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Most photovoltaic (PV) power system manufacturers sell their equipment through either specialized solar
distributors or electrical distributors that have a solar
department. Then, this equipment is typically installed and
maintained by companies that specialize in solar. However,
general electricians are often called upon after the fact to work
on the related wiring of these systems as part of a service call or
renovation request.
If you receive this call, are you prepared to accept the job? Or
are you going to have to pass this valuable lead on to someone
else? Given the declining price of PV components, these
systems are becoming much more common. Therefore, at
minimum, electrical contractors need to know how to safely
shut down PV systems in order to perform other electrical
work. Savvy contractors looking for new revenue streams will
take things a step further and gain new business.
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The inverter is no longer connected to AC power within the normal limits of voltage and frequency.
The inverter may have detected a ground fault on the DC side of the system.
The inverter may have failed.
Either the inverter, disconnects in the AC circuit, or breakers in the AC circuit may have been turned off.
A fuse in the system has opened.
Many string inverters have a simple digital display and a few LED indicators to show system status. Check these
first, and correct any external problems. If the inverter appears to be non-functioning, check the AC power
circuits, and measure the voltage across the output terminals of the inverter. An absence of AC voltage indicates
a problem with the AC circuit. Fuses might have opened or breakers in the AC circuit may have been turned off.
It is unlikely that the frequency of the power system has caused the outage. Inverters should be listed to UL 1741
and have a label that indicates the acceptable AC and DC voltage ranges the unit can operate within. If you do
find AC supply voltages that are out of specification, notify the electric utility of the problem.
If the inverter indicates a ground fault condition, this situation is a little more difficult to address. It also
requires you to follow safety procedures (seeSIDEBAR: Safety Warning) to limit your exposure to the
potential high voltages of the array. On one hand, the situation may be transient, due to moisture or pressure on
wire insulation that is not normally present. However, oftentimes the 1A fuse in the inverter has opened. If so,
replace the 600VDC fuse (verify proper size by referring to the inverter manual), and follow the reset procedure
outlined per the manufacturers instructions.
If the system has more than two strings of PV modules, there should be fuses for each string. They will be located
in the inverter or in a separate DC combiner enclosure. Turn off all switches (DC and AC) and use an insulated
tool to snap open all DC fuse holders. (Warning: There is a possibility of a long arc appearing if a ground fault is
located between the DC combiner and the inverter or within the inverter itself.) If a long arc does appear
during this operation, close the fuse holder quickly, and cover the entire array with opaque material so the
system stops producing electricity. At this point, it is now safe to start opening the DC fuse holders again.
Once all fuses have been removed, go ahead and remove the opaque material you placed on top of the panels,
and measure the voltage output of each string. A string with a ground fault will have a lower voltage. If a ground
fault is not detected, use a high-voltage resistance tester to check all wiring and the PV modules. The general
procedure is to isolate all wiring from ground and test all circuits. (Caution: The inverter must be isolated,
because it may be damaged by the high voltages of resistance testing.)
Most UL-listed PV modules are rated for use in systems up to 600VDC and can withstand test voltages of twice
that voltage. The typical test procedure is to connect the negative lead of the tester to ground and the positive
lead of the tester to the negative lead of a string and then test at 500V. A new system with good insulation
should indicate more than 2,000 M; however, readings greater than 200 M are acceptable. Lower values
should be investigated by disconnecting modules and testing parts separately until the source of the low reading
is pinpointed.
You may have to consult the inverter manufacturer if there are other error codes displayed on the inverter. Some
units have fans that can fail, which may be indicated by either a fan fail code or a high temperature code.
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Look for conduit fittings that may have become separated due to thermal cycling and wind.
Check for loose connections that may allow water to enter the conduits or other system components.
It is also recommended that you leave a copy of any measurements taken at the site as an aid to others who may
have to service the installation at a later date.
The bottom line is that most electrical contractors and technicians can handle the first level of troubleshooting
for a PV power system, provided they follow the proper safety precautions and understand the basics of PV
system operation. Take advantage of this niche market by educating yourself and your employees.
Kaszeta is the president of Photovoltaic Resources International in Mesa, Ariz. He can be reached at
bill@pvri.biz.
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The systems outlined in this article use high DC voltages that cannot be simply turned off. This discussion is
limited to test techniques that do not require disassembly of the PV array, but there is some exposure to
terminals within the equipment that will normally have high voltages. Any work on roofs requires fall protection
for safety.
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