors in raceways on rooftops

Once the exterior cables are brought to the first junction box, it is typical for the conductor type
to be transitioned from exterior rated cable to conduit-rated conductors due to the ease of
installation and lower cost of conduit-rated conductors. The most commonly available
conductors are dual rated THHN/THWN conductors. However, due to the fact that the NEC
treats conductors in exposed conduit as a wet location (NEC 300.9), the wet rating of the
conductor prevails. This often causes issues of insufficient conductor ampacity due to the 75°C
rating of THWN. It is therefore strongly recommended that contractor specify and install higher
rated THWN-2, XHHW-2, or RHW-2 conductors instead of THWN.

The use of 90°C rated conductors is particularly important in light of updates in the 2005 and
2008 versions of the NEC. In the 2005 NEC 310.10 FPN No.2, a note was added addressing the
concern of high operating temperatures in raceways in direct sunlight in close proximity to
rooftops. The 2008 NEC codified these concerns by establishing Table 310.15(B)(2)(c) that
provides required temperature adders for sunlit raceways on rooftops at differing distances
from the roof surface. Even more moderate temperature climates throughout the U.S. can have
rooftop raceway temperatures that severely impact the ampacity of 75C conductors. If more
than three current carrying conductors are enclosed in the raceway, additional ampacity
corrections must be made for four or more conductors according to Table 310.15(B)(2)(a).

Terminal temperature ratings are of keen concern to many jurisdictions, because this is the
most common type of ampacity correction for standard electrical wiring in buildings. The
reason terminal temperature rating limitations are common is that most wiring systems are
installed indoors in a temperature controlled environment. Field experience with PV system
design for rooftop PV system shows that the terminal temperature restrictions, covered in NEC
110.14(C), rarely constrain the ampacity of the conductors. Due to the high temperatures of
rooftops, the temperature and conduit corrections routinely supersede the terminal ampacity
concerns. Ground mounted PV systems are more likely to use the terminal temperature
limitations since the underground conduit does not require temperature corrections.

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.

14
Section 2. Specifics For Ground-Mounted Arrays

Inspecting ground-mounted PV systems is similar to inspecting roof-mounted systems with

several important differences. As with roof-mounted systems, the mounting structure being
installed according to plans is key.

a) Foundation review

Ground-mounted systems have foundations that must be reviewed, but these foundations are
common structural elements that jurisdictions are often quite familiar with. A common ground-
mounted PV foundation is galvanized steel poles set in concrete. With these simple
foundations, the depth of the concrete and cover of the concrete around the pole are the
important elements to inspect. The plans should clearly indicate the method of foundation
installation and have details for assembling the structure in the mounting system.

b) Mounting structure review

Next, the grounding of the structure and the structural elements should be inspected. It is
common for the steel elements in a structure to be bonded with bolted or welded connections.
Structural elements used for thermal expansion may be purposefully left loose and there may
not be effectively grounded. In this case, and other cases were firmly bolted connections are
not used, a bonding jumper may need to be installed to ensure the members are bonded to one
another. This bonding jumper may be as simple as a lug installed on both members with a 6
AWG bare copper wire run between the two lugs.

c) Electrical bonding of structural elements

Bonding aluminum elements requires more care and attention then required for the steel
elements since aluminum is prone to quick oxidation, or has a relatively thick anodized coating.
Regardless of whether the aluminum is anodized or not, the bond between aluminum parts
must be intentional with stainless star washers, pointed grounding clips, or lugs and grounding
jumpers or conductors to keep these aluminum pieces at the same electrical potential. The NEC
requires that all metal “likely to become energized” be grounded. At some point on the
structure, the equipment grounding conductor must be established and run in close proximity
to the supply conductors. This is normally done at or near the module framework. Some
installations may run a grounding conductor to each module frame. This method, although it
can be effective, places the copper conductor in close proximity to many aluminum members
that could eventually corrode and damage the grounding conductor. The copper conductor
method is slowly being replaced with improved methods that do away with the copper
15
conductor and bond modules to their support structures (NEC 250.136, NEC 690.43). This
allows a single grounding lug to be placed on each mounting rail with the grounding conductor
run to the combiner box, establishing an effective grounding path for proper ground-fault and
overcurrent device operation.

At some point in the structure, a transition is often made between the steel substructure and
the aluminum of the module frames. Wherever that transition occurs, proper techniques must
be employed. This transition can occur either at the module frame, or at aluminum rails that
fasten to the module frames. To make this transition properly, this connection is typically made
with stainless steel fasteners and stainless washers to isolate the steel from the aluminum.
Historically, in the California market due to the low corrosion rates, dissimilar metals are
commonly seen in contact with one another. The fact that installations often have this error
should not be seen as license to continue a practice that can have severe consequences in high
corrosion environments. Since this connection point is often a high-resistance electrical
connection, a bonding jumper is used to bond the aluminum mounting system to the steel
mounting system.

d) Additional array electrode

Lastly, the structure must be connected to a grounding electrode in the proximity of the
ground-mounted array. This additional array grounding electrode (NEC 690.47(D)) is primarily
for lightning protection and is required since the 2008 NEC. This may be as simple as a driven
ground rod at some point in the array with a grounding electrode conductor attached from the
mounting structure to the electrode. The electrode may be any method allowed in NEC 250.62
and would include steel mounting structures that have at least 8 feet of ground cover, which is
common with large pole mount structures.

e) Attachment method according to plans

As with any PV mounting system, the employed mounting system should be specifically allowed
in the installation manual for the modules. Some modules have specific restrictions on how
they are to be mounted. Sometimes these restrictions are due to limitations of the frame
extrusions to withstand extreme wind or snow loading. Mounting details should be supplied
with the structural documentation so that it is clear what method is to be used and so the field
inspector can evaluate whether or not the proper method was followed.

f) Wiring not readily accessible

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A common misunderstanding in the field relates to
wiring within a ground-mounted array. The 2008
NEC specifically requires that array conductors be
in a raceway or not readily accessible. Since
module wiring cannot be placed in raceways due
to the plug connectors used universally in the PV
industry, the wiring must be rendered “not readily
accessible.” Making wiring not readily accessible is
easier than some may initially think. Ready access
implies that anyone can walk up to the array and
touch the wires. Wiring is not readily accessible in Figure 18 typical ground mount system with
the following example situations: readily accessible wiring
1. Where conductors are protected by a fence
only allowing authorized personnel.
2. Where conductors are above 8 feet from the ground.
3. Where conductors are protected by guards that require tools to remove the guards.

The safety hazard of allowing children to touch wiring in a 500 Volt PV system is extreme. If an
array is mounted close to the ground with readily accessible wiring, the easiest and generally
most cost effective method to render the wiring not readily accessible is to place non-metallic
lattice work around the back, sides, and under the front of the PV array. By enclosing the array
with non-metallic guards, the guards require no grounding but allow air to flow to the backside
of the array for cooling.

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

a) Check proper sign construction

The signs should be of sufficient durability to withstand the environment involved. For
outdoor signs, the sign should be either metal or plastic with engraved or machine
printed letters, or electro-photo plating, in a contrasting color to the sign background.
Plexiglas-covered paper or laminated paper directories are also acceptable provided
that the signs are sufficiently protected from the environment involved. The signs or

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 directories should be attached to the electrical equipment or located adjacent to the
identified equipment.

b) Check for sign identifying PV power source system attributes at dc disconnect

[690.53. Photovoltaic Power Source]. This sign must include:
i. Operating current (provided in initial plan
review--sum of parallel source circuit
operating currents)
ii. Operating voltage (provided in initial plan
review--sum of series modules operating
voltage in source circuit)
iii. Maximum system voltage [690.7]
Figure 19 PV Power Source sign
iv. Short-circuit current [690.8] (maximum circuit
current)

c) Check for sign identifying ac point of

connection [690.54].
This sign must include:
i. Maximum ac operating
current
ii. Operating voltage (e.g. 240
Volts)

d) Check for sign identifying switch for

alternative power system.
Figure 20 sign in PV ac disconnect

A sign should be mounted on or next to the PV system disconnecting means with the
words to the effect of “PV System Disconnect” in a minimum of 3/8” high letters. If this
disconnect is not located at the service disconnect, follow the requirement in NEC
690.56 (B):

NEC 690.56 (B) Facilities with Utility Services and PV Systems. Buildings or structures
with both utility service and a photovoltaic system shall have a permanent plaque or
directory providing the location of the service disconnecting means and the photovoltaic
system disconnecting means, if not located at the same location.

Section 4. Check that equipment ratings

are consistent with application and signs

a) Check that inverter has a rating as high as

max voltage on PV Power Source sign.
b) Check that circuit breakers or fuses in
combiner or fused disconnect are dc
Figure 21 properly rated midget fuse

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 rated at least as high as max voltage on sign.
c) Check that switches and OCPDs are installed according to manufacturers specifications (i.e.
many 600Vdc switches require passing through the switch poles twice in a specific way).
Example: If the PV Power Source sign has a maximum system voltage of 553V, then the
inverter, dc disconnect, and any OCPD on the dc side of the inverter must be rated for
600Vdc.
d) Check that inverter is rated for the site ac voltage supplied and shown on the ac point of
connection sign.
e) Check that OCPD connected to the ac output of the
inverter is rated at least 125% of maximum current
on sign, and is no larger than the maximum OCPD on
the inverter listing label.
Example: If the ac point of connection sign has a
rated ac output current of 21 amps, then the
inverter OCPD on the ac side of the inverter must Figure 22 inverter listing label
be at least 30 amps (1.25 x 21amps = 26.25
amps—round up to next larger standard OCPD). If the inverter shows a maximum OCPD of
50 amps, then a 30-, 35-, 40-, 45-, or 50-amp OCPD would be acceptable for the listing of the
inverter.

f) Check that the sum of the main OCPD and the inverter OCPD is rated for not more than
120% of the busbar rating.

The 2008 NEC also requires that the inverter OCPD be located at the opposite end from the
input feeder location and that a sign be applied to the panelboard stating, “Warning,
Inverter Output Connection, Do Not Relocate This Overcurrent Device.”
The inverter OCPD is often a circuit breaker installed in a panelboard. In this case the final
limitation on OCPD size is the ratings of the panelboard that the inverter OCPD is installed
in. For instance, if the panelboard has a 200-amp bus rating and a 200-amp main breaker
rating, the breaker size is limited by the 120% rule in NEC 690.64(B)(2). The NEC allows for
the sum of the OCPDs to not exceed 120% of the 200-amp bus is 240-amps. Subtracting the
200-amp main breaker size from the 240-amp value yields 40-amps—the largest size PV
breaker allowed for this panelboard. With this panelboard, the allowable OCPDs in our
example would be 30-, 35-, 40-amps. The 45- and 50-amp breakers would exceed the 120%
rule.

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Section 5. Worksheet for PV System Field Inspection

Field Inspection Checklist for Array:

# of PV modules and model # matches plans and spec sheets number matches plans and spec sheets

Wire Management: Array conductors are neatly and professionally held in place

PV array is properly grounded

Check that electrical boxes are accessible and connections suitable for environment

Array Fastened and Sealed According To Attachment Detail

Check conductors ratings and sizes

Specifics For Ground-Mounted Arrays

Foundation review

Mounting structure review

Electrical bonding of structural elements

Additional array electrode

Attachment method according to plans

Wiring not readily accessible

Appropriate Signs Installed

Check proper sign construction:

Check for sign identifying PV power source system attributes at dc disconnect

Check for sign identifying ac point of connection [690.54].

Check for sign identifying switch for alternative power system.

Check that equipment ratings are consistent with application and signs

Check that inverter has a rating as high as max voltage on PV Power Source sign.

Check that dc-side OCPDs are dc rated at least as high as max voltage on sign.

Check that switches and OCPDs are installed according to manufacturers specifications
(i.e. many 600Vdc switches require passing through the switch poles twice in a specific way).
Check that inverter is rated for the site ac voltage supplied and shown on the ac point of connection sign.

Check that OCPD connected to the ac output of the inverter is rated at least 125% of maximum current on sign,
and is no larger than the maximum OCPD on the inverter listing label.
Check that the sum of the main OCPD and the inverter OCPD is rated for not more than 120% of the busbar rating.

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