Professional Documents
Culture Documents
SOLAR PV SYSTEMS
Install and Supervise Guidelines
for Accredited Installers
January 2013
(Effective 1 February 2013)
These guidelines have been developed by Clean Energy Council.
They represent latest industry best practice for the design and installation
of grid-connected PV systems. © Copyright 2013
While all care has been taken to ensure these guidelines are free from omission
and error, no responsibility can be taken for the use of this information in the
installation of any grid-connected power system.
CONTENTS
1 GENERAL 2
2 DEFINITIONS 2
3 STANDARDS FOR INSTALLATION 3
4 LICENSING 3
4.1 Extra Low Voltage (ELV) 3
4.2 Low Voltage (LV) 3
5 DOCUMENTATION 4
6 RESPONSIBILITIES OF ACCREDITED PERSON 4
7 PV ARRAY INSTALLATION 5
7.1 General 5
7.2 Roof mounting (not building integrated) 5
7.3 Free standing PV arrays 6
7.4 Building integrated (BIPV) installations 6
7.5 Verification of AS1170.2 6
7.6 Attaching modules to array mounting structure 7
7.7 Earthing of array with a PV array
maximum voltage greater than ELV 7
7.8 Wiring at the PV array 8
7.9 String protection 8
7.10 PV array isolator at array 9
7.11 PV array cable between array and inverter 10
8 INVERTER INSTALLATION 11
8.2 PV array isolator near inverter 11
8.3 AC isolator near inverter 12
8.4 AC cable selection 12
8.5 Solar supply main switch in switchboard 12
8.6 Shutdown procedure 12
9 METERING 13
10 SIGNAGE 13
11 COMMISSIONING 13
12 INSTALLATION AND COMMISSIONING 14
12.1 General 14
12.2 Insulation resistance measurement 14
12.3 Installation and commissioning sample 15
ATTACHMENT 1: Dangerous situation 18
ATTACHMENT 2: PV array roof mounting 18
ATTACHMENT 3: Hard wiring of PV arrays 19
→ encourage industry Best Practice for all design and installation work involving
solar photovoltaic power systems
→ provide a network of competent solar photovoltaic power systems designers and installers
→ increase the uptake of solar photovoltaic power systems , by giving customers increased
confidence in the design and installation work.
The performance of a reliable installation that fulfils customer expectations requires both
careful design and correct installation practice. Compliance with relevant state health and
safety regulations is also necessary.
NOTE: These guidelines alone do not constitute a fully definitive set of rules and
are to be read in conjunction with all relevant Australian standards. Where
these guidelines have additional requirements above that stated in the
Australian standards then these guidelines should be followed.
2 DEFINITIONS
This document uses the same terminology as outlined in AS/NZS 5033. Two important definitions are:
2.1.1 Where the word “shall” is used, this indicates that a statement is mandatory
2.1.2 Where the word “should” is used, this indicates that a statement is a recommendation
3.1.1 The grid-interactive inverter shall be tested in accordance with the AS 4777 (parts 2 and 3)
and listed on the Clean Energy Council’s approved inverter list.
3.1.2 The system shall comply with the relevant electrical service and installation rules for the
state where the system is installed.
(NOTE: the local electricity distributor may have additional requirements.)
3.1.3 These guidelines set additional requirements to the standards. An accredited installer
or supervisor is expected to follow these guidelines in addition to the requirements within
the relevant standards.
3.1.4 These guidelines will become mandatory on 1 February 2013
4 LICENSING
4.1 Extra Low Voltage (ELV)
4.1.1 All extra low voltage wiring should be performed by a ‘competent’ person, which is
defined by the Australian Standard AS/NZS 4509.1 stand-alone power systems as:
“a person who has acquired through training, qualifications, experience or a combination
of these, knowledge and skill enabling that person to correctly perform the task required.”
4.2 Low Voltage (LV)
4.2.1 All low voltage work: >120V DC or >50V AC shall be performed by a licensed electrician.
4.2.2 A licensed electrician is required to be responsible for the safety of the system wiring
prior to connection of the system to the grid.
4.2.2.a If the system contains ELV wiring installed by a non-licensed person, then
a minimum level of inspection by the electrician prior to closing the PV array
isolators would include: an open circuit voltage test on each PV string and
on the total array.
4.2.2.b A visual inspection of an open PV junction box (randomly selected) and
the master array junction box.
These inspections/checks shall confirm:
→ the array voltages are as designed and specified
→ the appropriate cables (CSA and insulation), junction fittings and
enclosures have been used.
Both the non-electrician ELV installer, as well as the licensed electrician,
are expected to carry out the checks on the ELV wiring.
6 RESPONSIBILITIES
OF ACCREDITED PERSON
6.1.1 The installer or supervisor shall not sign off on more than three (3) system installations per day.
6.1.2 As an accredited person, when signing off on a system you have either
6.1.2.a Undertaken the installation yourself or
6.1.2.b Supervised the installation by others
6.1.3 Supervision includes visiting the site at:
6.1.3.a Job set up
6.1.3.b Mid-installation check-up
6.1.3.c Testing and commissioning.
6.1.4 When installing a grid connect battery backup system the installation shall be performed by
a person(s) with CEC grid connected install accreditation and CEC stand-alone install accreditation.
7.5.3 The array frame shall be installed to the manufacturer’s instructions to ensure that
the array structure meets AS1170.2 certification. The installer shall consider the following:
7.5.3.a spacing between fixing for specific wind load regions
7.5.3.b area of roof that is applicable for panels to be installed (some manufacturers
only allow the frames to be installed in a specific internal zone of the roof)
7.5.3.c type, length and gauge of screws to be used
7.5.3.d number of screws required per fixing
7.5.3.e size of batten/purlin required for fixing.
7.5.4 The installation checklist now includes a clause stating that the system has been installed
in accordance with the recommendations of the supplier/manufacturer.
Copies of both these documents shall be included in the manual provided to the customer.
NOTE: If installers are manufacturing their own frames, then they shall provide
the certificates and include in the manual.
NOTE: Attaching a solar module in such a manner (e.g. drilling, pop riveting)
that causes a hole in the anodised aluminium frame of the solar module
typically voids the manufacturer’s product warranty with respect to
defects in material and workmanship. If the installer intends to undertake
an installation in this manner, they shall obtain written verification from
the manufacturer that it does not affect the warranty. This shall be
included in the system documentation supplied to the customer.
7.7 EARTHING OF ARRAY WITH A PV ARRAY MAXIMUM VOLTAGE GREATER THAN ELV
7.7.1 All exposed metal module frames shall be earthed.
7.7.2 If all array cabling is not protected in conduit or ducting, the array mounting frames
shall also be earthed.
7.7.3 Minimum cable size of 4mm shall be used and may be larger. See AS/NZS 5033
clause 4.4.2.1 for requirements.
7.7.4.b by purpose-made washers with serrations or teeth for the connection between
the PV module and mounting frame fitted to the manufacturer’s instructions, and
7.7.4.c be arranged so that the removal of a single module earth connection will not affect
the continuity of the earthing or bonding connections to any other module.
7.7.6 As per AS/NZS 3000 the earth cable can be insulated unsheathed cable except when
exposed to direct sunlight. If exposed to direct sunlight the cable shall have a physical
barrier to prevent exposure to direct sunlight.
7.8.3 Plastic cable ties are not to be used as the primary means of support (unless they have
a lifetime greater than 15 years).
7.8.4 The PV array wiring shall comply with the wiring requirements of AS/NZS 3000.
7.8.5 Cables shall be protected from mechanical damage.
7.8.6 The installer shall ensure that all connectors used are waterproof and connected securely
to avoid the possibility of a loose connection.
7.8.7 Only connectors which are the same type/model from the same manufacturer are allowed
to be married at a connection point.
7.8.8 Cables shall not lay on roofs or floors without an enclosure or conduit.
7.8.9 Cable size to be determined by AS/NZS 5033 Clause 4.3.6.1.
7.8.10 It is recommended that under maximum load conditions the voltage drop from the most
remote module in the array to the input of the inverter should not exceed 3% of the
Vmp voltage (at STC) for LV PV arrays.
7.8.11 In particular, refer to the clause in AS/NZS 3000 that refers to fauna which states: Where
the presence of fauna is expected to constitute a hazard, either the wiring system shall be
selected accordingly, or special protective measures shall be adopted.
7.9.2 AS/NZS 5033 Clause 3.3.4 defines the formula to calculate if string protection is required.
7.9.3 AS/NZS 5033 Clause 3.3.5.1 defines the rating of the fuse protection.
7.9.4 In LV arrays, overcurrent protective devices, where required, shall be placed in all current
carrying conductors not directly connected to earth.
7.9.5 In ELV arrays overcurrent protective devices where required for string and sub-array cables
shall be placed in either the positive or negative conductor (the number of current carrying
conductors minus one).
7.10.1 AS/NZS 5033:2012 Clause 4.4.1.4 makes it mandatory for an isolator to be installed
adjacent to the array for LV systems. This is to enable safe disconnection of the array
and isolation of the PV array cable.
7.10.2 Isolator shall be readily available (this is defined as “Capable of being reached for
inspection, maintenance or repairs without necessitating the dismantling of structural
parts, cupboards, benches or the like.”)
7.10.3 Be rated for DC use.
7.10.4 Rated to interrupt full load and prospective fault currents (rated operational current
suitable for a temperature of ambient plus 40°C if exposed to the sun).
7.10.5 Not be polarity sensitive.
7.10.6 Interrupt all live conductors simultaneously.
7.10.7 All equipment exposed to the outdoor environment shall be of an appropriate IP rating
in accordance with AS 60529, and shall be UV resistant.
7.10.8 Shall not have exposed live parts in connected or disconnected state.
7.10.9 Shall comply with the requirements of IEC 60947 (series).
7.10.10 Have a utilization category at least DC21B.
7.10.11 Isolator voltage rated as per AS/NZS5033:2012 Appendix B:
7.10.11.a for non-functionally earthed systems, isolated inverter (transformer based):
voltage rating of both poles together of the switch-disconnector shall be at least
the PV array maximum voltage (Voc Array adjust for lowest ambient temperature
of site)
7.10.11.b non-isolated inverter (transformerless based): voltage rating of each pole of the
isolator/switch disconnector shall be at least the PV array maximum voltage.
(Voc Array adjust for lowest ambient temperature of site)
7.10.12 Functionally earthed array presents specific issues. The voltage rating of isolators for these
systems are detailed in AS/NZS 5033:2012 Appendix B.
7.10.13 Labelled “PV ARRAY D.C. ISOLATOR”.
7.10.14 Manufacturer’s installation instructions for isolators shall be followed regarding mounting
orientation to ensure the IP rating is maintained.
7.10.15 The roof mounted isolator should be mounted such that the switch is in a sideways position
(see Figures 1a and 1b).
7.10.16 The conduit entry points should be on the lower end of the enclosure - either underneath
or facing down the roof.
7.10.17 It is recommended that junction boxes are mounted so that the access to the junction box
is made on the side of the junction box and not on a side facing up.
7.10.18 All screw cover caps that are supplied with the isolator box or junction box shall be installed.
7.10.19 All mounting holes should be silicone filled.
7.10.20 If the solar array is to be hard wired then the recommended procedure is provided
in Attachment 3.
NOTE: A dangerous situation can occur when the person installing the system is
able to come in contact with the positive and negative outputs of the solar
array or sub-array when the output voltage is 120V DC or above.
See Attachment 1 for more details.
NOTE: Ensure that the switch does not shade the array.
8.1.1.b comply with specific environmental requirements e.g. not in direct sunlight, direct rain, etc
8.1.1.c ensure mounting structure is able to support inverter weight
8.1.1.d ensure mounting structure material is appropriate for the inverter
8.1.1.e recommended clearances shall be followed.
8.1.2 The inverter heat sink shall be clear of any obstacles to facilitate cooling of the inverter.
8.1.3 Cables connected to the inverter shall be mechanically secured in such a manner that they
cannot be inadvertently unplugged from the inverter. This can be achieved by:
8.1.3.a having the inverter housed in an enclosure (with cables suitably supported)
8.1.3.b the use of an inverter which has the cable connection area of inverter covered by
a removable enclosure/cover which protects the supported cables so that there are
no exposed, unsupported cable loops
8.1.4 The installer shall ensure that the grid parameters of the inverter are set to the
utilities requirements.
8.2.4 Where multiple disconnection devices are required to isolate power conversion equipment
they shall be grouped so that they all operate simultaneously, or they shall all be grouped in
a common location and have warning signs indicating the need to isolate multiple supplies
to isolate the equipment.
10 SIGNAGE
10.1.1 All signage on switches, isolators and within distribution boards and switchboards shall be
in accordance with AS 4777 and AS/NZS 5033 and/or
10.1.2 the relevant electrical service and installation rules for the state where the system is installed.
11 COMMISSIONING
11.1.1 The commissioning sheets provided with these guidelines (or similar document) shall be completed
by the accredited installer or the accredited supervisor (with suitably licensed person).
11.1.2 A copy shall be provided to the customer in the system documentation and a copy retained
by the accredited person.
WARNING: Where short circuit currents are required, follow AS/NZS 5033
Appendix D for the steps that shall be undertaken to measure the
short circuit current safely.
NOTE: Some projects require that short circuit currents are recorded as part of
the contractual commissioning; otherwise a record of the actual operating
current of each string is sufficient. This could be done by using the meter
on the inverter or by using a clamp meter when the system is operational.
WARNING: PV array dc circuits are live during daylight and, unlike a conventional
ac circuit, cannot be isolated before performing this test.
Follow AS/NZS 5033 Appendix D4 for the steps that shall be
undertaken to measure the insulation resistance safely.
PV ARRAY
PV array tilt ..........……………………° PV array orientation ..........……………………°
Array frame is certified to AS1170.2 Array frame is installed to
for installation location manufacturer’s instructions
Roof penetrations are suitably sealed No galvanically dissimilar metals are
and weatherproofed in contact with the array frames or supports
Where PV array comprises multiple strings - PV wiring losses are less than 3%at the
string protection has been provided maximum current output of the array
Weatherproof PV array isolator mounted Wiring is protected from mechanical damage
adjacent to the array and is appropriately supported
(Rating:………………………………..Vdc, …………….Adc)
LV DC and AC INSTALLATION
All low voltage wiring has been installed by All wiring has been tested and approved
a licensed electrical tradesperson by qualified electrical tradesperson
INVERTER
PV array isolator mounted adjacent Isolator is mounted on output of the
to the inverter inverter (where required)
(Rating:………………………………..Vdc, …………….Adc)
SYSTEM CHECK
WARNING:
→ IF A STRING IS REVERSED AND CONNECTED TO OTHERS, FIRE MAY RESULT.
→ IF POLARITY IS REVERSED AT THE INVERTER DAMAGE MAY OCCUR TO THE INVERTER.
Polarity Voltage Short Circuit Operating Current
String 1 V A A
String 2 V A A
String 3 V A A
String 4 V A A
Sub-arrays where required V A A
PV array at PV array V A A
switch-disconnector
Irradiance at time of W/m2 W/m2
recording the current
INSTALLER INFORMATION
CEC Accredited installer’s name:
CEC Accreditation number:
I verify that the above system has been installed to all relevant standards
Signed: Date:
Fire emergency information is permanently fixed
on the main switchboard and/or meter box (if not
installed together)